John Deere Excavators 550LC Operation and Test Service Manual (TM1807)
John Deere Excavators 550LC Operation and Test Service Manual (TM1807)
TM1807 - John Deere 550LC Excavators Technical Manual - Operation and Test.PDF
Complete Diagnostic, Operation and Test manual with Electrical Wiring Diagrams for Excavators 550LC, with all the shop information to maintain, diagnostic, repair, refurbish/rebuild like professional mechanics.
John Deere Excavators 550LC 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.
TABLE OF CONTENTS
Foreword
Technical Information Feedback Form
General Information
Safety
General Specifications
Torque Values
Fuels and Lubricants
Predelivery Assembly Instructions
Operational Checkout Procedure
Operational Checkout Procedure
Engine
Theory of Operation
Diagnostic Information
Adjustments
Tests
Electrical
System Information
System Diagrams
Sub-System Diagnostics
References
Power Train
Theory of Operation
Diagnostic Information
Adjustments
Hydraulic System
Theory of Operation
Diagnostic Information
Adjustments
Tests
Air Conditioning System
Theory of Operation
Diagnostic Information
Adjustments
Tests
Total Pages/Size: 1,019 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English
CONTENTS - Expanded View
9000 - 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 and 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 - Predelivery 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
9005 - Operational Checkout Procedure
10 - System Operational Checks
Operational Checkout
9010 - Engine
05 - Theory of Operation
14L (875 cu. in.) N14 Series Cummins Engine
Auto-Idle Mode Speed Control Operation
Auto Warm Up Control
E (Economy) Mode Speed Control Operation
Engine Component Location
Engine Speed Control System Operation
Engine Speed Learning Control Operation
Speed Sensing Control Operation
Super Power (S _ P) Mode Speed Control Operation
15 - Diagnostic Information
Diagnose Engine Malfunctions
20 - Adjustments
Engine Speed Check
Engine Speed Control Linkage Adjustment
Engine Speed Learning Procedure
Inspect Belts and Check Tension
25 - Tests
Air Filter Restriction Indicator Switch Test
Cooling Differential Temperature Test
Engine Power Test Using Turbocharger Boost Pressure
Fuel Pressure Test
Radiator Cap Pressure Test
9015 - Electrical System
05 - System Information
Electrical Circuit Malfunctions
Electrical Schematic Symbols
Electrical System Visual Inspection
Grounded Circuit
High Resistance Circuit
Multimeter
Open Circuit
Reading a Component Location Diagram
Reading a Connector End View Diagram
Reading a System Functional Schematic
Reading a Wiring Diagram
Schematic, Wiring Diagram, and Component Location Information
Sensor Circuit Shorted to Ground
Sensor Circuit Shorted to Itself
Sensor Circuit Shorted to Power
Seven Step Electrical Test Procedure
Shorted Circuit
10 - System Diagrams
Air Conditioning Harness (W9) Component Location
Air Conditioning Harness (W9) Wiring Diagram
Cab Harness (W2) Component Location-Detail D (Fuse Block)
Cab Harness (W2) Component Location Diagram-Detail E (Harness Mating Connectors)
Cab Harness (W2) Component Location Diagram
Cab Harness (W2) Wiring Diagram
Component Identification Table
Engine and Frame Harness (W1) Component Location Diagram-Detail A (Harness Mating Connectors)
Engine and Frame Harness (W1) Component Location Diagram
Engine and Frame Harness (W1) Wiring Diagram
Functional Schematic and Component Location Master Legend
Fuse (Blade-Type) Color Codes
Fuse Specifications
Left Boom Work Light Harness (W14) Component Location
Left Boom Work Light Harness (W14) Wiring Diagram
Monitor and Relay Harness (W3) Component Location
Monitor and Relay Harness (W3) Wiring Diagram
Monitor and Relay (W3) Component Location-Detail A (Monitor Controller Connectors)
Monitor and Relay (W3) Component Location-Detail B (Monitor Controller Indicators)
System Functional Schematic (SE10-SE12)
System Functional Schematic (SE13-SE15)
System Functional Schematic (SE16-SE18)
System Functional Schematic (SE19-SE21)
System Functional Schematic (SE1-SE3)
System Functional Schematic (SE22)
System Functional Schematic (SE4-SE6)
System Functional Schematic (SE7-SE9)
System Functional Schematic Section Legend
15 - Sub-System Diagnostics
Accessory Circuit Operational Information
Accessory Circuits Schematic
Accessory Circuits Theory of Operation
Engine Controller Circuit Operational Information
Engine Controller Circuit Schematic
Engine Controller Circuit Specifications
Engine Controller Circuit Theory of Operation
Fuel Shutoff and Start Aid Circuit Operational Information
Fuel Shutoff and Start Aid Circuit Schematic
Fuel Shutoff and Start Aid Circuit Specifications
Fuel Shutoff and Start Aid Circuit Theory of Operation
Lubricator Circuit Operational Information
Lubricator Circuit Schematic
Lubricator Circuit Theory of Operation
Monitor Controller and Display Circuit Operational Information
Monitor Controller and Display Circuit Schematic
Monitor Controller and Display Circuit Specifications
Monitor Controller and Display Circuit Theory of Operation
Optional Connector Circuit Operational Information
Optional Connector Circuit Schematic
Optional Connector Circuit Theory of Operation
Power Circuit Operational Information
Power Circuit Schematic
Power Circuit Theory of Operation
Pump and Valve Controller Circuit Operational Information
Pump and Valve Controller Circuit Schematic
Pump and Valve Controller Circuit Specifications
Pump and Valve Controller Circuit Theory of Operation
Radio Circuit Operational Information
Radio Circuit Schematic
Radio Circuit Theory of Operation
Starting and Charging Circuit Operational Information
Starting and Charging Circuit Schematic
Starting and Charging Circuit Theory of Operation
Travel Alarm Circuit Operational Information
Travel Alarm Circuit Schematic
Travel Alarm Circuit Specifications
Travel Alarm Circuit Theory of Operation
Windshield Wiper and Washer Circuit Operational Information
Windshield Wiper and Washer Circuit Schematic
Windshield Wiper and Washer Circuit Theory of Operation
Work and Drive Light Circuit Operational Information
Work and Drive Light Circuit Schematic
Work and Drive Light Circuit Theory of Operation
20 - References
Adding 12 or 24 Volt Accessories
Battery Operation
Battery Specifications
Check Battery Electrolyte Level and Terminals
Connecting Engine Controller (EC) and Pump and Valve Controller (PVC) Harness Connector
Diagnose Battery Malfunctions
Disconnecting Spring Wire Clip Connectors
Disconnect Tab Retainer Connectors
Electronic Component Diagnostic Procedure
Electronic Control Bypass Procedure
Engine Controller (EC) Sensor Voltage Adjustment
Engine Control Systems
Engine Speed Learning Procedure
Engine Speed Programming Procedure After Battery Disconnection
Engine Speed Sensor Adjustment
Excavator Diagnostic Software Feature-Monitor Data
Excavator Diagnostic Software Feature-Service Codes
Excavator Diagnostic Software Overview
Excavator Diagnostic Software Special Function-Angle Sensor
Excavator Diagnostics Program Feature-Saving Monitor Data
Excavator Diagnostics Program-Install
Excavator Diagnostics Program-Starting
Excavator Diagnostics Program Troubleshooting
Excavator Diagnostics Program-Uninstall
Laptop Computer General Description
Monitor Data Items
Procedure for Testing Batteries
Pump Angle Sensor Adjustment
Pump Control Systems
Reading Service Codes Without JT07290 Laptop Computer
Replacing Batteries
Service Codes for Engine Controller (EC)
Service Codes for Pump and Valve Controller (PVC)
Troubleshooting Engine Controller (EC)
Troubleshooting Pump and Valve Controller (PVC)
Using Booster Batteries-24 Volt System
Work Mode Control Systems
9020 - Power Train
05 - Theory of Operation
Propel Gearbox Operation
Track Adjuster Operation
15 - Diagnostic Information
Diagnose Undercarriage Component Malfunctions
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
20 - Adjustments
Swing Bearing Wobble Test
Track Sag Adjustment
9025 - Hydraulic System
05 - Theory of Operation
Accumulator
Arm In Work Circuit
Arm Out Work Circuit
Arm Regenerative Valve
Boom Down Work Circuit
Boom Up Work Circuit
Bucket and Auxiliary Work Circuits
Check Block Operation
Circuit Relief-Anti-Cavitation
Combined Function Swing and Boom Up-Dig, Attachment, Precision Mode
Combined Function Swing and Boom Up-Dig Mode II
Combined Operation Propel and Swing
Control Valve Check Valve Cross Section
Control Valve Check Valve Identification and Function
Control Valve Check Valves Schematic
Control Valve Cross Section
Control Valve
Counterbalance Valve-Braking
Counterbalance Valve-Propel
Counterweight or Propel Pilot Controller Operation
Counterweight Removal Cylinder Operation
Counterweight Remove and Install Operation
Cylinder Operation
Flow Combiner Valve Circuit Operation
Flow Combiner Valve Schematic
Flow Regulator Valve Operation
Flow Sensing Valve
Hydraulic Schematic
Hydraulic System Schematic
Main Control Valve Operation
Main Hydraulic Pump
Make-Up Valve Operation
Pilot Controller Operation-Neutral
Pilot Pump and Filter Operation
Pilot Shut-Off Valve Operation
Power Boost Circuit
Propel Brake Operation
Propel Circuit Operation
Propel Flow Regulator Valve Operation
Propel Motor Crossover Relief Valve Operation
Propel Motor-Fast Speed
Propel Motor Operation
Propel Motor-Slow Speed
Propel Speed Control System
Propel System
Propel Work Circuit
Pump Displacement Decreasing-Minimum
Pump Displacement Increasing-Maximum
Pump Displacement Solenoid Valve
Pump Drive Gearbox
Pump Inlet and Delivery Circuits
Reduced Leakage Valve
Return Circuit Operation
Rotary Manifold
Solenoid Valve Manifold and Pilot Pressure Regulating Valve Operation
Swing Gearbox Operation
Swing Motor Crossover Relief Valve Operation
Swing Motor Operation
Swing Park Brake Release Circuit Operation
Swing Valve and End Section
Swing Work Circuit
System Relief Valve Operation
15 - Diagnostic Informtion
Control Valve Component and Line Identification
Diagnostic Procedure
Hydraulic Pump Angle Sensor Mechanical Check Diagnostic Procedure
Hydraulic System
Introduction to Flow Charts
Machine Malfunctions and Possible Causes
Main Hydraulic System Component Location
Pilot Circuit-SAE Pattern Component Location
Pilot System-JD Pattern Component Location
Pilot System-SAE Pattern Component Location
20 - Adjustments
Pilot Shut-Off Valve Linkage Adjustment
Pump Angle Sensor Adjustment
25 - Tests
Arm, Boom, and Bucket Cylinder Drift Test
Circuit Relief Valve Test and Adjustment
Combined Boom Up and Swing Function Test
Cycle Time Test
Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy
Hydraulic Oil Filter Inspection Procedure
Hydraulic Oil Tank Venting Procedure
Hydraulic Pump Flow Test
Hydraulic Pump Start-Up Procedure
Hydraulic System Warm-Up Procedure
JT02156A Digital Pressure _ Temperature Analyzer Installation
JT05800 Digital Thermometer Installation
JT05801 Clamp-On Electronic Tachometer Installation
Pilot Pressure Regulating Valve Test and Adjustment
Pilot Pump Flow Test
Power Boost Solenoid Valve (SA) Pressure Test
Propel Motor Crossover Relief Valve Test and Adjustment
Propel Motor Leakage Test
Propel Motor Start-Up Procedure
Propel Speed Change Solenoid Valve (SB) Pressure Test
Swing Brake Release Solenoid Valve (SC) Pressure Test
Swing Gearbox Start-Up Procedure
Swing Motor Crossover Relief Valve Test and Adjustment
Swing Motor Leakage Test
Swing Motor Start-Up Procedure
Swing Priority Solenoid Valve Pressure Test
System Relief and Power Boost Valve Test and Adjustment
Valve Spool Actuating Pilot Pressure Test
9031 - Heating and Air Conditioning
05 - Theory of Operation
Compressor Relief Valve Operation
Expansion Valve Operation
Heater and Air Conditioner Circuit Operational Information
Heater and Air Conditioner Circuit Schematic
Heater and Air Conditioner Circuit Theory of Operation
Heater and Air Conditioner Controller Operation
Proper Refrigerant Handling
R134a Refrigerant Cautions
Receiver _ Dryer Operation
Refrigerant Theory of Operation
15 - Diagnostic Informtion
Air Conditioner Component Location Diagram
Air Conditioner Harness (W9) Component Location Diagram
Diagnose Air Conditioning Electrical Malfunctions
Diagnose Heater System Malfunctions
Heating and Air Conditioning Circuit Diagnostic Checks
20 - Adjustments
Charge R134a System
Check and Adjust Compressor Belt Tension
Evacuate R134a System
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
25 - Tests
High and Low Pressure Switch Test
Leak Testing
Operating Pressure Diagnostic Chart
Proper Refrigerant Handling
R134a Air Conditioning System Test
R134a Refrigerant Cautions
Refrigerant Hoses and Tubing Inspection
