John Deere 180CW and 210CW Wheeled Excavator Repair Service Manual (TM2287)

TM2287 - John Deere 180CW and 210CW Wheeled Excavator Technical Manual (Repair).pdf

Complete official Repair service manual for John Deere 180CW and 210CW Wheeled Excavator, with all the technical information to maintain, repair, rebuild like professional mechanics.

John Deere 180CW and 210CW Wheeled Excavator 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.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* 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.

Covered Models: 180CW/210CW
Total Pages: 1,139 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English

MAIN SECTIONS
   Foreword
   Technical Information Feedback Form
   General Information
      Safety
      Torque Values
   Wheels
      Wheels and Fasteners
   Axles, Differentials and Suspension Systems
      Drive Axle Housing and Support
      Differential or Bevel Drive
      Axle Shaft, Bearings, and Reduction Gears
   Transmission
      Removal and Installation
      Gears, Shafts, Bearings, and Power Shift Clutch
      Hydraulic System
   Engine
      Removal and Installation
   Engine Auxiliary System
      Cooling System
      Speed Controls
      External Fuel Supply System
   Dampener Drive
      Removal and Installation
   Steering System
      Removal and Installation
      Steering Hydraulic System
   Service Brakes
      Service Brake Active Elements
      Service Brakes Hydraulics
   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

tm2287 - 180CW and 210CW Wheeled Excavator

Table of Contents

Foreword

Technical Information Feedback Form

Section 00: General Information

Group 01: Safety

Recognize Safety Information

Follow Safety Instructions

Operate Only If Qualified

Wear Protective Equipment

Avoid Unauthorized Machine Modifications

Add Cab Guarding for Special Uses

Inspect Machine

Stay Clear of Moving Parts

Avoid High-Pressure Oils

Beware of Exhaust Fumes

Prevent Fires

Prevent Battery Explosions

Handle Chemical Products Safely

Dispose of Waste Properly

Prepare for Emergencies

Use Steps and Handholds Correctly

Start Only From Operator's Seat

Use and Maintain Seat Belt

Prevent Unintended Machine Movement

Avoid Work Site Hazards

Keep Riders Off Machine

Avoid Backover Accidents

Avoid Machine Tip Over

Use Special Care When Lifting Objects

Add and Operate Attachments Safely

Park and Prepare for Service Safely

Service Cooling System Safely

Remove Paint Before Welding or Heating

Make Welding Repairs Safely

Drive Metal Pins Safely

Group 03: 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

Section 01: Wheels

Group 0110: Wheels and Fasteners

Wheel Remove and Install

Tire Remove and Install

Section 02: Axles, Differentials and Suspension Systems

Group 0201: Drive Axle Housing and Support

Front Axle Remove and Install—180CW

Front Axle Disassemble and Assemble—180CW

Front Axle Remove and Install—210CW

Front Axle Disassemble and Assemble—210CW

Front Axle Adjustment

Rear Axle Remove and Install

Group 0210: Differential or Bevel Drive

Front Axle Differential Disassemble and Assemble—180CW

Rear Axle Differential Disassemble and Assemble—180CW

Front Differential Carrier Disassemble and Assemble—210CW

Front and Rear Differential Disassemble and Assemble—210CW

Check Gear Tooth Contact Pattern

Group 0250: Axle Shaft, Bearings, and Reduction Gears

Front Axle Planetary Drive Disassemble

Front Axle Planetary Drive Assemble

Rear Axle Planetary Drive Disassemble

Rear Axle Planetary Drive Assemble

Section 03: Transmission

Group 0300: Removal and Installation

Transmission Remove and Install

Group 0350: Gears, Shafts, Bearings, and Power Shift Clutch

Transmission and Rear Axle Differential Disassemble

Transmission and Rear Axle Differential Assemble

Group 0360: Hydraulic System

Travel Motor Remove and Install

Travel Motor Start-Up Procedure

Travel Motor Disassemble

Travel Motor Assemble

Travel Motor Counterbalance Valve Remove and Install

Travel Motor Counterbalance Valve Disassemble and Assemble

Travel Circuit Make-Up Valve Remove and Install—210CW

Travel Pilot Valve Remove and Install

Travel and Auxiliary Pilot Valve Disassemble and Assemble

Transmission Control Valve Remove and Install

Transmission Control Valve Disassemble and Assemble

Shockless Travel Valve Remove and Install—180CW

Shockless Travel Valve Remove and Install—210CW

Shockless Travel Valve Disassemble and Assemble

Transmission Shift Interlock Remove and Install

Transmission Shift Interlock Disassemble and Assemble

Section 04: Engine

Group 0400: Removal and Installation

Engine Remove and Install

Turbocharger Remove and Install

Turbocharger Inspection

Exhaust Manifold Remove and Install

Valve Cover Remove and Install

Rocker Arm Assembly Remove and Install

Rocker Arm Assembly Disassemble and Assemble

Rocker Arm Assembly Inspection

Intake Manifold Remove and Install

Water Pump Remove and Install

Water Pump Disassemble and Assemble

Cylinder Head Remove and Install

Cylinder Head Disassemble and Assemble

Cylinder Head Inspection

Timing Gear Case Remove and Install

Cylinder Block Disassemble and Assemble

Cylinder Block Inspection

Rear Oil Seal Remove and Install

Camshaft Remove and Install

Camshaft Disassemble and Assemble

Camshaft Inspection

Flywheel Remove and Install

Flywheel Disassemble and Assemble

Flywheel Housing Remove and Install

Oil Pan Remove and Install

Crankshaft Remove and Install

Crankshaft Disassemble and Assemble

Crankshaft Inspection

Piston and Connecting Rod Remove and Install

Piston and Connecting Rod Disassemble and Assemble

Piston and Connecting Rod Inspection

Oil Pump Remove and Install

Oil Pump Disassemble and Assemble

Oil Pump Inspection

Engine Oil Cooler Remove and Install

Engine Oil Cooler Disassemble and Assemble

Thermostat Housing Remove and Install

Thermostat Housing Disassemble and Assemble

Thermostat Inspection

Fuel Injection Pump Remove and Install

Fuel Injection Nozzle Remove and Install

Fuel Injection Nozzle Disassemble and Assemble

Section 05: Engine Auxiliary System

Group 0510: Cooling System

Radiator Remove and Install

Charge Air Cooler Remove and Install

Fan, Fan Guard, and Fan Shroud Remove and Install

Fan Belt and A/C Compressor Belt Remove, Install, and Adjust

Group 0515: Speed Controls

Speed Control Linkage Remove and Install

Engine Control (EC) Motor and Sensor Remove and Install

Engine Stop Cable Replace

Group 0560: External Fuel Supply System

Fuel Tank Remove and Install

Primary Fuel Filter (Water Separator) Remove and Install

Final Fuel Filter Remove and Install

Section 07: Dampener Drive

Group 0700: Removal and Installation

Dampener Drive (Flex Coupling) Remove and Install

Section 09: Steering System

Group 0900: Removal and Installation

Steering Wheel Remove and Install

Steering Valve Remove and Install—180CW

Steering Valve Remove and Install—210CW

Group 0960: Steering Hydraulic System

Steering Valve Disassemble and Assemble—180CW

Steering Valve Disassemble and Assemble—210CW

Steering Cylinder Disassemble and Assemble—180CW

Steering Cylinder Disassemble and Assemble—210CW

Section 10: Service Brakes

Group 1011: Service Brake Active Elements

Front Axle Brake Disassemble

Front Axle Brake Assemble

Rear Axle Brake Disassemble

Rear Axle Brake Assemble

Group 1060: Service Brakes Hydraulics

Brake Valve Remove and Install

Brake Valve Disassemble and Assemble

Brake Accumulator Charge Valve Remove and Install—180CW

Brake Accumulator Charge Valve Remove and Install—210CW

Brake Accumulator Charge Valve Disassemble and Assemble

Brake Accumulator Check Valve Remove and Install

Section 17: Frame or Supporting Structure

Group 1740: Frame Installation

Welding on Machine

Welding Repair of Major Structure

Group 1749: Chassis Weights

Counterweight Remove and Install

Section 18: Operator's Station

Group 1800: Removal and Installation

Cab Remove and Install

Group 1810: Operator Enclosure

Sliding Windows Remove and Install

Bonded Windowpanes Remove and Install

Group 1821: Seat and Seat Belt

Seat Belt Remove and Install

Left and Right Console Covers Remove and Install

Seat and Base Assembly Remove and Install

Group 1830: Heating and Air Conditioning

Refrigerant Cautions and Proper Handling

Flush and Purge Air Conditioner System

R134a Refrigerant Oil Information

R134a Refrigerant Recovery / Recycling and Charging Station Installation Procedure

Recover R134a Refrigerant

Evacuate R134a System

Charge R134a System

Air Conditioner Compressor Remove and Install

Receiver-Dryer Remove and Install—180CW

Receiver-Dryer Remove and Install—210CW

Condenser Remove and Install—180CW

Condenser Remove and Install—210CW

Air Conditioner and Heater Unit Remove

Air Conditioner and Heater Unit Install

Blower Motor Disassemble and Assemble—180CW

Air Conditioner and Heater Unit Disassemble and Assemble—180CW

Air Conditioner and Heater Unit Disassemble and Assemble—210CW

Air Conditioner High/Low Pressure Switch Remove and Install—180CW

Air Conditioner High/Low Pressure Switch Remove and Install—210CW

Section 33: Excavator

Group 3302: Buckets

Bucket Remove and Install

Adjust Bucket Pivot End Play

Bucket Pin-Up Data

Group 3340: Frames

Bucket Links Remove and Install

Arm Remove and Install

Monoblock Boom Remove and Install

2-Piece Boom Upper Section Remove and Install—180CW

2-Piece Boom Upper Section Remove and Install—210CW

2-Piece Boom Lower Section Remove and Install—180CW

2-Piece Boom Lower Section Remove and Install—210CW

Inspect Boom, Arm, Bucket Pins, Bushings, and Bosses

Bushings and Seals Remove and Install

Stabilizer Remove and Install

Blade Assembly Remove and Install

Blade Disassemble and Assemble

Group 3360: Hydraulic System

Hydraulic Circuit Pressure Release Procedure

Apply Vacuum to Hydraulic Oil Tank

Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy

Hydraulic Pump Remove and Install

Hydraulic Pump Disassemble

Hydraulic Pump Inspection

Hydraulic Pump Assemble

Hydraulic Pump and Drive Gearbox Start-Up Procedure

Hydraulic Pump Regulators Remove and Install

Hydraulic Pump Regulators Disassemble and Assemble

Pilot and Steering Pump Remove and Install

Pilot and Steering Pump Disassemble and Assemble

Pilot Relief Valve Remove and Install—180CW

Pilot Relief Valve Remove and Install—210CW

Pilot Relief Valve Disassemble and Assemble

Pilot Control Shut-Off Valve Remove and Install

Pilot Control Shut-Off Valve Disassemble and Assemble

Pilot Controller Remove and Install

Pilot Controller Disassemble and Assemble

Four-Unit Solenoid Valve Remove and Install—180CW

Four-Unit Solenoid Valve Remove and Install—210CW

Four-Unit Solenoid Valve Disassemble and Assemble—180CW

Four-Unit Solenoid Valve Disassemble and Assemble—210CW

Axle Lock and Pump Control Solenoid Valve Remove and Install—210CW

Axle Lock and Pump Control Solenoid Valve Disassemble and Assemble—210CW

Proportional Solenoid Valve Disassemble and Assemble

Pilot Signal Control Valve Remove and Install—180CW

Pilot Signal Control Valve Remove and Install—210CW

Pilot Signal Control Valve Disassemble and Assemble

Control Valve Remove and Install—180CW

Control Valve Remove and Install—210CW

Control Valve Separation—180CW

Control Valve Separation—210CW

Control Valve 5-Spool Disassemble and Assemble—180CW

Control Valve 5-Spool Disassemble and Assemble—210CW

Control Valve 4-Spool Disassemble and Assemble—180CW

Control Valve 4-Spool Disassemble and Assemble—210CW

Auxiliary Pilot Valve Remove and Install

Auxiliary Control Valve Remove and Install—180CW

Auxiliary Control Valve Remove and Install—210CW

Auxiliary Control Valve Disassemble and Assemble

Blade and Stabilizer Solenoid Valve Remove and Install

Blade and Stabilizer Solenoid Valve Disassemble and Assemble

Hydraulic Oil Tank Remove and Install

Oil Cooler Bypass and Restriction Valves Remove and Install

Oil Cooler Remove and Install

Boom Cylinder Remove and Install

Boom Cylinder Disassemble and Assemble

Positioning Cylinder Remove and Install (2-Piece Boom Only)—180CW

Positioning Cylinder Disassemble and Assemble (2-Piece Boom Only)—180CW

Positioning Cylinder Remove and Install (2-Piece Boom Only)—210CW

Positioning Cylinder Disassemble and Assemble (2-Piece Boom Only)—210CW

Arm Cylinder Remove and Install

Arm Cylinder Disassemble and Assemble

Bucket Cylinder Remove and Install

Bucket Cylinder Disassemble and Assemble

Stabilizer Cylinder Remove and Install

Blade Cylinder Remove and Install

Blade and Stabilizer Cylinder Disassemble and Assemble

Axle Lock Cylinder Remove and Install

Axle Lock Cylinder Disassemble and Assemble

Axle Lock Cylinder Check Valve Remove and Install

Axle Lock Cylinder Check Valve Disassemble and Assemble

Hydraulic Cylinder Bleed Procedure

Section 43: Swing or Pivoting System

Group 4350: Mechanical Drive Elements

Swing Gearbox Remove and Install

Swing Gearbox Disassemble

Swing Gearbox Assemble

Swing Gearbox Start-Up Procedure

Upperstructure Remove and Install

Swing Bearing Remove and Install

Swing Bearing Disassemble and Assemble

Swing Bearing Upper Seal Install

Swing Bearing Lower Seal Install

Group 4360: Hydraulic System

Center Joint Remove and Install

Center Joint Disassemble, Inspect, and Assemble

Swing Motor and Park Brake Remove and Install

Swing Motor and Park Brake Disassemble

Swing Motor and Park Brake Inspection

Swing Motor and Park Brake Assemble

Swing Motor Start-Up Procedure

Crossover Relief Valve and Make-Up Valve Remove and Install

Crossover Relief Valve Disassemble and Assemble—210CW

Section 99: Dealer Fabricated Tools

Group 9900: Dealer Fabricated Tools

DF1002 Rolling Drag Torque Bar

DFT1144 Guide Pin

DFT1119 Pump Support

DFT1220 Swing Gearbox Nut Spanner Wrench

DFT1218 Split Flange Hose Cap

DFT1264 Locator Screw

DFT1265 Axle Support

DFT1266 Transmission Adapter

DFT1267 Split Flange Hose Cap

DFT1268 Transmission Clutch Pack Driver