Complete Diagnostics, Operation and Test manual with electrical wiring diagrams for John Deere Excavators 490D, 590D, with workshop information to maintain, diagnostic, service, and rebuild like professional mechanics.

John Deere Excavators 490D, 590D 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.

TM1389 - John Deere 490D and 590D Excavator Technical Manual - Operation and Test.PDF
TM1389 - John Deere 490D and 590D Excavator Technical Manual - Operation and Test.EPUB

Total Pages: 681 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
   Operational Checkout Procedure
      Operational Checkout Procedure
   Engine
      Theory Of Operation
      System Operational Checks
      Diagnostic Information
      Adjustments
      Tests
   Electrical System
      Electrical System Operation And Test
   Powertrain
      Theory Of Operation
      System Operational Checks
      Diagnostic Information
      Adjustments
      Tests
   Hydraulic System
      Theory Of Operation
      System Operational Checks
      Diagnostic Information
      Adjustments
      Tests

tm1389 - 490D and 590D Excavators Operation and Test

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

Metric Bolt And Cap Screw Torque Values

Unified Inch Bolt And Cap Screw Torque Values

Check Oil Lines And Fittings

Service Recommendations For 37° Flare And 30° Cone Seat Connectors

Service Recommendations for O-Ring Boss Fittings

Service Recommendations For Flat Face O-Ring Seal Fittings

Service Recommendations For Metric Series Four Bolt Flange Fitting

Service Recommendations For Inch Series Four Bolt Flange Fittings

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

Synthetic Lubricants

Engine Coolant

Section 9005: Operational Checkout Procedure

Group 10: Operational Checkout Procedure

Operational Checkout Record Sheet-490D, 590D

Complete Machine Operational Checkout

Section 9010: Engine

Group 05: Theory Of Operation

Cooling System Operation-490D

Cooling System Operation-590D

Radiator Cap Operation

Air Cleaner Operation

Engine Lubrication Operation

Oil Cooler Operation

Fuel System Operation

Fuel Supply Pump Operation

Fuel Filter Operation

Fuel Injection Pump Operation

Fuel Injection Nozzle Operation

Turbocharger Operation-590D

Cold Weather Starting Aid Operation

Engine Speed Control System Operation

Group 10: System Operational Checks

Engine Operational Checks

Group 15: Diagnostic Information

Diagnose Engine Malfunctions

Coolant Requirements

General Recommendations

Group 20: Adjustments

Fan Belt Tension Adjustment

Engine Speed Adjustment

Engine Speed Control Linkage Adjustment

Speed Control Lever Tension Adjustment

Engine Valve Clearance Adjustment

Injection Pump Static Timing Adjustment

Group 25: Tests

JT39000 Tachometer Reader Installation Procedure

D01084AA Tachometer Reader Installation Procedure

JT05801 Clamp-On Electronic Tachometer Installation

Compression Pressure Test

Engine Oil Pressure Test

Engine Performance Test

Valve Lift Test

Fuel Supply Pump Pressure Test

Air Filter Restriction Indicator Switch Test

Air Intake System Leakage Test

Turbocharger Shaft Axial End Play Test-590D

Turbocharger Shaft Radial Movement Test-590D

Engine Power Test Using Turbocharger Boost Pressure-590D

Radiator Air Flow Test

Fuel Line Leakage Test

Section 9015: Electrical System

Group 00: Electrical System Operation And Test

Safety Precautions

Battery Operation

Using Booster Batteries

Procedure For Testing Batteries

Diagnose Battery Malfunctions

Fuse Specifications

Engine Coolant Level Indicator Light

Hydraulic Reservoir Level Indicator Light

Engine Coolant Temperature Gauge

Engine Coolant Temperature Indicator Light

Fuel Gauge

Fuel Level Indicator Light

Battery Charge Indicator Light

Engine Oil Pressure Warning Light

Engine Oil Filter Restriction Indicator Light

Air Cleaner Restriction Indicator Light

Visually Inspect Electrical System

Testing The Electrical System

Common Circuit Test

Electrical Operational Checks

Wiring Diagram Information

Power Circuit Diagnose Malfunctions

Power Circuit Operation

Power Circuit Wiring Diagram

Power Circuit Test

Starting Circuit Diagnose Malfunctions

Start Circuit Operation

Starter Operation

Start Circuit Wiring Diagram

Start Circuit Test

Charging Circuit Diagnose Malfunctions

Charging Circuit Operation

Alternator Operation-65 Amp Motorola

Charging Circuit Wiring Diagram

Charging Circuit Test

Diagnose Accessory Circuit Malfunctions

Accessory Circuit Operation

Accessory Circuit Wiring Diagram

Accessory Circuit Test

Engine Speed And Pump Displacement Control Circuit Diagnose Malfunctions

Engine Speed And Pump Displacement Control Operation

Engine Speed And Pump Displacement Control Circuit Operational Charts

Engine Speed And Pump Displacement Control System Operation

Engine Speed And Pump Displacement Control Circuit Wiring Diagram

Engine Speed And Pump Displacement Control Circuit Test

Monitor Circuit Diagnose Malfunctions

Monitor Circuit Operation

Monitor Circuit Test

Section 9020: Powertrain

Group 05: Theory Of Operation

Track Adjuster Operation

Propel Gearbox Operation-490D

Propel Gearbox Operation-590D

Propel Circuit Operation

Rotary Manifold Operation

Propel Motor Operation-490D

Propel Motor Operation-590D

Counterbalance Valve Neutral Operation-490D

Counterbalance Valve Neutral Operation-590D

Counterbalance Valve Propel Operation-490D

Counterbalance Valve Propel Operation-590D

Counterbalance Valve Braking Operation-490D

Counterbalance Valve Dynamic Braking Operation-590D

Propel Motor Relief Valve Operation-490D

Propel Motor Relief Valve Operation-590D

Propel Brake Operation-490D

Propel Motor Brake Operation-590D

Group 10: System Operational Checks

Power Train Operational Checks

Group 15: Diagnostic Information

Diagnose Undercarriage Components Malfunctions

Diagnose Propel System Malfunctions

Measure Track Bushing Wear

Measure Track Chain Pitch

Measure Track Link Wear

Measure Track Shoe Grouser Wear

Measure Track Roller Wear

Group 20: Adjustments

Adjust Track Sag

Group 25: Tests

Propel Speed Cycle Time

JT39000 Tachometer/Temperature Reader Installation

D01084AA Tachometer/Temperature Reader Installation

JT05801 Clamp-On Electronic Tachometer Installation

JT05800 Digital Thermometer Installation

Propel System Relief Valve Adjustment

Propel Motor Crossover Relief Valve Test And Adjustment

Propel Motor Operating Leakage Test

Propel Motor Start-Up Procedure

Swing Bearing Wobble Test

Section 9025: Hydraulic System

Group 05: Theory Of Operation

Hydraulic System

Pilot System Operation

Pilot Pump Operation

Pilot Filter Operation

Solenoid Valve And Pilot Pressure Regulating Valve Operation

Solenoid Valve Operation-Energized

Engine Speed Control Operation

Check Block Operation

Main Hydraulic Pump Displacement Operation

Shut-Off Valve Operation

Pilot Controller Operation-Neutral

Pilot Controller Operation-Metering

Pilot Controller Operation-Full Stroke

Propel Pilot Controller Operation-Neutral

Pilot Operation Of Main Control Valve

Flow Regulator Operation

Warm-Up Circuit Operation

Pump Inlet And Delivery Circuits Operation

Return Circuit Operation

Drain Circuit Operation

Return Filter Operation

Main Control Valve Operation

System Relief Valve Circuit Operation

System Relief Valve Operation

Circuit Relief Valve Operation

Flow Combiner And Swing Brake Release Valve Circuit Operation

Bucket And Auxiliary Work Circuits Operation

Boom Raise Work Circuit Operation

Boom Lower Work Circuit Operation

Arm In Work Circuit Operation

Arm Out Work Circuit Operation

Swing Work Circuit Operation

Combined Functions Operation

Swing Motor Operation

Swing Cross-Over Relief Valves And Make-Up Valves Operation

Brake Release Circuit Operation

Swing Gearbox Operation

Cylinder Operation

Main Hydraulic Pump Operation

Regulator Components Operation

High-Low Maximum Displacement Operation

Fuel Saving System Operation

Constant Horsepower System Operation

Group 10: System Operational Checks

Hydraulic Operational Checks

Group 15: Diagnostic Information

Diagnose Hydraulic System Malfunctions

Diagnose Pilot Circuit Malfunctions

Diagnose Dig Circuit Malfunctions

Diagnose Swing Circuit Malfunctions

Hydraulic Circuit Symbols

Pressure And Return Circuits

Boom, Arm, Bucket And Swing Circuits

Pilot Circuit-Controllers To Flow Regulator

Pilot Circuit-Flow Regulator To Main Control Valve Assembly

Pilot Circuit-Swing Motor, Engine Speed, And Pump Displacement Controls

Pilot Control Lever Pattern Information

Group 20: Adjustments

Pilot Shut-Off Valve Linkage Adjustment

Main Hydraulic Pump Displacement Adjustment

Group 25: Tests

Cycle Time Test

JT39000 Tachometer/Temperature Reader Installation

D01084AA Tachometer/Temperature Reader Installation

JT05801 Clamp-On Electronic Tachometer Installation

JT05800 Digital Thermometer Installation

Hydraulic Pump Start-Up Procedure

Pilot System Regulating Valve Test And Adjustment

Pilot Controller Test

System Relief Valve Test And Adjustment

Circuit Relief Valve Test And Adjustment

Swing Motor Crossover Relief Valve Test And Adjustment

Flow Sensing Valve Test And Adjustment

Hydraulic Pump Regulator Test And Adjustment (Engine Pulldown)-490D

Hydraulic Pump Regulator Test And Adjustment (Engine Pulldown)-590D

Hydraulic Pump Flow Test

Pilot Pump Flow Test

Boom, Arm And Bucket Cylinder Drift Test

Swing Motor Leakage Test

Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy

Hydraulic Schematic

Electrical Schematic-490D/590D

John Deere Excavators 490D, 590D Operation and Test Service Manual (TM1389)