John Deere Wheeled Excavator 190E Operation & Test Technical Service Manual (TM1539)
Complete Technical Diagnostics, Operation and Test Manual with Electrical Wiring Diagrams for John Deere 190E Wheeled Excavators, with workshop information to maintain, diagnose, and rebuild like professional mechanics.
John Deere 190E 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.
TM1539 - John Deere 190E Wheeled Excavator Technical Manual - Operation and Test.pdf
TM1539 - John Deere 190E Wheeled Excavator Technical Manual - Operation and Test.epub
PRODUCT DETAILS:
Total Pages: 573 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English
MAIN SECTIONS
Foreword
General Information
Safety
General Specifications
Torque Values
Fuels And Lubricants
Operational Checkout
Operational Checkout Procedure
Engine
Theory Of Operation
System Operational Checks
Diagnostic Information
Adjustments
Tests
Electrical System
System Information
System Diagrams
Sub-System Diagnostics
Adjustments And Additional Information
Power Train
Theory Of Operation
Diagnostic Information
Adjustments
Hydraulic System
Theory Of Operation
Diagnostic Information
Adjustments
Tests
TABLE OF CONTENTS...1
Section 9000: General Information...11
Group 01: Safety...11
Follow Safe Procedures...14
Prepare for Emergencies...15
Prevent Acid Burns...16
Handle Chemical Products Safely...18
Handle Fluids Safely-Avoid Fires...19
Avoid High-Pressure Fluids...20
Warn Others of Service Work...21
Support Machine Properly...22
Operate Only from Operator's Seat...23
Park Machine Safely...24
Stay Clear of Moving Parts...25
Avoid Power Lines...26
Use Handholds and Steps...27
Keep Riders Off Machine...28
Move and Operate Machine Safely...29
Wear Protective Clothing...30
Protect Against Flying Debris...31
Protect Against Noise...32
Illuminate Work Area Safely...33
Service Machines Safely...34
Remove Paint Before Welding or Heating...35
Avoid Heating Near Pressurized Fluid Lines...36
Beware of Exhaust Fumes...37
Use Proper Lifting Equipment...38
Service Cooling System Safely...39
Dispose of Waste Properly...40
Work in a Clean Area...41
Use Tools Properly...42
Replace Safety Signs...43
Live With Safety...44
Group 02: General Specifications...11
190E...47
190E Drain And Refill Capacities...49
Group 03: Torque Values...12
Unified Inch Bolt and Cap Screw Torque Values...51
Metric Bolt and Cap Screw Torque Values...52
Additional Metric Cap Screw Torque Values...53
Service Recommendations for O-Ring Boss Fittings...55
Service Recommendations for Flat Face O-Ring Seal Fittings...57
Service Recommendations for 37° Flare and 30° Cone Seat Connectors...59
Service Recommendations For Flared Connections-Straight or Tapered Threads...61
Service Recommendations For Inch Series Four Bolt Flange Fittings...63
Service Recommendations for Metric Series Four Bolt Flange Fitting...65
Group 04: Fuels And Lubricants...12
Fuel Specifications...68
Engine Oil...69
Hydraulic Oil...70
Swing Gearbox And Propel Gearbox Oils...71
Track Roller, Front Idler, And Carrier Roller Oil...72
Grease...73
Section 9005: Operational Checkout...81
Group 10: Operational Checkout Procedure...74
Operational Checkout Record Sheet...78
Operational Checkout...81
Section 9010: Engine...119
Group 05: Theory Of Operation...119
4039 John Deere Engine-Use CTM8...168
General Engine Description...122
Engine-Sectional View...124
Engine Speed Control System Operation...126
Group 10: System Operational Checks...119
4039 John Deere Engine-Use CTM8...168
Engine Operational Checks...130
Group 15: Diagnostic Information...119
4039 John Deere Engine-Use CTM8...168
Diagnose Engine Malfunctions...147
Group 20: Adjustments...119
4039 John Deere Engine-Use CTM8...168
JT05801 Clamp-On Electronic Tachometer Installation...514
Fan Belt Tension Adjustment...162
Engine Speed And Control Linkage Adjustment...164
Group 25: Tests...119
4039 John Deere Engine-Use CTM8...168
Fuel Line Leakage Test...169
Air Filter Restriction Indicator Switch Test...170
Air Intake System Leakage Test...172
Radiator Air Flow Test...173
Section 9015: Electrical System...176
Group 05: System Information...176
Battery Specifications...180
Battery Operation...181
Diagnose Battery Malfunctions...182
Check Battery Electrolyte Level And Terminals...183
Procedure For Testing Batteries...186
Using Booster Batteries-24 Volt System...187
Visually Inspect Electrical System...189
Electrical Circuit Malfunctions...190
High Resistance Circuit...192
Open Circuit...194
Grounded Circuit...196
Shorted Circuit...198
Multimeter...200
Seven Step Electrical Test Procedure...201
Wiring Diagram And Schematic Information...203
Reading A System Functional Schematic...204
Reading A Wiring Diagram...205
Electrical Schematic Symbols...207
Group 10: System Diagrams...176
Component Identification Table...212
Replacing Fuses...214
Fuse (Blade-Type) Color Codes...215
Fuse Specifications...216
Wiring And Schematic Diagrams Legend...218
System Functional Schematic Section Legend...222
190E System Functional Schematic...223
Cab Harness (W6) Wiring Diagram...225
Cab Harness (W6) Component Location...226
Engine Harness (W5) Wiring Diagram...227
Engine Harness (W5) Component Location...228
Group 15: Sub-System Diagnostics...177
Power Circuit Operational Information...230
Power Circuit Theory Of Operation...231
Power Circuit Schematic...232
Charging Circuit Operational Information...238
Charging Circuit Theory Of Operation...239
Charging Circuit Schematic...240
Starting Circuit Operational Information...248
Starting Circuit Theory Of Operation...249
Starting Circuit Schematic...250
Windshield Wiper Circuit Operational Information...256
Windshield Wiper Circuit Theory Of Operation...257
Windshield Wiper Circuit Schematic...258
Switch Panel 1 Circuit Operational Information...262
Switch Panel 1 Theory Of Operation...263
Switch Panel 1 Circuit Schematic...264
Switch Panel 2 Circuit Operational Information...267
Switch Panel 2 Theory Of Operation...268
Switch Panel 2 Circuit Schematic...269
Light Circuit Operational Information...271
Light Circuit Theory Of Operation...272
Light Circuit Schematic...273
Horn, Dome Light, Optional Equipment And Heater Circuits Operational Information...278
Horn, Dome Light, Optional Equipment And Heater Circuits Theory Of Operation...279
Horn, Dome Light Optional Equipment And Heater Circuit Schematic...280
Monitor Circuit Operational Information...286
Monitor Circuit Theory Of Operation...287
Monitor Circuit Schematic...288
Auto Idle Circuit Operational Information...298
Auto Idle Circuit Theory Of Operation...299
Auto Idle Circuit Schematic...300
Warm-Up Circuit Operational Information...312
Warm-Up Circuit Theory Of Operation...313
Hydraulic Warm-Up Circuit Schematic...314
Engine And Pump Controller Circuit Operational Information...319
Engine And Pump Controller Circuit Theory Of Operation...320
Engine And Pump Controller Circuit Schematic...321
Starting Aid And Propel Alarm Circuit Operational Information...329
Starting Aid And Propel Alarm Circuit Theory Of Operation...330
Starting Aid And Travel Alarm Circuit Schematic...331
Group 20: Adjustments And Additional Information...178
Connecting Engine And Pump Controller (EPC) Harness Connector...342
Disconnect Tab Retainer Connectors...343
Connector Pin Location And Numbers...344
Monitor Panel And Switch Panels...345
Monitor Panel...347
Switch Panel 1...348
Switch Panel 2...349
Switch Specifications...351
Section 9020: Power Train...352
Group 05: Theory Of Operation...352
Track Adjuster Operation...354
Propel Gearbox Operation...355
Group 15: Diagnostic Information...352
Diagnose Undercarriage Components Malfunctions...359
Measure Track Chain Bushing Wear...361
Measure Track Chain Link Wear...362
Measure Lower Track Roller Wear...363
Measure Upper Track Roller Wear...364
Measure Front Idler Wear...365
Measure Track Chain Pitch...366
Measure Track Shoe Grouser Wear...367
Swing Bearing Wobble Test...368
Group 20: Adjustments...352
Adjust Track Sag...373
Section 9025: Hydraulic System...379
Group 05: Theory Of Operation...375
Hydraulic System...379
Pilot System Operation...380
Pilot Pump And Pilot Filter Operation...382
Pump Displacement Solenoid Valve Operation...384
Pilot Shut-Off Valve Operation...386
Pilot Controller Operation-Neutral...388
Pilot Controller Operation-Metering...390
Flow Regulator Valve Operation...392
Pilot Pressure Regulating Valve Operation...394
Main Control Valve Operation...395
Control Valve Passages...396
System Relief Valve Circuit Operation...398
System Relief Valve Operation...400
Circuit Relief Valve Operation...402
Flow Combiner And Swing Brake Release Valve Circuit Operation...404
Bucket And Auxiliary Work Circuits Operation...406
Boom Up Work Circuit Operation...408
Boom Down Work Circuit Operation...410
Arm In Work Circuit Operation...412
Arm Out Work Circuit Operation...414
Swing Work Circuit Operation...416
Combined Functions Operation...418
Combined Swing And Boom Operations...420
Combined Boom And Propel Operations...422
Swing Motor Cover Operation...424
Swing Motor Relief Valve Operation...426
Swing Motor...428
Swing Brake Release Circuit Operation...430
Swing Gearbox Operation...432
Hydraulic Cylinder Operation...434
Engine And Pump Control Operation...436
Main Hydraulic Pump Operation...438
Main Hydraulic Pump Regulator Operation-High Maximum Displacement...440
Main Hydraulic Pump Regulator Operation-Low Maximum Displacement...442
Constant Horsepower System...444
Propel Circuit Operation...446
Propel Control Valve Operation...448
Rotary Manifold Operation...450
Propel Motor Construction...451
Propel Motor Operation...453
Counterbalance Valve Neutral Operation...455
Counterbalance Valve Operation...457
Propel Relief Valve Operation...459
Propel Brake Operation...461
Suction, Supply And Return Circuits Operation...463
Hydraulic Oil Tank Operation...465
Pilot And Blade Pump Operation...467
Blade Control Valve Operation...468
Blade Hydraulic System Operation...469
Group 15: Diagnostic Information...376
Diagnose Hydraulic System Malfunctions...474
Diagnose Pilot Circuit Malfunctions...477
Diagnose Dig Circuit Malfunctions...479
Diagnose Swing Circuit Malfunctions...483
Diagnose Propel System Malfunctions...487
Hydraulic Circuit Symbols...492
Propel Circuit Component Location...493
Pilot Circuit Component Location...494
Main Hydraulic Circuit Component Location...495
Offset Boom And Blade Circuit Component Location...496
Pilot Control Lever Pattern Information...497
Group 20: Adjustments...376
Pilot Shut-Off Valve Linkage Adjustment...501
Group 25: Tests...376
Self Diagnosing Function Fault Codes-Engine And Pump Controller (EPC)...504
Component Abbreviations...505
Outline Of The Control System...506
Monitor Function Display List And Description...507
Cross Reference To Display Symbols And List, Unit Of Measure...509
Retry Procedure A...510
Retry Procedure B...512
JT05801 Clamp-On Electronic Tachometer Installation...514
JT05800 Digital Thermometer Installation...515
Hydraulic System Warm-Up Procedure...516
Hydraulic Pump Start-Up Procedure...518
Swing Motor Start-Up Procedure...519
Swing Gearbox Start-Up Procedure...520
Propel Motor Start-Up Procedure...522
Hydraulic Oil Filter Inspection Procedure...523
Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy...524
Cycle Time Test...526
Pilot Pressure Regulating Valve Test And Adjustment...529
Dig And Propel System Relief Valve Test And Adjustment...532
Circuit Relief Valve Test And Adjustment...536
Swing Motor Crossover Relief Valve Test And Adjustment...541
Main Hydraulic Pump Performance Test (Cycle Time Method)...544
Hydraulic Pump Regulator Test And Adjustment (Engine Pulldown)...546
Pilot Pump Flow Test...550
Hydraulic Pump Flow Test...552
Propel Motor Operating Leakage Test...555
Swing Motor Leakage Test...558
Arm, Boom, And Bucket Cylinder Drift Test...561
Blade System Relief Valve Test And Adjustment...563
Blade Circuit Relief Valve Test And Adjustment...566
Blade Hydraulic Pump Flow Test...569
TM Worksheet 190E...571
John Deere Wheeled Excavator 190E Operation & Test Technical Service Manual (TM1539)
