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

omat126018 English - 490D, 590D EXCAVATOR Operator's Manual

omat126031 French - Excavatrice 490D Excavatrice 590D John Deere

Total Pages: 711 pages
File Format: PDF (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

TABLE OF CONTENTS
Section I: General Information...14
  Group I: Safety...14
    Follow Safe Procedures...18
    Prepare for Emergencies...19
    Prevent Acid Burns...20
    Handle Chemical Products Safely...22
    Handle Fluids Safely-Avoid Fires...23
    Avoid High-Pressure Fluids...24
    Warn Others of Service Work...25
    Support Machine Properly...26
    Operate Only from Operator's Seat...27
    Park Machine Safely...28
    Stay Clear of Moving Parts...29
    Avoid Power Lines...30
    Use Handholds and Steps...31
    Keep Riders Off Machine...32
    Move and Operate Machine Safely...33
    Wear Protective Clothing...34
    Protect Against Flying Debris...35
    Protect Against Noise...36
    Illuminate Work Area Safely...37
    Service Machines Safely...38
    Remove Paint Before Welding or Heating...39
    Avoid Heating Near Pressurized Fluid Lines...40
    Beware of Exhaust Fumes...41
    Use Proper Lifting Equipment...42
    Service Cooling System Safely...43
    Dispose of Waste Properly...44
    Work in a Clean Area...45
    Use Tools Properly...46
    Replace Safety Signs...47
    Live With Safety...48
  Group II: General Specifications...666
    490D Specifications...666
    490D Working Ranges...53
    490D Drain And Refill Capacities...55
    490D...56
    490D Bucket Selection Chart-2.5 M (98 In.) Arm...58
    490D Bucket Selection Chart-3.0 M (118 In.) Arm...59
    490D Bucket Specifications...666
    490D with 2.5 m (8 ft 2 in.) Arm Lift Capacity-Kg (Lb)...61
    490D with 3.0 m (9 ft 10 in.) Arm Lift Capacity-Kg (Lb)...62
    590D Specifications...666
    590D Working Ranges...66
    590D Operating Specifications...666
    590D Drain And Refill Capacities...68
    590D Engine and Hydraulic Specifications...666
    590D Bucket Selection Chart-2.6 M (8 Ft 6 In.) Arm...71
    590D Bucket Selection Chart-3.1 M (10 Ft. 2 In.) Arm...72
    590D Bucket Specifications...666
    590D Lift Capacity-Kg (Lb)...74
    590D Lift Capacity-Kg (Lb)-Continued...76
  Group III: Torque Values...15
    Hardware Torque Specifications...666
    Check Track Shoe Torque...79
    Inch Cap Screw Torque Values...80
    Metric Cap Screw Torque Values...82
    Additional Metric Cap Screw Torque Values...84
    Service Recommendations for O-Ring Boss Fittings...86
    Service Recommendations For Flat Face O-Ring Seal Fittings...88
    Service Recommendations For Flared Connections-Straight or Tapered Threads...90
    SAE Four Bolt Flange Fitting Service Recommendations...92
  Group IV: Fuels And Lubricants...15
    Fuel Specifications...666
    Fuel Storage...96
    Engine Oil...97
    Hydraulic Oil...98
    Swing Gearbox, Propel Gearbox And Pump Gearbox Oils...99
    Track Rollers And Idlers Oil...100
    Swing Gear Grease...102
    Grease...102
    Lubricant Storage...103
    Alternative Lubricants...104
Section 01: Tracks...105
  Group 0130: Track System...105
    Service Equipment And Tools...664
    Other Material...665
    Specifications...666
    Measure Lower Track Roller Wear...110
    Remove And Install Lower Track Roller...111
    Disassemble And Assemble Lower Track Roller...113
    Inspect Metal Face Seals...221
    Measure Upper Track Roller Wear...122
    Remove And Install Upper Track Roller...123
    Assemble Upper Track Roller...126
    Measure Track Shoe Grouser Wear...128
    Remove And Install Track Shoe...129
    Measure Track Link Wear...130
    Measure Track Bushing Wear...131
    Measure Track Pitch...132
    Remove Track Chain...133
    Install Track Chain...135
    Disassemble And Assemble Track Chain...137
    Adjust Track Sag...138
    Measure Sprocket Wear...140
    Remove And Install Sprocket...141
    Measure Front Idler Wear...143
    Remove And Install Front Idler...144
    Disassemble Front Idler...145
    Assemble Front Idler...148
    Remove And Install Track Adjuster...151
    Disassemble Track Adjuster...154
    Assemble Track Adjuster...161
Section 02: Axles And Suspension Systems (Propel)...166
  Group 0250: Axle Shaft, Bearings, And Reduction Gears...166
    Service Equipment And Tools...664
    Other Material...665
    Specifications...666
    Towing The Excavator-490D...171
    Towing The Excavator-590D...174
    Remove And Install Propel Gearbox-490D...178
    Disassemble Propel Gearbox-490D...181
    Assemble Propel Gearbox-490D...191
    Remove And Install Propel Gearbox-590D...201
    Disassemble Propel Gearbox-590D...205
    Assemble Propel Gearbox-590D...214
    Inspect Metal Face Seals...221
  Group 0260: Hydraulic System...166
    Essential Tools...495
    Service Equipment And Tools...664
    Other Material...665
    Specifications...666
    Remove And Install Propel Motor-490D...228
    Disassemble Propel Motor-490D...233
    Inspect Propel Motor-490D...243
    Assemble Propel Motor-490D...247
    Remove And Install Propel Motor-590D...257
    Disassemble Propel Motor-590D...260
    Assemble Propel Motor-590D...269
    Remove And Install Propel Hydraulic Lines...276
    Remove And Install Rotary Manifold...278
    Disassemble And Assemble Rotary Manifold...281
    Rotary Manifold Air Test...283
Section 04: Engine...284
  Group 0400: Removal And Installation...284
    4276 John Deere Engine Repair-Use CTM-4...286
    Essential Tools...495
    Other Material...665
    Specifications...666
    Remove And Install Engine-490D...292
    Remove And Install Engine-590D...297
    Remove And Install Oil Pan...301
    Remove Fuel Injection Pump...302
    Install Fuel Injection Pump...304
    Remove And Install Fuel Injection Nozzles...306
    Bleed Fuel System...309
    Remove And Install Water Pump...311
    Remove And Install Turbocharger-590D...313
Section 05: Engine Auxiliary Systems...315
  Group 0505: Cold Weather Starting Aids...315
    Other Material...665
    Specifications...666
    Remove And Install Starting Aid Solenoid And Nozzle...319
    Remove And Install Engine Coolant Heater...321
  Group 0510: Cooling System...315
    Service Equipment And Tools...664
    Specifications...666
    Remove And Install Fan...326
    Remove And Install Fan Belt...327
    Fan Belt Tension Adjustment...328
    Remove And Install Radiator...329
  Group 0515: Speed Controls...315
    Other Material...665
    Specifications...666
    Remove And Install Speed Control Assembly...333
    Engine Speed Adjustment...334
    Speed Control Linkage Adjustment...337
    Speed Control Lever Tension Adjustment...340
  Group 0520: Intake System...315
    Service Equipment And Tools...664
    Specifications...666
    Remove And Install Air Cleaner-490D...344
    Remove And Install Air Cleaner-590D...345
    Air Intake System Leakage Test...346
  Group 0560: External Fuel Supply Systems...315
    Specifications...666
    Remove And Install Fuel Tank...350
    Remove And Install Fuel Filter...352
Section 07: Dampener Drive (Flex Coupling)...354
  Group 0752: Elements...354
    Other Material...665
    Specifications...666
    Disassemble And Assemble Flex Coupling-490D...358
    Disassemble And Assemble Flex Coupling-590D...361
Section 16: Electrical System...363
  Group 1671: Batteries, Support, And Cables...363
    Specifications...666
    Handle Batteries Safely...366
    Test Batteries Using Coolant And Battery Tester...367
    Test Batteries Using High Rate Discharge Test...368
    Prevent Fire Hazards When Using Booster Batteries...369
    Charge Battery...370
    Remove And Install Batteries...371
  Group 1672: Alternator, Regulator And Charging System Wiring...363
    John Deere Engine Accessories-Alternator Repair-Use CTM-11...373
    Service Equipment And Tools...664
    Specifications...666
    Remove And Install...376
  Group 1674: Wiring Harness And Switches...363
    Remove And Install Dome Light Switch...379
    Remove And Install Control Panel Switches...380
    Remove And Install Relay Starter Solenoid...381
    Remove And Install Engine Hourmeter Switch...382
    Remove And Install Engine Overheat Alarm Switch...383
    Remove And Install Air Cleaner Restriction Indicator...384
    Remove And Install Battery Relay...386
    Remove And Install Battery Relay...386
    Remove And Install Buzzer Stop Switch...387
    Remove And Install Travel Alarm-590D...388
    Changing Travel Alarm Volume...389
  Group 1677: Motors And Actuators...363
    John Deere Starting Motor Repair Use CTM-11...391
    Service Equipment And Tools...664
    Specifications...666
    Remove And Install Starting Motor...394
Section 17: Frame Or Supporting Structure...395
  Group 1740: Frame Installation...395
    Welding Repair Of Major Structure...397
  Group 1749: Chassis Weights...395
    Essential Tools...495
    Specifications...666
    Remove And Install Counterweight...401
Section 18: Operator’s Station...402
  Group 1800: Removal And Installation...402
    Other Material...665
    Specifications...666
    Remove And Install Cab And Cab Floor...406
    Remove And Install Cab (Without Floor)...413
  Group 1810: Operator Enclosure...402
    Service Equipment And Tools...664
    Other Material...665
    Remove And Install Windowpane And Two Piece Molding...418
    Remove And Install Windowpane And One Piece Molding...420
    Remove And Install Sliding Windows...421
    Windowpane Dimensions...423
    Remove And Install Cab Door...424
    Remove And Install Door Latch...425
    Remove And Install Inside Assist Handle...426
    Remove, Disassemble, Assemble, And Install Windshield Wiper...427
    Remove And Install Defroster Fan...428
    Disassemble And Assemble Defroster Fan...429
  Group 1821: Seat And Seat Belt...402
    Disassemble And Assemble Seat...431
  Group 1830: Heating And Air Conditioning...402
    Disassemble And Assemble Blower Motor...433
    Remove And Install 13,500 BTU Heater...434
    Remove And Install 13,500 BTU Cab Heater Lines And Controls...436
    Remove And Install 19,000 BTU Heater...438
    Remove And Install 19,000 BTU Cab Heater Lines And Controls...439
    Remove And Install 40,000 BTU Heater...441
    Remove And Install 40,000 BTU Cab Heater Lines And Controls...442
Section 19: Sheet Metal And Styling...444
  Group 1910: Hood Or Engine Enclosure...444
    Specifications...666
    Remove And Install Hood...447
    Adjust Hood Latch Catch...448
    Remove And Install Service Doors...449
    Remove And Install Top Cover...450
Section 33: Excavator...451
  Group 3302: Buckets...451
    Service Equipment And Tools...664
    Specifications...666
    Remove And Install Bucket And Linkage...458
    Remove And Install Bushings...492
    Inspect Bucket Linkage Pins And Bushings...465
    Adjust Bucket Pivot End Play...466
    Disassemble And Assemble Bucket...467
    Remove And Install Tooth Tip...468
    Remove Tooth Shank...469
    Install Tooth Shank...470
  Group 3340: Frames...451
    Service Equipment And Tools...664
    Other Material...665
    Specifications...666
    Remove Arm...477
    Install Arm...481
    Remove Boom...484
    Install Boom...488
    Inspect Arm And Boom Pins And Bushings...491
    Remove And Install Bushings...492
  Group 3360: Hydraulic Systems...451
    Essential Tools...495
    Service Equipment And Tools...664
    Other Material...665
    Specifications...666
    Hydraulic Cylinder Bleed Procedure...583
    Release Pressure In Hydraulic System...502
    Remove And Install Hydraulic Pump...504
    Hydraulic Pump Start-Up Procedure...506
    Disassemble Hydraulic Pump...507
    Assemble Hydraulic Pump...511
    Remove And Install Hydraulic Pump Regulator...514
    Disassemble Pump Regulator...515
    Assemble Pump Regulator...520
    Remove And Install Pilot Pump...524
    Disassemble And Assemble Pilot Pump...525
    Remove And Install Solenoid Valve And Pilot Pressure Regulating Valve...527
    Disassemble And Assemble Solenoid Valve And Pilot Pressure Regulating Valve...530
    Remove And Install Engine Speed Mode Selection Cylinders...533
    Disassemble And Assemble Engine Speed Mode Selection Cylinders...534
    Remove And Install Hydraulic Control Valve...535
    Disassemble Hydraulic Control Valve...542
    Assemble Hydraulic Control Valve...553
    Remove And Install Reservoir...564
    Remove And Install Return Filter And Suction Filter...569
    Remove And Install Oil Cooler Restriction Valve...572
    Disassemble And Assemble Oil Cooler Restriction Valve...573
    Remove And Install Oil Cooler Bypass Valve...574
    Disassemble And Assemble Oil Cooler Bypass Valve...575
    Remove And Install Oil Cooler...576
    Remove And Install Bucket Cylinder...577
    Remove And Install Arm Cylinder...579
    Remove And Install Boom Cylinder...581
    Hydraulic Cylinder Bleed Procedure...583
    Disassemble Bucket, Arm And Boom Cylinders...584
    Inspection Of Cylinder Rod...589
    Assemble Bucket, Arm, And Boom Cylinders...590
    Inspection Of Cylinder Pins And Bushings...596
    Remove And Install Auxiliary Shut-Off Valve...597
    Disassemble And Assemble Auxiliary Shut-Off Valve...599
    Remove And Install Propel Function Ler Valve...601
    Disassemble Propel Function Pilot Controller Valve...603
    Assemble Propel Function Pilot Controller Valve...606
    Remove And Install Dig Function Pilot Controller Valve...609
    Disassemble Dig Function Pilot Controller Valve...612
    Assemble Dig Function Pilot Controller Valve...615
    Remove And Install Pilot Shut-Off Valve...618
    Pilot Shut-Off Valve Linkage Adjustment...620
    Disassemble And Assemble Pilot Shut-Off Valve...621
    Disassemble And Assemble Pilot Filter...623
    Inspect Pilot Filter Relief Valve...624
    Remove And Install Flow Control Valve...625
    Disassemble And Assemble Flow Control Valve...627
    Remove And Install Check Valve Block...629
    Disassemble And Assemble Check Valve Block...631
Section 43: Swing Or Pivoting System...632
  Group 4350: Mechanical Drive Elements...632
    Service Equipment And Tools...664
    Other Material...665
    Specifications...666
    Remove And Install Swing Gearbox...637
    Disassemble And Assemble Swing Gearbox...639
    Remove And Install Swing Bearing...648
    Disassemble And Assemble Swing Bearing...657
    Install Swing Bearing Seals...662
  Group 4360: Hydraulic System...632
    Service Equipment And Tools...664
    Other Material...665
    Specifications...666
    Remove And Install Swing Motor...667
    Disassemble Swing Motor...669
    Assemble Swing Motor...676
    Disassemble And Assemble Crossover Relief Valves...682
    Remove And Install Make-Up Valves...686
    Disassemble And Assemble Swing Brake Release Valve...687
Section 99: Dealer Fabricated Tools...691
  Group 9900: Dealer Fabricated Tools...691
    DF1036 Propel Gearbox Nut Wrench-490D...693
    DFT1070 Propel Gearbox Nut Wrench-590D...694
    DF1038 Torque Adapter...695
    Rotary Manifold Lifting Tool...696
    ST4920 Track Recoil Spring Disassembly And Assembly Tool...697
    DFT1087 Track Recoil Spring Disassembly And Assembly Guard Tool...701

John Deere 490D and 590D Excavator Repair Technical Manual (TM1390)