Table of Content:
1 Introduction
1.1 Foreword
1.2 Emissions Performance and Tampering
1.3 Trademarks
1.4 A Message to Our Customers
1.5 John Deere Technical Information Bookstore
1.6 Download Instructions
2 Safety
2.1 Recognize Safety Information
2.2 Follow Safety Instructions
2.3 Understand Signal Words
2.4 Observe Road Traffic Regulations
2.5 Parking and Leaving the Machine
2.6 Prevent Machine Runaway
2.7 Use Safety Lights and Devices
2.8 Prepare for Emergencies
2.9 Wear Protective Clothing
2.10 Handle Agricultural Chemicals Safely
2.11 Handle Fuel Safely?Avoid Fires
2.12 Store Attachments Safely
2.13 Check Machine Safety
2.14 Use Steps and Handholds Correctly
2.15 Handle Electronic Components and Brackets Safely
2.16 Use Electronic Display Properly
2.17 Operate Guidance Systems Safely
2.18 Read the Guidance Manual
2.19 Cutterhead Access Foot Step
2.20 Engine Compartment Access Ladder
2.21 Keep Riders and Children off Machine
2.22 Instructional Seat
2.23 Use Seat Belts
2.24 Road Safety Mode Button
2.25 Drive the Machine
2.26 Avoid Backover Accidents
2.27 Guards and Shields
2.28 Handle Knives
2.29 Stay Clear of Harvesting Units
2.30 Keep Hands Away From Knives
2.31 Stay Clear of Rotating Drivelines
2.32 Avoid Entanglement
2.33 Transport with Header Installed
2.34 Emergency Exit
2.35 Radio Aerial
2.36 Work In Ventilated Area
2.37 Avoid Hot Exhaust
2.38 Avoid Static Electricity Risk When Refueling
2.39 Practice Safe Maintenance
2.40 Service Machines Safely
2.41 Support Machine Properly
2.42 Service Accumulator Systems Safely
2.43 Avoid High-Pressure Fluids
2.44 Prevent Battery Explosions
2.45 Prevent Acid Burns
2.46 Follow Tire Recommendations
2.47 Retorque Wheel Bolts and Nuts
2.48 Service Tires Safely
2.49 Service Cooling System Safely
2.50 Speed Limit
2.51 Decommissioning ? Proper Recycling and Disposal of Fluids and Components
2.52 Avoid High-Pressure Jet on Safety Decals
2.53 Machine Safety Features
2.54 Safety Decals
2.55 Quick Response (QR) Code
2.56 Remove Accumulated Crop Debris
2.57 Cleaning and Inspection – Instructions
2.58 Fire Extinguisher Recommendations
2.59 Fire Prevention – Instructions
2.60 Operate a Fire Extinguisher
2.61 In Case of Fire
2.62 Automatic Guidance System Detected
2.63 Use Electronic Display Properly
2.64 Prevent Electrical Shock and Fires
2.65 Avoid Exposure to High Radio Frequency Fields
3 Operating the Controls and Displays
3.1 Generation 4 Display
3.2 Cab Access
3.3 Cab Doors
3.4 Emergency Exit Cab Hammer
3.5 Steering Column
3.6 Windshield Wiper/Washer Selector Switch
3.7 ComfortCommand? Operator’s Seat (Premium Cloth Seat)
3.8 ComfortCommand? Operator’s Seat (Premium Leather Seat)
3.9 Left-Hand Armrest and Seat Back (Premium Cloth/Leather Seat)
3.10 Heated/Ventilated Seat Switch (Premium Cloth/Leather Seat)
3.11 Lumbar Support Switch (Premium Leather Seat)
3.12 Instructional Seat
3.13 Seat Belts
3.14 CommandTouch? Armrest and CommandARM? Control Consoles
3.15 CommandCenter? Display
3.16 Overhead Control Panel
3.17 Rear-View Mirror and Outside Mirrors
3.18 Cab Roof
3.19 Brake Pedals
3.20 Cab Interior Lights
3.21 Power Outlet Socket Strip
3.22 Cab 12-V Sockets
3.23 GreenStar? 4640 Display and Video Signal Socket
3.24 Images Collected From Camera Devices
3.25 Service ADVISOR? Diagnostic Socket
3.26 USB Port
3.27 Refrigerator (If Equipped)
3.28 Storage Locations
3.29 CommandTouch? Armrest Console
3.30 Road Safety Mode Button
3.31 Engine Speed Buttons
3.32 Main Clutch Switch
3.33 Park Brake Button
3.34 Differential Lock Button
3.35 Four-Wheel Drive Button
3.36 Traction Control Button
3.37 Left, Right, and Rear Wiper Buttons (If Equipped)
3.38 Air Compressor Button
3.39 Row Guidance Offset Control Dial (If Equipped)
3.40 Header Height/Ground Pressure Control Dial
3.41 ProTouch Functions Button (If Equipped)
3.42 CommandARM? Controls
3.43 Menu Button
3.44 Home Button
3.45 Header Settings Button
3.46 Cutterhead Assembly Settings Button
3.47 Additive Dosing System Settings Button (If Equipped)
3.48 Spout Settings Button
3.49 Engine Settings Button
3.50 Vehicle Settings Button
3.51 Operator Settings Button
3.52 Statistics Button
3.53 ClimaTrak? Automatic Temperature Control
3.54 Radio Controls (If Equipped)
3.55 Machine Lights (Depending on Machine Equipment)
3.56 Machine Hydraulic Functions
3.57 Spout Raise/Lower Switch
3.58 SCV I Switch
3.59 SCV II Switch
3.60 Wagon Dump Switch (If Equipped)
3.61 CommandCenter? Display
3.62 CommandCenter? Display Navigation
3.63 CommandCenter? Display Startup Sequence
3.64 CommandCenter? Display Functions Icons
3.65 Corner Post Display
3.66 GreenStar? 4640 Display
3.67 Multi-Function Lever
3.68 Quick Stop Button
3.69 Header Engage/Reverse Switch
3.70 Activation Buttons
3.71 Header Raise/Lower Switch
3.72 Header Tilt Switch (With AHC Option Only)
3.73 Spout Turn Switch
3.74 Spout Flap Raise/Lower Switch
3.75 Spout Return to Home Position Button (If Equipped with Automatic Spout Control Option)
3.76 Active Fill Control Button (If Equipped with Active Fill Control Option)
3.77 AutoTrac? Button
3.78 Configurable Switches
3.79 Configurable Switch R?T (Assigned to SCV I)
3.80 Configurable Switch P (Assigned to Horn)
3.81 Configurable Switch M?N (Assigned to Spout Raise/Lower)
3.82 Configurable Switch K?L (Assigned to SCV II)
3.83 Message Center Page
3.84 Display Main Page
3.85 Display Advanced Settings Page
3.86 Layout Manager Page
3.87 Access Manager Page
3.88 Home Page
3.89 Header Page
3.90 Header Drive Speed Control?Auto Mode
3.91 Header Drive Speed Control?Manual Mode
3.92 Header Setup Page
3.93 Header Advanced Settings Page
3.94 Selective Control Valve (SCV) and StalkBuster? Maintenance Mode (If Equipped) Tab
3.95 Automatic Header Control
3.96 Header Height Resume (Return to Position) – Operation
3.97 Active Header Float (Return to Pressure) – Operation
3.98 Header Height Sensing (Machines with AHC Option Only) – Operation
3.99 Cutterhead Assembly Setup Page
3.100 Cutterhead Assembly Advanced Settings Tab (1)
3.101 Stone/Metal Detector and Kernel Processor Settings Tab (2)
3.102 XStream KP? Kernel Processor Bearing Temperatures Tab (3)
3.103 Knife Sharpening/Stationary Knife Adjustment
3.104 AutoLoc? Page
3.105 Metal/Stone Detector Operation
3.106 Additive Dosing System Page (Option)
3.107 Additive Dosing System Page?High Volume (Option)
3.108 Additive Dosing System Page?High and Low Volume (Option)
3.109 Additive Dosing System?Water Injection Bar
3.110 Operate High and Low Volume Dosing System with Water Injection Bar
3.111 Operate Water Injection Bar
3.112 Spout Speeds Page
3.113 Spout Setup Page
3.114 Auto Spout Positioning Page
3.115 Spout Fold/Unfold Timeout
3.116 Automatic Spout Control (Option)
3.117 Store and Assign Spout Position
3.118 Active Fill Control (Option)
3.119 Engine Page
3.120 Engine Speed Management?Field Mode
3.121 Engine Speed Limit
3.122 Engine Settings Page
3.123 Vehicle Settings Page
3.124 Vehicle Lubrication
3.125 Header Lubrication
3.126 Tow Mode Page
3.127 Wiper Interval Page
3.128 Mass Flow Calibration
3.129 Diagnostics Information
3.130 Spout Fold Hydraulic Pressure Relief Function
3.131 Lighting Setup Page
3.132 Machine Lighting
3.133 Machine Lighting?Lower Front Location
3.134 Machine Lighting?Upper Front Location
3.135 Machine Lighting?Rear and Side Location
3.136 Operator Settings Page
3.137 Programmable Switch Function Assignment
3.138 ProTouch Page
3.139 ProTouch?Field Transition Status Page
3.140 ProTouch?Road Transition Status Page
3.141 Harvest Statistics Page
3.142 Machine Performances Page
3.143 Statistics Settings Page
3.144 Diagnostic Trouble Code Priorities
3.145 Access Diagnostic Trouble Codes Menu
3.146 AutoTrac? RowSense? Guidance (Option)
3.147 GreenStar? Settings Page
3.148 GreenStar? Guidance Page
3.149 GreenStar? Machine/Implement Pages
3.150 Enable/Activate/Operate AutoTrac? RowSense?
3.151 Calibrate the Row Sensor
3.152 Video Interface (Option)
3.153 Video Trigger Setup Page
3.154 Phone Interface (Option)
3.155 Audio Interface (Option)
3.156 Acoustic Alarm System
4 Field Operation
4.1 General
4.2 Quick Response (QR) Code
4.3 Prestarting Checks
4.4 Selective Catalytic Reduction (SCR) System Overview
4.5 Break in the Engine
4.6 Operate the Engine
4.7 Start the Engine With a Battery Booster or Charger
4.8 Disconnect the Battery
4.9 Battery Disconnect Switch
4.10 Transport Information
4.11 Tow the Machine
4.12 Ballast the Machine
4.13 Attach Weight Plates
4.14 Lateral Tilt Frame Locking Device (Machine without Lateral Tilt Float Option Only)
4.15 Machine Road Transport Guard (Germany and Italy Only)
4.16 Machine Road Transport Deflectors
4.17 Attach and Detach Header
4.18 Basic Settings of Machine
4.19 Operate Machine in Grass or Alfalfa Harvest
4.20 Operate Machine in Corn (Maize) Harvest
4.21 Operate Machine in Ear Corn Silage
4.22 Operate Machine in Whole Plant Silage
4.23 Operate Machine in Sorghum (Milo) Harvest
4.24 Operate the Air Compressor System
4.25 Operate the Grass Chute
4.26 Operate a 460plus StalkBuster? Header
4.27 Operate the Kernel Processor (Option)
4.28 Remove Kernel Processor
4.29 Install Kernel Processor
4.30 Adjust Premium KP? Kernel Processor Gap (Manual Adjustment)
4.31 Adjust XStream KP? Kernel Processor Gap (Manual Adjustment)
4.32 XStream KP? Kernel Processor Lubrication System Air Supply (If Equipped)
4.33 Adjust Lateral Tilt Frame Balance Springs
4.34 Open/Close Discharge Chute
4.35 Adjust Spiral/Recutter Floor
4.36 Adjust Smooth Roll Scraper
4.37 Adjust Feed Roll Springs
4.38 Adjust Feed Roll Bars
4.39 Cutterhead Knives
4.40 Stationary Knife
4.41 Kernel Processor Rolls
4.42 Feed Roll Paddles
4.43 Grass and Whole-Crop Machine Adaptation
4.44 Spiral Upper Front Feed Roll Option
4.45 Ear Corn Silage Machine Adaptation
4.46 Grain Panels (Corn)
4.47 Feed Roll Stone Deflector
4.48 Transfer Stereo Camera from Machine-to-Machine (If Equipped)
5 Lubrication and Maintenance
5.1 Required Emission-Related Information
5.2 Quick Response (QR) Code
5.3 General Maintenance Guidelines
5.4 Cutterhead Access Foot Step
5.5 Engine Compartment Access Ladder
5.6 Central Service Compartment Access
5.7 Tool Box Compartment
5.8 Service Lights (If Equipped)
5.9 12 V Power Outlets
5.10 Secure Cutterhead Lift Lock
5.11 Interactive Calibration Procedures
5.12 Break-in Service
5.13 After the First 10 Operating Hours
5.14 During the First 50 Operating Hours
5.15 After the First 100 Operating Hours
5.16 Diesel Engine Oil
5.17 Engine Oil and Filter Service Intervals
5.18 Transmission Oil
5.19 Hydraulic Oil
5.20 XStream KP? Kernel Processor Lubrication System Oil
5.21 Multipurpose Extreme Pressure Grease
5.22 General Multipurpose Grease
5.23 Grease for Automated Lubrication Systems
5.24 Capacities
5.25 Important Lubrication Instructions
5.26 Central Lubrication System
5.27 Refill/Bleed Central Lubrication System Reservoir
5.28 XStream KP? Kernel Processor Lubrication System Reservoir (If Equipped)
5.29 Greasing Points (Manually Lubricated)
5.30 Every 10 Operating Hours
5.31 Every 50 Operating Hours
5.32 Every 100 Operating Hours
5.33 Every 250 Operating Hours
5.34 Every 500 Operating Hours
5.35 Every 1000 Operating Hours
5.36 Every 1500 Operating Hours
5.37 Every 2000 Operating Hours
5.38 Every 8000 Operating Hours
5.39 Every 10000 Operating Hours
5.40 As Required
5.41 Annually
5.42 Every 2 Years
5.43 Every 3 Years or 4500 Operating Hours
5.44 Every 6 Years or 6000 Operating Hours
5.45 Hydraulic Hose Replacement
5.46 Hydraulic System Cleanliness
5.47 Change Hydraulic System Oil
5.48 Replace Hydraulic System Reservoir Filter
5.49 Change Power Distribution Gear Case Oil
5.50 Replace Power Distribution Gear Case Oil Filter
5.51 Change ProDrive? Transmission Oil
5.52 Replace ProDrive? Transmission Hydraulic Oil Filter
5.53 Change Final Drive Oil
5.54 Change Header Gear Case Oil
5.55 Change Left Feed Roll Gear Case Oil
5.56 Change Right Feed Roll Gear Case Oil
5.57 Change Rear Axle Oil
5.58 Diesel Exhaust Fluid (DEF) ? Use in Selective Catalytic Reduction (SCR) Equipped Engines
5.59 Storing Diesel Exhaust Fluid (DEF)
5.60 Testing Diesel Exhaust Fluid (DEF)
5.61 Disposal of Diesel Exhaust Fluid (DEF)
5.62 Fill the Diesel Exhaust Fluid (DEF) Tank
5.63 Diesel Fuel
5.64 Handling and Storing Diesel Fuel
5.65 Lubricity of Diesel Fuel
5.66 Testing Diesel Fuel
5.67 Biodiesel Fuel
5.68 Fill the Fuel Tank
5.69 Minimizing the Effect of Cold Weather on Diesel Engines
5.70 Mixing of Lubricants
5.71 Oilscan? and CoolScan?
5.72 Alternative and Synthetic Lubricants
5.73 Lubricant Storage
5.74 Oil Filters
5.75 Diesel Engine Coolant (engine with wet sleeve cylinder liners)
5.76 Supplemental Coolant Additives
5.77 Drain Intervals for Diesel Engine Coolant
5.78 Additional Information About Diesel Engine Coolants and John Deere LIQUID COOLANT CONDITIONER
5.79 Testing Diesel Engine Coolant
5.80 Operating in Warm Temperature Climates
5.81 Adjust Engine Valve Clearance
5.82 Check Engine Oil Level
5.83 Change Engine Oil and Filter
5.84 Change Crankcase Ventilation/Oil Separator Filter
5.85 Do Not Open High-Pressure Fuel System
5.86 Do Not Modify Fuel System
5.87 Fuel Tank Breather
5.88 Drain Water from Air Compressor Cooler
5.89 Drain Water Separator
5.90 Replace Fuel Filter Elements
5.91 Check Fuel Injection Nozzles
5.92 Check Cooling Elements
5.93 Check the Rotary Screen
5.94 Engine Coolant
5.95 Engine Coolant Drain Valves
5.96 Drain, Flush, and Refill Cooling System
5.97 Check Alternator and Compressor Drive Belt Wear
5.98 Check Fan Drive Belt Wear
5.99 Check Suction Fan Drive Belt Wear
5.100 Replace Air Compressor Dryer Element
5.101 Air Cleaner Elements
5.102 Air Intake Lines
5.103 Turbocharger
5.104 Clean Diesel Exhaust Fluid (DEF) Tank
5.105 Clean Diesel Exhaust Fluid (DEF) Tank Filler Neck Filter
5.106 Replace Diesel Exhaust Fluid (DEF) Tank Vent Filter
5.107 Open/Close Feed Roll Housing
5.108 Cutterhead Knives?General
5.109 Replace Cutterhead Knives
5.110 Replace Individual Knives
5.111 Replace Complete Set of Knives
5.112 Stationary Knife?General
5.113 Replace Stationary Knife
5.114 Knife Sharpening Device?General
5.115 Replace Sharpening Stone
5.116 Replace Spiral/Recutter Floor
5.117 Replace Recutter Floor Knives
5.118 Replace Feed Roll Stone Deflector
5.119 Replace Cutterhead Wear Plate
5.120 Replace Feed Roll Housing Wear Plate
5.121 Weld Near Electronic Control Units
5.122 Keep Electronic Control Unit Connectors Clean
5.123 Observe Electrical Precautions
5.124 Basic Electrical Component Handling – Precautions for Machines Equipped with Computer Controlled Systems
5.125 Battery Disconnect Switch
5.126 Fuse Center
5.127 Inline Fuses?12 V
5.128 Inline Fuses?24 V
5.129 Master Fuses?12 V
5.130 Master Fuses?24 V
5.131 Cab Fuse (Diode Module Fuse)
5.132 Kernel Processor Winch Relay (If Equipped)
5.133 Starter Relay (24 V)
5.134 Voltage Divider Relay
5.135 Heating Flange Relay
5.136 Safety Rules When Replacing Halogen Bulbs
5.137 Replace Cab Headlight Bulb (Non-Light Emitting Diode [LED] Lights)
5.138 Adjust Cab Headlights (Non-Light Emitting Diode [LED] Lights)
5.139 Replace Cab Headlights (Light Emitting Diode [LED] Lights?If Equipped)
5.140 Adjust Cab Headlights (Light Emitting Diode [LED] Lights?If Equipped)
5.141 Replace Cab Headlights Halogen Light Bulb (High- and Low-Beam)
5.142 Adjust Cab Headlights Halogen Light Bulb (High- and Low-Beam)
5.143 Replace Cab Headlights (High- and Low-Beam – Light Emitting Diode [LED] Lights?If Equipped)
5.144 Adjust Cab Headlights (High- and Low-Beam – Light Emitting Diode [LED] Lights?If Equipped)
5.145 Replace Fascia or Side Finder Light Bulb (If Equipped)
5.146 Replace Lower Driving or Lower Work Light Bulb (If Equipped)
5.147 Adjust Lower Driving or Lower Work Lights (If Equipped)
5.148 Replace Beacon Light (Light Emitting Diode [LED] Lights)
5.149 Replace Work Lights (If Equipped)
5.150 Replace Service Lights
5.151 Replace Tail, Stop or Turn Lights
5.152 Replace Cab Interior Light
5.153 Replace Map Light
5.154 Replace Toolbox Compartment Light
5.155 Replace Access Ladder Light
5.156 Replace License Plate Light
5.157 Rear Axle Toe-In
5.158 Brake System
5.159 Active Fill Control System (Option)
5.160 AutoTrac? RowSense? System (Option)
5.161 Additive Dosing System (Option)
5.162 Change Additive Dosing System Nozzle
5.163 Replace Fresh Air Filter
5.164 Replace Recirculation Air Filter
5.165 Check Refrigerant Level
5.166 Replace Blower Rear Wear Plates
5.167 Replace Blower Side Wear Plates
5.168 Replace Discharge Tower Wear Plates
5.169 Replace and Adjust Blower Paddles
5.170 Spout Service Opening and Wear Plates
5.171 Swap Discharge Spout Extensions (If Equipped)
5.172 Adjust Spout Motor Gear and Ring Gear
5.173 Jacking Points
5.174 Service Tires Safely
5.175 Care and Service of Tires
5.176 Wheel Bolts and Nuts
5.177 Mounting Tires
5.178 Changing Tires
5.179 Tire Sizes
5.180 Required Tire Load Indexes
5.181 Tire Pressures
5.182 Use Genuine John Deere Parts
5.183 Prepare Machine for Storage
5.184 Premium KP? Kernel Processor End-of-Season Maintenance
5.185 XStream KP? Kernel Processor End-of-Season Maintenance
5.186 Remove Machine from Storage
6 Specifications
6.1 9800 Forage Harvester
6.2 9900 Forage Harvester
6.3 9800 and 9900 Forage Harvesters
6.4 Dimensions
6.5 Type Plates
6.6 Identify Date Code
6.7 Forage Harvester (Machine Identification) Type Plate
6.8 Product Identification Number
6.9 Machine Component Serial Numbers
6.10 Metric Bolt and Screw Torque Values
6.11 Unified Inch Bolt and Screw Torque Values
6.12 UK Declaration of Conformity (United Kingdom Only)
6.13 UK Declaration of Conformity (United Kingdom Only)
6.14 UK Declaration of Conformity (United Kingdom Only)
6.15 EU Declaration of Conformity
6.16 EU Declaration of Conformity
6.17 EU Declaration of Conformity
6.18 Declaration of Conformity
6.19 Eurasian Economic Union?EAC
6.20 Eurasian Economic Union?EAC (English, Russian, and Kazakh)
6.21 Machine Design Life
6.22 Toxic or Hazardous Substances or Elements Disclosure?Image Processing Module (IPM)
6.23 Toxic or Hazardous Substances or Elements Disclosure?Motec Stereo Camera
6.24 John Deere Active Fill Control?Federal Communications Commission (FCC) Notifications to User
6.25 Safety Note Regarding the Subsequent Installation of Electrical and Electronic Appliances and/or Components
6.26 Fluorinated Greenhouse Gas
7 Index
8 John Deere Service Keeps You on the Job
8.1 John Deere Parts
8.2 The Right Tools
8.3 Well-Trained Technicians
8.4 Prompt Service
