John Deere 9450 9550 and 9650 Combine Diagnostic and Test Manual TM1802.pdf

9450, 9550 and
9650 Combines
Diagnosis
DIAGNOSIS AND TESTS MANUAL
Combines models 9450, 9550, 9650 (S.N: 000000-695100)
TM1802 04 AUG 15 (ENGLISH)
For complete service information also see:
9450, 9550, 9650 Combines Repair TM1801
PowerTech 8.1 L Diesel Engines Base
Engine
CTM86
Alternators and Starting Motors CTM77
OEM Engine Accessories CTM67
Cam Lobe Motors CTM19
PowerTech 6.8L and 8.1L, 6068 and 6081
Diesel Engines (Level 3 Electronic Fuel
Systems with Bosch In-Line Pump)
PowerTech 4.5L & 6.8L Diesel Engines Tier
1/Stage I, Tier 2/Stage II, Tier 3/Stage IIIA,
Tier 3/Stage IIA Tier 3/Stage III, (Base
Engine)
CTM134
CTM104
John Deere Agriculture

9450, 9550 and 9650 Combines Diagnosis (g) by Belgreen v2.1
<- Go to Global Table of contents 9450, 9550 and 9650 Combines Diagnosis
Table of contents
FOREWORD
Section 210 - GENERAL
Group 05 - Safety
Group 10 - Combine and Component Identification
Group 15 - General Specifications
Group 20 - Diagnostic and Testing Procedures
Section 211 - DIAGNOSTIC TROUBLE CODES
Group A00 - A00 - Engine Control Unit Diagnostic Trouble Codes
Group C00 - C00 - Armrest Control Unit Diagnostic Trouble Codes
Group C03 - C03 - Cornerpost Control Unit Diagnostic Trouble Codes
Group E00 - E00 - Tailing Master Sensor Diagnostic Trouble Codes
Group E01 - E01 - Header Control Unit Diagnostic Trouble Codes
Group E02 - E02 - Right Control Unit Diagnostic Trouble Codes
Group AMS - GREENSTAR Display Warning Messages and Fault Codes
Group AMS - GREENSTAR KeyCard and PC Data Storage Card Warning Messages
Group AMS - GREENSTAR Mobile Processor Warning Messages
Group AMS - HARVEST DOC Warning Messages
Group AMS - Moisture Sensor Warning Messages
Group AMS - STARFIRE Receiver Warning Messages
Group AMS - Terrain Compensation Module Fault Codes
Section 212 - OBSERVABLE SYMPTOMS
Group 220 - Engine System
Group 230 - Air Intake and Cooling Systems
Group 240 - Electrical System
Group 250 - Power Train System
Group 255 - Four Wheel Drive System
Group 260 - Brake System
Group 270 - Hydraulic System
Group 275 - Main Gearcase System
Group 280 - Steering System
Group 290 - CLIMATRAK System
Group 300 - Separator System
Section 220 - ENGINE SYSTEM
Group 05 - General Information
Group 10 - Test Procedures and Adjustments
Group 15A - Engine Type Identification
Group 15B - Engine Diagnostics - Type A
Group 15C - Engine Diagnostics - Type B
Group 20 - Component Identification and Location
Section 230 - AIR INTAKE AND COOLING SYSTEMS
Group 15A - Engine Type Identification
Group 15B - Air Intake System Diagnostics
Group 15C - Engine Cooling Package Diagnostics - Type A
Group 15D - Engine Cooling Package Diagnostics - Type B
Section 240 - ELECTRICAL SYSTEM
Group 10 - Diagnostic Trouble Codes
Group 15A - Active Header Height Control System -Height Sensing Diagnostics
Group 15B - Active Header Height Control System - Height Resume Diagnostics

Group 15C - Active Header Height Control System - HYDRAFLEXHYDRAFLEX is a trademark of Deere &
Company Diagnostics
Group 15D - 95 Ampere Alternator / Battery Diagnostics
Group 15E - 185 Ampere Alternator / Battery Diagnostics
Group 15F - Armrest Control Unit Overall Diagnostics
Group 15G - Auxiliary Power Strip Outlet Diagnostics (Power Strip)
Group 15H - CAN Bus Type Identification
Group 15I - CAN Bus Diagnostics - Type A
Group 15J - CAN Bus Diagnostics - Type B
Group 15K - Cleaning Fan Speed Adjust Diagnostics
Group 15L - CLIMATRAKCLIMATRAK is a trademark of Deere & Company Diagnostics
Group 15M - COMFORT COMMANDComfort Command is a trademark of Deere & Company Seat
Diagnostics
Group 15N - Concave Clearance Adjust Diagnostics
Group 15O - CONTOUR MASTERContour Master is a trademark of Deere & Company - Automatic Tilt
Diagnostics
Group 15P - CONTOUR MASTER Contour Master is a trademark of Deere & Company - Manual Tilt
Diagnostics
Group 15Q - Cornerpost Control Unit Overall Diagnostics
Group 15R - Cornerpost - Cleaning Fan Speed Diagnostics
Group 15S - Cornerpost - Concave Clearance Diagnostics
Group 15T - Cornerpost - CONTOUR MASTER Contour Master is a trademark of Deere & Company
Position Diagnostics
Group 15U - Cornerpost - Corn Head Deck Plate Spacing Diagnostics
Group 15V - Cornerpost - Cylinder Speed Diagnostics
Group 15W - Cornerpost - Engine Hours Diagnostics
Group 15X - Cornerpost - Engine Speed Type Identification
Group 15Y - Cornerpost - Engine Speed - 6068 Diagnostics
Group 15Z - Cornerpost - Engine Speed - 6081 Diagnostics
Group 15AA - Cornerpost - Engine Temperature Gauge Type Identification
Group 15AB - Cornerpost - Engine Temperature Gauge - 6068 Diagnostics
Group 15AC - Cornerpost - Engine Temperature Gauge - 6081 Diagnostics
Group 15AD - Cornerpost - Feeder House Backshaft Speed Diagnostics
Group 15AE - Cornerpost - Fuel Gauge Diagnostics
Group 15AF - Cornerpost - Ground Speed Diagnostics
Group 15AG - Cornerpost - HYDRAFLEXHYDRAFLEX is a trademark of Deere & Company Pressure
Diagnostics
Group 15AH - Cornerpost - Separator Hours Diagnostics
Group 15AI - Cylinder Speed Adjust Diagnostics
Group 15AJ - Deck Plate Adjustment Diagnostics
Group 15AK - DIAL-A-SPEEDDIAL-A-SPEED is a trademark of Deere & Company Diagnostics
Group 15AL - Draper Speed Adjust Diagnostics
Group 15AM - Electric Fuel Pump Diagnostics
Group 15AN - Engine and Fuel Control Diagnostics - 6068 Engine
Group 15AO - Engine and Fuel Control Diagnostics - 6081L3 Engine
Group 15AP - Engine Compartment Relay Panel Diagnostics
Group 15AQ - Engine Control Unit Overall Diagnostics - 6081L3
Group 15AR - Four Wheel Drive Type Identification
Group 15AS - Four Wheel Drive - Single Speed Diagnostics
Group 15AT - Four Wheel Drive - Two Speed Diagnostics
Group 15AU - GREENSTARGREENSTAR is a trademark of Deere & Company - Display Diagnostics
Group 15AV - GREENSTARGREENSTAR is a trademark of Deere & Company - GPS Receiver Type
Identification

Group 15AW - GREENSTARGREENSTAR is a trademark of Deere & Company - GPS Receiver
Diagnostics - Type A
Group 15AX - GREENSTARGREENSTAR is a trademark of Deere & Company - GPS Receiver Diagnostics
- Type B
Group 15AY - GREENSTARGREENSTAR is a trademark of Deere & Company - GPS Receiver Diagnostics
- Type C
Group 15AZ - GREENSTARGREENSTAR is a trademark of Deere & Company - GPS Receiver Diagnostics
- Type D
Group 15BA - GREENSTARGREENSTAR is a trademark of Deere & Company - KeyCard and PC Data
Storage Card Diagnostics
Group 15BB - GREENSTARGREENSTAR is a trademark of Deere & Company - Mass Flow Sensor Type
Identification
Group 15BC - GREENSTARGREENSTAR is a trademark of Deere & Company - Mass Flow Sensor
Group 15BD - GREENSTARGREENSTAR is a trademark of Deere & Company - Mass Flow Sensor
Diagnostics - Type B
Group 15BE - GREENSTARGREENSTAR is a trademark of Deere & Company - Mobile Processor
Diagnostics
Group 15BF - GREENSTARGREENSTAR is a trademark of Deere & Company - Moisture Sensor Type
Identification
Group 15BG - GREENSTARGREENSTAR is a trademark of Deere & Company - Moisture Sensor
Group 15BH - GREENSTARGREENSTAR is a trademark of Deere & Company - Moisture Sensor
Group 15BI - GREENSTARGREENSTAR is a trademark of Deere & Company - Harvest/Yield
Mapping/Monitoring Type Identification
Group 15BJ - GREENSTARGREENSTAR is a trademark of Deere & Company System - HARVEST
DOCHARVEST DOC is a trademark of Deere & Company Diagnostics
Group 15BK - GREENSTARGREENSTAR is a trademark of Deere & Company System - Harvest Monitor
Diagnostics
Group BL - GREENSTARGREENSTAR is a trademark of Deere & Company System - Parallel Tracking
Diagnostics
Group 15BM - GREENSTARGREENSTAR is a trademark of Deere & Company System - Yield Mapping
Diagnostics
Group 15BN - GREENSTARGREENSTAR is a trademark of Deere & Company - System - Yield Monitor
System
Group 15BO - Header Control Unit Overall Diagnostics
Group 15BP - Header Engage Diagnostics
Group 15BQ - Header Raise / Lower Diagnostics
Group 15BR - Horn Diagnostics
Group 15BS - HYDRAFLEXHYDRAFLEX is a trademark of Deere & Company Pressure Adjustment Type
Identification
Group 15BT - HYDRAFLEXHYDRAFLEX is a trademark of Deere & Company Pressure Adjustment
Group 15BU - HYDRAFLEXHYDRAFLEX is a trademark of Deere & Company Pressure Adjustment
Group 15BV - Lighting System - Overall Diagnostics
Group 15BW - Lighting System - Daytime Running Lighting Diagnostics
Group 15BX - Lighting System - Dome Light Diagnostics
Group 15BY - Lighting System—Exit Lights Diagnostics
Group 15BZ - Lighting System - Field Lights Type Identification
Group 15CA - Lighting System - Field Light Diagnostics - Type A
Group 15CB - Lighting System - Field Light Diagnostics - Type B

Group 15CC - Lighting System—Hazard/Turn Lights Diagnostics
Group 15CD - Lighting System - Marker Lamps Diagnostics
Group 15CE - Lighting System—Panel Lamps Diagnostics
Group 15CF - Lighting System—Rear Discharge Lamps Diagnostics
Group 15CG - Lighting System - Road Lamps Diagnostics
Group 15CH - Lighting System - Service Lamps - Engine Area Diagnostics
Group 15CI - Lighting System - Service Lamps - Gullwing Doors Diagnostics
Group 15CJ - Lighting System - Service Lamps - Shoe Area Diagnostics
Group 15CK - Lighting System—Side Finder Lamps Diagnostics
Group 15CL - Lighting System - Stubble Lights Diagnostics
Group 15CM - Lighting System—Unloading Auger Light Diagnostics
Group 15CN - Multifunction Control Handle Diagnostics
Group 15CO - Power Distribution Board 1 - Overall Diagnostics
Group 15CP - Power Distribution Board 1—Control Circuit Power Diagnostics
Group 15CQ - Power Distribution Board 1 - EMIP Power Diagnostics
Group 15CR - Power Distribution Board 1 - Engine Running Power Diagnostics
Group 15CS - Power Distribution Board 1 - Ignition Switch Power Diagnostics
Group 15CT - Power Distribution Board 1 - Light Switch Power Diagnostics
Group 15CU - Power Distribution Board 1—Service Power Diagnostics
Group 15CV - Quick-Stop System Diagnostics
Group 15CW - Radio System Diagnostics
Group 15CX - Reel Fore/Aft Diagnostics
Group 15CY - Reel Fore/Aft Resume Diagnostics
Group 15CZ - Reel Raise/Lower Type Identification
Group 15DA - Reel Raise/Lower Diagnostics - Type A
Group 15DB - Reel Raise/Lower Diagnostics - Type B
Group 15DC - Reel Raise/Lower Diagnostics - Type C
Group 15DD - Reel Raise/Lower Diagnostics - Type D
Group 15DE - Reel Raise/Lower Resume Diagnostics
Group 15DF - Reel/Belt Speed Adjust Diagnostics
Group 15DG - Right Control Unit Overall Diagnostics
Group 15DH - Road/Field System Diagnostics
Group 15DI - Separator Engage Diagnostics
Group 15DJ - Start Aid Diagnostics
Group 15DK - Starting System Diagnostics
Group 15DL - Tailings Monitor Diagnostics
Group 15DM - Unloading Auger Engage Diagnostics
Group 15DN - Unloading Auger Swing Diagnostics
Group 15DO - Variable Speed Feeder House Adjust Type Identification
Group 15DP - Variable Speed Feeder House Adjust Diagnostics - Type A
Group 15DQ - Variable Speed Feeder House Adjust Diagnostics - Type B
Group 15DR - VISIONTRAK VisionTrak is a trademark of Deere & Company Diagnostics
Group 15DS - Warning Display Panel Overall Diagnostics
Group 15DT - Warning—Grain Elevator Speed w/ GREENSTARGREENSTAR is a trademark of Deere &
Company Diag.
Group 15DU - Warning - Grain Elevator Speed w/o GREENSTARGREENSTAR is a trademark of Deere &
Company Diag.
Group 15DV - Warning - Conveyor Auger Speed Diagnostics
Group 15DW - Warning - Cylinder Speed Diagnostics
Group 15DX - Warning—Engine Air Filter Diagnostics
Group 15DY - Warning—Engine Oil Pressure Diagnostics
Group 15DZ - Warning - Engine Speed Diagnostics
Group 15EA - Warning - Engine Temperature Diagnostics

Group 15EB - Warning - Grain Separator Speed Diagnostics
Group 15EC - Warning—Grain Tank Full Diagnostics
Group 15ED - Warning-Hydraulic Oil Temperature Diagnostics
Group 15EE - Warning - Hydrostatic Charge Pressure Diagnostics
Group 15EF - Warning-Low Fuel
Group 15EG - Warning—Main Gearcase Filter Restricted Diagnostics
Group 15EH - Warning - Main Gearcase Pressure Diagnostics
Group 15EI - Warning - Main Gearcase Temperature Diagnostics
Group 15EJ - Warning—Parking Brake Diagnostics
Group 15EK - Warning - Separator Plugged Diagnostics
Group 15EL - Warning - Straw Chopper Speed Diagnostics
Group 15EM - Warning - Tailings Elevator Speed Diagnostics
Group 15EN - Warning - Unloading Auger Engaged Diagnostics
Group 15EO - Warning—Voltage Low Diagnostics
Group 15EP - Wiper System Diagnostics
Group 20 - Connector Information (end views, numbers, location photos)
Section 250 - POWER TRAIN SYSTEM
Group 15A - Final Drive Diagnostics
Group 15B - Transmission Diagnostics
Group 15C - Hydrostatic Diagnostics
Group 20D - Component Identification
Section 255 - FOUR WHEEL DRIVE SYSTEM
Group 15A - Four Wheel Drive System - Type Identification
Group 15B - Four Wheel Drive Single Speed Diagnostics
Group 15C - Four Wheel Drive Two Speed Diagnostics
Group 20 - Component Identification
Section 260 - BRAKE SYSTEM
Group 15A - Park Brake Diagnostics
Group 15B - Service Brakes Diagnostics
Section 270 - HYDRAULIC SYSTEM
Group 10 - Test Procedures And Adjustments
Group 15A - Basic Hydraulic System Type Identification
Group 15B - Basic Hydraulic System Diagnostics - Type A
Group 15C - Basic Hydraulic System Diagnostics - Type B
Group 15D - Basic Hydraulic System Diagnostics - Type C
Group 15E - Basic Hydraulic System Diagnostics - Type D
Group 15F - Chaff Spreader Drive Diagnostics
Group 15G - CONTOUR MASTER™ Header Tilt Diagnostics
Group 15H - Deck Plate Adjust Type Identification
Group 15I - Deck Plate Adjust Diagnostics - Type A
Group 15J - Deck Plate Adjust Diagnostics - Type B
Group 15K - Draper Belt Drive Diagnostics
Group 15L - Feeder House Gearcase Cooler Diagnostics
Group 15M - Header Raise/Lower Diagnostics
Group 15N - HYDRAFLEX™ Pressure Adjust Type Identification

Group 15O - HYDRAFLEX™ Pressure Adjust Diagnostics - Type A
Group 15P - HYDRAFLEX™ Pressure Adjust Diagnostics - Type B
Group 15Q - Hydraulic System Overheating Type Identification
Group 15R - Hydraulic System Overheating Diagnostics - Type A
Group 15S - Hydraulic System Overheating Diagnostics - Type B
Group 15T - Reel/Belt Drive Type Identification
Group 15U - Reel/Belt Drive Diagnostics - Type A
Group 15V - Reel/Belt Drive Diagnostics - Type B
Group 15W - Reel Fore/Aft Type Identification
Group 15X - Reel Fore/Aft Diagnostics - Type A
Group 15Y - Reel Fore/Aft Diagnostics - Type B
Group 15Z - Reel Raise/Lower Type Identification
Group 15AA - Reel Raise/Lower Diagnostics - Type A
Group 15AB - Reel Raise/Lower Diagnostics - Type B
Group 15AC - Reel Raise/Lower Diagnostics - Type C
Group 15AD - Reel Raise/Lower Diagnostics - Type D
Group 15AE - Reel Raise/Lower Diagnostics - Type E
Group 15AF - Reel Raise/Lower Diagnostics - Type F
Group 15AG - Reel Raise/Lower Diagnostics - Type G
Group 15AH - Reel Raise/Lower Diagnostics - Type H
Group 15AI - Threshing Speed Adjust Type Identification
Group 15AJ - Threshing Speed Adjust Diagnostics - Type A
Group 15AK - Threshing Speed Adjust Diagnostics - Type B
Group 15AL - Unloading Auger Swing Diagnostics
Group 15AM - Variable Speed Feeder House Type Identification
Group 15AN - Variable Speed Feeder House Diagnostics - Type A
Group 15AO - Variable Speed Feeder House Diagnostics - Type B
Group 15AP - Variable Speed Feeder House Diagnostics - Type C
Group 15AQ - Variable Speed Feeder House Diagnostics - Type D
Section 275 - MAIN GEARCASE SYSTEM
Group 15A - Main Gearcase Pressure Low Diagnostics
Group 15B - Main Gearcase Temperature High Diagnostics
Group 15C - Main Gearcase Filter Restricted Diagnostics
Group 15D - Separator Engage Diagnostics
Group 15E - Main Gearcase Diagnostics
Group 15F - Unloading Auger Engage Diagnostics
Section 280 - STEERING SYSTEM
Group 15 - Steering Diagnostics
Section 290 - CLIMATRAK SYSTEM
Group 15 - CLIMATRAK™ System Diagnostics
Section 300 - SEPARATOR SYSTEM
Group 15 - Separator Vibration Diagnostics

Section 210 page 1
<- Go to Section TOC 9450, 9550 and 9650 Combines Diagnosis
GENERAL (g) by Belgreen v2.0
Foreword
This manual is written for an experienced technician. Essential tools required in performing certain service work are identified
in this manual and are recommended for use.
Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text
of the manual.
CAUTION:
This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for
personal injury.
Technical manuals are divided in two parts: Repair and Diagnosis and Tests. Repair sections tell how to repair the components.
Diagnosis and Tests sections help you identify the majority of routine failures quickly.
Information is organized in groups for the various components requiring service instruction. At the beginning of each group are
summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service
parts kits, specifications, wear tolerances, and torque values.
Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information
needed for diagnosis, analysis, testing, and repair.
Fundamental service information is available from other sources covering basic theory of operation, fundamentals of
troubleshooting, general maintenance, and basic type of failures and their causes.
This technical manual covers information unique to the SideHill 9550 Combine.

Section 210 - GENERAL
Table of contents
Group 05 - Safety..................................................................................................................................................... 1
Recognize Safety Information ....................................................................................... 1
Handle Fluids Safely—Avoid Fires ................................................................................... 1
Prepare for Emergencies............................................................................................... 1
Prevent Battery Explosions ........................................................................................... 2
Prevent Acid Burns .................................................................................................... 3
Handle Chemical Products Safely ................................................................................... 3
Handle Starting Fluid Safely
Avoid High-Pressure Fluids
. ...................................................................................... 4
......................................................................................... 4
Park Machine Safely................................................................................................... 5
Support Machine Properly
Wear Protective Clothing
.......................................................................................... 6
. .......................................................................................... 7
Protect Against Noise.................................................................................................. 7
Work in Clean Area .................................................................................................... 8
Work In Ventilated Area .............................................................................................. 8
Illuminate Work Area Safely.......................................................................................... 8
Service Machines Safely .............................................................................................. 9
Construct Dealer-Made Tools Safely ................................................................................ 9
Service Cooling System Safely......................................................................................10
Wait Before Opening High-Pressure Fuel System.................................................................10
Replace Safety Signs .................................................................................................11
Use Proper Lifting Equipment.......................................................................................11
Remove Paint Before Welding or Heating.........................................................................12
Avoid Heating Near Pressurized Fluid Lines.......................................................................13
Service Tires Safely...................................................................................................14
Avoid Harmful Asbestos Dust .......................................................................................14
Practice Safe Maintenance ..........................................................................................16
Use Proper Tools......................................................................................................16
Dispose of Waste Properly..........................................................................................17
Live With Safety ......................................................................................................17
Group 10 - Combine and Component Identification.....................................................................................19
Identification Plates ..................................................................................................19
Combine Identification Number.....................................................................................19
Dual Range Cylinder Drive Gearcase ..............................................................................19
Engine Serial Number For 9450.....................................................................................19
Engine Serial Number For 9550 and 9650 ........................................................................20
Engine Gearcase .....................................................................................................20
Feeder House Reverser Gearcase ..................................................................................20
Hydrostatic Drive Unit Motor
Hydrostatic Drive Unit Pump
......................................................................................21
......................................................................................21
Transmission..........................................................................................................21
Single Speed Four Wheel Drive Motors............................................................................21
Two Speed Four Wheel Drive Motors ..............................................................................22
Group 15 - General Specifications .....................................................................................................................23
Operating Speeds ....................................................................................................23
Ground Speeds (Fast Idle)...........................................................................................24
Turning Radius........................................................................................................24
Specifications - 9450 Combines
. .................................................................................25
. .................................................................................27
. .................................................................................29

Dimensions ............................................................................................................31
Dimension Reference Points........................................................................................32
Unified Inch Bolt and Screw Torque Values .......................................................................33
Metric Bolt and Screw Torque Values ..............................................................................34
Face Seal Fittings Assembly and Installation—All Pressure Applications
Metric Face Seal Fitting Torque Chart—Standard Pressure Applications
...................................34
...................................36
SAE Face Seal Fitting Torque Chart—Standard Pressure Applications ........................................ 37
External Hexagon Port Plug Torque Chart ........................................................................38
O-Ring Boss Fitting Torque Chart ..................................................................................39
SAE Four Bolt Flange Fitting Torque Chart........................................................................41
Group 20 - Diagnostic and Testing Procedures ............................................................................................42
Troubleshooting......................................................................................................42

Section 210 - GENERAL Group 05: Safety
Section 210 page 1
Group 05 - Safety
Recognize Safety Information
Safety-alert symbol
This is a safety-alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal
injury.
Follow recommended precautions and safe operating practices.
Handle Fluids Safely—Avoid Fires
Avoid Fires
When you work around fuel, do not smoke or work near heaters or other fire hazards.
Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers.
Make sure machine is clean of trash, grease, and debris.
Do not store oily rags; they can ignite and burn spontaneously.
Prepare for Emergencies

Section 210 page 2
First Aid Kit
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.
Prevent Battery Explosions
Battery Explosions
Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode.
Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer.
Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).

Section 210 page 3
Prevent Acid Burns
Acid Burns
Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if
splashed into eyes.
Avoid the hazard by:
1. Filling batteries in a well-ventilated area.
2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is added.
4. Avoiding spilling or dripping electrolyte.
5. Use proper jump start procedure.
If you spill acid on yourself:
1. Flush your skin with water.
2. Apply baking soda or lime to help neutralize the acid.
3. Flush your eyes with water for 15—30 minutes. Get medical attention immediately.
If acid is swallowed:
1. Do not induce vomiting.
2. Drink large amounts of water or milk, but do not exceed 2 L (2 quarts).
3. Get medical attention immediately.

Section 210 page 4
Handle Chemical Products Safely
Material Safety Data Sheet
Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with John Deere
equipment include such items as lubricants, coolants, paints, and adhesives.
A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety
procedures, and emergency response techniques.
Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and
how to do the job safely. Then follow procedures and recommended equipment.
(See your John Deere dealer for MSDS’s on chemical products used with John Deere equipment.)
Handle Starting Fluid Safely
Store Safely
Starting fluid is highly flammable.
Keep all sparks and flame away when using it. Keep starting fluid away from batteries and cables.
To prevent accidental discharge when storing the pressurized can, keep the cap on the container, and store in a cool, protected
location.
Do not incinerate or puncture a starting fluid container.
Do not use starting fluid on an engine equipped with glow plugs or an air intake heater.

Section 210 page 5
Avoid High-Pressure Fluids
High Pressure
Inspect hydraulic hoses periodically – at least once per year – for leakage, kinking, cuts, cracks, abrasion, blisters, corrosion,
exposed wire braid or any other signs of wear or damage.
Replace worn or damaged hose assemblies immediately with John Deere approved replacement parts.
Escaping fluid under pressure can penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying
pressure.
Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours
or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such
information is available in English from Deere & Company Medical Department in Moline, Illinois, U.S.A., by calling
1-800-822-8262 or +1 309-748-5636.
Park Machine Safely
Remove the Key
Before working on the machine:
Lower all equipment to the ground.
Stop the engine and remove the key.
Disconnect the battery ground strap.
Hang a "DO NOT OPERATE" tag in operator station.

Section 210 page 6
Support Machine Properly
Support Properly
Always lower the attachment or implement to the ground before you work on the machine. If the work requires that the
machine or attachment be lifted, provide secure support for them. If left in a raised position, hydraulically supported devices
can settle or leak down.
Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load. Do not work
under a machine that is supported solely by a jack. Follow recommended procedures in this manual.
When implements or attachments are used with a machine, always follow safety precautions listed in the implement or
attachment operator′s manual.

Section 210 page 7
Wear Protective Clothing
Protective Clothing
Wear close fitting clothing and safety equipment appropriate to the job.
Prolonged exposure to loud noise can cause impairment or loss of hearing.
Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud
noises.
Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating
machine.
Protect Against Noise
Noise Exposure

Section 210 page 8
Prolonged exposure to loud noise can cause impairment or loss of hearing.
Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud
noises.
Work in Clean Area
Clean Work Area
Before starting a job:
Clean work area and machine.
Make sure you have all necessary tools to do your job.
Have the right parts on hand.
Read all instructions thoroughly; do not attempt shortcuts.
Work In Ventilated Area
Engine exhaust fumes
Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust
fumes from the area with an exhaust pipe extension.
If you do not have an exhaust pipe extension, open the doors and get outside air into the area.
Illuminate Work Area Safely

Section 210 page 9
Work Area Safely
Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure
the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil.
Service Machines Safely
Moving Parts
Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or
moving parts. If these items were to get caught, severe injury could result.
Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.
Construct Dealer-Made Tools Safely

Section 210 page 10
Construct Dealer-Made Tools Safely
Faulty or broken tools can result in serious injury. When constructing tools, use proper, quality materials, and good
workmanship.
Do not weld tools unless you have the proper equipment and experience to perform the job.
Service Cooling System Safely
Cooling System
Explosive release of fluids from pressurized cooling system can cause serious burns.
Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve
pressure before removing completely.
Wait Before Opening High-Pressure Fuel System

Section 210 page 11
High-Pressure Fuel Lines
High-pressure fluid remaining in fuel lines can cause serious injury. Only technicians familiar with this type of system should
perform repairs. Before disconnecting fuel lines, sensors, or any other components between the high-pressure fuel pump and
nozzles on engines with High-Pressure Common Rail (HPCR) fuel system, confirm that the fuel pressure is relieved.
Replace Safety Signs
Safety Signs
Replace missing or damaged safety signs. See the machine operator’s manual for correct safety sign placement.
Use Proper Lifting Equipment

Section 210 page 12
Proper Lifting Equipment
Lifting heavy components incorrectly can cause severe injury or machine damage.
Follow recommended procedure for removal and installation of components in the manual.
Remove Paint Before Welding or Heating
Toxic Fumes
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch.
Remove paint before heating:
Remove paint a minimum of 100 mm (4 in.) from area to be affected by heating. If paint cannot be removed, wear an
approved respirator before heating or welding.
If you sand or grind paint, avoid breathing the dust. Wear an approved respirator.
If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper
containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or
heating.
Do not use a chlorinated solvent in areas where welding will take place.
Do all work in an area that is well ventilated to carry toxic fumes and dust away.
Dispose of paint and solvent properly.

Section 210 page 13
Avoid Heating Near Pressurized Fluid Lines
Flammable Spray
Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and
bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials.
Pressurized lines can accidentally burst when heat goes beyond the immediate flame area.

Section 210 page 14
Service Tires Safely
Explosive Tire and Rim Parts
Explosive separation of a tire and rim parts can cause serious injury or death.
Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job.
Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. Never weld or heat a
wheel and tire assembly. The heat can cause an increase in air pressure resulting in a tire explosion. Welding can structurally
weaken or deform the wheel.
When inflating tires, use a clip-on chuck and extension hose long enough to allow you to stand to one side and NOT in front of
or over the tire assembly. Use a safety cage if available.
Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts.
Avoid Harmful Asbestos Dust

Section 210 page 15
Asbestos Dust
Avoid breathing dust that may be generated when handling components containing asbestos fibers. Inhaled asbestos fibers
may cause lung cancer.
Components in products that may contain asbestos fibers are brake pads, brake band and lining assemblies, clutch plates, and
some gaskets. The asbestos used in these components is usually found in a resin or sealed in some way. Normal handling is
not hazardous as long as airborne dust containing asbestos is not generated.
Avoid creating dust. Never use compressed air for cleaning. Avoid brushing or grinding material containing asbestos. When
servicing, wear an approved respirator. A special vacuum cleaner is recommended to clean asbestos. If not available, apply a
mist of oil or water on the material containing asbestos.
Keep bystanders away from the area.

Section 210 page 16
Practice Safe Maintenance
Keep Area Clean
Understand service procedure before doing work. Keep area clean and dry.
Never lubricate, service, or adjust machine while it is moving. Keep hands, feet , and clothing from power-driven parts.
Disengage all power and operate controls to relieve pressure. Lower equipment to the ground. Stop the engine. Remove the
key. Allow machine to cool.
Securely support any machine elements that must be raised for service work.
Keep all parts in good condition and properly installed. Fix damage immediately. Replace worn or broken parts. Remove any
buildup of grease, oil, or debris.
On self-propelled equipment, disconnect battery ground cable (-) before making adjustments on electrical systems or welding
on machine.
On towed implements, disconnect wiring harnesses from tractor before servicing electrical system components or welding on
machine.
Use Proper Tools

Section 210 page 17
Proper Tools
Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards.
Use power tools only to loosen threaded parts and fasteners.
For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners.
Avoid bodily injury caused by slipping wrenches.
Use only service parts meeting John Deere specifications.
Dispose of Waste Properly
Recycle Waste
Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with John Deere
equipment include such items as oil, fuel, coolant, brake fluid, filters, and batteries.
Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking
from them.
Do not pour waste onto the ground, down a drain, or into any water source.
Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regulations may require a
certified air conditioning service center to recover and recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your John
Deere dealer.

Section 210 - GENERAL Group 10: Combine and Component Identification
Section 210 page 18
Live With Safety
Safety Systems
Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all
guards and shields.

John Deere 9450 9550 and 9650 Combine Diagnostic and Test Manual TM1802.pdf

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