Complete service repair manual for John Deere 200LC Excavator, with all the workshop information to maintain, repair, and rebuild like professional mechanics.

John Deere 200LC workshop service repair manual includes:
* 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.
* 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.

TM1664 - John Deere 200LC Excavator Technical Manual - Repair.pdf

Total Pages: 849 pages
File Format: PDF (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English

MAIN SECTIONS
 Foreword
   Technical Information Feedback Form
   General Information
      Safety
      General Specifications
      Torque Values
      Fuels and Lubricants
   Tracks
      Track System
   Axles and Suspension Systems (Propel)
      Axle Shaft, Bearings, and Reduction Gears
      Hydraulic System
   Engine
      Removal and Installation
   Engine Auxiliary System
      Cold Weather Starting Aids
      Cooling System
      Speed Controls
      Intake System
      External Fuel Supply System
   Dampener Drive (Flex Coupling)
      Elements
   Electrical System
      Batteries, Support, and Cables
      Alternator, Regulator, and Charging System Wiring
      Wiring Harness and Switches
      System Controls
      Instruments and Indicators
   Frame or Supporting Structure
      Frame Installation
      Chassis Weights
   Operator’s Station
      Removal and Installation
      Operator Enclosure
      Seat and Seat Belt
      Heating and Air Conditioning
   Excavator
      Buckets
      Frames
      Hydraulic System
   Swing or Pivoting System
      Mechanical Drive Elements
      Hydraulic System
   Dealer Fabricated Tools

Table of Contents
Foreword
Technical Information Feedback Form
Section 00: General Information
Group 0001: Safety
Follow Safe Procedures
Prepare for Emergencies
Handle Fluids Safely—Avoid Fires
Prevent Battery Explosions
Handle Chemical Products Safely
Prevent Acid Burns
Avoid High-Pressure Fluids
Warn Others of Service Work
Park Machine Safely
Support Machine Properly
Operate Only from Operator's Seat
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
Excavator Overview
200LC Specifications
200LC Working Ranges
200LC Engine Specifications
200LC Drain and Refill Capacities
Group 0003: Torque Values
Unified Inch Bolt and Screw Torque Values
Metric Bolt and Screw Torque Values
Additional Metric Cap Screw Torque Values
Check Oil Lines And Fittings
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
Diesel Fuel
Lubricity of Diesel Fuels
Low Sulfur Diesel Fuel Conditioner
Diesel Fuel Storage
Fuel Tank
Do Not Use Galvanized Containers
Diesel Engine Oil — Non-Emissions Certified and Certified Tier 1 and Stage I
Hydraulic Oil
Swing Gearbox, Propel Gearbox and Pump Gearbox Oils
Track Roller, Front Idler, and Carrier Roller Oil
Track Adjuster, Working Tool Pivot, Swing Bearing, and Swing Bearing Gear Grease
Oil Filters
Lubricant Storage
Alternative and Synthetic Lubricants
Mixing of Lubricants
Section 01: Tracks
Group 0130: Track System
Service Equipment and Tools
Other Material
Specifications
Measure Track Roller Wear
Remove and Install Track Roller
Disassemble and Assemble Track Roller
Test Track Roller for Oil Leakage
Measure Track Carrier Roller Wear
Remove and Install Track Carrier Roller
Disassemble and Assemble Track Carrier Roller
Inspect Metal Face Seals
Measure Track Shoe Grouser Wear (S.N. —499999)
Measure Track Shoe Grouser Wear (S.N. 500000— )
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 (Serial No. —499999)
Disassemble and Assemble Track Chain (Serial No. 500000— )
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 and Recoil Spring
Disassemble and Assemble Track Adjuster and Recoil Spring
Disassemble and Assemble Track Adjuster Cylinder
Section 02: Axles and Suspension Systems (Propel)
Group 0250: Axle Shaft, Bearings, and Reduction Gears
Service Equipment and Tools
Other Material
Specifications
Towing the Excavator
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
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
POWERTECH POWERTECH is a trademark of Deere & Company. 6.8 L (6068) John Deere Engine—Use CTM104
Alternators and Starting Motors—Use CTM77
Essential Tools
Service Equipment and Tools
Other Material
Specifications
Remove Engine
Install Engine
Remove Oil Pan
Install Oil Pan
Remove In-Line Fuel Injection Pump
Repair In-Line Fuel injection Pump
Install In-Line Fuel Injection Pump
Bleed Fuel System
Clean the Engine Crankcase Ventilation Tube
Check and Adjust Engine Valve Lash (Clearance)
Firing Order, 6-Cylinder Engine:
Remove and Install Starter
Section 05: Engine Auxiliary System
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
Specifications
Remove and Install Radiator, Oil Cooler, and Fan Shroud
Remove and Install Fan and Fan Guard
Remove and Install Fan Belt
Remove and Install Thermostats
Cooling System Fill and Deaeration
Group 0515: Speed Controls
Service Equipment and Tools
Specifications
Injection Pump Fast and Slow Idle Stops Adjustment
Remove and Install Engine Speed Control Cable
Remove and Install Engine Control Motor and Sensor
Engine Control Motor and Sensor Adjustment
Engine Speed Learning Procedure
Remove and Install Fuel Shut-Off Solenoid Linkage
Check and Adjust Fuel Shut-Off Solenoid Linkage
Group 0520: Intake System
Essential Tools
Service Equipment and Tools
Specifications
Air Intake System Leakage Test
Remove and Install Air Cleaner
Disassemble and Assemble Air Cleaner
Group 0560: External Fuel Supply System
Other Material
Specifications
Remove and Install Fuel Tank
Remove and Install Primary Fuel Filter (Water Separator)
Remove and Install Primary Fuel Filter Element (Water Separator)
Remove and Install Final Fuel Filter
Remove and Install Final Fuel Filter Element
Bleed Fuel System
Section 07: Dampener Drive (Flex Coupling)
Group 0752: Elements
Service Equipment and Tools
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
Check Battery Electrolyte Level and Terminals
Using Booster Batteries—24 Volt System
Charge Battery
Engine Speed Learning Procedure
Remove and Install Batteries
Install Replacement Batteries
Adding 12 or 24 Volt Accessories
Group 1672: Alternator, Regulator, and Charging System Wiring
Alternators and Starting Motors—Use CTM77
Service Equipment and Tools
Specifications
Inspect, Remove, and Install Fan Belt
Remove and Install Alternator
Group 1674: Wiring Harness and Switches
Essential Tools
Excavator Overview
Front Chassis Electrical Component Identification
Functional Schematic And Component Location Legend
Cab Electrical Component Identification
Frame and Engine Electrical Component Identification
Monitor and Relay Harness Component Identification
Air Conditioner Harness Component Identification
Replacing Fuses
Fuse (Blade-Type) Color Codes
Remove and Install Control Panel Switches
Remove and Install Dome Light Switch
Remove and Install Propel Alarm Cancel Switch and Start Aid Switch
Remove and Install Starter Switch
Remove and Install Cab Ground Straps
Remove and Install Engine Temperature Switch
Remove and Install Coolant Level Switch
Remove and Install Engine Oil Pressure Switch
Remove and Install Engine Oil Level Switch
Remove and Install Engine Coolant Temperature Sensor
Remove and Install Fuel Level Switch
Remove and Install Fuel Level Sensor
Remove and Install Travel Alarm
Remove and Install Propel Pressure Switch
Remove and Install Dig Pressure Switch
Remove and Install Rear Pump Pressure Sensor
Remove and Install Front Pump Pressure Sensor
Remove and Install Engine Speed Sensor
Remove and Install Pump Control Pressure Sensor
Remove and Install Proportional Solenoids
Remove and Install Windshield Wiper Enable Switch
Remove and Install Air Cleaner Restriction Indicator Switch
Connecting Engine and Pump Controller (EPC) Harness Connector
Disconnecting Spring Wire Retainer Connectors
Disconnecting Tab Retainer Connectors
Remove and Install Battery Relay
Remove and Install Starter Relay
Remove and Install Fuel Shutoff Relay
Replace DEUTSCH DEUTSCH is a trademark of the Deutsch Co. 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
Specifications
Welding On Machine
Connecting Engine and Pump Controller (EPC) Harness Connector
Remove and Install Engine and Pump Controller (EPC)
Engine Speed Learning Procedure
Remove and Install Monitor Controller
Group 1676: Instruments and Indicators
Replace Monitor Panel Bulbs
Remove and Install Monitor Panel
Remove and Install Engine Hourmeter Switch
Changing Travel Alarm Volume
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
Check Seat Adjustments
Remove and Install Seat
Remove and Install Seat Belt
Inspect Seat Belt
Group 1830: Heating and Air Conditioning
Essential Tools
Service Equipment and Tools
Other Material
Specifications
Proper Refrigerant Handling
R134a Refrigerant Cautions
R134a Compressor Oil Charge Check
R134a Compressor Oil Removal
R134a Component Oil Charge
R134a Refrigerant Recovery, Recycling, and Charging Station Installation Procedure
Recover R134a System
Evacuate R134a System
Charge R134a System
Check and Adjust Compressor Belt Tension
Remove and Install Air Conditioning Compressor
Disassemble and Inspect Air Conditioning Compressor
Assemble Air Conditioning Compressor
Inspect Air Conditioning Compressor Manifolds
Remove and Install Receiver Dryer
Remove and Install Evaporator
Remove and Install Condenser
Remove and Install Heater Core—Machine With Air Conditioning
Remove and Install Heater Core and Blower Motor
Remove and Install Heater Hoses
Section 33: Excavator
Group 3302: Buckets
Specifications
Replace Bucket Tooth
Replace Bucket Tooth Tip—Heavy-Duty Bucket
Welding On Machine
Remove and Install Tooth Shank
Replace Welded Cutting Edge
Repair Cracked Cutting Edge
Remove and Install Bucket
Adjust Bucket Pivot End Play
Disassemble and Assemble Bucket
Bucket Pin-Up Data
Group 3340: Frames
Service Equipment and Tools
Other Material
Specifications
Remove and Install Bucket Links
Remove and Install Arm
Remove and Install Boom
Inspect Boom, Arm, and Bucket Pins, Bushings and Bosses
Remove and Install Bushings and Seals
Group 3360: Hydraulic System
Essential Tools
Service Equipment and Tools
Other Material
Specifications
Control Lever Pattern Conversion
Lower Boom with Engine Stopped
Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy
Remove and Install Hydraulic Pump and Drive Gearbox
Hydraulic Pump and Drive Gearbox Start-Up Procedure
Disassemble Hydraulic Pump and Drive Gearbox
Disassemble and Assemble Pilot Pump Drive Shaft and Gear
Assemble Hydraulic Pump and Drive Gearbox
Disassemble and Assemble Hydraulic Pump Regulator
Remove and Install Pilot Pump
Disassemble and Assemble Pilot Pump
Remove and Install Pilot Pressure Regulating Valve and Filter
Disassemble and Assemble Pilot Pressure Regulating Valve and Filter
Remove and Install Pilot Shut-Off Valve
Pilot Shut-Off Valve Linkage Adjustment
Disassemble and Assemble Pilot Shut-Off Valve
Remove and Install Proportional Solenoid Valve
Disassemble and Assemble Proportional Solenoid Valve
Remove and Install Dig Function Pilot Controller
Disassemble and Assemble Dig Function Pilot Controller
Remove and Install Propel Pilot Controller (Serial No. —050305)
Disassemble and Assemble Propel Pilot Controller (Serial No. —050305)
Remove and Install Propel Pilot Controller (Serial No. 050306—)
Disassemble and Assemble Propel Pilot Controller (Serial No. 050306—)
Remove and Install Flow Regulator Valve
Disassemble and Assemble Flow Regulator Valve
Remove and Install Control Valve
Disassemble and Assemble Control Valve
Disassemble and Assemble System Relief Valve
Disassemble and Assemble Circuit Relief and Anti-Cavitation Valve
Remove and Install Hydraulic Oil Tank
Disassemble and Assemble Hydraulic Oil Tank
Remove and Install Return Filter and Bypass Valve
Remove and Install Suction Strainer
Disassemble and Assemble Hydraulic Oil Tank Relief Valve and Breather Filter Cap
Remove and Install Swing Motor Make-Up Oil Restriction Valve
Remove and Install Oil Cooler Bypass Valve
Remove and Install Oil Cooler
Remove and Install Boom Cylinder
Remove and Install Arm Cylinder
Remove and Install Bucket Cylinder
Hydraulic Cylinder Bleed Procedure
Disassemble Boom, Arm or Bucket Cylinder
Assemble Boom, Arm or Bucket Cylinder
Section 43: Swing 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 Park Brake
Swing Motor and Park Brake Start-Up Procedure
Disassemble Swing Motor and Park Brake
Assemble Swing Motor and Park Brake
Disassemble and Assemble Swing Motor Make-Up and Crossover Relief Valves
Remove and Install Swing Park Brake Orifice and Check Valve
Remove and Install Swing Park Brake Release 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
DFT1144 Guide Pin
DFT1119 Pump Support

John Deere 200LC Excavator Service Technical Manual (Repair) (TM1664)