Complete Diagnostics, Operation and Test manual with electrical wiring diagrams for John Deere Excavators 490D, 590D, with workshop information to maintain, diagnose, service, and rebuild like professional mechanics.

John Deere Excavators 490D, 590D 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.

TM1389 English - John Deere 490D and 590D Excavator Technical Manual - Operation and Test.PDF
ctm104 English - 4.5L AND 6.8L DIESEL ENGINES (BASE ENGINE) -: (WORLDWIDE EDITION) CTM.pdf

Total Pages: 652 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable)
Language: English

MAIN SECTIONS
Foreword
   General Information
      Safety
      General Specifications
      Torque Values
      Fuels And Lubricants
   Operational Checkout Procedure
      Operational Checkout Procedure
   Engine
      Theory Of Operation
      System Operational Checks
      Diagnostic Information
      Adjustments
      Tests
   Electrical System
      Electrical System Operation And Test
   Powertrain
      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 I: General Information...12
  Group I: Safety...12
    Follow Safe Procedures...16
    Prepare for Emergencies...17
    Prevent Acid Burns...18
    Handle Chemical Products Safely...20
    Handle Fluids Safely-Avoid Fires...21
    Avoid High-Pressure Fluids...22
    Warn Others of Service Work...23
    Support Machine Properly...24
    Operate Only from Operator's Seat...25
    Park Machine Safely...26
    Stay Clear of Moving Parts...27
    Avoid Power Lines...28
    Use Handholds and Steps...29
    Keep Riders Off Machine...30
    Move and Operate Machine Safely...31
    Wear Protective Clothing...32
    Protect Against Flying Debris...33
    Protect Against Noise...34
    Illuminate Work Area Safely...35
    Service Machines Safely...36
    Remove Paint Before Welding or Heating...37
    Avoid Heating Near Pressurized Fluid Lines...38
    Beware of Exhaust Fumes...39
    Use Proper Lifting Equipment...40
    Service Cooling System Safely...41
    Dispose of Waste Properly...42
    Work in a Clean Area...43
    Use Tools Properly...44
    Replace Safety Signs...45
    Live With Safety...46
  Group II: General Specifications...13
    490D Specifications...49
    490D Working Ranges...51
    490D Drain And Refill Capacities...53
    490D...54
    490D Bucket Selection Chart-2.5 M (98 In.) Arm...56
    490D Bucket Selection Chart-3.0 M (118 In.) Arm...57
    490D Bucket Specifications...58
    490D with 2.5 m (8 ft 2 in.) Arm Lift Capacity-Kg (Lb)...59
    490D with 3.0 m (9 ft 10 in.) Arm Lift Capacity-Kg (Lb)...60
    590D Specifications...62
    590D Working Ranges...64
    590D Operating Specifications...65
    590D Drain And Refill Capacities...66
    590D Engine and Hydraulic Specifications...67
    590D Bucket Selection Chart-2.6 M (8 Ft 6 In.) Arm...69
    590D Bucket Selection Chart-3.1 M (10 Ft. 2 In.) Arm...70
    590D Bucket Specifications...71
    590D Lift Capacity-Kg (Lb)...72
    590D Lift Capacity-Kg (Lb)-Continued...74
  Group III: Torque Values...13
    Hardware Torque Specifications...77
    Check Track Shoe Torque...78
    Metric Bolt And Cap Screw Torque Values...79
    Unified Inch Bolt And Cap Screw Torque Values...80
    Check Oil Lines And Fittings...81
    Service Recommendations For 37° Flare And 30° Cone Seat Connectors...82
    Service Recommendations for O-Ring Boss Fittings...83
    Service Recommendations For Flat Face O-Ring Seal Fittings...85
    Service Recommendations For Metric Series Four Bolt Flange Fitting...87
    Service Recommendations For Inch Series Four Bolt Flange Fittings...89
  Group IV: Fuels And Lubricants...13
    Fuel Specifications...92
    Fuel Storage...93
    Engine Oil...94
    Hydraulic Oil...95
    Swing Gearbox, Propel Gearbox And Pump Gearbox Oils...96
    Track Rollers And Idlers Oil...97
    Swing Gear Grease...99
    Grease...99
    Lubricant Storage...100
    Alternative Lubricants...101
    Synthetic Lubricants...102
    Engine Coolant...103
Section 9005: Operational Checkout Procedure...104
  Group 10: Operational Checkout Procedure...104
    Operational Checkout Record Sheet-490D, 590D...108
    Complete Machine Operational Checkout...111
Section 9010: Engine...153
  Group 05: Theory Of Operation...153
    Cooling System Operation-490D...156
    Cooling System Operation-590D...157
    Radiator Cap Operation...158
    Air Cleaner Operation...159
    Engine Lubrication Operation...160
    Oil Cooler Operation...162
    Fuel System Operation...164
    Fuel Supply Pump Operation...165
    Fuel Filter Operation...166
    Fuel Injection Pump Operation...167
    Fuel Injection Nozzle Operation...168
    Turbocharger Operation-590D...170
    Cold Weather Starting Aid Operation...172
    Engine Speed Control System Operation...173
  Group 10: System Operational Checks...153
    Engine Operational Checks...190
  Group 15: Diagnostic Information...153
    Diagnose Engine Malfunctions...215
    Coolant Requirements...224
    General Recommendations...227
  Group 20: Adjustments...153
    Fan Belt Tension Adjustment...230
    Engine Speed Adjustment...232
    Engine Speed Control Linkage Adjustment...234
    Speed Control Lever Tension Adjustment...236
    Engine Valve Clearance Adjustment...237
    Injection Pump Static Timing Adjustment...241
  Group 25: Tests...153
    JT39000 Tachometer Reader Installation Procedure...244
    D01084AA Tachometer Reader Installation Procedure...245
    JT05801 Clamp-On Electronic Tachometer Installation...611
    Compression Pressure Test...247
    Engine Oil Pressure Test...249
    Engine Performance Test...250
    Valve Lift Test...252
    Fuel Supply Pump Pressure Test...254
    Air Filter Restriction Indicator Switch Test...256
    Air Intake System Leakage Test...258
    Turbocharger Shaft Axial End Play Test-590D...260
    Turbocharger Shaft Radial Movement Test-590D...261
    Engine Power Test Using Turbocharger Boost Pressure-590D...262
    Radiator Air Flow Test...264
    Fuel Line Leakage Test...267
Section 9015: Electrical System...268
  Group 00: Electrical System Operation And Test...268
    Safety Precautions...273
    Battery Operation...276
    Using Booster Batteries...277
    Procedure For Testing Batteries...278
    Diagnose Battery Malfunctions...279
    Fuse Specifications...280
    Engine Coolant Level Indicator Light...281
    Hydraulic Reservoir Level Indicator Light...282
    Engine Coolant Temperature Gauge...283
    Engine Coolant Temperature Indicator Light...284
    Fuel Gauge...285
    Fuel Level Indicator Light...286
    Battery Charge Indicator Light...287
    Engine Oil Pressure Warning Light...288
    Engine Oil Filter Restriction Indicator Light...289
    Air Cleaner Restriction Indicator Light...290
    Visually Inspect Electrical System...291
    Testing The Electrical System...292
    Common Circuit Test...293
    Electrical Operational Checks...294
    Wiring Diagram Information...296
    Power Circuit Diagnose Malfunctions...298
    Power Circuit Operation...303
    Power Circuit Wiring Diagram...304
    Power Circuit Test...305
    Starting Circuit Diagnose Malfunctions...307
    Start Circuit Operation...312
    Starter Operation...313
    Start Circuit Wiring Diagram...316
    Start Circuit Test...317
    Charging Circuit Diagnose Malfunctions...319
    Charging Circuit Operation...324
    Alternator Operation-65 Amp Motorola...325
    Charging Circuit Wiring Diagram...327
    Charging Circuit Test...328
    Diagnose Accessory Circuit Malfunctions...330
    Accessory Circuit Operation...341
    Accessory Circuit Wiring Diagram...345
    Accessory Circuit Test...346
    Engine Speed And Pump Displacement Control Circuit Diagnose Malfunctions...349
    Engine Speed And Pump Displacement Control Operation...353
    Engine Speed And Pump Displacement Control Circuit Operational Charts...354
    Engine Speed And Pump Displacement Control System Operation...356
    Engine Speed And Pump Displacement Control Circuit Wiring Diagram...357
    Engine Speed And Pump Displacement Control Circuit Test...358
    Monitor Circuit Diagnose Malfunctions...360
    Monitor Circuit Operation...375
    Monitor Circuit Test...377
Section 9020: Powertrain...379
  Group 05: Theory Of Operation...379
    Track Adjuster Operation...382
    Propel Gearbox Operation-490D...383
    Propel Gearbox Operation-590D...385
    Propel Circuit Operation...387
    Rotary Manifold Operation...390
    Propel Motor Operation-490D...391
    Propel Motor Operation-590D...393
    Counterbalance Valve Neutral Operation-490D...394
    Counterbalance Valve Neutral Operation-590D...395
    Counterbalance Valve Propel Operation-490D...396
    Counterbalance Valve Propel Operation-590D...397
    Counterbalance Valve Braking Operation-490D...398
    Counterbalance Valve Dynamic Braking Operation-590D...399
    Propel Motor Relief Valve Operation-490D...400
    Propel Motor Relief Valve Operation-590D...401
    Propel Brake Operation-490D...402
    Propel Motor Brake Operation-590D...403
  Group 10: System Operational Checks...379
    Power Train Operational Checks...416
  Group 15: Diagnostic Information...379
    Diagnose Undercarriage Components Malfunctions...430
    Diagnose Propel System Malfunctions...432
    Measure Track Bushing Wear...435
    Measure Track Chain Pitch...436
    Measure Track Link Wear...437
    Measure Track Shoe Grouser Wear...438
    Measure Track Roller Wear...439
  Group 20: Adjustments...379
    Adjust Track Sag...443
  Group 25: Tests...380
    Propel Speed Cycle Time...447
    JT39000 Tachometer/Temperature Reader Installation...607
    D01084AA Tachometer/Temperature Reader Installation...609
    JT05801 Clamp-On Electronic Tachometer Installation...611
    JT05800 Digital Thermometer Installation...612
    Propel System Relief Valve Adjustment...455
    Propel Motor Crossover Relief Valve Test And Adjustment...459
    Propel Motor Operating Leakage Test...463
    Propel Motor Start-Up Procedure...465
    Swing Bearing Wobble Test...466
Section 9025: Hydraulic System...472
  Group 05: Theory Of Operation...467
    Hydraulic System...472
    Pilot System Operation...474
    Pilot Pump Operation...476
    Pilot Filter Operation...477
    Solenoid Valve And Pilot Pressure Regulating Valve Operation...478
    Solenoid Valve Operation-Energized...480
    Engine Speed Control Operation...482
    Check Block Operation...483
    Main Hydraulic Pump Displacement Operation...484
    Shut-Off Valve Operation...486
    Pilot Controller Operation-Neutral...488
    Pilot Controller Operation-Metering...489
    Pilot Controller Operation-Full Stroke...490
    Propel Pilot Controller Operation-Neutral...491
    Pilot Operation Of Main Control Valve...492
    Flow Regulator Operation...493
    Warm-Up Circuit Operation...494
    Pump Inlet And Delivery Circuits Operation...496
    Return Circuit Operation...497
    Drain Circuit Operation...498
    Return Filter Operation...499
    Main Control Valve Operation...500
    System Relief Valve Circuit Operation...502
    System Relief Valve Operation...504
    Circuit Relief Valve Operation...505
    Flow Combiner And Swing Brake Release Valve Circuit Operation...506
    Bucket And Auxiliary Work Circuits Operation...507
    Boom Raise Work Circuit Operation...509
    Boom Lower Work Circuit Operation...511
    Arm In Work Circuit Operation...513
    Arm Out Work Circuit Operation...515
    Swing Work Circuit Operation...517
    Combined Functions Operation...519
    Swing Motor Operation...521
    Swing Cross-Over Relief Valves And Make-Up Valves Operation...523
    Brake Release Circuit Operation...524
    Swing Gearbox Operation...525
    Cylinder Operation...527
    Main Hydraulic Pump Operation...529
    Regulator Components Operation...530
    High-Low Maximum Displacement Operation...532
    Fuel Saving System Operation...534
    Constant Horsepower System Operation...536
  Group 10: System Operational Checks...468
    Hydraulic Operational Checks...556
  Group 15: Diagnostic Information...468
    Diagnose Hydraulic System Malfunctions...576
    Diagnose Pilot Circuit Malfunctions...578
    Diagnose Dig Circuit Malfunctions...579
    Diagnose Swing Circuit Malfunctions...581
    Hydraulic Circuit Symbols...584
    Pressure And Return Circuits...585
    Boom, Arm, Bucket And Swing Circuits...586
    Pilot Circuit-Controllers To Flow Regulator...587
    Pilot Circuit-Flow Regulator To Main Control Valve Assembly...588
    Pilot Circuit-Swing Motor, Engine Speed, And Pump Displacement Controls...589
    Pilot Control Lever Pattern Information...590
  Group 20: Adjustments...468
    Pilot Shut-Off Valve Linkage Adjustment...595
    Main Hydraulic Pump Displacement Adjustment...597
  Group 25: Tests...468
    Cycle Time Test...603
    JT39000 Tachometer/Temperature Reader Installation...607
    D01084AA Tachometer/Temperature Reader Installation...609
    JT05801 Clamp-On Electronic Tachometer Installation...611
    JT05800 Digital Thermometer Installation...612
    Hydraulic Pump Start-Up Procedure...613
    Pilot System Regulating Valve Test And Adjustment...614
    Pilot Controller Test...616
    System Relief Valve Test And Adjustment...619
    Circuit Relief Valve Test And Adjustment...624
    Swing Motor Crossover Relief Valve Test And Adjustment...628
    Flow Sensing Valve Test And Adjustment...630
    Hydraulic Pump Regulator Test And Adjustment (Engine Pulldown)-490D...634
    Hydraulic Pump Regulator Test And Adjustment (Engine Pulldown)-590D...640
    Hydraulic Pump Flow Test...647
    Pilot Pump Flow Test...652
    Boom, Arm And Bucket Cylinder Drift Test...654
    Swing Motor Leakage Test...656
    Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy...658
    Hydraulic Schematic...660
    Electrical Schematic-490D/590D...661

John Deere Excavators 490D, 590D Operation & Test Service Manual (TM1389)