John Deere 600CLC & 800C Excavator Operation and Test Workshop Manual (TM1922) PDF - MJODTM1922.zip
Operation and Test Technical Manual for John Deere 600CLC and 800C Excavators (TM1922)
TM1922 - Technical Manual for John Deere 600CLC and 800C Excavators, covering Operation and Testing. PDF format.
Complete Diagnostic, Operation and Test manual with Electrical Wiring Diagrams for Excavators 600CLC & 800C, with all the shop information to maintain, diagnostic, repair, refurbish/rebuild like professional mechanics.
John Deere Excavators 600CLC & 800C 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.
Total Pages: 751 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English
MAIN SECTIONS
Foreword
Technical Information Feedback Form
General Information
Safety
Torque Values
Operational Checkout Procedure
Operational Checkout Procedure
Engine
Theory of Operation
Diagnostic Information
Adjustments
Tests
Electrical System
System Information
System Diagrams
Sub-System Diagnostics
References
Power Train
Theory of Operation
Diagnostic Information
Hydraulic System
Theory of Operation
Diagnostic Information
Tests
Air Conditioning System
Theory of Operation
Diagnostic Information
Tests
tm1922 - 600CLC and 800C Excavator
Table of Contents
Foreword
Technical Information Feedback Form
Section 9000: General Information
Group 01: Safety
Recognize Safety Information
Follow Safety Instructions
Operate Only If Qualified
Wear Protective Equipment
Avoid Unauthorized Machine Modifications
Add Cab Guarding for Special Uses
Inspect Machine
Stay Clear of Moving Parts
Avoid High-Pressure Oils
Beware of Exhaust Fumes
Prevent Fires
Prevent Battery Explosions
Handle Chemical Products Safely
Dispose of Waste Properly
Prepare for Emergencies
Use Steps and Handholds Correctly
Start Only From Operator's Seat
Use and Maintain Seat Belt
Prevent Unintended Machine Movement
Avoid Work Site Hazards
Keep Riders Off Machine
Avoid Backover Accidents
Avoid Machine Tip Over
Use Special Care When Lifting Objects
Add and Operate Attachments Safely
Park and Prepare for Service Safely
Service Cooling System Safely
Remove Paint Before Welding or Heating
Make Welding Repairs Safely
Drive Metal Pins Safely
Group 03: Torque Values
Hardware Torque Specifications
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
Section 9005: Operational Checkout Procedure
Group 10: Operational Checkout Procedure
Operational Checkout
Section 9010: Engine
Group 05: Theory of Operation
Engine—Component Location
Engine Fuel System Operation
Engine Cooling System Operation
Engine Lubrication System Operation
Engine Turbocharger Operation
Engine Speed Control System Operation
Group 15: Diagnostic Information
Diagnose Engine Malfunctions
Group 20: Adjustments
Check and Adjust Engine Valve Lash (Clearance)
Group 25: Tests
Engine Speed Test
Air Filter Restriction Indicator Switch Test
Radiator Air Flow Test
Engine Power Test Using Turbocharger Boost Pressure
Section 9015: Electrical System
Group 05: System Information
Electrical Diagram Information
Group 10: System Diagrams
Explanation of Wire Markings
Fuse Specifications
System Functional Schematic Section Legend
Wiring and Schematic Diagrams Legend
System Functional Schematic
Overall Machine Harnesses Component Location Diagram (600CLC)
Overall Machine Harnesses Component Location Diagram (800C)
Cab Harness (W1) and 12 Volt Power Supply (W35) Harness Component Location Diagram
Cab Harness (W1) Component Location Diagram—Harness Connectors
12 Volt Power Supply (W35) Sub-Harness Component Location Diagram—Harness Connectors
Engine Harness (W2) Component Location Diagram (600CLC)
Engine Harness (W2) Component Location Diagram—Harness Connectors (600CLC)
Engine Harness (W20) Component Location Diagram (800C)
Engine Harness (W20) Component Location Diagram—Harness Connectors (800C)
Monitor Harness (W3) and Windshield Wiper Motor Sub-Harness (W5) Component Location Diagram
Monitor Harness (W3) Component Location Diagram—Harness Connectors
Windshield Wiper Motor Sub-Harness (W5) Component Location Diagram—Harness Connectors
Solenoid Harness (W6) Component Location Diagram (600CLC)
Solenoid Harness (W6) Component Location Diagram—Harness Connectors (600CLC)
Solenoid Harness (W7) Component Location Diagram (800C)
Solenoid Harness (W7) Component Location Diagram—Harness Connectors (800C)
Air Conditioner Controller Harness (W9) Component Location Diagram—Harness Mating Connectors
Vehicle Harness (W10) Component Location Diagram (600CLC)
Vehicle Harness (W10) Component Location Diagram—Harness Connectors (600CLC)
Vehicle Harness (W30) Component Location Diagram (800C)
Vehicle Harness (W30) Component Location Diagram—Harness Connectors (800C)
Pump Harness (W12) Component Location Diagram (600CLC)
Pump Harness (W12) Component Location Diagram—Harness Connectors (600CLC)
Pump Harness (W31) Component Location Diagram (800C)
Pump Harness (W31) Component Location Diagram—Harness Connectors (800C)
Engine Coolant Sensor Harness (W16) Component Location Diagram (600CLC)
Engine Coolant Sensor Harness (W16) Component Location Diagram—Harness Connectors (600CLC)
Engine Coolant Sensor Harness (W26) Component Location Diagram (800C)
Engine Coolant Sensor Harness (W26) Component Location Diagram—Harness Connectors (800C)
Control Valve Harness (W18) Component Location Diagram (600CLC)
Control Valve Harness (W18) Component Location Diagram—Harness Connectors (600CLC)
Control Valve Harness (W28) Component Location Diagram (800C)
Control Valve Harness (W28) Component Location Diagram—Harness Connectors (800C)
Fuel Tank Harness (W19) Component Location Diagram
Fuel Tank Harness (W19) Component Location Diagram—Harness Connectors
Air Conditioner Harness (W34), and Air Conditioner Controller Harness (W9) Component Location Diagram
Air Conditioner Harness (W34) Wiring Diagram—Harness Mating Connectors
Group 15: Sub-System Diagnostics
Starting Circuit Theory of Operation
Travel Alarm Circuit Theory of Operation
Monitor Controller and Display Circuit Theory of Operation
Engine Control Circuit Theory of Operation
Pump and Valve Controller Circuit Theory of Operation
Windshield Wiper And Washer Circuit Theory of Operation
Air Conditioner Controller Circuit Theory of Operation
Group 20: References
Laptop Computer Connection To Pump and Valve Controller Using Service ADVISOR or Excavator Diagnostic Program
Excavator Diagnostic Program General Description and Overview
Reading Service Codes Without Laptop Computer
Monitor Display Diagnostic System Operation
Monitor Data Items
Alternator Test Procedure
Fuse Test
Engine Speed Learning Procedure
Pump and Valve Controller Pressure Sensors Test
Pump and Valve Controller Solenoids Test
Pump and Valve Controller Temperature Sensor Test
Engine Speed (N) Sensor Test
Pump Angle Sensors and Engine Control Sensor Test
Pump Angle Sensor Adjustment
Electrical Component Checks
Disconnect Tab Retainer Connectors
Disconnecting Spring Wire Clip Connectors
Pump and Valve Controller Service Codes
Repair Batteries
Repair Pump and Valve Controller
Repair Travel Alarm Cancel Switch
Repair Key Switch
Repair Travel Alarm
Repair Windshield Wiper Enable Switch
Repair Rear Cover
Repair Switch Panel
Repair Monitor Controller and Display
Section 9020: Power Train
Group 05: Theory of Operation
Track Adjuster and Recoil Spring Operation
Propel Gearbox Operation—600CLC
Propel Gearbox Operation—800C
Group 15: Diagnostic Information
Diagnose Undercarriage Component Malfunctions
Measure Swing Bearing Wear—600CLC
Measure Swing Bearing Wear—800C
Section 9025: Hydraulic System
Group 05: Theory of Operation
Hydraulic System Diagram and Operation
Pilot System Diagram and Operation
Pilot Pump, Filter, and Bypass Valve Operation
Solenoid Valve and Pilot Pressure Regulating Valve Manifold Operation
Pilot Shut-Off Valve Operation
Pilot Check Valve Manifold And Accumulator Operation
Pilot Controller Operation
Propel Pilot Controller Operation
Counterweight Removal Pilot Controller Operation
Pilot Signal Manifold Operation
Hydraulic Pump and Drive Gearbox Operation
Hydraulic Pump Regulator and Control Solenoid Valve Operation
Hydraulic Pump Flow Rate Control Circuit Operation
Hydraulic Pump Speed Sensing Control Operation
Hydraulic Pump E (Economy) Mode Control Operation
Hydraulic Pump Horsepower Control Operation
Hydraulic Pump Flow Rate Reducing Control Operation
Hydraulic Pump Swing Horsepower Control Operation
Hydraulic Pump Power Limiter Control Operation
Control Valve Operation
Control Valve Check Valves Identification and Operation
System Relief and Power Boost Valve Circuit Operation
Circuit Relief and Anti-Cavitation Valve Operation
Make-Up Valve Operation
Boom and Arm Reduced Leakage Valve Operation
Boom Mode Circuit Operation
Precision Mode Control Operation
Propel Flow Combiner Valve Circuit Operation
Bucket Flow Combiner Valve Circuit Operation
Arm Regenerative Valve Operation
Swing and Boom Up Combined Function in Dig Mode II Operation
Swing Motor, Crossover Relief Valve, and Make-Up Valve Operation—600CLC
Swing Motor Park Brake Release Circuit Operation—600CLC
Swing Gearbox Operation—600CLC
Swing Motor, Crossover Relief Valve, and Make-Up Valve Operation—800C
Swing Motor Park Brake Release Circuit Operation—800C
Swing Gearbox Operation—800C
Boom, Arm, and Bucket Cylinder Operation
Counterweight Removal Cylinder Operation
Counterweight Removal Operation
Propel Motor and Brake Valve Housing Operation
Propel Motor Speed Control Circuit Operation
Rotary Manifold Operation
Hydraulic System Circuit Symbols
Hydraulic System Schematic
Group 15: Diagnostic Information
Machine Malfunctions and Possible Causes
Diagnose Electronic and Control Valve Component Malfunctions
Diagnose Hydraulic System Malfunctions
Diagnose Pilot Circuit Malfunctions
Diagnose Swing Circuit Malfunctions
Diagnose Propel Circuit Malfunctions
Diagnose Dig Circuit Malfunctions
Control Valve Line Identification
Propel Hydraulic System Component Location
Pilot Controllers-to-Pilot Signal Manifold Component Location—Excavator Pattern
Pilot Controllers-to-Pilot Signal Manifold Component Location—Backhoe Pattern
Pilot Signal Manifold-to-Main Control Valve Component Location—600CLC
Pilot Signal Manifold-to-Main Control Valve Component Location—800C
Group 25: Tests
JT05800 Digital Thermometer Installation
JT02156A Digital Pressure/Temperature Analyzer Installation
Hydraulic System Warm-Up Procedure
Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy—600CLC
Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy—800C
Pilot Pressure Regulating Valve Test and Adjustment
Valve Spool Actuating Pilot Pressure Test and Adjustment
Power Boost, Propel Speed, and Boom Mode Solenoid Valve Test
System Relief and Power Boost Valve Test and Adjustment—600CLC
System Relief and Power Boost Valve Test and Adjustment—800C
Circuit Relief Valve Test and Adjustment—600CLC
Circuit Relief Valve Test and Adjustment—800C
Boom Mode Circuit Relief Valve Test and Adjustment
Hydraulic Pump Control Solenoid Valve Test and Adjustment
Hydraulic Pump Displacement Rate Test and Adjustment—600CLC
Hydraulic Pump Displacement Rate Test and Adjustment—800C
Hydraulic Pump Servo Piston Minimum Flow Test and Adjustment—600CLC
Hydraulic Pump Servo Piston Minimum Flow Test and Adjustment—800C
Hydraulic Pump Servo Piston Maximum Flow Test and Adjustment—600CLC
Hydraulic Pump Servo Piston Maximum Flow Test and Adjustment—800C
Swing Motor Crossover Relief Valve Test and Adjustment—600CLC
Swing Motor Crossover Relief Valve Test and Adjustment—800C
Propel Motor Crossover Relief Valve Test and Adjustment
Cylinder Drift Test—Arm, Boom, and Bucket—600CLC
Cylinder Drift Test—Arm, Boom, and Bucket—800C
Propel Motor Leakage Test
Swing Motor Leakage Test—600CLC
Swing Motor Leakage Test—800C
Hydraulic Pump Flow Test—600CLC
Hydraulic Pump Flow Test—800C
Section 9031: Air Conditioning System
Group 05: Theory of Operation
Refrigerant Theory of Operation
Heater and Air Conditioner Circuit Operational Information
Heater and Air Conditioner Circuit Theory of Operation