John Deere Compact Excavator 50ZTS Operation and Test Service Manual (TM1817)

TM1817 - John Deere 50ZTS Compact Excavator Technical Manual - Operation and Test.PDF

Complete Diagnostic, Operation and Test manual with Electrical Wiring Diagrams for John Deere Compact Excavator 50ZTS, with all the shop information to maintain, diagnostic, repair, refurbish/rebuild like professional mechanics.

John Deere Compact Excavator 50 ZTS workshop Diagnostic, 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: 668 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

MAIN SECTIONS
Foreword
   Technical Information Feedback Form
   General Information
      Safety
      General Specifications
      Torque Values
      Fuels and Lubricants
   Operational Checkout Procedure
      Operational Checkout Procedure
   Engine
      Theory of Operation
      System Operational Checks
      Diagnostic Information
      Adjustments
      Tests
   Electrical System
      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

tm1817 - 50ZTS Excavator

Table of Contents

Foreword

Technical Information Feedback Form

Section 9000: General Information

Group 01: Safety

Follow Safe Procedures

Prepare for Emergencies

Handle Fluids Safely—Avoid Fires

Prevent Battery Explosions

Handle Chemical Products Safely

Prevent Acid Burns

Avoid High-Pressure Fluids

Warn Others of Service Work

Park Machine Safely

Support Machine Properly

Operate Only from Operator's Seat

Stay Clear of Moving Parts

Avoid Power Lines

Use Handholds and Steps

Keep Riders Off Machine

Move and Operate Machine Safely

Wear Protective Clothing

Protect Against Flying Debris

Protect Against Noise

Illuminate Work Area Safely

Service Machines Safely

Remove Paint Before Welding or Heating

Avoid Heating Near Pressurized Fluid Lines

Beware of Exhaust Fumes

Use Proper Lifting Equipment

Service Cooling System Safely

Dispose of Waste Properly

Work in a Clean Area

Use Tools Properly

Replace Safety Signs

Live With Safety

Group 02: General Specifications

50ZTS Excavator Overview

50ZTS Excavator

50ZTS Excavator Working Ranges

50ZTS Excavator Engine Specifications

50ZTS Excavator Drain and Refill Capacities

Group 03: Torque Values

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

Group 04: Fuels and Lubricants

Diesel Fuel

Lubricity of Diesel Fuels

Low Sulfur Diesel Fuel Conditioner

Diesel Fuel Storage

Fuel Tank

Do Not Use Galvanized Containers

Diesel Engine Oil

Hydraulic Oil

Propel Gearbox Oils

Track Adjuster, Working Tool Pivot, Swing Bearing, and Swing Bearing Gear Grease

Oil Filters

Lubricant Storage

Alternative and Synthetic Lubricants

Mixing of Lubricants

Section 9005: Operational Checkout Procedure

Group 10: Operational Checkout Procedure

Operational Checkout

Section 9010: Engine

Group 05: Theory of Operation

Engine—Sectional View

Fan Drive Operation

Cooling System Operation

Engine Lubrication System Operation

Air Cleaner Operation

Fuel Supply System Operation

Fuel Injection Pump Operation

Fuel Injection Nozzle Operation

Group 10: System Operational Checks

Engine Operational Checks

Group 15: Diagnostic Information

Diagnose Engine Malfunctions

Group 20: Adjustments

JT05801 Clamp-On Electronic Tachometer Installation

Group 25: Tests

Engine Speed Check

Engine Speed Control Cable Adjustment

Check and Adjust Fuel Injection Nozzle

Check and Adjust Injection Pump Timing

Adjust Fan Belt Tension

Check and Adjust Engine Valve Lash (Clearance)

Cooling System Fill and Deaeration

Air Intake System Leakage Test

Radiator Air Flow Test

Engine Compression Pressure Test

Cooling System Test

Engine Oil Pressure Test

Section 9015: Electrical System

Group 05: System Information

Visually Inspect Electrical System

Electrical Circuit Malfunctions

High Resistance Circuit

Open Circuit

Grounded Circuit

Shorted Circuit

Multimeter

Seven Step Electrical Test Procedure

Schematic Information

Electrical Schematic Symbols

Group 10: System Diagrams

Component Identification Table

Fuse Specifications

Fuse (Blade-Type) Color Codes

Component Location Drawing Legend

Control Box Component Location

Cab Control Box Connectors Wire and Pin Location

Propel Alarm Harness Component Location

Propel Alarm Connectors Wire and Pin Location

Main Frame Harness Component Location

Main Frame Connectors Wire and Pin Location

Cab Electrical Harness Component Location

Cab Harness Connectors Wire and Pin Location

System Functional Schematic

Group 15: Sub-System Diagnostics

Power Circuit Operational Information

Power Circuit Theory of Operation

Power Circuit Schematic

Starting Circuit Operational Information

Starting Circuit Theory of Operation

Starting Circuit Schematic

Starter Operation

Charging Circuit Operational Information

Charging Circuit Theory of Operation

Charging Circuit Schematic

Monitor Controller Circuit Specifications

Monitor Controller Circuit Operational Information

Monitor Controller Circuit Theory of Operation

Monitor Controller Circuit Schematic

Engine Sensor Circuit Operational Information

Engine Sensor Circuit Theory of Operation

Engine Sensor Circuit Schematic

Pilot/Propel Circuit Operational Information

Pilot/Propel Circuit Theory of Operation

Pilot/Propel Circuit Schematic

Propel Alarm Circuit Operational Information

Propel Alarm Circuit Theory of Operation

Propel Alarm Circuit Schematic

Windshield Wiper and Washer Circuit Operational Information

Windshield Wiper and Washer Circuit Theory of Operation

Windshield Wiper and Washer Circuit Schematic

Drive and Work Lights Circuit Operational Information

Drive and Work Lights Circuit Theory of Operation

Drive and Work Lights Circuit Schematic

Accessory Circuit Operational Information

Accessory Circuits Theory of Operation

Accessory Circuit Schematic

Heater Circuit Operational Information

Heater Circuit Theory of Operation

Heater Circuit Schematic

Group 20: References

Monitor Controller and Display Connector Wiring

Battery Operation

Battery Specifications

Diagnose Battery Malfunctions

Check Battery Electrolyte Level and Terminals

Procedure for Testing Batteries

Using Booster Batteries—12 Volt System

Replacing Battery

Adding 12 or 24 Volt Accessories

Section 9020: Power Train

Group 05: Theory of Operation

Track Adjuster and Recoil Spring Operation

Propel Gearbox Operation

Group 15: Diagnostic Information

Diagnose Undercarriage Components Malfunctions

Measure Track Chain Bushing Wear

Measure Track Chain Link Wear

Measure Track Chain Pitch

Measure Track Shoe Grouser Wear

Measure Track Roller Wear

Measure Track Carrier Roller Wear

Measure Front Idler Wear

Measure Swing Bearing Wear

Group 20: Adjustments

Adjust Track Sag (Rubber Track)

Adjust Track Sag (Steel Track)

Section 9025: Hydraulic System

Group 05: Theory of Operation

Hydraulic System Diagram

Pilot Pump Operation

Pilot Relief Valve Operation

Pilot Shut-Off Solenoid Valve and Propel Speed Change Solenoid Valve Operation

Pilot Controller Operation—Neutral

Pilot Controller Operation—Metering and Full Stroke

Propel Pilot Controller Operation

Pilot Controller Operation of Control Valve

Boom Swing Controller Operation

Auxiliary Controller Operation

Main Hydraulic Pump (P1, P2) Operation

Gear Pump (P3) Operation

Hydraulic Pump Regulator Component Operation

Main Control Valve Operation

Control Valve Circuit Schematic

Control Valve Pilot Pressure Signal Passage Operation

Control Valve Neutral and Power Passages Operation

System Relief Valve Operation

Blade and Boom Swing Anti-Cavitation Valve Operation

Circuit Relief Valve Operation

Flow Combiner Valve Operation

Boom Reduced Leakage Valve Operation

Swing Gearbox Operation

Swing Motor Operation

Swing Motor Crossover Relief Valves Operation

Swing Motor Anti-Cavitation Valves Operation

Swing Motor Park Brake Changeover Valve Operation

Rotary Manifold with Backfill Blade Function Operation

Propel Motor Operation

Propel Motor Speed Change Valve Operation

Propel Motor Counterbalance Valve Operation

Propel Motor Relief Valve Operation

Propel Motor Brake Valve Operation

Propel Motor Park Brake Operation

Backfill Blade Hydraulic System Operation

One-Way/Two-Way Valve Operation

Hydraulic Cylinder Operation

Hydraulic Oil Return Filter Operation

Hydraulic System Circuit Symbols

Controllers and Pilot Shut-Off Solenoid Valve Schematic

Control Valve Schematic

Main Pump Schematic

Swing Motor Schematic

Propel Motor Schematic

Group 15: Diagnostic Information

Diagnostic Procedure

Diagnose Hydraulic System Malfunctions

Diagnose Pilot Circuit Malfunctions

Diagnose Dig Circuit Malfunctions

Diagnose Swing Circuit Malfunctions

Diagnose Propel System Malfunctions

Diagnose Mechanically Actuated Control Valve Malfunctions

Control Lever Pattern Conversion

Pilot Controller to Pilot Shut-Off Valve Component Location—SAE Pattern

Pilot Controller to Pilot Shut-Off Valve Component Location—ISO Pattern

Backfill Blade Hydraulic System Component Location

Propel System Component Location

Main Control Valve Line Identification

Main Hydraulic System Component Location

Pressure and Return System Component Location

Group 20: Adjustments

Adjust Blade Control Lever

Adjust Boom Swing and Auxiliary Linkage

Group 25: Tests

JT05801 Clamp-On Electronic Tachometer Installation

JT05800 Digital Thermometer Installation

JT02156A Digital Pressure/Temperature Analyzer Installation

Hydraulic Pump Start-Up Procedure

Swing Motor Start-Up Procedure

Swing Gearbox Start-Up Procedure

Propel Motor Start-Up Procedure

Propel Gearbox Start-Up Procedure

Hydraulic System Warm-Up Procedure

Lower Boom With Engine Stopped

Cycle Time Test

Swing Dynamic Braking (Drift) Test

Pilot Pressure Regulating Valve Test and Adjustment

Control Valve Spool Pilot Actuation Pressure Test (Secondary Pilot Pressure)

Pumps 1 and 2 System Relief Valve Test and Adjustment

Pump 3 System Relief Valve Test and Adjustment

Circuit Relief Valve Test and Adjustment

Swing Motor Crossover Relief Valve Test and Adjustment

Propel Motor Crossover Relief Valve Test and Adjustment

Main Hydraulic Pump Regulator Test (Engine Pulldown)

Main Hydraulic Pumps P1 and P2 Flow Test

Gear Pump P3 Flow Test

Propel System Tracking Test

Cylinder Drift Test—Boom, Arm, and Bucket

Swing Motor Leakage Test

Propel Motor Leakage Test