John Deere Wheeled Excavator 190E Repair Technical Service Manual (TM1540)
Complete Technical repair manual for John Deere 190E, with all the workshop information to maintain, repair, and rebuild like professional mechanics.
John Deere 190E 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.
TM1540 - John Deere 190E Wheeled Excavator Technical Manual - Repair.pdf
TM1540 - John Deere 190E Wheeled Excavator Technical Manual - Repair.epub
PRODUCT DETAILS:
Total Pages: 612 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English
N.B.: for Electrical Wiring Diagrams, please use TM1539.
MAIN SECTIONS
Foreword
General Information
Safety
General Specifications
Torque Values
Fuels And Lubricants
Tracks
Tracks 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
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
Bulldozers
Blade
Control Linkage
Hydraulic System
Excavator
Bucket
Frames
Hydraulic System
Swing Rotation Or Pivoting System
Mechanical Drive Elements
Hydraulic System
Dealer Fabricated Tools
TABLE OF CONTENTS...1
Section 00: General Information...13
Group 0001: Safety...13
Follow Safe Procedures...16
Prepare for Emergencies...17
Prevent Acid Burns...18
Handle Chemical Products Safely...20
Handle Fluids Safely—Avoid Fires...21
Avoid High-Pressure Fluids...22
Warn Others of Service Work...23
Support Machine Properly...24
Operate Only from Operator's Seat...25
Park Machine Safely...26
Stay Clear of Moving Parts...27
Avoid Power Lines...28
Use Handholds and Steps...29
Keep Riders Off Machine...30
Move and Operate Machine Safely...31
Wear Protective Clothing...32
Protect Against Flying Debris...33
Protect Against Noise...34
Illuminate Work Area Safely...35
Service Machines Safely...36
Remove Paint Before Welding or Heating...37
Avoid Heating Near Pressurized Fluid Lines...38
Beware of Exhaust Fumes...39
Use Proper Lifting Equipment...40
Service Cooling System Safely...41
Dispose of Waste Properly...42
Work in a Clean Area...43
Use Tools Properly...44
Replace Safety Signs...45
Live With Safety...46
Group 0002: General Specifications...582
190E...49
190E Drain And Refill Capacities...51
Group 0003: Torque Values...14
Unified Inch Bolt and Screw Torque Values...54
Metric Bolt and Screw Torque Values...56
Additional Metric Cap Screw Torque Values...58
Service Recommendations for O-Ring Boss Fittings...60
Service Recommendations For Flat Face O-Ring Seal Fittings...62
Service Recommendations for 37° Flare and 30° Cone Seat Connectors...64
Service Recommendations For Flared Connections—Straight or Tapered Threads...66
Service Recommendations For Inch Series Four Bolt Flange Fittings...68
Service Recommendations for Metric Series Four Bolt Flange Fitting...70
Group 0004: Fuels And Lubricants...14
Fuel Specifications...582
Engine Oil...74
Hydraulic Oil...75
Swing Gearbox And Propel Gearbox Oils...76
Track Roller, Front Idler, And Carrier Roller Oil...77
Grease...78
Section 01: Tracks...79
Group 0130: Tracks System...79
Service Equipment And Tools...544
Other Material...545
Specifications...582
Track Pitch And Wear Specifications...582
Remove And Install Lower Track Roller...85
Disassemble Lower Track Roller...87
Assemble Lower Track Roller...89
Test Lower Track Roller For Oil Leakage...91
Remove And Install Upper Track Roller...92
Disassemble And Assemble Upper Track Roller...94
Inspect Metal Face Seals...144
Remove And Install Track Shoe...99
Remove Track Chain...101
Install Track Chain...103
Disassemble And Assemble Track Chain...106
Disassemble And Assemble Track Chain To Replace Broken Part...108
Adjust Track Sag...111
Remove And Install Sprocket...113
Remove And Install Front Idler...114
Disassemble Front Idler...115
Assemble Front Idler...117
Test Front Idler For Oil Leakage...119
Remove And Install Track Adjuster Cylinder And Recoil Spring...120
Disassemble And Assemble Track Adjuster Recoil Spring...122
Disassemble And Assemble Track Adjuster Cylinder...127
Section 02: Axles And Suspension Systems...130
Group 0250: Axle Shaft, Bearings, And Reduction Gears...130
Service Equipment And Tools...544
Other Material...545
Specifications...582
Towing Machine...135
Remove And Install Propel Gearbox...137
Disassemble Propel Gearbox...140
Inspect Metal Face Seals...144
Disassemble And Assemble First Planet Pinion Carrier...146
Disassemble And Assemble Second Planet Pinion Carrier...147
Assemble Propel Gearbox...148
Group 0260: Hydraulic System...130
Service Equipment And Tools...544
Other Material...545
Specifications...582
Remove And Install Propel Motor And Brake...158
Propel Motor Start-Up Procedure...161
Disassemble And Assemble Propel Motor And Brake...162
Remove And Install Propel Motor Valve Housing And Cover...165
Disassemble And Assemble Propel Motor Valve Housing And Cover...166
Overload Relief And Check Valve...170
Counterbalance Valve...171
Shuttle Valve...172
Remove And Install Rotary Manifold...173
Disassemble And Assemble Rotary Manifold...178
Bench Test Rotary Manifold...181
Section 04: Engine...182
Group 0400: Removal And Installation...182
4039 John Deere Engine—Use CTM8...184
Special Or Essential Tools...427
Other Material...545
Specifications...582
Remove And Install Engine...188
Bleed Fuel System...195
Remove And Install Oil Pan...196
Remove And Install Starter...199
Section 05: Engine Auxiliary Systems...201
Group 0505: Cold Weather Starting Aids...201
Other Material...545
Specifications...582
Remove And Install Starting Aid Solenoid And Nozzle...205
Remove And Install Engine Coolant Heater...207
Group 0510: Cooling System...201
Specifications...582
Remove And Install Fan, Shroud, And Guards...211
Remove And Install Radiator...213
Remove And Install Fan Belt...215
Group 0515: Speed Controls...201
Service Equipment And Tools...544
Other Material...545
Specifications...582
Remove And Install Speed Control Linkage...220
Engine Speed And Control Linkage Adjustment...222
Remove And Install Engine Control (EC) Motor And Sensor...225
Disassemble And Assemble Engine Control (EC) Motor And Sensor...227
Group 0520: Intake System...201
Special Or Essential Tools...427
Service Equipment And Tools...544
Specifications...582
Remove And Install Air Cleaner...234
Air Intake System Leakage Test...236
Group 0560: External Fuel Supply Systems...201
Other Material...545
Specifications...582
Remove And Install Fuel Tank...240
Section 16: Electrical System...242
Group 1671: Batteries, Support, And Cables...242
Service Equipment And Tools...544
Specifications...582
Handle Batteries Safely...247
Procedure For Testing Batteries...248
Checking Electrolyte Specific Gravity...250
Check Battery Electrolyte Level And Terminals...253
Using Booster Batteries—24-Volt System...256
Charge Battery...258
Remove And Install Batteries...261
Adding 12-Volt Accessories...263
Group 1672: Alternator, Regulator, And Charging System Wiring...242
John Deere Engine Accessories—Alternator Repair—Use CTM77...265
Specifications...582
Remove And Install Alternator...267
Group 1674: Wiring Harness And Switches...242
Special Or Essential Tools...427
Front Chassis Electrical Component Identification...270
Hydraulic Electrical Component Identification...272
Engine Electrical Component Identification...274
Front Cab Electrical Component Identification...276
Rear Cab Electrical Component Identification...278
Connect Engine And Pump Controller (EPC)...280
Disconnecting Tab Retainer Connectors...281
Replacing Fuses...282
Fuse Specifications...582
Fuse (Blade-Type) Color Codes...285
Remove And Install Cab Ground Straps...286
Remove And Install Starter Switch...287
Remove And Install Dome Light Switch...289
Remove And Install Propel Alarm Cancel Switch And Start Aid Switch...290
Replace DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Connectors...243
Install DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Contact...243
Replace WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Connector...243
Install WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Contact...243
Remove Connector Body from Blade Terminals...299
Group 1675: System Controls...243
Welding On Machine...401
Connect Engine And Pump Controller (EPC) Harness Connector...304
Remove And Install Engine And Pump Controller (EPC)...305
Remove And Install Monitor Controller...306
Group 1676: Instruments And Indicators...243
Replace Monitor Panel Bulbs...308
Remove And Install Monitor Panel And Switch Panel 1...309
Replace Switch Panel 2 Bulb...312
Remove And Install Switch Panel 2...313
Remove And Install Travel Alarm...315
Changing Travel Alarm Volume...316
Section 17: Frame Or Supporting Structure...317
Group 1740: Frame Installation...317
Specifications...582
Welding On Machine...401
Welding Repair Of Major Structure...322
Group 1749: Chassis Weights...317
Service Equipment And Tools...544
Specifications...582
Remove And Install Counterweight...327
Section 18: Operator’s Station...329
Group 1800: Removal And Installation...329
Specifications...582
Remove And Install Cab...332
Group 1810: Operator Enclosure...329
Service Equipment And Tools...544
Other Material...545
Remove And Install Windowpane And Two Piece Molding...339
Remove And Install Windowpane And One Piece Molding...341
Windowpane Dimensions...342
Remove And Install Sliding Windows...344
Group 1821: Seat And Seat Belt...329
Specifications...582
Remove And Install Seat...348
Disassemble And Assemble Seat...350
Group 1830: Heating And Air Conditioning...329
Remove And Install Heater Core...353
Remove And Install Blower Motor...354
Section 32: Bulldozers...356
Group 3200: Blade...356
Specifications...582
Remove And Install Blade...359
Group 3215: Control Linkage...356
Remove And Install Control Lever And Linkage...363
Adjust Control Lever And Linkage...365
Group 3260: Hydraulic System...356
Special Or Essential Tools...427
Specifications...582
Remove And Install Blade Hydraulic Pump...370
Disassemble And Assemble Brake Hydraulic Pump...372
Remove And Install Blade Control Valve...374
Disassemble And Assemble Blade Control Valve...376
Remove And Install Blade Cylinder...377
Disassemble Blade Cylinder...379
Assemble Blade Cylinder...526
Section 33: Excavator...386
Group 3302: Bucket...386
Specifications...582
Replacing Bucket Teeth...390
Replacing Bucket Tooth Tip—Heavy-Duty Bucket...392
Remove And Install Tooth Shank...394
Remove And Install Bucket And Linkage...397
Adjust Bucket Linkage...399
Welding On Machine...401
Replace Welded Bucket Cutting Edges...403
Repair Cracked Cutting Edge...404
Group 3340: Frames...386
Service Equipment And Tools...544
Specifications...582
Remove And Install Arm...410
Remove And Install Boom...414
Remove And Install Boom Offset...418
Inspect Arm And Boom Pins And Bushings...420
Remove And Install Bushings And Seals...424
Group 3360: Hydraulic System...386
Special Or Essential Tools...427
Other Material...545
Specifications...582
Hydraulic Cylinder Bleed Procedure...431
Release Pressure In Hydraulic System...432
Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy...434
Remove And Install Hydraulic Pump...436
Hydraulic Pump Start-Up Procedure...439
Disassemble Hydraulic Pump...440
Assemble Hydraulic Pump...449
Remove And Install Dampener Drive (Flex Coupling)...464
Remove And Install Hydraulic Pump Displacement Solenoid Valve...466
Remove And Install Pilot Pump...468
Disassemble And Assemble Pilot Pump...470
Remove And Install Pilot Filter...472
Hydraulic Oil Filter Inspection Procedure...474
Remove And Install Pilot Pressure Regulating Valve...475
Disassemble And Assemble Pilot Pressure Regulating Valve...477
Remove And Install Pilot Shut-Off Valve...478
Disassemble And Assemble Pilot Shut-Off Valve...479
Pilot Shut-Off Valve Linkage Adjustment...481
Remove And Install Dig Function Pilot Controller...483
Disassemble And Assemble Dig Function Pilot Controller...486
Remove And Install Dig Function Pilot Flow Regulator Valve...489
Disassemble And Assemble Dig Function Pilot Flow Regulator Valve...491
Remove And Install Propel Control Valve Linkage...493
Remove And Install Main Control Valve And Propel...494
Disassemble And Assemble Main Control Valve...499
Disassemble And Assemble Dig And Propel System Relief Valve...505
Disassemble And Assemble Circuit Relief And Anti-Cavitation Valve...506
Remove And Install Boom Cylinder...507
Remove And Install Offset Boom Cylinder...509
Remove And Install Arm Cylinder...511
Remove And Install Bucket Cylinder...513
Disassemble and Assemble Boom, Bucket, Arm, and Offset Cylinders...515
Assemble Blade Cylinder...526
Remove And Install Hydraulic Oil Cooler...531
Remove And Install Hydraulic Oil Cooler Bypass Valve...534
Remove And Install Return Filter And Bypass Valve...536
Remove And Install Reservoir...538
Disassemble And Assemble Hydraulic Reservoir...540
Section 43: Swing Rotation Or Pivoting System...542
Group 4350: Mechanical Drive Elements...542
Service Equipment And Tools...544
Other Material...545
Specifications...582
Remove And Install Swing Gearbox...547
Swing Gearbox Start-Up Procedure...549
Disassemble And Assemble Swing Gearbox...550
Remove Upperstructure...562
Install Upperstructure...570
Remove And Install Swing Bearing...574
Disassemble And Assemble Swing Bearing...576
Install Swing Bearing Upper Seal...579
Install Swing Bearing Lower Seal...580
Group 4360: Hydraulic System...542
Specifications...582
Remove And Install Swing Motor And Brake...583
Swing Motor Start-Up Procedure...585
Disassemble Swing Motor And Brake...586
Assemble Swing Motor And Brake...591
Disassemble And Assemble Swing Motor Valve Housing And Cover...596
Remove And Install Swing Brake Release Valve...600
Disassemble And Assemble Swing Brake Valve...601
Section 99: Dealer Fabricated Tools...602
Group 9900: Dealer Fabricated Tools...602
ST4920 Track Recoil Spring Disassembly And Assembly Tool...607
DFT1087 Track Recoil Spring Disassembly And Assembly Guard Tool...611
DFT1112A Spacer...612
DFT1123 Propel Gearbox Nut Wrench...613
Rotary Manifold Lifting Tool...614
DFT1089 Barrel Support...615
DFT1077 Spool Holding Fixture...616
DFT1108 Spool Holding Fixture...617
John Deere Wheeled Excavator 190E Repair Technical Service Manual (TM1540)
