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

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

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

• P/N: OMT253406_60
• Language: English
• Division: Forestry
• Product Lines: Tracked Harvesters
• Publication Type: Operator’s Manuals
• Associated Models: 903KH, 909KH
• Series: K SERIES
• Serial: 244761—
• Additional Information: For complete service information also see: PC10147, PC10149, TM11623, T267785

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

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

Contents 17
Safety—Safety and Operator Conveniences 21
Safety and Operator Convenience Features 21
Safety—General Precautions 22
Information for European Union Directives Compliance 22
Recognize Safety Information 24
Follow Safety Instructions 24
Operate Only If Qualified 24
Wear Protective Equipment 25
Avoid Unauthorized Machine Modifications 25
Inspect Machine 25
Stay Clear of Moving Parts 26
Avoid High-Pressure Oils 26
Avoid High-Pressure Fluids 26
Work In Ventilated Area 27
Handle Starting Fluid Safely 27
Prevent Fires 28
In Case of Machine Fire 28
Prevent Battery Explosions 29
Handle Chemical Products Safely 29
Decommissioning — Proper Recycling and Disposal of Fluids and Components 30
Prepare for Emergencies 30
Clean Debris from Machine 31
Add Cab Guarding for Special Uses 31
Control Pattern 31
Safety—Operating Precautions 32
Use Steps and Handholds Correctly 32
Start Only From Operator’s Seat 32
Use and Maintain Seat Belt 32
Avoid Work Site Hazards 32
Prevent Unintended Machine Movement 33
Operate Machine Safely 33
Avoid Machine Tip Over and Machine Damage 34
Keep Riders Off Machine 35
Use Care When Swinging Machine 35
Operate Hoist (Boom) With Care 35
Avoid Backover Accidents 36
Operating On Slopes 36
Add and Operate Attachments Safely 36
Travel Safely 36
Avoid Power Lines 37
Inspect and Maintain ROPS 37
Saw Chain Hazard 38
Safety—Maintenance Precautions 39
Park and Prepare for Service Safely 39
Service Machines Safely 39
Service Cooling System Safely 39
Service Accumulator Systems Safely 40
Remove Paint Before Welding or Heating 40
Make Welding Repairs Safely 40
Drive Metal Pins Safely 41
Chain Shot Guard Inspection 41
Safety—Safety Signs 43
Cab Safety Signs 43
Engine Safety Signs 45
Enclosure Safety Signs 46
909KH Leveler Area Safety Signs 47
Operation—Operator’s Station 48
Operator Controls and Instruments 48
TimberRite™ System 50
Joystick (Multi-Function Control Lever)—Right-Hand 51
Joystick (Multi-Function Control Lever)—Left-Hand 51
Track Drive Foot Pedals 52
Sealed Switch Module (SSM) 53
Sealed Switch Module (SSM) Functions 54
Dome Light 57
AM/FM Stereo CD Player 58
Horn 58
Air Conditioner/Heater Controls 59
Check Air Filter Restriction Indicator 59
Air Ride Operator’s Seat 60
Mechanical Operator’s Seat 62
Fire Extinguisher 63
Fire Extinguisher Mounting Location 64
Rear Window Secondary Exit 65
Skylight Secondary Exit 66
Cab Door Handles 66
Cab Door Stop 67
Operation—Operating the Machine 68
Before Starting Work 68
Driving Up a Steep or Slippery Slope 68
Off Level Operation 68
Inspect Machine Daily Before Starting 68
Engine Break-In Period 69
Before Starting Engine 69
Normal Starting Procedure—Above 0 °C (32 °F) 70
Cold Weather Starting—Below 0 °C (32 °F) 71
Hydraulic Warmup Procedure 72
Stopping Procedure 75
Operating the Track Drive 76
Extend Undercarriage Life 78
Operating the Implements—General 79
Joystick (Multi-Function Control Lever)—Right-Hand 80
Joystick (Multi-Function Control Lever)—Left-Hand 81
Dual Joystick (Multi-Function Control Lever)—Leveler (909KH Only) 83
Lowering Hoist (Boom) With Engine Stopped 85
Preparation of Machine Before Leaving for Cutting Area 87
Felling Technique 88
Harvesting Head 88
Towing Machine 88
Loading Machine on Trailer 89
Tiedown Points 90
Machine Recovery 91
Operating in Water and Mud 92
Battery Disconnect Switch 92
Parking the Machine 93
Lifting 93
Operation—Monitor Operation 94
Advanced Display Unit (ADU)—Basic Display 94
Advanced Display Unit (ADU)—Basic Display Functions 95
Advanced Display Unit (ADU)—Advanced Display 96
Advanced Display Unit (ADU)—Advanced Display Functions 97
Advanced Display Unit (ADU)—Main Menu 98
Advanced Display Unit (ADU)—Menu—Adjustments 99
Advanced Display Unit (ADU)—Menu—Diagnostics 100
Advanced Display Unit (ADU)—Menu—Fault Codes 101
Advanced Display Unit (ADU)—Menu—Change Operator 101
Advanced Display Unit (ADU)—Menu—Calibration 102
Advanced Display Unit (ADU)—Menu—Machine Configuration 102
Advanced Display Unit (ADU)—Menu—Security 103
Advanced Display Unit (ADU)—Menu—Restore Factory Settings 104
Maintenance—Machine 105
Modifications or Repairs to Roll-Over Protective Structures (ROPS) 105
Checking Windows Regularly 105
Diesel Engine Break-In™ Oil— Non-Emissions Certified and Certified Tier 1, Tier 2, Tier 3, Stage I, Stage II, and Stage III 106
Diesel Engine Oil—Tier 3 and Stage III A Engines 107
Diesel Engine Oil and Filter Service Intervals—Tier 3/Stage III A Engine 108
Diesel Engine Oil—Tier 2 and Stage II Engines 109
Diesel Engine Oil and Filter Service Intervals—Tier 2/Stage II Engine 110
Oil Filters 110
Track Drive and Swing Drive Gear Case Oil 111
Hydraulic Oil 112
Enclosure Door Pump Oil 113
Diesel Fuel 114
Lubricity of Diesel Fuel 115
Handling and Storing Diesel Fuel 115
Biodiesel Fuel 116
Testing Diesel Fuel 117
Minimizing the Effect of Cold Weather on Diesel Engines 118
Starting Aid Can Replacement 119
Multipurpose Extreme Pressure (EP) Grease 120
Alternative and Synthetic Lubricants 120
Lubricant Storage 120
Mixing of Lubricants 121
Diesel Engine Coolant (engine with wet sleeve cylinder liners) 122
Drain Intervals for Diesel Engine Coolant 123
John Deere COOL-GARD™ II Coolant Extender 123
Supplemental Coolant Additives 124
Operating in Warm Temperature Climates 124
Additional Information About Diesel Engine Coolants and John Deere COOL-GARD™ II Coolant Extender 125
Testing Diesel Engine Coolant 126
Disposing of Coolant 126
Maintenance—Periodic Maintenance 127
Engine Identification 127
Service Machine at Specified Intervals 129
Check the Advance Monitor Display (ADU) Regularly 129
Service Lights 129
Engine Service Light Adjustment 129
Enclosure Doors and Access Openings 130
Prepare Machine for Maintenance 134
Machine Service Position—Attachment 135
Fluid Analysis Program Test Kits and 3-Way Coolant Test Kit 135
Fuel Tank 136
Service Intervals 137
Required Parts 139
Maintenance—As Required 141
Inspect Serpentine Belt 141
Change Engine Air Filter Elements 142
Clean Cab Recirculation Filter 143
Clean Cab Fresh Air Filter 144
Check Coolant 145
Maintenance—Every 10 Hours or Daily 146
Lubricate Leveler Pivot Joints and Cylinders (909KH Only) 146
Fire Suppression System Time Delay—If Equipped 147
Check Swing Drive Gear Case Oil Level 147
Check Hydraulic Oil Level 148
Check Engine Oil Level 148
Check and Drain Fuel/Water Separator 149
Check and Drain Auxiliary Fuel Filter/Water Separator—If Equipped 149
Check Surge Tank Coolant Level 150
Check and Clean Radiator Pre-Screen, Coolers, and Condenser Fins 150
Check Track Sag 151
Adjust Track Sag 151
Lubricate Hoist (Boom) Joints and Cylinder Ends (S N —244761) 152
Lubricate Hoist (Boom) Joints and Cylinder Ends (S N 244761— ) 153
Lubricate Swing Pinion and Bearing 153
Inspect Fire Extinguisher 153
Chain Shot Guard Inspection 154
Maintenance—Every 100 Hours 156
Lubricate Door Hinges 156
Check Track Drive Planetary Oil Level 156
Lubricate Secondary Exit Latches and Knobs 157
Check Skylight Latch Tension 158
Lubricate Swing Gear Case Bearing 158
Lubricate Rotary Manifold (909KH Only) 158
Maintenance—Initial Service – 250 Hours 159
Change Swing Drive Gear Case Oil 159
Check Hydraulic Pressures 159
Change Engine Break-In Oil and Filter 160
Change Track Drive Planetary Oil 161
Check Planetary and Sprocket Mounting Cap Screw Torque 161
Check Swing Bearing Cap Screw Torque 162
Check Lower Roller Mounting Cap Screw Torque 162
Check Track Shoe/Pad Cap Screw Torque 163
Maintenance—Every 250 Hours 164
Take Engine Oil Sample 164
Maintenance—Every 500 Hours 165
Clean or Replace Fuel Prefilter Screen—If Equipped 165
Change Fuel/Water Separator Filter 166
Change Auxiliary Fuel Filter/Water Separator—If Equipped 167
Change Final Fuel Filter 168
Change Engine Oil and Filter 169
Check Battery Electrolyte Level and Terminals 170
Check Enclosure Door Pump Oil Level 172
Take Fluid Samples 172
Maintenance—Every 1000 Hours 173
Change Swing Drive Gear Case Oil 173
Check Coolant 173
Change Track Drive Planetary Oil 173
Maintenance—Every 2000 Hours 174
Change Hydraulic Oil 174
Change Hydraulic Oil Return Filters 175
Change Hydraulic Oil Breather Filter 176
Check and Adjust Engine Valve Clearance 176
Change Enclosure Door Pump Oil 177
Maintenance—Every 4000 Hours 179
Change Engine Crankshaft Damper 179
Maintenance—Every 6000 Hours 180
Change Engine Coolant 180
Miscellaneous—Machine 183
Perform Overall Visual Inspection 183
Inspect and Clean Windows 184
Clean Fuel Tank Inlet Screen 184
Clean Track Drive Planetaries 185
Left-Hand Side Engine Access Door Stop 185
Circuit Breakers 186
Using Booster Batteries—24-Volt System 186
Using Battery Charger 187
Handling, Checking, and Servicing Batteries Carefully 188
Replacing Batteries 189
Removing and Installing Batteries 189
Precautions for Alternator and Regulator 190
Welding on Machine 191
Keep Electronic Control Unit Connectors Clean 191
Engine Enclosure Door Hand Pump 192
Check Hydraulic Oil Filters 192
Inspect for Hydraulic Oil Leaks 193
Lubricate Attachment 193
Check Air Intake Hoses 193
Drain Fuel Tank Sump 194
Bleed Fuel System 194
Do Not Service or Adjust Injection Nozzles or High Pressure Fuel Pump 194
Do Not Service Control Valves, Cylinders, Pumps, or Motors 195
Clean the Crankcase Vent Tube 195
Fluid Sampling Test Ports 196
Check Track Shoe Hardware 197
Accessory Outlets 197
Auxiliary Power Supply 198
Replacing Fuses 199
JDLink™ Machine Monitoring System (MMS)—If Equipped 201
Check Hydraulic Pump Mounting Cap Screw Torque 202
Check Cab Mounting Cap Screw Torque 202
Check Swing Gear Case Cap Screw Torque 203
Check Swing Drive Mounting Cap Screw Torque 204
Check Engine Mounting Cap Screw Torque 205
Check Rotary Manifold Cap Screw Torque (903KH) 206
Check Rotary Manifold Cap Screw Torque (909KH) 206
Check Front Idler Cap Screw Torque (903KH) 207
Check Track Drive Planetary and Motor Mounting Cap Screw Torque 207
Remove and Install Halogen Bulbs 208
Hardware Torque Specifications 208
Unified Inch Bolt and Screw Torque Values 209
Metric Bolt and Screw Torque Values 210
Miscellaneous—Operational Checkout 211
Operational Checkout 211
Diagnostic Trouble Code Check 211
Ignition OFF, Engine OFF Checks 211
Ignition ON, Engine OFF Checks 212
Operational Checks—Ignition ON, Engine ON Checks 214
Miscellaneous—Troubleshooting 232
Troubleshooting Procedure 232
Engine 233
Electrical System 238
Hydraulic System 240
Miscellaneous—Storage 242
Prepare Machine for Storage 242
Monthly Storage Procedure 243
Miscellaneous—Machine Numbers 245
Record Product Identification Number (PIN) 245
Record Engine Serial Number 245
Record Attachment Serial Number 245
Record Saw Hydraulic Motor Serial Number 245
Record Attachment Pump Serial Number 246
Record Main Pump Serial Number 246
Record Saw Pump Serial Number 246
Record Left-Hand Track Drive Planetary Serial Number 247
Record Left-Hand Track Drive Hydraulic Motor Serial Number 247
Record Right-Hand Track Drive Planetary Serial Number 247
Record Right-Hand Track Drive Hydraulic Motor Serial Number 248
Record Swing Drive Hydraulic Motors Serial Numbers 248
Record Advance Display Unit (ADU) Serial Number 248
Record Engine Control Unit (ECU) Serial Number 249
Record Hydraulic Control Unit (HCU) Serial Number 249
Record Transmission Control Unit (TCU) Serial Number 249
Record Cab Control Unit (CCU) Serial Number 250
Keep Proof of Ownership 250
Keep Machines Secure 250
Miscellaneous—Specifications 251
Engine Specifications 251
903KH System Specifications 252
909KH System Specifications 252
Undercarriage Specifications 253
Drain and Refill Capacities 255
903KH Working Ranges 256
909KH Working Ranges 258
903KH Machine Weights and Ground Pressures 260
909KH Machine Weights and Ground Pressures 264
Machine Harvesting Specifications 267
903KH Shipping Dimensions 271
909KH Shipping Dimensions 273
EC Declaration of Conformity 275
Page Number 17
Section 1-1 21
Section 1-2 22
Section 1-3 32
Section 1-4 39
Section 1-5 43
Section 2-1 48
Section 2-2 68
Section 2-3 94
Section 3-1 105
Section 3-2 127
Section 3-3 141
Section 3-4 146
Section 3-5 156
Section 3-6 159
Section 3-7 164
Section 3-8 165
Section 3-9 173
Section 3-10 174
Section 3-11 179
Section 3-12 180
Section 4-1 183
Section 4-2 211
Section 4-3 232
Section 4-4 242
Section 4-5 245
Section 4-6 251

S.V 04/24