Massey Ferguson Models MF9690 MF9790 Combine Repair Manual

Contents Massey Ferguson 9690 / 9790 Combine WORKSHOP SERVICE MANUAL 01 - General Information Contents SAFETY Safety Alert Symbol ....................................................................................................................................... 01-1 Signal Words ................................................................................................................................................. 01-1 Safety Signs ................................................................................................................................................... 01-8 Transport Latches And Shield Latches ........................................................................................................ 01-24 Header Lift Cylinder Stop ............................................................................................................................. 01-25 Rear Hook .................................................................................................................................................... 01-25 Travel On Public Roads ............................................................................................................................... 01-26 GENERAL INFORMATION How A Combine Works ................................................................................................................................ 01-29 Cutting and Feeding .............................................................................................................................. 01-29 Threshing and Separating ..................................................................................................................... 01-30 Cleaning ................................................................................................................................................ 01-30 Combine Identification ................................................................................................................................. 01-31 Machine Serial Number ......................................................................................................................... 01-31 Engine Serial Number ........................................................................................................................... 01-32 Fuel Injection Pump Dataplate .............................................................................................................. 01-33 ECM Dataplate ...................................................................................................................................... 01-33 Transmission Serial Number ................................................................................................................. 01-34 Final Drive Serial Number ..................................................................................................................... 01-35 Headers ....................................................................................................................................................... 01-35 Lubrication and Maintenance ....................................................................................................................... 01-36 Lubricants .................................................................................................................................................... 01-36 Service Procedures ..................................................................................................................................... 01-36 Service Periods ............................................................................................................................................ 01-36 Lubrication and Maintenance ....................................................................................................................... 01-37 Lubrication Details ....................................................................................................................................... 01-43 Front of Combine ................................................................................................................................... 01-45 Left-hand Side ....................................................................................................................................... 01-48 Right-hand Side ..................................................................................................................................... 01-50 Rear Axle ............................................................................................................................................... 01-53 Engine .......................................................................................................................................................... 01-54 Type of Engine Oil ................................................................................................................................. 01-54 Viscosity ................................................................................................................................................ 01-54 Recommended Oil Change Period ........................................................................................................ 01-54 Oil Additives .......................................................................................................................................... 01-54 Checking Oil Level ................................................................................................................................ 01-55 Changing Engine Oil and Filter ............................................................................................................. 01-55 Centrifugal Oil Filter ............................................................................................................................... 01-56 Rotor Gearbox ............................................................................................................................................. 01-57 Transmission ............................................................................................................................................... 01-58 Checking and Changing Lubricant ........................................................................................................ 01-58 Brakes .......................................................................................................................................................... 01-59

Contents Master Cylinder Oil Reservoir ............................................................................................................... 01-59 Final Drive .................................................................................................................................................... 01-59 Without Risers ....................................................................................................................................... 01-59 With Risers ............................................................................................................................................ 01-59 Tires and Wheels ......................................................................................................................................... 01-60 Tire Pressure ......................................................................................................................................... 01-60 Removing Wheel from Combine and Removing Tire. ........................................................................... 01-60 Tire Mounting ........................................................................................................................................ 01-61 Wheel Installation .................................................................................................................................. 01-62 Wheel Bolt Torque ................................................................................................................................. 01-62 Maintenance of Tires ............................................................................................................................. 01-63 Drive Belts ................................................................................................................................................... 01-64 Banded Drive Belt ................................................................................................................................. 01-64 Maintenance of Belts ............................................................................................................................. 01-65 Belt Changing Guides ........................................................................................................................... 01-66 Belt Sheave Alignment .......................................................................................................................... 01-68 Belt Run In Procedure ........................................................................................................................... 01-68 Belt Troubleshooting ............................................................................................................................. 01-69 Belt Problem and Wear Guide ............................................................................................................... 01-69 Roller Chains ............................................................................................................................................... 01-83 Inspection of Drive Chains and Sprockets ............................................................................................ 01-83 Drive Chain Adjustment and Tightening ................................................................................................ 01-84 Drive Chain Sprocket and Idler Alignment ............................................................................................ 01-85 Drive Chain Elongation and Sprocket Wear .......................................................................................... 01-86 Normal Tooth Wear ............................................................................................................................... 01-87 Not Normal Tooth Wear ........................................................................................................................ 01-87 Worn Chain on New Sprockets ............................................................................................................. 01-87 Drive Chain Service Tips ....................................................................................................................... 01-88 Chain Replacement ............................................................................................................................... 01-89 Cleaning and Lubricating Chains .......................................................................................................... 01-90 Drive Chain Lubrication ......................................................................................................................... 01-91 Drive Chain Lubricants .......................................................................................................................... 01-91 Good Drive Chain Lubrication ............................................................................................................... 01-92 Roller Chain Drive Troubleshooting Guide ............................................................................................ 01-93 Speed Of Components ................................................................................................................................ 01-96 Drives Speeds And Specifications ............................................................................................................... 01-98 Engine Compartment ................................................................................................................................. 01-100 Engine Fuel System ................................................................................................................................... 01-102 Fueling the Combine ........................................................................................................................... 01-102 Important Storage and Handling Precautions ..................................................................................... 01-102 Fuel Conditioners ................................................................................................................................ 01-102 Fuel Specifications .............................................................................................................................. 01-103 Fuel Vent Breather .............................................................................................................................. 01-103 Fuel Filter / Water Separator ............................................................................................................... 01-104 Bleeding the Fuel System ................................................................................................................... 01-107 Engine Cooling System ............................................................................................................................. 01-108 Coolant Type ....................................................................................................................................... 01-108 Coolant Change Period ....................................................................................................................... 01-108 Engine Cooling System Coolant .......................................................................................................... 01-108 Coolant System Monitoring ................................................................................................................. 01-108 Monitor Warnings ................................................................................................................................ 01-108 Checking Coolant Level ...................................................................................................................... 01-109 Radiator ............................................................................................................................................... 01-109 Thermostat .......................................................................................................................................... 01-110 Draining System .................................................................................................................................. 01-110 Filling System ...................................................................................................................................... 01-110 Engine Air Cleaner ..................................................................................................................................... 01-111 Outer Filter Element ............................................................................................................................ 01-111 Cleaning Outer Element ...................................................................................................................... 01-111 Inner Filter Element ............................................................................................................................. 01-112 Hydraulics .................................................................................................................................................. 01-113 Checking Oil Level .............................................................................................................................. 01-113 Changing Hydraulic Oil ........................................................................................................................ 01-113

Contents Hydrostatic Drives - 9690 .......................................................................................................................... 01-115 General Information ............................................................................................................................. 01-115 Hydrostatic Drives - 9790 .......................................................................................................................... 01-116 General Information ............................................................................................................................. 01-116 Hydrostatic Drives ...................................................................................................................................... 01-117 Hydrostatic Oil Filter ............................................................................................................................ 01-117 Hydrostatic Oil Cooler ......................................................................................................................... 01-117 Rotor Speed Control ............................................................................................................................ 01-117 Air Conditioning System ............................................................................................................................ 01-118 Condenser ........................................................................................................................................... 01-118 Cab Air Filters ............................................................................................................................................ 01-119 Cab Filter - Primary ............................................................................................................................. 01-119 Cab Filter - Secondary ........................................................................................................................ 01-119 Recirculation Filter ............................................................................................................................... 01-119 Air Filter Cleaning Procedure .............................................................................................................. 01-120 Storage Preparation ................................................................................................................................... 01-121 Combine .............................................................................................................................................. 01-121 Engine ................................................................................................................................................. 01-121 Preparation For Use After Storage ............................................................................................................ 01-121 Combine .............................................................................................................................................. 01-121 Engine ................................................................................................................................................. 01-121 Torque Charts ............................................................................................................................................ 01-122 Standard Torque Specifications .......................................................................................................... 01-122 Metric Capscrew Markings and Torque Values ................................................................................... 01-123 Metric Conversions .................................................................................................................................... 01-124 Fractions, Decimals, and Millimeters Conversion Chart ............................................................................ 01-125 Decimal Equivalents of 8ths, 16ths, 32nds, and 64ths .............................................................................. 01-128 Decimal Equivalents Of Letter Size Drills .................................................................................................. 01-129 Decimal Equivalents of Number Size Drills ............................................................................................... 01-130 Tap Drill Sizes - S.A.E. & Metric ................................................................................................................ 01-131 American Standard Pipe Thread and Tap Drill Sizes ................................................................................ 01-134 Electrical Formulas .................................................................................................................................... 01-135 Amperes (Current Flow) ...................................................................................................................... 01-135 Volts (Electromotive Force) ................................................................................................................. 01-135 Ohms (Resistance) .............................................................................................................................. 01-135 Watts ................................................................................................................................................... 01-135 Horsepower ......................................................................................................................................... 01-135 Belt Speed Calculation Formulas .............................................................................................................. 01-135 Geometrical Formulas ............................................................................................................................... 01-136 Circumference of a Circle .................................................................................................................... 01-136 Area of a Circle .................................................................................................................................... 01-136 Volume of a Cylinder ........................................................................................................................... 01-136 Volume of a Sphere ............................................................................................................................. 01-136 Area of a Triangle ................................................................................................................................ 01-136 Metric to Imperial and Imperial to Metric Conversion Factors ................................................................... 01-137 Measures of Temperature ................................................................................................................... 01-137 Measures of Power ............................................................................................................................. 01-137 Measures of Pressure ......................................................................................................................... 01-137 Measures of Length ............................................................................................................................. 01-138 Measures of Area ................................................................................................................................ 01-139 Measures of Volume (Dry) .................................................................................................................. 01-140 Measures of Volume (Liquid) .............................................................................................................. 01-141 Measures of Mass (Weight) ................................................................................................................ 01-142 Measures of Effort (Torque) ................................................................................................................ 01-143 Reference Tables ................................................................................................................................ 01-144 INDEX ........................................................................................................................................................... 01-145

Contents NOTES

Safety SAFETY SAFETY ALERT SYMBOL FIG. 1: This is the safety alert symbol. This symbol stands for ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Look for this symbol, both in this manual and on safety decals on the combine. This symbol will direct you to information that includes your personal safety and the personal safety of others. SIGNAL WORDS FIG. 2: The words DANGER, WARNING, or CAUTION are used with the safety alert symbol. Learn to know these safety alert symbols, and follow the given recommendations, precautions, and safe procedures. m DANGER: Indicates an immediate hazardous situation that, if not avoided, will result in DEATH OR VERY SERIOUS INJURY. m WARNING: Indicates a potentially hazardous situation that, if not avoided, can result in DEATH OR SERIOUS INJURY. m CAUTION: Indicates a potentially hazardous situation that, if not avoided, can result in a MINOR INJURY. Replace any DANGER, WARNING, CAUTION, or instruction decal that can not be read or is missing. The location and part number of these decals is shown later in this section of the manual. IMPORTANT: The word IMPORTANT is used to show special instructions or procedures which, if not followed can result in damage to, or destruction of the machine, process, or the surroundings. NOTE: The word NOTE is used to indicate points of special interest for more efficient and easier repair or operation. FIG. 1 Saf FIG. 2 Wc1957

Safety FIG. 3: Read and understand this manual and the manual for all attachments before operating the combine. Learn how to operate the combine and how to use the controls properly. Do not operate the combine without instruction and training. For your personal safety and the personal safety of others, follow all safety precautions and instructions found in the manual and on decals fastened to the combine and the attachments. Personal injury or death can result if these precautions are not followed. FIG. 4: Be prepared for an emergency. Always carry one or more suitable fire extinguishers - ABC rating, dry chemical, 2.2 kg (5 lb). Check fire extinguishers regularly to make sure extinguishers are properly charged and in operating condition. Mounting a fire extinguisher near the cab and a fire extinguisher near the engine compartment is a recommendation. To reduce the risk of fire, frequently remove crop material from the combine and engine platform and check for components becoming too hot. Keep a first aid kit close for treatment of minor cuts and scratches. FIG. 5: Wear close fitting clothing and personal protection equipment correct for operating or doing lubrication and maintenance on the combine. Tie up long hair to prevent the hair from becoming entangled in the moving parts. m WARNING: An operator must not use alcohol or drugs which can affect alertness or coordination. An operator taking prescription or over the counter drugs needs medical advice on whether or not the operator can properly operate machines. FIG. 3 S-1123 FIG. 4 S-1131 FIG. 5 S-1127A

Safety FIG. 6: Face the ladder and use the handrails when getting on or off the combine. FIG. 7: Never operate the engine in a closed building unless exhaust is vented outside. FIG. 8: Make sure that all shields, guards, and access doors are in location and properly closed before starting the engine. Start the engine from the operator seat only. Be sure that the transmission is in neutral and the header, separator, and unloader clutches are disengaged. Be sure that every person is clear of the combine before starting the engine. FIG. 9: Always wear the seat belt when the combine is moving. If another person is riding in the instructor seat that person must wear the seat belt. Seat belts must be worn fitted snugly around the hips and not twisted. FIG. 6 Wc1940 FIG. 7 Wc1949 FIG. 8 Wc1955 FIG. 9 Wc1953a

Safety FIG. 10: Never permit any person to be on any part of the combine or the attachments except in the operator seat or the instructor seat when the engine is running. Do not get on or off the combine while the combine is moving. FIG. 11: Prevent contact with electrical power lines. Always put the grain tank unloader tube in the transport position and lower radio antenna before moving the combine near electrical wires. Contact with electrical power lines can cause electrical shock, very serious injury, or death. FIG. 12: Use extra caution and reduce speed when operating on hill sides, near ditches or embankments especially with a full grain tank to prevent an over turn of the combine. Travel speed must be such that the machine has complete control and stability at all times. Shift to a lower gear before going down a steep hill. FIG. 13: Always turn off the engine, shift the transmission to neutral, set parking brake, and remove the start key before leaving the operator seat or before permitting a person to inspect, clean, lubricate, adjust, or repair any part of the combine or the attachments. Unless specifically given instruction different in this manual. Never leave the operator seat as long as the engine is operating. FIG. 10 Wc1945 FIG. 11 Wc1937 FIG. 12 Wc1937a FIG. 13 Wc1958

Safety FIG. 14: Never work under the header or feeder house, unless the stop is properly engaged on the header lift cylinder, the engine is stopped, the parking brake is set, and the start key is removed from the start switch. FIG. 15: Fluid under high pressure can be almost invisible but can go into the skin causing serious injury. See a doctor immediately if you sustain an injury from escaping fluids. Fluid injected into the skin must be surgically removed within a few hours or gangrene can result. FIG. 16: Use a piece of cardboard or wood to search for possible leaks. Never use your hands. Relieve pressure from the hydraulic and fuel injection systems by lowering raised equipment, shutting off accumulator valve, and turning off the engine before loosening any part of the systems. Tighten all connections securely before applying pressure. FIG. 17: The surfaces in and around the engine compartment will be hot if the engine has been running, even for a short time. Always permit parts that contain hot fluid to cool before handling or disconnecting. FIG. 14 Wc1954 FIG. 15 Wc1938 FIG. 16 D-5842a FIG. 17 Wc1947

Safety FIG. 18: Do not remove radiator cap if engine is hot. Only remove the cap when the cap is cool enough to touch with bare hands. Loosen cap slowly to first notch to relieve pressure, then remove cap. FIG. 19: Remove any spilled oil, antifreeze, or fuel immediately from operator ladder and platform and other access areas. Keep all access areas clean and free of obstructions. FIG. 20: Never permit any flame cutting, welding, or arc welding to be done on or near the sound proofing upholstery used in the cab. This material is flame resistant to normal exposure to cigarettes or other smoking material. But will ignite and sustain combustion when exposed to the heat of gas or electrical welding. The build up of chaff and crop debris in the engine compartment, on the engine, and near moving parts is a fire hazard. Check and clean these areas frequently. FIG. 21: Always stop the combine engine before fueling. Do not smoke while fueling. FIG. 18 Wc1951 FIG. 19 Wc1939 FIG. 20 Wc1946 FIG. 21 Wc1959