John Deere Harvester Boom: Warning
John Deere Harvester Boom: Warning
John Deere Harvester Boom: Warning
Harvester Boom
OPERATOR’S MANUAL
John Deere CH8 Harvester Boom
OMF0669911 Issue 15JUL05 (ENGLISH)
CALIFORNIA
Proposition 65 Warning
WARNING
The engine exhaust from this product contains chemicals
known to the State of California to cause cancer, birth
defects or other reproductive harm.
Worldwide Construction
And Forestry Division
LITHO IN FINLAND
Contents
Page Page
Introduction Operating
Base Machine Requirements . . . . . . . . . . . . . . . 01-1 Operating Safety Precautions . . . . . . . . . . . . . . . 06-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2 General Operating Instructions . . . . . . . . . . . . . . 06-2
John Deere Contact Information . . . . . . . . . . . . . 01-2
Technical Information Feedback Form . . . . . . . . 01-3 Maintenance—General
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1-1
Warranty Servicing safety precautions . . . . . . . . . . . . . . . 7-1-1
Standard warranty . . . . . . . . . . . . . . . . . . . . . . . 02-1 General maintenance instructions. . . . . . . . . . . 7-1-2
Tightening torques for bolted joints. . . . . . . . . . 7-1-3
Fluids and lubricants . . . . . . . . . . . . . . . . . . . . 7-1-4
Safety - General Precautions
Oil capasities . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1-5
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03-1-1
Welding Instructions . . . . . . . . . . . . . . . . . . . . . 7-1-6
Recognize Safety Information. . . . . . . . . . . . . 03-1-1
Bleeding the Hydraulic System . . . . . . . . . . . . . 7-1-6
Understand Signal Words. . . . . . . . . . . . . . . . 03-1-2
Prepare for Emergencies . . . . . . . . . . . . . . . . 03-1-2
Maintenance
Wear Protective Clothing . . . . . . . . . . . . . . . . 03-1-3
Maintenance Intervals. . . . . . . . . . . . . . . . . . . . 7-2-1
Handle Chemical Products Safely. . . . . . . . . . 03-1-4
Every 10 Hours or Daily . . . . . . . . . . . . . . . . . . 7-2-2
Replace Safety Signs . . . . . . . . . . . . . . . . . . . 03-1-5
Every 50 Hours or Weekly . . . . . . . . . . . . . . . . 7-2-2
Every 250 Hours . . . . . . . . . . . . . . . . . . . . . . . 7-2-4
Safety - Operating Precautions Every 1000 Hours. . . . . . . . . . . . . . . . . . . . . . . 7-2-5
Keep Danger Zone Clear . . . . . . . . . . . . . . . . 03-2-1 Every 2000 Hours. . . . . . . . . . . . . . . . . . . . . . . 7-2-5
Avoid Power Cables . . . . . . . . . . . . . . . . . . . . 03-2-2 Expander Fitting Instuctions . . . . . . . . . . . . . . . 7-2-6
Driving/Transporting on Public Roads. . . . . . . 03-2-3 Dismantling of Expander Bolts . . . . . . . . . . . . . 7-2-9
General
General Description of the CH8 . . . . . . . . . . . . . 04-1
Installation
Assembly instructions . . . . . . . . . . . . . . . . . . . . . 05-1
How to install the hydraulic system. . . . . . . . . . . 05-1
Requirements for the hydraulic installation . . . . . 05-2
BOOM INSTALLATION REPORT. . . . . . . . . . . . 05-3
Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-4
All information, illustrations and specifications in this manual are based on
the latest information available at the time of publication. The right is
reserved to make changes at any time without notice.
COPYRIGHT 2004
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION Manual
i 080305
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Contents
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Introduction
Base Machine Requirements
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01-1 080305
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Introduction
General
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EL62757,000015B –19–19APR02–1/1
01-2 080305
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Introduction
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Company Name
Address
Phone
FAX No.
Dealer Acct. No.
THANK YOU!
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Warranty
Standard warranty
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02-1 080305
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Safety - General Precautions
General
–UN–23AUG88
As the maintainer ensure that you become familiar with all
occupational safety regulations pertaining to forest
machinery as well as all safety instructions pertaining to
TS201
this equipment. Observe the instructions provided in this
manual and on all hazard and information decals on the Read Manual
machine.
AK12300,000003C –19–28FEB02–1/1
–UN–07DEC88
Follow recommended precautions and safe operating
practices.
T81389
Safety-alert symbol
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Safety - General Precautions
–19–30SEP88
specific hazards. General precautions are listed on
CAUTION safety signs. CAUTION also calls attention to
safety messages in this manual.
TS187
Signal Words
AK12300,000003E –19–28FEB02–1/1
–UN–23AUG88
Learn to use first aid equipment and fire extinguishers.
Keep emergency numbers always available or save those
to your portable phone.
TS291
First Aid Kit
AK12300,000003F –19–28FEB02–1/1
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Safety - General Precautions
–UN–23AUG88
device such as earmuffs or earplugs to protect against
objectionable or uncomfortable loud noises.
TS206
used as protection from pressurized fluid spray, flying
debris, and other airborne matter when working with tools, Wear Protective Clothing
power tools, welding equipment, and corrosive or
dangerous chemicals.
AK12300,0000040 –19–28FEB02–1/1
03-1-3 080305
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Safety - General Precautions
–UN–26NOV90
A Material Safety Data Sheet (MSDS) provides specific
details on chemical products: physical and health hazards,
safety procedures, and emergency response techniques.
TS1132
Check the MSDS before you start any job using a
hazardous chemical. That way you will know exactly what Material Safety Data Sheet
the risks are and how to do the job safely. Then follow
procedures and recommended equipment.
AK12300,0000042 –19–28FEB02–1/1
03-1-4 080305
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Safety - General Precautions
–UN–23AUG88
TS201
Safety Signs
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03-1-5 080305
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Safety - Operating Precautions
Keep Danger Zone Clear
–UN–06JUN01
the foreman.
T139370
Maintain a safe operating distance between the equipment
and other personnel. Never swing the boom, attachment,
or trees over the heads of bystanders.
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03-2-1 080305
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Safety - Operating Precautions
–UN–03OCT02
When planning the work, check with the local power
company to find out if there are any overhead cables in
the working zone and the safe distance to them.
T152796
Safety distances to electric lines
Grip firmly with a bare hand on the wrist of the other hand
holding a handle while pushing the door open. Jump out
of the cab both feet together. Keep on jumping feet
together until you are at least 10 meters (33 ft) from the
machine and the powerline. If you fall earlier do not stand
up, but keep on rolling on the ground toward the same
direction.
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Safety - Operating Precautions
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Safety - Maintenance Precautions
General
AK12300,0000114 –19–06NOV01–1/1
–UN–08NOV89
Secure that portable light has a bulb enclosed by a wire
cage. The hot filament of an accidentally broken bulb can
cause a risk of fire.
TS779
Use power tools only to loosen threaded parts and
fasteners. DO NOT use U.S. measurement tools on metric
fasteners.
AK12300,000004E –19–28FEB02–1/1
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Safety - Maintenance Precautions
Prevent Fires
–UN–23AUG88
To reduce the chance of a fire starting, observe the
following instructions:
TS227
• Remove dust and debris especially from the boom
• Clean the radiator grille and cooling ducts regularly.
• Inspect the machine daily for potential fire hazards and
make any necessary repairs immediately.
• Inspect hydraulic hose runs and fixturing to ensure they
are secure and not rubbing against other components.
• Clean up any excess grease and oil accumulation and
repair the leak immediately.
• Use only nonflamable solutions for cleaning the
machine or components.
• Store rags in a safe, fireproof location.
• Before starting repair work, such as welding, the
surrounding area should be cleaned and a fire
extinguisher should be close by.
• Maintain a charged fire extinguisher on the vehicle at all
times and know how to use it.
AK12300,000004B –19–28FEB02–1/1
–UN–07SEP00
• Turn the engine off.
• Turn the main switch off.
• Fight the fire by means of the fire extinguisher, if T133554
possible.
• Make sure that the fire will not spread to the
surrounding area. Fire extinguisher
• Call for help if necessary.
AK12300,000004C –19–28FEB02–1/1
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Safety - Maintenance Precautions
–UN–23AUG88
X9811
AK12300,0000115 –19–06NOV01–1/2
–UN–20SEP00
an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be
surgically removed within a few hours or
gangrene may result.
T133840
Fluid leaks under pressure may not be visible. Escaping
fluid can penetrate the skin causing serious injury. When
searching for leaks, wear work gloves and use a piece of
cardboard or wood. Never use your bare hand. Protect
body and wear safety goggles for eye protection.
AK12300,0000115 –19–06NOV01–2/2
03-3-3 080305
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Safety - Maintenance Precautions
–UN–15MAY90
pressurized fluid lines or other flammable materials.
TS953
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–UN–06JUN01
3. Disconnect all connectors at the under side of the cab
T139381
Have a charged fire extinguisher available and know how
to use it.
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Safety - Maintenance Precautions
–UN–26NOV90
Use leakproof containers when draining fluids. Do not
pour waste onto the ground or down a drain.
TS1133
Government regulations may require a certified air
conditioning service center to recover and recycle used air
conditioning refrigerants. Recycle Waste
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General
General Description of the CH8
5
4
3
9
7 6
8
10 2
–UN–27OCT03
1
T195708
1—Base 4—Main boom cylinder 7—Outer boom 9—Rotator link
2—Slewing cylinders 5—Outer boom cylinder 8—Extension boom 10—Rotator
3—Pillar 6—Main boom
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Installation
Assembly instructions
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Installation
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05-2 080305
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Installation
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Installation
Couplings
1. Main boom cylinder couplings
Lifting cylinder Piece CH8
Piston side 1 JIC 1 1/16-12 UNF
Rod side 1 JIC 1 1/16-12 UNF
3. Slewing
Lifting cylinder Piece CH8
Base piping 2 JIC 1 1/16-12 UNF
05-4 080305
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Installation
–UN–27APR05
T210888
05-5 080305
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Installation
05-6 080305
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Installation
–UN–02AUG05
T213183
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Installation
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Operating
Operating Safety Precautions
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06-1 080305
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Operating
1. After start
First, operate the boom smoothly without load in order
to allow the grease to warm up and a coherent
lubrication film to be formed in boom joints.
2. During Operation:
• Observe the lifting ratings given on the boom decal.
The weight of the harvester head is included in the
load to be lifted.
• When handling a maximum load, exercise great
caution.
• Operate the control levers smoothly; avoid jerky
movements.
• Always exercise extra caution when a boom or the
booms are in their extreme positions.
• Keep an eye on the machine stability.
Constant alertness is required, particularly when
operating on sloping ground.
If necessary, decrease loads or drive the machine
closer.
When you notice that the machine is about to fall
over, pull extension in, move the outer boom in, and
lower the load smoothly onto the ground.
• It is possible that you exceed the lifting capacity of
the boom (the booms will go over relief) if you pick
up a load that is close to the machine and then
move this load away from the machine. When this
happens you must bring the load closer to the
machine by pulling the outer boom or extension
inwards. This is necessary because otherwise the
power of the main boom cylinder will not be sufficient
to handle the load.
• Bear in mind the potential operation of the frame
brake, should you move the machine while also
operating the boom.
• Always when possible move the extension boom in
before processing a stem to avoid excessive strain
on the outer boom.
06-2 080305
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Operating
–UN–19APR05
• Never leave the boom unsupported by relying on the
hydraulic system only.
Secure the harvester head by means of a chain for
long drives to other working sites. Lock the harvester
T153883
head tilt if needed. Bring the booms down as
displayed in the figure.
Position the harvester head on the ground even for Boom after operation
short breaks, and always before leaving the cab.
AK12300,00000DA –19–22OCT01–2/2
06-3 080305
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Maintenance—General
General
• CH883 / 8,3m
• CH810 / 9,7m
• CH811 / 10,7m
JK11466,00000E9 –19–01AUG03–1/1
JK11466,00000EC –19–01AUG03–1/1
7-1-1 080305
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Maintenance—General
Keep eye on bolted joints daily between the boom and the
frame. Keep tightening until the bolts maintain their
tightness. Check the hose joints, too. During ordinary
operation, the joints should be frequently checked in
addition to scheduled maintenance.
JK11466,00000ED –19–01AUG03–1/1
7-1-2 080305
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Maintenance—General
JK11466,000002C –19–30OCT03–1/1
7-1-3 080305
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Maintenance—General
Grease
• Neste Yleisrasva EP 2
• Esso Beacon EP2
• Shell Retinax LX Lithium
• Mobilgrease
• Castrol LM Grease
• Texaco Molytex Grease EP 2
• BP Energrease
Hydraulic fluid
7-1-4 080305
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Maintenance—General
• Neste Biohydrauli SE 46
• BP BIOHYD SE 46
Gear oil
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Oil capasities
JK11466,0000030 –19–31OCT03–1/1
7-1-5 080305
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Maintenance—General
Welding Instructions
Before you start welding the machine bear in mind the • castings
following: • boom ends
• cylinder fastening lugs
1. Before starting welding work: • corners of box girders
a. Switch off the power with the main switch.
b. Detach the ground wire from the batteries. 6. Welding
Weld inside, if possible, in facilities reserved for this
2. Ground connection: purpose where the temperature is at least 10°C
• Connect the ground wire as close to the welding (50°F). If welding in other places, pay attention to
point as possible. local regulations and to circumstances as well as to
• The welding current must never pass through the environment before you start welding.
bearings, joints, electrical equipment, or hydraulic The welder must possess adequate skills and the
systems. permits required.
AK12300,0000059 –19–12OCT01–1/1
EL62757,00001C8 –19–22APR02–1/1
7-1-6 080305
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Maintenance
Maintenance Intervals
Every 10 Hours or Daily
❒ Check boom structures visually
Every 50 Hours or Weekly
❒ Check boom shafts, circlips and joints ❒ Drain the water deposited in the base
❒ Check the boom slew housing oil level ❒ Grease the rocker and cylinder bearings and the slewing system
bearing of the boom
Every 250 Hours
❒ Clean the boom ❒ Check boom structures
❒ Check the extension boom for vertical and horizontal clearance ❒ Check the tightness of screw joints
❒ Drain water from the boom slewing system ❒ Check the tightness of expander pins
Every 1000 Hours
❒ Clean the magnetic plug of the rotator
Every 2000 Hours
❒ Change the boom slewing system oil
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7-2-1 080305
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Maintenance
AK12300,0000096 –19–16OCT01–1/1
7-2-2 080305
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Maintenance
2 3
4 3
5
–UN–26APR05
T195702
3. Grease the rocker and cylinder bearings of the boom
and the slewing system bearing. See the figure.
–UN–26APR05
cylinders.
5
6
T210853
6
–UN–26APR05
6
T195703
AK12300,0000097 –19–16OCT01–2/2
7-2-3 080305
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Maintenance
–UN–27OCT03
point where the boom pillar and base meet (A).
T195704
• Boom bearings, pins, and links.
• Hydraulic system.
• Rotator linkage and rotator.
–UN–27OCT03
5. Drain water from the boom slewing system.
T195705
1
2
–UN–27OCT03
T195706
AK12300,000009A –19–16OCT01–1/1
7-2-4 080305
PN=42
Maintenance
–UN–08MAR02
of oil to drain. Screw in the magnetic plug and tighten
with a torque of about 60 Nm (44 lb-ft).
T152547
AK12300,000009F –19–16OCT01–1/1
–UN–20APR05
T195707
AK12300,00000A1 –19–16OCT01–1/1
7-2-5 080305
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Maintenance
–UN–28OCT03
T195762
Expander fitting picture A
JK11466,0000002 –19–07OCT03–1/6
–UN–28OCT03
T195763
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Maintenance
–UN–28OCT03
T195764
JK11466,0000002 –19–07OCT03–3/6
Table1
Tihghtening torques
Bolt size M12 M14 M16 M20 M24 M30 M36 M40
(mm)
Torque 80 130 180 400 500 600 700 900
(Nm)
Table2
–UN–28OCT03
Tihghtening torques
Sleeve M17 M25 M35 M45 M55 M65 M75 M85
size(mm)
Torque 30 90 195 265 340 460 630 700
T195765
(Nm)
7-2-7 080305
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Maintenance
–UN–28OCT03
T195766
Expander fitting picture D
7-2-8 080305
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Maintenance
–UN–28OCT03
T195767
Expander Tightening instruction
JK11466,0000002 –19–07OCT03–6/6
1—Dismantling tools
–UN–28OCT03
T195768
7-2-9 080305
PN=47
Maintenance
–UN–28OCT03
T195769
Expander dismantling picture F
JK11466,0000003 –19–07OCT03–2/7
–UN–28OCT03
T195770
7-2-10 080305
PN=48
Maintenance
–UN–28OCT03
T195771
Expander dismantling picture H
JK11466,0000003 –19–07OCT03–4/7
–UN–28OCT03
T195772
Expander dismantling picture I
7-2-11 080305
PN=49
Maintenance
Repeat G - K if necessary.
–UN–28OCT03
T195773
Expander dismantling picture J
JK11466,0000003 –19–07OCT03–6/7
–UN–28OCT03
T195774
JK11466,0000003 –19–07OCT03–7/7
7-2-12 080305
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Technical data
CH8 Specifications
Technical data CH8
Lifting capacity, gross 210 kNm (147510 lb-ft)
Slewing torque, gross 60 kNm (44250 lb-ft)
Slewing angle 220°
Tilting angle -15°...+25°
CH885
Outreach, max 8250 mm 27 ft 1 in
Stroke of boom extension 800 mm 2 ft 7 in
Weight, without oil 2850 kg 6280 lbs
CH810
Outreach, max 9700 mm 31 ft 8 in
Stroke of boom extension 1250 mm 4 ft 1 in
Weight, without oil 3250 kg 7165 lbs
CH811
Outreach, max 10700 mm 35 ft 1 in
Stroke of boom extension 2250 mm 7 ft 5 in
Weight, without oil 3300 kg 7275 lbs
JK11466,000002B –19–30OCT03–1/1
Rotators
Rotator CH8
AV12S AV14S H122
Weight 56 kg 56 kg 57kg
(123 lbs) (123 lbs)
Slewing 2,1 kNm 3,3 kNm 2,2 kNm
torque (1550 lb-ft) (2435 lb-ft)
Slewing unlimited unlimited unlimited
angle (±180° with (±180° with (±180° with
harvester harvester head) harvester head)
head)
AK12300,00000DE –19–22OCT01–1/1
08-1 080305
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Technical data
08-2 080305
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Index
Page Page
CH811 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08-1
CH883 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08-1
Rotators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08-1
Index-1 080305
PN=1
Index
Index-2 080305
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