John Deere Excavators 550LC Service Repair Manual (TM1808)
Complete service repair manual for Excavators 550LC, with technical information to maintain, repair, and servicelike professional mechanics.
John Deere Excavators 550LC workshop service & repair 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.
* 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.
TM1808 - John Deere 550LC Excavators Technical Manual - Repair
TABLE OF CONTENTS
Foreword
Technical Information Feedback Form
General Information
Safety
General Specifications
Torque Values
Fuels and Lubricants
Predelivery Assembly Instructions
Tracks
Track System
Axles and Suspension Systems (Propel)
Axle Shaft, Bearings and Reduction Gears
Hydraulic System
Engine
Removal and Installation
Engine Auxiliary System
Cold Weather Starting Aids
Cooling Systems
Speed Controls
Intake System
External Exhaust Systems
Connector Drive
Elements
Transfer or Splitter Drive
Removal and Installation
Gears, Shafts and Bearings
Electrical System
Batteries, Support, and Cables
Alternator, Regulator, and Charging System Wiring
Wiring Harness and Switches
System Controls
Instruments and Indicators
Frame or Supporting Structure
Frame Installation
Chassis Weights
Operator`s Station
Removal and Installation
Operator Enclosure
Seat and Seat Belt
Heating and Air Conditioning
Safety and Convenience
Horn and Warning Devices
Excavator
Buckets
Frames
Hydraulic System
Swing or Pivoting System
Mechanical Drive Elements
Hydraulic System
Dealer Fabricated Tools
Total Pages/Size: 1,093 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English
CONTENTS - Expanded View
00 - General Information
01 - Safety
Avoid Heating Near Pressurized Fluid Lines
Avoid High-Pressure Fluids
Avoid Power Lines
Beware of Exhaust Fumes
Dispose of Waste Properly
Follow Safe Procedures
Handle Chemical Products Safely
Handle Fluids Safely-Avoid Fires
Illuminate Work Area Safely
Keep Riders Off Machine
Live With Safety
Move and Operate Machine Safely
Operate Only from Operator's Seat
Park Machine Safely
Prepare for Emergencies
Prevent Acid Burns
Prevent Battery Explosions
Protect Against Flying Debris
Protect Against Noise
Remove Paint Before Welding or Heating
Replace Safety Signs
Service Cooling System Safely
Service Machines Safely
Stay Clear of Moving Parts
Support Machine Properly
Use Handholds and Steps
Use Proper Lifting Equipment
Use Tools Properly
Warn Others of Service Work
Wear Protective Clothing
Work in a Clean Area
02 - General Specifications
550LC Excavator Overview
550LC Excavator
550LC Lift Capacity-KG (LB)
Drain and Refill Capacities
Engine Specifications
Working Ranges
03 - Torque Values
Additional Metric Cap Screw Torque Values
Check Oil Lines And Fittings
Hardware Torque Specifications
Metric Bolt and Screw Torque Values
Service Recommendations for 37° Flare and 30° Cone Seat Connectors
Service Recommendations For Flared Connections-Straight or Tapered Threads
Service Recommendations For Flat Face O-Ring Seal Fittings
Service Recommendations For Inch Series Four Bolt Flange Fittings
Service Recommendations for Metric Series Four Bolt Flange Fitting
Service Recommendations for O-Ring Boss Fittings
Unified Inch Bolt and Screw Torque Values
04 - Fuels & Lubricants
Alternative and Synthetic Lubricants
Diesel Engine Oil
Diesel Fuel
Diesel Fuel Storage
Do Not Use Galvanized Containers
Fuel Tank
Grease
Hydraulic Oil
Low Sulfur Diesel Fuel Conditioner
Lubricant Storage
Lubricity of Diesel Fuels
Mixing of Lubricants
Oil Filters
Swing Gearbox, Propel Gearbox and Pump Gearbox Oils
Track Adjuster, Working Tool Pivot, Swing Bearing, and Swing Bearing Gear Grease
Track Roller, Front Idler, and Carrier Roller Oil
06 - Predelievery Assembly Instructions
Adjusting Bucket Linkage
Attach Windshield Wiper
Avoid High-Pressure Fluids
Check Hydraulic Oil Level
Connecting Arm Cylinder Rod
Connecting Boom Cylinder Rod
Connecting Bucket Cylinder Hoses
Connecting Hoses Between Boom and Machine
Counterweight Installation (With Hydraulic Removal Option)
Extending the Side Frame
Installing Arm
Installing Boom Cylinder
Installing Boom
Installing Bucket
Installing Counterweight (Without Hydraulic Removal Option)
Lubricate Working Tool Pivots
Precautions for Assembling
Precautions for Lifting Work
Precautions for Operating Machine
Retracting the Side Frame
Specifications
01 - Wheels or Tracks
Assemble Front Idler
Assemble Track Adjuster Recoil Spring
Disassemble and Assemble Lower Track Roller
Disassemble and Assemble Track Adjuster Cylinder
Disassemble and Assemble Track Carrier Roller
Disassemble and Assemble Track Chain
Disassemble Front Idler
Disassemble Track Adjuster Recoil Spring
Essential Tools
Inspect Metal Face Seals
Install Track Chain
Measure Front Idler Wear
Measure Lower Track Roller Wear
Measure Track Carrier Roller Wear
Measure Track Chain Bushing Wear
Measure Track Chain Link Wear
Measure Track Chain Pitch
Measure Track Shoe Grouser Wear
Other Material
Remove and Install Front Idler
Remove and Install Lower Track Roller
Remove and Install Sprocket
Remove and Install Track Adjuster Cylinder and Recoil Spring
Remove and Install Track Carrier Roller
Remove and Install Track Shoe
Remove Track Chain
Service Equipment and Tools
Specifications
Track Sag Adjustment
02 - Axles and Suspension Systems
50 - Axle Shaft, Bearings, and Reduction Gears
Assemble Propel Gearbox
Disassemble Propel Gearbox
Inspect Metal Face Seals
Other Material
Remove and Install Propel Gearbox
Service Equipment and Tools
Specifications
60 - Hydraulic System
Disassemble and Assemble Counterbalance Valve
Disassemble and Assemble Propel Flow Regulator
Disassemble and Assemble Propel Motor and Brake
Disassemble and Assemble Rotary Manifold
Other Material
Propel Motor Start-Up Procedure
Remove and Install Counterbalance Valve
Remove and Install Propel Flow Regulator
Remove and Install Propel Motor and Brake
Remove and Install Propel Motor Crossover Relief Valves
Remove and Install Propel Speed Change Solenoid Valve
Remove and Install Rotary Manifold
Remove and Install Speed Selector Valve
Rotary Manifold Air Test
Service Equipment and Tools
Specifications
04 - Engine
14L (875 cu. in.) N14 Series Cummins Engine
Essential Tools
Inspect Crankcase Ventilation Tube
Measure And Adjust Injector And Engine Valve Clearances
Remove And Install Engine
Remove and Install Starting Motor
Service Equipment and Tools
Specifications
05 - Engine Auxiliary Systems
05 - Cold Weather Starting Aids
Other Material
Remove and Install Starting Aid Solenoid and Nozzle
10 - Cooling System
Inspect Belts and Check Tension
Remove and Install Alternator Belts
Remove and Install Fan Belt
Remove and Install Fan, Shroud, and Guard
Remove and Install Radiator
Remove and Install Water Pump Belt
Service Equipment and Tools
Specifications
15 - Speed Controls
Disassemble and Assemble Engine Controller (EC) Motor and Sensor
Engine Speed Control Linkage Adjustment
Engine Speed Programming Procedure After Battery Disconnection
Other Material
Remove and Install Engine Control (EC) Motor and Sensor
Remove and Install Speed Control Linkage
Service Equipment and Tools
Specifications
20 - Intake System
Air Intake Leakage Check
Remove and Install Air Cleaner
Specifications
30 - External Exhaust System
60 - External Fuel Supply Systems
Remove and Install Fuel Tank
Specifications
07 - Dampener Drive (Flex Coupling)
Remove and Install Connector Drive Coupling
08 - Transfer or Splitter Drive
00
Remove and Install Pump Drive Gearbox
Specifications
51
Disassemble and Assemble Pump Drive Gearbox
Specifications
16 - Electrical System
71 - Batteries, Support, and Cables
Adding 12 or 24 Volt Accessories
Charging Battery
Check Battery Electrolyte Level and Terminals
Engine Speed Programming Procedure After Battery Disconnection
Handle Batteries Safely
Procedure for Testing Batteries
Remove and Install Batteries
Service Equipment and Tools
Specifications
Using Booster Batteries-24 Volt System
72 - Alternator, Regulator, and Charging System Wiring
Alternator Belt Tension Adjustment
Alternators and Starting Motors-Use CTM77
Remove and Install Alternator
Service Equipment and Tools
Specifications
74 - Wiring Harness and Switches
Cab Harness (W2) Component Location Diagram
Connecting Engine Controller (EC) and Pump and Valve Controller (PVC) Harness Connector
Disconnecting Spring Wire Clip Connectors
Disconnect Tab Retainer Connectors
Engine and Frame Harness (W1) Component Location Diagram
Essential Tools
Fuse (Blade-Type) Color Codes
Install DEUTSCH™ Contact
Install WEATHER PACK™ Contact
Monitor and Relay Harness (W3) Component Location
Remove and Install Key Switch
Remove Connector Body from Blade Terminals
Replace DEUTSCH™ Connectors
Replace WEATHER PACK™ Connector
Replacing Fuses
75 - System Controls
Specifications
Welding On Machine
Welding Repair of Major Structure
76 - Instruments and Indicators
Remove and Install Right Console Controller
17 - Frames, Chassis, or Supporting Structure
40 - Frame Installation
Specifications
Welding On Machine
Welding Repair of Major Structure
49 - Chassis Weight
Counterweight Installation (With Hydraulic Removal Option)
Hydraulic Counterweight Removal Option Component Location
Remove and Install Counterweight (Without Hydraulic Removal Option)
Remove Counterweight (With Hydraulic Removal Option)
Specifications
18 - Operator's Station
00 - Removal & Installation
Remove and Install Cab
Specifications
10 - Operator Enclosure
Other Material
Remove and Install Sliding Windows
Remove and Install Windowpane and One Piece Molding
Remove and Install Windowpane and Two Piece Molding
Service Equipment and Tools
21 - Seat & Seat Belt
Check Seat Adjustments
Inspect Seat Belt
Remove and Install Seat Belt
Remove and Install Seat
Specifications
30 - Heating & Air Conditioning System
Air Conditioner Self-Diagnostic Procedure
Charge R134a System
Check and Adjust Compressor Belt Tension
Disassemble and Assemble Air Conditioning Compressor
Essential Tools
Evacuate R134a System
Heater and Air Conditioner Component Location
Other Material
Proper Refrigerant Handling
R134a Component Oil Charge
R134a Compressor Oil Charge Check
R134a Compressor Oil Removal
R134a Refrigerant Cautions
R134a Refrigerant Recovery, Recycling, and Charging Station Installation Procedure
Recover R134a System
Remove and Install Air Conditioning Compressor
Remove and Install Condenser
Remove and Install Heater Core and Evaporator
Remove and Install Heater Hoses
Remove and Install Receiver Dryer
Service Equipment and Tools
Specifications
20 - Safety & Convenience
Changing Travel Alarm Volume
Remove and Install Travel Alarm
33 - Excavator
02 - Buckets
Adjusting Bucket Linkage
Installing Bucket
Remove and Install Tooth Shank
Repair Cracked Cutting Edge
Replace Welded Bucket Cutting Edges
Replacing Bucket Teeth
Replacing Bucket Tooth Tip (Heavy Duty Bucket)
Specifications
Welding On Machine
40 - Frames
Inspect Arm and Boom Pins and Bushings
Remove and Install Arm
Remove and Install Boom
Remove and Install Bushings and Seals
Service Equipment and Tools
Specifications
60 - Hydraulic System
Assemble Boom, Arm, or Bucket Cylinder
Assemble Hydraulic Pump
Control Lever Pattern Conversion
Disassemble and Assemble Circuit Relief and Anti-Cavitation Valve
Disassemble and Assemble Counterweight Lift Cylinder
Disassemble and Assemble Counterweight Pilot Controller
Disassemble and Assemble Dig and Swing Function Pilot Shuttle Check Valve
Disassemble and Assemble Dig Flow Regulator Valve
Disassemble and Assemble Dig Function Pilot Controller
Disassemble and Assemble Hydraulic Pump Regulator Cover
Disassemble and Assemble Main Control Valve
Disassemble and Assemble Pilot Check Valve Block
Disassemble and Assemble Pilot Pump
Disassemble and Assemble Pilot Shut-Off Valve
Disassemble and Assemble Propel Function Pilot Check Valve
Disassemble and Assemble Propel Pilot Controller
Disassemble and Assemble Solenoid Valve Manifold and Pilot Pressure Regulating Valve
Disassemble and Assemble Swing Priority Solenoid Valve
Disassemble and Assemble System Relief Valve
Disassemble Boom, Arm or Bucket Cylinder
Disassemble Hydraulic Pump
Electronic Control Bypass Procedure
Hydraulic Cylinder Bleeding Procedure
Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy
Hydraulic Oil Filter Inspection Procedure
Hydraulic Pump Start-Up Procedure
Lower Boom With Engine Stopped
Other Material
Pilot Shut-Off Valve Linkage Adjustment
Pump Angle Sensor Adjustment
Remove and Install Arm Cylinder
Remove and Install Boom Cylinder
Remove and Install Bucket Cylinder
Remove and Install Counterweight Lift Cylinder
Remove and Install Counterweight Pilot Controller
Remove and Install Dig and Swing Function Pilot Shuttle Check Valve
Remove and Install Dig Flow Regulator Valve
Remove and Install Hydraulic Oil Cooler Bypass Valve
Remove and Install Hydraulic Oil Cooler
Remove and Install Hydraulic Oil Reservoir
Remove and Install Hydraulic Pump Angle Sensor
Remove and Install Hydraulic Pump Displacement Solenoid Valve
Remove and Install Hydraulic Pump
Remove and Install Hydraulic Pump Pressure Sensor
Remove and Install Hydraulic Pump Regulator Cover
Remove and Install Main Control Valve
Remove and Install Pilot Check Valve Block
Remove and Install Pilot Controller
Remove and Install Pilot Filter
Remove and Install Pilot Pump
Remove and Install Pilot Shut-Off Valve
Remove and Install Pressure Differential (DP) Sensor
Remove and Install Propel Function Pilot Check Valve
Remove and Install Propel Pilot Controller
Remove and Install Restriction Valve
Remove and Install Solenoid Valve Manifold and Pilot Pressure Regulating Valve
Remove and Install Swing Priority Solenoid Valve
Service Equipment and Tools
Specifications
43 - Swing or Pivoting System
50 - Mechanical Drive Elements
Assemble Swing Gearbox
Disassemble and Assemble Swing Bearing
Disassemble Swing Gearbox
Install Swing Bearing Lower Seal
Install Swing Bearing Upper Seal
Install Upperstructure
Other Material
Remove and Install Swing Bearing
Remove and Install Swing Gearbox
Remove Upperstructure
Service Equipment and Tools
Specifications_{4039}
Specifications
Swing Gearbox Start-Up Procedure
60 - Hydraulic System
Assemble Swing Motor and Brake
Disassemble Swing Motor and Brake
Remove and Install Crossover Relief Valves and Make-Up Valves
Remove and Install Swing Brake Release Solenoid Valve
Remove and Install Swing Motor and Brake
Service Equipment and Tools
Specifications
Swing Motor Start-Up Procedure
99 - Dealer Fabricated Tools
DFT1075 Propel Gearbox Nut Wrench
DFT1077 Spool Holding Fixture
John Deere Excavators 550LC Service Repair Manual (TM1808)
