Complete service repair manual for John Deere 892E-LC Excavator, with all the shop information to maintain, repair, and rebuild like professional mechanics.

John Deere 892E-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.

TM1542 - John Deere 892E-LC Excavator Technical Manual - Repair.PDF
TM1542 - John Deere 892E-LC Excavator Technical Manual - Repair.epub

Total Pages: 734 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
   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
   Splitter Drive
      Gears, Shafts, And Bearings
   Electrical System
      Batteries, Support, And Cables
      Alternator, Regulator, And Charging System Wiring
      Wiring Harness And Switches
      System Controls
      Instruments And Indicators
   Frame Or Supporting Structure
      Frame Installation
      Chassis Weights
   Operator’s Station
      Removal And Installation
      Operator Enclosure
      Seat And Seat Belt
      Heating And Air Conditioning
   Excavator
      Bucket
      Frames
      Hydraulic System
   Swing Or Pivoting System
      Mechanical Drive Elements
      Hydraulic System
   Dealer Fabricated Tools
 

tm1542 - 892ELC Excavator Repair

Table of Contents

Foreword

Technical Information Feedback Form

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

892E LC

892E 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

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

Engine Coolant

Lubricant Storage

Section 01: Tracks

Group 0130: Track System

Service Equipment And Tools

Other Material

Specifications

Measure Track Chain And Roller Wear

Remove And Install Track Roller

Disassemble And Assemble Track Roller

Test Track Roller For Oil Leakage

Remove And Install Track Carrier Roller

Disassemble And Assemble Track Carrier Roller

Inspect Metal Face Seals

Remove And Install Track Shoe

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

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

Group 0250: Axle Shaft, Bearings, And Reduction Gears

Service Equipment And Tools

Other Material

Specifications

Towing Machine

Remove And Install Propel Gearbox

Disassemble Propel Gearbox

Inspect Metal Face Seals

Disassemble And Assemble First Planet Carrier

Disassemble And Assemble Second Planet Carrier

Disassemble And Assemble Third Planet Carrier

Assemble Propel Gearbox

Group 0260: Hydraulic System

Special Or Essential Tools

Service Equipment And Tools

Other Material

Specifications

Remove And Install Propel Motor And Brake (S.N. -010999)

Disassemble Propel Motor And Brake (S.N. -010999)

Assemble Propel Motor And Brake (S.N. -010999)

Disassemble And Assemble Propel Motor Brake Valve Housing (S.N. -010999)

Remove And Install Propel Motor And Brake (S.N. 011000-)

Disassemble Propel Motor And Brake (S.N. 011000-)

Assemble Propel Motor And Brake (S.N. 011000-)

Disassemble And Assemble Propel Motor Brake Valve Housing (S.N. 011000- )

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

6076 John Deere Engine-Use CTM42

Starting Motor-Use CTM77

Special Or Essential Tools

Service Equipment And Tools

Specifications

Remove And Install Engine

Remove And Install Oil Pan

Bleed Fuel System

Measure And Adjust Engine Valve Clearances

Remove And Install Starter

Section 05: Engine Auxiliary Systems

Group 0505: Cold Weather Starting Aids

Other Material

Specifications

Remove And Install Starting Aid Solenoid And Nozzle

Remove And Install Engine Coolant Heater

Group 0510: Cooling System

Specifications

Remove And Install Air Inlet Screen

Remove And Install Fan, Shroud, And Guards

Remove And Install Radiator

Fill And Deaerate Cooling System

Remove And Install Fan Belts

Fan Belt Tension Adjustment

Group 0515: Speed Controls

Other Material

Specifications

Remove And Install Engine Speed Control Linkage

Engine Speed Control Linkage Adjustment

Remove And Install Engine Control (EC) Motor And Sensor

Disassemble And Assemble Engine Control (EC) Motor And Sensor

Group 0520: Intake System

Special Or Essential Tools

Service Equipment And Tools

Specifications

Remove And Install Air Cleaner

Air Intake System Leakage Test

Group 0560: External Fuel Supply Systems

Other Material

Specifications

Remove And Install Fuel Tank

Section 08: Splitter Drive

Group 0851: Gears, Shafts, And Bearings

Other Material

Specifications

Remove And Install Splitter Housing

Disassemble Splitter Housing

Assemble Splitter Housing

Remove And Install Dampener Drive (Flex Coupling)

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

Modification For Replacement Batteries

Adding 12-Volt Accessories

Group 1672: Alternator, Regulator, And Charging System Wiring

Alternator Repair-Use CTM77

Specifications

Remove And Install Alternator

Alternator Belt Tension Adjustment

Group 1674: Wiring Harness And Switches

Special Or Essential Tools

Front Cab Electrical Component Identification (S.N. -010999)

Rear Cab Electrical Component Identification (S.N. -010999)

Front Chassis Electrical Component Identification (S.N. -010999)

Hydraulic Electrical Component Identification (S.N. -010999)

Engine Electrical Component Identification (S.N. -010999)

Front Cab Electrical Component Identification (S.N. 011000-)

Rear Cab Electrical Component Identification (S.N. 011000-)

Front Chassis Electrical Component Identification (S.N. 011000- )

Hydraulic Electrical Component Identification (S.N. 011000-)

Engine Electrical Component Identification (S.N. 011000-)

Connect Engine And Pump Controller (EPC) Harness Connector (S.N. -010999), Engine Controller (EC) And Pump And Valve Controller Harness Connector (S.N. 011000-)

Disconnect Tab Retainer Connectors

Replacing Fuses

Fuse (Blade-Type) Color Codes

Fuse Specifications

Remove And Install Ground Strap

Remove And Install Starter Switch

Remove And Install Dome Light Switch

Remove And Install Propel Alarm Cancel Switch And Start Aid Switch

Replace DEUTSCH DEUTSCH is a trademark of Deutsch Co. Connectors

Install DEUTSCH DEUTSCH is a trademark of 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 1675: System Controls

Welding On Machine

Connect Engine And Pump Controller (EPC) Harness Connector (S.N. -010999), Engine Controller (EC) And Pump And Valve Controller Harness Connector (S.N. 011000-)

Remove And Install Engine And Pump Controller (EPC) (S.N. -010999)

Remove And Install Engine Controller (EC), And Pump And Valve Controller (PCV) (S.N. 011000-)

Remove And Install Monitor Controller

Group 1676: Instruments And Indicators

Replace Monitor Panel Bulbs

Remove And Install Monitor Panel And Switch Panel 1

Remove And Install Hour Meter, Coolant Temperature And Fuel Level Gauges

Replace Switch Panel 2 Bulb

Remove And Install Switch Panel 2

Remove And Install Travel Alarm

Changing Travel Alarm Volume

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

Group 1810: Operator Enclosure

Remove And Window Pane And Two Piece Molding

Remove And Install Windowpane And One Piece Molding

Remove And Install Sliding Windows

Windowpane Dimensions

Group 1821: Seat And Seat Belt

Specifications

Remove And Install Seat

Disassemble And Assemble Seat (S.N. -010999)

Disassemble And Assemble Seat (S.N. 011000-)

Disassemble And Assemble Seat Stand (S.N. -010999)

Disassemble And Assemble Seat Stand (S.N. 011000-)

Group 1830: Heating And Air Conditioning

Remove And Install Heater Core

Remove And Install Blower Motor

Section 33: Excavator

Group 3302: Bucket

Other Material

Specifications

Replacing Bucket Teeth

Replacing Bucket Tooth Tip-Heavy-Duty Bucket

Welding On Machine

Remove And Install Tooth Shank

Remove And Install Bucket And Linkage

Adjust Bucket Linkage

Replace Welded Bucket Cutting Edges

Repair Cracked Cutting Edge

Group 3340: Frames

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

Service Equipment And Tools

Other Material

Specifications

Engine And Pump Controller (EPC) Bypass Procedure (S.N. -010999)

Electronic Control (EC) Bypass Procedure (S.N. 011000-)

Control Lever Pattern Conversion (S.N. -010999)

Control Lever Pattern Conversion (S.N. 011000-)

Lower Boom With Engine Stopped

Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy

Remove And Install Main Hydraulic Pump (S.N. -010999)

Remove And Install Main Hydraulic Pump (S.N. 011000-)

Hydraulic Pump Start-Up Procedure

Disassemble Main Hydraulic Pump

Assemble Main Hydraulic Pump

Remove And Install Main Hydraulic Pump Regulator (S.N. -010999)

Remove And Install Main Hydraulic Pump Regulator (S.N. 011000- )

Disassemble And Assemble Main Hydraulic Pump Regulator

Remove And Install Pilot Pump

Disassemble And Assemble Pilot Pump

Remove And Install Pilot Filter

Hydraulic Oil Filter Inspection Procedure

Remove And Install Pilot Control Manifold (S.N. -010999)

Disassemble And Assemble Pilot Control Manifold (S.N. -010999)

Remove And Install Pilot Pressure Regulating And Solenoid Valve Manifold (S.N. 011000-)

Disassemble And Assemble Pilot Pressure Regulating And Solenoid Valve Manifold (S.N. 011000-)

Remove And Install Pump Maximum Displacement Solenoid Valve (S.N. 011000- )

Disassemble And Assemble Pump Maximum Displacement Solenoid Valve (S.N. 011000-)

Remove And Install Grading And Precision Mode Shuttle Valve (S.N. 011000- )

Remove And Install GPII Quick Boom Response Solenoid Valve (S.N. 011000- )

Remove And Install Pilot Shut-Off Valve

Disassemble And Assemble Pilot Shut-Off Valve

Pilot Shut-Off Valve Linkage Adjustment

Remove And Install Pilot Controller

Disassemble And Assemble Pilot Controller

Remove And Install Propel Pilot Controller (S.N. -010999)

Remove And Install Propel Pilot Controller (S.N. 011000-)

Disassemble And Assemble Propel Pilot Controller

Remove And Install Propel Pilot Shuttle Valve (S.N. 011000-)

Remove And Install Flow Regulator (S.N. -010999)

Remove And Install Flow Regulator (S.N. 011000-)

Disassemble And Assemble Flow Regulator

Remove And Install Main Control Valve

Disassemble And Assemble Main Control Valve

Dig System Relief Valve

Propel System Relief And Swing Circuit Relief Valves

Flow Sense Valve

Flow Combiner Valve

Circuit Relief And Anticavitation Valve (Bucket, Boom, Arm)

Remove And Install Boom Cylinder

Remove And Install Arm Cylinder

Remove And Install Bucket Cylinder

Hydraulic Cylinder Bleed Procedure

Disassemble Bucket, Arm, Or Boom Cylinder

Assemble Bucket, Arm, Or Boom Cylinder

Remove And Install Bypass Check Valve-In Return Line From Control Valve To Hydraulic Oil Tank

Remove And Install Hydraulic Oil Cooler

Remove And Install Restriction Valve-In Line From Oil Cooler To Hydraulic Oil Tank

Remove And Install Return Filter And Bypass Valve

Remove And Install Suction Filter

Disassemble And Assemble Hydraulic Oil Tank Relief Valve And Breather Filter Cap

Remove And Install Hydraulic Oil Tank

Disassemble And Assemble Hydraulic Oil Tank

Section 43: Swing Or Pivoting System

Group 4350: Mechanical Drive Elements

Service Equipment And Tools

Other Material

Specifications

Remove And Install Swing Gearbox

Swing Gearbox Start-Up Procedure

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

Remove And Install Swing Motor And Brake

Swing Motor Start-Up Procedure

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

DF1063 Lift Bracket

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

John Deere 892E-LC Excavator Service Repair Manual (TM1542)