John Deere 550LC Excavator Repair Technical Manual – PDF DOWNLOAD
DESCRIPTION:
John Deere 550LC Excavator Repair Technical Manual – PDF DOWNLOAD
For complete service information also see:
550LC Excavator Operation and Tests. . . . . TM1807
Alternators and Starting Motors. . . . . . . . . . CTM77
Undercarriage Appraisal Manual . . . . . . . . . SP326
Foreword :
This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use. Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.
- This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury. Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components.
- Operation and tests sections help you identify the majority of routine failures quickly. Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values.
- Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair.
- Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.
TABLE OF CONTENTS:
John Deere 550LC Excavator Repair Technical Manual – PDF DOWNLOAD
Contents………………………………………………………………………………………………………. 5
General Information…………………………………………………………………………………………. 7
Safety Information………………………………………………………………………………………. 9
Handle Fluids Safely—Avoid Fires………………………………………………………………………. 9
Prevent Battery Explosions……………………………………………………………………………. 9
Prepare for Emergencies………………………………………………………………………………. 9
Prevent Acid Burns…………………………………………………………………………………… 10
Handle Chemical Products Safely……………………………………………………………………….. 11
Avoid High-Pressure Fluids……………………………………………………………………………. 11
Park Machine Safely………………………………………………………………………………….. 12
Support Machine Properly……………………………………………………………………………… 12
Wear Protective Clothing……………………………………………………………………………… 12
Work in Clean Area…………………………………………………………………………………… 13
Service Machines Safely………………………………………………………………………………. 13
Work In Ventilated Area………………………………………………………………………………. 13
Illuminate Work Area Safely…………………………………………………………………………… 13
Replace Safety Signs…………………………………………………………………………………. 14
Use Proper Lifting Equipment………………………………………………………………………….. 14
Remove Paint Before Welding or Heating…………………………………………………………………. 14
Avoid Heating Near Pressurized Fluid Lines……………………………………………………………… 15
Keep ROPS Installed Properly………………………………………………………………………….. 15
Service Tires Safely…………………………………………………………………………………. 16
Avoid Harmful Asbestos Dust…………………………………………………………………………… 16
Practice Safe Maintenance…………………………………………………………………………….. 17
Use Proper Tools…………………………………………………………………………………….. 17
Dispose of Waste Properly…………………………………………………………………………….. 18
Live With Safety…………………………………………………………………………………….. 18
General Specifications…………………………………………………………………………………… 19
544G Specifications………………………………………………………………………………….. 19
544G Drain And Refill Capacities………………………………………………………………………. 22
544G LL Specifications……………………………………………………………………………….. 23
544G LL Drain And Refill Capacities……………………………………………………………………. 27
544G TC Specifications……………………………………………………………………………….. 28
544G TC Drain And Refill Capacities……………………………………………………………………. 31
624G Specifications………………………………………………………………………………….. 32
624G Drain And Refill Capacities………………………………………………………………………. 35
644G Specifications………………………………………………………………………………….. 36
644G Drain And Refill Capacities………………………………………………………………………. 38
Torque Values…………………………………………………………………………………………… 39
Hardware Torque Specifications………………………………………………………………………… 39
ROPS Torque Specifications……………………………………………………………………………. 39
Metric Bolt and Cap Screw Torque Values………………………………………………………………… 40
Additional Metric Cap Screw Torque Values………………………………………………………………. 41
Unified Inch Bolt and Cap Screw Torque Values…………………………………………………………… 43
Check Oil Lines And Fittings………………………………………………………………………….. 44
Service Recommendations for O-Ring Boss Fittings………………………………………………………… 45
Service Recommendations for Flat Face O-Ring Seal Fittings……………………………………………….. 47
Service Recommendations for Metric Series Four Bolt Flange Fitting………………………………………… 48
Service Recommendations For Inch Series Four Bolt Flange Fittings…………………………………………. 49
Fuels And Lubricants…………………………………………………………………………………….. 51
Fuel Specifications………………………………………………………………………………….. 51
Storing Fuel………………………………………………………………………………………… 51
Do Not Use Galvanized Containers………………………………………………………………………. 52
Fuel Tank…………………………………………………………………………………………… 52
Engine Oil………………………………………………………………………………………….. 53
Hydraulic System Oil And Differential Oil………………………………………………………………. 54
Transmission Oil…………………………………………………………………………………….. 55
Grease……………………………………………………………………………………………… 56
Alternative and Synthetic Lubricants…………………………………………………………………… 57
Lubricant Storage……………………………………………………………………………………. 57
Mixing of Lubricants…………………………………………………………………………………. 58
Diesel Engine Coolant………………………………………………………………………………… 59
Operational Checkout Procedure……………………………………………………………………………….. 61
Operational Checkout Procedure……………………………………………………………………………. 63
Operational Checkout Record Sheet—544G, 624G, And 644G…………………………………………………… 63
Complete Machine Operational Checkout………………………………………………………………….. 69
Monitor Indicator And Gauge Checks—Engine Off…………………………………………………………… 69
…………………………………………………………………………………………………… 69
…………………………………………………………………………………………………… 70
…………………………………………………………………………………………………… 71
…………………………………………………………………………………………………… 72
Transmission Controls, Axle And Engine Linkages, Neutral Start Switch, And Reverse Warning Alarm Switch Checks…. 72
…………………………………………………………………………………………………… 72
…………………………………………………………………………………………………… 73
…………………………………………………………………………………………………… 73
…………………………………………………………………………………………………… 74
…………………………………………………………………………………………………… 74
…………………………………………………………………………………………………… 75
Monitor Indicator And Gauge Checks—Engine Running……………………………………………………….. 75
…………………………………………………………………………………………………… 76
…………………………………………………………………………………………………… 78
…………………………………………………………………………………………………… 78
…………………………………………………………………………………………………… 79
Brake System, Clutch Cut-Off, And Differential Lock Checks……………………………………………….. 79
…………………………………………………………………………………………………… 79
…………………………………………………………………………………………………… 80
…………………………………………………………………………………………………… 80
…………………………………………………………………………………………………… 81
…………………………………………………………………………………………………… 81
…………………………………………………………………………………………………… 82
…………………………………………………………………………………………………… 82
…………………………………………………………………………………………………… 82
…………………………………………………………………………………………………… 83
…………………………………………………………………………………………………… 83
…………………………………………………………………………………………………… 84
Driving Checks………………………………………………………………………………………. 84
…………………………………………………………………………………………………… 85
…………………………………………………………………………………………………… 85
…………………………………………………………………………………………………… 86
…………………………………………………………………………………………………… 87
…………………………………………………………………………………………………… 87
…………………………………………………………………………………………………… 88
…………………………………………………………………………………………………… 88
…………………………………………………………………………………………………… 89
…………………………………………………………………………………………………… 89
…………………………………………………………………………………………………… 90
Hydraulic System Checks………………………………………………………………………………. 90
…………………………………………………………………………………………………… 90
…………………………………………………………………………………………………… 91
…………………………………………………………………………………………………… 91
…………………………………………………………………………………………………… 91
…………………………………………………………………………………………………… 92
…………………………………………………………………………………………………… 92
…………………………………………………………………………………………………… 92
…………………………………………………………………………………………………… 93
…………………………………………………………………………………………………… 93
…………………………………………………………………………………………………… 93
…………………………………………………………………………………………………… 94
…………………………………………………………………………………………………… 94
…………………………………………………………………………………………………… 94
…………………………………………………………………………………………………… 95
Steering System Checks……………………………………………………………………………….. 95
…………………………………………………………………………………………………… 95
…………………………………………………………………………………………………… 96
…………………………………………………………………………………………………… 96
…………………………………………………………………………………………………… 96
…………………………………………………………………………………………………… 97
…………………………………………………………………………………………………… 97
Accessory Checks…………………………………………………………………………………….. 97
…………………………………………………………………………………………………… 98
…………………………………………………………………………………………………… 98
…………………………………………………………………………………………………… 98
…………………………………………………………………………………………………… 99
…………………………………………………………………………………………………… 99
…………………………………………………………………………………………………… 99
……………………………………………………………………………………………………100
……………………………………………………………………………………………………100
……………………………………………………………………………………………………100
……………………………………………………………………………………………………101
Cab Component And Vandal Protection Checks………………………………………………………………101
……………………………………………………………………………………………………101
……………………………………………………………………………………………………102
……………………………………………………………………………………………………102
……………………………………………………………………………………………………102
……………………………………………………………………………………………………103
……………………………………………………………………………………………………103
……………………………………………………………………………………………………103
……………………………………………………………………………………………………104
……………………………………………………………………………………………………104
……………………………………………………………………………………………………105
……………………………………………………………………………………………………105
……………………………………………………………………………………………………105
……………………………………………………………………………………………………106
……………………………………………………………………………………………………106
……………………………………………………………………………………………………106
……………………………………………………………………………………………………107
……………………………………………………………………………………………………107
Engine Operation And Tests……………………………………………………………………………………109
Theory Of Operation………………………………………………………………………………………111
Air Cleaner Operation…………………………………………………………………………………111
Fuel System Operation—544G And 624G…………………………………………………………………….112
Fuel System Operation—644G…………………………………………………………………………….113
System Operational Checks…………………………………………………………………………………115
Engine Operational Checks……………………………………………………………………………..115
Cooling System Checks…………………………………………………………………………………115
……………………………………………………………………………………………………115
……………………………………………………………………………………………………116
……………………………………………………………………………………………………116
……………………………………………………………………………………………………117
……………………………………………………………………………………………………117
……………………………………………………………………………………………………117
……………………………………………………………………………………………………118
……………………………………………………………………………………………………118
……………………………………………………………………………………………………118
……………………………………………………………………………………………………119
……………………………………………………………………………………………………119
Air System Checks…………………………………………………………………………………….119
……………………………………………………………………………………………………119
……………………………………………………………………………………………………120
……………………………………………………………………………………………………120
Lubrication System Checks……………………………………………………………………………..120
……………………………………………………………………………………………………121
Fuel System Checks……………………………………………………………………………………121
……………………………………………………………………………………………………121
……………………………………………………………………………………………………121
……………………………………………………………………………………………………122
……………………………………………………………………………………………………122
Engine Speed And Performance Checks…………………………………………………………………….122
……………………………………………………………………………………………………123
……………………………………………………………………………………………………123
……………………………………………………………………………………………………124
……………………………………………………………………………………………………124
……………………………………………………………………………………………………124
Diagnostic Information……………………………………………………………………………………125
Diagnose Engine Malfunctions…………………………………………………………………………..125
Coolant Requirements………………………………………………………………………………….138
Adjustments……………………………………………………………………………………………..143
JT05801 Clamp-On Electronic Tachometer Installation………………………………………………………143
JT05800 Digital Thermometer Installation………………………………………………………………..143
Display Monitor Tachometer…………………………………………………………………………….143
JT07158 TIME TRAC® Installation………………………………………………………………………..144
Injection Pump Timing…………………………………………………………………………………145
Fan Belt Tension Adjustment……………………………………………………………………………147
Slow And Fast Idle Adjustment—544G, 624G………………………………………………………………..148
Slow Idle Adjustment—644G……………………………………………………………………………..150
Fast Idle Adjustment—644G……………………………………………………………………………..151
Speed Control Linkage Adjustment……………………………………………………………………….152
Fuel Shut-Off Solenoid Adjustment—644G………………………………………………………………….153
Primary Fuel Filter, Drain Water—544G, 624G……………………………………………………………..154
Primary Fuel Filter, Drain Water—644G…………………………………………………………………..154
Bleed The Fuel System—544G, 624G……………………………………………………………………….155
Bleed The Fuel System—644G…………………………………………………………………………….155
Tests…………………………………………………………………………………………………..157
Display Monitor Tachometer…………………………………………………………………………….157
Display Monitor Hydraulic Oil Temperature……………………………………………………………….157
Display Monitor Hydraulic Oil Pressure………………………………………………………………….158
Air Filter Restriction Indicator Switch Test…………………………………………………………….159
Radiator Cap Pressure Test…………………………………………………………………………….160
Cooling System Pressure Test…………………………………………………………………………..161
Radiator Air Flow…………………………………………………………………………………….162
Engine Power Test Using Engine Pulldown…………………………………………………………………165
Engine Power Test Using Turbocharger Boost Pressure………………………………………………………166
Compression Pressure Test……………………………………………………………………………..169
Air Intake System Leakage Test…………………………………………………………………………171
Fuel Supply Pump Pressure Test…………………………………………………………………………172
Fuel Line Leakage Test………………………………………………………………………………..174
Electrical System……………………………………………………………………………………………175
System Information……………………………………………………………………………………….179
Procedure To Isolate Whether Problem In Transmission Control System Is Electrical Or Hydraulic………………..179
Example Of Simple Electrical Test To Find Problem………………………………………………………..180
Visually Inspect Electrical System……………………………………………………………………..182
Electrical Circuit Malfunctions………………………………………………………………………..183
High Resistance Circuit……………………………………………………………………………….184
Open Circuit…………………………………………………………………………………………185
Grounded Circuit……………………………………………………………………………………..187
Shorted Circuit………………………………………………………………………………………189
Multimeter…………………………………………………………………………………………..190
Seven Step Electrical Test Procedure……………………………………………………………………191
Wiring Diagram And Schematic Information………………………………………………………………..193
Reading A System Functional Schematic…………………………………………………………………..194
Reading A Wiring Diagram………………………………………………………………………………195
Electrical Schematic Symbols…………………………………………………………………………..196
System Diagrams………………………………………………………………………………………….201
Component Identification Table…………………………………………………………………………201
Fuse Block…………………………………………………………………………………………..203
Wiring And Schematic Diagrams Legend……………………………………………………………………204
System Functional Schematic Section Legend………………………………………………………………208
System Functional Schematic……………………………………………………………………………210
Steering Column Harness (W2) Wiring Diagram……………………………………………………………..219
Steering Column Harness (W2) Component Location………………………………………………………….220
Loader Frame Harness (W3) Wiring Diagram………………………………………………………………..221
Loader Frame Harness (W3) Component Location…………………………………………………………….222
Transmission Harness (W4) Wiring Diagram………………………………………………………………..223
Transmission Harness (W4) Component Location…………………………………………………………….224
Load Center Harness (W5) Wiring Diagram (Page 1 of 4)…………………………………………………….225
Load Center Harness (W5) Wiring Diagram (Page 2 of 4)…………………………………………………….226
Load Center Harness (W5) Wiring Diagram (Page 3 of 4)…………………………………………………….227
Load Center Harness (W5) Wiring Diagram (Page 4 of 4)…………………………………………………….228
Load Center Harness (W5) Component Location……………………………………………………………..229
Load Center Harness (W5) Component Location—Continued (Detail A)…………………………………………..230
Load Center Harness (W5) Component Location—Continued (Detail B)…………………………………………..231
Load Center Harness (W5) Component Location—Continued (Detail C)…………………………………………..232
Load Center Harness (W5) Component Location—Continued (Detail D)…………………………………………..233
Load Center Harness (W5) Component Location—Continued (Detail E)…………………………………………..234
Canopy Work Lights Harness (W6) Wiring Diagram…………………………………………………………..235
Canopy Work Lights Harness (W6) Component Location……………………………………………………….236
Cab Work Lights Harness (W7) Wiring Diagram……………………………………………………………..237
Cab Work Lights Harness (W7) Component Location………………………………………………………….238
Left Panel Temperature Control Harness (W8) Wiring Diagram………………………………………………..239
Left Panel Temperature Control Harness (W8) Component Location…………………………………………….240
Engine Frame Harness (W9) Wiring Diagram………………………………………………………………..241
Engine Frame Harness (W9) Component Location…………………………………………………………….242
Engine Harness (W10) Wiring Diagram…………………………………………………………………….243
Engine Harness (W10) Component Location…………………………………………………………………244
Rear Frame Harness (W11) Wiring Diagram…………………………………………………………………245
Rear Frame Harness (W11) Component Location……………………………………………………………..246
A/C Compressor Harness (W12) Wiring Diagram……………………………………………………………..247
A/C Compressor Harness (W12) Component Location………………………………………………………….248
Secondary Steering Harness (W13) Wiring Diagram………………………………………………………….249
Secondary Steering Harness (W13) Component Location………………………………………………………250
Start Aid Lead (W14) Wiring Diagram…………………………………………………………………….251
Start Aid Lead (W14) Component Location…………………………………………………………………252
Ride Control Harness (W15) Wiring Diagram……………………………………………………………….253
Ride Control Harness (W15) Component Location……………………………………………………………254
Pin Disconnect Harness (W16) Wiring Diagram……………………………………………………………..255
Pin Disconnect Harness (W16) Component Location………………………………………………………….256
Sub-System Diagnostics……………………………………………………………………………………257
Special Or Essential Tools…………………………………………………………………………….257
Power Circuit Operational Information…………………………………………………………………..257
Power Circuit Theory Of Operation………………………………………………………………………258
Power Circuit Functional Schematic……………………………………………………………………..259
Power Circuit Diagnostics……………………………………………………………………………..260
Power Circuit Diagnostic Procedures…………………………………………………………………….260
……………………………………………………………………………………………………260
……………………………………………………………………………………………………260
……………………………………………………………………………………………………261
……………………………………………………………………………………………………261
……………………………………………………………………………………………………261
Charging Circuit Operational Information………………………………………………………………..262
Charging Circuit Theory Of Operation……………………………………………………………………263
Charging Circuit Functional Schematic…………………………………………………………………..264
Charging Circuit Diagnostics…………………………………………………………………………..265
Charging Circuit Diagnostic Procedures………………………………………………………………….265
……………………………………………………………………………………………………265
……………………………………………………………………………………………………265
……………………………………………………………………………………………………266
……………………………………………………………………………………………………266
……………………………………………………………………………………………………266
Start Aid And Fuel Control Circuit Operational Information………………………………………………..266
Start Aid And Fuel Control Circuit Theory Of Operation……………………………………………………267
Start Aid And Fuel Control Circuit Functional Schematic…………………………………………………..268
Start Aid And Fuel Control Circuit Diagnostics…………………………………………………………..269
Start Aid And Fuel Control Circuit Diagnostic Procedures………………………………………………….269
……………………………………………………………………………………………………269
……………………………………………………………………………………………………269
……………………………………………………………………………………………………269
……………………………………………………………………………………………………270
……………………………………………………………………………………………………270
……………………………………………………………………………………………………271
Park Brake Sensing/Clutch Cutoff/Quickshift/Backup Alarm Circuit Specifications……………………………..271
Park Brake Sensing/Clutch Cutoff/Quickshift/Backup Alarm Circuit Operational Information……………………..272
Park Brake Sensing/Clutch Cutoff/Quickshift/Backup Alarm Circuit Theory Of Operation…………………………273
Park Brake Sensing/Clutch Cutoff/Quickshift/Backup Alarm Circuit Functional Schematic………………………..274
Park Brake Sensing/Clutch Cutoff/Quickshift/Backup Alarm Circuit Diagnostics………………………………..275
Park Brake Sensing/Clutch Cutoff/Quickshift/Backup Alarm Circuit Diagnostic Procedures……………………….275
……………………………………………………………………………………………………275
……………………………………………………………………………………………………275
……………………………………………………………………………………………………276
……………………………………………………………………………………………………276
……………………………………………………………………………………………………276
……………………………………………………………………………………………………276
……………………………………………………………………………………………………277
……………………………………………………………………………………………………277
Transmission Control Circuit Operational Information……………………………………………………..278
Transmission Control Circuit Theory Of Operation…………………………………………………………279
Transmission Control Circuit Functional Schematic………………………………………………………..283
Jumper Wire For Display Monitor………………………………………………………………………..284
Replace CPC™, Large MATE-N-LOC™, And METRIMATE™ Pin Type Connectors………………………………………..285
Pin Identification On Transmission Controller……………………………………………………………286
Procedure To Isolate Whether Problem In Transmission Control System Is Electrical Or Hydraulic………………..287
Transmission Control Circuit Diagnostics………………………………………………………………..287
Transmission Control Circuit Diagnostic Procedures……………………………………………………….288
……………………………………………………………………………………………………288
……………………………………………………………………………………………………289
……………………………………………………………………………………………………290
Start Circuit Operational Information…………………………………………………………………..291
Start Circuit Theory Of Operation………………………………………………………………………291
Start Circuit Functional Schematic……………………………………………………………………..292
Start Circuit Diagnostics……………………………………………………………………………..293
Start Circuit Diagnostic Procedures…………………………………………………………………….293
……………………………………………………………………………………………………293
……………………………………………………………………………………………………293
……………………………………………………………………………………………………294
……………………………………………………………………………………………………294
……………………………………………………………………………………………………294
Park Brake Circuit Operational Information………………………………………………………………295
Park Brake Circuit Theory Of Operation………………………………………………………………….295
Park Brake Circuit Functional Schematic…………………………………………………………………296
Park Brake Circuit Diagnostics…………………………………………………………………………297
Park Brake Circuit Diagnostic Procedures………………………………………………………………..297
……………………………………………………………………………………………………297
……………………………………………………………………………………………………298
……………………………………………………………………………………………………298
……………………………………………………………………………………………………298
Secondary Steering Circuit Specifications……………………………………………………………….298
Secondary Steering Circuit Operational Information……………………………………………………….299
Secondary Steering Circuit Theory Of Operation…………………………………………………………..299
Secondary Steering Circuit Functional Schematic………………………………………………………….300
Secondary Steering Circuit Diagnostics………………………………………………………………….301
Secondary Steering Circuit Diagnostic Procedures…………………………………………………………301
……………………………………………………………………………………………………301
……………………………………………………………………………………………………302
……………………………………………………………………………………………………303
Differential Lock And Boom Down Circuit Operational Information……………………………………………303
Differential Lock And Boom Down Circuit Theory Of Operation……………………………………………….304
Differential Lock And Boom Down Circuit Functional Schematic………………………………………………305
Differential Lock And Boom Down Circuit Diagnostics………………………………………………………306
Differential Lock And Boom Down Circuit Diagnostic Procedures……………………………………………..306
……………………………………………………………………………………………………306
……………………………………………………………………………………………………306
……………………………………………………………………………………………………306
……………………………………………………………………………………………………307
Switch Inputs To Monitor Circuit Specifications………………………………………………………….307
Switch Inputs To Monitor Circuit Operational Information………………………………………………….308
Switch Inputs To Monitor Circuit Theory Of Operation……………………………………………………..309
Switch Inputs To Monitor Circuit Functional Schematic…………………………………………………….310
Switch Inputs To Monitor Circuit Diagnostics…………………………………………………………….311
Switch Inputs To Monitor Circuit Diagnostic Procedures……………………………………………………311
……………………………………………………………………………………………………311
……………………………………………………………………………………………………311
……………………………………………………………………………………………………312
……………………………………………………………………………………………………312
……………………………………………………………………………………………………312
……………………………………………………………………………………………………313
……………………………………………………………………………………………………313
Electronic Monitor Signals Circuit Operational Information………………………………………………..313
Electronic Monitor Signals Circuit Theory Of Operation……………………………………………………314
Electronic Monitor Signals Circuit Functional Schematic…………………………………………………..316
Electronic Monitor Signals Circuit Diagnostics…………………………………………………………..317
Electronic Monitor Signals Diagnostic Procedures…………………………………………………………317
……………………………………………………………………………………………………317
……………………………………………………………………………………………………317
Electronic Monitor And Gauge Inputs Circuit Specifications………………………………………………..318
Electronic Monitor/Gauge Inputs Circuit Operational Information……………………………………………321
Electronic Monitor/Gauge Inputs Circuit Theory Of Operation……………………………………………….321
Electronic Monitor/Gauge Inputs Circuit Functional Schematic………………………………………………322
Electronic Monitor/Gauge Inputs Circuit Diagnostics………………………………………………………322
Electronic Monitor/Gauge Inputs Circuit Diagnostic Procedures……………………………………………..323
……………………………………………………………………………………………………323
……………………………………………………………………………………………………323
……………………………………………………………………………………………………324
Boom Height Kickout And Return-To-Dig Circuit Operational Information………………………………………324
Boom Height Kickout And Return-To-Dig Circuit Theory Of Operation………………………………………….325
Boom Height Kickout And Return-To-Dig Circuit Functional Schematic…………………………………………326
Boom Height Kickout And Return-To-Dig Circuit Diagnostics…………………………………………………327
Boom Height Kickout And Return-To-Dig Circuit Diagnostic Procedures………………………………………..327
……………………………………………………………………………………………………327
……………………………………………………………………………………………………327
……………………………………………………………………………………………………327
……………………………………………………………………………………………………328
……………………………………………………………………………………………………328
Front And Rear Wiper Circuit Operational Information……………………………………………………..328
Front And Rear Wiper Circuit Theory Of Operation…………………………………………………………329
Front And Rear Wiper Circuit Functional Schematic………………………………………………………..330
Front And Rear Wiper Circuit Diagnostics………………………………………………………………..331
Front And Rear Wiper Circuit Diagnostic Procedures……………………………………………………….331
……………………………………………………………………………………………………331
……………………………………………………………………………………………………331
……………………………………………………………………………………………………332
……………………………………………………………………………………………………332
……………………………………………………………………………………………………332
……………………………………………………………………………………………………332
……………………………………………………………………………………………………333
Brake Light Circuit Specifications……………………………………………………………………..333
Brake Light Circuit Operational Information……………………………………………………………..333
Brake Light Circuit Theory Of Operation…………………………………………………………………334
Brake Light Circuit Functional Schematic………………………………………………………………..335
Brake Light Circuit Diagnostics………………………………………………………………………..336
Brake Light Circuit Diagnostic Procedures……………………………………………………………….336
……………………………………………………………………………………………………336
……………………………………………………………………………………………………336
……………………………………………………………………………………………………336
……………………………………………………………………………………………………337
Heater/Pressurizer Circuit Operational Information……………………………………………………….337
Heater/Pressurizer Circuit Theory Of Operation…………………………………………………………..337
Heater/Pressurizer Circuit Functional Schematic………………………………………………………….338
Heater/Pressurizer Circuit Diagnostics………………………………………………………………….339
Heater/Pressurizer Circuit Diagnostic Procedures…………………………………………………………339
……………………………………………………………………………………………………339
……………………………………………………………………………………………………340
……………………………………………………………………………………………………340
……………………………………………………………………………………………………340
Air Conditioning Circuit Specifications…………………………………………………………………341
Air Conditioning Circuit Operational Information…………………………………………………………341
Air Conditioning Circuit Theory Of Operation…………………………………………………………….342
Air Conditioning Circuit Functional Schematic……………………………………………………………343
Air Conditioning Circuit Diagnostics……………………………………………………………………344
Air Conditioning Circuit Diagnostic Procedures…………………………………………………………..344
……………………………………………………………………………………………………344
……………………………………………………………………………………………………344
……………………………………………………………………………………………………345
……………………………………………………………………………………………………345
……………………………………………………………………………………………………345
……………………………………………………………………………………………………346
……………………………………………………………………………………………………346
……………………………………………………………………………………………………346
Defroster Pressurization Circuit Operational Information………………………………………………….346
Defroster Pressurization Circuit Theory Of Operation……………………………………………………..347
Defroster Pressurization Circuit Functional Schematic…………………………………………………….348
Defroster Pressurization Circuit Diagnostics…………………………………………………………….349
Defroster Pressurization Circuit Diagnostic Procedures……………………………………………………349
……………………………………………………………………………………………………349
……………………………………………………………………………………………………350
……………………………………………………………………………………………………350
Turn Signal And 4-Way Flasher Circuit Operational Information……………………………………………..350
Turn Signal And 4-Way Flasher Circuit Theory Of Operation…………………………………………………351
Turn Signal And 4-Way Flasher Circuit Functional Schematic………………………………………………..352
Turn Signal And 4-Way Flasher Circuit Diagnostics………………………………………………………..353
Turn Signal And 4-Way Flasher Circuit Diagnostic Procedures……………………………………………….353
……………………………………………………………………………………………………353
……………………………………………………………………………………………………353
……………………………………………………………………………………………………354
……………………………………………………………………………………………………354
Cab And Canopy Work Light Circuit Operational Information…………………………………………………354
Cab And Canopy Work Light Circuit Theory Of Operation…………………………………………………….355
Cab And Canopy Work Light Circuit Functional Schematic……………………………………………………356
Cab And Canopy Work Light Circuit Diagnostics……………………………………………………………357
Cab And Canopy Work Light Circuit Diagnostic Procedures…………………………………………………..357
……………………………………………………………………………………………………357
……………………………………………………………………………………………………357
……………………………………………………………………………………………………357
Drive Light/Dome Light Circuit Operational Information……………………………………………………358
Drive Light/Dome Light Circuit Theory Of Operation……………………………………………………….358
Drive Light/Dome Light Circuit Functional Schematic………………………………………………………359
Drive Light/Dome Light Circuit Diagnostics………………………………………………………………360
Drive Light/Dome Light Circuit Diagnostic Procedures……………………………………………………..360
……………………………………………………………………………………………………360
……………………………………………………………………………………………………360
……………………………………………………………………………………………………360
……………………………………………………………………………………………………361
……………………………………………………………………………………………………361
……………………………………………………………………………………………………361
……………………………………………………………………………………………………361
……………………………………………………………………………………………………362
……………………………………………………………………………………………………362
Door Release/Radio/Horn/Rotary Beacon Circuit Operational Information………………………………………362
Door Release/Radio/Horn/Rotary Beacon Circuit Theory Of Operation………………………………………….363
Door Release/Radio/Horn/Rotary Beacon Circuit Functional Schematic…………………………………………364
Door Release/Radio/Horn/Rotary Beacon Circuit Diagnostics…………………………………………………365
Door Release/Radio/Horn/Rotary Beacon Circuit Diagnostic Procedures………………………………………..365
……………………………………………………………………………………………………365
……………………………………………………………………………………………………365
……………………………………………………………………………………………………365
……………………………………………………………………………………………………366
……………………………………………………………………………………………………366
……………………………………………………………………………………………………366
……………………………………………………………………………………………………366
Pin Disconnect/Ride Control/Spare Circuit Operational Information………………………………………….367
Pin Disconnect/Ride Control/Spare Circuit Theory Of Operation……………………………………………..368
Pin Disconnect/Ride Control/Spare Circuit Functional Schematic…………………………………………….369
Pin Disconnect/Ride Control/Spare Circuit Diagnostics…………………………………………………….370
Pin Disconnect/Ride Control/Spare Circuit Diagnostic Procedures……………………………………………370
……………………………………………………………………………………………………370
……………………………………………………………………………………………………370
……………………………………………………………………………………………………370
……………………………………………………………………………………………………371
……………………………………………………………………………………………………371
References………………………………………………………………………………………………373
Battery Specifications………………………………………………………………………………..373
Battery Operation…………………………………………………………………………………….373
Diagnose Battery Malfunctions………………………………………………………………………….374
Batteries……………………………………………………………………………………………375
Check Electrolyte Level and Terminals……………………………………………………………….375
Procedure For Testing Batteries………………………………………………………………………..377
Using Booster Batteries—12 Volt System………………………………………………………………….379
Starter Operation…………………………………………………………………………………….380
Alternator Operation—95 Amp Or 135 Amp Bosch…………………………………………………………….382
Accessing Monitor Service Code Display………………………………………………………………….383
Monitor Service Code Interpretation…………………………………………………………………….386
Program Monitor Display To Match Machine………………………………………………………………..387
Calibrate Tachometer………………………………………………………………………………….388
Transmission Electrical Circuit Test Procedure…………………………………………………………..391
Jumper Wire For Display Monitor………………………………………………………………………..394
Replace CPC™, Large MATE-N-LOC™, And METRIMATE™ Pin Type Connectors………………………………………..395
Transmission Sensor Adjustment…………………………………………………………………………396
Disconnecting Tab Retainer Connectors…………………………………………………………………..397
Secondary Steering Controller Bench Test………………………………………………………………..397
Power Train Operation And Tests……………………………………………………………………………….399
Theory Of Operation………………………………………………………………………………………401
Clutch Engagement and Solenoid Activation Charts…………………………………………………………401
Power Train Component Overview…………………………………………………………………………402
Drive Dampener……………………………………………………………………………………….403
Torque Converter Operation…………………………………………………………………………….404
Transmission Operation—Neutral…………………………………………………………………………406
Transmission Operation—1st Gear Forward…………………………………………………………………408
Transmission Operation—2nd Gear Forward…………………………………………………………………410
Transmission Operation—3rd Gear Forward…………………………………………………………………412
Transmission Operation—4th Gear Forward…………………………………………………………………414
Transmission Operation—1st Gear Reverse…………………………………………………………………416
Transmission Operation—2nd Gear Reverse…………………………………………………………………418
Transmission Operation—3rd Gear Reverse…………………………………………………………………420
Clutch Operation……………………………………………………………………………………..422
Transmission Hydraulic Components………………………………………………………………………424
Transmission Hydraulic System………………………………………………………………………….426
Transmission Pump Operation……………………………………………………………………………428
Transmission Control Valve Components (5-Solenoid Valve)………………………………………………….430
Modulation Components And Shift Time (5-Solenoid Valve)…………………………………………………..432
Completed Shift—First Speed Forward (5-Solenoid)…………………………………………………………434
Shift Modulation Starts For 2nd, 3rd, Or 4th (5-Solenoid)…………………………………………………436
Shift Modulation For 2nd, 3rd, And 4th (5-Solenoid)………………………………………………………438
Completed Shift Modulation For 2nd, 3rd, Or 4th (5-Solenoid)………………………………………………440
Transmission Clutch Engagement And Solenoids Activated (5-Solenoid)………………………………………..442
Third Speed Neutral (5-Solenoid)……………………………………………………………………….444
First Speed—Forward (5-Solenoid)……………………………………………………………………….446
Second Speed—Forward (5-Solenoid)………………………………………………………………………448
Third Speed—Forward (5-Solenoid)……………………………………………………………………….450
Fourth Speed—Forward (5-Solenoid)………………………………………………………………………451
First Speed—Reverse (5-Solenoid)……………………………………………………………………….452
Second Speed—Reverse (5-Solenoid)………………………………………………………………………454
Third Speed—Reverse (5-Solenoid)……………………………………………………………………….456
Thermal Bypass Valve Operation…………………………………………………………………………458
Transmission Control Valve Components (6-Solenoid Valve)………………………………………………….460
Modulation Components And Shift Time (6-Solenoid Valve)…………………………………………………..462
Control Valve In Neutral (6-Solenoid)…………………………………………………………………..464
Transmission Clutch Engagement And Solenoids Activated (6-Solenoid)………………………………………..466
Shift Modulation (6-Solenoid)………………………………………………………………………….468
First Speed—Forward (6-Solenoid)……………………………………………………………………….470
Second Speed—Forward (6-Solenoid)………………………………………………………………………472
Third Speed—Forward (6-Solenoid)……………………………………………………………………….474
Fourth Speed—Forward (6-Solenoid)………………………………………………………………………476
First Speed—Reverse (6-Solenoid)……………………………………………………………………….478
Second Speed—Reverse (6-Solenoid)………………………………………………………………………480
Third Speed—Reverse (6-Solenoid)……………………………………………………………………….482
TeamMate™ II Axle Operation……………………………………………………………………………484
John Deere TeamMate™ II Axles………………………………………………………………………….485
Differential Lock Operation……………………………………………………………………………486
Hydraulic Differential Lock Air Boost System…………………………………………………………….487
Turbocharger Boost For Differential Lock………………………………………………………………..488
Axle Shaft And Housing………………………………………………………………………………..489
Axle Disconnect Operation……………………………………………………………………………..490
Brake Hydraulic System Operation……………………………………………………………………….491
Brake Pump Operation………………………………………………………………………………….492
Brake Pump Pressure Compensator—At Standby………………………………………………………………493
Pressure Compensator—Pump Going Into Stroke……………………………………………………………..494
Brake Accumulator Operation……………………………………………………………………………495
Wet Chambered Brake Valve Operation…………………………………………………………………….496
Park Brake Operation………………………………………………………………………………….498
Pressure Reducing Valve—Differential Lock Off, Park Brake On………………………………………………500
Pressure Reducing Valve—Differential Lock On, Park Brake Off………………………………………………502
Hydraulic Tank Operation………………………………………………………………………………504
System Operational Checks…………………………………………………………………………………505
Power Train Operational Checks…………………………………………………………………………505
Brake System, Clutch Cut-Off, Differential Lock And Front Axle Disconnect Checks…………………………….505
……………………………………………………………………………………………………505
……………………………………………………………………………………………………506
……………………………………………………………………………………………………506
……………………………………………………………………………………………………507
……………………………………………………………………………………………………508
……………………………………………………………………………………………………508
……………………………………………………………………………………………………509
……………………………………………………………………………………………………509
……………………………………………………………………………………………………509
……………………………………………………………………………………………………510
……………………………………………………………………………………………………510
……………………………………………………………………………………………………511
Transmission Checks…………………………………………………………………………………..511
……………………………………………………………………………………………………512
……………………………………………………………………………………………………512
……………………………………………………………………………………………………513
……………………………………………………………………………………………………514
……………………………………………………………………………………………………515
……………………………………………………………………………………………………515
……………………………………………………………………………………………………516
……………………………………………………………………………………………………516
……………………………………………………………………………………………………517
……………………………………………………………………………………………………517
Diagnostic Information……………………………………………………………………………………519
Procedure To Isolate Whether Transmission Control System Problem Is Electrical Or Hydraulic…………………..519
Diagnose Transmission System Malfunctions……………………………………………………………….520
Diagnose Service Brake Malfunctions…………………………………………………………………….529
Diagnose Differential/Axle Malfunctions…………………………………………………………………532
Diagnose Drive Line Malfunctions……………………………………………………………………….536
Diagnose Park Brake Malfunctions……………………………………………………………………….537
Hydraulic Circuit Symbols……………………………………………………………………………..538
Brake, Differential Lock, And Boom Lower Circuit Schematic………………………………………………..539
Power Train And Brakes System Component Location Diagram………………………………………………….540
First Forward Schematic……………………………………………………………………………….541
Adjustments……………………………………………………………………………………………..543
Front Axle Disconnect Adjustment……………………………………………………………………….543
Clutch Cut-Off Adjustment……………………………………………………………………………..543
Adjust Park Brake (S.N. 788774—)……………………………………………………………………….544
External Service Brake Inspection………………………………………………………………………545
Hydraulic Brake Bleeding Procedure……………………………………………………………………..547
Charge Brake Accumulator………………………………………………………………………………548
Brake Pump And Differential Lock System Oil Clean-Up Procedure Using Portable Filter Caddy……………………549
Transmission Sensor Adjustment…………………………………………………………………………550
Tests…………………………………………………………………………………………………..553
JT05801 Clamp-On Electronic Tachometer Installation………………………………………………………553
JT05800 Digital Thermometer Installation………………………………………………………………..553
Display Monitor Tachometer…………………………………………………………………………….553
Transmission Oil Warm-Up Procedure……………………………………………………………………..554
Brake, Differential Lock, And Hydraulic System Oil Warm-Up Procedure……………………………………….554
Transmission Pump Flow Test……………………………………………………………………………555
Transmission System Pressure, Element Leakage, And Shift Modulation Test……………………………………557
Transmission Lube Pressure Test………………………………………………………………………..560
Converter Relief Pressure Test…………………………………………………………………………562
Converter-In Pressure Test…………………………………………………………………………….564
Converter-Out Pressure Test……………………………………………………………………………566
Converter-Out Flow Test……………………………………………………………………………….568
Transmission Oil Cooler Backflush Procedure……………………………………………………………..570
Transmission Oil Cooler Restriction Test………………………………………………………………..571
Pressure Reducing Valve Manifold Leakage Test……………………………………………………………573
Transmission Oil Cooler Thermal Bypass Valve Test………………………………………………………..575
Transmission Oil Cooler Bypass Valve Pressure Test……………………………………………………….576
Torque Converter Stall Speed Test………………………………………………………………………577
Brake Pump Flow Test………………………………………………………………………………….578
Brake Pump Standby Pressure Test……………………………………………………………………….580
Brake Accumulator Precharge Test……………………………………………………………………….582
Brake Valve Pressure Test……………………………………………………………………………..584
Brake Valve Leakage Test………………………………………………………………………………586
Brake Accumulator Inlet Check Valve Leakage Test…………………………………………………………588
Park Brake Pressure Test………………………………………………………………………………590
Differential Lock Pressure Test………………………………………………………………………..592
Differential Lock Leakage Test…………………………………………………………………………594
Axle Bearing Adjustment Check………………………………………………………………………….596
No-Spin Differential Test……………………………………………………………………………..597
Hydraulic System Operation And Tests…………………………………………………………………………..599
Theory Of Operation………………………………………………………………………………………601
Main Hydraulic Pump Operation………………………………………………………………………….601
Steering System Components Operation……………………………………………………………………602
Steering Circuit Operation—Right Turn…………………………………………………………………..604
Priority Valve Operation………………………………………………………………………………606
Steering Valve Operation………………………………………………………………………………610
Steering Cylinder Operation……………………………………………………………………………611
Secondary Steering System Operation…………………………………………………………………….612
Secondary Steering Inlet Manifold Operation……………………………………………………………..614
Loader Hydraulic System Operation………………………………………………………………………615
Pressure Reducing Valve—Secondary Boom Lower Operation……………………………………………………616
Pilot Controller Operation (Serial Number —563542)……………………………………………………….618
Pilot Controller—Boom Float (Serial Number 563543—)………………………………………………………620
Pilot Controller—Bucket Rollback (Serial Number 563543— )…………………………………………………622
Boom Section Operation………………………………………………………………………………..624
Bucket And Boom Section Pilot Orifice Check Valve………………………………………………………..626
Bucket Section Operation—544G, 624G, And 644G……………………………………………………………628
Bucket Section Operation—544G TC And 544G LL…………………………………………………………….630
Auxiliary Section Operation……………………………………………………………………………632
System Relief Valve Operation………………………………………………………………………….634
Circuit Relief Valve Operation…………………………………………………………………………635
Anti-Cavitation Valve Operation………………………………………………………………………..637
Loader Cylinder Information……………………………………………………………………………638
Return Filter Operation……………………………………………………………………………….639
Hydraulic Reservoir Operation………………………………………………………………………….640
Pin Disconnect Circuit Operation—544G TC………………………………………………………………..641
Ride Control Operation—In “On” Position…………………………………………………………………642
Ride Control Operation—In “Off” Position………………………………………………………………..644
System Operational Checks…………………………………………………………………………………645
Hydraulic Operational Checks…………………………………………………………………………..645
Hydraulic System Checks……………………………………………………………………………….645
……………………………………………………………………………………………………645
……………………………………………………………………………………………………646
……………………………………………………………………………………………………646
……………………………………………………………………………………………………646
……………………………………………………………………………………………………647
……………………………………………………………………………………………………647
……………………………………………………………………………………………………647
……………………………………………………………………………………………………648
……………………………………………………………………………………………………648
……………………………………………………………………………………………………649
……………………………………………………………………………………………………649
……………………………………………………………………………………………………649
……………………………………………………………………………………………………650
……………………………………………………………………………………………………650
……………………………………………………………………………………………………650
……………………………………………………………………………………………………651
……………………………………………………………………………………………………652
Steering System Checks………………………………………………………………………………..652
……………………………………………………………………………………………………653
……………………………………………………………………………………………………653
……………………………………………………………………………………………………653
……………………………………………………………………………………………………654
……………………………………………………………………………………………………654
……………………………………………………………………………………………………654
Diagnostic Information……………………………………………………………………………………655
Diagnose Hydraulic System Malfunctions………………………………………………………………….655
Hydraulic Circuit Symbols……………………………………………………………………………..664
Adjustments……………………………………………………………………………………………..669
Hydraulic Oil Clean-Up Procedure Using Portable Filter Caddy………………………………………………669
Boom Height Kickout Adjustment…………………………………………………………………………670
Return-To-Dig Adjustment………………………………………………………………………………671
Charge Ride Control Accumulator………………………………………………………………………..672
Test……………………………………………………………………………………………………675
JT05801 Clamp-On Electronic Tachometer Installation………………………………………………………675
JT05800 Digital Thermometer Installation………………………………………………………………..675
Display Monitor Tachometer…………………………………………………………………………….675
Hydraulic Oil Warm-Up Procedure………………………………………………………………………..676
Main Hydraulic Pump Flow Test………………………………………………………………………….677
Loader System And Circuit Relief Valve Pressure Test……………………………………………………..679
Hydraulic System Restriction Test………………………………………………………………………683
Loader Cylinder Drift Test…………………………………………………………………………….685
Boom And Bucket Cylinder Leakage Test…………………………………………………………………..687
Hydraulic Oil Cooler Restriction Test…………………………………………………………………..689
Steering Valve Leakage Test……………………………………………………………………………691
Steering Valve Drift Test……………………………………………………………………………..693
Priority Valve Pressure Test…………………………………………………………………………..695
Priority Valve “LS” Port Flow Test……………………………………………………………………..697
Priority Valve Relief Cartridge Leakage Test…………………………………………………………….699
Secondary Steering Pump Relief Valve Pressure Test……………………………………………………….700
Secondary Steering Manifold Primary Check Valve Leakage Test………………………………………………702
Secondary Steering Manifold Secondary Check Valve Leakage Test…………………………………………….704
Pilot Control Valve Pressure Test (Serial Number —563542)…………………………………………………706
Pilot Control Valve Pressure Test (Serial Number 563543—)…………………………………………………710
Pressure Reducing Valve Pressure Test…………………………………………………………………..714
Cycle Time Test………………………………………………………………………………………716
Hydraulic Oil Filter Inspection Procedure……………………………………………………………….717
Pin Disconnect Solenoid Valve Leakage Test………………………………………………………………718
Pin Disconnect Cylinder Leakage Test……………………………………………………………………720
Air Conditioning System………………………………………………………………………………………723
Theory Of Operation………………………………………………………………………………………725
Proper Refrigerant Handling……………………………………………………………………………725
R12 And R134a Refrigerant Cautions……………………………………………………………………..725
Refrigerant Theory Of Operation………………………………………………………………………..726
Air Conditioner Circuit Operational Information………………………………………………………….727
Air Conditioning Circuit Theory Of Operation…………………………………………………………….728
Air Conditioning Circuit Schematic……………………………………………………………………..730
Defroster Pressurization Circuit Operational Information………………………………………………….732
Defroster Pressurization Circuit Operation………………………………………………………………732
Heater/Pressurizer Circuit Operational Information……………………………………………………….734
Heater/Pressurizer Circuit Theory Of Operation…………………………………………………………..734
Receiver/Dryer Operation………………………………………………………………………………736
Expansion Valve Operation……………………………………………………………………………..738
Compressor Relief Valve Operation………………………………………………………………………739
Temperature Control…………………………………………………………………………………..739
System Operational Checks…………………………………………………………………………………741
Air Conditioning Operational Checks…………………………………………………………………….741
Visual Inspection Of Components………………………………………………………………………..741
……………………………………………………………………………………………………741
……………………………………………………………………………………………………742
……………………………………………………………………………………………………742
……………………………………………………………………………………………………742
……………………………………………………………………………………………………743
……………………………………………………………………………………………………743
……………………………………………………………………………………………………743
System Operating Checks……………………………………………………………………………….743
……………………………………………………………………………………………………744
……………………………………………………………………………………………………744
……………………………………………………………………………………………………744
……………………………………………………………………………………………………744
……………………………………………………………………………………………………745
……………………………………………………………………………………………………745
……………………………………………………………………………………………………745
……………………………………………………………………………………………………746
……………………………………………………………………………………………………746
System Performance Checks……………………………………………………………………………..746
……………………………………………………………………………………………………747
……………………………………………………………………………………………………747
……………………………………………………………………………………………………747
……………………………………………………………………………………………………748
Air Conditioner Electrical Circuit Checks……………………………………………………………….748
……………………………………………………………………………………………………748
……………………………………………………………………………………………………748
……………………………………………………………………………………………………749
……………………………………………………………………………………………………749
……………………………………………………………………………………………………749
……………………………………………………………………………………………………750
……………………………………………………………………………………………………750
……………………………………………………………………………………………………750
……………………………………………………………………………………………………751
……………………………………………………………………………………………………751
……………………………………………………………………………………………………752
……………………………………………………………………………………………………752
……………………………………………………………………………………………………753
……………………………………………………………………………………………………753
……………………………………………………………………………………………………753
Diagnostic Information……………………………………………………………………………………755
Diagnose Air Conditioning Electrical Malfunctions………………………………………………………..755
Air Conditioning Component Location Drawing……………………………………………………………..757
Adjustments……………………………………………………………………………………………..759
Special Or Essential Tools…………………………………………………………………………….759
Proper Refrigerant Handling……………………………………………………………………………760
R12 And R134a Refrigerant Cautions……………………………………………………………………..760
R12 Component Oil Charge………………………………………………………………………………761
R12 Refrigerant Evacuation And Charging Station Installation Procedure……………………………………..762
Recover R12 System……………………………………………………………………………………764
Evacuate R12 System…………………………………………………………………………………..765
Charge R12 System…………………………………………………………………………………….768
R134a Compressor Oil Information……………………………………………………………………….770
R134a Compressor Oil Charge Check………………………………………………………………………770
R134a Compressor Oil Removal…………………………………………………………………………..771
R134a Component Oil Charge…………………………………………………………………………….772
R134a Refrigerant Recovery/Recycling And Charging Station Installation Procedures……………………………773
R134a Refrigerant Recovery…………………………………………………………………………….775
Evacuate R134a System…………………………………………………………………………………777
Charge R134a System…………………………………………………………………………………..779
Check And Adjust Compressor Belt Tension………………………………………………………………..781
Tests…………………………………………………………………………………………………..783
Special Or Essential Tools…………………………………………………………………………….783
Proper Refrigerant Handling……………………………………………………………………………784
R12 And R134a Refrigerant Cautions……………………………………………………………………..784
R12 Air Conditioning System Test……………………………………………………………………….785
R134a Air Conditioning System Test……………………………………………………………………..787
Operating Pressure Diagnostic Chart…………………………………………………………………….789
Pressure Diagnostic Chart……………………………………………………………………………..793
Low Pressure Switch Test………………………………………………………………………………794
High Pressure Switch Test……………………………………………………………………………..796
Clutch Cycle Switch…………………………………………………………………………………..798
Leak Testing…………………………………………………………………………………………799
Refrigerant Hoses And Tubing Inspection…………………………………………………………………799
IMAGES PREVIEW OF THE MANUAL:
VIDEO PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the same manual used by the DEALERSHIPS to SERVICE your vehicle.
- The manual can be all yours – Once payment is complete, you will be taken to the download page from where you can download the manual. All in 2-5 minutes time!!
- Need any other service / repair / parts manual, please feel free to contact us at [email protected] . We may surprise you with a nice offer
S.V