John Deere Excavators 600CLC & 800C Operation and Test Service Manual (TM1922)

TM1922 - John Deere 600CLC and 800C Excavators Technical Manual - Operation and Test.PDF

Complete Diagnostic, Operation and Test manual with Electrical Wiring Diagrams for Excavators 600CLC & 800C, with all the shop information to maintain, diagnostic, repair, refurbish/rebuild like professional mechanics.

John Deere Excavators 600CLC & 800C workshop Operation and Test manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

Total Pages: 751 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

MAIN SECTIONS
 Foreword
   Technical Information Feedback Form
   General Information
      Safety
      Torque Values
   Operational Checkout Procedure
      Operational Checkout Procedure
   Engine
      Theory of Operation
      Diagnostic Information
      Adjustments
      Tests
   Electrical System
      System Information
      System Diagrams
      Sub-System Diagnostics
      References
   Power Train
      Theory of Operation
      Diagnostic Information
   Hydraulic System
      Theory of Operation
      Diagnostic Information
      Tests
   Air Conditioning System
      Theory of Operation
      Diagnostic Information
      Tests

tm1922 - 600CLC and 800C Excavator

Table of Contents

Foreword

Technical Information Feedback Form

Section 9000: General Information

Group 01: Safety

Recognize Safety Information

Follow Safety Instructions

Operate Only If Qualified

Wear Protective Equipment

Avoid Unauthorized Machine Modifications

Add Cab Guarding for Special Uses

Inspect Machine

Stay Clear of Moving Parts

Avoid High-Pressure Oils

Beware of Exhaust Fumes

Prevent Fires

Prevent Battery Explosions

Handle Chemical Products Safely

Dispose of Waste Properly

Prepare for Emergencies

Use Steps and Handholds Correctly

Start Only From Operator's Seat

Use and Maintain Seat Belt

Prevent Unintended Machine Movement

Avoid Work Site Hazards

Keep Riders Off Machine

Avoid Backover Accidents

Avoid Machine Tip Over

Use Special Care When Lifting Objects

Add and Operate Attachments Safely

Park and Prepare for Service Safely

Service Cooling System Safely

Remove Paint Before Welding or Heating

Make Welding Repairs Safely

Drive Metal Pins Safely

Group 03: Torque Values

Hardware Torque Specifications

Unified Inch Bolt and Screw Torque Values

Metric Bolt and Screw Torque Values

Additional Metric Cap Screw Torque Values

Check Oil Lines And Fittings

Service Recommendations for O-Ring Boss Fittings

Service Recommendations For Flat Face O-Ring Seal Fittings

Service Recommendations for 37° Flare and 30° Cone Seat Connectors

Service Recommendations For Flared Connections—Straight or Tapered Threads

Service Recommendations For Inch Series Four Bolt Flange Fittings

Service Recommendations for Metric Series Four Bolt Flange Fitting

Section 9005: Operational Checkout Procedure

Group 10: Operational Checkout Procedure

Operational Checkout

Section 9010: Engine

Group 05: Theory of Operation

Engine—Component Location

Engine Fuel System Operation

Engine Cooling System Operation

Engine Lubrication System Operation

Engine Turbocharger Operation

Engine Speed Control System Operation

Group 15: Diagnostic Information

Diagnose Engine Malfunctions

Group 20: Adjustments

Check and Adjust Engine Valve Lash (Clearance)

Group 25: Tests

Engine Speed Test

Air Filter Restriction Indicator Switch Test

Radiator Air Flow Test

Engine Power Test Using Turbocharger Boost Pressure

Section 9015: Electrical System

Group 05: System Information

Electrical Diagram Information

Group 10: System Diagrams

Explanation of Wire Markings

Fuse Specifications

System Functional Schematic Section Legend

Wiring and Schematic Diagrams Legend

System Functional Schematic

Overall Machine Harnesses Component Location Diagram (600CLC)

Overall Machine Harnesses Component Location Diagram (800C)

Cab Harness (W1) and 12 Volt Power Supply (W35) Harness Component Location Diagram

Cab Harness (W1) Component Location Diagram—Harness Connectors

12 Volt Power Supply (W35) Sub-Harness Component Location Diagram—Harness Connectors

Engine Harness (W2) Component Location Diagram (600CLC)

Engine Harness (W2) Component Location Diagram—Harness Connectors (600CLC)

Engine Harness (W20) Component Location Diagram (800C)

Engine Harness (W20) Component Location Diagram—Harness Connectors (800C)

Monitor Harness (W3) and Windshield Wiper Motor Sub-Harness (W5) Component Location Diagram

Monitor Harness (W3) Component Location Diagram—Harness Connectors

Windshield Wiper Motor Sub-Harness (W5) Component Location Diagram—Harness Connectors

Solenoid Harness (W6) Component Location Diagram (600CLC)

Solenoid Harness (W6) Component Location Diagram—Harness Connectors (600CLC)

Solenoid Harness (W7) Component Location Diagram (800C)

Solenoid Harness (W7) Component Location Diagram—Harness Connectors (800C)

Air Conditioner Controller Harness (W9) Component Location Diagram—Harness Mating Connectors

Vehicle Harness (W10) Component Location Diagram (600CLC)

Vehicle Harness (W10) Component Location Diagram—Harness Connectors (600CLC)

Vehicle Harness (W30) Component Location Diagram (800C)

Vehicle Harness (W30) Component Location Diagram—Harness Connectors (800C)

Pump Harness (W12) Component Location Diagram (600CLC)

Pump Harness (W12) Component Location Diagram—Harness Connectors (600CLC)

Pump Harness (W31) Component Location Diagram (800C)

Pump Harness (W31) Component Location Diagram—Harness Connectors (800C)

Engine Coolant Sensor Harness (W16) Component Location Diagram (600CLC)

Engine Coolant Sensor Harness (W16) Component Location Diagram—Harness Connectors (600CLC)

Engine Coolant Sensor Harness (W26) Component Location Diagram (800C)

Engine Coolant Sensor Harness (W26) Component Location Diagram—Harness Connectors (800C)

Control Valve Harness (W18) Component Location Diagram (600CLC)

Control Valve Harness (W18) Component Location Diagram—Harness Connectors (600CLC)

Control Valve Harness (W28) Component Location Diagram (800C)

Control Valve Harness (W28) Component Location Diagram—Harness Connectors (800C)

Fuel Tank Harness (W19) Component Location Diagram

Fuel Tank Harness (W19) Component Location Diagram—Harness Connectors

Air Conditioner Harness (W34), and Air Conditioner Controller Harness (W9) Component Location Diagram

Air Conditioner Harness (W34) Wiring Diagram—Harness Mating Connectors

Group 15: Sub-System Diagnostics

Starting Circuit Theory of Operation

Travel Alarm Circuit Theory of Operation

Monitor Controller and Display Circuit Theory of Operation

Engine Control Circuit Theory of Operation

Pump and Valve Controller Circuit Theory of Operation

Windshield Wiper And Washer Circuit Theory of Operation

Air Conditioner Controller Circuit Theory of Operation

Group 20: References

Laptop Computer Connection To Pump and Valve Controller Using Service ADVISOR or Excavator Diagnostic Program

Excavator Diagnostic Program General Description and Overview

Reading Service Codes Without Laptop Computer

Monitor Display Diagnostic System Operation

Monitor Data Items

Alternator Test Procedure

Fuse Test

Engine Speed Learning Procedure

Pump and Valve Controller Pressure Sensors Test

Pump and Valve Controller Solenoids Test

Pump and Valve Controller Temperature Sensor Test

Engine Speed (N) Sensor Test

Pump Angle Sensors and Engine Control Sensor Test

Pump Angle Sensor Adjustment

Electrical Component Checks

Disconnect Tab Retainer Connectors

Disconnecting Spring Wire Clip Connectors

Pump and Valve Controller Service Codes

Repair Batteries

Repair Pump and Valve Controller

Repair Travel Alarm Cancel Switch

Repair Key Switch

Repair Travel Alarm

Repair Windshield Wiper Enable Switch

Repair Rear Cover

Repair Switch Panel

Repair Monitor Controller and Display

Section 9020: Power Train

Group 05: Theory of Operation

Track Adjuster and Recoil Spring Operation

Propel Gearbox Operation—600CLC

Propel Gearbox Operation—800C

Group 15: Diagnostic Information

Diagnose Undercarriage Component Malfunctions

Measure Swing Bearing Wear—600CLC

Measure Swing Bearing Wear—800C

Section 9025: Hydraulic System

Group 05: Theory of Operation

Hydraulic System Diagram and Operation

Pilot System Diagram and Operation

Pilot Pump, Filter, and Bypass Valve Operation

Solenoid Valve and Pilot Pressure Regulating Valve Manifold Operation

Pilot Shut-Off Valve Operation

Pilot Check Valve Manifold And Accumulator Operation

Pilot Controller Operation

Propel Pilot Controller Operation

Counterweight Removal Pilot Controller Operation

Pilot Signal Manifold Operation

Hydraulic Pump and Drive Gearbox Operation

Hydraulic Pump Regulator and Control Solenoid Valve Operation

Hydraulic Pump Flow Rate Control Circuit Operation

Hydraulic Pump Speed Sensing Control Operation

Hydraulic Pump E (Economy) Mode Control Operation

Hydraulic Pump Horsepower Control Operation

Hydraulic Pump Flow Rate Reducing Control Operation

Hydraulic Pump Swing Horsepower Control Operation

Hydraulic Pump Power Limiter Control Operation

Control Valve Operation

Control Valve Check Valves Identification and Operation

System Relief and Power Boost Valve Circuit Operation

Circuit Relief and Anti-Cavitation Valve Operation

Make-Up Valve Operation

Boom and Arm Reduced Leakage Valve Operation

Boom Mode Circuit Operation

Precision Mode Control Operation

Propel Flow Combiner Valve Circuit Operation

Bucket Flow Combiner Valve Circuit Operation

Arm Regenerative Valve Operation

Swing and Boom Up Combined Function in Dig Mode II Operation

Swing Motor, Crossover Relief Valve, and Make-Up Valve Operation—600CLC

Swing Motor Park Brake Release Circuit Operation—600CLC

Swing Gearbox Operation—600CLC

Swing Motor, Crossover Relief Valve, and Make-Up Valve Operation—800C

Swing Motor Park Brake Release Circuit Operation—800C

Swing Gearbox Operation—800C

Boom, Arm, and Bucket Cylinder Operation

Counterweight Removal Cylinder Operation

Counterweight Removal Operation

Propel Motor and Brake Valve Housing Operation

Propel Motor Speed Control Circuit Operation

Rotary Manifold Operation

Hydraulic System Circuit Symbols

Hydraulic System Schematic

Group 15: Diagnostic Information

Machine Malfunctions and Possible Causes

Diagnose Electronic and Control Valve Component Malfunctions

Diagnose Hydraulic System Malfunctions

Diagnose Pilot Circuit Malfunctions

Diagnose Swing Circuit Malfunctions

Diagnose Propel Circuit Malfunctions

Diagnose Dig Circuit Malfunctions

Control Valve Line Identification

Propel Hydraulic System Component Location

Pilot Controllers-to-Pilot Signal Manifold Component Location—Excavator Pattern

Pilot Controllers-to-Pilot Signal Manifold Component Location—Backhoe Pattern

Pilot Signal Manifold-to-Main Control Valve Component Location—600CLC

Pilot Signal Manifold-to-Main Control Valve Component Location—800C

Group 25: Tests

JT05800 Digital Thermometer Installation

JT02156A Digital Pressure/Temperature Analyzer Installation

Hydraulic System Warm-Up Procedure

Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy—600CLC

Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy—800C

Pilot Pressure Regulating Valve Test and Adjustment

Valve Spool Actuating Pilot Pressure Test and Adjustment

Power Boost, Propel Speed, and Boom Mode Solenoid Valve Test

System Relief and Power Boost Valve Test and Adjustment—600CLC

System Relief and Power Boost Valve Test and Adjustment—800C

Circuit Relief Valve Test and Adjustment—600CLC

Circuit Relief Valve Test and Adjustment—800C

Boom Mode Circuit Relief Valve Test and Adjustment

Hydraulic Pump Control Solenoid Valve Test and Adjustment

Hydraulic Pump Displacement Rate Test and Adjustment—600CLC

Hydraulic Pump Displacement Rate Test and Adjustment—800C

Hydraulic Pump Servo Piston Minimum Flow Test and Adjustment—600CLC

Hydraulic Pump Servo Piston Minimum Flow Test and Adjustment—800C

Hydraulic Pump Servo Piston Maximum Flow Test and Adjustment—600CLC

Hydraulic Pump Servo Piston Maximum Flow Test and Adjustment—800C

Swing Motor Crossover Relief Valve Test and Adjustment—600CLC

Swing Motor Crossover Relief Valve Test and Adjustment—800C

Propel Motor Crossover Relief Valve Test and Adjustment

Cylinder Drift Test—Arm, Boom, and Bucket—600CLC

Cylinder Drift Test—Arm, Boom, and Bucket—800C

Propel Motor Leakage Test

Swing Motor Leakage Test—600CLC

Swing Motor Leakage Test—800C

Hydraulic Pump Flow Test—600CLC

Hydraulic Pump Flow Test—800C

Section 9031: Air Conditioning System

Group 05: Theory of Operation

Refrigerant Theory of Operation

Heater and Air Conditioner Circuit Operational Information

Heater and Air Conditioner Circuit Theory of Operation

Group 15: Diagnostic Information

Diagnose Air Conditioning Controller Service Codes

Diagnose Air Conditioning Electrical Malfunctions

Diagnose Heater System Malfunctions

Heating and Air Conditioning Component Location Diagram

Group 25: Tests

R134a Air Conditioning System Test

High and Low Pressure Switch Test

Refrigerant Leak Testing

Refrigerant Hoses and Tubing Inspection