John Deere 9400/9500/9600 Combine Manual Set, 1988–1997 (P/N TM1401)

The repair and diagnostic volumes work together, with the SideHill manual supplying procedures unique to that configuration. The supplement was issued for the 1994 base-manual revisions; this download includes it alongside the later editions listed above.

Engine and attachment scope: Complete internal engine repair requires separate component manuals: CTM4 for the 6359, CTM8 for the 6068, and CTM6 for the 6076 through engine serial 499999 or CTM42 beginning at 500000. Complete cam-lobe four-wheel-drive motor repair requires CTM19; cutting platforms, corn heads, and row-crop heads are covered in TM1581. These component and header manuals are not included.

PDF Search, Section Bookmarks, and Page Totals

Search and diagram detail: All four PDFs have bookmarks for their main sections. Text search is restricted by character encoding in the repair, diagnostic, and SideHill volumes; the supplement’s body pages are not searchable. Small wiring labels require zooming, and some fine labels in the supplement are faint.

The ZIP contains 4 printable English PDFs totaling 3,886 pages, including 26 pages of covers, introductory material, contents, and blank front matter. Internal blank pages and indexes are also included in the total.

Combine Drivetrain, Crop Handling, and Leveling Systems

These selected contents outline the main workshop areas rather than the complete contents of the publications; further topics include air-suspension seat repair and gull-wing door service.

• Engine and powertrain repair: Engine removal, cooling-system service, transmission and differential overhaul, final-drive work, and hydrostatic pump and motor repair.

• Hydraulics, steering, and brakes: Reservoir, pump, valve, cylinder, motor, and accumulator service, steering and brake repairs, and hydraulic and parking-brake diagnosis.

• Feeder house and separator: Conveyor and reverser repair, CONTOUR MASTER tilt components, cylinder drives, straw walkers, and cleaning-fan and shoe assemblies.

• Grain handling: Clean-grain elevator and cross-auger service, grain-tank repairs, and unloading-auger and drive-gearcase procedures.

• Electrical diagnosis: System-specific fault routines, wiring diagrams, circuit-code listings, connector end views, header controls, engine controls, and HVAC troubleshooting.

• SideHill leveling: Automatic leveling controls, electrical and hydraulic fault isolation, operational checks, and leveling-valve and cylinder service.

These manuals are written for experienced technicians, with essential service tools identified for the work described.

Engine Variants and Powertrain Repair Depth

Engine applications: The 9400 repair specifications identify the 6359A and 6068H; the diagnostic specifications identify the 6359T through machine serial 639999 and the 6068H beginning at 640000. The 9500 material distinguishes 6076T and 6076H applications, while the repair references for the 9600 and SideHill 9500 identify the 6076H.

The engine section covers removal and installation and cooling-system work; its lower-engine group covers the oil-pan access sheet. Fuel-delivery and air-intake components have separate repair groups.

Transmission and hydrostatic work: Step-by-step procedures cover internal disassembly and reassembly, differential and shift-component service, and ring-and-pinion and planetary final drives. Hydrostatic coverage extends to control-valve service, flushing, and final checks.

Final-drive cautions address plastic-shim placement against cast surfaces and the aluminum quill’s vulnerability to overtightening; hydrostatic-motor instructions warn against damage to the valve block, end cover, and finished sealing surfaces.

Feeder-House, Separator, and Unloading Repairs

Feeder-house procedures cover the front drum, upper shaft and slip clutch, variable-speed drives, reverser gearcase, and platform driveshafts. Conveyor-shaft procedures separate round and hex top-shaft versions at model-specific serial breaks. CONTOUR MASTER repair extends to the tilt cylinder and frame.

Separator work includes straw-walker crankshafts, chopper and spreader systems, shoe supply augers, chaffer and sieve frames, and the tailings system. Primary countershaft gearcase and header electromagnetic clutch repairs are also covered.

Electrical Variants and Hydraulic Fault Isolation

The diagnostic volume organizes each system around component identification, operation, schematics, and troubleshooting. Bosch, John Deere, and Nippondenso 6076 engine-control sections and Stanadyne 6359/6068 identification pages distinguish the test paths, helping the technician select the correct schematic and routine.

Header and cab systems: Dial-A-Matic Types A, B, and C, multiple tachometer and fan-speed types, relay panels, and power-distribution boards are separated where hardware or diagnosis differs. HVAC material distinguishes R-12 Type A and R-134a Type B systems.

Reference material includes Connector Number Listing and End Views and CONTOUR MASTER header-tilt diagnostic charts. Hydraulic references include Hydrostatic Drive System Theory of Operation and Separator Drive System diagrams.

Coverage also includes corner-post gauges, warning displays, four-wheel drive, hydrostatic propulsion, brakes, steering, main engine gearcase, unloading-auger controls, and reel functions. Combine Data Center procedures include bushel-counter calibration against a weighed quantity of grain.

SideHill-Specific Service

The SideHill volume adds control-box and dashpot work, limit-switch adjustment, leveling valves and cylinders, and model-specific transmission and final-drive removal. Brake-drum, header-driveshaft, and feeder-house repairs are included; shared engine, separator, and grain-handling procedures remain in the base manuals.

Section 350 combines electrical and hydraulic diagnostics, operational checks, and theory for the electrohydraulic leveling system. Its cautions explain that incorrect limit-switch adjustment can damage the hydraulics and that leveling cables must not be reset before the cylinders are rephased.

Supplement Procedures and Control Systems

The supplement includes hydraulic solenoid-control valve-stack disassembly, hydrostatic lever and armrest-switch work, and CONTOUR MASTER feeder-house procedures. Other groups address the cleaning shoe, upper clean-grain elevator, Bosch Type C engine controls, and Dial-A-Matic diagnostics. Bosch Type C material includes stored-fault recall and clearing and use of the JT05829 Electronic Governor Tester.

Factory References and Safe Handling

Repair and diagnostic groups provide torque tables, pressure-test data, capacities, wear limits, adjustment information, and electrical test values. Listed specialty tools include the JDG-23 engine lifting sling, JDG-699 brake setting gauge, and JDG351 hydrostatic seal remover.

Before removing components, follow the publication’s procedures for supporting the machine and heavy assemblies, locking a raised feeder house with the safety stop, relieving hydraulic pressure, isolating electrical power, and controlling separator and drive parts that can rotate or coast.

Preview of Final-Drive Bearing Settings

For the ring-and-pinion final drive, the pinion-shaft setting ranges from 0.1 mm (0.004 in.) preload to 0.05 mm (0.002 in.) end play. The planetary final-drive procedures specify pinion-shaft end play of 0.02–0.2 mm (0.0008–0.008 in.).

These are separate assembly specifications, presented with bearing and shim setup procedures for the corresponding final-drive design.