Complete Diagnostics, Operation and Test manual with electrical wiring diagrams for John Deere 490E Excavator, with all the service information to maintain, diagnose, and rebuild like professional mechanics.

John Deere 490E Excavator 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.

TM1504 - John Deere 490E Excavator Technical Manual - Operation and Test.PDF
TM1504 - John Deere 490E Excavator Technical Manual - Operation and Test.EPUB

PRODUCT DETAILS:
Total Pages: 860 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality) & EPUB/MOBI/AZW for Kindle/iPad/iPhone/Android.
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
      References
   Power Train
      Theory Of Operation
      System Operational Checks
      Diagnostic Information
      Adjustments
      Tests
   Hydraulic System
      Theory Of Operation
      System Operational Checks
      Diagnostic Information
      Adjustments
      Tests

 

tm1504 - 490E Excavator Operation and Tests

Table of Contents

Foreword

Section 9000: General Information

Group 01: Safety

Follow Safe Procedures

Prepare for Emergencies

Prevent Acid Burns

Handle Chemical Products Safely

Handle Fluids Safely-Avoid Fires

Avoid High-Pressure Fluids

Warn Others of Service Work

Support Machine Properly

Operate Only from Operator's Seat

Park Machine Safely

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

Group 02: General Specifications

490E

490E Drain And Refill Capacities

Group 03: Torque Values

Unified Inch Bolt and Cap Screw Torque Values

Metric Bolt and Cap Screw Torque Values

Additional Metric Cap Screw Torque Values

Service Recommendations for O-Ring Boss Fittings

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 Fittings

Service Recommendations for Metric Series Four Bolt Flange Fitting

Group 04: Fuels And Lubricants

Fuel Specifications

Engine Oil

Hydraulic Oil

Swing Gearbox, Propel Gearbox and Pump Gearbox Oils

Track Roller, Front Idler, And Carrier Roller Oil

Track Adjuster, Working Tool Pivot, Swing Bearing, And Swing Bearing Gear Grease

Section 9005: Operational Checkout

Group 10: Operational Checkout Procedure

Operational Checkout Record Sheet-490E

Operational Checkout

Section 9010: Engine

Group 05: Theory Of Operation

4045 John Deere Engine-Use CTM8

General Engine Description

Engine-Sectional View

Fan Drive Operation

Engine Speed Control System Operation

Group 10: System Operational Checks

4045 John Deere Engine-Use CTM8

Engine Operational Checks

Group 15: Diagnostic Information

4045 John Deere Engine-Use CTM8

Diagnose Engine Malfunctions

Group 20: Adjustments

4045 John Deere Engine-Use CTM8

JT05801 Clamp-On Electronic Tachometer Installation

Engine Speed And Control Linkage Adjustment

Group 25: Tests

4045 John Deere Engine-Use CTM8

Fuel Line Leakage Test

Air Filter Restriction Indicator Switch Test

Air Intake System Leakage Test

Radiator Air Flow Test

JT05529 Air Flow Meter Test Record

Section 9015: Electrical System

Group 05: System Information

Visually Inspect Electrical System

Electrical Circuit Malfunctions

High Resistance Circuit

Open Circuit

Grounded Circuit

Shorted Circuit

Multimeter

Seven Step Electrical Test Procedure

Wiring Diagram And Schematic Information

Reading A System Functional Schematic

Reading A Wiring Diagram

Electrical Schematic Symbols

Group 10: System Diagrams

Replacing Fuses

Fuse (Blade-Type) Color Codes

Fuse Specifications

Switch Specifications

Component Identification Table

Wiring And Schematic Diagrams Legend

Component Location Diagram

System Functional Schematic

Engine Harness (W5) Wiring Diagram

Cab Harness (W6) Wiring Diagram

Power Circuit Operational Information

Power Circuit Theory Of Operation

Power Circuit Schematic

Charging Circuit Operational Information

Charging Circuit Theory Of Operation

Charging Circuit Schematic

Windshield Wiper And Washer Circuit Operational Information

Windshield Wiper And Washer Circuit Theory Of Operation

Windshield Wiper And Washer Circuit Schematic

Switch Panel 1 Circuit Operational Information

Switch Panel 1 Theory Of Operation

Switch Panel 1 Circuit Schematic

Switch Panel 2 Circuit Operational Information

Switch Panel 2 Theory Of Operation

Switch Panel 2 Circuit Schematic

Light Circuit Operational Information

Light Circuit Theory Of Operation

Light Circuit Schematic

Horn, Dome Light, Cigar Lighter And Heater Circuits Operational Information

Horn, Dome Light, Cigar Lighter And Heater Circuits Theory Of Operation

Horn, Dome Light, Cigarette Lighter And Heater Circuits Schematic

Monitor Circuit Specifications

Monitor Circuit Operational Information

Monitor Circuit Theory Of Operation

Monitor Circuit Schematic

Auto Idle Circuit Operational Information

Auto Idle Circuit Theory Of Operation

Auto Idle Circuit Schematic

Warm-Up Circuit Operational Information

Warm-Up Circuit Theory Of Operation

Hydraulic Warm-Up Circuit Schematic

Pump And Valve Controller Circuit Operational Information

Pump And Valve Controller Circuit Theory Of Operation

Pump And Valve Controller Circuit Schematic

Engine Controller Circuit Operational Information

Engine Controller Circuit Theory Of Operation

Engine Controller Circuit Schematic

Start Aid And Travel Alarm Circuit Operational Information

Start Aid And Propel Alarm Circuit Theory Of Operation

Start Aid And Propel Alarm Circuit Schematic

Group 20: References

Monitor And Switch Panels

Monitor Panel

Switch Panel 1

Switch Panel 2

Resetting Engine Controller (EC)

Electrical Component Identification

Alternator Voltage Output Test-Delco

Alternator Operation-40 Amp Delco Remy

Replacing Batteries

Battery Operation

Diagnose Battery Malfunctions

Check Battery Electrolyte Level And Terminals

Procedure For Testing Batteries

Using Booster Batteries-24 Volt System

Engine Speed And Control Linkage Adjustment

Electronic Control Bypass Procedure

Hydraulic Pump Angle Sensor (A Sensor) Mechanical Check Diagnostic Procedure

Hydraulic Pump Angle Sensor (A Sensor) Adjustment

Troubleshooting Pump And Valve Controller (PVC)

Troubleshooting Engine Controller (EC)

Engine Control Sensor (EC Sensor) Harness Test

Connecting Engine Controller (EC) And Pump And Valve Controller (PVC) Harness Connector

Disconnect Tab Retainer Connectors

Disconnecting Spring Wire Retainer Connectors

Connector Pin Location And Numbers

Section 9020: Power Train

Group 05: Theory Of Operation

Power Train Components

Propel System Operation

Propel Pilot Circuit Operation

Propel Pilot Controller Operation-Neutral

Propel Pilot Check Valve Block Operation-Forward

Propel Control Valve Operation

Variable Pressure Compensator Valve Operation

Propel Proportional Solenoid Valve Operation

Propel Speed Control System Operation

Propel Speed Change Solenoid Valve Operation

Rotary Manifold Operation

Propel Brake Valve Operation

Propel Brake Pressure Reducing Valve Operation

Counterbalance Valve Operation-Neutral

Counterbalance Valve Operation-Propel

Counterbalance Valve Operation-Braking

Propel Motor Crossover Relief Valve Operation

Propel Motor Operation

Propel Speed Operation-Super Low And Normal

Propel Motor Operation-Max. Speed

Charge Valve Operation-Normal Maximum Speed

Charge Valve Maximum Speed Operation-Braking

Propel Gearbox Operation

Track Adjuster Operation

Group 10: System Operational Checks

Power Train Operational Checks

Group 15: Diagnostic Information

Diagnose Undercarriage Components Malfunctions

Diagnose Propel System Malfunctions

Measure Track Chain Bushing Wear

Measure Track Chain Pitch

Measure Track Chain Link Wear

Measure Track Shoe Grouser Wear

Measure Lower Track Roller Wear

Measure Front Idler Wear

Measure Upper Track Roller Wear

Propel System Component Location

Group 20: Adjustments

Adjust Track Sag

Propel Speed Cycle Time

Group 25: Tests

JT07058 Diagnostic Computer Operating Procedure

JT07059 Diagnostic Computer Function

JT05801 Clamp-On Electronic Tachometer Installation

JT05800 Digital Thermometer Installation

Hydraulic System Warm-Up Procedure

Propel Motor Start-Up Procedure

Engine Speed Programming Procedure After Battery Disconnection

Propel Motor Crossover Relief Valve Test And Adjustment

Propel Speed Change Solenoid Valve Test And Adjustment

Propel Proportional Solenoid Valve Test And Adjustment

Propel Motor Operating Leakage Test

Swing Bearing Wobble Test

Section 9025: Hydraulic System

Group 05: Theory Of Operation

Hydraulic System

Control Systems Operation

Switch Panel 2

Engine (EC), Pump And Valve (PVC) Controllers

Engine Control Circuit

Engine Power Modes

Hydraulic System Block Diagram

Load Sense System-Control Valves In Neutral

Load Sense System-Single Function Actuated

Load Sense System-Function Held Over Relief

Pump Control-Speed Sensing

Flow Dividing Control System

Work Mode Chart

Propel Speed Control System

Swing Brake Release Circuit Operation

Swing Stop Cushion Valve Circuit Operation

Warm-Up Control Circuit

Pilot Circuit Operation

Pilot Pump Operation

Pilot Filter Operation

Solenoid Valve Assembly Operation

Pilot Pressure Regulating Valve Operation

Pilot Pressure Reducing Valve Operation

Proportional Solenoid Valve Operation

Pilot Shut-Off Valve Operation

Pilot Controller Operation-Neutral

Pilot Controller Operation-Metering

Pilot Controller Operation-Full Stroke

Pilot Operation Of Main Control Valve

Dig Function Pilot Controller Check Valve Operation

Flow Regulator Valve Operation

Warm-Up Circuit Operation

Main Hydraulic Pump Operation

Main Hydraulic Pump Displacement Solenoid Valves Operation

Main Hydraulic Pump Control Operation

Main Hydraulic Pump Operation-Maximum Displacement

Main Hydraulic Pump Operation-Minimum Displacement

Main Hydraulic Pump Angle Sensor (A Sensor) Operation

Main Hydraulic Pump And Drive Gearbox-Serial No. (025000-)

Main Control Valve Operation

Control Valve Inlet Section Operation

Surge Relief Valve Operation (Serial No. -024999) System Relief Valve Operation (Serial No. 025000- )

System Relief Valve And Unloading Valve Operation-Neutral

System Relief Valve And Unloading Valve Operation-Activated

Circuit Relief Valve Operation

Differential Pressure Sensor Operation

Variable Pressure Compensator Valves Operation

Auxiliary Valve Operation

Arm, Boom, And Bucket Valve Operation

Anti-Drift Valve Operation

Swing Valve Operation

Shuttle Valve Operation

Combined Function Operation

Swing Motor And Brake Operation

Swing Motor Cover Operation-Start Of Swing

Swing Motor Cover Operation-Normal Swing

Swing Motor Cover Operation-Stopping

Swing Brake Release Solenoid Valve Operation

Swing Stop Cushion Valve Operation

Swing Stop Cushion Valve Operation-Swinging

Swing Gearbox Operation

Cylinder Operation

Return Filter Operation

Suction Screen Operation

Oil Cooler Operation

Pump Inlet And Delivery Circuits Operation

Return Circuit Operation

Drain Circuit Operation

Group 10: System Operational Checks

Hydraulic Operational Checks

Group 15: Diagnostic Information

Diagnostic Procedure

JT07058 Diagnostic Computer Operating Procedure

JT07059 Diagnostic Computer Function

Troubleshooting Differential Pressure Sensor (DP Sensor)

Troubleshooting Pump And Valve Controller (PVC)

Troubleshooting Engine Controller (EC)

Troubleshooting Engine Speed Sensor (N Sensor)

Troubleshooting Pump Displacement Angle Sensor (A Sensor)

Troubleshooting Pressure Sensor (P Sensor)

Troubleshooting Engine Control Sensor (EC Sensor)

Troubleshooting Hydraulic Oil Temperature Sensor (T Sensor)

Troubleshooting Boom Up Pilot Pressure Sensor (BPI Sensor)-Serial No. (025000- )

Troubleshooting Arm In Pressure Sensor (ABP Sensor)-Serial No. (025000- )

Troubleshooting Pump Displacement Solenoid Valve (PDSV)

Troubleshooting Proportional Solenoid Valve

Troubleshooting Propel Speed Change Solenoid Valve

Troubleshooting Swing Brake Release Solenoid Valve

Troubleshooting Swing Stop Cushion Valve

Troubleshooting Engine Control Motor (EC Motor)

Hydraulic Pump Angle Sensor (A Sensor) Mechanical Check Diagnostic Procedure

Introduction To Flow Charts

Diagnose Hydraulic System Malfunctions

Diagnose Pilot Circuit Malfunctions

Diagnose Dig Circuit Malfunctions

Diagnose Swing Circuit Malfunctions

Pilot Circuit Component Location

Hydraulic System Component Location

Pilot System SAE Pattern

Pilot System John Deere Pattern

Group 20: Adjustments

Pilot Shut-Off Valve Linkage Adjustment

Group 25: Tests

JT07058 Diagnostic Computer Operating Procedure

JT07058 Diagnostic Computer Initial Setup

Connecting JT07058 Diagnostic Computer To Machine

Begin JT07058 Diagnostic Computer Function

JT07059 Diagnostic Computer Function

Retry Procedure A

Retry Procedure B

Self Diagnostic Function Fault Codes For Engine Controller (EC)

Self Diagnostic Function Fault Codes For Pump And Valve Controller (PVC)

Monitor Data Function Display List And Description

Component Abbreviations And Location

Cross Reference To Monitor Data Function And Display Symbol

Reading Fault Codes Without JT07058 Diagnostic Computer

Reading Fault Codes With JT07058 Diagnostic Computer

Monitor Data Function Worksheet-490E

Example Of Monitor Data Function Worksheet

JT05801 Clamp-On Electronic Tachometer Installation

JT05800 Digital Thermometer Installation

Hydraulic System Warm-Up Procedure

Hydraulic Pump Start-Up Procedure

Swing Motor Start-Up Procedure

Swing Gearbox Start-Up Procedure

Hydraulic Oil Filter Inspection Procedure

Engine Speed Programming Procedure After Battery Disconnection

Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy

Cycle Time Test

Proportional Solenoid Valve Harness Test

Swing Brake Solenoid Valve Harness Test

Pump Displacement Solenoid Valve Harness Test

Swing Stop Cushion Valve Harness Test

Engine Control Motor (EC Motor) Harness Test

Differential Pressure Sensor Voltage Test And Adjustment

Engine Control Sensor (EC Sensor) Test

Miscellaneous Harness Test

Pilot Pressure Regulating Valve Test And Adjustment

Pilot Pressure Reducing Valve Test And Adjustment

Surge Relief Valve Test And Adjustment-Serial No. ( -024999)

System Relief Valve Test And Adjustment-(Serial No. -024999)

System Relief Valve Test And Adjustment-(Serial No. 025000- )

Circuit Relief Valve Test And Adjustment

Proportional Solenoid Valve (PSV) Test And Adjustment

Swing Motor Crossover Relief Valve Test And Adjustment

Hydraulic Pump Flow Test

Engine Power Or Hydraulic Pump Test Using Flow Meter Method

Pilot Pump Flow Test

Arm, Boom, And Bucket Cylinder Drift Test

Swing Motor Leakage Test

Oil Cooler Flow And Pressure Drop Test

John Deere 490E Excavator Operation and Test Service Manual (TM1504)