![John Deere 9540i 9560i 9580i 9640i 9660i 9680i and 9780i CTS Repair Manual [Combines]](https://youfixthis.com/wp-content/uploads/2012/02/Manual_Download-300x300.jpg)
Part of the John Deere Repair Manuals.
What's inside: John Deere publication TM4697, dated 01NOV01, the factory repair manual for the 9540 through 9680 combines in both WTS straw-walker and CWS form - twelve machines in one 1,204-page book. It works the whole machine: engine removal and installation for the 6068AZ and 6081HZ diesels plus lower engine, cooling, air intake and diesel fuel system repair; hydrostatic drive teardown to the charge pump, cylinder barrel and reassembly shims; the cam lobe motor and Hillmaster II leveling hardware; steering, brakes and hydraulic valves; feeder house drives and reverser gear case; separator, straw walkers, cleaning shoe, grain tank and the horizontal and vertical unloading augers. Electrical coverage is the hands-on kind - harness and connector repair, harness routing, fuses, relays, sensors and switches, alternator, starting motor and GreenStar components. One honest limit, stated by the book itself on page 151: the wiring DIAGRAMS live in the companion manual TM4698, Section 240, not in this volume. This is a scanned book with a searchable text layer added, so you can search it.
What's Inside This John Deere 9540-9680 WTS/CWS Repair Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety, Identification & Specifications | 1-55 | Identification Number Location, Tune Up and Adjustment, Fuels and Lubricants |
| Remove and Install Engine | 56-134 | Lower Engine Repair, Cooling System, Air Intake System, Diesel Fuel System, Batteries |
| Harness and Connector Repair | 135-204 | Wiring Harness Routing, Fuses, Circuit Breakers and Relays, Lighting, Operator's Station |
| Sensors and Switches | 205-248 | Starting Motor, Greenstar Components |
| Transmission and Differential | 249-300 | - |
| Hydrostatic System | 301-380 | Dowel Pin, Cylinder Barrel, Retainer, Charge Pump, End Cover, Shims |
| Cam Lobe Motor | 381-450 | Tires and Wheels, Hillmaster Ii |
| Steering | 451-502 | Bearing Cone, Cotter Pin, Check Ball, Roll Pin, Sleeve, Tie Rod |
| Brakes | 503-558 | Hydraulic Reservoir, Hydraulic Pumps |
| Hydraulic Valves | 559-608 | Hydraulic Cylinders, Accumulator |
| Gull Wing Doors | 609-644 | - |
| System Components | 645-732 | Conveyor, Top Shaft and Slip Clutch |
| Feeder House Drives and Reverser Gear Case | 733-782 | Headertrak Tilt Cylinder and Frame |
| Separator Repair | 783-836 | Lubrication Line, Tooth, Connector, Fitting, Tooth Straightening Tool, Lube Fitting |
| Cylinder Drives | 837-884 | Sheave |
| Straw Walkers and Crankshafts | 885-934 | - |
| Shoe Supply Augers, Cleaning Fan and Chaffer and Sieve Frame | 935-1024 | Tailings Elevator and Augers, Primary Countershaft Gear Case |
| Header Electromagnetic Clutch | 1025-1062 | Grain Tank Cross Augers, Unloading Auger System Drives, Vertical Unloading Auger and Lower Gear Case |
| Horizontal Unloading Auger and Gear Case | 1063-1132 | Clean Grain Elevator and Loading Auger Gear Case, Grain Tank and Extensions |
| Engine Gear Case and Valve | 1133-1204 | Dealer Fabricated Tools, Index |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| Engine Model | John Deere 6068AZ (9540) / John Deere 6081HZ (9560, 9580, 9640, 9660, 9680) | p. 22 |
| Engine Power | 152 kW (206 hp) (9540) / Ranges from 175 kW (238 hp) to 272 kW (370 hp) boost (9560, 9580, 9640, 9660, 9680) | p. 22 |
| Grain Tank Capacity | 7,500 L (213 bu.) (9540, 9560) / 8,000 L (227 bu.) (9580, 9640) / 9,000 L (255 bu.) (9660) / 11,000 L (312 bu.) (9680) | p. 22 |
| All models | ||
| Cylinder Speed Range | Standard (350-950 rpm), Dual (200-475 rpm) | p. 22 |
| Fuel Tank Capacity | 700 L (185 gal.) | p. 22 |
| Average Unloading Rate | 4,200 L/min. (120 bu./min.) | p. 22 |
| 9540 | ||
| Weight (Less header) | 10,700 kg (23,594 lb.) | p. 22 |
John Deere 9540-9680 WTS/CWS Common Problems This Manual Covers
Ground drive gets weak or jerky under load, especially once the oil is hot
The Hydrostatic System section strips the unit in factory order - charge pump, cylinder barrel, retainer, end cover and the shims that matter at reassembly. A tired charge pump is the cheap fix, so inspect it per the section before condemning the whole pump and motor.
Manual Section: Hydrostatic System p. 301Feeder house plugs and the reverser groans without clearing the slug
Work through the Feeder House Drives And Reverser Gear Case section, which covers teardown of the reverser gear case and the feeder drives, along with the Headertrak tilt cylinder and frame. Fixing the reverser properly beats digging slugs out by hand every damp morning.
Manual Section: Feeder House Drives And Reverser Gear Case p. 733Bent or broken separator teeth after swallowing a rock or fence wire
The Separator Repair section covers tooth replacement and shows the tooth straightening tool for the ones worth saving, plus the lube fittings, lubrication lines, connectors and fittings you should check while the guards are already off. Straightening what you can keeps the parts bill sane.
Manual Section: Separator Repair p. 783Unloading auger turns slow, chatters, or the gear case runs hot and noisy
Start with the Horizontal Unloading Auger And Gear Case section for the boom end, and the vertical unloading auger and lower gear case coverage for the base of the system. Both walk removal and teardown so you can catch worn gears before they take the housing with them.
Manual Section: Horizontal Unloading Auger And Gear Case p. 1063Frequently Asked Questions
Does this manual include wiring diagrams?
No, and the book says so itself: the wiring diagrams are in TM4698, Section 240, the companion diagnostics manual. What this volume does carry is the hands-on electrical work - harness and connector repair, wiring harness routing, fuses, circuit breakers and relays, plus sensors, switches, the starting motor and GreenStar components. If you need to trace a circuit on paper, budget for TM4698 as well.
Does it cover the hydrostatic drive rebuild, or just removal?
It covers the rebuild. The Hydrostatic System section goes inside the unit - charge pump, cylinder barrel, retainer, end cover, dowel pins and the shim work on reassembly. That is the job most owners buy this book for, because guessing at hydro assembly is an expensive way to learn. p. 301
Will this work for my 9660 WTS? The listing mentions a lot of models.
Yes. One book covers the 9540 through 9680 range in both the WTS straw-walker and CWS versions, model year 2001 onward. The page footer reads 'WTS and CWS Combines Repair', so you are looking at the right publication regardless of which of those machines is in your shed.
How deep does the engine coverage go?
You get engine removal and installation for the 6068AZ (152 kW / 206 hp) and 6081HZ (175 kW up to 272 kW with boost), plus lower engine repair, cooling system, air intake, the diesel fuel system and batteries. That handles the work you would actually do with the engine in or coming out of the combine. p. 56
Is the Hillmaster II hillside leveling system covered?
Yes. Hillmaster II sits in the Cam Lobe Motor section alongside tires and wheels, so the drive and leveling hardware for hillside machines is in this book, not a separate supplement. If your combine is a flatland unit you simply skip that chapter.
Reviews
There are no reviews yet.