John Deere 790E LC Excavator Repair Service Manual (TM1507)

TM1507 - John Deere 790E LC Excavator Technical Manual - Repair.PDF

Complete service repair manual for John Deere 790E LC Excavator, with all the shop information to maintain, diagnostic, repair, service like professional mechanics.

John Deere 790E LC Excavator workshop technical 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.

Total Pages: 783 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
   Tracks
      Track 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 System
   Dampener Drive (Flex Coupling)
      Elements
   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
   Safety And Convenience
      Horn And Warning Devices
   Excavator
      Bucket
      Frames
      Hydraulic System
   Swing Rotation Or Pivoting System
      Mechanical Drive Elements
      Hydraulic System
   Dealer Fabricated Tools
      Dealer Fabricated Tools

tm1507 - 790E-LC Excavator Repair

Table of Contents

Foreword

Section 00: General Information

Group 0001: 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 0002: General Specifications

790E LC General Specifications

790E LC Working Ranges Specifications

790E LC Engine Specifications

790E LC Long Front Specifications

790E LC Drain And Refill Capacities

790E LC Lift Capacity in kg (lb)-1 of 5)

790E LC Lift Capacity in kg (lb)-2 of 5

790E LC Lift Capacity in kg (lb)-3 of 5

790E LC Lift Capacity in kg (lb)-4 of 5

790E LC Lift Capacity in kg (lb)-5 of 5

790E LC Lift Capacity-KG (LB)

Group 0003: 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 0004: Fuels And Lubricants

Fuel Specifications

Fuel Storage

Engine Oil

Hydraulic Oil

Swing Gearbox, Propel Gearbox And Pump Gearbox Oils

Track Roller, Front Idler, And Carrier Roller Oil

Grease

Engine Coolant

Cold Weather Operation

Alternative and Synthetic Lubricants

Lubricant Storage

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

Test Lower Track Roller For Oil Leakage

Measure Upper Track Roller Wear

Remove And Install Upper Track Roller

Disassemble And Assemble Upper Track Roller

Inspect Metal Face Seals

Measure Track Shoe Grouser Wear

Remove And Install Track Shoe

Measure Track Chain Link Wear

Measure Track Chain Bushing Wear

Measure Track Chain Pitch

Remove Track Chain

Install Track Chain

Disassemble And Assemble Track Chain

Disassemble And Assemble Track Chain To Replace Broken Part

Adjust Track Sag

Remove And Install Sprocket

Measure Front Idler Wear

Remove And Install Front Idler

Disassemble Front Idler

Assemble Front Idler

Test Front Idler For Oil Leakage

Remove And Install Track Adjuster Cylinder And Recoil Spring

Disassemble And Assemble Track Adjuster Recoil Spring

Disassemble And Assemble Track Adjuster Cylinder

Section 02: Axles And Suspension Systems

Group 0250: Axle Shaft, Bearings, And Reduction Gears

Service Equipment And Tools

Other Material

Specifications

Towing Machine

Remove And Install Propel Gearbox

Disassemble Propel Gearbox

Inspect Metal Face Seals

Disassemble And Assemble First And Second Planet Carriers

Disassemble And Assemble Third Planet Carrier

Assemble Propel Gearbox

Group 0260: Hydraulic System

Special Or Essential Tools

Service Equipment And Tools

Other Material

Specifications

Remove And Install Propel Motor And Brake

Propel Motor Start-Up Procedure

Disassemble Propel Motor And Brake

Assemble Propel Motor And Brake

Disassemble And Assemble Propel Motor Brake Valve Housing

Remove And Install Rotary Manifold

Disassemble And Assemble Rotary Manifold

Rotary Manifold Air Test

Section 04: Engine

Group 0400: Removal And Installation

6068 John Deere Engine-Use CTM8

Special Or Essential Tools

Service Equipment And Tools

Other Material

Specifications

Remove Engine

Install Engine

Remove And Install Oil Pan

Removing DB4 Fuel Injection Pump

Installing DB4 Fuel Injection Pump

Bleed Fuel System

Measure And Adjust Engine Valve Lash (Clearance)

Remove And Install Starter

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

Remove And Install Fan, Shroud, And Guards

Remove And Install Radiator

Remove And Install Fan Belt

Group 0515: Speed Controls

Other Material

Specifications

Remove And Install Engine Speed Control Linkage

Engine Speed And Control Linkage Adjustment

Remove And Install Engine Control (EC) Motor And Sensor

Disassemble And Assemble Engine Control (EC) Motor And Sensor

Group 0520: Intake System

Special Or Essential Tools

Service Equipment And Tools

Specifications

Remove And Install Air Cleaner

Air Intake System Leakage Test

Group 0560: External Fuel Supply System

Other Material

Specifications

Remove And Install Fuel Tank

Remove And Install Water Separator Filter

Disassemble And Assemble Water Separator Filter

Section 07: Dampener Drive (Flex Coupling)

Group 0752: Elements

Other Material

Specifications

Remove And Install Dampener Drive (Flex Coupling)

Section 16: Electrical System

Group 1671: Batteries, Support, And Cables

Service Equipment And Tools

Specifications

Handle Batteries Safely

Procedure For Testing Batteries

Checking Electrolyte Specific Gravity

Check Battery Electrolyte Level And Terminals

Using Booster Batteries-24-Volt System

Charge Battery

Remove And Install Batteries

Adding 12-Volt Accessories

Group 1672: Alternator, Regulator, And Charging System Wiring

Alternators And Starting Motors-Use CTM77

Specifications

Remove And Install Alternator

Group 1674: Wiring Harness And Switches

Special Or Essential Tools

Front Chassis Electrical Component Identification

Cab Electrical Component Identification

Hydraulic Electrical Component Identification

Engine Electrical Component Identification

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

Disconnecting Spring Wire Retainer Connectors

Disconnecting Tab Retainer Connectors

Replacing Fuses

Fuse (Blade-Type) Color Codes

Remove And Install Cab Ground Straps

Remove And Install Starter Switch

Remove And Install Dome Light Switch

Remove And Install Propel Alarm Cancel Switch And Start Aid Switch

Replace Deutsch Deutsch is a trademark of Deutsch Company Connectors

Install Deutsch DEUTSCH is a trademark of the Deutsch Co. Contact

Replace Weather Pack Weather Pack is a trademark of Packard Electric. Connector

Install Weather Pack WEATHER PACK is a trademark of Packard Electric. Contact

Remove Connector Body From Blade Terminals

Group 1675: System Controls

Welding On Machine

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

Remove And Install Engine Controller (EC), And Pump And Valve Controller (PVC)

Remove And Install Monitor Controller

Group 1676: Instruments And Indicators

Replace Monitor Panel Bulbs

Remove And Install Monitor Panel

Remove And Install Switch Panel 1

Remove And Install Hour Meter, Coolant Temperature And Fuel Level Gauges

Replace Switch Panel 2 Bulb

Remove And Install Switch Panel 2

Section 17: Frame Or Supporting Structure

Group 1740: Frame Installation

Specifications

Welding On Machine

Welding Repair Of Major Structure

Group 1749: Chassis Weights

Service Equipment And Tools

Specifications

Remove And Install Counterweight

Section 18: Operator’s Station

Group 1800: Removal And Installation

Specifications

Remove And Install Cab

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

Group 1821: Seat And Seat Belt

Specifications

Remove And Install Seat

Disassemble And Assemble Seat (Early Machine)

Disassemble And Assemble Seat (S.N. 538405-)

Disassemble And Assemble Seat Stand (Early Machine)

Disassemble And Assemble Seat Stand (S.N. 538405-)

Group 1830: Heating And Air Conditioning

Remove And Install Blower Motor

Remove And Install Heater Core And Blower Motor Relay

Section 20: Safety And Convenience

Group 2004: Horn And Warning Devices

Remove And Install Travel Alarm

Changing Travel Alarm Volume

Section 33: Excavator

Group 3302: Bucket

Specifications

Replacing Bucket Teeth

Replacing Bucket Tooth Tip-Heavy-Duty Bucket

Remove And Install Tooth Shank

Remove And Install Bucket And Linkage

Adjust Bucket Linkage

Welding On Machine

Replace Welded Bucket Cutting Edges

Repair Cracked Cutting Edge

Group 3340: Frames

Service Equipment And Tools

Specifications

Remove And Install Arm

Remove And Install Boom

Inspect Arm And Boom Pins And Bushings

Remove And Install Bushings And Seals

Group 3360: Hydraulic System

Special Or Essential Tools

Service Equipment And Tools

Other Material

Specifications

Control Lever Pattern Conversion

Release Pressure In Hydraulic System

Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy

Remove And Install Hydraulic Pump

Hydraulic Pump Start-Up Procedure

Disassemble Hydraulic Pump (S.N. -014999)

Assemble Hydraulic Pump (S.N. -014999)

Disassemble Hydraulic Pump (S.N. 015000-)

Assemble Hydraulic Pump (S.N. 015000-)

Remove And Install Hydraulic Pump Displacement Solenoid Valve

Remove And Install Engine Speed Sensor

Remove And Install Hydraulic Pump Angle Sensor

Hydraulic Pump Angle Sensor (A Sensor) Adjustment

Remove And Install Pilot Pump (S.N. -014999)

Remove And Install Pilot Pump (S.N. 015000-)

Disassemble And Assemble Pilot Pump

Remove And Install Pilot Filter

Hydraulic Oil Filter Inspection Procedure

Remove And Install Proportional Solenoid Valve

Disassemble And Assemble Proportional Solenoid Valve

Remove And Install Pilot Pressure Regulating Valve

Remove And Install Pilot Pressure Reducing Valve

Remove And Install Pilot Shut-Off Valve

Disassemble And Assemble Pilot Shut-Off Valve

Pilot Shut-Off Valve Linkage Adjustment

Remove And Install Dig Function Pilot Controller

Disassemble And Assemble Dig Function Pilot Controller

Remove And Install Dig Function Pilot Controller Check Valve

Disassemble And Assemble Dig Function Pilot Controller Check Valve

Remove And Install Dig Function Pilot Flow Regulator Valve

Disassemble And Assemble Dig Function Pilot Flow Regulator Valve (S.N. -010025)

Disassemble And Assemble Dig Function Pilot Flow Regulator Valve (S.N. 010026-014999)

Disassemble And Assemble Dig Function Pilot Flow Regulator Valve (S.N. 015000-)

Remove And Install Propel Pilot Controller

Disassemble And Assemble Propel Pilot Controller

Remove And Install Propel Pilot Check Valve Block (S.N. -014999)

Disassemble And Assemble Propel Pilot Check Valve Block (S.N. -014999)

Remove And Install Propel Pilot Function Flow Regulator Valve

Disassemble And Assemble Propel Pilot Function Flow Regulator Valve (S.N. -014999)

Disassemble And Assemble Propel Pilot Function Flow Regulator Valve (S.N. 015000-)

Remove And Install Main Control Valve

Disassemble And Assemble Main Control Valve

Remove And Install Differential Pressure Sensor

Remove And Install Surge Relief Valve

Remove And Install System Relief Valve

Disassemble And Assemble System Relief Valve (S.N. -014999)

Disassemble And Assemble System Relief Valve (S.N. 015000-)

Remove And Install Unloading Valve

Remove And Install Circuit Relief And Anti-Cavitation Valve

Disassemble And Assemble Circuit Relief And Anti-Cavitation Valve

Remove And Install Regenerative Valve

Remove And Install Variable Pressure Compensator Valve

Remove And Install Anti-Drift Valve

Remove And Install Shuttle Valve

Remove And Install Arm In Pressure Sensor (S.N. 015000-)

Remove And Install Boom Cylinder

Remove And Install Arm Cylinder

Remove And Install Bucket Cylinder

Hydraulic Cylinder Bleed Procedure

Disassemble Bucket, Arm, Or Boom Cylinder

Assemble Bucket, Arm, Or Boom Cylinder

Remove And Install Hydraulic Oil Cooler

Remove And Install Hydraulic Oil Cooler Bypass Valve

Remove And Install Swing Make-Up Restriction Valve

Remove And Install Return Filter And Bypass Valve

Remove And Install Reservoir

Disassemble And Assemble Reservoir

Section 43: Swing Rotation Or Pivoting System

Group 4350: Mechanical Drive Elements

Service Equipment And Tools

Other Material

Specifications

Remove And Install Swing Gearbox

Swing Gearbox Start-Up Procedure

Disassemble And Assemble Swing Gearbox

Remove Upperstructure

Install Upperstructure

Remove And Install Swing Bearing

Disassemble And Assemble Swing Bearing

Install Swing Bearing Upper Seal

Install Swing Bearing Lower Seal

Group 4360: Hydraulic System

Specifications

Remove And Install Swing Motor And Brake

Swing Motor Start-Up Procedure

Disassemble Swing Motor And Brake

Assemble Swing Motor And Brake

Disassemble And Assemble Swing Motor Make-Up And Crossover Relief Valves

Remove And Install Swing Stop Cushion Valve

Disassemble And Assemble Swing Stop Cushion Valve

Disassemble And Assemble Swing Brake Release Solenoid Valve

Section 99: Dealer Fabricated Tools

Group 9900: Dealer Fabricated Tools

ST4920 Track Recoil Spring Disassembly And Assembly Tool

DFT1087 Track Recoil Spring Disassembly And Assembly Guard Tool

DFT1110 Spacer

DF1036A Propel Gearbox Nut Wrench

DFT1109 Holding Bar

Rotary Manifold Lifting Tool

DFT1089 Barrel Support

DFT1114 Guide Pin

DFT1119 Pump Support