200d and 200dlc excavator repair deere 507y...200d and 200dlc excavator repair technical manual 200d...

200D and 200DLCExcavator

Repair

TECHNICAL MANUAL200D and 200DLC Excavator Repair

TM10079 17MAR09 (ENGLISH)

For complete service information also see:

200D and 200DLC Excavator Operation andTests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM10076200D and 200DLC Excavator Operator’sManual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OMT226908POWERTECH 4.5L/6.8L POWERTECH E6.8L Diesel Engines—Base Engine . . . . . . . CTM104POWERTECH E 6.8L DieselEngines—Level 16 Electronic Fuel Systemwith Denso HPCR . . . . . . . . . . . . . . . . . . . . . CTM502Alternators and Starter Motors. . . . . . . . . . . CTM77Undercarriage Appraisal Manual . . . . . . . . . SP326Super Caddy Oil Cleanup Procedure . . . . . . CTM310

Worldwide ConstructionAnd Forestry Division

LITHO IN U.S.A.

Introduction

DX,TMIFC –19–29SEP98–1/1

Foreword

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

Live with safety: Read the safety messages in theintroduction of this manual and the cautions presentedthroughout the text of the manual.

This is the safety-alert symbol. When you see thissymbol on the machine or in this manual, be alert tothe potential for personal injury.

Technical manuals are divided in two parts: repair andoperation and tests. Repair sections tell how to repairthe components. Operation and tests sections help youidentify the majority of routine failures quickly.

Information is organized in groups for the variouscomponents requiring service instruction. At thebeginning of each group are summary listings of allapplicable 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 specificmachines. They are on-the-job guides containing onlythe vital information needed for diagnosis, analysis,testing, and repair.

Fundamental service information is available fromother sources covering basic theory of operation,fundamentals of troubleshooting, general maintenance,and basic type of failures and their causes.

TM10079 (17MAR09) 200D and 200DLC Excavator Repair031709

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Introduction

TX,TM,FAX –19–03JUL01–1/1

Technical Information Feedback Form

We need your help to continually improve our technicalpublications. Please copy this page and FAX or mail yourcomments, ideas and improvements.

SEND TO: John Deere Dubuque WorksP.O. Box 538Attn: Publications Supervisor, Dept. 303Dubuque, IA 52004-0538

FAX NUMBER: 563-589-5800

Ideas, Comments (Please State Page Number):

OVERALL, how would you rate the quality of this publication? (Check one)

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THANK YOU!


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Introduction


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Contents00

SECTION 00—General InformationGroup 01—SafetyGroup 0003—Torque Values

SECTION 01—Tracks01Group 0130—Track System

SECTION 02—Axles, Differentials and SuspensionSystems

Group 0250—Axle Shaft, Bearings, and ReductionGears

Group 0260—Hydraulic System

SECTION 04—EngineGroup 0400—Removal and Installation

02

SECTION 05—Engine Auxiliary SystemGroup 0510—Cooling SystemGroup 0520—Intake SystemGroup 0560—External Fuel Supply System

SECTION 07—Dampener Drive (Flex Coupling)Group 0752—Elements

SECTION 17—Frame or Supporting StructureGroup 1740—Frame InstallationGroup 1749—Chassis Weights

04

SECTION 18—Operator’s StationGroup 1800—Removal and InstallationGroup 1810—Operator EnclosureGroup 1821—Seat and Seat BeltGroup 1830—Heating and Air Conditioning

SECTION 33—ExcavatorGroup 3302—BucketsGroup 3340—FramesGroup 3360—Hydraulic System

05

SECTION 43—Swing or Pivoting SystemGroup 4350—Mechanical Drive ElementsGroup 4360—Hydraulic System

SECTION 99—Dealer Fabricated ToolsGroup 9900—Dealer Fabricated Tools

All information, illustrations and specifications in this manual are based onthe latest information available at the time of publication. The right isreserved to make changes at any time without notice.

07

COPYRIGHT 2009DEERE & COMPANY

Moline, IllinoisAll rights reserved

A John Deere ILLUSTRUCTION ManualPrevious Editions

Copyright 2007, 2008

17

18

33

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TM10079 (17MAR09) i 200D and 200DLC Excavator Repair031709

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Contents

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TM10079 (17MAR09) ii 200D and 200DLC Excavator Repair031709

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TM10079 (17MAR09) iii 200D and 200DLC Excavator Repair031709

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TM10079 (17MAR09) iv 200D and 200DLC Excavator Repair031709

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00

Section 00General Information

Contents

Page

Group 01—Safety . . . . . . . . . . . . . . . . . . . . . .00-01-1

Group 0003—Torque ValuesTorque Value

Metric Bolt and Cap Screw . . . . . . . . . . . .00-0003-1Additional Metric Cap Screw Torque

Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-2Torque Value

Unified Inch Bolt and Cap Screw . . . . . . . .00-0003-4Service Recommendations for 37° Flare

and 30° Cone Seat Connectors . . . . . . . . .00-0003-5Service Recommendations for O-Ring

Boss Fittings . . . . . . . . . . . . . . . . . . . . . . .00-0003-6Service Recommendation

O-Ring Boss Fittings In AluminumHousingExcavators. . . . . . . . . . . . . . . . .00-0003-8

Service Recommendations For FlaredConnections—Straight or TaperedThreads . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-10

Service Recommendations For Flat FaceO-Ring Seal Fittings. . . . . . . . . . . . . . . . .00-0003-11

Service RecommendationO-Ring Face Seal Fittings with SAE

Inch Hex Nut and Stud End for HighPressure. . . . . . . . . . . . . . . . . . . . . . . .00-0003-12

O-Ring Face Seal Fittings with MetricHex Nut and Stud End for StandardPressure. . . . . . . . . . . . . . . . . . . . . . . .00-0003-14

O-Ring Face Seal Fittings with MetricHex Nut and Stud End for HighPressure. . . . . . . . . . . . . . . . . . . . . . . .00-0003-16

Service Recommendations for MetricSeries Four Bolt Flange Fitting . . . . . . . .00-0003-18

Service Recommendations For InchSeries Four Bolt Flange Fittings. . . . . . . .00-0003-19

Inch Series Four Bolt Flange Fitting ForHigh Pressure ServiceRecommendations . . . . . . . . . . . . . . . . . .00-0003-20

TM10079 (17MAR09) 00-1 200D and 200DLC Excavator Repair031709

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Contents

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TM10079 (17MAR09) 00-2 200D and 200DLC Excavator Repair031709

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Group 01Safety

00011

TX03679,00016CC –19–03JAN07–1/1

Recognize Safety Information

T13

3555

–UN

–28A

UG

00T

1335

88–1

9–28

AU

G00

This is the safety alert symbol. When this symbol isnoticed on the machine or in this manual, be alert forthe potential of personal injury.

Follow the precautions and safe operating practiceshighlighted by this symbol.

A signal word — DANGER, WARNING, or CAUTION — isused with the safety alert symbol. DANGER identifies themost serious hazards.

On the machine, DANGER signs are red in color,WARNING signs are orange, and CAUTION signs areyellow. DANGER and WARNING signs are located nearspecific hazards. General precautions are on CAUTIONlabels.

TX03679,00016F9 –19–03JAN07–1/1

Follow Safety Instructions

T13

3556

–UN

–24A

UG

00

Read the safety messages in this manual and on themachine. Follow these warnings and instructions carefully.Review them frequently.

Be sure all operators of this machine understand everysafety message. Replace operator’s manual and safetylabels immediately if missing or damaged.

TX03679,00016FA –19–03JAN07–1/1

Operate Only If Qualified

Do not operate this machine unless the operator’smanual has been read carefully, and you have beenqualified by supervised training and instruction.

Operator should be familiar with the job site andsurroundings before operating. Try all controls and

machine functions with the machine in an open areabefore starting to work.

Know and observe all safety rules that may apply toevery work situation and work site.

TM10079 (17MAR09) 00-01-1 200D and 200DLC Excavator Repair031709

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Safety

0001

2

TX03679,00016D0 –19–03JAN07–1/1

Wear Protective Equipment

TS

206

–UN

–23A

UG

88

Guard against injury from flying pieces of metal or debris;wear goggles or safety glasses.

Wear close fitting clothing and safety equipmentappropriate to the job.

Prolonged exposure to loud noise can cause impairmentor loss of hearing. Wear suitable hearing protection suchas earmuffs or earplugs to protect against objectionable oruncomfortable loud noises.

AM40430,00000A9 –19–29JUL08–1/1

Avoid Unauthorized Machine Modifications

John Deere recommends using only genuine JohnDeere replacement parts to ensure machineperformance. Never substitute genuine John Deereparts with alternate parts not intended for theapplication as these can create hazardous situations orhazardous performance. Non-John Deere Parts, or anydamage or failures resulting from their use are notcovered by any John Deere warranty.

Modifications of this machine, or addition ofunapproved products or attachments, may affect

machine stability or reliability, and may create a hazardfor the operator or others near the machine. Theinstaller of any modification which may affect theelectronic controls of this machine is responsible forestablishing that the modification does not adverselyaffect the machine or its performance.

Always contact an authorized dealer before makingmachine modifications that change the intended use,weight or balance of the machine, or that altermachine controls, performance or reliability.


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Safety

00013

TX03679,00016CE –19–03JAN07–1/1

Add Cab Guarding for Special Uses

T13

3733

–UN

–15S

EP

00

Special work situations or machine attachments maycreate an environment with falling or flying objects.Working near an overhead bank, doing demolition work,using a hydraulic hammer, or working in a wooded area,for example, may require added guarding to protect theoperator.

FOPS (falling object protective structures) and specialscreens or guarding should be installed when falling orflying objects may enter or damage the machine. Contactyour authorized dealer for information on devices intendedto provide protection in special work situations.

TX03679,0001734 –19–03JAN07–1/1

Inspect Machine

T66

07A

Q–U

N–1

8OC

T88

Inspect machine carefully each day by walking around itbefore starting.

Keep all guards and shields in good condition andproperly installed. Fix damage and replace worn or brokenparts immediately. Pay special attention to hydraulichoses and electrical wiring.

TX03679,00016D2 –19–03JAN07–1/1

Stay Clear of Moving Parts

T13

3592

–UN

–12S

EP

01Entanglements in moving parts can cause serious injury.

Stop engine before examining, adjusting or maintainingany part of machine with moving parts.

Keep guards and shields in place. Replace any guard orshield that has been removed for access as soon asservice or repair is complete.


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Safety

0001

4

DX,FLUID –19–03MAR93–1/1

Avoid High-Pressure Fluids

X98

11–U

N–0

8DE

C08

Escaping fluid under pressure can penetrate the skincausing serious injury.

Avoid the hazard by relieving pressure beforedisconnecting hydraulic or other lines. Tighten allconnections before applying pressure.

Search for leaks with a piece of cardboard. Protect handsand body from high pressure fluids.

If an accident occurs, see a doctor immediately. Any fluidinjected into the skin must be surgically removed within afew hours or gangrene may result. Doctors unfamiliar withthis type of injury should reference a knowledgeablemedical source. Such information is available from Deere& Company Medical Department in Moline, Illinois, U.S.A.

TX03679,00016D3 –19–03NOV08–1/1

Avoid High-Pressure Oils

T13

3509

–UN

–17M

AR

06T

1338

40–U

N–2

0SE

P00

This machine uses a high-pressure hydraulic system.Escaping oil under pressure can penetrate the skincausing serious injury.

Never search for leaks with your hands. Protect hands.Use a piece of cardboard to find location of escaping oil.Stop engine and relieve pressure before disconnectinglines or working on hydraulic system.

If hydraulic oil penetrates your skin, see a doctorimmediately. Injected oil must be removed surgicallywithin hours or gangrene may result. Contact aknowledgeable medical source or the Deere & CompanyMedical Department in Moline, Illinois, U.S.A.


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Safety

00015

TX03679,00016D4 –19–03NOV08–1/1

Beware of Exhaust Fumes

T13

3546

–UN

–24A

UG

00

Prevent asphyxiation. Engine exhaust fumes can causesickness or death.

If you must operate in an enclosed space, provideadequate ventilation. Use an exhaust pipe extension toremove the exhaust fumes or open doors and windows tobring outside air into the area.

TX03679,00016F5 –19–03NOV08–1/1

Prevent Fires

T13

3552

–UN

–14S

EP

00T

1335

53–U

N–0

7SE

P00

T13

3554

–UN

–07S

EP

00

Handle Fuel Safely: Store flammable fluids away fromfire hazards. Never refuel machine while smoking or whennear sparks or flame.

Clean Machine Regularly: Keep trash, debris, greaseand oil from accumulating in engine compartment, aroundfuel lines, hydraulic lines, exhaust components, andelectrical wiring. Never store oily rags or flammablematerials inside a machine compartment.

Maintain Hoses and Wiring: Replace hydraulic hosesimmediately if they begin to leak, and clean up any oilspills. Examine electrical wiring and connectors frequentlyfor damage.

Keep A Fire Extinguisher Available: Always keep amultipurpose fire extinguisher on or near the machine.Know how to use extinguisher properly.

TX03679,000174A –19–03NOV08–1/1

Prevent Battery Explosions

TS

204

–UN

–23A

UG

88

Battery gas can explode. Keep sparks, lighted matches,and open flame away from the top of battery.

Never check battery charge by placing a metal objectacross the posts. Use a voltmeter or hydrometer.

Do not charge a frozen battery; it may explode. Warmbattery to 16°C (60°F).


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Safety

0001

6

TX03679,00016D7 –19–03JAN07–1/1

Handle Chemical Products Safely

T13

3580

–UN

–25A

UG

00

Exposure to hazardous chemicals can cause seriousinjury. Under certain conditions, lubricants, coolants,paints and adhesives used with this machine may behazardous.

If uncertain about safe handling or use of these chemicalproducts, contact your authorized dealer for a MaterialSafety Data Sheet (MSDS) or go to internet websitehttp://www.jdmsds.com. The MSDS describes physicaland health hazards, safe use procedures, and emergencyresponse techniques for chemical substances. FollowMSDS recommendations to handle chemical productssafely.

TX03679,0001733 –19–03JAN07–1/1

Dispose of Waste Properly

T13

3567

–UN

–25A

UG

00

Improper disposal of waste can threaten the environment.Fuel, oils, coolants, filters and batteries used with thismachine may be harmful if not disposed of properly.

Never pour waste onto the ground, down a drain, or intoany water source.

Air conditioning refrigerants can damage the atmosphere.Government regulations may require using a certifiedservice center to recover and recycle used refrigerants.

If uncertain about the safe disposal of waste, contact yourlocal environmental or recycling center or your authorizeddealer for more information.

TX03679,000174B –19–03JAN07–1/1

Prepare for Emergencies

TS

291

–UN

–23A

UG

88

Be prepared if an emergency occurs or a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service,hospital, and fire department near your telephone.


PN=14

Safety

00017

TX03679,00016F2 –19–15MAR07–1/1

Use Steps and Handholds Correctly

T13

3468

–UN

–30A

UG

00

Prevent falls by facing the machine when getting on andoff. Maintain 3-point contact with steps and handrails.Never use machine controls as handholds.

Use extra care when mud, snow, or moisture presentslippery conditions. Keep steps clean and free of greaseor oil. Never jump when exiting machine. Never mount ordismount a moving machine.

TX03679,0001799 –19–03JAN07–1/1

Start Only From Operator’s Seat

T13

3715

–UN

–07S

EP

00Avoid unexpected machine movement. Start engine onlywhile sitting in operator’s seat. Ensure all controls andworking tools are in proper position for a parked machine.

Never attempt to start engine from the ground. Do notattempt to start engine by shorting across the startersolenoid terminals.

TX03679,00016DD –19–02DEC08–1/1

Use and Maintain Seat Belt

T13

3716

–19–

14S

EP

00Use seat belt when operating machine. Remember tofasten seat belt when loading and unloading from trucksand during other uses.

Examine seat belt frequently. Be sure webbing is not cutor torn. Replace seat belt immediately if any part isdamaged or does not function properly.

The complete seat belt assembly should be replacedevery three years, regardless of appearance.


PN=15

Safety

0001

8

DW90712,00002C0 –19–03JAN07–1/1

Prevent Unintended Machine Movement

T21

6779

–UN

–22N

OV

05

Be careful not to accidentally actuate control levers whenco-workers are present. Pull pilot control shutoff lever tolocked position during work interruptions. Pull pilot controlshutoff lever to locked position and stop engine beforeallowing anyone to approach machine.

Always lower work equipment to the ground and pull pilotcontrol shutoff lever to locked position before standing upor leaving the operator’s seat. Stop engine before exiting.


PN=16

Safety

00019

AM40430,0000098 –19–24JAN07–1/1

Avoid Work Site Hazards

T19

2984

–UN

–26A

UG

03T

1419

04–U

N–1

5MA

Y01

Avoid contact with gas lines, buried cables and waterlines. Call utility line location services to identify allunderground utilities before starting work.

Prepare work site properly. Avoid operating nearstructures or objects that could fall onto the machine.Clear away debris that could move unexpectedly if runover.

Avoid boom or attachment contact with overheadobstacles or overhead electrical lines. Never movemachine closer than 3 m (10 ft) plus twice the lineinsulator length to overhead wires.

Keep bystanders clear at all times. Use barricades or asignal person to keep vehicles and pedestrians away. Usea signal person if moving machine in congested areas orwhere visibility is restricted. Always keep signal person inview. Coordinate hand signals before starting machine.

Operate only on solid footing with strength sufficient tosupport machine. Be especially alert working nearembankments or excavations.

Avoid working under over-hanging embankments orstockpiles that could collapse under or on machine.

Reduce machine speed when operating with tool on ornear ground when obstacles may be hidden (e.g., duringsnow removal or clearing mud, dirt, etc.). At high speedshitting obstacles (rocks, uneven concrete or manholes)can cause a sudden stop. Always wear your seat belt.

TX03679,0001726 –19–03JAN07–1/1

Keep Riders Off Machine

T72

73A

H–U

N–0

8JU

N90

Only allow operator on machine.

Riders are subject to injury. They may fall from machine,be caught between machine parts, or be struck by foreignobjects.

Riders may obstruct operator’s view or impair his ability tooperate machine safely.


PN=17

Safety

000110

TX03679,00016F3 –19–03JAN07–1/1

Avoid Backover Accidents

T13

3548

–UN

–24A

UG

00

Before moving machine, be sure all persons are clearof both travel and swing paths. Turn around and lookdirectly for best visibility. Use mirrors to assist in checkingall around machine. Keep windows and mirrors clean,adjusted, and in good repair.

Be certain travel alarm is working properly.

Use a signal person when backing if view isobstructed or when in close quarters. Keep signalperson in view at all times. Use prearranged hand signalsto communicate.

TX03679,00016DF –19–03JAN07–1/1

Avoid Machine Tip Over

T13

3716

–19–

14S

EP

00T

1335

45–U

N–1

5SE

P00

T13

3803

–UN

–27S

EP

00

Use seat belt at all times.

Do not jump if the machine tips. You will be unlikely tojump clear and the machine may crush you.

Load and unload from trucks or trailers carefully. Besure truck is wide enough and on a firm level surface. Useloading ramps and attach them properly to truck bed.Avoid trucks with steel beds because tracks slip moreeasily on steel.

Be careful on slopes. Use extra care on soft, rocky orfrozen ground. Machine may slip sideways in theseconditions. When traveling up or down slopes, keep thebucket on uphill side and just above ground level.

Be careful with heavy loads. Using oversize buckets orlifting heavy objects reduces machine stability. Extendinga heavy load or swinging it over side of undercarriagemay cause machine to tip.

Ensure solid footing. Use extra care when operatingnear banks or excavations that may cave-in and causemachine to tip or fall.


PN=18

Safety

000111

TX03679,00016E1 –19–03JAN07–1/1

Use Special Care When Lifting Objects

T13

3839

–UN

–27S

EP

00

Never use this machine to lift people.

Never lift a load above another person. Keep bystandersclear of all areas where a load might fall if it breaks free.Do not leave the seat when there is a raised load.

Do not exceed lift capacity limits posted on machine andin this manual. Extending heavy loads too far or swingingover undercarriage side may cause machine to tip over.

Use proper rigging to attach and stabilize loads. Be sureslings or chains have adequate capacity and are in goodcondition. Use tether lines to guide loads and prearrangedhand signals to communicate with co-workers.

TX03679,00016F0 –19–12FEB07–1/1

Add and Operate Attachments Safely

Always verify compatibility of attachments by contactingyour authorized dealer. Adding unapproved attachmentsmay affect machine stability or reliability and may create ahazard for others near the machine.

Ensure that a qualified person is involved in attachmentinstallation. Add guards to machine if operator protectionis required or recommended. Verify that all connectionsare secure and attachment responds properly to controls.

Carefully read attachment manual and follow allinstructions and warnings. In an area free of bystandersand obstructions, carefully operate attachment to learn itscharacteristics and range of motion.


PN=19

Safety

000112

TX03679,00016E9 –19–03JAN07–1/1

Park and Prepare for Service Safely

T13

3332

–19–

14D

EC

01T

S22

9–U

N–2

3AU

G88

Warn others of service work. Always park and prepareyour machine for service or repair properly.

• Park machine on a level surface and lower equipmentand attachments to the ground.

• Place pilot shutoff lever in “lock” position. Stop engineand remove key.

• Attach a “Do Not Operate” tag in an obvious place inthe operator’s station.

Securely support machine or attachment before workingunder it.

• Do not support machine with boom, arm, or otherhydraulically actuated attachments.

• Do not support machine with cinder blocks or woodenpieces that may crumble or crush.

• Do not support machine with a single jack or otherdevices that may slip out of place.

Understand service procedures before beginning repairs.Keep service area clean and dry. Use two peoplewhenever the engine must be running for service work.

DX,RCAP –19–04JUN90–1/1

Service Cooling System Safely

TS

281

–UN

–23A

UG

88Explosive release of fluids from pressurized coolingsystem can cause serious burns.

Shut off engine. Only remove filler cap when cool enoughto touch with bare hands. Slowly loosen cap to first stopto relieve pressure before removing completely.


PN=20

200d and 200dlc excavator repair deere 507y...200d and 200dlc excavator repair technical manual 200d...

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