Complete service repair manual for John Deere 790D, 790D-LC, 892D-LC Excavator, with all the shop information to maintain, repair, and rebuild like professional mechanics.

John Deere 790D, 790D-LC, 892D-LC Excavator 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.

TM1396 - John Deere 790D, 790D-LC, 892D-LC Excavator Technical Manual - Repair.PDF
TM1396 - John Deere 790D, 790D-LC, 892D-LC Excavator Technical Manual - Repair.EPUB

Total Pages: 653 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English

MAIN SECTIONS
   Foreword
   Tracks
      Track System
   Axles And Suspension Systems (PROPEL)
      Axle Shaft, Bearings, And Reduction Gears
      Hydraulic System
   Engine
      Removal And Installation
   Engine Auxiliary System
      Cold Weather Starting Aids
      Cooling System
      Speed Controls
      Intake System
      External Fuel Supply Systems
   Dampener Drive (Flex Coupling)
      Elements
   Splitter Drive
      Gears, Shafts And Bearings
   Electrical System
      Batteries, Support, And Cables
      Alternator, Regulator And Charging System Wiring
      Wiring Harness And Switches
      Motors And Actuators
   Frame, Chassis Or Supporting Structure
      Frame Installation
      Chassis Weights
   Operator’s Station
      Removal And Installation
      Operator Enclosure
      Seat And Seat Belt
      Heater And Air Conditioning
   Sheet Metal And Styling
      Hood Or Engine Enclosure
   Excavator
      Buckets
      Frames
      Hydraulic System
   Swing Rotation Or Pivoting System
      Mechanical Drive Elements
      Hydraulic System
   Dealer Fabricated Tools

tm1396 - 790D, 790D-LC, and 892D-LC Excavator Repair

Table of Contents

Foreword

Section 01: Tracks

Group 0130: Track System

Service Equipment And Tools

Other Material

Specifications

Measure Track Lower Roller Wear

Remove And Install Lower Track Roller

Disassemble Lower Track Roller

Inspect Metal Face Seals

Assemble Lower Track Roller

Measure Upper Track Roller Wear

Remove And Install Upper Track Roller

Disassemble Upper Track Roller

Inspect Metal Face Seals

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 Materials

Towing The Excavator

Remove And Install Propel Gearbox

Disassemble Propel Gearbox

Assemble Propel Gearbox

Group 0260: Hydraulic System

Essential Tools

Service Equipment And Tools

Other Material

Remove And Install Propel Motor

Disassemble Propel Motor

Inspect Propel Motor

Assemble Propel Motor

Adjust Rotor Drive Shaft Rolling Drag Torque

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

Essential Tools

Other Material

Specifications

Avoid High-Pressure Fluids

Remove And Install Engine

Remove And Install Oil Pan

Remove Fuel Injection Pump

Install Fuel Injection Pump

Remove And Install Fuel Filter Check Valve Assembly

Remove Fuel Injection Nozzles

Inspect And Clean Cylinder Head Nozzle Bore

Inspect And Clean Nozzle Seating Surface

Install Fuel Injection Nozzles

Bleed Fuel System

Remove Turbocharger

Install Turbocharger

Remove And Install Water Pump

Section 05: Engine Auxiliary System

Group 0505: Cold Weather Starting Aids

Specifications

Remove And Install Starting Aid Solenoid And Nozzle

Remove And Install Engine Coolant Heater

Group 0510: Cooling System

Specifications

Remove And Install Fan

Remove And Install Fan Belts

Fan Belt Tension Adjustment

Remove And Install Radiator

Repair Radiator

Group 0515: Speed Controls

Other Material

Specifications

Remove And Install Speed Control Assembly

Engine Speed Control Linkage Adjustment

Fuel Shut-Off Cable Adjustment

Group 0520: Intake System

Service Equipment And Tools

Specifications

Air Intake System Leakage Test

Remove And Install Air Cleaner

Group 0560: External Fuel Supply Systems

Remove And Install Fuel Tank

Remove And Install Fuel Filter Check Valve Assembly

Section 07: Dampener Drive (Flex Coupling)

Group 0752: Elements

Specifications

Disassemble And Assemble Flex Coupling

Section 08: Splitter Drive

Group 0851: Gears, Shafts And Bearings

Service Equipment And Tools

Other Materials

Remove And Install Splitter Housing

Disassemble Splitter Housing

Assemble Splitter Housing

Section 16: Electrical System

Group 1671: Batteries, Support, And Cables

Specifications

Handle Batteries Safely

Procedure For Testing Batteries

Check Battery Electrolyte Level And Terminals

Using Booster Batteries -24-Volt System

Charge Battery

Remove And Install Batteries

Group 1672: Alternator, Regulator And Charging System Wiring

Service Equipment And Tools

Other Material

Specifications

Disassemble Alternator And Test Components-Motorola

Assemble Alternator-Motorola

Group 1674: Wiring Harness And Switches

Remove And Install Control Panel Switches

Remove And Install Dome Light Switch

Remove And Install Engine Overheat Alarm Switch

Remove And Install Buzzer Stop Switch

Remove And Install Dig Function Pressure Switch

Remove And Install Propel Function Pressure Switch

Remove And Install Engine Hourmeter Switch

Remove And Install Air Cleaner Restriction Indicator Switch

Remove And Install Battery Relay

Remove And Install Relay Starter Solenoid

Group 1677: Motors And Actuators

John Deere Starting Motor Repair CTM-11

Service Equipment And Tools

Specifications

John Deere Starting Motor Repair-Use CTM-11

Remove And Install Starting Motor

Section 17: Frame, Chassis 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

Windowpanes Dimensions

Remove And Install Windowpane And Two Piece Molding

Remove And Install Windowpane And One Piece Molding

Remove And Install Right Upper Windows

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: Heater And Air Conditioning

Essential Tools

Service Equipment And Tools

Specifications

Other Material

Refrigerant (R-12) Cautions

Remove And Install D18018KD Air Conditioning Gauge Set

Discharge The System

Purge The System

Evacuate The System

Charge The System

Flush The System

Check And Add Compressor Oil

Remove And Install Compressor And High Pressure Switch

Volumetric Efficiency Test

Shaft Seal Leak Test

Disassemble And Inspect Compressor

Clutch Pulley, Bearing And Hub Inspection

Replacing Clutch Pulley Bearing

Replace Shaft Seal Seat

Assemble Compressor

Remove And Install Condenser

Remove And Install Evaporator And Expansion Valve

Expansion Valve Bench Test And Adjustment

Remove And Install Receiver/Dryer And Low Pressure Switch

Remove And Install Air Conditioning Switches And Resistor

Thermostat Switch Bench Test

Remove And Install 13,500 BTU Heater

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

Disassemble And Assemble Blower Motor

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

Remove And Install Hood

Adjust Hood

Remove And Install Right Hand Service Door

Remove And Install Top Cover

Remove And Install Left Hand Service Door

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 System

Essential Tools

Service Equipment And Tools

Other Material

Specifications

Hydraulic Cylinder Bleed Procedure

Release Pressure In Hydraulic System Using Air Pressure

Remove And Install Hydraulic Pump

Disassemble Hydraulic Pump

Inspect Hydraulic Pump

Assemble Hydraulic Pump

Hydraulic Pump Start-Up Procedure

Remove And Install Main Hydraulic Pump Regulator

Disassemble Main Hydraulic Pump Regulator

Assemble Main Hydraulic Pump Regulator

Remove And Install Pilot Pump

Disassemble Pilot Pump

Inspect Pilot Pump

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 Control Cylinders

Disassemble And Assemble Engine Speed Control Cylinders

Remove Relief Valves To Disassemble Hydraulic Control Valve-790D

Remove Relief Valves To Disassemble Hydraulic Control Valve-892D-LC

Disassemble Hydraulic Control Valve

Assemble Hydraulic Control Valve

Install Relief Valves To Assemble Hydraulic Control Valve-790D

Install Relief Valves To Assemble Hydraulic Control Valve-892D-LC

Remove And Install Reservoir

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

Repair 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 Propel Function Pilot Controller 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

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 Rotation Or Pivoting System

Group 4350: Mechanical Drive Elements

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 Upper Seal

Install Swing Bearing Lower Seal

Group 4360: Hydraulic System

Service Equipment And Tools

Other Material

Specifications

Remove And Install Swing Motor

Disassemble Swing Motor (Serial No. -007786)

Assemble Swing Motor (Serial No.-007786)

Disassemble And Assemble Swing Motor 790D S.N. (007787-) 892D LC S.N. (005478-)

Inspect 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

DF1036A Propel Gearbox Nut Wrench

DF1037 Hydraulic Pump Torque Adapter

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 790D, 790D-LC, 892D-LC Excavator Service Repair Manual (TM1396)