John Deere 992E-LC Excavator Service Repair Manual (TM1559)

Complete service Operation and Test manual with Electrical Wiring Diagrams for John Deere 992E-LC Excavator, with workshop information to maintain, diagnose, and service like professional mechanics.

John Deere 992E-LC Excavator 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.

TM1559 - John Deere 992E-LC Excavator Technical Manual - Operation and Test.PDF
TM1559 - John Deere 992E-LC Excavator Technical Manual - Operation and Test.epub

Total Pages: 822 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English

MAIN SECTIONS
Foreword
   General Information
      Safety
      General Specifications
      Torque Values
      Fuels And Lubricants
      Predelivery Assembly Instructions
   Operational Checkout
      Operational Checkout Procedure
   Engine
      Theory Of Operation
      Diagnostic Information
      Adjustments
      Tests
   Electrical System
      System Information
      System Diagrams
      Sub-System Diagnostics
      Adjustments And Additional Information
   Power Train
      Theory Of Operation
      Diagnostic Information
      Adjustments
   Hydraulic System
      Theory Of Operation
      Diagnostic Information
      Adjustments
      Tests

Table of Contents - Expanded View

Foreword

General Information

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

General Specifications

992E LC

992E LC Drain And Refill Capacities

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

Fuels And Lubricants

Fuel Specifications

Engine Oil

Hydraulic Oil

Swing Gearbox, Propel Gearbox And Pump Gearbox Oils

Track Roller, Front Idler, And Carrier Roller Oil

Grease

Predelivery Assembly Instructions

Install Boom, Arm, Bucket And Counterweight

Adjusting Bucket Linkage

Attach Windshield Wiper

Track Gauge Work Position Adjustment

Track Gauge Transport Position Adjustment

Check Hydraulic Oil Level

Lubricate Working Tool Pivots

Install Counterweight

Install Counterweight With Hydraulic Removal Option

Operational Checkout

Operational Checkout Procedure

Operational Checkout

Engine

Theory Of Operation

6101 John Deere Engine-Use CTM61

Radiator Cap Operation

Recovery Tank Operation

Radiator Operation And Deaeration

Thermostats

Engine Sectional View

Engine Speed Control System Operation

Diagnostic Information

6101 John Deere Engine-Use CTM61

John Deere Engine Accessories-Use CTM11

Diagnose Engine Malfunctions

Adjustments

6101 John Deere Engine-Use CTM61

Fan Belt Adjustment

Engine Speed Control Linkage Adjustment

Fuel Shut-Off Solenoid Adjustment

Tests

6101 John Deere Engine-Use CTM61

John Deere Engine Accessories-Use CTM11

JT05801 Clamp-On Electronic Tachometer Installation

JT05800 Digital Thermometer Installation

Fuel Line Leakage Test

Air Filter Restriction Indicator Switch Test

Air Intake System Leakage Test

Radiator Air Flow Test

Electrical System

System Information

Visually Inspect Electrical System

Electrical Circuit Malfunctions

High Resistance Circuit

Open Circuit

Grounded Circuit

Shorted Circuit

Multimeter

Seven Step Electrical Test Procedure

Wiring Diagram And Schematic Information

Reading A System Functional Schematic

Reading A Wiring Diagram

Electrical Schematic Symbols

System Diagrams

Component Identification Table

Replacing Fuses

Fuse (Blade-Type) Color Codes

Wiring And Schematic Diagrams Legend

System Functional Schematic Section Legend

System Functional Schematic

Cab Harness (W4) Wiring Diagram

Cab Harness (W4) Component Location

Engine Harness (W5) Wiring Diagram

Engine Harness (W5) Component Location

Sub-System Diagnostics

Power Circuit Operational Information

Power Circuit Theory Of Operation

Power Circuit Schematic

Charging And Fuel Control Circuit Operational Information

Charging And Fuel Control Circuit Theory Of Operation

Charging And Fuel Control Circuits Schematic

Starting Circuit Operational Information

Starting Circuit Theory Of Operation

Starting Circuit Schematic

Switch Panel 1, Wiper And Light Circuits Operational Information

Switch Panel 1, Wiper And Light Circuits Theory Of Operation

Switch Panel 1, Wiper And Light Circuits Schematic

Switch Panel 2 Circuit Operational Information

Switch Panel 2 Theory Of Operation

Switch Panel 2 Circuit Schematic

Monitor, Monitor Controller And Switch Panel 1 Circuit Specifications

Monitor Circuit Operational Information

Monitor Circuit Theory Of Operation

Monitor Circuit Schematic

Pump And Valve Controller Circuit Operational Information

Pump And Valve Controller Circuit Theory Of Operation

Pump And Valve Controller Circuit Schematic

Switch And Sender Specifications

Engine Controller Circuit Operational Information

Engine Controller Circuit Theory Of Operation

Engine Controller Circuit Schematic

Auto Idle And Hydraulic Warm-Up Circuits Operational Information

Auto Idle And Hydraulic Warm-Up Circuits Theory Of Operation

Auto Idle And Hydraulic Warm-Up Circuits Schematic

Start Aid And Travel Alarm Circuit Operational Information

Start Aid And Propel Alarm Circuit Theory Of Operation

Start Aid And Propel Alarm Circuit Schematic

Horn, Dome Light And Cigarette Lighter Circuits Operational Information

Horn, Dome Light, And Cigarette Lighter Circuits Theory Of Operation

Horn, Dome Light And Cigarette Lighter Circuits Schematic

Heater And Optional Equipment Circuits Operational Information

Heater And Optional Equipment Circuit Theory Of Operation

Heater And Optional Equipment Circuits Schematic

Adjustments And Additional Information

Monitor And Switch Panels

Monitor Panel

Switch Panel 1

Switch Panel 2

Resetting Engine Controller (EC)

Replacing Fusible Link

Alternator Voltage Output Test-Delco

Replacing Batteries

Battery Operation

Diagnose Battery Malfunctions

Check Battery Electrolyte Level And Terminals

Procedure For Testing Batteries

Using Booster Batteries-24 Volt System

Engine Speed Control Linkage Adjustment

Pump Angle Sensor (A Sensor) Adjustment

Hydraulic Pump Angle Sensor (A Sensor) Mechanical Check Diagnostic Procedure

Troubleshooting Engine Controller (EC)

Troubleshooting Pump And Valve Controller (PVC)

Electronic Control Bypass Procedure

Electrical Component Identification

Engine Control Sensor (EC Sensor) Harness Test

Connecting Engine Controller (EC) And Pump And Valve Controller (PVC) Harness Connector

Disconnect Tab Retainer Connectors

Disconnecting Spring Wire Retainer Connectors

Connector Pin Location And Numbers

Power Train

Theory Of Operation

Track Adjuster Operation

Propel Gearbox Operation

Diagnostic Information

Diagnose Undercarriage Component Malfunctions

Measure Track Chain And Roller Wear

Adjustments

Swing Bearing Wobble Test

Track Sag Adjustment

Hydraulic System

Theory Of Operation

Control Systems Operation

Switch Panel 2

Engine (EC), Pump And Valve (PVC) Controllers

Engine Speed Control System Operation

Engine Power Modes

Pump Control Circuit

Pump Control Circuit-Maximum Displacement

Hydraulic Pump Angle Sensor (A Sensor) Operation

Pump Control-Speed Sensing

Work Mode Chart

Pilot Circuit Operation

Pilot Pump And Filter Operation

Solenoid Valve Manifold And Pilot Pressure Regulating Valve Operation

Pilot Shut-Off Valve Operation

Check Block Operation

Pilot Controller Operation-Neutral

Pilot Controller Operation-Metering

Propel Pilot Controller Operation-Neutral

Auxiliary Or Counterweight Removal Pilot Controller Operation

Flow Regulator Valve Operation

Propel Flow Regulator Operation

Main Control Valve Operation

Control Valve

Control Valve Cross Section

Control Valve Check Valve Identification And Function

Control Valve Check Valves Schematic

Control Valve Check Valve Cross Section

Power Boost Circuit

System Relief Valve Operation

Circuit Relief-Anti-Cavitation

Make Up Valve Operation

Anti-Drift Valve

Flow Combiner Valve Circuit Operation

Flow Combination Valve Schematic

Flow Sensing Valve

Propel Work Circuit

Bucket And Auxiliary Work Circuit

Boom Up Work Circuit

Boom Down Work Circuit

Arm In Work Circuit

Arm Out Work Circuit

Arm Regenerative Valve

Swing Work Circuit

Swing Valve And End Section

Combined Operation Propel And Swing

Combined Function Swing And Boom Up-GPII

Combine Function Swing And Boom Up-GPI

Swing Motor Operation

Swing Motor Crossover Relief Valve Operation

Swing Brake Release Valve Circuit Operation

Swing Gearbox Operation

Cylinder Operation

Counterweight Removal Cylinder Operation

Main Hydraulic Pump

Pump Displacement Increasing-Maximum

Pump Displacement Decreasing-Minimum

Pump Displacement Solenoid

Propel Circuit Operation

Propel Speed Control System

Propel Motor Operation

Propel Motor-Slow Speed

Propel Motor-Max. Speed

Counterbalance Valve-Propel

Counterbalance Valve-Braking

Propel Brake Operation

Propel Motor Crossover Relief Valve Operation

Rotary Manifold

Pump Inlet And Delivery Circuits

Return Circuit Operation

Hydraulic Schematic

Propel System

Diagnostic Information

Diagnostic Procedure

Introduction To Flow Charts

Machine Malfunctions And Possible Causes

Electronic Component Diagnostic Procedure

Troubleshooting Pump And Valve Controller (PVC)

Troubleshooting Engine Controller (EC)

Hydraulic Pump Angle Sensor (A Sensor) Mechanical Check Diagnostic Procedure

Hydraulic Pump Angle Sensor (A Sensor) Electrical Check Using Diagnostic Computer

Pump Angle Sensor (A Sensor) Adjustment

Hydraulic System

Control Valve Component And Line Identification

Counterweight Component Location

Adjustments

Pilot Shut-Off Valve Linkage Adjustment

Tests

JT07058 Diagnostic Computer Operating Procedure

JT07058 Diagnostic Computer Initial Setup

Connecting JT07058 Diagnostic Computer To Machine

Begin JT07058 Diagnostic Computer Function

JT07058 Diagnostic Computer Function

Retry Procedure A

Retry Procedure B

Self Diagnostic Function Fault Codes For Engine Controller (EC)

Self Diagnostic Function Fault Codes For Pump And Valve Controller (PVC)

Monitor Function Display List And Description

Component Abbreviations

Component Abbreviations And Location

Cross Reference To Display Symbols And List

Reading Fault Codes Without JT07058 Diagnostic Computer

Reading Fault Codes With JT07058 Diagnostic Computer

Hydraulic Pump Angle Sensor (A Sensor) Electrical Check Using Diagnostic Computer

Approximate Pump Displacement (D4 And D5) Using The Diagnostic Computer

Approximate Pump Displacement (D4 And D5) Using The Diagnostic Computer Work Sheet

Monitor Data Function-992E LC

Example 1 Of Monitor Data Function-Typical New 992E LC

Example 2 Of Monitor Data Function-Typical New 992E LC

Example 3 Of Monitor Data Function-Typical New 992E LC

Example 4 Of Monitor Data Function-Typical New 992E LC

JT05801 Clamp-On Electronic Tachometer Installation

JT05800 Digital Thermometer Installation

Hydraulic System Warm-Up Procedure

Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy

Lower Boom With Engine Stopped

Engine Speed Programming Procedure After Battery Disconnection

Power Boost Solenoid Valve (SA) Harness Test

Propel Speed Change Solenoid Valve (SB) Harness Test

Swing Brake Release Solenoid Valve (SC) Harness Test

Swing Stop Cushion Solenoid Valve Harness Test

Pump Displacement Solenoid Valve Harness Test

Engine Control Sensor (EC Sensor) Harness Test

Engine Control Motor (EC Motor) Harness Test

Differential Pressure Sensor (DP Sensor) Voltage Test

GP II Solenoid Valve Harness Test

Miscellaneous Component Harness Test

Hydraulic Pump Start-Up Procedure

Swing Motor Start-Up Procedure

Swing Gearbox Start-Up Procedure

Propel Motor Start-Up Procedure

Cycle Time Test

Combined Boom Up And Swing Function Test

Pilot Pressure Regulating Valve Test And Adjustment

Valve Spool Actuating Pilot Pressure Test And Adjustment

Boom Flow Reduction Valve Control Pressure Test And Adjustment

Power Boost Solenoid Valve (SA) Test

Propel Speed Change Solenoid Valve (SB) Test

Swing Brake Release Solenoid Valve (SC) Test

System Relief Valve And Power Boost 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

Arm, Boom, And Bucket Cylinder Drift Test

Propel Motor Operating Leakage Test

Swing Motor Leakage Test

Pilot Pump Flow Test

Hydraulic Pump Flow Test

TM Worksheet-992E LC Excavator