JOHN DEERE S-SERIES COMBINE 5000 SERIES TRACK …...2 a0585b 0-stop, lh jd s combine vehicle inline gearbox 1 3 a0586b 0-stop, rh jd s combine vehicle inline gearbox 1 4 a0584 pin,

INSTALLATION MANUAL

JOHN DEERE

S-SERIES COMBINE

5000 SERIES TRACK MODULES IN-LINE GEARBOX

INSTALLATION MANUAL

JD S-SERIES COMBINE IN-LINE GEARBOX INSTALLATION MANUAL

Rev 0 10-8-2015

INSTALLATION MANUAL

JD S-SERIES COMBINE IN-LINE GEARBOX INSTALLATION MANUAL i

TABLE OF CONTENTS Section Page

1 Definitions & Abbreviations ........................................................................................... 1-1

2 Recommended Tools and Equipment ........................................................................... 2-1

3 Parts List ....................................................................................................................... 3-1

4 Track Module Lifting Instructions .................................................................................. 4-1

5 Oscillation Stop Installation ........................................................................................... 5-1

6 In-Line Gearbox Installation .......................................................................................... 6-1

7 Determining the Left-hand and Right-hand Track Module ............................................ 7-1

8 Module Oscillation Stops .............................................................................................. 8-1

9 Module Installation ........................................................................................................ 9-1

10 Combine Software Adjustments .................................................................................. 10-1

11 Break-in and Belt Care/Conditioning ........................................................................... 11-1

12 Specifications .............................................................................................................. 12-0

13 Index of Figures, Sketches, and Tables ...................................................................... 13-1

INSTALLATION MANUAL

JD S-SERIES COMBINE IN-LINE GEARBOX INSTALLATION MANUAL 1-1

1 Definitions & Abbreviations

HHCS - Hex Head Cap Screw

O-Stops -Oscillation Stops used to prevent the Track Module from rolling too far forward or backward during operation. These are mounted to the vehicle and Track Module frame.

- Indicates possible hazardous situation that, if not avoided, may cause minor or moderate personal injury. This may also be used to indicate possible equipment damage, if not avoided.

- Indicates possible hazardous situation that, if not avoided, may cause death or serious personal injury.

- Indicates a prohibitive situation, DO NOT PERFORM

INSTALLATION MANUAL


2 Recommended Tools and Equipment

2.1 Standard Tool List

36 mm Socket ¾” Drive

30 mm Socket ¾” Drive

30 mm Combination Wrench

15” Extension ¾” Drive

17 mm Socket ½” Drive

12” Extension ½” Drive

½” Drive Ratchet

½” Drive Impact Wrench

½” to ¾” Drive Adapter

¾” Drive Ratchet

600 ft. lb. Torque Wrench ¾” Drive

100 ft. lb. Torque Wrench ½” Drive

Flat Head Screw Driver

Hammer

Small Punch

Paint Marker

2.2 Material Handling Equipment

Service Truck with Jib Hoist or Rigging for Forklift to remove Final Drives

8000 lb. Capacity Fork Lift

Air Jack

Safety Stands

INSTALLATION MANUAL


3 Parts List

INSTALLATION MANUAL


Item ATI P/N Description Qty

1 A0583 IN-LINE GEARBOX 2

2 A0585B 0-STOP, LH JD S COMBINE VEHICLE INLINE GEARBOX 1

3 A0586B 0-STOP, RH JD S COMBINE VEHICLE INLINE GEARBOX 1

4 A0584 PIN, 3 STEP DOWEL 4

5 A0624B TOW GUIDE, JD COMBINE 2

6 A0587B O-STOP, BOLT-ON COMBINE MODULE 4

7 A0239 WASHER, M20, HARDENED,GRADE 10.9, PLATED, FLAT 64

8 A0338 NUT, M20, GR 10.9, HEX, PLATED 32

9 A0267 BOLT, M24-3 X 100mm, GRADE 10.9, PLATED, HEX HEAD 8

10 A0270 BOLT, M24-3 X 120 mm, GRADE 10.9, PLATED, HEX HEAD 8

11 A0268 WASHER, M24 STRUCTURAL GRADE 10.9, PLATED 16

12 A0269 JD COMBINE SPACER FOR M24 HARDWARE, PLATED 4

13 A0299 BOLT, M20-2.5 x 120 mm, GR 10.9, PLATED, HEX HEAD 32

14 A0603 PIN, 16MM X 50MM LONG, HARDENED DOWEL 4

15 A0674 BOLT, M10-1.5 X 50MM, SHCS, GRADE 12.9 PLATED 30

16 A0605 WASHER, M10 STRUCTURAL FOR GRADE 10.9 HARDWARE PLATED 30

17 A0607 VENT, WEATHER RESISTANT BREATHER (140 MICRON) ZINC PLATED, 1/2 NPT 2

18 A0606 PLUG, 1/2 NPT HEX HEAD, ZINC PLATED 4

19 A0117 PLUG, SAE-8 O-RING FLUSH MALE 4

20 JD AXLE EXTENSION 300MM 2

21 JD FINAL DRIVE 2

22 JD WHEEL BOLTS AND WASHERS 20

Notice: The combine must be equipped with 300 mm Axle Extensions. If it is not, these parts must be sourced

and changed during the installation process.

INSTALLATION MANUAL


4 Track Module Lifting Instructions

DO NOT USE FORKS WITH SHARP EDGES OR CORNERS. GRIND ANY SHARP EDGES SMOOTH BEFORE ATTEMPTING TO LIFT TRACK MODULES.

BE CAREFUL NOT TO DAMAGE THE BELT DRIVE LUGS, BOGIES, OR IDLERS WITH THE FORKS.

4.1 Bring the forklift to the side of the Track Module with the forks aligned with the space between the bogie and idler wheels. (See Figure 4-1) The forks should be on the bottom side of the wheels but high enough to clear the drive lugs of the belt.

Figure 4-1 Lifting Points

4.2 A spotter should watch as the forklift drives forward into the Track Module. Allow the forks to enter the space between the belt and wheels. (See Figure 4-1) Be careful not to damage the drive lugs with the forks. Be sure forklift tips are even with the far edge of the belt. Tilt the forks back towards the mast of the forklift and raise Track Module off the trailer. Unload the Track Module and position in the installation area so a forklift can access both sides.

INSTALLATION MANUAL


5 Oscillation Stop Installation

5.1 Raise and support the combine per manufacturer’s specifications.

5.2 Remove wheel assembly.

Figure 5-1Final Drive Preparation.

5.3 Disconnect and remove final drive input shaft.

Figure 5-2 Final Drive Input Shaft.

5.4 Remove the final drive from the combine. The bolt spacers will be re-used later in the installation.

Figure 5-3 Front Bolt Removal.

INSTALLATION MANUAL


5.5 The combine must have 300mm axle extensions. If it is not equipped with 300mm extensions, they need to be installed at this point.

5.6 Clean the machined surfaces of the axle extension flange, O-stop plates, and final drive mounting faces. These surfaces are to be free of oil, grease, or rust preventative. Use an angle grinder with a wire wheel, and isopropyl alcohol, acetone or lacquer thinner.

YOU CAN BE SERIOUSLY INJURED IF YOU ARE EXPOSED OR COME IN CONTACT WITH THESE CHEMICALS. WEAR

PROTECTIVE CLOTHING.

DO NOT INSTALL THE FINAL DRIVE ONTO THE AXLE EXTENSION.

Figure 5-4 300mm Axle Extension

5.7 The Three Step Dowel Pin, A0584, is to be used in place of the dowel pin furnished with the extension; see Figure 5-5 for orientation.

5.8 Identify the correct oscillation stop for the side of the combine. See Figure 5-6.

Figure 5-5 Three Step Dowel Pin A0584

Figure 5-6 Oscillation Stop Identification

INSTALLATION MANUAL


5.9 Clean the machined surfaces of the oscillation stop. These surfaces are to be free of oil, grease, or rust preventative.

5.10 Install the oscillation stop onto the axle extension with the gearbox mounting surface towards the front of the combine. Use the Three Step Dowel Pins, A0584 to position the oscillation stop onto the axle flange.

Figure 5-7 Install O-stop

5.11 Clean the mounting surfaces of the final drive. These surfaces are to be free of oil, grease, or rust preventative.

5.12 Install the final drive onto the machined surface on the outside of the oscillation stop.

5.13 Attach the final drive with four (4) Bolts, M24-3 x 100mm Gr 10.9 Plated Hex Head, four (4) M24 Structural Washers, and four (4) spacers A0269 in the top four (4) holes of the final drive, oscillation stop, and axle extension. Lubricate the threads of the bolts with motor oil.

Figure 5-8 Install Final Drive

5.14 Install the Tow Guide Bracket onto the back side of the Axle Extension flange. The large hole should be offset towards the rear of the combine. Use four spacers A0269 between the Tow Guide and the flange, and four (4) Bolts, M24-3 x 120 Gr. 10.9 Plated Hex Head with four (4) M24 Structural Washers. Lubricate the threads of the bolts with motor oil.

5.15 Tighten the eight (8) M24 bolts to 535 ft-lbs lubricated.

Figure 5-9 Install Tow Guide Bracket

INSTALLATION MANUAL


6 In-Line Gearbox Installation

PRIOR TO INSTALLAION ON COMBINE:

6.1 Fill gearbox with 80W-90 oil to centerline of bottom gear (1 liter).

6.2 Install breather vent into 1/2 NPT on the gearbox as indicated in Figure 6-1. Use Teflon tape on the threads.

6.3 Remove the rust preventative coating from the machined face of the gearbox and O-stop mounting face. These surfaces are to be free of oil, grease, or rust preventative. Use isopropyl alcohol, acetone or lacquer thinner.

Figure 6-1 In-Line Gearbox Preparation

YOU CAN BE SERIOUSLY INJURED IF YOU ARE EXPOSED OR COME IN CONTACT WITH THESE CHEMICALS. WEAR PROTECTIVE CLOTHING.

6.4 Install two (2) 16mm OD x 50mm long, hardened dowel pins into the gearbox.

6.5 Lubricate the final drive input spline with grease.

6.6 Align the dowel pins with the holes in the O-stop.

Figure 6-2 In-Line Gearbox Mounting Face

6.7 Align the gearbox spline with the final drive spline.

6.8 Install fifteen (15) M10-1.5 X 50mm Socket Head Cap Screws Gr. 12.9, Zinc Plated with M10 Washers through the gearbox flange into the threaded holes of the O-stop.

6.9 Tighten the bolts in a crossing pattern. Final torque to 40 ft.-lbs. dry.

6.10 With the gearbox in place the 300mm drive shaft extension is not needed. Lubricate the spline on gearbox with grease.

6.11 Install the drive shaft from the transmission onto the spline of the gearbox.

Figure 6-3 Install In-Line Gearbox

INSTALLATION MANUAL


7 Determining the Left-hand and Right-hand Track Module

7.1 The machined mounting surface of the Drive Wheel is on the inside of the Track Module and will be oriented towards the combine.

Figure 7-1 Inside View

Figure 7-2 Outside View

7.2 The High Idler Wheels are on the front of the Track Module, and will be oriented towards the front of the Combine.

Figure 7-3 Left Hand Track Module

Figure 7-4 Right Hand Track Module

INSTALLATION MANUAL


8 Module Oscillation Stops

8.1 Remove the sixteen (16) HHCS M24-3 X 60 GR 10.9 from the Track Module frame. Install the Module O-Stops (A0587B) onto the Track Modules as shown in Figure 8-1. Two O-stops are required per Track Module.

Figure 8-1 Install Module Oscillation Stops

8.2 Tighten the M24 Bolts to 400 ft. lbs. dry.

Figure 8-2 A0587B Module Oscillation Stop

INSTALLATION MANUAL


9 Module Installation

9.1 Clean final drive to wheel mounting flange of rust and/or oil and grease. Use an angle grinder with a wire wheel, and isopropyl alcohol, acetone or lacquer thinner.

9.2 Clean Adaptor Plate of oil, grease, or rust preventative. Use isopropyl alcohol, acetone or lacquer thinner.



Figure 9-1 Clean Mounting Surface.

9.3 Mount the Adaptor Plate (A0101) to the final drive wheel mounting flange, using the wheel mounting hardware. Either of the hardware combinations listed below are acceptable.

(10) HHCS M22-2.5 x 100 mm GR 10.9 Zinc Plated (R111437) with M22 Hardened Washers

Or

(10) HHCS M22-2.5 x 70 GR 10.9 Zinc Plated with M22 Hardened Washers.

9.4 Check that the heads of the bolts are below the mounting surface of the Adaptor Plate by placing a straight edge across the mounting surface.

9.5 Torque the M22 wheel mounting hardware to the Vehicle Manufacturer’s specification

Figure 9-2 Adaptor Plate Installation

INSTALLATION MANUAL


9.6 Remove all surface preservative from the contact surface of Drive Spindle to Adapter Plate and all bolt holes. Use isopropyl alcohol, acetone or lacquer thinner.



Figure 9-3 Clean Drive Spindle Surface.

9.7 Bring the forklift to the outside of the Track Module with the forks aligned with the space between the bogie and idler wheels. The forks should be on the bottom side of the wheels but high enough to clear the drive lugs of the belt.

BE CAREFUL NOT TO DAMAGE THE BELT DRIVE LUGS, BOGIES, OR IDLERS WITH THE FORKS.

9.8 A spotter should watch as the forklift drives forward into the Track Module. Allow the forks to enter the space between the belt and wheels. Be careful not to damage the drive lugs with the forks.

Figure 9-4 Lifting position for forklift

9.9 Raise the Track Module off the floor and align with the Adaptor Plate. The Track Module should be slightly tilted back, away from the combine.

9.10 Align the mounting holes on the Drive Wheel with the holes in the Adaptor Plate by rotating the Adaptor Plate. Note: the drive shaft must be removed.

9.11 Slowly bring the Track Module into contact with the Adapter Plate.

DO NOT GET BETWEEN THE TRACK MODULE AND THE COMBINE!

KEEP HANDS AND FEET CLEAR WHEN ALIGNING TRACK MODULE TO COMBINE!

Figure 9-5 Align Mounting Holes

INSTALLATION MANUAL


Figure 9-6 Track Module Mounting Hardware

9.12 Install sixteen (16) M20-2.5 x 120 GR 10.9 Bolts with sixteen (16) M20 Hardened Washers through the Adaptor Plate and Track Module Drive Wheel.

9.13 On the outside of the Track Module Drive Wheel, install as many M20-2.5 GR 10.9 Hex Nuts, and M20 Hardened Washers as the structure will permit; typically five (5) to six (6).

9.14 Using an impact wrench, tighten these fasteners to a maximum of 250 ft. lbs. Final torque will be performed later.

9.15 Reinstall the final drive input shaft.

9.16 Repeat steps 9.6 to 9.15 to mount the remaining Track Module.

9.17 Lower the combine onto the floor, remove the air jack and safety stands. Clear all tools, parts, and air lines from the path of equipment.

9.18 Start the combine and move forward enough to enable installation of the next group of five (5) to six (6) M20-2.5 GR 10.9 Hex Nuts, and M20 Hardened Washers.

9.19 Install five (5) to six (6) M20-2.5 GR 10.9 Hex Nuts, and M20 Hardened Washers on both Track Modules. Tighten using an impact wrench to a maximum of 250 ft. lbs. Final torque will be performed later.

9.20 Repeat Steps 9.18 and 9.19 until all nuts and washers are installed.

9.21 After all nuts are installed, torque to 400 ft. lbs. (542 Nm).

9.22 After each nut has been torqued to specification, mark the end of the bolt with the paint marker to indicate specified torque is complete.

INSTALLATION MANUAL


9.23 After installing and tightening the fasteners, examine the gap between the Adaptor Plate and the Track Module Drive Spindle. The Adaptor Plate must be centered on the Drive Spindle Face with a uniform gap.

9.24 If the Adaptor Plate is not centered, or the gap is not uniform, loosen the sixteen (16) M20-2.5 x 120 GR 10.9 Bolts and M20-2.5 GR 10.9 Hex Nuts. Reposition the Track Module and re-tighten the mounting hardware as in steps 9.14 -9.22.

9.25 Check to assure the Adaptor Plate is centered on the Drive Spindle Face with a uniform gap.

9.26 Touch-up paint as needed.

Figure 9-7 Check Alignment

INSTALLATION MANUAL


10 Combine Software Adjustments

10.1 In order to optimize performance some settings in the combine’s software need to be verified/adjusted.

Tire Size

10.2 The tire size needs to be changed in order for the speedometer to display the correct speed.

10.3 On the armrest controller select Menu on the touch screen display.

10.4 Select message center

10.5 Select addresses

10.6 Select cab.001

10.7 Scroll down to address 130

10.8 First 3 digits of the number displayed are the front tire size, and the last 3 digits are rear tire size.

10.9 Change front tire size to 900. (e.g. 9000752)

10.10 Menu > message center > addresses > cab.001 > 130 > 9620752

Hydro Pressure Setting

10.11 Select the additional screens menu on the home screen of the display.

10.12 Select the message center icon

10.13 Select PTP controller from the drop-down menu.

10.14 Scroll down to address 105 and ensure it is set to 0.

10.15 Menu > message center > addresses > PTP > 105 >0

INSTALLATION MANUAL


11 Break-in and Belt Care/Conditioning

Break-in Procedure

11.1 The following is the break-in procedure for the modular track system after installation of a new track system on a vehicle, or installation of a new belt on an existing track module. Prior to operating/running the equipment, talc must be applied to the drive lugs of the rubber track belt to aid in the proper belt conditioning.

11.2 The talc should be poured into the inside of the drive wheel from the inside of the track module,

11.3 Pour one cup of talc into the front of the drive wheel and one cup into the rear of the drive wheel.

11.4 Moving the equipment forward (or reverse) will spread the talc over the drive lug teeth.

11.5 Be sure all the guide/drive lugs have talc on all surfaces.

11.6 Always expose new or clean track to dry and dusty soil conditions as soon as possible.

11.7 Run vehicle for ten (10) hours after installation. Then, check the hydraulic pressure on the belt tension system and the torque on all wheel bolts and Track Module mounting bolts.

11.8 Repeat checking the pressures and torque values until stabilized.

Figure 11-1 Inside View Talc Pouring Locations

Figure 11-2 All lug surfaces must be covered in talc

VEHICLE MUST BE STATIONARY AND ENGINE OFF BEFORE POURING TALC INTO TRACK MODULES!

Roading

11.9 High speed roading increases tread wear rates up to 15 times the field wear rates and builds excessive heat which can reduce drive lug and traction lug life. Roading should be avoided prior to the completion of the break-in phase, particularly on asphalt roads. If road travel is necessary with new tracks, then reduce speed and use a dry lubricant such as talc.

11.10 Extended roading of a new track during the break-in period and especially prior to the initial field use is not recommended, and may lead to significant drive lug and traction lug scuffing due to heat. Break-in wear is non-warrantable.

INSTALLATION MANUAL


12 Specifications

TORQUE SPECIFICATIONS FOR HARDWARE

BOLT SIZE

BOLT TYPE BOLT

GRADE DRY

FT-LB (N-m) WET

FT-LB (N-m) LOCATION

QTY PER

MODULE

M10 Hex Head Bolt 10.9 40 (54) 30 (41) Wheel Hub Caps, In-Line Gearbox 55

M10 Button Head Bolt 8.8 15 (20) 11 (15) Drive Hub Cover 6

M10 Hex Head Bolt 8.8 15 (20) 11 (15) Remote Gauge Bracket 1

M12 Hex Head Bolt 8.8 75 (101) 56 (76) Drive Spindle Lock Nut (6) 6

M14 Hex Head Bolt 8.8 120 (162) 90 (122) Cylinder Pins (2) & Drive Wheel Attachment to Drive Spindle (4)

6

M20 Hex Head Bolt 10.9 400 (542) 300 (407) Wheel Bolts 100

M20 Hex Head Bolt 10.9 400 (542) 300 (407) Drive Wheel to Adapter (16) 16

M20 Hex Head Nut 10.9 400 (542) 300 (407) Pivot Pin Retaining Bolt 1

M24 Hex Head Bolt 10.9 400 (542) 300 (407) Module Stops & Drive Wheel

Scraper 20

M24 Hex Head Bolt 10.9 713 (967) 535 (725) Axle Extension to Final Drive 8

TORQUE SPECIFICATIONS FOR JIC 37° CONNECTORS

TORQUE TOLERANCE

SAE DASH SIZE THREAD SIZE FT-LB N-m FT-LB N-M FFFT

-6 9/16 -18 21 28 +/- 1 +/- 1 1 1/4

TORQUE SPECIFICATIONS FOR O-RING BOSS CONNECTORS

TORQUE TOLERANCE

SAE DASH SIZE THREAD SIZE FT-LB N-M FT-LB N-m

-6 9/16 -18 27 37 +/- 2 +/- 3

-8 3/4 -16 48 65 +/- 2 +/- 3

LUBRICATION CAPACITIES

AMBIENT TEMPERATURE RANGE

LUBRICATION SYSTEM

METHOD OF LUBRICATION

TYPE OF LUBRICATION

CAPACITY

20°F (7°C) to 100°F (38°C)

Hydraulic System Reservoir Hy-Gard Hydraulic/ Transmission Oil

0.5 gal (2L)

Drive Spindle Bearings Grease Packed Mobilith SHC 220 4 lbs. (2 Kg)

Each Wheel Hub Oil Bath SAE 15W-40 11 oz. (325mL))

In-Line Gearbox Oil Bath SAE 80W-90 1 qt (1 L)

PRESSURE SETTING FOR TENSIONING SYSTEM BEARING PRELOAD

SUB SYSTEM CHARGED WITH INITIAL

PRESSURE SETTING

PRESSURE SETTING

AFTER BREAK-IN

LOCATION PRELOAD

Accumulator Nitrogen 580 psi (4.00 MPa) 580 psi (4.00 MPa) Wheel Hub 1.5 Tangs

Hydraulic System

Hy-Gard Hydraulic/ Transmission Oil

850 psi (5.86 MPa) 750 psi (5.17 MPa)

Drive Spindle 15°

INSTALLATION MANUAL


13 Index of Figures, Sketches, and Tables

Figure 4-1 Lifting Points ..................................................................................................................................................... 4-1 Figure 5-1Final Drive Preparation. .................................................................................................................................... 5-1 Figure 5-2 Final Drive Input Shaft. .................................................................................................................................... 5-1 Figure 5-3 Front Bolt Removal. ......................................................................................................................................... 5-1 Figure 5-4 300mm Axle Extension .................................................................................................................................... 5-2 Figure 5-5 Three Step Dowel Pin A0584 ........................................................................................................................... 5-2 Figure 5-6 Oscillation Stop Identification .......................................................................................................................... 5-2 Figure 5-7 Install O-stop .................................................................................................................................................... 5-3 Figure 5-8 Install Final Drive .............................................................................................................................................. 5-3 Figure 5-9 Install Tow Guide Bracket ................................................................................................................................ 5-3 Figure 6-1 In-Line Gearbox Preparation ............................................................................................................................ 6-1 Figure 6-2 In-Line Gearbox Mounting Face ...................................................................................................................... 6-1 Figure 6-3 Install In-Line Gearbox ..................................................................................................................................... 6-1 Figure 7-1 Inside View ....................................................................................................................................................... 7-1 Figure 7-2 Outside View .................................................................................................................................................... 7-1 Figure 7-3 Left Hand Track Module ................................................................................................................................... 7-1 Figure 7-4 Right Hand Track Module ................................................................................................................................ 7-1 Figure 8-1 Install Module Oscillation Stops ...................................................................................................................... 8-1 Figure 8-2 A0587B Module Oscillation Stop .................................................................................................................... 8-1 Figure 9-1 Clean Mounting Surface. ................................................................................................................................. 9-1 Figure 9-2 Adaptor Plate Installation ................................................................................................................................. 9-1 Figure 9-3 Clean Drive Spindle Surface. ........................................................................................................................... 9-2 Figure 9-4 Lifting position for forklift .................................................................................................................................. 9-2 Figure 9-5 Align Mounting Holes ....................................................................................................................................... 9-2 Figure 9-6 Track Module Mounting Hardware ................................................................................................................... 9-3 Figure 9-7 Check Alignment .............................................................................................................................................. 9-4 Figure 10-1 Inside View Talc Pouring Locations ............................................................................................................. 11-1 Figure 10-2 All lug surfaces must be covered in talc....................................................................................................... 11-1

Documents

JOHN DEERE S-SERIES COMBINE 5000 SERIES TRACK …...2 a0585b 0-stop, lh jd s combine vehicle inline gearbox 1 3 a0586b 0-stop, rh jd s combine vehicle inline gearbox 1 4 a0584 pin,