John Deere 230LC Excavator Repair Service Manual (TM1666)

Complete service repair manual for John Deere 230LC Excavator, with all the shop information to maintain, diagnostic, repair, refurbish/rebuild like professional mechanics.

John Deere 230LC 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.

TM1666 - John Deere 230LC Excavator Technical Manual - Repair (Metric).pdf

Total Pages: 845 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
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

tm1666 - 230LC Excavator (Metric)

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

230LC Specifications

Working Ranges

Engine Specifications

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. —599999)

Measure Track Shoe Grouser Wear (S.N. 600000— )

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. —599999)

Disassemble and Assemble Track Chain (Serial No. 600000—)

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

Specifications

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

Remove and Install Charge Air Cooler

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 Charge Air 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

Disassemble and Assemble Propel Pilot Controller

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