John Deere 803MH, 853MH & 859MH Operator’s Manual OMT444764X019 PDF

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John Deere 803MH, 853MH & 859MH Tracked Harvesters Operator’s Manual OMT444764X019 – PDF DOWNLOAD

TABLE OF CONTENTS:

John Deere 803MH, 853MH & 859MH Tracked Harvesters Operator’s Manual OMT444764X019 – PDF DOWNLOAD

Contents 31
Safety—Safety and Operator Conveniences 37
Safety and Operator Convenience Features 37
Safety—General Precautions 38
Information for European Union Directives and Eurasian Economic Union Technical Regulations Compliance 38
Recognize Safety Information 40
Follow Safety Instructions 40
Operate Only If Qualified 40
Wear Protective Equipment 41
Protect Against Noise 41
Avoid Unauthorized Machine Modifications 41
Inspect Machine 42
Stay Clear of Moving Parts 42
Avoid High-Pressure Oils and Fluids 42
Work In Ventilated Area 43
Handle Starting Fluid Safely 43
Avoid Static Electricity Risk When Refueling 43
Prevent Fires, Clean Debris From Machine 44
In Case of Machine Fire 44
Prevent Battery Explosions 45
Handle Chemical Products Safely 45
Decommissioning — Proper Recycling and Disposal of Fluids and Components 46
Prepare for Emergencies 46
Add Cab Guarding for Special Uses 46
Control Pattern 47
Exhaust Filter Ash Handling and Disposal 47
Safety—Operating Precautions 48
Use Steps and Handholds Correctly 48
Start Only From Operator’s Seat 48
Use and Maintain Seat Belt 48
Avoid Work Site Hazards 49
Prevent Unintended Machine Movement 49
Operate Machine Safely 50
Avoid Machine Tip Over and Machine Damage 51
Keep Riders Off Machine 51
Use Care When Swinging Machine 52
Operate Boom With Care 52
Avoid Backover Accidents 52
Operating On Slopes 52
Prevent Acid Burns 53
Add and Operate Attachments Safely 53
Travel Safely 53
Avoid Power Lines 54
Inspect and Maintain ROPS 54
Keep the Operator Protective Structure (OPS) in Place 54
Tool Storage 55
Saw Chain Hazard 56
Safety—Maintenance Precautions 57
Park and Prepare for Service Safely 57
Service Machines Safely 57
Service Cooling System Safely 58
Service Accumulator Systems Safely 58
Remove Paint Before Welding or Heating 58
Make Welding Repairs Safely 59
Drive Metal Pins Safely 59
Use Proper Lifting Equipment 59
Clean Exhaust Filter Safely 60
Chain Shot Guard Inspection 61
Safety—Safety Signs and Other Instructions 63
Safety Signs and Other Instructions 63
Operation—Operator’s Station 79
Operator Controls and Instruments 79
TimberRite™ System 80
Sealed Switch Module (SSM) 81
Sealed Switch Module (SSM) Functions 82
Primary Display Unit (PDU) Functions 86
Using the Seat Belt 89
Dome Light 90
Radio—If Equipped 90
Diesel Fired Coolant Heater (DFCH) Timer—If Equipped 90
Horn 91
Accessory Outlets 91
Air Conditioning and Heating Controls 92
Operator’s Seat—Air Suspension 93
Fire Extinguisher 94
Alternative Exits 95
Cab Door Handles 97
Cab Door Stop 97
Operation—Operating the Machine 98
Before Starting Work 98
Driving Up a Steep or Slippery Slope 98
Off Level Operation 98
Inspect Machine Daily Before Starting 99
Battery Disconnect Switch 100
Engine Break-In Period 100
Before Starting Engine 101
Operator Ability 101
Engine Block Heater—If Equipped 101
Normal Starting Procedure—Above 0°C (32°F) 102
Cold Weather Starting—Below 0°C (32°F) 103
Hydraulic Warm-Up Procedure 104
Diesel Fired Coolant Heater (DFCH) Operation—If Equipped 105
Stopping Procedure 107
Required Machine Stop Warning 107
Operating the Track Drive 109
Extend Undercarriage Life 110
Operating the Implements—General 110
Operating Functions—Left Joystick 111
Operating Functions—Right Joystick 114
Operating Functions—Leveling Platform—If Equipped 116
Lowering Boom With Engine Stopped 118
Operating Slope Indicator System—If Equipped 119
Preparation of Machine Before Leaving for Cutting Area 120
Harvesting Technique 121
Harvesting Head 121
Recovering the Machine 122
Loading Machine on Trailer 127
Operating in Water and Mud 128
Service ADVISOR™ Remote (SAR) Software Delivery Process 128
Parking the Machine 129
Lifting the Machine 130
Exhaust Filter 131
Selective Catalytic Reduction (SCR) System Overview 133
US EPA Qualified Emergency Use — SCR Derate Override Option 134
EU Qualified Emergency Use — SCR Derate Override Option 135
Operation—Monitor Operation 136
Main Menu 136
Operation—Motions 136
Operation—Power Management 137
Operation—RCS Adjustments—If Equipped 137
Operation—IBC Adjustments—If Equipped 137
Operation—Joystick Lever Pattern 137
Operation—Aux Leveling Control—If Equipped 138
Operation—Copy Operator Settings 138
Operation—Exhaust Filter 138
Operation—Exhaust Filter Auto Cleaning 139
Operation—Exhaust Filter Parked Cleaning 140
Operation—Fluid Economy 141
Operation—Change Operator 141
Operation—Engine Speed Adjustments 142
Operation—Restore All Factory Defaults 142
Diagnostics—Machine Readings 143
Diagnostics—Codes 146
Diagnostics—Controller ID 147
Diagnostics—Engine Readings 148
Diagnostics—Machine ID 148
Diagnostics—Software Delivery 149
Diagnostics—JDLink Readings 150
Setup—Monitor 151
Setup—Calibration 152
Setup—Anti-Theft/Security 153
Setup—Auto Fan Reversing 154
Aftertreatment Indicators Overview 155
Operation—Boom Control Systems 156
Boom Control System Options 156
Rapid Cycle System (RCS) General Operation 156
Rapid Cycle System (RCS) Joystick Controls 156
Rapid Cycle System (RCS) Monitor Adjustments 157
Intelligent Boom Control (IBC) General Operation 157
Intelligent Boom Control (IBC) Joystick Controls 158
Intelligent Boom Control (IBC) Monitor Adjustments 159
Maintenance—Machine 161
Required Emission-Related Information 161
John Deere Break-In Plus™ Engine Oil — Interim Tier 4, Final Tier 4, Stage IIIB, Stage IV, and Stage V 161
Diesel Engine Oil — Interim Tier 4, Final Tier 4, Stage IIIB, Stage IV, and Stage V 162
Engine Oil and Filter Service Intervals — Interim Tier 4, Final Tier 4, Stage IIIB, Stage IV, and Stage V Engines 163
Engines With Tier 3-Stage IIIA/MAR-I Emission Control 163
Diesel Engine Break-In™ Oil 164
Diesel Engine Oil — Tier 3 and Stage IIIA 165
Engine Oil and Filter Service Intervals—Tier 3 and Stage IIIA Engines 166
Diesel Engine Oil — Tier 2 and Stage II 167
Engine Oil and Filter Service Intervals — Tier 2 and Stage II Engines 168
Diesel Engine Oil Service Interval for Operation at High Altitude 168
Oil Filters 169
Track Drive and Swing Drive Gear Case Oil 169
Hydraulic Oil 170
Enclosure Door Pump Oil 171
Pump Drive Gear Case Oil 171
Diesel Fuel 172
Lubricity of Diesel Fuel 172
Handling and Storing Diesel Fuel 173
Biodiesel Fuel 174
Testing Diesel Fuel 175
Supplemental Diesel Fuel Additives 175
Fuel Filters 175
Minimizing the Effect of Cold Weather on Diesel Engines 176
Starting Aid Can Replacement 177
Multipurpose Extreme Pressure (EP) Grease 178
Alternative and Synthetic Lubricants 178
Lubricant Storage 178
Mixing of Lubricants 179
Diesel Engine Coolant (engine with wet sleeve cylinder liners) 180
Water Quality for Mixing with Coolant Concentrate 181
Operating in Warm Temperature Climates 181
Testing Coolant Freeze Point 182
Disposing of Coolant 182
Diesel Exhaust Fluid (DEF) — Use in Selective Catalytic Reduction (SCR) Equipped Engines 183
Refilling Diesel Exhaust Fluid (DEF) Tank 184
Testing Diesel Exhaust Fluid (DEF) 185
Storing Diesel Exhaust Fluid (DEF) 185
Disposal of Diesel Exhaust Fluid (DEF) 186
Maintenance—Periodic Maintenance 187
Engine Identification 187
Service Machine at Specified Intervals 188
Check the Hour Meter Regularly 188
Service Lights 189
Enclosure Door and Maintenance Doors 190
Prepare Machine for Maintenance 194
Machine Service Position—Attachment 195
Fluid Analysis Program Test Kits and 3-Way Coolant Test Kit 195
Fuel Tank 195
Diesel Exhaust Fluid (DEF) Tank 196
Service Intervals 197
Required Parts 201
Maintenance—As Required 204
Inspect Serpentine Belt 204
Replace Engine Air Filter Elements 205
Lubricate Door Hinges 206
Lubricate Toolbox Door Hinges—If Equipped 206
Service Exhaust Filter 206
Check and Clean Cooling System and Condenser Fins 208
Clean and Tighten Battery Terminals 209
Maintenance—Every 10 Hours or Daily 210
Lubricate Leveler Pivot Joints and Cylinders—If Equipped 210
Check Fire Suppression System—If Equipped 212
Check Swing Drive Gear Case Oil Level 212
Check Hydraulic Oil Level 213
Check Engine Oil Level 215
Check Pump Drive Gear Case Oil Level—If Equipped 215
Check and Drain Primary Fuel Filter and Water Separator 216
Check and Drain Final Fuel Filter 217
Check and Drain Auxiliary Fuel Filter and Water Separator—If Equipped 217
Check Engine Coolant Level 218
Lubricate Boom Joints and Cylinder Ends 219
Lubricate Swing Drive Pinion and Bearing 219
Check Track Sag 220
Adjust Track Sag 220
Inspect Fire Extinguisher 221
Inspect Chain Shot Guard 222
Maintenance—Initial Service—100 Hours 223
Check Track Shoe Cap Screw Torque 223
Maintenance—Every 100 Hours 224
Lubricate Swing Drive Gear Case Bearing 224
Check Idler Oil Level 224
Maintenance—Initial Service—250 Hours 225
Drain and Refill Swing Drive Gear Case Oil 225
Drain and Refill Track Drive Planetary Oil 226
Drain and Refill Pump Drive Gear Case Oil—If Equipped 227
Check Lower Roller Mounting Cap Screw Torque 228
Maintenance—Every 250 Hours 229
Check Rear Window Alternative Exit Latches and Retainer Knobs 229
Check Skylight Latch Tension 230
Take Engine Oil Sample 230
Check Track Drive Planetary Oil Level 230
Check Track Shoe Cap Screw Torque 231
Maintenance—Every 500 Hours 232
Replace Fuel Prefilter—If Equipped 232
Replace Primary Fuel Filter and Water Separator 233
Replace Auxiliary Fuel Filter and Water Separator—If Equipped 235
Replace Final Fuel Filter 236
Drain and Refill Engine Oil and Replace Filter 238
Check Hybrid Battery Electrolyte Level—If Equipped 240
Check Enclosure Door Pump Oil Level 242
Check Air Intake Hoses 242
Drain Water and Sediment From Fuel Tank 242
Take Fluid Samples 242
Maintenance—Every 1000 Hours 243
Drain and Refill Swing Drive Gear Case Oil 243
Check Coolant Condition 244
Drain and Refill Pump Drive Gear Case Oil—If Equipped 245
Drain and Refill Track Drive Planetary Oil 246
Check Cab Fresh Air and Cab Recirculation Filters 247
Maintenance—Every 2000 Hours 248
Drain and Refill Hydraulic Oil 248
Replace Hydraulic Oil Return Filters 250
Replace Hydraulic Oil Breather Filter 251
Replace Hydrostatic Charge Oil Filter—If Equipped 251
Replace Hydrostatic Pump Case Oil Filter—If Equipped 252
Drain and Refill Enclosure Door Pump Oil 253
Check and Adjust Engine Valve Lash 253
Replace Fuel Cap Breather Element 254
Access Diesel Exhaust Fluid (DEF) Dosing Unit Filter 254
Replace Diesel Exhaust Fluid (DEF) Dosing Unit Filter 255
Check Open Crankcase Vent (OCV) 256
Maintenance—Every 4000 Hours 257
Replace Diesel Exhaust Fluid (DEF) Tank Breather Filter 257
Maintenance—Every 6000 Hours 258
Drain and Refill Engine Coolant 258
Replace Diesel Exhaust Fluid (DEF) In-Line Filter—If Equipped 260
Miscellaneous—Machine 264
Clean Machine Regularly 264
Service Ladder 264
Inspect and Clean Polycarbonate Windows 265
Clean Fuel Tank Inlet Screen 266
Circuit Breakers 266
Using Booster Batteries—24-Volt System 267
Using Battery Charger 268
Handling, Checking, and Servicing Batteries Carefully 270
Replacing Batteries 271
Removing and Installing Batteries 271
Precautions for Alternator and Regulator 272
Welding On Machine 272
Keep Electronic Control Unit Connectors Clean 273
Lubricate Attachment 273
Bleed Fuel System 273
Do Not Service or Adjust Injection Nozzles or High-Pressure Fuel Pump 274
Do Not Service Control Valves, Cylinders, Pumps, or Motors 274
Clean the Crankcase Vent Tube 274
Fluid Sampling Test Ports 275
Replacing Fuses 277
JDLink Machine Monitoring System (MMS)—If Equipped 279
Inspect Seat Belt 280
Replacing Seat Belt 282
Remove and Install Halogen Bulbs 284
Remove and Install Light-Emitting Diode (LED) Lights 285
Track Sag General Information 287
Check Track Shoe Hardware 288
Hardware Torque Specifications 288
Unified Inch Bolt and Screw Torque Values 289
Metric Bolt and Screw Torque Values 290
Miscellaneous—Operational Checkout 291
Operational Checkout 291
Diagnostic Trouble Code (DTC) Check 291
Operational Checks—Switched Power Off, Engine Off Checks 291
Operational Checks—Switched Power On, Engine Off Checks 292
Operational Checks—Switched Power On, Engine On Checks 294
Cycle Times 303
Miscellaneous—Troubleshooting 307
Troubleshooting Procedure 307
Engine 308
Electrical System 313
Hydraulic System 315
Software Update 316
Miscellaneous—Storage 317
Prepare Machine for Storage 317
Monthly Storage Procedure 318
Preparing Engine for Long-Term Storage 319
Removing Engine From Long-Term Storage 320
Miscellaneous—Machine Numbers 321
Record Product Identification Number (PIN) 321
Record Engine Serial Number 321
Record Attachment Serial Number 321
Record Saw Hydraulic Motor Serial Number 322
Record Attachment Pump Serial Number 322
Record Main Pump Serial Number 322
Record Saw Pump Serial Number 323
Record Left-Hand Track Drive Planetary Serial Number 323
Record Left-Hand Track Drive Hydraulic Motor Serial Number 323
Record Right-Hand Track Drive Planetary Serial Number 324
Record Right-Hand Track Drive Hydraulic Motor Serial Number 324
Record Swing Drive Gear Case Serial Numbers 324
Record Primary Display Unit (PDU) Serial Number 325
Record Engine Control Unit (ECU) Serial Number 325
Record Cab Controller (CAB) Serial Number 325
Record Vehicle Control Unit (VCU) Serial Number 326
Record Head Control Unit (HCU) Serial Number 326
Record Hydraulic Motor Controller (HMC) Serial Number 326
Record Sealed Switch Module (SSM) Serial Number 327
Record Lower Angle Sensor (VSS) Serial Number—If Equipped 327
Record Hydraulic Pump Controller (HPC) Serial Number 328
Record Intelligent Boom Controller (IBC) Serial Number—If Equipped 328
Keep Proof of Ownership 328
Keep Machines Secure 328
Miscellaneous—Specifications 329
Engine Specifications 329
System Specifications 330
Undercarriage Specifications 331
Drain and Refill Capacities 333
803MH Working Ranges 334
853MH Working Ranges 336
859MH Working Ranges 338
803MH Machine Weights and Ground Pressures 340
853MH Machine Weights and Ground Pressures 342
859MH Machine Weights and Ground Pressures 344
Machine Harvesting Specifications 345
803MH Shipping Dimensions 346
853MH Shipping Dimensions 348
859MH Shipping Dimensions 350
EC Declaration of Conformity 352
Eurasian Economic Union 353
Machine Design Life 353
Page Number 31
Section 1-1 37
Section 1-2 38
Section 1-3 48
Section 1-4 57
Section 1-5 63
Section 2-1 79
Section 2-2 98
Section 2-3 136
Section 2-4 156
Section 3-1 161
Section 3-2 187
Section 3-3 204
Section 3-4 210
Section 3-5 223
Section 3-6 224
Section 3-7 225
Section 3-8 229
Section 3-9 232
Section 3-10 243
Section 3-11 248
Section 3-12 257
Section 3-13 258
Section 4-1 264
Section 4-2 291
Section 4-3 307
Section 4-4 317
Section 4-5 321
Section 4-6 329

S.V 04/24