John Deere 790ELC Excavator Repair Manual TM1507 25MAY21

Table of contents
FOREWORD
Section 00 – GENERAL INFORMATION
Group 0001 – 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 0002 – General Specifications
790E LC General Specifications
790E LC Working Ranges Specifications
790E LC Engine Specifications
790E LC Long Front Specifications
790E LC Drain And Refill Capacities
790E LC Lift Capacity in kg (lb)-1 of 5)
790E LC Lift Capacity in kg (lb)-2 of 5
790E LC Lift Capacity in kg (lb)-3 of 5
790E LC Lift Capacity in kg (lb)-4 of 5
790E LC Lift Capacity in kg (lb)-5 of 5
790E LC Lift Capacity-KG (LB)
Group 0003 – 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 0004 – Fuels And Lubricants
Fuel Specifications
Fuel Storage
Engine Oil
Hydraulic Oil
Swing Gearbox, Propel Gearbox And Pump Gearbox Oils
Track Roller, Front Idler, And Carrier Roller Oil
Grease
Engine Coolant
Cold Weather Operation
Alternative and Synthetic Lubricants
Lubricant Storage
Section 01 – TRACKS
Group 0130 – Track System
Service Equipment And Tools
Other Material
Specifications
Measure Lower Track Roller Wear
Remove And Install Lower Track Roller
Disassemble And Assemble Lower Track Roller
Test Lower Track Roller For Oil Leakage
Measure Upper Track Roller Wear
Remove And Install Upper Track Roller
Disassemble And Assemble Upper Track Roller
Inspect Metal Face Seals
Measure Track Shoe Grouser Wear
Remove And Install Track Shoe
Measure Track Chain Link Wear
Measure Track Chain Bushing Wear
Measure Track Chain Pitch
Remove Track Chain
Install Track Chain
Disassemble And Assemble Track Chain
Disassemble And Assemble Track Chain To Replace Broken Part
Adjust Track Sag
Remove And Install Sprocket
Measure Front Idler Wear
Remove And Install Front Idler
Disassemble Front Idler
Assemble Front Idler
Test Front Idler For Oil Leakage
Remove And Install Track Adjuster Cylinder And Recoil Spring
Disassemble And Assemble Track Adjuster Recoil Spring
Disassemble And Assemble Track Adjuster Cylinder
Section 02 – AXLES AND SUSPENSION SYSTEMS
Group 0250 – Axle Shaft, Bearings, And Reduction Gears
Service Equipment And Tools
Other Material
Specifications
Towing Machine
Remove And Install Propel Gearbox
Disassemble Propel Gearbox
Inspect Metal Face Seals
Disassemble And Assemble First And Second Planet Carriers
Disassemble And Assemble Third Planet Carrier
Assemble Propel Gearbox
Group 0260 – Hydraulic System
Special Or Essential Tools
Service Equipment And Tools
Other Material
Specifications
Remove And Install Propel Motor And Brake
Propel Motor Start-Up Procedure
Disassemble Propel Motor And Brake
Assemble Propel Motor And Brake
Disassemble And Assemble Propel Motor Brake Valve Housing
Remove And Install Rotary Manifold
Disassemble And Assemble Rotary Manifold
Rotary Manifold Air Test
Section 04 – ENGINE
Group 0400 – Removal And Installation
6068 John Deere Engine-Use CTM8
Special Or Essential Tools
Service Equipment And Tools
Other Material
Specifications
Remove Engine
Install Engine
Remove And Install Oil Pan
Removing DB4 Fuel Injection Pump
Installing DB4 Fuel Injection Pump
Bleed Fuel System
Measure And Adjust Engine Valve Lash (Clearance)
Remove And Install Starter
Section 05 – ENGINE AUXILIARY SYSTEMS
Group 0505 – Cold Weather Starting Aids
Other Material
Specifications
Remove And Install Starting Aid Solenoid And Nozzle
Remove And Install Engine Coolant Heater
Group 0510 – Cooling System
Remove And Install Fan, Shroud, And Guards
Remove And Install Radiator
Remove And Install Fan Belt
Group 0515 – Speed Controls
Other Material
Specifications
Remove And Install Engine Speed Control Linkage
Engine Speed And Control Linkage Adjustment
Remove And Install Engine Control (EC) Motor And Sensor
Disassemble And Assemble Engine Control (EC) Motor And Sensor
Group 0520 – Intake System
Special Or Essential Tools
Service Equipment And Tools
Specifications
Remove And Install Air Cleaner
Air Intake System Leakage Test
Group 0560 – External Fuel Supply System
Other Material
Specifications
Remove And Install Fuel Tank
Remove And Install Water Separator Filter
Disassemble And Assemble Water Separator Filter
Section 07 – DAMPENER DRIVE (FLEX COUPLING)
Group 0752 – Elements
Other Material
Specifications
Remove And Install Dampener Drive (Flex Coupling)
Section 16 – ELECTRICAL SYSTEM
Group 1671 – Batteries, Support, And Cables
Service Equipment And Tools
Specifications
Handle Batteries Safely
Procedure For Testing Batteries
Checking Electrolyte Specific Gravity
Check Battery Electrolyte Level And Terminals
Using Booster Batteries-24-Volt System
Charge Battery
Remove And Install Batteries
Adding 12-Volt Accessories
Group 1672 – Alternator, Regulator, And Charging System Wiring
Alternators And Starting Motors-Use CTM77
Specifications
Remove And Install Alternator
Group 1674 – Wiring Harness And Switches
Special Or Essential Tools
Front Chassis Electrical Component Identification
Cab Electrical Component Identification
Hydraulic Electrical Component Identification
Engine Electrical Component Identification
Connecting Engine Controller (EC) And Pump And Valve Controller (PVC) Harness Connector
Disconnecting Spring Wire Retainer Connectors
Disconnecting Tab Retainer Connectors
Replacing Fuses
Fuse (Blade-Type) Color Codes
Remove And Install Cab Ground Straps
Remove And Install Starter Switch
Remove And Install Dome Light Switch
Remove And Install Propel Alarm Cancel Switch And Start Aid Switch
Replace Deutsch Deutsch is a trademark of Deutsch Company Connectors
Install Deutsch DEUTSCH is a trademark of the Deutsch Co.Contact
Replace Weather Pack Weather Pack is a trademark of Packard Electric.Connector
Install Weather Pack WEATHER PACK is a trademark of Packard Electric.Contact
Remove Connector Body From Blade Terminals
Group 1675 – System Controls
Welding On Machine
Connecting Engine Controller (EC) And Pump And Valve Controller (PVC) Harness Connector
Remove And Install Engine Controller (EC), And Pump And Valve Controller (PVC)
Remove And Install Monitor Controller
Group 1676 – Instruments And Indicators
Replace Monitor Panel Bulbs
Remove And Install Monitor Panel
Remove And Install Switch Panel 1
Remove And Install Hour Meter, Coolant Temperature And Fuel Level Gauges
Replace Switch Panel 2 Bulb
Remove And Install Switch Panel 2
Section 17 – FRAME OR SUPPORTING STRUCTURE
Group 1740 – Frame Installation
Specifications
Welding On Machine
Welding Repair Of Major Structure
Group 1749 – Chassis Weights
Service Equipment And Tools
Specifications
Remove And Install Counterweight
Section 18 – OPERATOR’S STATION
Group 1800 – Removal And Installation
Specifications
Remove And Install Cab
Group 1810 – Operator Enclosure
Service Equipment And Tools
Other Material
Remove And Install Windowpane And Two Piece Molding
Remove And Install Windowpane And One Piece Molding
Remove And Install Sliding Windows
Windowpane Dimensions
Group 1821 – Seat And Seat Belt
Specifications
Remove And Install Seat
Disassemble And Assemble Seat (Early Machine)
Disassemble And Assemble Seat (S.N. 538405-)
Disassemble And Assemble Seat Stand (Early Machine)
Disassemble And Assemble Seat Stand (S.N. 538405-)
Group 1830 – Heating And Air Conditioning
Remove And Install Blower Motor
Remove And Install Heater Core And Blower Motor Relay
Section 20 – SAFETY AND CONVENIENCE
Group 2004 – Horn And Warning Devices
Remove And Install Travel Alarm
Changing Travel Alarm Volume
Section 33 – EXCAVATOR
Group 3302 – Bucket
Specifications
Replacing Bucket Teeth
Replacing Bucket Tooth Tip-Heavy-Duty Bucket
Remove And Install Tooth Shank
Remove And Install Bucket And Linkage
Adjust Bucket Linkage
Welding On Machine
Replace Welded Bucket Cutting Edges
Repair Cracked Cutting Edge
Group 3340 – Frames
Service Equipment And Tools
Specifications
Remove And Install Arm
Remove And Install Boom
Inspect Arm And Boom Pins And Bushings
Remove And Install Bushings And Seals
Group 3360 – Hydraulic System
Special Or Essential Tools
Service Equipment And Tools
Other Material
Specifications
Control Lever Pattern Conversion
Release Pressure In Hydraulic System
Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy
Remove And Install Hydraulic Pump
Hydraulic Pump Start-Up Procedure
Disassemble Hydraulic Pump (S.N. -014999)
Assemble Hydraulic Pump (S.N. -014999)
Disassemble Hydraulic Pump (S.N. 015000-)
Assemble Hydraulic Pump (S.N. 015000-)
Remove And Install Hydraulic Pump Displacement Solenoid Valve
Remove And Install Engine Speed Sensor
Remove And Install Hydraulic Pump Angle Sensor
Hydraulic Pump Angle Sensor (A Sensor) Adjustment
Remove And Install Pilot Pump (S.N. -014999)
Remove And Install Pilot Pump (S.N. 015000-)
Disassemble And Assemble Pilot Pump
Remove And Install Pilot Filter
Hydraulic Oil Filter Inspection Procedure
Remove And Install Proportional Solenoid Valve
Disassemble And Assemble Proportional Solenoid Valve
Remove And Install Pilot Pressure Regulating Valve
Remove And Install Pilot Pressure Reducing Valve
Remove And Install Pilot Shut-Off Valve
Disassemble And Assemble Pilot Shut-Off Valve
Pilot Shut-Off Valve Linkage Adjustment
Remove And Install Dig Function Pilot Controller
Disassemble And Assemble Dig Function Pilot Controller
Remove And Install Dig Function Pilot Controller Check Valve
Disassemble And Assemble Dig Function Pilot Controller Check Valve
Remove And Install Dig Function Pilot Flow Regulator Valve
Disassemble And Assemble Dig Function Pilot Flow Regulator Valve (S.N. -010025)
Disassemble And Assemble Dig Function Pilot Flow Regulator Valve (S.N. 010026-014999)
Disassemble And Assemble Dig Function Pilot Flow Regulator Valve (S.N. 015000-)
Remove And Install Propel Pilot Controller
Disassemble And Assemble Propel Pilot Controller
Remove And Install Propel Pilot Check Valve Block (S.N. -014999)
Disassemble And Assemble Propel Pilot Check Valve Block (S.N. -014999)
Remove And Install Propel Pilot Function Flow Regulator Valve
Disassemble And Assemble Propel Pilot Function Flow Regulator Valve (S.N. -014999)
Disassemble And Assemble Propel Pilot Function Flow Regulator Valve (S.N. 015000-)
Remove And Install Main Control Valve
Disassemble And Assemble Main Control Valve
Remove And Install Differential Pressure Sensor
Remove And Install Surge Relief Valve
Remove And Install System Relief Valve
Disassemble And Assemble System Relief Valve (S.N. -014999)
Disassemble And Assemble System Relief Valve (S.N. 015000-)
Remove And Install Unloading Valve
Remove And Install Circuit Relief And Anti-Cavitation Valve
Disassemble And Assemble Circuit Relief And Anti-Cavitation Valve
Remove And Install Regenerative Valve
Remove And Install Variable Pressure Compensator Valve
Remove And Install Anti-Drift Valve
Remove And Install Shuttle Valve
Remove And Install Arm In Pressure Sensor (S.N. 015000-)
Remove And Install Boom Cylinder
Remove And Install Arm Cylinder
Remove And Install Bucket Cylinder
Hydraulic Cylinder Bleed Procedure
Disassemble Bucket, Arm, Or Boom Cylinder
Assemble Bucket, Arm, Or Boom Cylinder
Remove And Install Hydraulic Oil Cooler
Remove And Install Hydraulic Oil Cooler Bypass Valve
Remove And Install Swing Make-Up Restriction Valve
Remove And Install Return Filter And Bypass Valve
Remove And Install Reservoir
Disassemble And Assemble Reservoir
Section 43 – SWING ROTATION OR PIVOTING SYSTEM
Group 4350 – Mechanical Drive Elements
Service Equipment And Tools
Other Material
Specifications
Remove And Install Swing Gearbox
Swing Gearbox Start-Up Procedure
Disassemble And Assemble Swing Gearbox
Remove Upperstructure
Install Upperstructure
Remove And Install Swing Bearing
Disassemble And Assemble Swing Bearing
Install Swing Bearing Upper Seal
Install Swing Bearing Lower Seal
Group 4360 – Hydraulic System
Specifications
Remove And Install Swing Motor And Brake
Swing Motor Start-Up Procedure
Disassemble Swing Motor And Brake
Assemble Swing Motor And Brake
Disassemble And Assemble Swing Motor Make-Up And Crossover Relief Valves
Remove And Install Swing Stop Cushion Valve
Disassemble And Assemble Swing Stop Cushion Valve
Disassemble And Assemble Swing Brake Release Solenoid Valve
Section 99 – DEALER FABRICATED TOOLS
Group 9900 – Dealer Fabricated Tools
ST4920 Track Recoil Spring Disassembly And Assembly Tool
DFT1087 Track Recoil Spring Disassembly And Assembly Guard Tool
DFT1110 Spacer
DF1036A Propel Gearbox Nut Wrench
DFT1109 Holding Bar
Rotary Manifold Lifting Tool
DFT1089 Barrel Support
DFT1114 Guide Pin
DFT1119 Pump Support

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For complete service information also see:
790E LC Excavator Diagnostic TM1506
North American 3029 , 4039, 4045, 6059
and 6068 Diesel Engines CTM8
Alternators and Starting Motors CTM77
PowerTech 4.5L & 6.8L Diesel Engines
Tier 1/Stage I, Tier 2/Stage II, Tier
3/Stage IIIA, Tier 3/Stage IIA Tier 3/Stage
III, (Base Engine)
CTM104
JDG10274 Ultrasonic Undercarriage
Measurement Gauge CTM10001