John Deere Compact Excavator 50ZTS Service Repair Manual (TM1818)

TM1818 - John Deere 50ZTS Compact Excavator Technical Manual - Repair.PDF

Complete service repair manual for John Deere Compact Excavator 50ZTS, with all the shop information to maintain, diagnostic, repair, service like professional mechanics.

John Deere Compact Excavator 50 ZTS 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.
* 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: 811 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
   Tracks
      Track System
   Axles and Suspension Systems
      Axle Shaft, Bearings, and Reduction Gears
      Hydraulic System
   Engine
      Removal and Installation
   Engine Auxiliary Systems
      Cold Weather Starting Aids
      Cooling System
      Speed Controls
      Intake System
      External Fuel Supply Systems
   Dampener Drive (Flex Coupling)
      Elements
   Electrical System
      Batteries, Support, and Cables
      Alternator, Regulator, and Charging System Wiring
      Wiring Harness and Switches
      Instruments and Indicators
   Frame or Supporting Structure
      Frame Installation
      Chassis Weights
   Operator`s Station
      Removal and Installation
      Operator Enclosure
      Seat and Seat Belt
      Heating
   Bulldozers (Backfill Blade)
      Blades
      Control Linkage
      Hydraulic System
   Excavator
      Buckets
      Frames
      Hydraulic System
   Swing or Pivoting System
      Mechanical Drive Elements
      Hydraulic System
   Dealer Fabricated Tools

tm1818 - 50ZTS Excavator

Table of Contents

Foreword

Technical Information Feedback Form

Section 00: General Information

Group 0001: 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 0002: General Specifications

50ZTS Excavator Overview

50ZTS Excavator

50ZTS Excavator Working Ranges

50ZTS Excavator Engine Specifications

50ZTS Excavator Drain and Refill Capacities

Group 0003: 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 0004: 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 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 Lower Track Roller

Measure Track Carrier Roller Wear

Remove and Install Track Carrier Roller

Inspect Metal Face Seals

Measure Track Shoe Grouser Wear

Remove and Install Track Shoe

Measure Rubber Track Lugs

Measure Track Chain Link Wear

Measure Track Chain Bushing Wear

Measure Track Chain Pitch

Remove and Install Rubber Track

Remove and Install Steel Track

Disassemble and Assemble Track Chain

Disassemble and Assemble Track Chain to Replace Broken Part

Adjust Track Sag (Rubber Track)

Adjust Track Sag (Steel Track)

Remove and Install Sprocket

Measure Front Idler Wear

Remove and Install Front Idler

Disassemble and Assemble Front Idler

Remove and Install Track Adjuster and Recoil Spring

Disassemble and Assemble Track Adjuster and Recoil Spring

Disassemble and Assemble Track Adjuster Cylinder

Section 02: Axles and Suspension Systems

Group 0250: Axle Shaft, Bearings, and Reduction Gears

Service Equipment and Tools

Other Material

Specifications

Towing Machine

Remove and Install Propel Gearbox

Propel Gearbox Start-Up Procedure

Disassemble Propel Gearbox

Inspect Metal Face Seals

Disassemble and Assemble First Planet Carrier

Assemble Propel Gearbox

Group 0260: Hydraulic System

Essential Tools

Service Equipment and Tools

Specifications

Remove and Install Propel Motor and Brake

Disassemble Propel Motor and Brake

Assemble Propel Motor and Brake

Disassemble and Assemble Propel Motor Brake Valve Housing

Propel Motor Start-Up Procedure

Remove and Install Rotary Manifold

Disassemble and Assemble Rotary Manifold

Rotary Manifold Air Test

Section 04: Engine

Group 0400: Removal and Installation

Essential Tools

Service Equipment and Tools

Other Material

Specifications

Remove and Install Engine

Disassemble Engine

Inspect and Repair Cylinder Head

Inspect Valve

Inspect and Repair Valve Spring

Inspect and Repair Tappet (Cam Follower or Valve Lifter)

Inspect and Repair Push Rod

Inspect and Repair Rocker Arm Shaft and Rocker Arm

Inspect and Repair Idler Gear and Idler Gear Shaft

Inspect Camshaft

Inspect and Repair Cylinder Block

Inspect and Repair Piston and Piston Ring

Inspect and Replace Piston Pin

Inspect and Repair Connecting Rod

Inspect and Repair Crankshaft

Inspect and Repair Flywheel and Flywheel Housing (Rear Oil Seal)

Timing Gear Case Cover Oil Seal Removal and Installation

Assemble Engine

Remove and Install Oil Pan

Remove and Install Oil Pump

Disassemble and Assemble Oil Pump

Remove and Install Water Pump

Disassemble and Assemble Water Pump

Remove and Install Thermostat

Remove and Install Fuel Injection Pump

Repair Fuel Injection Pump

Injection Timing Test and Adjustment

Remove and Install Fuel Injection Nozzle

Disassemble and Assemble Fuel Injection Nozzle

Bleed Fuel System

Remove and Install Engine Crankcase Breather

Engine Valve Clearance Adjustment

Remove and Install Starter

Disassemble and Assemble Starter

Section 05: Engine Auxiliary Systems

Group 0505: Cold Weather Starting Aids

Remove and Install Engine Glow Plugs

Group 0510: Cooling System

Specifications

Remove and Install Fan, Shroud and Guard

Remove and Install Radiator

Remove and Install Fan Belt

Group 0515: Speed Controls

Other Material

Specifications

Remove and Install Engine Speed Control Cable

Remove and Install Fuel Shut-Off Solenoid

Remove and Install Fuel Shut-Off Solenoid Linkage

Group 0520: Intake System

Remove and Install Air Cleaner

Disassemble and Assemble Air Cleaner

Group 0560: External Fuel Supply Systems

Remove and Install Fuel Tank

Disassemble and Assemble Fuel Tank

Remove and Install Fuel Lines

Remove and Install Fuel Pump

Remove and Install Primary Fuel Filter (Water Separator)

Disassemble and Assemble Primary Fuel Filter (Water Separator)

Remove and Install Final Fuel Filter

Disassemble and Assemble Final Fuel Filter

Bleed Fuel System

Section 07: Dampener Drive (Flex Coupling)

Group 0752: Elements

Service Equipment and Tools

Other Material

Specifications

Remove and Install Dampener Drive Element

Section 16: Electrical System

Group 1671: Batteries, Support, and Cables

Specifications

Handle Batteries Safely

Procedure for Testing Batteries

Checking Electrolyte Specific Gravity

Check Battery Electrolyte Level and Terminals

Using Booster Batteries—12 Volt System

Charge Battery

Remove and Install Batteries

12-Volt Accessory

Group 1672: Alternator, Regulator, and Charging System Wiring

Remove and Install Alternator

Disassemble and Assemble Alternator

Group 1674: Wiring Harness and Switches

Essential Tools

Service Equipment and Tools

Disconnecting Tab Retainer Connectors

Disconnecting Pull-Tab Retainer Connectors

Replacing Fuses

Fuse (Blade-Type) Color Codes

Remove and Install Key Switch

Remove and Install Dome Light

Replace DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Connectors

Install DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Contact

Replace WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Connector

Install WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Contact

Remove Connector Body from Blade Terminals

Group 1676: Instruments and Indicators

Replace Monitor Panel Bulbs

Remove and Install Monitor Panel

Section 17: Frame or Supporting Structure

Group 1740: Frame Installation

Specifications

Welding on Machine

Welding Repair of Major Structure

Group 1749: Chassis Weights

Service Equipment and Tools

Specifications

Remove and Install Counterweight

Section 18: Operator's Station

Group 1800: Removal and Installation

Specifications

Remove and Install Cab

Remove and Install Canopy

Group 1810: Operator Enclosure

Remove and Install Windowpane and One Piece Molding

Remove and Install Bonded Windowpane

Remove and Install Sliding Windows

Windowpane Dimensions

Group 1821: Seat and Seat Belt

Specifications

Check Seat Adjustments

Remove and Install Seat

Remove and Install Seat Base

Disassemble and Assemble Seat

Remove and Install Seat Belt

Inspect Seat Belt

Group 1830: Heating

Remove and Install Heater Core and Blower Motor

Remove and Install Heater Hoses

Section 32: Bulldozers (Backfill Blade)

Group 3201: Blades

Remove and Install Backfill Blade

Disassemble and Assemble Backfill Blade

Group 3215: Control Linkage

Remove and Install Backfill Blade Control Lever and Linkage

Adjust Backfill Blade Control Lever and Linkage

Group 3260: Hydraulic System

Service Equipment and Tools

Other Material

Specifications

Remove and Install One Way/Two Way Valve

Disassemble and Assemble One Way/Two Way Valve

Remove and Install Backfill Blade Control Valve

Disassemble and Assemble Backfill Blade Control Valve

Remove and Install Blade Make-Up Valve

Disassemble and Assemble Blade Make-Up Valve

Remove and Install Backfill Blade Cylinder

Disassemble and Assemble Backfill Blade Cylinder

Section 33: Excavator

Group 3302: Buckets

Other Material

Specifications

Replacing Bucket Teeth

Replace Bucket Tooth Tip—Heavy-Duty Bucket

Welding on Machine

Remove and Install Tooth Shank

Replace Welded Cutting Edge

Repair Cracked Cutting Edge

Remove and Install Bucket

Adjust Bucket Pivot End Play

Disassemble and Assemble Bucket

Group 3340: Frames

Service Equipment and Tools

Other Material

Specifications

Remove and Install Bucket Links

Remove and Install Arm

Remove and Install Boom

Remove and Install Boom Swing

Inspect Arm, Boom, and Boom Swing Pins and Bushings

Remove and Install Bushings and Seals

Group 3360: Hydraulic System

Essential Tools

Service Equipment and Tools

Other Material

Specifications

Control Lever Pattern Conversion

Lower Boom With Engine Stopped

Remove and Install Gear Pump—P3

Disassemble and Assemble Gear Pump—P3

Remove and Install Main Hydraulic Pump

Hydraulic Pump Start-Up Procedure

Disassemble Main Hydraulic Pump

Assemble Main Hydraulic Pump

Remove and Install Pilot Pump

Disassemble and Assemble Pilot Pump

Disassemble and Assemble Pilot Relief Valve

Remove and Install Pilot Shut-Off and Propel Speed Change Solenoid Valves

Disassemble and Assemble Pilot Shut-Off and Propel Speed Change Solenoid Valves

Remove and Install Pilot Controllers

Disassemble and Assemble Pilot Controller

Remove and Install Propel Pilot Controller

Disassemble and Assemble Propel Pilot Controller

Remove and Install Flow Combiner Valve

Remove and Install Main Control Valve

Disassemble and Assemble Main Control Valve

Remove and Install Hydraulic Oil Tank

Disassemble and Assemble Hydraulic Oil Tank

Remove and Install Return Filter

Remove and Install Suction Filter

Remove and Install Oil Cooler

Remove and Install Boom Cylinder

Remove and Install Arm Cylinder

Disassemble Boom and Arm Cylinders

Assemble Boom and Arm Cylinders

Remove and Install Bucket Cylinder

Disassemble Bucket Cylinder

Assemble Bucket Cylinder

Hydraulic Cylinder Bleed Procedure

Section 43: Swing or Pivoting System

Group 4350: Mechanical Drive Elements

Service Equipment and Tools

Other Material

Specifications

Remove and Install Swing Gearbox

Disassemble Swing Gearbox

Assemble Swing Gearbox

Remove Upperstructure

Install Upperstructure

Remove and Install Swing Bearing

Install Swing Bearing Upper Seal

Install Swing Bearing Lower Seal

Group 4360: Hydraulic System

Service Equipment and Tools

Other Material

Specifications

Remove and Install Swing Motor and Park Brake

Swing Motor Start-Up Procedure

Disassemble Swing Motor and Park Brake

Assemble Swing Motor and Park Brake

Disassemble and Assemble Cover For Swing Motor and Park Brake

Disassemble and Assemble Swing Motor Crossover Relief Valve

Remove and Install Swing Motor Park Brake Changeover Valve

Disassemble and Assemble Swing Motor Park Brake Changeover 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

DFT1089 Barrel Support

DFT1169 Travel and Swing Gearbox Nut Wrench