Complete service repair manual for John Deere Excavators 490D, 590D, with service information to maintain, repair, and rebuild like professional mechanics.

John Deere Excavators 490D, 590D 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.

TM1390 - John Deere 490D and 590D Excavator Technical Manual - Repair.PDF
TM1390 - John Deere 490D and 590D Excavator Technical Manual - Repair.EPUB

Total Pages: 723 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English

MAIN SECTIONS
 Foreword
   General Information
      Safety
      General Specifications
      Torque Values
      Fuels And Lubricants
   Tracks
      Track System
   Axles And Suspension Systems (Propel)
      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
   Dampener Drive (Flex Coupling)
      Elements
   Electrical System
      Batteries, Support, And Cables
      Alternator, Regulator And Charging System Wiring
      Wiring Harness And Switches
      Motors And Actuators
   Frame Or Supporting Structure
      Frame Installation
      Chassis Weights
   Operator’s Station
      Removal And Installation
      Operator Enclosure
      Seat And Seat Belt
      Heating And Air Conditioning
   Sheet Metal And Styling
      Hood Or Engine Enclosure
   Excavator
      Buckets
      Frames
      Hydraulic Systems
   Swing Or Pivoting System
      Mechanical Drive Elements
      Hydraulic System
   Dealer Fabricated Tools

tm1390 - 490D and 590D Excavator

Table of Contents

Foreword

Section I: General Information

Group I: 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 II: General Specifications

490D Specifications

490D Working Ranges

490D Drain And Refill Capacities

490D

490D Bucket Selection Chart-2.5 M (98 In.) Arm

490D Bucket Selection Chart-3.0 M (118 In.) Arm

490D Bucket Specifications

490D with 2.5 m (8 ft 2 in.) Arm Lift Capacity-Kg (Lb)

490D with 3.0 m (9 ft 10 in.) Arm Lift Capacity-Kg (Lb)

590D Specifications

590D Working Ranges

590D Operating Specifications

590D Drain And Refill Capacities

590D Engine and Hydraulic Specifications

590D Bucket Selection Chart-2.6 M (8 Ft 6 In.) Arm

590D Bucket Selection Chart-3.1 M (10 Ft. 2 In.) Arm

590D Bucket Specifications

590D Lift Capacity-Kg (Lb)

590D Lift Capacity-Kg (Lb)-Continued

Group III: Torque Values

Hardware Torque Specifications

Check Track Shoe Torque

Inch Cap Screw Torque Values

Metric 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 Flared Connections-Straight or Tapered Threads

SAE Four Bolt Flange Fitting Service Recommendations

Group IV: Fuels And Lubricants

Fuel Specifications

Fuel Storage

Engine Oil

Hydraulic Oil

Swing Gearbox, Propel Gearbox And Pump Gearbox Oils

Track Rollers And Idlers Oil

Swing Gear Grease

Grease

Lubricant Storage

Alternative Lubricants

Section 01: Tracks

Group 0130: Track System

Service Equipment And Tools

Other Material

Specifications

Measure Lower Track Roller Wear

Remove And Install Lower Track Roller

Disassemble And Assemble Lower Track Roller

Inspect Metal Face Seals

Measure Upper Track Roller Wear

Remove And Install Upper Track Roller

Assemble Upper Track Roller

Measure Track Shoe Grouser Wear

Remove And Install Track Shoe

Measure Track Link Wear

Measure Track Bushing Wear

Measure Track Pitch

Remove Track Chain

Install Track Chain

Disassemble And Assemble Track Chain

Adjust Track Sag

Measure Sprocket Wear

Remove And Install Sprocket

Measure Front Idler Wear

Remove And Install Front Idler

Disassemble Front Idler

Assemble Front Idler

Remove And Install Track Adjuster

Disassemble Track Adjuster

Assemble Track Adjuster

Section 02: Axles And Suspension Systems (Propel)

Group 0250: Axle Shaft, Bearings, And Reduction Gears

Service Equipment And Tools

Other Material

Specifications

Towing The Excavator-490D

Towing The Excavator-590D

Remove And Install Propel Gearbox-490D

Disassemble Propel Gearbox-490D

Assemble Propel Gearbox-490D

Remove And Install Propel Gearbox-590D

Disassemble Propel Gearbox-590D

Assemble Propel Gearbox-590D

Inspect Metal Face Seals

Group 0260: Hydraulic System

Essential Tools

Service Equipment And Tools

Other Material

Specifications

Remove And Install Propel Motor-490D

Disassemble Propel Motor-490D

Inspect Propel Motor-490D

Assemble Propel Motor-490D

Remove And Install Propel Motor-590D

Disassemble Propel Motor-590D

Assemble Propel Motor-590D

Remove And Install Propel Hydraulic Lines

Remove And Install Rotary Manifold

Disassemble And Assemble Rotary Manifold

Rotary Manifold Air Test

Section 04: Engine

Group 0400: Removal And Installation

4276 John Deere Engine Repair-Use CTM-4

Essential Tools

Other Material

Specifications

Remove And Install Engine-490D

Remove And Install Engine-590D

Remove And Install Oil Pan

Remove Fuel Injection Pump

Install Fuel Injection Pump

Remove And Install Fuel Injection Nozzles

Bleed Fuel System

Remove And Install Water Pump

Remove And Install Turbocharger-590D

Section 05: Engine Auxiliary Systems

Group 0505: Cold Weather Starting Aids

Other Material

Specifications

Remove And Install Starting Aid Solenoid And Nozzle

Remove And Install Engine Coolant Heater

Group 0510: Cooling System

Service Equipment And Tools

Specifications

Remove And Install Fan

Remove And Install Fan Belt

Fan Belt Tension Adjustment

Remove And Install Radiator

Group 0515: Speed Controls

Other Material

Specifications

Remove And Install Speed Control Assembly

Engine Speed Adjustment

Speed Control Linkage Adjustment

Speed Control Lever Tension Adjustment

Group 0520: Intake System

Service Equipment And Tools

Specifications

Remove And Install Air Cleaner-490D

Remove And Install Air Cleaner-590D

Air Intake System Leakage Test

Group 0560: External Fuel Supply Systems

Specifications

Remove And Install Fuel Tank

Remove And Install Fuel Filter

Section 07: Dampener Drive (Flex Coupling)

Group 0752: Elements

Other Material

Specifications

Disassemble And Assemble Flex Coupling-490D

Disassemble And Assemble Flex Coupling-590D

Section 16: Electrical System

Group 1671: Batteries, Support, And Cables

Specifications

Handle Batteries Safely

Test Batteries Using Coolant And Battery Tester

Test Batteries Using High Rate Discharge Test

Prevent Fire Hazards When Using Booster Batteries

Charge Battery

Remove And Install Batteries

Group 1672: Alternator, Regulator And Charging System Wiring

John Deere Engine Accessories-Alternator Repair-Use CTM-11

Service Equipment And Tools

Specifications

Remove And Install

Group 1674: Wiring Harness And Switches

Remove And Install Dome Light Switch

Remove And Install Control Panel Switches

Remove And Install Relay Starter Solenoid

Remove And Install Engine Hourmeter Switch

Remove And Install Engine Overheat Alarm Switch

Remove And Install Air Cleaner Restriction Indicator

Remove And Install Battery Relay

Remove And Install Battery Relay

Remove And Install Buzzer Stop Switch

Remove And Install Travel Alarm-590D

Changing Travel Alarm Volume

Group 1677: Motors And Actuators

John Deere Starting Motor Repair Use CTM-11

Service Equipment And Tools

Specifications

Remove And Install Starting Motor

Section 17: Frame Or Supporting Structure

Group 1740: Frame Installation

Welding Repair Of Major Structure

Group 1749: Chassis Weights

Essential Tools

Specifications

Remove And Install Counterweight

Section 18: Operator’s Station

Group 1800: Removal And Installation

Other Material

Specifications

Remove And Install Cab And Cab Floor

Remove And Install Cab (Without Floor)

Group 1810: Operator Enclosure

Service Equipment And Tools

Other Material

Remove And Install Windowpane And Two Piece Molding

Remove And Install Windowpane And One Piece Molding

Remove And Install Sliding Windows

Windowpane Dimensions

Remove And Install Cab Door

Remove And Install Door Latch

Remove And Install Inside Assist Handle

Remove, Disassemble, Assemble, And Install Windshield Wiper

Remove And Install Defroster Fan

Disassemble And Assemble Defroster Fan

Group 1821: Seat And Seat Belt

Disassemble And Assemble Seat

Group 1830: Heating And Air Conditioning

Disassemble And Assemble Blower Motor

Remove And Install 13,500 BTU Heater

Remove And Install 13,500 BTU Cab Heater Lines And Controls

Remove And Install 19,000 BTU Heater

Remove And Install 19,000 BTU Cab Heater Lines And Controls

Remove And Install 40,000 BTU Heater

Remove And Install 40,000 BTU Cab Heater Lines And Controls

Section 19: Sheet Metal And Styling

Group 1910: Hood Or Engine Enclosure

Specifications

Remove And Install Hood

Adjust Hood Latch Catch

Remove And Install Service Doors

Remove And Install Top Cover

Section 33: Excavator

Group 3302: Buckets

Service Equipment And Tools

Specifications

Remove And Install Bucket And Linkage

Remove And Install Bushings

Inspect Bucket Linkage Pins And Bushings

Adjust Bucket Pivot End Play

Disassemble And Assemble Bucket

Remove And Install Tooth Tip

Remove Tooth Shank

Install Tooth Shank

Group 3340: Frames

Service Equipment And Tools

Other Material

Specifications

Remove Arm

Install Arm

Remove Boom

Install Boom

Inspect Arm And Boom Pins And Bushings

Remove And Install Bushings

Group 3360: Hydraulic Systems

Essential Tools

Service Equipment And Tools

Other Material

Specifications

Hydraulic Cylinder Bleed Procedure

Release Pressure In Hydraulic System

Remove And Install Hydraulic Pump

Hydraulic Pump Start-Up Procedure

Disassemble Hydraulic Pump

Assemble Hydraulic Pump

Remove And Install Hydraulic Pump Regulator

Disassemble Pump Regulator

Assemble Pump Regulator

Remove And Install Pilot Pump

Disassemble And Assemble Pilot Pump

Remove And Install Solenoid Valve And Pilot Pressure Regulating Valve

Disassemble And Assemble Solenoid Valve And Pilot Pressure Regulating Valve

Remove And Install Engine Speed Mode Selection Cylinders

Disassemble And Assemble Engine Speed Mode Selection Cylinders

Remove And Install Hydraulic Control Valve

Disassemble Hydraulic Control Valve

Assemble Hydraulic Control Valve

Remove And Install Reservoir

Remove And Install Return Filter And Suction Filter

Remove And Install Oil Cooler Restriction Valve

Disassemble And Assemble Oil Cooler Restriction Valve

Remove And Install Oil Cooler Bypass Valve

Disassemble And Assemble Oil Cooler Bypass Valve

Remove And Install Oil Cooler

Remove And Install Bucket Cylinder

Remove And Install Arm Cylinder

Remove And Install Boom Cylinder

Hydraulic Cylinder Bleed Procedure

Disassemble Bucket, Arm And Boom Cylinders

Inspection Of Cylinder Rod

Assemble Bucket, Arm, And Boom Cylinders

Inspection Of Cylinder Pins And Bushings

Remove And Install Auxiliary Shut-Off Valve

Disassemble And Assemble Auxiliary Shut-Off Valve

Remove And Install Propel Function Ler Valve

Disassemble Propel Function Pilot Controller Valve

Assemble Propel Function Pilot Controller Valve

Remove And Install Dig Function Pilot Controller Valve

Disassemble Dig Function Pilot Controller Valve

Assemble Dig Function Pilot Controller Valve

Remove And Install Pilot Shut-Off Valve

Pilot Shut-Off Valve Linkage Adjustment

Disassemble And Assemble Pilot Shut-Off Valve

Disassemble And Assemble Pilot Filter

Inspect Pilot Filter Relief Valve

Remove And Install Flow Control Valve

Disassemble And Assemble Flow Control Valve

Remove And Install Check Valve Block

Disassemble And Assemble Check Valve Block

Section 43: Swing Or Pivoting System

Group 4350: Mechanical Drive Elements

Service Equipment And Tools

Other Material

Specifications

Remove And Install Swing Gearbox

Disassemble And Assemble Swing Gearbox

Remove And Install Swing Bearing

Disassemble And Assemble Swing Bearing

Install Swing Bearing Seals

Group 4360: Hydraulic System

Service Equipment And Tools

Other Material

Specifications

Remove And Install Swing Motor

Disassemble Swing Motor

Assemble Swing Motor

Disassemble And Assemble Crossover Relief Valves

Remove And Install Make-Up Valves

Disassemble And Assemble Swing Brake Release Valve

Section 99: Dealer Fabricated Tools

Group 9900: Dealer Fabricated Tools

DF1036 Propel Gearbox Nut Wrench-490D

DFT1070 Propel Gearbox Nut Wrench-590D

DF1038 Torque Adapter

Rotary Manifold Lifting Tool

ST4920 Track Recoil Spring Disassembly And Assembly Tool

DFT1087 Track Recoil Spring Disassembly And Assembly Guard Tool

John Deere Excavators 490D, 590D Service Repair Manual (TM1390)