Complete service repair manual for John Deere 490E Excavator, with all the service information to maintain, repair, and rebuild like professional mechanics.

John Deere 490E 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.

TM1505 - John Deere 490E Excavator Technical Manual - Repair.PDF
ctm104 English - 4.5L AND 6.8L DIESEL ENGINES (BASE ENGINE) -: (WORLDWIDE EDITION) CTM
CTM8 English - Series 300 3029 (S.N. -499999), 4039, 4045, 6059 and 6068 Diesel Engines CTM

PRODUCT DETAILS:
Total Pages: 664 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

TABLE OF CONTENTS
Section 00: General Information...14
  Group 0001: Safety...14
    Follow Safe Procedures...17
    Prepare for Emergencies...18
    Prevent Acid Burns...19
    Handle Chemical Products Safely...21
    Handle Fluids Safely-Avoid Fires...22
    Avoid High-Pressure Fluids...23
    Warn Others of Service Work...24
    Support Machine Properly...25
    Operate Only from Operator's Seat...26
    Park Machine Safely...27
    Stay Clear of Moving Parts...28
    Avoid Power Lines...29
    Use Handholds and Steps...30
    Keep Riders Off Machine...31
    Move and Operate Machine Safely...32
    Wear Protective Clothing...33
    Protect Against Flying Debris...34
    Protect Against Noise...35
    Illuminate Work Area Safely...36
    Service Machines Safely...37
    Remove Paint Before Welding or Heating...38
    Avoid Heating Near Pressurized Fluid Lines...39
    Beware of Exhaust Fumes...40
    Use Proper Lifting Equipment...41
    Service Cooling System Safely...42
    Dispose of Waste Properly...43
    Work in a Clean Area...44
    Use Tools Properly...45
    Replace Safety Signs...46
    Live With Safety...47
  Group 0002: General Specifications...670
    490E...15
    490E Drain And Refill Capacities...15
  Group 0003: Torque Values...15
    Unified Inch Bolt and Cap Screw Torque Values...54
    Metric Bolt and Cap Screw Torque Values...55
    Additional Metric Cap Screw Torque Values...56
    Service Recommendations for O-Ring Boss Fittings...58
    Service Recommendations for Flat Face O-Ring Seal Fittings...60
    Service Recommendations for 37° Flare and 30° Cone Seat Connectors...62
    Service Recommendations For Flared Connections-Straight or Tapered Threads...64
    Service Recommendations For Inch Series Four Bolt Flange Fittings...66
    Service Recommendations for Metric Series Four Bolt Flange Fitting...68
  Group 0004: Fuels and Lubricants...15
    Fuel Specifications...670
    Engine Oil...72
    Hydraulic Oil...74
    Swing Gearbox, Propel Gearbox and Pump Gearbox Oils...75
    Track Roller, Front Idler, And Carrier Roller Oil...76
    Track Adjuster, Working Tool Pivot, Swing Bearing, And Swing Bearing Gear Grease...77
Section 01: Tracks...78
  Group 0130: Track System...78
    Service Equipment and Tools...634
    Other Material...635
    Specifications...670
    Measure Lower Track Roller Wear...83
    Remove and Install Lower Track Roller...84
    Disassemble and Assemble Lower Track Roller...86
    Test Lower Track Roller for Oil Leakage...89
    Measure Upper Track Roller Wear...90
    Remove and Install Upper Track Roller...91
    Disassemble and Assemble Upper Track Roller...93
    Inspect Metal Face Seals...153
    Measure Track Shoe Grouser Wear...98
    Remove and Install Track Shoe...99
    Measure Track Chain Link Wear...101
    Measure Track Chain Bushing Wear...102
    Measure Track Chain Pitch...103
    Remove Track Chain...104
    Install Track Chain...107
    Disassemble and Assemble Track Chain...110
    Disassemble and Assemble Track Chain to Replace Broken Part...112
    Adjust Track Sag...115
    Remove and Install Sprocket...117
    Measure Front Idler Wear...119
    Remove and Install Front Idler...120
    Disassemble Front Idler...121
    Assemble Front Idler...123
    Test Front Idler for Oil Leakage...125
    Remove and Install Track Adjuster Cylinder and Recoil Spring...127
    Disassemble and Assemble Track Adjuster Recoil Spring...130
    Disassemble and Assemble Track Adjuster Cylinder...135
Section 02: Axles and Suspension Systems...138
  Group 0250: Axle Shaft, Bearings, and Reduction Gears...138
    Service Equipment and Tools...634
    Other Material...635
    Specifications...670
    Towing Machine...143
    Remove and Install Propel Gearbox...145
    Disassemble Propel Gearbox...148
    Inspect Metal Face Seals...153
    Disassemble and Assemble First Planet Carrier...155
    Disassemble and Assemble Second Planet Carrier...156
    Assemble Propel Gearbox...157
  Group 0260: Hydraulic System...138
    Service Equipment and Tools...634
    Other Material...635
    Specifications...670
    Remove and Install Propel Motor and Brake...166
    Propel Motor Start-Up Procedure...169
    Disassemble Propel Motor and Brake...170
    Assemble Propel Motor and Brake...174
    Disassemble and Assemble Propel Motor Brake Valve Housing...179
    Remove and Install Rotary Manifold...190
    Disassemble and Assemble Rotary Manifold...194
    Rotary Manifold Air Test...197
Section 04: Engine...198
  Group 0400: Removal and Installation...198
    4045 John Deere Engine-Use CTM8...198
    Special or Essential Tools...459
    Service Equipment and Tools...634
    Other Material...635
    Specifications...670
    Remove Engine...206
    Install Engine...211
    Remove and Install Oil Pan...216
    Removing DB4 Fuel Injection Pump...219
    Installing DB4 Fuel Injection Pump...223
    JT07158 TIME TRAC TIME TRAC is a registered trademark of the Stanadyne Automotive Corp. Installation...198
    Bleed Fuel System...229
    Adjust Engine Valve Lash (Clearance)...230
    Remove and Install Starter...233
Section 05: Engine Auxiliary Systems...235
  Group 0505: Cold Weather Starting Aids...235
    Other Material...635
    Specifications...670
    Remove and Install Starting Aid Solenoid and Nozzle...239
    Remove and Install Engine Coolant Heater...241
  Group 0510: Cooling System...235
    Specifications...670
    Remove and Install Fan, Shroud, and Guards...245
    Remove and Install Radiator...247
    Remove and Install Fan Belt...250
  Group 0515: Speed Controls...235
    Service Equipment and Tools...634
    Other Material...635
    Specifications...670
    Remove and Install Engine Speed and Control Linkage...255
    Engine Speed and Control Linkage Adjustment...257
    Remove and Install Engine Control (EC) Motor and Sensor...260
    Disassemble and Assemble Engine Control (EC) Motor and Sensor...262
  Group 0520: Intake System...235
    Special or Essential Tools...459
    Service Equipment and Tools...634
    Specifications...670
    Remove and Install Air Cleaner...269
    Air Intake System Leakage Test...270
  Group 0560: External Fuel Supply Systems...235
    Other Material...635
    Specifications...670
    Remove and Install Fuel Tank...274
    Remove and Install Water Separator Filter...276
    Disassemble and Assemble Water Separator Filter...277
Section 07: Dampener Drive (Flex Coupling)...279
  Group 0752: Elements...279
    Specifications...670
    Remove and Install Dampener Drive (Flex Coupling)...282
Section 16: Electrical System...287
  Group 1671: Batteries, Support, and Cables...287
    Service Equipment and Tools...634
    Specifications...670
    Handle Batteries Safely...292
    Procedure for Testing Batteries...293
    Checking Electrolyte Specific Gravity...294
    Check Battery Electrolyte Level and Terminals...297
    Using Booster Batteries-24-Volt System...300
    Charge Battery...302
    Batteries Remove and Install...305
    Adding 12-Volt Accessories...307
  Group 1672: Alternator, Regulator, and Charging System Wiring...287
    Alternators and Starting Motors-Use CTM77...309
    Specifications...670
    Remove and Install Alternator...311
  Group 1674: Wiring Harness and Switches...287
    Special or Essential Tools...459
    Front Chassis Electrical Component Identification...315
    Cab Electrical Component Identification...317
    Hydraulic Electrical Component Identification...320
    Engine Electrical Component Identification...322
    Connecting Engine Controller (EC) and Pump and Valve Controller (PVC) Harness Connector...352
    Disconnecting Spring Wire Retainer Connectors...325
    Disconnecting Tab Retainer Connectors...326
    Replacing Fuses...327
    Fuse (Blade-Type) Color Codes...330
    Remove and Install Cab Ground Straps...331
    Remove and Install Starter Switch...332
    Remove and Install Dome Light Switch...334
    Remove and Install Propel Alarm Cancel Switch and Start Aid Switch...335
    Replace DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Connectors...287
    Install DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Contact...288
    Replace WEATHER PACK WEATHER PACK is a trademark of Packard Electric Connector...288
    Install WEATHER PACK WEATHER PACK is a trademark of Packard Electric Contact...288
    Remove Connector Body From Blade Terminals...345
  Group 1675: System Controls...288
    Welding on Machine...435
    Connecting Engine Controller (EC) and Pump and Valve Controller (PVC) Harness Connector...352
    Remove and Install Pump and Valve Controller (PVC)...353
    Remove and Install Monitor Controller...355
  Group 1676: Instruments and Indicators...288
    Replace Monitor Panel Bulbs...357
    Remove and Install Monitor Panel...358
    Remove and Install Switch Panel 1...360
    Remove and Install Hour Meter, Coolant Temperature and Fuel Level Gauges...361
    Replace Switch Panel 2 Bulb...363
    Remove and Install Switch Panel 2...364
Section 17: Frame or Supporting Structure...366
  Group 1740: Frame Installation...366
    Specifications...670
    Welding on Machine...435
    Welding Repair of Major Structure...372
  Group 1749: Chassis Weights...366
    Service Equipment and Tools...634
    Specifications...670
    Remove and Install Counterweight...377
Section 18: Operator's Station...379
  Group 1800: Removal and Installation...379
    Specifications...670
    Remove and Install Cab...382
  Group 1810: Operator Enclosure...379
    Service Equipment and Tools...634
    Other Material...635
    Remove and Install Windowpane and Two Piece Molding...390
    Remove and Install Windowpane and One Piece Molding...392
    Remove and Install Sliding Windows...393
    Windowpane Dimensions...395
  Group 1821: Seat and Seat Belt...379
    Specifications...670
    Remove and Install Seat...399
    Disassemble and Assemble Seat (Early Machine)...401
    Disassemble and Assemble Seat Stand (Early Machine)...403
  Group 1830: Heating and Air Conditioning...379
    Remove and Install Blower Motor...408
    Remove and Install Heater Core and Blower Motor Relay...410
Section 20: Safety and Convenience...411
  Group 2004: Horn and Warning Devices...411
    Remove and Install Travel Alarm...413
    Changing Travel Alarm Volume...414
Section 33: Excavator...416
  Group 3302: Bucket...416
    Specifications...670
    Replacing Bucket Teeth...421
    Replacing Bucket Tooth Tip-Heavy-Duty Bucket...423
    Remove and Install Tooth Shank...425
    Remove and Install Bucket and Linkage...428
    Adjust Bucket Linkage...433
    Welding on Machine...435
    Replace Welded Bucket Cutting Edges...437
    Repair Cracked Cutting Edge...438
  Group 3340: Frames...416
    Service Equipment and Tools...634
    Specifications...670
    Remove and Install Arm...443
    Remove and Install Boom...449
    Inspect Arm and Boom Pins and Bushings...454
    Remove and Install Bushings and Seals...456
  Group 3360: Hydraulic System...416
    Special or Essential Tools...459
    Service Equipment and Tools...634
    Other Material...635
    Specifications...670
    Hydraulic Cylinder Bleed Procedure...597
    Release Pressure in Hydraulic System...466
    Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy...468
    Remove and Install Hydraulic Pump...470
    Hydraulic Pump Start-Up Procedure...474
    Disassemble Hydraulic Pump...475
    Assemble Hydraulic Pump...482
    Remove and Install Hydraulic Pump Displacement Solenoid Valve...496
    Remove and Install Engine Speed Sensor (S.N. -024999)...498
    Remove and Install Engine Speed Sensor (S.N. 025000-)...499
    Remove and Install Hydraulic Pump Angle Sensor (A Sensor)...500
    Hydraulic Pump Angle Sensor (A Sensor) Adjustment...503
    Remove and Install Pilot Pump (S.N. -024999)...505
    Remove and Install Pilot Pump (S.N. 025000-)...506
    Disassemble and Assemble Pilot Pump...508
    Remove and Install Pilot Filter...512
    Hydraulic Oil Filter Inspection Procedure...514
    Remove and Install Proportional Solenoid Valve...515
    Disassemble and Assemble Proportional Solenoid Valve...518
    Remove and Install Pilot Pressure Regulating Valve...522
    Remove and Install Pilot Pressure Reducing Valve...523
    Remove and Install Pilot Shut-Off Valve...524
    Disassemble and Assemble Pilot Shut-Off Valve...526
    Pilot Shut-Off Valve Linkage Adjustment...528
    Remove and Install Dig Function Pilot Controller...530
    Disassemble and Assemble Dig Function Pilot Controller...534
    Remove and Install Dig Function Pilot Controller Check Valve...537
    Disassemble and Assemble Dig Function Pilot Controller Check Valve...539
    Remove and Install Dig Function Pilot Flow Regulator Valve...540
    Disassemble and Assemble Dig Function Pilot Flow Regulator Valve...542
    Remove and Install Propel Pilot Controller...544
    Disassemble and Assemble Propel Pilot Controller...546
    Remove and Install Propel Pilot Check Valve Block...550
    Disassemble and Assemble Propel Pilot Check Valve Block...552
    Remove and Install Main Control Valve...553
    Disassemble and Assemble Main Control Valve...558
    Remove and Install Differential Pressure Sensor...572
    Remove and Install Surge Relief Valve (S.N. -024999) System Relief Valve (S.N. 025000-)...573
    Disassemble and Assemble Surge Relief Valve (S.N. -024999) System Relief Valve (S.N. 025000-)...574
    Remove and Install System Relief Valve and Unloading Valve (S.N. -024999)...576
    Disassemble and Assemble System Relief Valve and Unloading Valve (S.N. -024999)...577
    Remove and Install Circuit Relief and Anti-Cavitation Valve...579
    Disassemble and Assemble Circuit Relief and Anti-Cavitation Valve...580
    Remove and Install Variable Pressure Compensator Valve...583
    Disassemble and Assemble Variable Pressure Compensator Valve...585
    Remove and Install Holding Valve...586
    Remove and Install Shuttle Valve...587
    Remove and Install Arm in Pressure Sensor (S.N. 025000-)...589
    Remove and Install Boom Cylinder...590
    Remove and Install Arm Cylinder...593
    Remove and Install Bucket Cylinder...595
    Hydraulic Cylinder Bleed Procedure...597
    Disassemble Bucket, Arm, or Boom Cylinder...598
    Assemble Bucket, Arm, or Boom Cylinder...604
    Remove and Install Hydraulic Oil Cooler...618
    Remove and Install Hydraulic Oil Cooler Bypass Valve...621
    Remove and Install Swing Make-Up Restriction Valve...623
    Remove and Install Return Filter and Bypass Valve...625
    Remove and Install Reservoir...627
    Disassemble and Assemble Reservoir...630
Section 43: Swing Rotation or Pivoting System...632
  Group 4350: Mechanical Drive Elements...632
    Service Equipment and Tools...634
    Other Material...635
    Specifications...670
    Remove and Install Swing Gearbox...637
    Swing Gearbox Start-Up Procedure...639
    Disassemble and Assemble Swing Gearbox...640
    Remove Upperstructure...649
    Install Upperstructure...657
    Remove and Install Swing Bearing...661
    Disassemble and Assemble Swing Bearing...663
    Install Swing Bearing Upper Seal...667
    Install Swing Bearing Lower Seal...668
  Group 4360: Hydraulic System...632
    Specifications...670
    Remove and Install Swing Motor and Brake...671
    Swing Motor Start-Up Procedure...673
    Disassemble Swing Motor and Brake...674
    Assemble Swing Motor and Brake...679
    Disassemble and Assemble Swing Motor Valve Housing and Cover...684
    Disassemble and Assemble Swing Relief Valve...686
    Remove and Install Swing Stop Cushion Valve...689
    Disassemble and Assemble Swing Stop Cushion Valve...691
    Disassemble and Assemble Swing Brake Release Solenoid Valve...696
Section 99: Dealer Fabricated Tools...698
  Group 9900: Dealer Fabricated Tools...698
    ST4920 Track Recoil Spring Disassembly and Assembly Tool...704
    DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool...709
    DFT1112 Spacer...710
    DF1036A Propel Gearbox Nut Wrench...711
    DFT1109 Holding Bar...712
    Rotary Manifold Lifting Tool...713
    DFT1089 Barrel Support...714
    DFT1113 Guide Pin...716
    DFT1119 Pump Support...717

John Deere 490E Excavator Service Repair Manual (TM1505)