John Deere 792D LC Excavator Service Repair Manual (TM1596)
TM1596 - John Deere 792D LC Excavator Technical Manual - Repair.PDF
Complete service repair manual for John Deere 792D LC Excavator, with all the shop information to maintain, repair, service like professional mechanics.
John Deere 792D LC Excavator 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.
Total Pages: 682 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English
MAIN SECTIONS
Foreword
Help!! Help!! Help!! Help!!
General Information
Safety
General Specifications
Torque Values
Fuels And Lubricants
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 System
Speed Controls
Intake System
External Fuel Supply System
Dampener Drive (Flex Coupling)
Elements
Splitter Drive (Pump Drive Gearbox)
Gears, Shafts, And Bearings
Electrical System
Batteries, Support, And Cables
Alternator, Regulator, And Charging System Wiring
Wiring Harness And Switches
Frame Or Supporting Structure
Frame Installation
Chassis Weights
Operator’s Station
Removal And Installation
Operator Enclosure
Seat And Seat Belt
Heater
Sheet Metal And Styling
Hood Or Engine Enclosure
Safety And Convenience
Horn And Warning Device
Excavator
Bucket
Frames
Hydraulic System
Swing Rotation Or Pivoting System
Mechanical Drive Elements
Hydraulic System
Dealer Fabricated Tools
tm1596 - 792D LC Excavator Repair
TABLE OF CONTENTS - Expanded View
Foreword
Help!! Help!! Help!! Help!!
Section 00: General Information
Group 0001: Safety
Follow Safe Procedures
Prepare for Emergencies
Prevent Acid Burns
Handle Chemical Products Safely
Handle Fluids Safely-Avoid Fires
Avoid High-Pressure Fluids
Warn Others of Service Work
Support Machine Properly
Operate Only from Operator's Seat
Park Machine Safely
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 0002: General Specifications
792D LC Specifications
792D LC Drain And Refill Capacities
Group 0003: Torque Values
Unified Inch Bolt and Cap Screw Torque Values
Metric Bolt and Cap Screw Torque Values
Additional Metric Cap Screw Torque Values
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 0004: Fuels And Lubricants
Diesel Fuel
Low Sulfur Diesel Fuel Conditioner
Storing Fuel
Fuel Tank
Do Not Use Galvanized Containers
Diesel Engine Oil
Hydraulic Oil
Swing Gearbox, Propel Gearbox And Pump Gearbox Oils
Track Roller, Front Idler, And Carrier Roller Oil
Track Adjuster, Working Tool Pivot, Swing Bearing, And Swing Bearing Gear Grease
Oil Filters
Lubricant Storage
Alternative and Synthetic Lubricants
Mixing of Lubricants
Section 01: Tracks
Group 0130: Track System
Service Equipment And Tools
Other Material
Specifications
Measure Track Roller Wear
Remove And Install Lower Track Roller
Disassemble And Assemble Track Roller
Test Track Roller For Oil Leakage
Measure Track Carrier Roller Wear
Remove And Install Track Carrier Roller
Disassemble And Assemble Track Carrier Roller
Inspect Metal Face Seals
Measure Track Shoe Grouser Wear
Remove And Install Track Shoe
Measure Track Link Wear
Measure Track Bushing Wear
Measure Track Chain Pitch
Remove Track Chain
Install Track Chain
Disassemble And Assemble Track Chain
Disassemble And Assemble Track Chain To Replace Broken Part
Adjust Track Sag
Remove And Install Sprocket
Measure Front Idler Wear
Remove And Install Front Idler
Disassemble And Assemble Front Idler
Test Front Idler For Oil Leakage
Remove And Install Track Adjuster Cylinder And Recoil Spring
Disassemble And Assemble Track Adjuster Recoil Spring
Disassemble And Assemble Track Adjuster Cylinder
Section 02: Axles And Suspension Systems (Propel)
Group 0250: Axle Shaft, Bearings, And Reduction Gears
Service Equipment And Tools
Other Material
Specifications
Towing The Excavator
Remove And Install Propel Gearbox
Disassemble Propel Gearbox
Assemble Propel Gearbox
Group 0260: Hydraulic System
Special Or Essential Tools
Service Equipment And Tools
Other Material
Remove And Install Propel Motor
Disassemble Propel Motor And Brake
Assemble Propel Motor And Brake
Disassemble And Assemble Propel Motor Brake Valve Housing
Remove And Install Propel Hydraulic Lines
Remove And Install Rotary Manifold
Disassemble And Assemble Rotary Manifold
Rotary Manifold Air Test
Section 04: Engine
Group 0400: Removal And Installation
6076 John Deere Engine-Use CTM42
Starting Motor-Use CTM77
Special Or Essential Tools
Service Equipment And Tools
Other Material
Specifications
Remove And Install Engine
Remove And Install Oil Pan
Remove And Install Fuel Injection Pump
Relieve Fuel System Pressure
Replace Rectangular Fuel Filter Element
Replace Fuel Check Valve
Bleed Fuel System
Remove Turbocharger
Install Turbocharger
Remove Water Pump
Install Engine Water Pump
Remove And Test Thermostat
Install Thermostat
Remove And Install Starter
Section 05: Engine Auxiliary System
Group 0505: Cold Weather Starting Aids
Specifications
Remove And Install Starting Aid Solenoid And Nozzle
Remove And Install Engine Coolant Heater
Group 0510: Cooling System
Specifications
Remove And Install Fan
Remove And Install Belts
Fan Belt Tension Adjustment
Remove And Install Radiator
Group 0515: Speed Controls
Other Material
Specifications
Remove And Install Speed Control Lever
Engine Speed Control Linkage Adjustment
Remove And Install Fuel Shut-Off Solenoid
Fuel Shut-Off Solenoid Adjustment
Group 0520: Intake System
Special Or Essential Tools
Service Equipment And Tools
Specifications
Air Intake System Leakage Test
Remove And Install Air Cleaner
Group 0560: External Fuel Supply System
Remove And Install Fuel Tank
Remove And Install Fuel Filter Check Valve Assembly
Section 07: Dampener Drive (Flex Coupling)
Group 0752: Elements
Other Material
Specifications
Disassemble And Assemble Flex Coupling
Section 08: Splitter Drive (Pump Drive Gearbox)
Group 0851: Gears, Shafts, And Bearings
Service Equipment And Tools
Other Material
Specifications
Remove And Install Hydraulic Pump Drive Gear Box
Disassemble Hydraulic Pump Drive Gear Box
Assemble Hydraulic Pump Drive Gear Box
Section 16: Electrical System
Group 1671: Batteries, Support, And Cables
Service Equipment And Tools
Specifications
Handle Batteries Safely
Procedure For Testing Batteries
Checking Electrolyte Specific Gravity
Check Battery Electrolyte Level And Terminals
Using Booster Batteries-24-Volt System
Charge Battery
Remove And Install Batteries
Adding 12-Volt Accessories
Group 1672: Alternator, Regulator, And Charging System Wiring
Alternator Repair-Use CTM77
Service Equipment And Tools
Other Material
Specifications
Alternator Belt Tension Adjustment
Remove And Install Alternator
Group 1674: Wiring Harness And Switches
Remove And Install Control Panel Switches
Remove And Install Dome Light Switch
Remove And Install Engine Overheat Alarm Switch
Remove And Install Buzzer Stop Switch
Remove And Install Dig Function Pressure Switch
Remove And Install Propel Function Pressure Switch
Remove And Install Engine Hourmeter Switch
Remove And Install Air Cleaner Restriction Indicator Switch
Remove And Install Battery Relay
Remove And Install Starter Relay Solenoid
Remove And Install Fuel Shut-Off Relay Solenoid
Section 17: Frame Or Supporting Structure
Group 1740: Frame Installation
Welding Repair Of Major Structure
Group 1749: Chassis Weights
Special Or Essential Tools
Specifications
Remove And Install Counterweight
Section 18: Operator’s Station
Group 1800: Removal And Installation
Other Material
Specifications
Remove And Install Cab And Cab Floor
Remove And Install Cab (Without Floor)
Group 1810: Operator Enclosure
Special Or Essential Tools
Windowpanes Dimensions
Remove And Install Windowpane And Two Piece Molding
Remove And Install Windowpane And One Piece Molding
Remove And Install Right Upper Windows
Remove And Install Cab Door
Remove And Install Door Latch
Remove And Install Inside Assist Handle
Remove, Disassemble, Assemble, And Install Windshield Wiper
Remove And Install Defroster Fan
Disassemble And Assemble Defroster Fan
Group 1821: Seat And Seat Belt
Disassemble And Assemble Seat
Group 1830: Heater
Remove And Install 13,500 BTU Heater-(S.N. 010001 And 010002)
Remove And Install 13,500 BTU Cab Heater Lines And Controls
Disassemble And Assemble Blower Motor
Section 19: Sheet Metal And Styling
Group 1910: Hood Or Engine Enclosure
Remove And Install Hood
Adjust Hood
Remove And Install Right Hand Service Door
Remove And Install Left Hand Service Door
Remove And Install Battery Box Cover
Section 20: Safety And Convenience
Group 2004: Horn And Warning Device
Remove And Install Travel Alarm
Section 33: Excavator
Group 3302: Bucket
Other Material
Specifications
Service Equipment And Tools
Replacing Bucket Teeth
Replacing Bucket Tooth Tip-Heavy-Duty Bucket
Remove And Install Tooth Shank
Remove And Install Bucket And Linkage
Remove And Install Bushings
Adjust Bucket To Arm Clearance
Replace Welded Bucket Cutting Edges
Repair Cracked Cutting Edge
Group 3340: Frames
Service Equipment And Tools
Other Material
Specifications
Remove And Install Arm
Remove And Install Boom
Inspect Arm And Boom Pins And Bushings
Remove And Install Bushings And Seals
Group 3360: Hydraulic System
Special Or Essential Tools
Service Equipment And Tools
Other Material
Specifications
Hydraulic Cylinder Bleed Procedure
Release Pressure In Hydraulic System Using Air Pressure
Remove And Install Hydraulic Pump
Hydraulic Pump Start-Up Procedure
Disassemble Main Hydraulic Pump
Assemble Main Hydraulic Pump
Remove And Install Main Hydraulic Pump Regulator
Disassemble And Assemble Main Hydraulic Pump Regulator
Remove And Install Pilot Pump
Disassemble Pilot Pump
Inspect Pilot Pump
Assemble Pilot Pump
Remove And Install Pilot Filter
Hydraulic Oil Filter Inspection Procedure
Remove And Install Solenoid Valve And Pilot Pressure Regulating Valve
Disassemble And Assemble Solenoid Valve And Pilot Pressure Regulating Valve
Remove And Install Engine Speed Control Cylinders
Disassemble And Assemble Engine Speed Control Cylinders
Remove And Install Hydraulic Control Valve
Disassemble And Assemble Hydraulic Control Valve
Dig System Relief Valve
Propel System Relief And Swing Circuit Relief Valves
Remove And Install Hydraulic Tank
Remove And Install Return And Suction Filters
Remove And Install Restriction Valve
Disassemble And Assemble Restriction Valve
Remove And Install Oil Cooler Bypass Valve
Disassemble And Assemble Oil Cooler Bypass Valve
Remove And Install Hydraulic Oil Cooler
Remove And Install Bucket Cylinder
Remove And Install Arm Cylinder
Remove And Install Boom Cylinder
Hydraulic Cylinder Bleed Procedure
Disassemble Bucket, Arm, And Boom Cylinders
Assemble Bucket, Arm, Or Boom Cylinder
Remove And Install Pilot Controller
Pilot Controllers
Disassemble And Assemble Pilot Controller
Remove And Install Propel Pilot Controller
Disassemble And Assemble Propel Pilot Controller
Remove And Install Pilot Shut-Off Valve
Disassemble And Assemble Pilot Shut-Off Valve
Pilot Shut-Off Valve Linkage Adjustment
Disassemble And Assemble Pilot Filter
Inspect Pilot Filter Relief Valve
Remove And Install Flow Control Valve
Disassemble And Assemble Flow Control Valve
Remove And Install Check Valve Block
Disassemble And Assemble Check Valve Block
Section 43: Swing Rotation Or Pivoting System
Group 4350: Mechanical Drive Elements
Service Equipment And Tools
Other Material
Specifications
Remove And Install Swing Gearbox
Disassemble And Assemble Swing Gearbox
Remove Upperstructure
Install Upperstructure
Remove And Install Swing Bearing
Disassemble And Assemble Swing Bearing
Install Swing Bearing Upper Seal
Install Swing Bearing Lower Seal
Group 4360: Hydraulic System
Other Material
Specifications
Swing Motor Start-Up Procedure
Remove And Install Swing Motor And Brake
Disassemble Swing Motor And Brake
Assemble Swing Motor And Brake
Disassemble And Assemble Swing Motor Valve Housing
Remove And Install Swing Brake Release Valve
Section 99: Dealer Fabricated Tools
Group 9900: Dealer Fabricated Tools
ST4920 Track Recoil Spring Disassembly And Assembly Tool
DFT1087 Track Recoil Spring Disassembly And Assembly Guard Tool
DFT1129 Spacer
DF1036A Propel Gearbox Nut Wrench
DFT1109 Holding Bar
DF1038 Torque Adapter
DF1060 Lift Bracket
DF1060 Lift Bracket Dimensions
DFT1130 Adapter
DFT1119 Pump Support
DF1037 Hydraulic Pump Torque Adapter
Rotary Manifold Lifting Tool
DFT1089 Barrel Support
DFT1077 Spool Holding Fixture
DFT1108 Spool Holding Fixture
