John Deere 903KH & 909KH Harvester Operator’s Manual OMT253406 PDF

Description

John Deere 903KH & 909KH Tracked Harvester Operator’s Manual OMT253406 – PDF DOWNLOAD

• Product Number (P/N): OMT253406_24
• Language: English
• Division: Construction
• Series: K SERIES
• Product Lines: Tracked Harvesters
• Publication Type: Operator’s Manuals
• Associated Models: 903KH, 909KH
• Serial: 244761—

TABLE OF CONTENTS:

John Deere 903KH & 909KH Tracked Harvester Operator’s Manual OMT253406 – PDF DOWNLOAD

903KH and 909KH Tracked Harvester 1
Introduction 2
Foreword 2
IMPORTANT 2
Conformity Marking 2
EPA Non-road Emissions Control Warranty Statement—Compression Ignition 3
CARB Non-road Emissions Control Warranty Statement—Compression Ignition 5
Required Emission-Related Information 11
FCC Notifications to User 11
Technical Information Feedback Form 12
Contents 13
Safety—Safety and Operator Conveniences 17
Safety and Operator Convenience Features 17
Safety—General Precautions 18
Information for European Union Directives Compliance 18
Recognize Safety Information 20
Follow Safety Instructions 20
Operate Only If Qualified 20
Wear Protective Equipment 21
Avoid Unauthorized Machine Modifications 21
Inspect Machine 21
Stay Clear of Moving Parts 22
Avoid High-Pressure Oils 22
Avoid High-Pressure Fluids 22
Work In Ventilated Area 23
Handle Starting Fluid Safely 23
Prevent Fires, Clean Debris From Machine 24
In Case of Machine Fire 24
Prevent Battery Explosions 25
Handle Chemical Products Safely 25
Decommissioning — Proper Recycling and Disposal of Fluids and Components 26
Prepare for Emergencies 26
Clean Debris from Machine 27
Add Cab Guarding for Special Uses 27
Control Pattern 27
Safety—Operating Precautions 28
Use Steps and Handholds Correctly 28
Start Only From Operator’s Seat 28
Use and Maintain Seat Belt 28
Avoid Work Site Hazards 29
Prevent Unintended Machine Movement 29
Operate Machine Safely 30
Avoid Machine Tip Over and Machine Damage 31
Keep Riders Off Machine 31
Use Care When Swinging Machine 32
Operate Hoist (Boom) With Care 32
Avoid Backover Accidents 32
Operating On Slopes 32
Add and Operate Attachments Safely 33
Travel Safely 33
Avoid Power Lines 33
Inspect and Maintain ROPS 34
Saw Chain Hazard 35
Safety—Maintenance Precautions 36
Park and Prepare for Service Safely 36
Service Machines Safely 36
Service Cooling System Safely 36
Service Accumulator Systems Safely 37
Remove Paint Before Welding or Heating 37
Make Welding Repairs Safely 37
Drive Metal Pins Safely 38
Chain Shot Guard Inspection 38
Safety—Safety Signs 40
Cab Safety Signs 40
Engine Safety Signs 42
Enclosure Safety Signs 43
909KH Leveler Area Safety Signs 44
Operation—Operator’s Station 45
Operator Controls and Instruments 45
TimberRite™ System 46
Joystick (Multi-Function Control Lever)—Right-Hand 47
Joystick (Multi-Function Control Lever)—Left-Hand 47
Track Drive Foot Pedals 48
Sealed Switch Module (SSM) 49
Sealed Switch Module (SSM) Functions 50
Dome Light 53
AM/FM Stereo CD Player 54
Horn 54
Air Conditioner/Heater Controls 55
Check Air Filter Restriction Indicator 55
Air Ride Operator’s Seat 56
Mechanical Operator’s Seat 58
Fire Extinguisher 59
Fire Extinguisher Mounting Location 60
Rear Window Secondary Exit 61
Skylight Secondary Exit 62
Cab Door Handles 62
Cab Door Stop 63
Operation—Operating the Machine 64
Before Starting Work 64
Driving Up a Steep or Slippery Slope 64
Off Level Operation 64
Inspect Machine Daily Before Starting 64
Engine Break-In Period 65
Before Starting Engine 65
Normal Starting Procedure—Above 0 °C (32 °F) 66
Cold Weather Starting—Below 0 °C (32 °F) 66
Hydraulic Warmup Procedure 68
Stopping Procedure 71
Operating the Track Drive 71
Extend Undercarriage Life 74
Operating the Implements—General 74
Joystick (Multi-Function Control Lever)—Right-Hand 75
Joystick (Multi-Function Control Lever)—Left-Hand 76
Dual Joystick (Multi-Function Control Lever)—Leveler (909KH Only) 78
Lowering Hoist (Boom) With Engine Stopped 80
Preparation of Machine Before Leaving for Cutting Area 81
Felling Technique 82
Harvesting Head 83
Towing Machine 83
Loading Machine on Trailer 83
Tiedown Points 85
Machine Recovery 86
Operating in Water and Mud 87
Battery Disconnect Switch 87
Parking the Machine 87
Lifting 88
Operation—Monitor Operation 89
Advanced Display Unit (ADU)—Basic Display 89
Advanced Display Unit (ADU)—Basic Display Functions 90
Advanced Display Unit (ADU)—Advanced Display 91
Advanced Display Unit (ADU)—Advanced Display Functions 92
Advanced Display Unit (ADU)—Main Menu 93
Advanced Display Unit (ADU)—Menu—Adjustments 94
Advanced Display Unit (ADU)—Menu—Diagnostics 95
Advanced Display Unit (ADU)—Menu—Fault Codes 96
Advanced Display Unit (ADU)—Menu—Change Operator 96
Advanced Display Unit (ADU)—Menu—Calibration 97
Advanced Display Unit (ADU)—Menu—Machine Configuration 97
Advanced Display Unit (ADU)—Menu—Security 98
Advanced Display Unit (ADU)—Menu—Restore Factory Settings 99
Maintenance—Machine 100
Modifications or Repairs to Roll-Over Protective Structures (ROPS) 100
Checking Windows Regularly 100
Diesel Engine Break-In™ Oil 101
Diesel Engine Oil—Tier 3 and Stage III A Engines 101
Diesel Engine Oil and Filter Service Intervals—Tier 3/Stage III A Engine 102
Diesel Engine Oil—Tier 2 and Stage II Engines 103
Diesel Engine Oil and Filter Service Intervals—Tier 2/Stage II Engine 104
Oil Filters 104
Track Drive and Swing Drive Gear Case Oil 105
Hydraulic Oil 106
Enclosure Door Pump Oil 107
Diesel Fuel 108
Lubricity of Diesel Fuel 109
Handling and Storing Diesel Fuel 109
Biodiesel Fuel 110
Testing Diesel Fuel 111
Minimizing the Effect of Cold Weather on Diesel Engines 112
Starting Aid Can Replacement 113
Multipurpose Extreme Pressure (EP) Grease 114
Alternative and Synthetic Lubricants 114
Lubricant Storage 114
Mixing of Lubricants 114
Diesel Engine Coolant (engine with wet sleeve cylinder liners) 115
Drain Intervals for Diesel Engine Coolant 116
John Deere COOL-GARD™ II Coolant Extender 116
Supplemental Coolant Additives 116
Operating in Warm Temperature Climates 117
Additional Information About Diesel Engine Coolants and John Deere COOL-GARD™ II Coolant Extender 117
Testing Diesel Engine Coolant 118
Disposing of Coolant 118
Maintenance—Periodic Maintenance 119
Engine Identification 119
Service Machine at Specified Intervals 121
Check the Advance Monitor Display (ADU) Regularly 121
Service Lights 121
Engine Service Light Adjustment 121
Enclosure Doors and Access Openings 122
Prepare Machine for Maintenance 126
Machine Service Position—Attachment 127
Fluid Analysis Program Test Kits and 3-Way Coolant Test Kit 127
Fuel Tank 128
Service Intervals 129
Required Parts 131
Maintenance—As Required 132
Inspect Serpentine Belt 132
Change Engine Air Filter Elements 133
Clean Cab Recirculation Filter 134
Clean Cab Fresh Air Filter 135
Check Coolant 136
Maintenance—Every 10 Hours or Daily 137
Lubricate Leveler Pivot Joints and Cylinders (909KH Only) 137
Fire Suppression System Time Delay—If Equipped 139
Check Swing Drive Gear Case Oil Level 139
Check Hydraulic Oil Level 140
Check Engine Oil Level 140
Check and Drain Fuel/Water Separator 141
Check and Drain Auxiliary Fuel Filter/Water Separator—If Equipped 141
Check Surge Tank Coolant Level 142
Check and Clean Radiator Pre-Screen, Coolers, and Condenser Fins 142
Check Track Sag 143
Adjust Track Sag 143
Lubricate Hoist (Boom) Joints and Cylinder Ends (S N —244761) 144
Lubricate Hoist (Boom) Joints and Cylinder Ends (S N 244761— ) 145
Lubricate Swing Pinion and Bearing 145
Inspect Fire Extinguisher 145
Chain Shot Guard Inspection 146
Maintenance—Every 100 Hours 148
Lubricate Door Hinges 148
Check Track Drive Planetary Oil Level 148
Lubricate Secondary Exit Latches and Knobs 149
Check Skylight Latch Tension 150
Lubricate Swing Gear Case Bearing 150
Lubricate Rotary Manifold (909KH Only) 150
Maintenance—Initial Service – 250 Hours 151
Change Swing Drive Gear Case Oil 151
Check Hydraulic Pressures 151
Change Engine Break-In Oil and Filter 152
Change Track Drive Planetary Oil 153
Check Planetary and Sprocket Mounting Cap Screw Torque 153
Check Swing Bearing Cap Screw Torque 154
Check Lower Roller Mounting Cap Screw Torque 154
Check Track Shoe/Pad Cap Screw Torque 155
Maintenance—Every 250 Hours 156
Take Engine Oil Sample 156
Maintenance—Every 500 Hours 157
Clean or Replace Fuel Prefilter Screen—If Equipped 157
Change Fuel/Water Separator Filter 158
Change Auxiliary Fuel Filter/Water Separator—If Equipped 159
Change Final Fuel Filter 160
Change Engine Oil and Filter 161
Check Battery Electrolyte Level and Terminals 162
Check Enclosure Door Pump Oil Level 164
Take Fluid Samples 164
Maintenance—Every 1000 Hours 165
Change Swing Drive Gear Case Oil 165
Check Coolant 165
Change Track Drive Planetary Oil 165
Maintenance—Every 2000 Hours 166
Change Hydraulic Oil 166
Change Hydraulic Oil Return Filters 167
Change Hydraulic Oil Breather Filter 168
Check and Adjust Engine Valve Clearance 168
Change Enclosure Door Pump Oil 169
Maintenance—Every 4000 Hours 171
Change Engine Crankshaft Damper 171
Maintenance—Every 6000 Hours 172
Change Engine Coolant 172
Miscellaneous—Machine 174
Perform Overall Visual Inspection 174
Inspect and Clean Windows 175
Clean Fuel Tank Inlet Screen 175
Clean Track Drive Planetaries 176
Left-Hand Side Engine Access Door Stop 176
Circuit Breakers 177
Using Booster Batteries—24-Volt System 177
Using Battery Charger 178
Handling, Checking, and Servicing Batteries Carefully 180
Replacing Batteries 181
Removing and Installing Batteries 181
Precautions for Alternator and Regulator 182
Welding on Machine 183
Keep Electronic Control Unit Connectors Clean 183
Engine Enclosure Door Hand Pump 184
Check Hydraulic Oil Filters 184
Inspect for Hydraulic Oil Leaks 184
Lubricate Attachment 185
Check Air Intake Hoses 185
Drain Fuel Tank Sump 185
Bleed Fuel System 185
Do Not Service or Adjust Injection Nozzles or High Pressure Fuel Pump 186
Do Not Service Control Valves, Cylinders, Pumps, or Motors 186
Clean the Crankcase Vent Tube 186
Fluid Sampling Test Ports 187
Check Track Shoe Hardware 188
Accessory Outlets 188
Auxiliary Power Supply 189
Replacing Fuses 189
JDLink Machine Monitoring System (MMS)—If Equipped 192
Check Hydraulic Pump Mounting Cap Screw Torque 193
Check Cab Mounting Cap Screw Torque 193
Check Swing Gear Case Cap Screw Torque 194
Check Swing Drive Mounting Cap Screw Torque 195
Check Engine Mounting Cap Screw Torque 196
Check Rotary Manifold Cap Screw Torque (903KH) 197
Check Rotary Manifold Cap Screw Torque (909KH) 197
Check Front Idler Cap Screw Torque (903KH) 198
Check Track Drive Planetary and Motor Mounting Cap Screw Torque 198
Remove and Install Halogen Bulbs 199
Hardware Torque Specifications 199
Unified Inch Bolt and Screw Torque Values 200
Metric Bolt and Screw Torque Values 201
Miscellaneous—Operational Checkout 202
Operational Checkout 202
Miscellaneous—Troubleshooting 222
Troubleshooting Procedure 222
Engine 223
Electrical System 228
Hydraulic System 230
Miscellaneous—Storage 232
Prepare Machine for Storage 232
Monthly Storage Procedure 233
Miscellaneous—Machine Numbers 235
Record Product Identification Number (PIN) 235
Record Engine Serial Number 235
Record Attachment Serial Number 235
Record Saw Hydraulic Motor Serial Number 235
Record Attachment Pump Serial Number 236
Record Main Pump Serial Number 236
Record Saw Pump Serial Number 236
Record Left-Hand Track Drive Planetary Serial Number 237
Record Left-Hand Track Drive Hydraulic Motor Serial Number 237
Record Right-Hand Track Drive Planetary Serial Number 237
Record Right-Hand Track Drive Hydraulic Motor Serial Number 238
Record Swing Drive Hydraulic Motors Serial Numbers 238
Record Advance Display Unit (ADU) Serial Number 238
Record Engine Control Unit (ECU) Serial Number 239
Record Hydraulic Control Unit (HCU) Serial Number 239
Record Transmission Control Unit (TCU) Serial Number 239
Record Cab Control Unit (CCU) Serial Number 240
Keep Proof of Ownership 240
Keep Machines Secure 240
Miscellaneous—Specifications 241
Engine Specifications 241
903KH System Specifications 242
909KH System Specifications 242
Undercarriage Specifications 243
Drain and Refill Capacities 245
903KH Working Ranges 246
909KH Working Ranges 248
903KH Machine Weights and Ground Pressures 250
909KH Machine Weights and Ground Pressures 253
Machine Harvesting Specifications 255
903KH Shipping Dimensions 259
909KH Shipping Dimensions 261
EC Declaration of Conformity 263
Page Number 17
Section 1-1 17
Section 1-2 18
Section 1-3 28
Section 1-4 36
Section 1-5 40
Section 2-1 45
Section 2-2 64
Section 2-3 89
Section 3-1 100
Section 3-2 119
Section 3-3 132
Section 3-4 137
Section 3-5 148
Section 3-6 151
Section 3-7 156
Section 3-8 157
Section 3-9 165
Section 3-10 166
Section 3-11 171
Section 3-12 172
Section 4-1 174
Section 4-2 202
Section 4-3 222
Section 4-4 232
Section 4-5 235
Section 4-6 241

S.V 04/24