John Deere Excavators 550LC Operation and Test Service Manual (TM1807)
Complete Diagnostics, Operation and Test manual with Electrical Wiring Diagrams for John Deere Excavators 550LC, with all the shop information to maintain, diagnose, and 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.
TM1807 - John Deere 550LC Excavators Technical Manual - Operation and Test.PDF
MAIN SECTIONS
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
TABLE OF CONTENTS............1
Section 9000: General Information.............16
Group 01: Safety.............16
Follow Safe Procedures.............20
Prepare for Emergencies.............21
Handle Fluids Safely-Avoid Fires.............22
Prevent Battery Explosions.............23
Handle Chemical Products Safely.............24
Prevent Acid Burns.............25
Avoid High-Pressure Fluids.............128
Warn Others of Service Work.............28
Park Machine Safely.............29
Support Machine Properly.............30
Operate Only from Operator's Seat.............31
Stay Clear of Moving Parts.............32
Avoid Power Lines.............33
Use Handholds and Steps.............34
Keep Riders Off Machine.............35
Move and Operate Machine Safely.............36
Wear Protective Clothing.............37
Protect Against Flying Debris.............38
Protect Against Noise.............39
Illuminate Work Area Safely.............40
Service Machines Safely.............41
Remove Paint Before Welding or Heating.............42
Avoid Heating Near Pressurized Fluid Lines.............43
Beware of Exhaust Fumes.............44
Use Proper Lifting Equipment.............45
Service Cooling System Safely.............46
Dispose of Waste Properly.............47
Work in a Clean Area.............48
Use Tools Properly.............49
Replace Safety Signs.............50
Live With Safety.............51
Group 02: General Specifications.............17
550LC Excavator Overview.............53
550LC Excavator.............54
Working Ranges.............56
Engine Specifications.............59
Drain and Refill Capacities.............60
550LC Lift Capacity-KG (LB).............61
Group 03: Torque Values.............17
Hardware Torque Specifications.............84
Unified Inch Bolt and Screw Torque Values.............85
Metric Bolt and Screw Torque Values.............87
Additional Metric Cap Screw Torque Values.............89
Check Oil Lines And Fittings.............91
Service Recommendations for O-Ring Boss Fittings.............92
Service Recommendations For Flat Face O-Ring Seal Fittings.............94
Service Recommendations for 37° Flare and 30° Cone Seat Connectors.............96
Service Recommendations For Flared Connections-Straight or Tapered Threads.............98
Service Recommendations For Inch Series Four Bolt Flange Fittings.............100
Service Recommendations for Metric Series Four Bolt Flange Fitting.............102
Group 04: Fuels and Lubricants.............17
Diesel Fuel.............105
Lubricity of Diesel Fuels.............106
Low Sulfur Diesel Fuel Conditioner.............107
Diesel Fuel Storage.............108
Fuel Tank.............109
Do Not Use Galvanized Containers.............110
Grease.............111
Diesel Engine Oil.............112
Hydraulic Oil.............113
Swing Gearbox, Propel Gearbox and Pump Gearbox Oils.............115
Track Roller, Front Idler, and Carrier Roller Oil.............116
Track Adjuster, Working Tool Pivot, Swing Bearing, and Swing Bearing Gear Grease.............117
Oil Filters.............118
Lubricant Storage.............119
Alternative and Synthetic Lubricants.............120
Mixing of Lubricants.............121
Group 06: Predelivery Assembly Instructions.............18
Precautions for Assembling.............124
Precautions for Lifting Work.............126
Precautions for Operating Machine.............127
Avoid High-Pressure Fluids.............128
Installing Boom Cylinder.............129
Installing Boom.............133
Connecting Hoses Between Boom and Machine.............136
Connecting Boom Cylinder Rod.............138
Installing Arm.............140
Connecting Arm Cylinder Rod.............142
Connecting Bucket Cylinder Hoses.............145
Installing Bucket.............147
Adjusting Bucket Linkage.............149
Attach Windshield Wiper.............151
Retracting the Side Frame.............152
Extending the Side Frame.............154
Check Hydraulic Oil Level.............159
Lubricate Working Tool Pivots.............163
Installing Counterweight (Without Hydraulic Removal Option).............166
Counterweight Installation (With Hydraulic Removal Option).............170
Section 9005: Operational Checkout Procedure.............176
Group 10: Operational Checkout Procedure.............176
Operational Checkout.............228
Section 9010: Engine.............279
Group 05: Theory of Operation.............279
14L (875 cu. in.) N14 Series Cummins Engine.............281
Engine Component Location.............282
Engine Speed Control System Operation.............283
Super Power (S/P) Mode Speed Control Operation.............285
Auto-Idle Mode Speed Control Operation.............286
E (Economy) Mode Speed Control Operation.............288
Auto Warm Up Control.............289
Engine Speed Learning Control Operation.............290
Speed Sensing Control Operation.............291
Group 15: Diagnostic Information.............279
Diagnose Engine Malfunctions.............295
Group 20: Adjustments.............279
Inspect Belts and Check Tension.............299
Engine Speed Check.............301
Engine Speed Control Linkage Adjustment.............302
Engine Speed Learning Procedure.............610
Group 25: Tests.............279
Air Filter Restriction Indicator Switch Test.............307
Radiator Cap Pressure Test.............309
Fuel Pressure Test.............310
Cooling Differential Temperature Test.............312
Engine Power Test Using Turbocharger Boost Pressure.............313
Section 9015: Electrical.............315
Group 05: System Information.............315
Electrical System Visual Inspection.............321
Electrical Circuit Malfunctions.............322
High Resistance Circuit.............324
Open Circuit.............326
Grounded Circuit.............328
Shorted Circuit.............330
Sensor Circuit Shorted to Power.............332
Sensor Circuit Shorted to Itself.............334
Sensor Circuit Shorted to Ground.............336
Multimeter.............338
Seven Step Electrical Test Procedure.............339
Schematic, Wiring Diagram, and Component Location Information.............341
Reading a System Functional Schematic.............342
Reading a Wiring Diagram.............344
Reading a Component Location Diagram.............346
Reading a Connector End View Diagram.............348
Electrical Schematic Symbols.............349
Group 10: System Diagrams.............315
Fuse Specifications.............353
Fuse (Blade-Type) Color Codes.............355
Component Identification Table.............356
Functional Schematic and Component Location Master Legend.............358
System Functional Schematic Section Legend.............363
System Functional Schematic (SE1-SE3).............364
System Functional Schematic (SE4-SE6).............365
System Functional Schematic (SE7-SE9).............366
System Functional Schematic (SE10-SE12).............367
System Functional Schematic (SE13-SE15).............368
System Functional Schematic (SE16-SE18).............369
System Functional Schematic (SE19-SE21).............370
System Functional Schematic (SE22).............371
Engine and Frame Harness (W1) Component Location Diagram.............372
Engine and Frame Harness (W1) Component Location Diagram-Detail A (Harness Mating Connectors).............373
Engine and Frame Harness (W1) Wiring Diagram.............374
Cab Harness (W2) Component Location Diagram.............376
Cab Harness (W2) Component Location-Detail D (Fuse Block).............377
Cab Harness (W2) Component Location Diagram-Detail E (Harness Mating Connectors).............378
Cab Harness (W2) Wiring Diagram.............379
Monitor and Relay Harness (W3) Component Location.............381
Monitor and Relay (W3) Component Location-Detail A (Monitor Controller Connectors).............382
Monitor and Relay (W3) Component Location-Detail B (Monitor Controller Indicators).............383
Monitor and Relay Harness (W3) Wiring Diagram.............384
Air Conditioning Harness (W9) Component Location.............385
Air Conditioning Harness (W9) Wiring Diagram.............386
Left Boom Work Light Harness (W14) Component Location.............387
Left Boom Work Light Harness (W14) Wiring Diagram.............388
Group 15: Sub-System Diagnostics.............316
Power Circuit Operational Information.............390
Power Circuit Theory of Operation.............391
Power Circuit Schematic.............392
Starting and Charging Circuit Operational Information.............399
Starting and Charging Circuit Theory of Operation.............400
Starting and Charging Circuit Schematic.............401
Fuel Shutoff and Start Aid Circuit Specifications.............413
Fuel Shutoff and Start Aid Circuit Operational Information.............414
Fuel Shutoff and Start Aid Circuit Theory of Operation.............415
Fuel Shutoff and Start Aid Circuit Schematic.............416
Monitor Controller and Display Circuit Specifications.............424
Monitor Controller and Display Circuit Operational Information.............425
Monitor Controller and Display Circuit Theory of Operation.............426
Monitor Controller and Display Circuit Schematic.............429
Optional Connector Circuit Operational Information.............467
Optional Connector Circuit Theory of Operation.............468
Optional Connector Circuit Schematic.............469
Engine Controller Circuit Specifications.............472
Engine Controller Circuit Operational Information.............473
Engine Controller Circuit Theory of Operation.............474
Engine Controller Circuit Schematic.............476
Pump and Valve Controller Circuit Specifications.............498
Pump and Valve Controller Circuit Operational Information.............499
Pump and Valve Controller Circuit Theory of Operation.............500
Pump and Valve Controller Circuit Schematic.............501
Travel Alarm Circuit Specifications.............550
Travel Alarm Circuit Operational Information.............551
Travel Alarm Circuit Theory of Operation.............552
Travel Alarm Circuit Schematic.............553
Windshield Wiper and Washer Circuit Operational Information.............561
Windshield Wiper and Washer Circuit Theory of Operation.............562
Windshield Wiper and Washer Circuit Schematic.............564
Work and Drive Light Circuit Operational Information.............572
Work and Drive Light Circuit Theory of Operation.............573
Work and Drive Light Circuit Schematic.............574
Radio Circuit Operational Information.............580
Radio Circuit Theory of Operation.............581
Radio Circuit Schematic.............582
Accessory Circuit Operational Information.............585
Accessory Circuits Theory of Operation.............586
Accessory Circuits Schematic.............587
Lubricator Circuit Operational Information.............591
Lubricator Circuit Theory of Operation.............592
Lubricator Circuit Schematic.............593
Group 20: References.............317
Battery Operation.............599
Battery Specifications.............600
Diagnose Battery Malfunctions.............601
Check Battery Electrolyte Level and Terminals.............602
Procedure for Testing Batteries.............605
Using Booster Batteries-24 Volt System.............606
Replacing Batteries.............608
Adding 12 or 24 Volt Accessories.............609
Engine Speed Learning Procedure.............610
Engine Control Systems.............611
Pump Control Systems.............615
Work Mode Control Systems.............623
Laptop Computer General Description.............624
Excavator Diagnostic Software Overview.............625
Excavator Diagnostics Program-Install.............626
Excavator Diagnostics Program-Uninstall.............630
Excavator Diagnostics Program-Starting.............631
Excavator Diagnostic Software Feature-Service Codes.............635
Excavator Diagnostic Software Feature-Monitor Data.............637
Excavator Diagnostics Program Feature-Saving Monitor Data.............639
Excavator Diagnostic Software Special Function-Angle Sensor.............640
Service Codes for Engine Controller (EC).............641
Service Codes for Pump and Valve Controller (PVC).............643
Monitor Data Items.............645
Excavator Diagnostics Program Troubleshooting.............648
Reading Service Codes Without JT07290 Laptop Computer.............649
Engine Speed Programming Procedure After Battery Disconnection.............651
Engine Speed Sensor Adjustment.............652
Engine Controller (EC) Sensor Voltage Adjustment.............653
Pump Angle Sensor Adjustment.............842
Electronic Component Diagnostic Procedure.............811
Troubleshooting Engine Controller (EC).............661
Troubleshooting Pump and Valve Controller (PVC).............662
Electronic Control Bypass Procedure.............663
Connecting Engine Controller (EC) and Pump and Valve Controller (PVC) Harness Connector.............665
Disconnect Tab Retainer Connectors.............666
Disconnecting Spring Wire Clip Connectors.............667
Section 9020: Power Train.............668
Group 05: Theory of Operation.............668
Track Adjuster Operation.............670
Propel Gearbox Operation.............671
Group 15: Diagnostic Information.............668
Diagnose Undercarriage Component Malfunctions.............675
Measure Track Chain Bushing Wear.............677
Measure Track Chain Link Wear.............678
Measure Track Chain Pitch.............679
Measure Track Shoe Grouser Wear.............680
Measure Lower Track Roller Wear.............681
Measure Track Carrier Roller Wear.............682
Measure Front Idler Wear.............683
Group 20: Adjustments.............668
Swing Bearing Wobble Test.............687
Track Sag Adjustment.............690
Section 9025: Hydraulic System.............814
Group 05: Theory of Operation.............693
Hydraulic System Schematic.............699
Pilot Pump and Filter Operation.............701
Solenoid Valve Manifold and Pilot Pressure Regulating Valve Operation.............703
Pilot Shut-Off Valve Operation.............705
Check Block Operation.............707
Accumulator.............708
Pilot Controller Operation-Neutral.............709
Counterweight or Propel Pilot Controller Operation.............711
Flow Regulator Valve Operation.............713
Propel Flow Regulator Valve Operation.............715
Main Control Valve Operation.............717
Control Valve.............718
Control Valve Cross Section.............719
Control Valve Check Valve Identification and Function.............720
Control Valve Check Valves Schematic.............722
Control Valve Check Valve Cross Section.............723
Power Boost Circuit.............724
System Relief Valve Operation.............726
Circuit Relief-Anti-Cavitation.............728
Make-Up Valve Operation.............730
Reduced Leakage Valve.............731
Flow Combiner Valve Circuit Operation.............733
Flow Combiner Valve Schematic.............735
Flow Sensing Valve.............736
Propel Work Circuit.............738
Bucket and Auxiliary Work Circuits.............740
Boom Up Work Circuit.............742
Boom Down Work Circuit.............744
Arm In Work Circuit.............746
Arm Out Work Circuit.............748
Arm Regenerative Valve.............750
Swing Work Circuit.............752
Swing Valve and End Section.............754
Combined Operation Propel and Swing.............756
Combined Function Swing and Boom Up-Dig Mode II.............758
Combined Function Swing and Boom Up-Dig, Attachment, Precision Mode.............760
Swing Motor Operation.............762
Swing Motor Crossover Relief Valve Operation.............764
Swing Park Brake Release Circuit Operation.............767
Swing Gearbox Operation.............768
Cylinder Operation.............770
Counterweight Removal Cylinder Operation.............772
Counterweight Remove and Install Operation.............773
Pump Drive Gearbox.............775
Main Hydraulic Pump.............777
Pump Displacement Increasing-Maximum.............779
Pump Displacement Decreasing-Minimum.............781
Pump Displacement Solenoid Valve.............783
Propel Circuit Operation.............785
Propel Speed Control System.............787
Propel Motor Operation.............789
Propel Motor-Slow Speed.............791
Propel Motor-Fast Speed.............793
Counterbalance Valve-Propel.............795
Counterbalance Valve-Braking.............797
Propel Brake Operation.............799
Propel Motor Crossover Relief Valve Operation.............801
Rotary Manifold.............803
Pump Inlet and Delivery Circuits.............805
Return Circuit Operation.............807
Hydraulic Schematic.............808
Propel System.............809
Group 15: Diagnostic Information.............694
Diagnostic Procedure.............811
Introduction to Flow Charts.............812
Machine Malfunctions and Possible Causes.............813
Hydraulic System.............814
Control Valve Component and Line Identification.............821
Pilot Circuit-SAE Pattern Component Location.............827
Main Hydraulic System Component Location.............828
Pilot System-SAE Pattern Component Location.............829
Pilot System-JD Pattern Component Location.............830
Hydraulic Pump Angle Sensor Mechanical Check Diagnostic Procedure.............831
Group 20: Adjustments.............695
Pilot Shut-Off Valve Linkage Adjustment.............840
Pump Angle Sensor Adjustment.............842
Group 25: Tests.............695
JT05800 Digital Thermometer Installation.............845
JT05801 Clamp-On Electronic Tachometer Installation.............846
JT02156A Digital Pressure/Temperature Analyzer Installation.............847
Hydraulic System Warm-Up Procedure.............848
Hydraulic Oil Filter Inspection Procedure.............850
Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy.............851
Hydraulic Pump Start-Up Procedure.............853
Swing Motor Start-Up Procedure.............855
Swing Gearbox Start-Up Procedure.............856
Propel Motor Start-Up Procedure.............857
Hydraulic Oil Tank Venting Procedure.............859
Cycle Time Test.............860
Combined Boom Up and Swing Function Test.............863
Pilot Pressure Regulating Valve Test and Adjustment.............865
Valve Spool Actuating Pilot Pressure Test.............868
Power Boost Solenoid Valve (SA) Pressure Test.............870
Propel Speed Change Solenoid Valve (SB) Pressure Test.............872
Swing Priority Solenoid Valve Pressure Test.............874
Swing Brake Release Solenoid Valve (SC) Pressure Test.............876
System Relief and Power Boost Valve Test and Adjustment.............878
Circuit Relief Valve Test and Adjustment.............882
Swing Motor Crossover Relief Valve Test and Adjustment.............886
Propel Motor Crossover Relief Valve Test and Adjustment.............890
Arm, Boom, and Bucket Cylinder Drift Test.............894
Propel Motor Leakage Test.............896
Swing Motor Leakage Test.............900
Pilot Pump Flow Test.............903
Hydraulic Pump Flow Test.............905
Section 9031: Air Conditioning System.............909
Group 05: Theory of Operation.............909
Proper Refrigerant Handling.............959
R134a Refrigerant Cautions.............960
Refrigerant Theory of Operation.............914
Heater and Air Conditioner Circuit Operational Information.............916
Heater and Air Conditioner Circuit Theory of Operation.............917
Heater and Air Conditioner Circuit Schematic.............918
Receiver/Dryer Operation.............919
Expansion Valve Operation.............921
Compressor Relief Valve Operation.............922
Heater and Air Conditioner Controller Operation.............923
Group 15: Diagnostic Information.............909
Heating and Air Conditioning Circuit Diagnostic Checks.............930
Diagnose Air Conditioning Electrical Malfunctions.............936
Diagnose Heater System Malfunctions.............938
Air Conditioner Component Location Diagram.............939
Air Conditioner Harness (W9) Component Location Diagram.............940
Group 20: Adjustments.............909
Proper Refrigerant Handling.............959
R134a Refrigerant Cautions.............960
R134a Compressor Oil Charge Check.............944
R134a Compressor Oil Removal.............945
R134a Component Oil Charge.............946
R134a Refrigerant Recovery, Recycling, and Charging Station Installation Procedure.............948
Recover R134a System.............950
Evacuate R134a System.............952
Charge R134a System.............955
Check and Adjust Compressor Belt Tension.............957
Group 25: Tests.............909
Proper Refrigerant Handling.............959
R134a Refrigerant Cautions.............960
R134a Air Conditioning System Test.............961
Operating Pressure Diagnostic Chart.............964
High and Low Pressure Switch Test.............965
Leak Testing.............967
Refrigerant Hoses and Tubing Inspection.............968
John Deere Excavators 550LC Operation and Test Service Manual (TM1807)
