1166, 1169H, 1174, 1177, e 1177 Hydro/4, 1188, 1188 Hydro/4 Combines John Deere Werke Zweibriicken TM-4452 Printad in Germany (English)SUMMARY OF MOST IMPORTANT SPECIFICATIONS 1166, 1169H, 1174, 1177, 1177 HYDRO/4, 1188, 1188 HYDRO/4 6468 Engine Valve clearance, intake valve Valve clearance, exhaust valve Compression ........ Max. difference in compression pressure between cylinders... ..ssesseeeeseee Opening pressure of a new injection nozzle Maximum difference in opening pressure Fastidle .... see eccseeeseeee Slow idle . 6359 Engine Valve clearance, intake valve - ae Valve clearance, exhaust valve veces Compression «0.02.6 .++5 reer? Max. difference in compression pressure between cylinders Minimum opening pressure of a used nozzle Maximum difference in opening pressure Fast idle SlOW idle... -- eee eeeeeeeeeeees Ar Intake System ‘Air cleanerrstcton nestor Hight wil glow at a vacuum of Minimum opening pressure of aused nozzle... Opening pressure of a new injection nozzle ....... SPECIFICATIONS 0.45 mm (0.018 in.) 0.70 mm (0.028 in.) 2450 to 2860 kPa (24.5 to 28.6 bar; ‘955 10 416 psi) 350 kPa (8.5 bar; 50 psi) 27900 kPa (279 bar; 4050 psi) 26200 kPa (262 bar; 3800 psi 350 kPa (8.5 bar; 50 psi) 22400 ++ 50 rpm 41200 +: 50 rpm 0.35 mm (0.014 in.) 0.45 mm (0.018 in.) 2100 kPa (21 bar; 300 psi) 350 kPa (3.5 bar; 50 psi) 25100 to 25800 kPa (251 to 258 bar; 3650 to 3750 psi} 244100 kPa (241 bar; 3500 psi) 700 kPa (7 bar; 100 psi) 2675 + 50 cpm 1200 + 50 rpm 500 mm (20 in.) waterhead ‘TM-4452 (Jan-89)LB Printed in Germany Combines ~ JOWZSUMMARY OF MOST IMPORTANT SPECIFICATIONS 1166, 1169H, 1174, 1177, 1177 HYDRO/4, 1188, 1188 HYDRO/4 Cooling System Radiator cap valve opening pressure Electrical System Battery voltage .......... Hydraulic System Hyaraute pump delivery (except 11684) = main circuit = steering circuit oi Hydraulic pump delivery (1169+) = main cifCult ses ee ects ewes = secondary circuit .... = leveling system... Pressure relief valve setting ~ in electro-magnetic control valve Steering System Pressure reliet valve setting ...... ‘Shock valve setting ... Clutch Minimum thickness of clutch disk Wheels Wheel bolt torques ~ Front wheels (except 1169H) . = Front wheels (1169H) = Rear wheels Thermostat opening temperature ........ Aiternator output current (at 14 volts)... —in mechanical control valve... ..6...eceeeeeeeee = im leveling system... eee SPECIFICATIONS (Continued) 7110 82°C (160 to 180°F) 100 to 120 kPa (1.0 to 1.2 bar; 14 to 17 psi) 12 volts 65 amps 40 liters/min (10.5 gpm) 12 lters/min (3.2 gpm) 29 iters/min (7.6 gpm) 10.5 liters/min (2.8 gpm) 21 liters/min (5.5 gpm) 19800 to 14500 kPa (198 to 145 bar; 2000 to 2100 psi) 17200 to 18000 kPa (172 to 180 ber; 2500 to 2610 psi) 16600 to 17400 kPa (166 to 174 bar; 2400 to 2520 psi) 19500 kPa (135 bar; 1960 psi) 18000 to 19500 kPa (180 to 195 bar; £2610 to 2890 psi) 7 mm (0.28 in.) 420 Nm (804 fi-ib) 550 Nm (400 ft-lb) 180 Nm (190 ft-lb) srecomancovree ‘TM-4452 (Jan-89)L8 Printed in Germany Combines - JOWZSUMMARY OF MOST IMPORTANT SPECIFICATIONS 1166, 1169H, 1174, 1177, 1177 HYDRO/4, 1188, 1188 HYDRO/4 Engine lubrication system = 1177 Hydro/4, 1188, 1188 Hydro/4 PAT idee renee = 1186, 1174, 1169H . Hydrostatic ground speed drive Final drive (each) Complete hydraulic system ......-. Clutch and brake operating assembly Hydrostatic reel drive .. Cylinder drive reduction gear... Engine cooling system = 1177 Hydro/4, 1188, 1188 Hydro/4 = 1166, 1169H, 1174, 1177 ‘Compressor oil charge Fuel tank capacity... ‘Transmission with differential ..........002s200+ Chain transmission (cutting platform drive) ........ Refrigerant capacity (air conditioning) ...... CAPACITIES 2 iters (6:3 US.gal.) 17 liters (4.5 U.S.gal.) 13 liters (3.4 U.S.gal.) 24 ters (6.3 US.gal) 66 liters (1.75 U.S.gal,) 22 liters (06 US.gal}) . 25 liters (6.6 US.gal.) 1 Siiters (0.4 US.gal) 0.5 liters (0.13 U.S.gal.) 12iiters (3.17 US.gal) 1.9llters (0.5 U.S.gal,) ey 1950 9 (68.8 02.) 320 cm? (19.5 cuin) 300 titers (80 US.gal.) TM-4462 (Jan-89)L8 Printed in Germany a Combines — JDWZSECTION 10 - GENERAL Group 05 - Specifications SECTION 20 - ENGINE REPAIR, Group 01 — Engine pulley Group 05 — Removing 6465 engine ‘Group 06 — Removing 6358 engine Group 10 - Cooling system SECTION 30 - FUEL SYSTEM Group 05 - Fuel system Group 10 ~ Speed control and engine shut-off ‘components ‘SECTION 40 - ELECTRICAL EQUIPMENT REPAIR, Group 05 - Connectors Group 10 - Electrical system components Group 15 - Low shaft speed monitor system Group 20 - Harvest performance monitor Group 25 ~ Electromagnetic transmission brake Group 30 - Starting motor (John Deere) Group 31 - Starting motor (Bosch) Group 35 - Alternator Group 40 ~ Dial-A-Matic Group 45 - Sidehil leveling system COPYRIGHT 1500 DEERE & CO. European fee Mannheim stg esarvea ‘Jom Dears LLUSTRUCTIONY Maru PREVIOUS EDTONS. COPYRIGHT: 8681588 Combines 1166, 1169H, 1174, 1177, 1177 Hydro/4, 1188, 1188 Hydro/4 TECHNICAL MANUAL TM4452 (Apr-90) CONTENTS OF SECTIONS ‘SECTION 50 - POWER TRAIN ‘Group 02 - Variable ground speed drive Group 05 — Posi-Torq ground drive ~ upper unit Group 10 ~ Posi-Torg ground drive — lower unit Group 18 Clutch operating assembly Group 20— Engine clutch Group 25 — Hydrostatic drive, oll and fiter ‘change (Saver) Group 28 - Hydrostatic drive, oll and fer ‘change (Eaton) Group 30 — Hydrostatic drive, variable pump (Sauer) Group 31 — Hydrostatic drive, variable pump (Eaton) Group 35 ~ Hydrostatic drive, fixed- displacement motor (Sauer) Group 98 — Hydrostatic drive, fixed- displacement motor (Eaton) Group 40 = Hydrostatic drive, oll cooler Group 48 ~ Transmission with differential Group 50 Fine! crives Group 55 ~ Final drives (rice combine) Group 60 — Final drives (sidehill combine) ‘SECTION 60 - BRAKES, REAR AXLE AND ‘STEERING Group 05 - Parking brake Group 10- Brake operating assembly Group 15 - Foot brakes (internal slave oytinder) Group 16 - Foot brakes (external slave cytinder) Group 18 - Foot brakes (sidehill combine) Group 20 - Hydrostatic steering Group 25 - Rear axle Group 20 - Rear axle (sidehill combine) ‘TMA452 (Apr-90)B0 Printed in Germany o1 ‘Combines ~ JOWZ‘SECTION 70 ~ HYDRAULIC SYSTEM Group 05 - Hydraulic ines Group 10~ Dual hydraulic pump Group 11 ~ Triple hydraulic pump Group 15 ~ Mechanical four-spooi control valve Group 16 — Mechanical seven-spool control valve Group 18 ~ Leveling system control valve Group 20 - Electro-magnetic control valve Group 25 ~ Hydraulic cylinders Group 30 - Hydraulic reverser motor Group 35 Hydrostatic reel drive Group 40 — Hydraulic accumulator/header pressure gauge SECTION 80 - MISCELLANEOUS Group 05 ~ Bearings and shafts Group 10 ~ Drive belts Group 15 — Drive chains ‘SECTION 90 - OPERATOR’S PLATFORM WITH CAB Group 05 - Cab ventilation system Group 10 ~ Sefe handling of refrigerants, Group 15 Air conditioning system service Group 20 - Air conditioning compressor Group 25 - System components Group 26 ~ Air conditioning with integrated ‘condenser cooling Group 30 - Cab heating system Group 35 — Operator's cab Group 40 — Platform control levers Group 45 - Steering column Group 50 - Operator's seat ‘SECTION 100— CUTTING PLATFORMS AND CORN HEADS Refer to Technical Manual for harvesting units (TM-4468) ‘SECTION 110- FEEDER HOUSE Group 05 ~ Feeder house drive Group 10 - Feeder house Group 15 ~ Chain transmission ~ cutting platform drive Group 20 — Hydraulic reverser CONTENTS OF SECTIONS ~ CONTD. SECTION 120~ SEPARATOR AND CLEANING UNIT Group 05 - Separator drive Group 10 Beater Group 15 — Variable oylinder drive — upper unit Group 20 — Variable cylinder drive — lower unit Group 21 - Variable cylinder drive - mechanically adjustable Group 25 - Cylinder drive reduction gear Group 30 - Threshing cylinder Group 35 - Concave Group 40 - Straw walkers Group 45 - Cross shaker Group 50 ~ Fan, variable fan drive Group 65 ~ Cleaning shoe with sieves ‘SECTION 130 ~ ELEVATORS, GRAIN TANK AND UNLOADING AUGERS Group 05 ~ Tailings auger and elevator Group 10 Clean grain auger and elevator ‘SECTION 140 - SPECIAL EQUIPMENT Group 05 - Straw chopper countershaft Group 10- Straw chopper Group 15~ Straw spreader ‘SECTION 220 - ENGINE COOLING SYSTEM ‘OPERATION Group 05 ~ Cooling system ‘SECTION 230 - FUEL AND AIR INTAKE SYSTEM ‘OPERATION Group 05 - Air intake system Group 10-Fuel system ‘TMAé52 (Apr-90)BO Printed in Germany ‘Combines — JDWZ‘SECTION 240 - ELECTRICAL SYSTEM — OPERATION AND TESTS: Group 05 - General information Group 10 ~ Circuit plan, wiring diagram and wiring harnesses Group 15 ~ Circuit tasting Group 20 - Checking individual components Group 25 ~ Checking electro-magnetic control valve Group 30 ~ Checking speed monitor system Group 35 Checking harvest performance monitor Group 40 - Starting motor Group 45 — Alternator Group 50 - Checking Dial-A-Matic header height control ‘SECTION 250 - POWER TRAIN ~ OPERATION AND TESTS Group 05 — Posi-Torq ground drive Group 10— Clutch operating assembly Group 15- Clutch Group 20 — Hydrostatic ground speed drive ‘Group 25 - Testing hydrostatic drive (Sauer) Group 26 - Testing hydrostatic drive (Eaton) Group 30- Transmission CONTENTS OF SECTIONS - CONTD. ‘SECTION 260 - BRAKES, STEERING AND REAR AXLE — OPERATION AND TESTS Group 05 — Full disk brakes Group 06 — Partial disk brakes Group 10 — Hydrostatic steering Group 15 — Hydrostatic steering - diagnosing ‘matfunctions Group 20 — Testing hydrostatic steering SECTION 270— HYDRAULIC SYSTEM ~ OPERATION AND TESTS Group 05 — Hydraulic circuits Group 10 - Mechanical four-spool control valve Group 11 - Mechanical seven-spool control valve Group 15 ~ Electro-magnetic control valve Group 20 — Testing hydraulic system ‘SECTION 290 - OPERATOR'S PLATFORM AND. CAB - OPERATION AND TESTS Group 05 — Cab ventilation — operation and tests Group 10 ~ Air conditioning system operation Group 15 — Air conditioning system tests ‘TM4452 (Apr-90)B0 Printed in Germany Combines - JDWZIntroduction TECHNICAL MANUAL TABS INTRODUCTION To fully utilize this manual, you must understand how it is organized. Only two tab colors are used ~ green and yellow, each representing a different type of in- formation. Spend a minute reading this now and save many minutes of searching later. ‘AcGroon Tabe BLYellow Tabe GREEN TAB SECTIONS ‘The green tab sections are REPAIR sections, telling you how to repair components of the various systems. Repair of a component includes = Rlemovai from machine (if necessary) — Disassembly = Inspection — Replacement of parts = Assembly Adjustment ~ Installation on machine (it necessary) ‘The numbers used for the repair (green tab) sections are part of an overall service publication numbering system. The numbers identify the same sections in the parts catalog, flat rate manual, service information bulletins, and service training courses. YELLOW TAB SECTIONS Each yellow tab section contains information on: ~System Operation ~ System Tests ‘System operation explains how the system and its ‘components work. - ‘System tests tell you how to test the system and diagnose the problem. ‘TM-4452 (Jan-89)L8 Printed in Germany 04 Combines ~ JOWZIntroduction TAB POSITIONS Each green tab and its corresponding yellow tab have the same tab position. This helps you to quickly locate the related information. ‘AcGreen tab BLYellow tab = Section 70 = Section 270, = Hyrule Repair = Hydrautle Operation/Teste THREE-STEP PROCEDURE Use the following three-step procedure to locate the desired information. 1. Determine the type of information you need. Is it? A-Repair B-Operation CTests 2. Go to the appropriate section tab’ Green ~ for Repair Yellow — for Operation or Tests 3. Use the Table of Contents on the first page of each section to locate the information. TM-4452 (Jan-89)L8 Printed in Germany 05 Combines - JOWZSection 10 3g CONTENTS OF THIS SECTION =| | (=| Jz |@| 3 | by rae 3} GROUP 05 - SPECIFICATIONS Slesesiele Standard torques — general ........-.....- 10-05-1 xx} x} xp x} xp Recommended torques for UNG and UNF COP SOLEWS so evesesveveeescs veces ese 10-054 x}x|x| x] x] x} « Recommended torques for metric cap Screws .... 210-052 x[x |x] x] x| x] x Recommended torques for pipe a ‘and hose connections... 40.052 x}x|x] x] x] x] x Metric and inch threads - 10-05-3 xi xixpxpx|xtx ‘TM-4452 (Jan-89)L8 Printed in Germany 10-1 Combines — JOWZGroup 05 SPECIFICATIONS STANDARD TORQUES - GENERAL Al specified torques are only valid for non-greased or @ | recites ‘A Variation of +: 10% is permissible forall torques speci- fied below. e RECOMMENDED TORQUES FOR UNC AND UNF CAP SCREWS 71S © » : A Nn oe Nm tm 1/4 15 10 20 15, 5/16 30 20 40 30 38 50 35 70 50, 76 80 55 110 80 V2 120 85 170 120 9/16 180, 130 240 175 5/8 230 170 320 240 3/4 400 300, 580 425 78 600 445 930 685 1 910 670 1400 1030 1-1/8 1240 910 1980 1460 18 1700 1250 2800 2060 zi08047 scToread 0. in) 10.9— Tempered stoe high 129~ Tempered see extra S-Heed merking streogth cap sorews igh strength cap screws freeones TM-4452 (Feb-88)K7 Printed in Germany 10-05-1 Combines ~ JOWZ,Specifications RECOMMENDED TORQUES FOR NETRIC CAP SCREWS A 88 109 na B oo fu Nm fet Nm fe M5 7 5 9 65 T 10 85 M6 10 a5 15 10 20 15 me 30 20 40 30 40 30 M10 50 35 80 60 90 70 M12 100 75 140 100 160 120 M14 160 120 210 155 260 190 M16 240 175 350 260 400 300 M20 480 355 650 480 780 575 M24 820 605 1150 850 1350 995, M30 1640 1210 2250 1660 2700 | 1990 M36 2850 2110 4000 2950 4700 | 3465, 2103048 ‘AcHoad marking ‘28-Regular cop screws 129-Tempered steel extra (aentiying steength) 105-Tempered steel high high strength eap screws BeThread 0.. (eum) ‘strengit cap screws, Firm zeensneo coe RECOMMENDED TORQUES FOR PIPE AND HOSE CONNECTIONS A | B c (fee ee cs ms (3/8-24 UNF 75 55 8 6 7/16-20 UNF 10 He 12 9 1/2-20 UNF 12 9 15, WW 9/16-18 UNF 15, a 25 18 3/4-16 UNE ri 20 45 35 7/8-14 UNE 40 30 60 35 1-1/16-12 UNC 60 45 100 75 1-3/16-12 UNC 70 50 120 90 1-5/16-12 UNC 80 60 140 105 1-5/8-12 UNC 110 80 190 140 1-7/8-12 UNC 150 110 220 160, z109848 sctorend sce Bath ong cit cone ‘TM-4452 (Feb-88)K7 Printed in Germany 10-05-2 ‘Combines - JDWZSpecifications METRIC AND INCH THREADS ‘The adjacent chart compares the diameters of “metric” and “inch* threads. ‘Adinch thresd Motte thread 516 a8 76 Ww one 518 a4 78 © dlabd | sue mae 1908 [> ae CDODdo Do ooo M6 = z 6 z a z 8 z 8 2103960 ‘TM-4452 (Feb-88)K7 Printed in Germany 10-05-3 Combines - JDWZCONTENTS OF THIS SECTION NOTE: Only engine removal and installation is described in this Technical Manual. For Section 20 ENGINE REPAIR tog engine repair, refer to relevant Technical FE Manuals. xl ln l=loles elale|n|e 3/3 GROUP 01 - ENGINE PULLEY SlEiS\SlSlele Special tools ........-. eooors — |x|xtx}xfac}x |x Torques for hardware.» foot fxfxfx/xtx|x|x Engine pulley removal looove — | x|xtx|x}x|x|x Engine puley installation 2002 | x|x|x}x|x|x]x ‘GROUP 05 - REMOVING 6466 ENGINE Special tools ...... x]x|x Preparations x|x}x Remove air conditioning unit 1 20-05-2 x|x}x Romove muffler and ar cleaner * 20-05-3 xfxlx Disconnect heater hoses .....J... ss... 1. 20-05-4 x|x]x Remove electromagnet canoe... 20.055 x|x]x Remove drive belts...» coetsess BOSS x|x]x 20-05-7 x|x}x 20.05.7 x{x}x Engine installation 2005-7 x|x}x GROUP 06 - REMOVING 6359 ENGINE Special tools ... x |x [x] x Preparations |.” : x|x|x] x Liftoff engine. TI poge6 |x fx px} Engine repair 2006-6 | x|x|x|x Engine installation 2006s = | x|x}x]x GROUP 10- COOLING SYSTEM Engine radiator components zoos — |x |x]x|x]x]x]x Rotary sereen components... Teotoe = |xix|x}x}x|x{x Rotary screen drive components .........-- 20-103 x |x|x| x|x]xIx mason ‘TMé452 (Apr-90)B0 Printed in Germany 20-1 Combines — sOWw2Group 01 ENGINE PULLEY ‘SPECIAL TOOLS ‘A-Puller (0-01204A0) e TORQUES FOR HARDWARE Belt pulley to engine shaft, attaching screws 78Nm (67 ft-b) ‘T4452 (Apr-90)B0 Printed in Germany 20-01-1 ‘Combines ~ JDWZEngine Pulley REMOVE DRIVE BELTS ‘AcDrive bett (Posi Tora or variable ‘ground speed dive) B-Separstor dive bot ‘C-Hydrauiic pump drive belt ‘D-Grain tank uniooding auger dive belt E-Siraw chopper drive belt Air canditfoning system ctv belt ce ENGINE PULLEY REMOVAL Remove indirectly flanged pulley, using special tool Assemble and install engine pulley in reverse ‘sequence of disassembly and removal. Tighten cap ‘sorews (J) to 78 Nm (57 ft-lb). D-01204AA. ENGINE PULLEY INSTALLATION 2107067 ~ Centering ring D~shatt Driven ask E-Snep ring C= Flywheel housing J—Cap screw ‘TM4452 (Apr-90)B0 Printed in Germany 20-01.2 ‘Combines ~ JDWZ