John Deere 490D & 590D Excavator Operation and Test Workshop Manual (TM1389) PDF - MJODTM1389.zip
This is a full Operation, Test, and Diagnostics guide with electrical schematics for the John Deere 490D and 590D Excavators, containing workshop-level instructions so you can maintain, troubleshoot, service, and rebuild these machines the way a professional technician would.
Inside this Operation and Test guide for the John Deere 490D and 590D Excavators, you'll find:
* 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 - John Deere 490D and 590D Excavator Technical Manual - Operation and Test.PDF
TM1389 - John Deere 490D and 590D Excavator Technical Manual - Operation and Test.EPUB
Total Pages: 681 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; 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
tm1389 - 490D and 590D Excavators Operation and Test
Table of Contents
Foreword
Section I: General Information
Group I: Safety
Follow Safe Procedures
Prepare for Emergencies
Prevent Acid Burns
Handle Chemical Products Safely
Handle Fluids Safely-Avoid Fires
Avoid High-Pressure Fluids
Warn Others of Service Work
Support Machine Properly
Operate Only from Operator's Seat
Park Machine Safely
Stay Clear of Moving Parts
Avoid Power Lines
Use Handholds and Steps
Keep Riders Off Machine
Move and Operate Machine Safely
Wear Protective Clothing
Protect Against Flying Debris
Protect Against Noise
Illuminate Work Area Safely
Service Machines Safely
Remove Paint Before Welding or Heating
Avoid Heating Near Pressurized Fluid Lines
Beware of Exhaust Fumes
Use Proper Lifting Equipment
Service Cooling System Safely
Dispose of Waste Properly
Work in a Clean Area
Use Tools Properly
Replace Safety Signs
Live With Safety
Group II: General Specifications
490D Specifications
490D Working Ranges
490D Drain And Refill Capacities
490D
490D Bucket Selection Chart-2.5 M (98 In.) Arm
490D Bucket Selection Chart-3.0 M (118 In.) Arm
490D Bucket Specifications
490D with 2.5 m (8 ft 2 in.) Arm Lift Capacity-Kg (Lb)
490D with 3.0 m (9 ft 10 in.) Arm Lift Capacity-Kg (Lb)
590D Specifications
590D Working Ranges
590D Operating Specifications
590D Drain And Refill Capacities
590D Engine and Hydraulic Specifications
590D Bucket Selection Chart-2.6 M (8 Ft 6 In.) Arm
590D Bucket Selection Chart-3.1 M (10 Ft. 2 In.) Arm
590D Bucket Specifications
590D Lift Capacity-Kg (Lb)
590D Lift Capacity-Kg (Lb)-Continued
Group III: Torque Values
Hardware Torque Specifications
Check Track Shoe Torque
Metric Bolt And Cap Screw Torque Values
Unified Inch Bolt And Cap Screw Torque Values
Check Oil Lines And Fittings
Service Recommendations For 37° Flare And 30° Cone Seat Connectors
Service Recommendations for O-Ring Boss Fittings
Service Recommendations For Flat Face O-Ring Seal Fittings
Service Recommendations For Metric Series Four Bolt Flange Fitting
Service Recommendations For Inch Series Four Bolt Flange Fittings
Group IV: Fuels And Lubricants
Fuel Specifications
Fuel Storage
Engine Oil
Hydraulic Oil
Swing Gearbox, Propel Gearbox And Pump Gearbox Oils
Track Rollers And Idlers Oil
Swing Gear Grease
Grease
Lubricant Storage
Alternative Lubricants
Synthetic Lubricants
Engine Coolant
Section 9005: Operational Checkout Procedure
Group 10: Operational Checkout Procedure
Operational Checkout Record Sheet-490D, 590D
Complete Machine Operational Checkout
Section 9010: Engine
Group 05: Theory Of Operation
Cooling System Operation-490D
Cooling System Operation-590D
Radiator Cap Operation
Air Cleaner Operation
Engine Lubrication Operation
Oil Cooler Operation
Fuel System Operation
Fuel Supply Pump Operation
Fuel Filter Operation
Fuel Injection Pump Operation
Fuel Injection Nozzle Operation
Turbocharger Operation-590D
Cold Weather Starting Aid Operation
Engine Speed Control System Operation
Group 10: System Operational Checks
Engine Operational Checks
Group 15: Diagnostic Information
Diagnose Engine Malfunctions
Coolant Requirements
General Recommendations
Group 20: Adjustments
Fan Belt Tension Adjustment
Engine Speed Adjustment
Engine Speed Control Linkage Adjustment
Speed Control Lever Tension Adjustment
Engine Valve Clearance Adjustment
Injection Pump Static Timing Adjustment
Group 25: Tests
JT39000 Tachometer Reader Installation Procedure
D01084AA Tachometer Reader Installation Procedure
JT05801 Clamp-On Electronic Tachometer Installation
Compression Pressure Test
Engine Oil Pressure Test
Engine Performance Test
Valve Lift Test
Fuel Supply Pump Pressure Test
Air Filter Restriction Indicator Switch Test
Air Intake System Leakage Test
Turbocharger Shaft Axial End Play Test-590D
Turbocharger Shaft Radial Movement Test-590D
Engine Power Test Using Turbocharger Boost Pressure-590D
Radiator Air Flow Test
Fuel Line Leakage Test
Section 9015: Electrical System
Group 00: Electrical System Operation And Test
Safety Precautions
Battery Operation
Using Booster Batteries
Procedure For Testing Batteries
Diagnose Battery Malfunctions
Fuse Specifications
Engine Coolant Level Indicator Light
Hydraulic Reservoir Level Indicator Light
Engine Coolant Temperature Gauge
Engine Coolant Temperature Indicator Light
Fuel Gauge
Fuel Level Indicator Light
Battery Charge Indicator Light
Engine Oil Pressure Warning Light
Engine Oil Filter Restriction Indicator Light
Air Cleaner Restriction Indicator Light
Visually Inspect Electrical System
Testing The Electrical System
Common Circuit Test
Electrical Operational Checks
Wiring Diagram Information
Power Circuit Diagnose Malfunctions
Power Circuit Operation
Power Circuit Wiring Diagram
Power Circuit Test
Starting Circuit Diagnose Malfunctions
Start Circuit Operation
Starter Operation
Start Circuit Wiring Diagram
Start Circuit Test
Charging Circuit Diagnose Malfunctions
Charging Circuit Operation
Alternator Operation-65 Amp Motorola
Charging Circuit Wiring Diagram
Charging Circuit Test
Diagnose Accessory Circuit Malfunctions
Accessory Circuit Operation
Accessory Circuit Wiring Diagram
Accessory Circuit Test
Engine Speed And Pump Displacement Control Circuit Diagnose Malfunctions
Engine Speed And Pump Displacement Control Operation
Engine Speed And Pump Displacement Control Circuit Operational Charts
Engine Speed And Pump Displacement Control System Operation
Engine Speed And Pump Displacement Control Circuit Wiring Diagram
Engine Speed And Pump Displacement Control Circuit Test
Monitor Circuit Diagnose Malfunctions
Monitor Circuit Operation
Monitor Circuit Test
Section 9020: Powertrain
Group 05: Theory Of Operation
Track Adjuster Operation
Propel Gearbox Operation-490D
Propel Gearbox Operation-590D
Propel Circuit Operation
Rotary Manifold Operation
Propel Motor Operation-490D
Propel Motor Operation-590D
Counterbalance Valve Neutral Operation-490D
Counterbalance Valve Neutral Operation-590D
Counterbalance Valve Propel Operation-490D
Counterbalance Valve Propel Operation-590D
Counterbalance Valve Braking Operation-490D
Counterbalance Valve Dynamic Braking Operation-590D
Propel Motor Relief Valve Operation-490D
Propel Motor Relief Valve Operation-590D
Propel Brake Operation-490D
Propel Motor Brake Operation-590D
Group 10: System Operational Checks
Power Train Operational Checks
Group 15: Diagnostic Information
Diagnose Undercarriage Components Malfunctions
Diagnose Propel System Malfunctions
Measure Track Bushing Wear
Measure Track Chain Pitch
Measure Track Link Wear
Measure Track Shoe Grouser Wear
Measure Track Roller Wear
Group 20: Adjustments
Adjust Track Sag
Group 25: Tests
Propel Speed Cycle Time
JT39000 Tachometer/Temperature Reader Installation
D01084AA Tachometer/Temperature Reader Installation
JT05801 Clamp-On Electronic Tachometer Installation
JT05800 Digital Thermometer Installation
Propel System Relief Valve Adjustment
Propel Motor Crossover Relief Valve Test And Adjustment
Propel Motor Operating Leakage Test
Propel Motor Start-Up Procedure
Swing Bearing Wobble Test
Section 9025: Hydraulic System
Group 05: Theory Of Operation
Hydraulic System
Pilot System Operation
Pilot Pump Operation
Pilot Filter Operation
Solenoid Valve And Pilot Pressure Regulating Valve Operation
Solenoid Valve Operation-Energized
Engine Speed Control Operation
Check Block Operation
Main Hydraulic Pump Displacement Operation
Shut-Off Valve Operation
Pilot Controller Operation-Neutral
Pilot Controller Operation-Metering
Pilot Controller Operation-Full Stroke
Propel Pilot Controller Operation-Neutral
Pilot Operation Of Main Control Valve
Flow Regulator Operation
Warm-Up Circuit Operation
Pump Inlet And Delivery Circuits Operation
Return Circuit Operation
Drain Circuit Operation
Return Filter Operation
Main Control Valve Operation
System Relief Valve Circuit Operation
System Relief Valve Operation
Circuit Relief Valve Operation
Flow Combiner And Swing Brake Release Valve Circuit Operation
Bucket And Auxiliary Work Circuits Operation
Boom Raise Work Circuit Operation
Boom Lower Work Circuit Operation
Arm In Work Circuit Operation
Arm Out Work Circuit Operation
Swing Work Circuit Operation
Combined Functions Operation
Swing Motor Operation