John Deere 9760 Sts 9860 Sts Combine Repair Manual.pdf

9560 STS, 9660 STS,
9760 STS and 9860 STS
Combine Repair
TECHNICAL MANUAL
9560 STS, 9660 STS, 9760 STS and
9860 STS Combine Repair
TM2181 29AUG06 (ENGLISH)
For complete service information also see:
9560 STS, 9660 STS, 9760 STS and 9860
STS Combines
Diagnosis and Tests . . . . . . . . . . . . . . . . . . . TM2182
Alternators and Starting Motors. . . . . . . . . .
POWERTECH 4.5 L & 6.8 L Diesel
CTM77
Engines—Base Engines . . . . . . . . . . . . . . . . CTM104
POWERTECH 6.8 L Diesel Engine—Level 14
Diagnostics - Electronic Fuel Systems with
Denso HPCR . . . . . . . . . . . . . . . . . . . . . . . . . CTM320
POWERTECH 8.1 L Diesel Engines—Base
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CTM86
POWERTECH 8.1 L Engines—Level 9
Electronic Fuel Systems with Denso In-Line
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CTM255
POWERTECH 9.0 L Tier 3/Stage IIIA OEM
Diesel Engines—Base Engine . . . . . . . . . . . CTM400
POWERTECH 9.0 L Diesel Engine—Level 14
Diagnostics - Electronic Fuel Systems with
Denso HPCR . . . . . . . . . . . . . . . . . . . . . . . . . CTM385
POWERTECH 10.5 L and 12.5 L Diesel
Engines—Base Engine . . . . . . . . . . . . . . . . . CTM100
POWERTECH 10.5 L & 12.5 L Diesel
Engines—Operation and Diagnostics for
Deere Level 6 ECU . . . . . . . . . . . . . . . . . . . . CTM188
100 Series Hydraulic Cylinders . . . . . . . . . . TMH100A
John Deere Harvester Works
LITHO IN U.S.A.

083006
PN=2
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.
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
operation and tests. Repair sections tell how to repair
the components. Operation 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.
DX,TMIFC –19–29SEP98–1/1
Introduction

083006
PN=2
TM2181 (29AUG06)
60 Series STS Combine Repair

i
TM2181 (29AUG06) 60 Series STS Combine Repair
083006
PN=1
SECTION 10—General Group 16—Hydraulic Valve Stack (S.N. —715300)
Group 05—Safety Group 17—Hydraulic Valve Stack (S.N. 715301—)
Group 10—Specifications Group 20—Hydraulic Cylinders
Group 15—Tune-Up and Adjustment Group 25—Motors
Group 20—Fuels and Lubricants Group 30—Accumulator
SECTION 20—Engine SECTION 80—Separator Shell
Group 05—Remove and Install Engine Group 05—Gull Wing Doors
Group 10—Cooling System
Group 15—Lower Engine Repair
SECTION 90—Operator Station Repair
SECTION 30—Fuel and Air Repair
Group 05—Air Conditioning System (R134a)
Group 05—Air Intake System
Group 10—System Components
Group 10—Diesel Fuel System
Group 15—Cab
SECTION 40—Electrical System SECTION 110—Feeder House Repair
Group 05—Batteries
Group 05—Conveyor
Group 10—Harness and Connector Repair
Group 10—Top Shaft and Slip Clutch
Group 15—Wire Harness Routing Group 15—Feeder House Drives and Reverser
Group 20—Fuses, Circuit Breakers and Relays
Gear Case
Group 25—Lighting Group 20—CONTOUR MASTER Tilt Cylinder
Group 30—Operators Station Group 25—CONTOUR MASTER Tilt Frame
Group 35—Sensors and Switches
Group 40—Wiper SECTION 120—Separator
Group 45—Alternator Group 05—Separator Repair
Group 50—Starting Motor Group 10—Separator Drives
Group 55—Electrical Engine Control Group 15—Residue Disposal
Group 60—GREENSTAR Components Group 20—Conveyor Augers, Cleaning Fan And
Chaffer And Sieve Frame
SECTION 50—Power Train Repair Group 25—Tailings Elevator and Augers
Group 05—Transmission and Differential Group 30—Primary Countershaft Gear Case
Group 10—Single Reduction Final Drive—Heavy Group 35—Header Electromagnetic Clutch
Duty
Group 15—Hydrostatic System SECTION 130—Grain Tank and Unloading System
Group 20—Cam Lobe Motor Repair
Group 25—Tires and Wheels Group 05—Grain Tank Cross Augers
Group 10—Unloading Auger System Drives
SECTION 60—Power Steering and Brakes Group 15—Vertical Unloading Auger and Lower
Group 05—Steering Gear Case
Group 10—Brakes Group 20—Horizontal Unloading Auger and Gear
Case
SECTION 70—Hydraulic Repair Group 25—Clean Grain Elevator
Group 05—Hydraulic Reservoir Group 30—Grain Tank and Extensions
Group 10—Hydraulic Pumps
Group 15—Hydraulic Valves Continued on next page
All information, illustrations and specifications in this manual are based on
the latest information available at the time of publication. The right is
reserved to make changes at any time without notice.
COPYRIGHT ©
2006
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION
Manual
Previous Editions
Copyright ©
2003, 2004, 2005
10
20
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40
50
60
70
80
90
110
Contents

Contents
ii
083006
PN=2
10
SECTION 140—Engine Gear Case and Control
Valve Repair
Group 05—Engine Gear Case and Valve
SECTION 199—Dealer Fabricated Tools
20
Group 05—Dealer Fabricated Tools
30
40
50
60
70
80
90
110

Contents
iii
083006
PN=3
120
130
140
199
INDX

Contents
iv
083006
PN=4
120
130
140
199
INDX

10-1
083006
PN=1
Section 10
General
Contents
Page Page
Group 05—Safety . . . . . . . . . . . . . . . . . . . . . .10-05-1 SAE Four Bolt Flange Cap Screw Torque
Values—High Pressure Applications ............ 10-10-36
Group 10—Specifications External Hexagon Port Plug Torque Chart....... 10-10-37
Ground Speeds (Fast Idle) Two Speed Four Prevent Hydraulic System Contamination ........ 10-10-38
Wheel Drive. . . . . . . . . . . . . . . . . . . . . . . . . .10-10-1 Check Oil Lines and Fittings............................. 10-10-39
Turning Radius . . . . . . . . . . . . . . . . . . . . . . . . .10-10-2 Basic Electrical Component Handling /
Operating Speeds—9560 STS . . . . . . . . . . . . .10-10-3 Precautions For Vehicles Equipped With
Specifications—9560 STS Combine . . . . . . . . .10-10-5 Computer Controlled Systems ...................... 10-10-40
Dimensions—9560 STS Combine...................... 10-10-7
Dimension Reference Points—9560 STS Group 15—Tune-Up and Adjustment
Combine . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-8 Tune-Up and Adjustment.................................... 10-15-1
Operating Speeds—9660 STS, 9760 STS Care and Maintenance of Belts.......................... 10-15-2
Combines . . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-9 Defective Belts.................................................... 10-15-4
Specifications—9660 STS Combine................. 10-10-11
Specifications—9760 STS Combine . . . . . . . .10-10-13 Group 20—Fuels and Lubricants
Dimensions—9660 STS, 9760 STS Handle Fuel Safely—Avoid Fires........................ 10-20-1
Combines . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-15 Handling and Storing Diesel Fuel....................... 10-20-1
Dimension Reference Points—9660 STS, Diesel Fuel.......................................................... 10-20-2
9760 STS Combines . . . . . . . . . . . . . . . . . .10-10-17 Bio-Diesel Fuel.................................................... 10-20-3
Operating Speeds—9860 STS Combine . . . . .10-10-18 Lubricity of Diesel Fuel ....................................... 10-20-4
Specifications—9860 STS Combine (S.N. — Testing Diesel Fuel............................................. 10-20-4
715700) . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-20 Diesel Engine Coolant ........................................ 10-20-5
Specifications—9860 STS Combine (S.N. Operating in Warm Temperature Climates......... 10-20-6
715701—) . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-22 Supplemental Coolant Additives......................... 10-20-7
Dimensions—9860 STS Combine . . . . . . . . . .10-10-24 Additional Information About Diesel
Dimension Reference Points—9860 STS Engine Coolants and Supplemental Coolant
Combine . . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-25 Additives.......................................................... 10-20-8
Metric Bolt and Screw Torque Values . . . . . . .10-10-26 Testing Diesel Engine Coolant ........................... 10-20-9
Unified Inch Bolt and Screw Torque Diesel Engine Break-In Oil ............................... 10-20-10
Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-27 Diesel Engine Oil .............................................. 10-20-11
Sealants and Adhesives Cross-Reference Extended Diesel Engine Oil Service
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-28 Intervals......................................................... 10-20-12
Face Seal Fittings Assembly and OILSCANand COOLSCAN............................ 10-20-12
Installation—All Pressure Applications . . . . .10-10-29 Hydrostatic Drive System, Main Hydraulic
Metric Face Seal Fitting Torque System and Main Engine Gear Case
Chart—Standard Pressure Applications . . . .10-10-30 Oils ................................................................ 10-20-13
Metric Face Seal Fitting Torque Chart—High Transmission, Final Drives, Feeder House
Pressure Applications . . . . . . . . . . . . . . . . .10-10-31 Reverser, Loading Auger, Primary
SAE Face Seal Fitting Torque Countershaft and Two-Speed Separator Chart—
Standard Pressure Applications . . . .10-10-32 Drive Gear Cases ......................................... 10-20-14
SAE Face Seal Fitting Torque Chart—High Grease .............................................................. 10-20-15
Pressure Applications . . . . . . . . . . . . . . . . .10-10-33 Brake Fluid........................................................ 10-20-15
Four Bolt Flange Fittings Assembly and Lubricant Storage ............................................. 10-20-16
Installation—All Pressure Applications . . . . .10-10-34 Alternative and Synthetic Lubricants ................ 10-20-16
SAE Four Bolt Flange Cap Screw Torque
Values—Standard Pressure Applications . . .10-10-35 Continued on next page
10

10-2
083006
PN=2
10
Page
Mixing of Lubricants...........................................10-20-17
Contents

10-05-1
083006
PN=7
T81389
–UN–07DEC88
Recognize Safety Information
10
05
1
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.
DX,ALERT –19–29SEP98–1/1
Group 05
Safety
Understand Signal Words
A signal word—DANGER, WARNING, or CAUTION—is
used with the safety-alert symbol. DANGER identifies the
most serious hazards.
DANGER or WARNING safety signs are located near
specific hazards. General precautions are listed on
CAUTION safety signs. CAUTION also calls attention to
safety messages in this manual.
DX,SIGNAL –19–03MAR93–1/1
Handle Fluids Safely—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.
DX,FLAME –19–29SEP98–1/1
TS227
–UN–23AUG88
TS187
–19–30SEP88

Safety
10-05-2
083006
PN=8
10
05
2
Prevent 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).
DX,SPARKS –19–03MAR93–1/1
TS204
–UN–23AUG88

Safety
10-05-3
083006
PN=9
TS203
–UN–23AUG88
TS204
–UN–23AUG88
Handling Batteries Safely
10
05
3
CAUTION: Battery gas can explode. Keep
sparks and flames away from batteries. Use a
flashlight to check battery electrolyte level.
Never check battery charge by placing a metal
object across the posts. Use a voltmeter or
hydrometer.
Always remove grounded (-) battery clamp first
and replace it last.
CAUTION: 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.
WARNING: Battery posts, terminals, and related
accessories contain lead and lead compounds, chemicals
known to the State of California to cause cancer and
reproductive harm. Wash hands after handling.
AG,OUMX005,1408 –19–01MAY00–1/1

Safety
10-05-4
083006
PN=10
10
05
4
Prepare for Emergencies
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.
DX,FIRE2 –19–03MAR93–1/1
Prevent 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.
DX,POISON –19–21APR93–1/1
TS203
–UN–23AUG88
TS291
–UN–23AUG88

Safety
10-05-5
083006
PN=11
TS1132
–UN–26NOV90
Handle Chemical Products Safely
10
05
5
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.)
DX,MSDS,NA –19–03MAR93–1/1
Avoid High-Pressure Fluids
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 from Deere
& Company Medical Department in Moline, Illinois, U.S.A.
DX,FLUID –19–03MAR93–1/1
X9811
–UN–23AUG88

Safety
083006
PN=12
10
05
6
Service Accumulator Systems Safely
Escaping fluid or gas from systems with pressurized
accumulators that are used in air conditioning, hydraulic,
and air brake systems can cause serious injury. Extreme
heat can cause the accumulator to burst, and pressurized
lines can be accidentally cut. Do not weld or use a torch
near a pressurized accumulator or pressurized line.
Relieve pressure from the pressurized system before
removing accumulator.
Relieve pressure from the hydraulic system before
removing accumulator. Never attempt to relieve hydraulic
system or accumulator pressure by loosening a fitting.
Accumulators cannot be repaired.
DX,WW,ACCLA2 –19–22AUG03–1/1
TM2181 (29AUG06) 10-05-6 60 Series STS Combine Repair
Wait Before Opening High-Pressure Fuel
System
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, wait a
minimum of 15 minutes after engine is stopped.
DX,WW,HPCR2 –19–07JAN03–1/1
Park Machine Safely
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.
DX,PARK –19–04JUN90–1/1
TS230
–UN–24MAY89
TS1343
–UN–18MAR92
TS281
–UN–23AUG88

Safety
083006
PN=13
TS229
–UN–23AUG88
Support Machine Properly
10
05
7
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.
DX,LOWER –19–24FEB00–1/1
Wear 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.
DX,WEAR –19–10SEP90–1/1
Work in Clean 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.
DX,CLEAN –19–04JUN90–1/1
T6642EJ
–UN–18OCT88
TS206
–UN–23AUG88

Safety
10-05-8
083006
PN=14
10
05
8
Service Machines Safely
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.
DX,LOOSE –19–04JUN90–1/1
Work In Ventilated Area
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
DX,AIR –19–17FEB99–1/1
Illuminate 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.
DX,LIGHT –19–04JUN90–1/1
Replace Safety Signs
Replace missing or damaged safety signs. See the
machine operator’s manual for correct safety sign
placement.
DX,SIGNS1 –19–04JUN90–1/1
TS201
–UN–23AUG88
TS223
–UN–23AUG88
TS220
–UN–23AUG88
TS228
–UN–23AUG88

Safety
10-05-9
083006
PN=15
TS226
–UN–23AUG88
Use Proper Lifting Equipment
10
05
9
Lifting heavy components incorrectly can cause severe
injury or machine damage.
Follow recommended procedure for removal and
installation of components in the manual.
DX,LIFT –19–04JUN90–1/1
Remove Paint Before Welding or Heating
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.
DX,PAINT –19–24JUL02–1/1
TS220
–UN–23AUG88

Safety
10-05-10
083006
PN=16
10
05
10
Avoid Heating Near Pressurized Fluid Lines
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.
DX,TORCH –19–10DEC04–1/1
Service Tires Safely
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.
DX,RIM –19–24AUG90–1/1
TS211
–UN–23AUG88
TS953
–UN–15MAY90

Safety
10-05-11
083006
PN=17
TS220
–UN–23AUG88
Avoid Harmful Asbestos Dust
10
05
11
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.
DX,DUST –19–15MAR91–1/1

Safety
10-05-12
083006
PN=18
10
05
12
Practice Safe Maintenance
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.
DX,SERV –19–17FEB99–1/1
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.
DX,SAFE,TOOLS –19–10OCT97–1/1
LX1016749
–UN–01JUL97
TS218
–UN–23AUG88

Safety
10-05-13
083006
PN=19
TS779
–UN–08NOV89
Use Proper Tools
10
05
13
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.
DX,REPAIR –19–17FEB99–1/1
Dispose of Waste Properly
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.
DX,DRAIN –19–03MAR93–1/1
TS1133
–UN–26NOV90

Safety
10-05-14
083006
PN=20
10
05
14
Use Adequate Service Facilities
Keep the service area clean and dry. Wet or oily floors
are slippery. Wet spots can be dangerous when working
with electrical equipment.
Make sure the service area is adequately vented.
Periodically check the shop exhaust system for leakage.
Engine exhaust gas is dangerous.
Be sure all electrical outlets and tools are properly
grounded.
Use adequate light for the job at hand.
Service the machine on a level, hard-surfaced area.
Use lifting equipment and safety stands which have
adequate strength for the job being performed.
HX,1401,1005,A –19–11DEC92–1/1
Live With Safety
Before returning machine to customer, make sure
machine is functioning properly, especially the safety
systems. Install all guards and shields.
DX,LIVE –19–25SEP92–1/1
TS231
–19–07OCT88

10-10-1
083006
PN=21
10
Ground Speeds (Fast Idle) Two Speed Four 10
Wheel Drive 1
NOTE: Speeds shown are for combines equipped with
18.4 x 26 R1 rear tires. Except combines
equipped with 35.5 x 32 R2 drive tires are shown
with 28L x 26 R2 rear tires.
Speed in Km/h (mph)
Front Tire 2WD 2-Speed 4WD First Gear Second Gear Third Gear
30.5 x 32 R1 X 6.1 (3.8) 11.4 (7.1) 30.4 (19.0)
30.5 x 32 R1 Low
High
4.7 (2.9)
5.4 (3.4)
7.3 (4.6)
9.1 (5.7)
12.1 (7.6)
18.1 (11.3)
800/65R32 X 6.1 (3.8) 11.4 (7.1) 30.4 (19.0)
800/65R32 Low
High
4.7 (2.9)
5.4 (3.4)
7.3 (4.6)
9.1 (5.7)
12.1 (7.6)
18.1 (11.3)
30.5L x 32R2 X 6.3 (3.9) 11.7 (7.3) 31.2 (19.5)
30.5L x 32 R2 Low
High
4.8 (3.)
5.5 (3.4)
7.4 (4.6)
9.3 (5.8)
12.3 (7.7)
18.5 (11.6)
30.5L x 32 R3 X 5.8 (3.6) 10.8 (6.8) 28.8 (18.0)
18.4 x 38 R1 X 5.9 (3.7) 11.1 (6.9) 29.5 (18.4)
18.4 x 38 R1 Low
High
4.6 (2.9)
5.2 (3.3)
7.1 (4.4)
8.9 (5.6)
11.9 (7.4)
17.8 (11.1)
18.4 x 38 R2 X 6.1 (3.8) 11.4 (7.1) 30.4 (19.0)
18.4 x 38 R2 Low
High
4.7 (2.9)
5.4 (3.4)
7.3 (4.6)
9.1 (5.7)
12.2 (7.6)
18.3 (11.4)
20.8 x 38 R1 X 6.1 (3.8) 11.4 (7.1) 30.4 (19.0)
20.8 x 38 R1 Low
High
4.7 (2.9)
5.4 (3.4)
7.3 (4.6)
9.1 (5.7)
12.1 (7.6)
18.1 (11.3)
18.4 x 42 R1 X 6.3 (3.9) 11.8 (7.4) 31.3 (19.6)
18.4 x 42 R1 Low
High
4.8 (3.0)
5.5 (3.4)
7.4 (4.6)
9.3 (5.8)
12.2 (7.6)
18.4 (11.5)
35.5 x 32 R2 X 6.8 (4.3) 12.7 (7.9) 33.8 (21.1)
35.5 x 32 R2 Low
High
5.2 (3.3)
6 (3.8)
8.1 (5.1)
10.1 (6.3)
13.5 (8.4)
20.2 (12.6)
68 x 50-32, HF3 X 5.8 (3.6) 10.8 (6.8) 28.8 (18.0)
68 x 50-32, HF3 Low
High
4.5 (2.8)
5.1 (3.2)
7 (4.4)
8.7 (5.4)
11.8 (7.4)
17.5 (10.9)
AG,OUO6022,1688 –19–24JUL00–1/1
Group 10
Specifications

Specifications
10-10-2
083006
PN=22
10
10 Turning Radius
2
OUO6083,0000655 –19–22DEC03–1/1
Combine
Model
Front Tires Rear Tires Non-Powered Rear Axle
Two Speed Powered
Rear Axle
9560 STS 30.5L-32 18.4-26
7.4 m
(24 ft 2 in.)
7.4 m
(24 ft 2 in.)
9660 STS, 97560 STS
and 9860 STS 30.5L-32 18.4-26
7.73 m
(25 ft 3 in.)
8.19 m
(26 ft 10 in.)

Specifications
10-10-3
083006
PN=23
Operating Speeds—9560 STS
Speeds shown are average and can vary from
machine to machine. Speeds are rated at high idle
with separator engaged, no load.
10
10
3
Operating speeds specifications and design subject to
change without notice.
Engine Speed
Slow Idle (Separator Off) (6.8 L Engine) 1300 rpm
Slow Idle (Separator Off) (8.1 L Engine) 1200 rpm
Mid Speed (Separator Off) (6.8 L Engine) 1850 rpm
Mid Speed (Separator Off) (8.1 L Engine) 1680 rpm
Fast Idle (Separator Off) (6.8 L Engine) 2550 rpm
Fast Idle (Separator Off) (8.1 L Engine) 2340 rpm
Full Load Rated Speed (6.8 L Engine) 2400 rpm
Full Load Rated Speed (8.1 L Engine) 2200 rpm
Separator Drive Shaft Speed 1546 rpm
Main Countershaft Speed 1546 rpm
Single Tine Separator Speed
High Range 480 - 1300 rpm
Low Range 230 - 600 rpm
Feeder House Lower Shaft Speed
Standard Variable Speed 520 - 780 rpm
Heavy Duty Variable Speed 520 - 780 rpm
Fixed Speed 520 rpm
Fixed Speed Feeder House Drive Chain Speed
22 Tooth Fixed Speed Chain 48 rpm
26 Tooth Fixed Speed Chain 57 rpm
38 Tooth Fixed Speed Chain (Optional) 83 rpm
Feed Accelerator Speed
Feed Accelerator 440/800 rpm
Feed Accelerator (Optional Slow Speed) 320/790 rpm
Discharge Beater Speed 849 rpm
Jackshaft Speed
Right-Hand Jackshaft, Front 532 rpm
Right-Hand Jackshaft, Rear 532 rpm
Cleaning Fan Speed
Standard Speed 500 - 1200 rpm
Special Slow Speed 300 - 600 rpm
Continued on next page OUO6083,0000DA0 –19–18JUL06–1/2

Specifications
10-10-4
083006
PN=24
10
10
4
OUO6083,0000DA0 –19–18JUL06–2/2
Elevator Speed
Clean Grain Elevator 400 rpm
Clean Grain Loading Auger 424 rpm
Tailings Elevator, Lower Auger 405 rpm
Tailings Elevator, Upper Auger 640 rpm
Shoe Drive 297 rpm
Conveyor Augers 433 rpm
Unloading System Speed
Unloading System Countershaft 1087 rpm
Unloading Auger Gear Box, Input Shaft 450 rpm
Unloading Vertical Auger 450 rpm
Unloading Outer Auger 450 rpm
Grain Tank Horizontal Augers 420 rpm
Chopper Speed
Chopper/Discharge Beater Jackshaft 2002 rpm
Chopper (Two Speed) 1603/2500 rpm

Specifications
10-10-5
083006
PN=25
10
Specifications—9560 STS Combine 10
5
NOTE: Specifications and design subject to change
without notice.
Engine
Make John Deere
Model (6.8 L Engine) 6068HH
Model (8.1 L Engine) 6081HH
Type six-cylinder, in line, valve-in-head, air-to-air
aftercooled diesel turbocharged
Rated Power at 2400 rpm (6.8 L Engine) 198 kW (265 hp)
Rated Power at 2200 rpm (8.1 L Engine) 198 kW (265 hp)
Power Bulge at 2300 rpm (6.8 L Engine) 212 kW (284 hp)
Power Bulge at 2100 rpm (8.1 L Engine) 212 kW (284 hp)
Power Boost 220 kW (295 hp)
Displacement (6.8 L Engine) 6.8 L (415 cu. in.)
Displacement (8.1 L Engine) 8.1L (496 cu. in.)
Firing Order 1-5-3-6-2-4
Air Cleaner Dry-type with safety element
Thermostats (two) 82 C (180 F)
Electrical System
Type 12 volt, negative ground with 200 amp
alternator
Transmission
Speeds Three Speeds
Brakes
Type Hydraulic Shoe
Feed Accelerator
Number of Wings 10
Separator Elements
Threshing Elements Corn/Small Grain 15
Tines 18
Concave
Number of Concaves 3
Number of Bars Per Concave Grain—Front 20, Mid/rear 20; Corn 25
Separating
Number of Grates 3
Continued on next page OUO6083,0000DA1 –19–18JUL06–1/2

Specifications
10-10-6
083006
PN=26
10
10
6
Discharge Beater
Number of Wings 5
Grain Tank
Capacity 7750 L (220 bu.)
Capacity (Optional) 8850 L (250 bu.)
Average Unloading rate 4650 L/min (132 bu/min)
Maximum Unloading rate 5285 L/min (150 bu/min)
Weight
Corn Combine — less header 13,053 kg (28,777 lbs)
Turning Radius
Rear Wheel Tread Width 3.3 m (10 ft. 10 in.)
Turning radius 7.4 m (24 ft. 3 in.)
Capacities
Fuel Tank 757 L (200 gal)
Cooling System w/heater (6.8 L Engine) 44 L (47 U.S. qts)
Cooling System w/heater (8.1 L Engine) 53.3 L (56 U.S. qts)
Engine Crankcase w/filter (6.8 L Engine) 32 L (34 U.S. qts)
Engine Crankcase w/filter (8.1 L Engine) 29.5 L (31 U.S. qts)
Transmission 9.6 L (10 U.S. qts)
Final Drives 8 L (8.5 U.S. qts)
Heavy Duty Feeder House Reverser Gear
Case w/o cooler
2.3 L (4.75 U.S. pts)
Heavy Duty Feeder House Reverser Gear
Case w/ cooler
3.5 L (7.4 U.S. pts)
Countershaft Drive Gear Case 1.2 L (2.5 U.S. pts)
Loading Auger Gear Case 3.8 L (4 U.S. qts)
Two Speed Separator Drive Gear Case 2.4 L (2.5 U.S. qts)
Engine Gear Case w/transfer 21.3 L (22.5 U.S. qts)
Hydraulic/Hydrostatic Reservoir 35 L (37 U.S. qts)
OUO6083,0000DA1 –19–18JUL06–2/2
Discharge Grate
Number of Grates 3

Specifications
10-10-7
083006
PN=27
10
Dimensions—9560 STS Combine 10
7
NOTE: Dimension specifications subject to change
without notice.
Dimensions 9560 STS
800/70R38 R1 Front Tires and 600/65R28 R1 Rear Tires
A 8.36 m (27 ft. 4 in.) w/ 4.80 m (15 ft. 7 in.) Unload Auger
9.31 m (30 ft. 5 in.) w/ 5.64 m (18 ft. 5 in.) Unload Auger
B 8.36 m (27 ft. 4 in.)
C 4.46 m (14 ft. 6 in.)
D 4.02 m (13 ft. 2 in.) w/ 7750 L (220 bu.) Extensions
4.16 m (13 ft. 6 in.) w/ 8850 L (250 bu.) Extensions
E 3.88 m (12 ft. 7 in.)
F 0.57 m (1 ft. 9 in.)
G 3.53 m (11 ft. 6 in.)
H 5.30 m (17 ft. 4 in.) w/ 4.80 m (15 ft. 7 in.) Unload Auger
7.05 m (23 ft. 1 in.) w/ 6.55 m (21 ft. 5 in.) Unloading Auger
I 4.56 m (15 ft. 0 in.) w/ 4.80 m (15 ft. 7 in.) Unload Auger
J 3.97 m (13 ft. 0 in.) w/ 4.80 m (15 ft. 7 in.) Unload Auger
Ka 3.98 m (13 ft. 1 in.) w/ 4.80 m (15 ft. 7 in.) Unload Auger
L Refer to Ground Drive and Rear Axle Section b
M Refer to Ground Drive and Rear Axle Section c
• For 18.4R38*** R1 Duals and 480/80R38 (149A8) R1,
subtract 141 mm (5.6 in.)
• For 20.8R38** R1 Duals and 520/85R38 (155A8) R1,
subtract 103 mm (4.1 in.)
• For 30.5L-32 14PR R1, subtract 111 mm (4.4 in.)
• For 30.5L-32 14PR R2, subtract 82 mm (3.2 in.)
• For 30.5LR32*** R1, subtract 118 mm (4.7 in.)
• For 800/65R32 (172A8) R1W, subtract 93 mm (3.7 in.)
a
Dimension is measured 1.22 m from grain spill point. This represents the unloading auger when centered over the grain cart.
b
See Front Tire Selection, Header Compatibility, Final Drives, Row Spacing Charts in Ground Drive and Rear Axle Section for specific
dimensions.
c
See Rear Tire Selection, Tire Spacing, and Front to Rear Tire Compatibility Charts in Ground Drive and Rear Axle Section for specific
dimensions.
OUO6083,0000DA2 –19–18JUL06–1/1

Specifications
10
10 Dimension Reference Points—9560 STS Combine
8
OUO6083,0000D9F –19–18JUL06–1/1
083006
PN=28
H85640
–UN–05APR06

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