John Deere 200CLC 230CLC & 270CLC Excavator Repair Manual – PDF DOWNLOAD

Description

John Deere 200CLC 230CLC & 270CLC Excavator Repair Manual – PDF DOWNLOAD

DESCRIPTION:

John Deere 200CLC 230CLC & 270CLC Excavator Repair Manual – PDF DOWNLOAD

For complete service information also see:
200CLC, 230CLC, and 270CLC Excavator
Operation and Tests . . . . . . . . . . . . . . . . . . . TM1930
POWERTECHâ 4.5 L & 6.8 L (4045 and 6068)
Diesel Engines, Base Engine . . . . . . . . . . . . CTM104
POWERTECHâ 4.5 L & 6.8 L (4045 and 6068)
Diesel Engines, Level 4 Electronic Fuel
Systems with Bosch VP44 Pump . . . . . . . . . CTM170
Alternators and Starting Motors. . . . . . . . . . CTM77
Undercarriage Appraisal Manual . . . . . . . . . SP326

Introduction
Foreword :

This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use.

• Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual. This is the safety-alert symbol.
• When you see this symbol on the machine or in this manual, be alert to the potential for personal injury. Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components. Operation and tests sections help you identify the majority of routine failures quickly.
• Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values.
• Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair.
• Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.

TABLE OF CONTENTS:

John Deere 200CLC 230CLC & 270CLC Excavator Repair Manual – PDF DOWNLOAD

Contents 5
General Information 9
Safety 11
Recognize Safety Information 11
Follow Safety Instructions 11
Operate Only If Qualified 11
Wear Protective Equipment 12
Avoid Unauthorized Machine Modifications 12
Add Cab Guarding For Special Uses 12
Inspect Machine 13
Stay Clear Of Moving Parts 13
Avoid High-Pressure Fluids 13
Beware Of Exhaust Fumes 14
Prevent Fires 14
Prevent Battery Explosions 14
Handle Chemical Products Safely 15
Dispose Of Waste Properly 15
Prepare For Emergencies 15
Use Steps And Handholds Correctly 16
Start Only From Operator’s Seat 16
Use And Maintain Seat Belt 16
Prevent Unintended Machine Movement 17
Avoid Work Site Hazards 17
Keep Riders Off Machine 18
Avoid Backover Accidents 18
Avoid Machine Tip Over 19
Use Special Care When Lifting Objects 19
Add And Operate Attachments Safely 20
Park And Prepare For Service Safely 20
Service Cooling System Safely 21
Remove Paint Before Welding or Heating 21
Make Welding Repairs Safely 21
Drive Metal Pins Safely 22
Safety Signs 23
Torque Values 25
Unified Inch Bolt and Cap Screw Torque Values 25
Metric Bolt and Cap Screw Torque Values 26
Additional Metric Cap Screw Torque Values 27
Check Oil Lines And Fittings 29
Service Recommendations for O-Ring Boss Fittings 30
Service Recommendations for Flat Face O-Ring Seal Fittings 32
Service Recommendations for 37° Flare and 30° Cone Seat Connectors 33
Service Recommendations For Flared Connections—Straight or Tapered Threads 34
Service Recommendations For Inch Series Four Bolt Flange Fittings 35
Service Recommendations for Metric Series Four Bolt Flange Fitting 36
Tracks 37
Track System 39
Track Roller, Front Idler, and Carrier Roller Oil 39
Track Roller 39
Track Carrier Roller 43
Metal Face Seals Repair 46
Track Shoe 47
Track Chain 48
Broken Track Chain Part Repair 51
Sprocket 52
Front Idler 54
Track Adjuster and Recoil Spring 57
Track Adjuster Cylinder 63
Axles and Suspension Systems (Propel) 65
Axle Shaft, Bearings, and Reduction Gears 67
Propel Gearbox 67
Hydraulic System 81
Propel Motor 81
Propel Motor102
Start-Up Procedure102
Rotary Manifold102
Engine107
Removal and Installation109
Engine Repair109
Fuel Injection Pump Repair112
Starter113
Engine Auxiliary System115
Cooling System117
Radiator117
Fan, Fan Guard and Fan Shroud117
Fan Belt118
Intake System121
Air Intake System Leakage Test121
Air Cleaner122
External Fuel Supply System123
Fuel Tank123
Primary Fuel Filter (Water Separator)125
Final Fuel Filter126
Dampener Drive (Flex Coupling)127
Elements129
Dampener Drive (Flex Coupling)129
Frame or Supporting Structure131
Frame Installation133
Welding On Machine133
Welding Repair of Major Structure134
Chassis Weights135
Counterweight135
Operator’s Station137
Removal and Installation139
Cab139
Operator Enclosure143
Windowpane143
Two Piece Molding143
One Piece Molding144
Sliding Windows145
Windowpanes146
Seat and Seat Belt147
Seat Belt147
Heating and Air Conditioning149
Refrigerant Cautions and Proper Handling149
Flush and Purge Air Conditioner System151
R134a Refrigerant Oil Information154
R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure155
Recover R134a Refrigerant156
Evacuate R134a System157
Charge R134a System158
Compressor159
Receiver-Dryer160
Air Conditioner and Heater162
Condenser164
Excavator165
Buckets167
Bucket167
Repair167
Adjust Pivot End Play169
Pin-Up Data170
Frames171
Bucket Links171
Arm173
Boom176
Inspect Boom, Arm, and Bucket Pins, Bushings and Bosses181
Bushings and Seals184
Hydraulic System185
Hydraulic Oil Tank Pressure Release Procedure185
Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy186
Hydraulic Pump and Drive Gearbox187
Repair187
Start-Up Procedure204
Pilot Pump Drive Shaft and Gear205
Hydraulic Pump Regulator206
Pilot Pump211
Pilot Pressure Regulating Valve and Filter Repair214
Pilot Shut-Off Valve215
Power Boost, Propel Speed, Swing Priority, and Arm Regenerative Solenoid Valve219
Pilot Controller221
Propel Pilot Controller224
Pilot Signal Manifold227
Control Valve233
Hydraulic Oil Tank250
Restriction Valve Repair253
Oil Cooler Bypass Valve255
Oil Cooler258
Remove and Install Boom Cylinder259
Boom Cylinder Disassemble and Assemble—200CLC, 270CLC264
Boom Cylinder Disassemble and Assemble—230CLC278
Arm Cylinder Remove and Install284
Arm Cylinder Disassemble and Assemble—200CLC, 270CLC288
Arm Cylinder Disassemble and Assemble—230CLC302
Bucket Cylinder Remove and Install308
Bucket Cylinder Disassemble and Assemble—200CLC, 270CLC314
Bucket Cylinder Disassemble and Assemble—230CLC328
Hydraulic Cylinder Bleed Procedure336
Swing or Pivoting System337
Mechanical Drive Elements339
Swing Gearbox339
Swing Gearbox349
Start-Up Procedure349
Upperstructure350
Swing Bearing357
Hydraulic System365
Swing Motor and Park Brake365
Crossover Relief Valve and Make-Up Valve375
Swing Motor377
Start-Up Procedure377
Brake Release Valve—270CLC 377
Dealer Fabricated Tools379
Dealer Fabricated Tools381
DF1063 Lift Bracket381
ST4920 Track Recoil Spring383
Disassembly and Assembly Tool383
DFT1087 Track Recoil Spring387
Disassembly and Assembly Guard Tool387
DFT1110 Spacer388
DFT1130 Adapter389
DF1036A Propel Gearbox Nut Wrench390
DF1038 Torque Adapter391
DFT1109 Holding Bar392
Rotary Manifold Lifting Tool393
DFT1089 Barrel Support394
DFT1144 Guide Pin395
DFT1119 Pump Support396
DFT1220 Swing Gearbox Nut Spanner Wrench398

IMAGES PREVIEW OF THE MANUAL:

JOHN DEERE 200CLC 230CLC & 270CLC EXCAVATOR REPAIR MANUAL – PDF DOWNLOAD:

PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

S.V