John Deere 27ZTS Excavator Operation and Test Technical Manual TM1838 PDF

For complette service information also see:
27ZTS Excavator Repair ………………………………………………… TM1837
27ZTS Excavator Operation and Test ………………………………. TM1838
Undercarriage Appraisal Manual Volume 1 John Deere
Models Operation and Test …………………………………………….. SP326VOL1
Test and Service Specifications……………………………………….. SP458VOL1

Introduction
Foreword
Technical Information Feedback Form
Contents
General Information
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
General Specifications
27ZTS Excavator Overview
27ZTS Excavator
27ZTS Excavator Working Ranges
27ZTS Excavator Engine Specifications
27ZTS Excavator Drain and Refill Capacities
Torque Values
Unified Inch Bolt and Cap Screw Torque Values
Metric Bolt and Cap Screw Torque Values
Additional Metric Cap Screw Torque Values
Check Oil Lines and Fittings
Service Recommendations for O-Ring Boss Fittings
Straight Fitting
Angle Fitting
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 Fitting
Service Recommendations for Metric Series Four Bolt Flange Fitting
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 Roller, Front Idler, and Carrier Roller Oil
Track Adjuster, Working Tool Pivot, Swing Bearing, and Swing Bearing Gear Grease
Oil Filters
Lubricant Storage
Alternative and Synthetic Lubricants
Mixing of Lubricants
Operational Checkout Procedure
Operational Checkout Procedure
Operational Checkout
Engine
Theory of Operation
Engine-Sectional View
Fan Drive Operation
Cooling System Operation
Engine Lubrication System Operation
Air Cleaner Operation
Fuel Supply System Operation
Fuel Injection Pump Operation
Fuel Injection Nozzle Operation
System Operational Checks
Engine Operational Checks
Diagnostic Information
Diagnose Engine Malfunctions
Adjustments
JT05801 Clamp-On Electronic Tachometer Installation
Tests
Engine Speed Check
Engine Speed Control Cable Adjustment
Check and Adjust Fuel Injection Nozzle
Check and Adjust Injection Pump Timing
Preparation
Adjustment
Adjust Fan Belt Tension
Check and Adjust Engine Valve Lash (Clearance)
Cooling System Fill and Deaeration
Fill
Deaeration
Air Intake System Leakage Test
Radiator Air Flow Test
Engine Compression Pressure Test
Cooling System Test
Engine Oil Pressure Test
Electrical System
System Information
Visually Inspect Electrical System
Electrical Circuit Malfunctions
Malfunctions
High Resistance Circuit
Open Circuit
Grounded Circuit
Shorted Circuit
Multimeter
Seven Step Electrical Test Procedure
Schematic Information
Electrical Schematic Symbols
System Diagrams
Component Identification Table
Fuse Specifications
Fuse (Blade-Type) Color Codes
Component Location Drawing Legend
Control Box Component Locator
Control Box Connectors Wire and Pin Location
Main Frame Harness Component Locator
Main Frame Connectors Wire and Pin Location
Cab Electrical Harness Component Locator
Cab Harness Connectors Wire and Pin Location
System Functional Schematic
Sub-System Diagnostics
Power Circuit Operational Information
Power Circuit Theory of Operation
Power Circuit Schematic
Starting Circuit Operational Information
Starting Circuit Theory of Operation
Starting Circuit Schematic
Starter Operation
Charging Circuit Operational Information
Charging Circuit Theory of Operation
Alternator
Charging Circuit Schematic
Monitor Controller Circuit Specifications
Monitor Controller Circuit Operational Information
Monitor Controller Circuit Theory of Operation
Monitor Controller Circuit Schematic
Engine Sensor Circuit Operational Information
Engine Sensor Circuit Theory of Operation
Engine Sensor Circuit Schematic
Pilot/Propel Circuit Operational Information
Pilot/Propel Circuit Theory of Operation
Pilot/Propel Circuit Schematic
Propel Alarm Circuit Operational Information
Propel Alarm Circuit Theory of Operation
Propel Alarm Circuit Schematic
Windshield Wiper and Washer Circuit Operational Information
Windshield Wiper and Washer Circuit Theory of Operation
WASH Position
ON Position
ON/WASH Position
OFF Position
Windshield Wiper and Washer Circuit Schematic
Drive and Work Lights Circuit Operational Information
Drive and Work Lights Circuit Theory of Operation
Drive and Work Lights Circuit Schematic
Accessory Circuit Operational Information
Accessory Circuits Theory of Operation
Accessory Circuit Schematic
Heater Circuit Operational Information
Heater Circuit Theory of Operation
Heater Circuit Schematic
References
Monitor Controller and Display Connector Wiring
Battery Operation
Battery Specifications
Diagnose Battery Malfunctions
Check Battery Electrolyte Level and Terminals
Procedure for Testing Batteries
Visual Check
Hydrometer Test
Load Test
Using Booster Batteries-12 Volt System
Using Booster Batteries-12 Volt System
Replacing Battery
Adding 12 or 24 Volt Accessories
Power Train
Theory of Operation
Track Adjuster and Recoil Spring Operation
Propel Gearbox Operation
Diagnostic Information
Diagnose Undercarriage Components Malfunctions
Measure Track Chain Bushing Wear
Measure Track Chain Link Wear
Measure Track Chain Pitch
Measure Track Shoe Grouser Wear
Measure Track Roller Wear
Measure Track Carrier Roller Wear
Measure Front Idler Wear
Measure Swing Bearing Wear
Adjustments
Adjust Track Sag (Rubber Track)
Adjust Track Sag (Steel Track)
Hydraulic System
Theory of Operation
Hydraulic System Diagram
Pilot Pump Operation
Pilot Shut-Off Solenoid Valve, Propel Speed Change Solenoid Valve and Pilot Relief Valve Operation
Pilot Shut-Off Solenoid Valve
Propel Speed Change Solenoid Valve
Pilot Relief Valve
Pilot Controller Operation-Neutral
Pilot Controller Operation-Metering and Full Stroke
Propel Pilot Controller Operation
Pilot Controller Operation of Control Valve
Boom Swing Controller Operation
Auxiliary Controller Operation
Main Hydraulic Pump (P1, P2) Operation
Gear Pump (P3) Operation
Hydraulic Pump Regulator Component Operation
Main Control Valve Operation
Control Valve Circuit Schematic
Control Valve Pilot Pressure Signal Passage Operation
Control Valve Neutral and Power Passages Operation
System Relief Valve Operation
Blade and Swing Anti-Cavitation Valve Operation
Circuit Relief Valve Operation
Relief Operation
Flow Combiner Valve Operation
Boom Reduced Leakage Valve Operation
Boom Spool in Neutral
Boom Raise Operation
Boom Lower Operation
Arm Regenerative Valve Operation
Swing Gearbox Operation
Swing Motor Operation
Swing Motor Crossover Relief Valves Operation
Swing Motor Anti-Cavitation Valves Operation
Swing Motor Park Brake Operation
Brake Released
Brake Applied
Rotary Manifold with Backfill Blade Function Operation
Propel Motor Operation
Propel Motor Speed Change Valve Operation
Slow Speed Operation
Fast Speed Operation
When Engine Stops
Propel Motor Counterbalance Valve Operation
Propel Operation
Descending Operation
Propel Motor Brake Valve Operation
Propel Motor Park Brake Operation
Propel Park Brake Released
Propel Park Brake Applied
Backfill Blade Hydraulic System Operation
One-Way/Two-Way Valve Operation
One-Way Operation
Two-Way Operation
Hydraulic Cylinder Operation
Hydraulic Oil Return Filter Operation
Hydraulic System Circuit Symbols
Controllers and Pilot Shut-Off Solenoid Valve Schematic
Control Valve Schematic
Main Pump Schematic
Swing Motor Schematic
Propel Motor Schematic
Diagnostic Information
Diagnostic Procedure
Diagnose Hydraulic System Malfunctions
Diagnose Pilot Circuit Malfunctions
Diagnose Dig Circuit Malfunctions
Diagnose Swing Circuit Malfunctions
Diagnose Propel System Malfunctions
Diagnose Mechanically Actuated Control Valve Malfunctions
Control Lever Pattern Conversion
Pilot Controller to Pilot Shut-Off Valve Component Location-SAE Pattern
Pilot Controller to Pilot Shut-Off Valve Component Location-ISO Pattern
Backfill Blade Hydraulic System Component Location
Propel System Component Location
Main Control Valve Line Identification
Main Hydraulic System Component Location
Pressure and Return System Component Location
Adjustments
Adjust Blade Control Lever
Adjust Boom Swing and Auxiliary Linkage
Tests
JT05801 Clamp-On Electronic Tachometer Installation
JT05800 Digital Thermometer Installation
JT02156A Digital Pressure/Temperature Analyzer Installation
Hydraulic Pump Start-Up Procedure
Swing Motor Start-Up Procedure
Propel Motor Start-Up Procedure
Propel Gearbox Start-Up Procedure
Hydraulic System Warm-Up Procedure
Cycle Time Test
Swing Dynamic Braking (Drift) Test
Pilot Pressure Regulating Valve Test and Adjustment
Control Valve Spool Pilot Actuation Pressure Test (Secondary Pilot Pressure)
Pumps 1 and 2 System Relief Valve Test and Adjustment
Pump 3 System Relief Valve Test and Adjustment
Circuit Relief Valve Test and Adjustment
Swing Motor Crossover Relief Valve Test and Adjustment
Main Hydraulic Pump Regulating Test and Adjustment (Engine Pulldown)
Main Hydraulic Pumps P1 and P2 Flow Test
Gear Pump P3 Flow Test
Propel System Tracking Test
Cylinder Drift Test-Boom, Arm, and Bucket
Swing Motor Leakage Test
Propel Motor Leakage Test