Complete Operation and Test manual with electrical wiring diagrams for John Deere 892E-LC Excavator, with all the technical information to maintain, diagnose, and rebuild like professional mechanics.

John Deere 892E-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.

TM1541 - John Deere 892E-LC Excavator Technical Manual - Operation and Test.PDF
TM1541 - John Deere 892E-LC Excavator Technical Manual - Operation and Test.EPUB

Total Pages: 814 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
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
      Adjustments And Additional Information
   Power Train
      Theory Of Operation
      Diagnostic Information
      Adjustments
   Hydraulic System
      Theory Of Operation
      Diagnostic Information
      Adjustments
      Tests
 

tm1541 - 892ELC Excavator Operation and Tests

Table of Contents

Foreword

Technical Information Feedback Form

Section 9000: General Information

Group 01: 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 02: General Specifications

892E LC

892E LC Drain And Refill Capacities

Group 03: 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 04: Fuels And Lubricants

Fuel Specifications

Low Sulfur Diesel Fuel Conditioner

Engine Oil

Hydraulic Oil

Swing Gearbox, Propel Gearbox And Pump Gearbox Oils

Track Roller, Front Idler, And Carrier Roller Oil

Grease

Section 9005: Operational Checkout Procedure

Group 10: Operational Checkout Procedure

Operational Checkout Record Sheet-892E-LC

Operational Checkout

Section 9010: Engine

Group 05: Theory Of Operation

6076 John Deere Engine Use CTM42

General Engine Description

Engine-Sectional View

Engine Speed Control System Operation

Group 10: System Operational Checks

6076 John Deere Engine-Use CTM42

Engine Operational Checks

Group 15: Diagnostic Information

6076 John Deere Engine-Use CTM42

Diagnose Engine Malfunctions

Group 20: Adjustments

6076 John Deere Engine-Use CTM42

JT05801 Clamp-On Electronic Tachometer Installation

Alternator Belt Tension Adjustment

Fan Belt Tension Adjustment

Engine Speed Control Linkage Adjustment

Fuel Shut-Off Solenoid Adjustment

Coolant Deaeration Procedure

Group 25: Tests

6076 John Deere Engine-Use CTM42

Fuel Line Leakage Test

Air Filter Restriction Indicator Switch Test

Air Intake System Leakage Test

Radiator Air Flow Test

Section 9015: Electrical System

Group 05: System Information

Battery Specifications

Battery Operation

Diagnose Battery Malfunctions

Check Battery Electrolyte Level And Terminals

Procedure For Testing Batteries

Using Booster Batteries-24 Volt System

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

Group 10: System Diagrams

Component Identification Table

Replacing Fuses

Fuse (Blade-Type) Color Codes

Fuse Specifications

Wiring And Schematic Diagrams Legend

System Functional Schematic Section Legend

System Functional Schematic-SN (-010999)

Cab Harness (W6) Wiring Diagram-SN (-010999)

Engine Harness (W5) Wiring Diagram-SN (-010999)

System Functional Schematic-SN (011000-)

Cab Harness (W6) Wiring Diagram-SN (011000-)

Engine Harness (W5) Component Location-SN (011000-)

Cab Harness (W6) Component Location-SN (011000-)

Engine Harness (W5) Wiring Diagram-SN (011000-)

Group 15: Sub-System Diagnostics

Power Circuit Operational Information-SN (-010999)

Power Circuit Theory Of Operation-SN (-010999)

Power Circuit Schematic-SN (-010999)

Power Circuit Operational Information-SN (011000-)

Power Circuit Theory Of Operation-SN (011000-)

Power Circuit Schematic-SN (011000-)

Charging Circuit Operational Information-SN (-010999)

Charging Circuit Theory Of Operation-SN (-010999)

Charging Circuit Schematic-SN (-010999)

Charging & Fuel Control Circuits Operational Information-SN (011000-)

Charging And Fuel Control Circuits Theory Of Operation-SN (011000-)

Charging And Fuel Control Circuits Schematic-SN (011000-)

Starting Circuit Operational Information-SN (-010999)

Starting Circuit Theory Of Operation-SN (-010999)

Starting Circuit Schematic-SN (-010999)

Starting Circuit Operational Information-SN (011000-)

Starting Circuit Theory Of Operation-SN (011000-)

Starting Circuit Schematic-(SN 011000-)

Windshield Wiper And Washer Circuit Operational Information

Windshield Wiper And Washer Circuit Theory Of Operation

Windshield Wiper And Washer Circuit Schematic

Switch Panel 1 Circuit Operational Information

Switch Panel 1 Theory Of Operation

Switch Panel 1 Circuit Schematic

Switch Panel 2 Circuit Operational Information

Switch Panel 2 Theory Of Operation-SN (-010999)

Switch Panel 2 Circuit Schematic-SN (-010999)

Switch Panel 2 Theory Of Operation-SN (011000-)

Switch Panel 2 Circuit Schematic-SN (011000-)

Light Circuit Operational Information

Light Circuit Theory Of Operation

Light Circuit Schematic

Horn, Dome Light, Optional Equipment And Heater Circuits Operational Information

Horn, Dome Light, Optional Equipment And Heater Circuits Theory Of Operation

Horn, Dome Light Optional Equipment And Heater Circuit Schematic

Switch And Sender Specifications

Monitor Circuit Operational Information

Monitor Circuit Theory Of Operation

Monitor Circuit Schematic

Auto Idle Circuit Operational Information-SN (-010999)

Auto Idle Circuit Theory Of Operation-SN (-010999)

Auto Idle Circuit Schematic-SN (-010999)

Auto Idle Circuit Operational Information-SN (011000-)

Auto Idle Circuit Theory Of Operation-SN (011000-)

Auto Idle Circuit Schematic-SN (011000-)

Warm-Up Circuit Operational Information-SN (-010999)

Warm-Up Circuit Theory Of Operation-SN (-010999)

Hydraulic Warm-Up Circuit Schematic-SN (-010999)

Warm-Up Circuit Operational Information-SN (011000-)

Warm-Up Circuit Theory Of Operation-SN (011000-)

Hydraulic Warm-Up Circuit Schematic-SN (011000-)

Engine Controller Circuit Operational Information-SN (011000-)

Engine Controller Circuit Theory Of Operation-SN (011000-)

Engine Controller Circuit Schematic-SN (011000-)

Pump And Valve Controller Circuit Operational Information- SN (011000-)

Pump And Valve Controller Circuit Theory Of Operation-SN (011000-)

Pump And Valve Controller Circuit Schematic-SN (011000-)

Starting Aid And Propel Alarm Circuit Operational Information

Starting Aid And Propel Alarm Circuit Theory Of Operation

Starting Aid And Travel Alarm Circuit Schematic-SN (-010999)

Starting Aid And Travel Alarm Circuit Schematic-SN (011000-)

Group 20: Adjustments And Additional Information

Connecting Engine And Pump Controller (EPC) Harness Connector-SN (-010999)

Connecting Engine Controller (EC) And Pump And Valve Controller (PVC) Harness Connector- SN (011000-)

Disconnect Tab Retainer Connectors

Disconnecting Spring Wire Retainer Connectors

Connector Pin Location And Numbers

Monitor And Switch Panels

Monitor Panel

Switch Panel 1

Switch Panel 2

Engine And Pump Controller (EPC) Bypass Procedure-SN (-010999)

Electronic Control (EC) Bypass Procedure SN (011000-)

Engine Control Sensor (EC Sensor) Harness Test

Modification For Replacement Batteries

Section 9020: Power Train

Group 05: Theory Of Operation

Track Adjuster Operation

Propel Gearbox Operation

Group 15: Diagnostic Information

Diagnose Undercarriage Components Malfunctions

Measure Track Bushing Wear

Measure Track Pitch

Measure Track Link Wear

Measure Track Shoe Grouser Wear

Measure Track Carrier Roller Wear

Measure Track Roller Wear

Swing Bearing Wobble Test

Group 20: Adjustments

Adjust Track Sag

Section 9025: Hydraulic System

Group 05: Theory Of Operation

Hydraulic System Diagram

Hydraulic System Control Operation-(Serial No. 011000-)

Switch Panel 2 Operation-(Serial No. -010999)

Switch Panel 2 Operation-(Serial No. 011000-)

Engine And Pump Controller (EC) Operation-(Serial No. -010999)

Engine Controller (EC) And Pump And Valve Controller (PVC)- Operation-(Serial No. 011000-)

Engine Speed Control System Operation

Work Mode Chart-(Serial No. 011000-)

Engine Power Modes

Pilot System Operation-(Serial No. -010999)

Pilot System Operation-(Serial No. 011000-)

Pilot Pump And Filter Operation

Pilot Control Manifold Operation-(Serial No. -010999)

Pilot Pressure Regulating And Solenoid Valve Manifold Operation -(Serial No. 011000-)

Pilot Pressure Regulating Valve Operation

Pilot Shut-Off Valve Operation

Pilot Controller Operation-Neutral

Pilot Controller Operation-Metering

Propel Pilot Controller Operation-Neutral

Flow Regulator Operation

Warm-Up Circuit Operation

GPII Quick Boom Response Solenoid Valve-(Serial No. 011000-)

Main Control Valve Operation

Main Control Valve Check Valves Schematic

Main Control Valve Check Valve Passages

Dig And Propel System Relief Valves Circuit Operation

Dig System Relief Valve Operation

Propel System Relief And Swing Circuit Relief Valve Operation

Circuit Relief And Anticavitation Valve Operation

Flow Combiner And Swing Brake Release Valve Circuit Operation

Flow Sense Valve Operation

Bucket And Auxiliary Work Circuits Operation

Boom Up Work Circuit Operation

Boom Down Work Circuit Operation

Arm In Work Circuit Operation

Arm Out Work Circuit Operation

Swing Work Circuit Operation

Control Valve Combined Function Operation

Swing And Arm Work Circuit Combined Function Operation

Propel And Bucket Work Circuit Combined Function Operation

Cylinder Operation

Swing Motor Operation

Swing Motor Crossover Relief Valve Operation

Swing Brake Release Valve Circuit Operation

Swing Gearbox Operation

Engine And Pump Controller (EPC) Operation-(Serial No. -010999)

Pump And Valve Controller, Engine Controller Operation- (Serial No. 011000-)

Main Hydraulic Pump Operation

Main Hydraulic Pump Regulator Operation

Main Hydraulic Pump Increasing, Maximum, And Decreasing Displacement Operation

Main Hydraulic Pump Minimum Displacement Operation

Main Hydraulic Pump Constant Horsepower System Operation

Main Hydraulic Pump Summation System Operation

Main Hydraulic Pump High-Low Maximum Displacement Operation

Pump Maximum Displacement Solenoid Valve Operation

Speed Sensing System Operation-(Serial No. 011000-)

Speed Sensing Solenoid Valve (SB) Operation-(Serial No. 011000-)

Grading And Precision Mode Solenoid Valve (SC) Operation- (Serial No. 011000-)

Splitter Drive Operation

Propel Circuit Operation

Propel Control Valve Operation

Rotary Manifold Operation

Propel Motor Operation-(Serial No. -010999)

Propel Motor Counterbalance Valve Propel Operation- (Serial No. -010999)

Propel Motor Counterbalance Valve Braking Operation- (Serial No. -010999)

Propel Motor Crossover Relief Valve Operation-(Serial No. -010999)

Propel Motor Brake Operation-(Serial No. -010999)

Propel Motor Brake Release Valve Operation-(Serial No. -010999)

Propel Motor Operation-(Serial No. 011000-)

Propel Motor Brake Valve Operation-(Serial No. 011000-)

Propel Motor Brake Pressure Reducing Valve-(Serial No. 011000-)

Propel Motor Counterbalance Valve-Neutral-(Serial No. 011000-)

Propel Motor Counterbalance Valve-Propel-(Serial No. 011000-)

Propel Motor Counterbalance Valve-Braking-(Serial No. 011000-)

Propel Motor Crossover Relief Valve Operation-(Serial No. 011000-)

Propel Motor Super Low And Normal Speed Propel Operation-(Serial No. 011000-)

Propel Motor Max Speed Propel Operation-(Serial No. 011000- )

Propel Speed Change Solenoid Valve (SA) Operation- (Serial No. 011000-)

Pump Inlet And Delivery Circuits Operation

Return Circuit Operation

Drain Circuit Operation

Return Filter Operation

Hydraulic System Schematic

Group 15: Diagnostic Information

Diagnostic Procedure

Electronic Component Diagnostic Procedure-(SN 011000-)

Diagnose Hydraulic System Malfunctions

Diagnose Pilot Circuit Malfunctions

Diagnose Dig Circuit Malfunctions

Diagnose Swing Circuit Malfunctions

Diagnose Propel System Malfunctions

Diagnose Control Valve Check Valves Malfunctions

Hydraulic Circuit Symbols

Component Location

Control Lever Pattern Conversion-(SN -010999)

Control Lever Pattern Conversion-(SN 011000-)

Group 20: Adjustments

Pilot Shut-Off Valve Linkage Adjustment

Group 25: 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 Self-Diagnostic Function-(SN -010999)

JT07058 Diagnostic Computer Self-Diagnostic Function-(SN 011000-)

Retry Procedure A

Retry Procedure B

Self Diagnosing Fault Codes-Engine And Pump Controller (EPC) (SN -010999)

Self Diagnosing Fault Codes For Engine Controller (EC) (SN 011000-)

Self Diagnosing Fault Codes For Pump And Valve Controller (PVC) (SN 011000-)

Monitor Data Display List And Description-(SN -010999)

Monitor Data Display List And Description-(SN 011000-)

Component And Symbol Abbreviations

Component Abbreviations And Location-(SN -010999)

Component Abbreviations And Location-(SN 011000-)

Cross Reference To Display Symbols, List, And Unit Of Measure- (SN -010999)

Cross Reference To Display Symbols, List, And Unit Of Measure- (SN 011000-)

Reading Fault Codes Without JT07058 Diagnostic Computer

Reading Fault Codes With JT07058 Diagnostic Computer

Monitor Data Worksheet-892E LC-(SN 011000-)

JT05801 Clamp-On Electronic Tachometer Installation

JT05800 Digital Thermometer Installation

Hydraulic System Warm-Up Procedure

Lower Boom With Engine Stopped

Swing Brake Release Procedure (With Engine Off)

Engine Speed Programming Procedure After Battery Disconnection

Propel Speed Change Solenoid Valve (SA) Harness Test-(SN 011000-)

Speed Sensing Solenoid Valve (SB) Harness Test-(SN 011000-)

Grading And Precision Mode Solenoid Valve (SC) Harness Test- (SN 011000-)

GPII Quick Boom Response Solenoid Valve Harness Test-(SN 011000-)

Pump Maximum Displacement Solenoid Valve Harness Test- (SN 011000-)

Propel Pilot Pressure Sensor Harness Test-(SN 011000-)

Engine Control Sensor (EC Sensor) Harness Test-(SN 011000-)

Engine Control Motor (EC Motor) Harness Test-(SN 011000-)

Miscellaneous Component Harness Test-(SN 011000-)

Hydraulic Pump Start-Up Procedure

Swing Motor Start-Up Procedure

Swing Gearbox Start-Up Procedure

Propel Motor Start-Up Procedure

Hydraulic Oil Filter Inspection Procedure

Cycle Time Test

Pilot Pressure Regulating Valve Test And Adjustment

Valve Spool Actuating Pilot Pressure Test-(SN 011000-)

Propel Speed Change Solenoid Valve (SA) Test-(SN 011000-)

Speed Sensing Solenoid Valve (SB) Test-(SN 011000-)

Grading And Precision Mode Solenoid Valve (SC) Test- (SN 011000-)

General Purpose II Quick Boom Response Solenoid Valve Pressure Test-(SN 011000-)

Pump Maximum Displacement Solenoid Valve Test

Dig And Propel 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

Flow Sense Valve Test

Main Hydraulic Pump Displacement Adjustment

Main Hydraulic Pump Performance Test (Cycle Time Method)

Pump Regulator High And Low Maximum Flow Test And Adjustment

Hydraulic Pump Regulator Test And Adjustment-Minimum Flow

Hydraulic Pump Regulator Test And Adjustment (Engine Pulldown)

Hydraulic Pump Flow Test

Pilot Pump Flow Test

Swing Brake Release Pressure Test

Propel Motor Operating Leakage Test

Swing Motor Operating Leakage Test

Cylinder Drift Test-Boom, Arm And Bucket

TM Worksheet-892E LC Excavator

John Deere 892E-LC Excavator Operation and Test Technical Manual (TM1541)