Complete Diagnostics, Operation and Test manual with electrical wiring diagrams for John Deere 490E Excavator, with all the service information to maintain, diagnose, and rebuild like professional mechanics.

John Deere 490E Excavator 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.

TM1504 - John Deere 490E Excavator Technical Manual - Operation and Test.PDF

PRODUCT DETAILS:
Total Pages: 860 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
   Operational Checkout
      Operational Checkout Procedure
   Engine
      Theory Of Operation
      System Operational Checks
      Diagnostic Information
      Adjustments
      Tests
   Electrical System
      System Information
      System Diagrams
      References
   Power Train
      Theory Of Operation
      System Operational Checks
      Diagnostic Information
      Adjustments
      Tests
   Hydraulic System
      Theory Of Operation
      System Operational Checks
      Diagnostic Information
      Adjustments
      Tests

TABLE OF CONTENTS
Section 9000: General Information....14
  Group 01: 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 02: General Specifications....14
    490E....15
    490E Drain And Refill Capacities....15
  Group 03: 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 04: Fuels And Lubricants....15
    Fuel Specifications....71
    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 9005: Operational Checkout....85
  Group 10: Operational Checkout Procedure....78
    Operational Checkout Record Sheet-490E....82
    Operational Checkout....85
Section 9010: Engine....133
  Group 05: Theory Of Operation....133
    4045 John Deere Engine-Use CTM8....133
    General Engine Description....136
    Engine-Sectional View....138
    Fan Drive Operation....140
    Engine Speed Control System Operation....141
  Group 10: System Operational Checks....133
    4045 John Deere Engine-Use CTM8....133
    Engine Operational Checks....145
  Group 15: Diagnostic Information....133
    4045 John Deere Engine-Use CTM8....133
    Diagnose Engine Malfunctions....162
  Group 20: Adjustments....133
    4045 John Deere Engine-Use CTM8....133
    JT05801 Clamp-On Electronic Tachometer Installation....795
    Engine Speed And Control Linkage Adjustment....401
  Group 25: Tests....133
    4045 John Deere Engine-Use CTM8....133
    Fuel Line Leakage Test....182
    Air Filter Restriction Indicator Switch Test....183
    Air Intake System Leakage Test....185
    Radiator Air Flow Test....187
    JT05529 Air Flow Meter Test Record....189
Section 9015: Electrical System....191
  Group 05: System Information....191
    Visually Inspect Electrical System....195
    Electrical Circuit Malfunctions....196
    High Resistance Circuit....198
    Open Circuit....200
    Grounded Circuit....202
    Shorted Circuit....204
    Multimeter....206
    Seven Step Electrical Test Procedure....207
    Wiring Diagram And Schematic Information....209
    Reading A System Functional Schematic....231
    Reading A Wiring Diagram....212
    Electrical Schematic Symbols....214
  Group 10: System Diagrams....191
    Replacing Fuses....218
    Fuse (Blade-Type) Color Codes....219
    Fuse Specifications....220
    Switch Specifications....222
    Component Identification Table....223
    Wiring And Schematic Diagrams Legend....225
    Component Location Diagram....230
    System Functional Schematic....231
    Engine Harness (W5) Wiring Diagram....233
    Cab Harness (W6) Wiring Diagram....234
    Power Circuit Operational Information....235
    Power Circuit Theory Of Operation....236
    Power Circuit Schematic....237
    Charging Circuit Operational Information....243
    Charging Circuit Theory Of Operation....244
    Charging Circuit Schematic....245
    Windshield Wiper And Washer Circuit Operational Information....250
    Windshield Wiper And Washer Circuit Theory Of Operation....251
    Windshield Wiper And Washer Circuit Schematic....252
    Switch Panel 1 Circuit Operational Information....258
    Switch Panel 1 Theory Of Operation....259
    Switch Panel 1 Circuit Schematic....260
    Switch Panel 2 Circuit Operational Information....263
    Switch Panel 2 Theory Of Operation....264
    Switch Panel 2 Circuit Schematic....265
    Light Circuit Operational Information....268
    Light Circuit Theory Of Operation....269
    Light Circuit Schematic....270
    Horn, Dome Light, Cigar Lighter And Heater Circuits Operational Information....275
    Horn, Dome Light, Cigar Lighter And Heater Circuits Theory Of Operation....276
    Horn, Dome Light, Cigarette Lighter And Heater Circuits Schematic....277
    Monitor Circuit Specifications....283
    Monitor Circuit Operational Information....284
    Monitor Circuit Theory Of Operation....285
    Monitor Circuit Schematic....286
    Auto Idle Circuit Operational Information....302
    Auto Idle Circuit Theory Of Operation....303
    Auto Idle Circuit Schematic....305
    Warm-Up Circuit Operational Information....315
    Warm-Up Circuit Theory Of Operation....316
    Hydraulic Warm-Up Circuit Schematic....317
    Pump And Valve Controller Circuit Operational Information....327
    Pump And Valve Controller Circuit Theory Of Operation....328
    Pump And Valve Controller Circuit Schematic....329
    Engine Controller Circuit Operational Information....353
    Engine Controller Circuit Theory Of Operation....354
    Engine Controller Circuit Schematic....356
    Start Aid And Travel Alarm Circuit Operational Information....365
    Start Aid And Propel Alarm Circuit Theory Of Operation....366
    Start Aid And Propel Alarm Circuit Schematic....367
  Group 20: References....192
    Monitor And Switch Panels....379
    Monitor Panel....381
    Switch Panel 1....382
    Switch Panel 2....546
    Resetting Engine Controller (EC)....385
    Electrical Component Identification....386
    Alternator Voltage Output Test-Delco....388
    Alternator Operation-40 Amp Delco Remy....389
    Replacing Batteries....391
    Battery Operation....392
    Diagnose Battery Malfunctions....393
    Check Battery Electrolyte Level And Terminals....394
    Procedure For Testing Batteries....397
    Using Booster Batteries-24 Volt System....399
    Engine Speed And Control Linkage Adjustment....401
    Electronic Control Bypass Procedure....404
    Hydraulic Pump Angle Sensor (A Sensor) Mechanical Check Diagnostic Procedure....715
    Hydraulic Pump Angle Sensor (A Sensor) Adjustment....409
    Troubleshooting Pump And Valve Controller (PVC)....700
    Troubleshooting Engine Controller (EC)....701
    Engine Control Sensor (EC Sensor) Harness Test....413
    Connecting Engine Controller (EC) And Pump And Valve Controller (PVC) Harness Connector....417
    Disconnect Tab Retainer Connectors....418
    Disconnecting Spring Wire Retainer Connectors....419
    Connector Pin Location And Numbers....420
Section 9020: Power Train....421
  Group 05: Theory Of Operation....421
    Power Train Components....424
    Propel System Operation....425
    Propel Pilot Circuit Operation....571
    Propel Pilot Controller Operation-Neutral....583
    Propel Pilot Check Valve Block Operation-Forward....430
    Propel Control Valve Operation....432
    Variable Pressure Compensator Valve Operation....434
    Propel Proportional Solenoid Valve Operation....579
    Propel Speed Control System Operation....438
    Propel Speed Change Solenoid Valve Operation....440
    Rotary Manifold Operation....442
    Propel Brake Valve Operation....443
    Propel Brake Pressure Reducing Valve Operation....445
    Counterbalance Valve Operation-Neutral....447
    Counterbalance Valve Operation-Propel....448
    Counterbalance Valve Operation-Braking....450
    Propel Motor Crossover Relief Valve Operation....451
    Propel Motor Operation....453
    Propel Speed Operation-Super Low And Normal....455
    Propel Motor Operation-Max. Speed....457
    Charge Valve Operation-Normal Maximum Speed....459
    Charge Valve Maximum Speed Operation-Braking....460
    Propel Gearbox Operation....461
    Track Adjuster Operation....463
  Group 10: System Operational Checks....421
    Power Train Operational Checks....475
  Group 15: Diagnostic Information....421
    Diagnose Undercarriage Components Malfunctions....488
    Diagnose Propel System Malfunctions....490
    Measure Track Chain Bushing Wear....498
    Measure Track Chain Pitch....499
    Measure Track Chain Link Wear....500
    Measure Track Shoe Grouser Wear....501
    Measure Lower Track Roller Wear....502
    Measure Front Idler Wear....503
    Measure Upper Track Roller Wear....504
    Propel System Component Location....505
  Group 20: Adjustments....422
    Adjust Track Sag....508
    Propel Speed Cycle Time....510
  Group 25: Tests....422
    JT07058 Diagnostic Computer Operating Procedure....760
    JT07059 Diagnostic Computer Function....767
    JT05801 Clamp-On Electronic Tachometer Installation....795
    JT05800 Digital Thermometer Installation....796
    Hydraulic System Warm-Up Procedure....797
    Propel Motor Start-Up Procedure....521
    Engine Speed Programming Procedure After Battery Disconnection....803
    Propel Motor Crossover Relief Valve Test And Adjustment....523
    Propel Speed Change Solenoid Valve Test And Adjustment....527
    Propel Proportional Solenoid Valve Test And Adjustment....529
    Propel Motor Operating Leakage Test....532
    Swing Bearing Wobble Test....534
Section 9025: Hydraulic System....542
  Group 05: Theory Of Operation....535
    Hydraulic System....542
    Control Systems Operation....544
    Switch Panel 2....546
    Engine (EC), Pump And Valve (PVC) Controllers....548
    Engine Control Circuit....550
    Engine Power Modes....552
    Hydraulic System Block Diagram....553
    Load Sense System-Control Valves In Neutral....555
    Load Sense System-Single Function Actuated....557
    Load Sense System-Function Held Over Relief....559
    Pump Control-Speed Sensing....560
    Flow Dividing Control System....562
    Work Mode Chart....564
    Propel Speed Control System....565
    Swing Brake Release Circuit Operation....567
    Swing Stop Cushion Valve Circuit Operation....568
    Warm-Up Control Circuit....569
    Pilot Circuit Operation....571
    Pilot Pump Operation....573
    Pilot Filter Operation....574
    Solenoid Valve Assembly Operation....575
    Pilot Pressure Regulating Valve Operation....577
    Pilot Pressure Reducing Valve Operation....578
    Proportional Solenoid Valve Operation....579
    Pilot Shut-Off Valve Operation....581
    Pilot Controller Operation-Neutral....583
    Pilot Controller Operation-Metering....584
    Pilot Controller Operation-Full Stroke....585
    Pilot Operation Of Main Control Valve....586
    Dig Function Pilot Controller Check Valve Operation....588
    Flow Regulator Valve Operation....589
    Warm-Up Circuit Operation....591
    Main Hydraulic Pump Operation....592
    Main Hydraulic Pump Displacement Solenoid Valves Operation....594
    Main Hydraulic Pump Control Operation....595
    Main Hydraulic Pump Operation-Maximum Displacement....597
    Main Hydraulic Pump Operation-Minimum Displacement....599
    Main Hydraulic Pump Angle Sensor (A Sensor) Operation....601
    Main Hydraulic Pump And Drive Gearbox-Serial No. (025000-)....602
    Main Control Valve Operation....603
    Control Valve Inlet Section Operation....605
    Surge Relief Valve Operation (Serial No. -024999) System Relief Valve Operation (Serial No. 025000- )....607
    System Relief Valve And Unloading Valve Operation-Neutral....609
    System Relief Valve And Unloading Valve Operation-Activated....611
    Circuit Relief Valve Operation....613
    Differential Pressure Sensor Operation....615
    Variable Pressure Compensator Valves Operation....617
    Auxiliary Valve Operation....619
    Arm, Boom, And Bucket Valve Operation....621
    Anti-Drift Valve Operation....623
    Swing Valve Operation....625
    Shuttle Valve Operation....626
    Combined Function Operation....628
    Swing Motor And Brake Operation....630
    Swing Motor Cover Operation-Start Of Swing....632
    Swing Motor Cover Operation-Normal Swing....634
    Swing Motor Cover Operation-Stopping....636
    Swing Brake Release Solenoid Valve Operation....638
    Swing Stop Cushion Valve Operation....640
    Swing Stop Cushion Valve Operation-Swinging....642
    Swing Gearbox Operation....643
    Cylinder Operation....645
    Return Filter Operation....646
    Suction Screen Operation....647
    Oil Cooler Operation....648
    Pump Inlet And Delivery Circuits Operation....649
    Return Circuit Operation....651
    Drain Circuit Operation....652
  Group 10: System Operational Checks....537
    Hydraulic Operational Checks....670
  Group 15: Diagnostic Information....537
    Diagnostic Procedure....691
    JT07058 Diagnostic Computer Operating Procedure....760
    JT07059 Diagnostic Computer Function....767
    Troubleshooting Differential Pressure Sensor (DP Sensor)....699
    Troubleshooting Pump And Valve Controller (PVC)....700
    Troubleshooting Engine Controller (EC)....701
    Troubleshooting Engine Speed Sensor (N Sensor)....702
    Troubleshooting Pump Displacement Angle Sensor (A Sensor)....703
    Troubleshooting Pressure Sensor (P Sensor)....704
    Troubleshooting Engine Control Sensor (EC Sensor)....705
    Troubleshooting Hydraulic Oil Temperature Sensor (T Sensor)....706
    Troubleshooting Boom Up Pilot Pressure Sensor (BPI Sensor)-Serial No. (025000- )....707
    Troubleshooting Arm In Pressure Sensor (ABP Sensor)-Serial No. (025000- )....708
    Troubleshooting Pump Displacement Solenoid Valve (PDSV)....709
    Troubleshooting Proportional Solenoid Valve....710
    Troubleshooting Propel Speed Change Solenoid Valve....711
    Troubleshooting Swing Brake Release Solenoid Valve....712
    Troubleshooting Swing Stop Cushion Valve....713
    Troubleshooting Engine Control Motor (EC Motor)....714
    Hydraulic Pump Angle Sensor (A Sensor) Mechanical Check Diagnostic Procedure....715
    Introduction To Flow Charts....717
    Diagnose Hydraulic System Malfunctions....730
    Diagnose Pilot Circuit Malfunctions....735
    Diagnose Dig Circuit Malfunctions....737
    Diagnose Swing Circuit Malfunctions....743
    Pilot Circuit Component Location....749
    Hydraulic System Component Location....750
    Pilot System SAE Pattern....751
    Pilot System John Deere Pattern....752
  Group 20: Adjustments....538
    Pilot Shut-Off Valve Linkage Adjustment....756
  Group 25: Tests....538
    JT07058 Diagnostic Computer Operating Procedure....760
    JT07058 Diagnostic Computer Initial Setup....762
    Connecting JT07058 Diagnostic Computer To Machine....764
    Begin JT07058 Diagnostic Computer Function....765
    JT07059 Diagnostic Computer Function....767
    Retry Procedure A....769
    Retry Procedure B....771
    Self Diagnostic Function Fault Codes For Engine Controller (EC)....773
    Self Diagnostic Function Fault Codes For Pump And Valve Controller (PVC)....775
    Monitor Data Function Display List And Description....778
    Component Abbreviations And Location....785
    Cross Reference To Monitor Data Function And Display Symbol....787
    Reading Fault Codes Without JT07058 Diagnostic Computer....789
    Reading Fault Codes With JT07058 Diagnostic Computer....791
    Monitor Data Function Worksheet-490E....792
    Example Of Monitor Data Function Worksheet....794
    JT05801 Clamp-On Electronic Tachometer Installation....795
    JT05800 Digital Thermometer Installation....796
    Hydraulic System Warm-Up Procedure....797
    Hydraulic Pump Start-Up Procedure....799
    Swing Motor Start-Up Procedure....800
    Swing Gearbox Start-Up Procedure....801
    Hydraulic Oil Filter Inspection Procedure....802
    Engine Speed Programming Procedure After Battery Disconnection....803
    Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy....804
    Cycle Time Test....806
    Proportional Solenoid Valve Harness Test....809
    Swing Brake Solenoid Valve Harness Test....810
    Pump Displacement Solenoid Valve Harness Test....812
    Swing Stop Cushion Valve Harness Test....814
    Engine Control Motor (EC Motor) Harness Test....816
    Differential Pressure Sensor Voltage Test And Adjustment....818
    Engine Control Sensor (EC Sensor) Test....821
    Miscellaneous Harness Test....824
    Pilot Pressure Regulating Valve Test And Adjustment....826
    Pilot Pressure Reducing Valve Test And Adjustment....830
    Surge Relief Valve Test And Adjustment-Serial No. ( -024999)....833
    System Relief Valve Test And Adjustment-(Serial No. -024999)....837
    System Relief Valve Test And Adjustment-(Serial No. 025000- )....840
    Circuit Relief Valve Test And Adjustment....844
    Proportional Solenoid Valve (PSV) Test And Adjustment....848
    Swing Motor Crossover Relief Valve Test And Adjustment....852
    Hydraulic Pump Flow Test....856
    Engine Power Or Hydraulic Pump Test Using Flow Meter Method....860
    Pilot Pump Flow Test....866
    Arm, Boom, And Bucket Cylinder Drift Test....869
    Swing Motor Leakage Test....872
    Oil Cooler Flow And Pressure Drop Test....875

John Deere 490E Excavators Diagnostics Technical Manual (TM1504)