John Deere 690E LC Excavator 2011 – Operation & Tests Manual (P/N TM1508)

John Deere’s 690E LC Excavator Operation and Tests manual (P/N TM1508), dated June 30, 2008, covers the standard machine and Long Front configuration. It provides system theory, operational checks, troubleshooting, tests and adjustments; full machine repair and component overhaul require separate publications.

PDF Search, Diagram Detail and Page Count

Text search and diagram detail: PDF text search and embedded bookmarks are not available. Small labels in dense wiring and hydraulic schematics require zooming.

One printable English PDF with 1,015 pages total: 1,014 pages of the Operation and Tests volume, including its cover, contents, foreword and two-page feedback form, plus one appended foreword page from the separate repair manual.

Engine, Propel and Hydraulic System Testing

These selected coverage highlights are not a complete table of contents. Further topics include control-pattern conversion and moving the boom or upperstructure with the engine stopped.

• 6068 engine: Cooling, intake, lubrication and fuel checks, speed-control adjustments, blow-by evaluation, turbocharger boost and radiator airflow testing.

• Propel and undercarriage: Variable-displacement motor, counterbalance and crossover-relief diagnosis; brake-release checks, tracking, cycle-time, track-sag and component-wear evaluation.

• Load-sensing hydraulics: Pilot and main-pump pressure, flow and case-drain tests, cylinder-drift checks, relief adjustments and standard/Long Front cycle-time worksheets.

• Swing and dig functions: Boom, arm and bucket circuits, regenerative and anti-drift valves, power boost, swing-brake checks and Long Front swing-torque control.

• Electrical diagnosis: Seven-step circuit testing, fuse data, component identification, vehicle/cab/engine harness wiring diagrams and a four-sheet functional schematic.

• Factory air conditioning: R-12 operational, electrical and pressure diagnosis, refrigerant recovery, evacuation and charging procedures for machines through serial 541550.

Written for experienced technicians, this manual identifies the service equipment and essential tools required for its tests.

Operational Checkout and Engine Diagnosis

The machine-wide checkout record establishes a baseline before system-specific testing. It covers cooling condition, key-on and engine-running checks, monitors, gauges, controller modes, pilot shut-off and manual override.

Hydraulic control patterns, pump-regulator response, swing-brake release, drift, tracking, travel speeds and work modes are checked alongside lights, wipers, heater/A/C, seats, doors, windows and access panels. That baseline is designed to expose a symptom before the mechanic moves into the system-specific diagnostic group.

Engine fault charts connect symptoms to fuel-line leakage, air-filter restriction, intake leakage, lubrication and loaded-engine checks. Serial-specific fan-drive descriptions and the Engine—Sectional View support component identification.

Propel Circuits and Undercarriage Wear

The rotary manifold, pilot/drive circuits and planetary gearboxes are explained alongside the spring-applied, hydraulically released propel brakes. Tests address the propel transducer, speed-change solenoid, counterbalance valve, crossover relief, brake-release pressure and motor case-drain leakage.

Measurement procedures cover track-chain bushings and links, lower and upper rollers, front idlers, pitch and shoe grouser wear. Tool callouts include the JT05518/JT05523 undercarriage inspection kits.

Hydraulic Adjustments and Serial Breaks

Configuration changes: Major diagrams, test-port locations and worksheets distinguish machines through serial 556935 from 556936 onward. Main-pump and regulator information changes at 559603.

Earlier changes at 543990, 545157 and 546277 distinguish propel-pilot restrictions, boom/arm regenerative hardware and Long Front swing-torque control. This mapping matters before selecting a schematic, pressure connection or adjustment procedure.

Tests and adjustments: Step-by-step procedures cover pilot-pressure and system-relief adjustment, dig-function relief testing, pump-displacement solenoid adjustment and load-sense differential setting.

Further tests cover the manual-bypass pressure-reducing valve, swing crossover and torque control, oil-cooler pressure drop, auxiliary relief settings and swing lubrication flow. Warm-up and component start-up instructions accompany filter inspection and hydraulic-failure cleanup procedures.

Pilot and Main Hydraulic Schematics show the early and late circuits. Swing And Swing Torque Control Valves and Boom/Arm Regenerative And Anti-Drift Valves diagrams identify passages, ports and component relationships.

Component damage cautions: Drained hydraulic pumps, swing motors, brakes and gearboxes can be damaged by operation without the specified initial oil fill and lubrication flow. On Long Front machines, backing out spool-stop screws to beat factory cycle times can damage the boom or arm and cause jerky combined boom/propel operation.

Electrical Circuits and Factory A/C

The System Functional Schematic traces starting, charging, wipers, work/interior lights, monitor, A/C, switch panels and system-controller circuits. Wire numbers, colors and component references connect it to the harness diagrams.

Air-conditioning scope: The documented factory system applies through serial 541550. Its circuit and component-location views accompany blower/clutch-control checks, pressure-based fault charts, expansion-valve operating and bench tests, pressure-switch tests, leak inspection and refrigerant hose/tubing inspection.

Reference Data, Tools and Repair Limits

Reference tables cover unified-inch and metric bolt grades, special metric cap screws, O-ring boss and flat-face fittings, flare/cone-seat connections and four-bolt flanges. Approved fuels, lubricants, viscosity charts, refill capacities, wear limits and electrical test specifications accompany the diagnostic sections.

Tests specify the JT05801 clamp-on tachometer, JT05800 digital thermometer, JT02156A pressure/temperature analyzer and JT07077 differential-pressure gauge. A/C bench work calls for the JT05419 service-fitting kit.

Separate repair publications: The cover points to TM1509 for machine repair, CTM8 through machine serial 559602 or CTM104 from 559603 for additional 6068 engine information, CTM77 for alternators and starting motors, and SP326 for undercarriage appraisal. These companion manuals are not included; the appended repair-manual foreword contains no component repair procedures.

Many tests move the machine, raise the attachment, or open pressurized hydraulic and refrigerant circuits. Lower or securely support the working equipment, release reservoir and line pressure, keep the test area clear, and follow the manual’s R-12 recovery and electrical-test precautions.

Cooling Capacity and Track-Sag Specification Preview

Cooling-system refill: The capacity table specifies 34 L through machine serial 559602 and 41.5 L from 559603, illustrating the serial-specific refill information.

Track adjustment: The sag specification is 305–325 mm, measured at the middle track roller between the bottom of the track frame and the top of the track shoe, with the machine raised and supported as shown in the manual.