John Deere 290D Excavator Operation And Test Manual TM1442

[Martin Welker]

Download this document, you need 750 Gallons

John Deere 290D Excavator Operation And Test Manual TM1442
Size: 19.14 MB
Format: PDF
Language: English
Brand: John Deere
Type of Machine: Excavator
Type of Manual: Operation And Test Manual
Model: John Deere 290D Excavator
Part Number: TM1442
Publication Date: 2005
Number of Pages: 404 Pages

Contents:
FOREWORD
Section 9000 - GENERAL INFORMATION
Group 01 - 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 02 - General Specifications
290D Specifications
290D Drain And Refill Capacities
290D Working Ranges
290D Bucket Selection Chart-1.89 M (74 In.) Arm
290D Bucket Selection Chart-2.41 M (95 In.) Arm
290D Lift Capacity-Kg (Lb)
290D Bucket Specifications
Group 03 - Torque Values
Unified Inch Bolt and Cap Screw Torque Values
Metric Bolt and Cap Screw Torque Values
Additional Metric Cap Screw Torque Values
Service Recommendations for O-Ring Boss Fittings
Service Recommendations for Flat Face O-Ring Seal Fittings
Service Recommendations for 37° Flare and 30° Cone Seat Connectors
Service Recommendations For Flared Connections-Straight or Tapered Threads
Service Recommendations For Inch Series Four Bolt Flange Fittings
Service Recommendations for Metric Series Four Bolt Flange Fitting
Group 04 - Fuels And Lubricants
Fuel Specifications
Engine Oil
Hydraulic Oil
Swing Gearbox, Propel Gearbox, And Pump Drive (Splitter) Gearbox Oils
Track Rollers And Idlers Oil
Grease
Engine Coolant
Cold Weather Operation
Alternative and Synthetic Lubricants
Lubricant Storage
Section 9005 - OPERATIONAL CHECKOUT PROCEDURE
Group 10 - Operational Checkout Procedure
Operational Checkout Record Sheet-290D
Seat, Doors, Windows, Latches, And Locks Check
Gauges, Monitor, And Battery Disconnect Relay Checks
Pilot Shut Off Valve Linkage Checks
Hydraulic Function Control Check
Monitor Circuit, And Hour Meter Checks
Engine Speed Control Linkage Checks
Pilot Shut Off Valve Checks
Auto Idle Circuit Check
Power And Economy Mode Circuit Checks
Monitor Buzzer Check
Track Sag Check
Roller And Idler Leakage Checks
Sprocket Wear Check
Grouser Wear, Bent Track Shoe, And Loose Hardware Checks
Track Link Roller And Front Idler Wear Checks
Visual Inspection
Hydraulic System Warm-Up Procedure
Oil Cooler Circuit Check
Pressurized Tank Check
Pilot Shut-Off Valve Checks
Pilot Hand Controller Pattern John Deere Or SAE Check
Dynamic Swing Brake Check
Mechanical Swing Brake Check
Mechanical Swing Brake Capacity Check
Swing Circuit Leakage Check
Dig Function Drift Checks
Control Valve Lift Check Test
Hydraulic Pump Performance And Propel Cycle Time Checks
Propel System Tracking Check (Propel Only)
Propel System Tracking Checks (While Operating A Digging Function)
Propel Motor Counter-Balance Valve Check
Mode Switch Check (Engine Speed And Pump Displacement)
Mode Switch Check (Pump Displacement Only)
System Relief Valve, Arm, Bucket, And Propel Circuit Relief Valves Check
Boom Raise Circuit Relief Valve Check
Engine RPM Pulldown Slow Idle Check (Single Pump Pulldown)
Engine RPM Pulldown Fast Idle Check (Single Pump Pulldown)
Engine RPM Pulldown Fast Idle Check (Combined Pump Pulldown)
Arm Cylinder Head End, Rod End And Boom Cylinder Rod End Cushion Check
Cycle Time Check
Travel Alarm Circuit Check
Light Circuit Checks
Wiper Circuit Check
Cab Dome Light Circuit Checks
Left Control Lever Horn Circuit Checks
Starting Aid System Check
Cigar Lighter Circuit Check
Heater Controls Checks
Heater Temperature Checks
Seat Control Checks
Front Window Check
Lower Front Window Store Position Check
Right And Left Side Window Checks
Roof Vent Panel Check
Cab Door Latch Check
Air Filter, Battery Access And Tool Box Doors Check
Hood Checks
Fuel Cap Lock Check
Service Decal Check
Gauges, Monitor, And Battery Disconnect Relay Checks
Pilot Shut Off Valve Linkage Checks
Hydraulic Function Control Check
Monitor Circuit, And Hour Meter Checks
Engine Speed Control Linkage Checks
Pilot Shut Off Valve Checks
Auto Idle Circuit Check
Power And Economy Mode Circuit Checks
Monitor Buzzer Check
Track Sag Check
Roller And Idler Leakage Checks
Sprocket Wear Check
Grouser Wear, Bent Track Shoe, And Loose Hardware Checks
Track Link Roller And Front Idler Wear Checks
Visual Inspection
Hydraulic System Warm-Up Procedure
Oil Cooler Circuit Check
Pressurized Tank Check
Pilot Shut-Off Valve Checks
Pilot Hand Controller Pattern John Deere Or SAE Check
Dynamic Swing Brake Check
Mechanical Swing Brake Check
Mechanical Swing Brake Capacity Check
Swing Circuit Leakage Check
Dig Function Drift Checks
Control Valve Lift Check Test
Hydraulic Pump Performance And Propel Cycle Time Checks
Propel System Tracking Check (Propel Only)
Propel System Tracking Checks (While Operating A Digging Function)
Propel Motor Counter-Balance Valve Check
Mode Switch Check (Engine Speed And Pump Displacement)
Mode Switch Check (Pump Displacement Only)
System Relief Valve, Arm, Bucket, And Propel Circuit Relief Valves Check
Boom Raise Circuit Relief Valve Check
Engine RPM Pulldown Slow Idle Check (Single Pump Pulldown)
Engine RPM Pulldown Fast Idle Check (Single Pump Pulldown)
Engine RPM Pulldown Fast Idle Check (Combined Pump Pulldown)
Arm Cylinder Head End, Rod End And Boom Cylinder Rod End Cushion Check
Cycle Time Check
Travel Alarm Circuit Check
Light Circuit Checks
Wiper Circuit Check
Cab Dome Light Circuit Checks
Left Control Lever Horn Circuit Checks
Starting Aid System Check
Cigar Lighter Circuit Check
Heater Controls Checks
Heater Temperature Checks
Seat Control Checks
Front Window Check
Lower Front Window Store Position Check
Right And Left Side Window Checks
Roof Vent Panel Check
Cab Door Latch Check
Air Filter, Battery Access And Tool Box Doors Check
Hood Checks
Fuel Cap Lock Check
Service Decal Check
Section 9010 - ENGINE
Group 05 - Theory Of Operation
Cooling System Operation
Radiator Cap Operation
Thermostat Operation
Air Cleaner Operation
Engine Lubrication Operation
Fuel System Operation
Fuel Supply Pump Operation
Fuel Injection Pump Operation
Fuel Injection Nozzle Operation
Fuel Filter Operation
Engine Speed Control System Operation
Group 10 - System Operational Checks
Engine Speed And Performance Checks
Radiator Cap Checks
Coolant Level And Coolant Condition In Overflow Tank Checks
Coolant Level And Coolant Condition In Radiator Checks
Radiator Outside Air Flow Check
Radiator Internal Core Check
Radiator Bubble Check
Hoses, Clamps, And Water Pump Checks
Fan Checks
Fan Shroud And Fan Guard Checks
Fan Belt Checks
Air Filter Restriction Indicator Switch Check
Starting Aid Checks
Exhaust Smoke Check
Oil Level Check
Water Trap Check
Fuel Cap And Fuel Strainer
Inside Fuel Tank Check
Fuel Pump Check
Fuel System Check
Engine Speed Check
Engine Power Check (Tachometer Installed)
Low Compression Check
Engine Blow-By Check
Loose Or Worn Engine Parts
Radiator Cap Checks
Coolant Level And Coolant Condition In Overflow Tank Checks
Coolant Level And Coolant Condition In Radiator Checks
Radiator Outside Air Flow Check
Radiator Internal Core Check
Radiator Bubble Check
Hoses, Clamps, And Water Pump Checks
Fan Checks
Fan Shroud And Fan Guard Checks
Fan Belt Checks
Air Filter Restriction Indicator Switch Check
Starting Aid Checks
Exhaust Smoke Check
Oil Level Check
Water Trap Check
Fuel Cap And Fuel Strainer
Inside Fuel Tank Check
Fuel Pump Check
Fuel System Check
Engine Speed Check
Engine Power Check (Tachometer Installed)
Low Compression Check
Engine Blow-By Check
Loose Or Worn Engine Parts
Group 15 - Diagnostic Information
Cross Section Of Engine
Diagnose Engine Malfunctions
Group 20 - Adjustments
Fan Belt Tension Adjustment
Engine Speed Control Linkage Adjustment
Speed Control Lever Tension Adjustment
Engine Speed Adjustment
Engine Valve Clearance Adjustment
Injection Pump Static Timing Adjustment
Group 25 - Tests
JT39000 Tachometer Reader Installation Procedure
D-01084AA Tachometer Reader Installation Procedure
JT05801 Clamp-On Electronic Tachometer Installation
Compression Pressure Test
Engine Oil Pressure Test
Engine Performance Test
Valve Lift Test
Fuel Pump Pressure Test
Air Filter Restriction Indicator Switch Test
Air Intake System Leakage Test
Radiator Air Flow Test
Section 9015 - ELECTRICAL SYSTEM
Group 00 - Electrical System
Safety Precautions
Using Booster Batteries-24 Volt System
Visually Inspect Electrical System
Testing The Electrical System
Common Circuit Test
Electrical Operational Checks
Electrical Schematic Symbols
Wiring Diagram Information
Battery Diagnose Malfunctions
Battery Operation
Procedure For Testing Batteries
Fuse Specifications
Engine Coolant Temperature Gauge
Engine Coolant Temperature Indicator Light
Fuel Gauge
Battery Charge Indicator Light
Engine Oil Pressure Warning Light
Air Cleaner Restriction Indicator Light
Work Light Indicator
Power Circuit Operational Checks
Battery
Battery Relay Check
Key Switch Check
Start Aid Switch Check
Start Aid Solenoid Check
Battery
Battery Relay Check
Key Switch Check
Start Aid Switch Check
Start Aid Solenoid Check
Power Circuit Wiring Diagram
Power Circuit Operation
Starting Circuit Operational Checks
Start Relay Check
Starter Solenoid Check
Starter Motor Check
Start Relay Check
Starter Solenoid Check
Starter Motor Check
Starting Circuit Wiring Diagram
Starting Motor Operation
Starting Circuit Operation
Charging System Operational Checks
Charge Light Check
Alternator Check
Load Dump Relay Check
Charge Light Check
Alternator Check
Load Dump Relay Check
Alternator Operation-40 Amp Motorola
Charging Circuit Wiring Diagram
Charging Circuit Operation
Charging And Load Dump Circuit Wiring Diagram
Charging And Load Dump Circuit Operation
Accessory Circuit Checks
Cigarette Lighter Check
Horn Switch Check (On Hydraulic Lever Or Steering Wheel)
Horn Solenoid Check
Work Light Checks
Cigarette Lighter Check
Horn Switch Check (On Hydraulic Lever Or Steering Wheel)
Horn Solenoid Check
Work Light Checks
Accessory Circuit Wiring Diagram
Accessory Circuit Operation
Auto Idle Circuit Check
Control Box Check
Dig Functions Pressure Switch Check
Propel Functions Pressure Switch Check
Control Box Check
Dig Functions Pressure Switch Check
Propel Functions Pressure Switch Check
Auto Idle Circuit Wiring Diagram
Auto Idle Circuit Operation
Windshield Wiper, Heater And Travel Alarm Circuit Checks
Windshield Wiper Switch Check
Windshield Washer Motor Check
Propel Alarm Check
Propel Alarm Pressure Switch Check
Windshield Wiper Switch Check
Windshield Washer Motor Check
Propel Alarm Check
Propel Alarm Pressure Switch Check
Wiper, Heater, And Propel Alarm Circuit Wiring Diagram
Wiper, Heater, And Propel Alarm Circuit Operation
Monitor Circuit Operational Checks
Monitor Bulb Check Circuit
Monitor Panel Check
Hourmeter Switch Check
Hourmeter Check
Charge Indicator Light Check
Coolant Temperature Gauge Check
Fuel Gauge Check
Fuel Gauge Sender Check
Engine Oil Pressure Light And Buzzer Check
AIR RESTRICTION INDICATOR LIGHT CHECK
Buzzer Stop Switch Check
Auto Idle Switch Check
Monitor Bulb Check Circuit
Monitor Panel Check
Hourmeter Switch Check
Hourmeter Check
Charge Indicator Light Check
Coolant Temperature Gauge Check
Fuel Gauge Check
Fuel Gauge Sender Check
Engine Oil Pressure Light And Buzzer Check
AIR RESTRICTION INDICATOR LIGHT CHECK
Buzzer Stop Switch Check
Auto Idle Switch Check

Monitor Circuit Wiring Diagram
Monitor Circuit Operation
Section 9020 - POWERTRAIN
Group 05 - Theory Of Operation
Track Adjuster Operation
Propel Gearbox Operation
Propel Circuit Operation
Propel Control Valve Operation
Rotary Manifold Operation
Propel Motor Operation
Counterbalance Valve Neutral Operation
Counterbalance Valve Propel Operation
Counterbalance Valve Braking Operation
Propel Motor Crossover Relief Valve Operation
Group 10 - System Operational Checks
Undercarriage Checks
Pilot Shut Off Valve Checks
Propel Lever Check
Propel System Tracking Checks
Propel System Tracking Checks (While Operating A Digging Function)
Hydraulic Pump Performance And Propel Cycle Time Checks
Propel Motor Counter Balance Valve Checks
Propel System Relief Valve Check
Propel Brake Check
Track Sag Check
Roller And Idler Leakage Checks
Sprocket Wear Check
Grouser Wear, Bent Track Shoe, And Loose Hardware Checks
Track Link Roller And Front Idler Wear Checks
Pilot Shut Off Valve Checks
Propel Lever Check
Propel System Tracking Checks
Propel System Tracking Checks (While Operating A Digging Function)
Hydraulic Pump Performance And Propel Cycle Time Checks
Propel Motor Counter Balance Valve Checks
Propel System Relief Valve Check
Propel Brake Check
Track Sag Check
Roller And Idler Leakage Checks
Sprocket Wear Check
Grouser Wear, Bent Track Shoe, And Loose Hardware Checks
Track Link Roller And Front Idler Wear Checks
Group 15 - Diagnostic Information
Diagnose Undercarriage Components Malfunctions
Diagnose Propel System Malfunction
Measure Track Bushing Wear
Measure Track Pitch
Measure Track Link Wear
Measure Track Shoe Grouser Wear
Measure Track Roller Wear
Undercarriage Component Location
Group 20 - Adjustments
Adjust Track Sag
Group 25 - Tests
Propel Speed Cycle Time
JT05801 Clamp-On Electronic Tachometer Installation
JT05800 Digital Thermometer Installation
JT39000 Tachometer/Temperature Reader Installation
D-01084AA Tachometer/Temperature Reader Installation
Propel Motor Crossover Relief Valve Test And Adjustment
Propel Motor Operating Leakage Test
Propel Motor Start-Up Procedure
Section 9025 - HYDRAULIC SYSTEM
Group 05 - Theory Of Operation
Hydraulic System
Pilot System Operation
Pilot Pump Operation
Pilot Filter Operation
Solenoid Valve Operation-De-Energized
Solenoid Valve Operation-Energized
Engine Speed Control Operation
Main Hydraulic Pump Displacement Operation
Shut-Off Valve Operation
Pilot Controller Operation-Neutral
Pilot Controller Operation-Metering
Pilot Controller Operation-Full Stroke
Pilot Operation Of Main Control Valve
Flow Regulator Operation
Pressure Regulating Valve 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 Up Work Circuit Operation
Boom Down Work Circuit Operation
Arm In Work Circuit Operation
Arm Out Work Circuit Operation
Swing Work Circuit Operation
Combined Functions Operation
Swing Motor Operation
Swing Cross-Over Relief Valves And Make-Up Valves Operation
Brake Release Circuit Operation
Swing Gearbox Operation
Cylinder Operation
Main Hydraulic Pump Operation
Regulator Components Operation
High-Low Maximum Displacement Operation
Summation System Operation
Constant Horsepower System Operation
Group 10 - System Operational Checks
Hydraulic System Checks
Visual Inspection
Hydraulic System Warmup Procedure
Pilot Shut Off Valve Linkage Checks
Hydraulic Function Control Check
Pressurized Reservoir Check
Pilot Shut Off Valve Checks
Pilot Hand Controller Pattern John Deere Or SAE Check
Dynamic Swing Brake Check
Mechanical Swing Brake Check
Swing Circuit Leakage Check
Dig Function Drift Checks
Control Valve Lift Check Test
Arm Cylinder Head End, Rod End And Boom Cylinder Rod End Cushion Check
Oil Cooler Circuit Check
Engine RPM Pulldown
Engine Rpm Pulldown Fast Idle Check (Combined Pump Pulldown)
System Relief Valve, Arm, Bucket, And Propel Circuit Relief Valves Check
Boom Raise Circuit Relief Valve Check
Cycle Time Check
Hydraulic Pump Performance And Propel Cycle Time Checks
Visual Inspection
Hydraulic System Warmup Procedure
Pilot Shut Off Valve Linkage Checks
Hydraulic Function Control Check
Pressurized Reservoir Check
Pilot Shut Off Valve Checks
Pilot Hand Controller Pattern John Deere Or SAE Check
Dynamic Swing Brake Check
Mechanical Swing Brake Check
Swing Circuit Leakage Check
Dig Function Drift Checks
Control Valve Lift Check Test
Arm Cylinder Head End, Rod End And Boom Cylinder Rod End Cushion Check
Oil Cooler Circuit Check
Engine RPM Pulldown
Engine Rpm Pulldown Fast Idle Check (Combined Pump Pulldown)
System Relief Valve, Arm, Bucket, And Propel Circuit Relief Valves Check
Boom Raise Circuit Relief Valve Check
Cycle Time Check
Hydraulic Pump Performance And Propel Cycle Time Checks
Group 15 - Diagnostic Information
Diagnose Hydraulic System Malfunctions
Diagnose Pilot Circuit Malfunctions
Diagnose Dig Circuit Malfunctions
Diagnose Swing Circuit Malfunctions
Hydraulic Circuit Symbols
Pressure And Return Circuit Component Location
Boom, Arm, Bucket, And Swing Circuits Component Location
Pilot Control Lever Pattern Information
Group 20 - Adjustments
Pilot Shut-Off Valve Linkage Adjustment
Main Hydraulic Pump Displacement Adjustment
Group 25 - Tests
JT39000 Tachometer/Temperature Reader Installation
D01084AA Tachometer/Temperature Reader Installation
JT05801 Clamp-On Electronic Tachometer Installation
JT05800 Digital Thermometer Installation
Hydraulic Pump Start-Up Procedure
Cycle Time Test
Pilot System Regulating Valve Test And Adjustment
Dig System Relief Valve Test And Adjustment
Circuit Relief Valve Test And Adjustment
Swing Motor Crossover Relief Valve Test And Adjustment
Main Hydraulic Pump Performance Test (Cycle Time Method)
Hydraulic Pump Regulator Test And Adjustment (Engine Pulldown)
Hydraulic Pump Flow Test
Pilot Pump Flow Test
Boom, Arm And Bucket Cylinder Drift Test
Swing Motor Leakage Test
Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy