JOHN DEERE 230LC EXCAVATOR (METRIC) TM1666 TECHNICAL MANUAL

230LC Excavator Repair (Metric)

REPAIR TECHNICAL MANUAL 230LC TM1666 08AUG14 (ENGLISH)

For complete service information also see: 230LC Excavator Diagnostictm1665

John Deere Construction and Forestry

230LC Excavator Repair (Metric)

(g) by Belgreen v2.1

Table of contents FOREWORD TECHNICAL INFORMATION FEEDBACK FORM Section 00 - GENERAL INFORMATION Group 0001 - Safety Group 0002 - General Specifications Group 0003 - Torque Values Group 0004 - Fuels and Lubricants Section 01 - TRACKS Group 0130 - Track System Section 02 - AXLES AND SUSPENSION SYSTEMS (PROPEL) Group 0250 - Axle Shaft, Bearings, and Reduction Gears Group 0260 - Hydraulic System Section 04 - ENGINE Group 0400 - Removal and Installation Section 05 - ENGINE AUXILIARY SYSTEM Group 0505 - Cold Weather Starting Aids Group 0510 - Cooling System Group 0515 - Speed Controls Group 0520 - Intake System Group 0560 - External Fuel Supply System Section 07 - DAMPENER DRIVE (FLEX COUPLING) Group 0752 - Elements Section 16 - ELECTRICAL SYSTEM Group 1671 - Batteries, Support, and Cables Group 1672 - Alternator, Regulator, and Charging System Wiring Group 1674 - Wiring Harness and Switches Group 1675 - System Controls Group 1676 - Instruments and Indicators Section 17 - FRAME OR SUPPORTING STRUCTURE Group 1740 - Frame Installation Group 1749 - Chassis Weights Section 18 - OPERATOR’S STATION Group 1800 - Removal and Installation Group 1810 - Operator Enclosure Group 1821 - Seat and Seat Belt Group 1830 - Heating and Air Conditioning Section 33 - EXCAVATOR Group 3302 - Buckets Group 3340 - Frames Group 3360 - Hydraulic System Section 43 - SWING OR PIVOTING SYSTEM Group 4350 - Mechanical Drive Elements Group 4360 - Hydraulic System Section 99 - DEALER FABRICATED TOOLS Group 9900 - Dealer Fabricated Tools

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230LC Excavator Repair (Metric)

For the full PDF version of this manual, Please click on the above download PDF button.

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230LC Excavator Repair (Metric)

230LC Excavator Repair (Metric)

(g) by Belgreen v2.1

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.

CAUTION: 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.

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230LC Excavator Repair (Metric)

GENERAL INFORMATION

(g) by Belgreen v2.0

Technical Information Feedback Form We need your help to continually improve our technical publications. Please copy this page and FAX or mail your comments, ideas and improvements.

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Section 00 page 1

230LC Excavator Repair (Metric)

230LC Excavator Repair (Metric)

(g) by Belgreen v2.1

Section 00 - GENERAL INFORMATION Table of contents Group 0001 - Safety ................................................................................................................................. 1 Follow Safe Procedures ......................................................................................................................... 1 Prepare for Emergencies ...................................................................................................................... 1 Handle Fluids Safely—Avoid Fires ......................................................................................................... 1 Prevent Battery Explosions ................................................................................................................... 2 Handle Chemical Products Safely ......................................................................................................... 3 Prevent Acid Burns ............................................................................................................................... 4 Avoid High-Pressure Fluids ................................................................................................................... 4 Warn Others of Service Work ............................................................................................................... 6 Park Machine Safely ............................................................................................................................. 6 Support Machine Properly .................................................................................................................... 6 Operate Only from Operator′s Seat ...................................................................................................... 7 Stay Clear of Moving Parts ................................................................................................................... 7 Avoid Power Lines ................................................................................................................................ 8 Use Handholds and Steps ..................................................................................................................... 8 Keep Riders Off Machine ...................................................................................................................... 9 Move and Operate Machine Safely ....................................................................................................... 9 Wear Protective Clothing .................................................................................................................... 11 Protect Against Flying Debris ............................................................................................................. 11 Protect Against Noise ......................................................................................................................... 11 Illuminate Work Area Safely ............................................................................................................... 12 Service Machines Safely ..................................................................................................................... 12 Remove Paint Before Welding or Heating ........................................................................................... 13 Avoid Heating Near Pressurized Fluid Lines ........................................................................................ 14 Beware of Exhaust Fumes .................................................................................................................. 14 Use Proper Lifting Equipment ............................................................................................................. 14 Service Cooling System Safely ........................................................................................................... 15 Dispose of Waste Properly .................................................................................................................. 15 Work in a Clean Area .......................................................................................................................... 16 Use Tools Properly .............................................................................................................................. 16 Replace Safety Signs .......................................................................................................................... 17 Live With Safety ................................................................................................................................. 17 Group 0002 - General Specifications .................................................................................................. 18 Excavator Overview ............................................................................................................................ 18 230LC Specifications .......................................................................................................................... 19 Working Ranges ................................................................................................................................. 21 Engine Specifications ......................................................................................................................... 22 Drain and Refill Capacities .................................................................................................................. 22 Group 0003 - Torque Values ................................................................................................................. 23 Unified Inch Bolt and Screw Torque Values ........................................................................................ 23 Metric Bolt and Screw Torque Values ................................................................................................. 24 Additional Metric Cap Screw Torque Values ....................................................................................... 25 Check Oil Lines And Fittings ............................................................................................................... 26 Service Recommendations for O-Ring Boss Fittings ........................................................................... 28 Service Recommendations For Flat Face O-Ring Seal Fittings ............................................................ 30 Service Recommendations for 37° Flare and 30° Cone Seat Connectors ........................................... 31 Service Recommendations For Flared Connections—Straight or Tapered Threads ............................ 32 Service Recommendations For Inch Series Four Bolt Flange Fittings ................................................. 34 Service Recommendations for Metric Series Four Bolt Flange Fitting ................................................. 35 Group 0004 - Fuels and Lubricants ..................................................................................................... 36

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230LC Excavator Repair (Metric)

230LC Excavator Repair (Metric)

(g) by Belgreen v2.1

Diesel Fuel .......................................................................................................................................... 36 Lubricity of Diesel Fuels ...................................................................................................................... 36 Low Sulfur Diesel Fuel Conditioner ..................................................................................................... 36 Diesel Fuel Storage ............................................................................................................................. 37 Fuel Tank ............................................................................................................................................ 37 Do Not Use Galvanized Containers ..................................................................................................... 37 Diesel Engine Oil — Non-Emissions Certified and Certified Tier 1 and Stage I ................................... 38 Hydraulic Oil ....................................................................................................................................... 40 Swing Gearbox, Propel Gearbox and Pump Gearbox Oils ................................................................... 41 Track Roller, Front Idler, and Carrier Roller Oil ................................................................................... 41 Track Adjuster, Working Tool Pivot, Swing Bearing, and Swing Bearing Gear Grease ........................ 42 Oil Filters ............................................................................................................................................

42 Lubricant Storage ............................................................................................................................... 42 Alternative and Synthetic Lubricants .................................................................................................. 43 Mixing of Lubricants ........................................................................................................................... 43

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230LC Excavator Repair (Metric)

Section 00 - GENERAL INFORMATION

Group 0001: Safety

Group 0001 - Safety Follow Safe Procedures

Follow Safe Procedures Unsafe work practices are dangerous. Understand service procedure before doing work; do not attempt shortcuts.

Prepare for Emergencies

First Aid Kit Be prepared if 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.

Handle Fluids Safely—Avoid Fires

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Section 00 page 1

230LC Excavator Repair (Metric)

Section 00 - GENERAL INFORMATION

Group 0001: Safety

Handle Fuel Safely—Avoid Fires Handle fuel with care; it is highly flammable. Do not refuel the machine while smoking or when near open flame or sparks.

Always stop engine before refueling machine. Fill fuel tank outdoors.

Handle Fluids Safely—Avoid Fires Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers.

Make sure machine is clean of trash, grease, and debris.

Do not store oily rags; they can ignite and burn spontaneously.

Prevent Battery Explosions

Battery Explosions <- Go to Section TOC

Section 00 page 2

230LC Excavator Repair (Metric)

For the full PDF version of this manual, Please click on the above download PDF button.