John Deere 200LC Excavator Operation and Tests Manual TM1663

[Martin Welker]

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John Deere 200LC Excavator Operation and Tests Manual TM1663
Size: 10.83 MB
Format: PDF
Language: English
Brand: John Deere
Type of Machine: Excavator
Type of Manual: Operation and Tests Manual
Model: John Deere 200LC Excavator
Part Number: TM1663
Publication Date: 2001
Number of Pages: 696 Pages

Contents:
General Information
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
General Specifications
Excavator Overview
200LC Specifications
200LC Working Ranges
200LC Engine Specifications
200LC Drain and Refill Capacities
Torque Values
Unified Inch Bolt and Cap Screw Torque Values
Metric Bolt and Cap 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
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
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
Operational Checkout Procedure
Operational Checkout Procedure
Operational Checkout
Operator Station Checks—Key Switch On, Engine Off

Operator Station Checks—Engine On
Hydraulic System Checks
Undercarriage Checks
Accessories Checks
Heating and Air Conditioning Checks
Seat, Doors, Windows, Latches, and Locks Checks
Engine Cooling System Checks
Air Intake System Checks
Fuel System Checks
Visual Inspection
Engine
Theory of Operation
POWERTECH® 6.8 L (6068) John Deere Engine—Use CTM104
Engine—Sectional View
Fan Drive
Engine Speed Control
System Operational Checks
Engine
Cooling System Checks
Lubrication System Checks
Engine Speed and Performance Checks
Diagnostic Information
POWERTECH® 6.8 L (6086) John Deere Engine—Use CTM104
Adjustments
JT05801 Clamp-On Electronic Tachometer
Fuel Shut-Off Solenoid Linkage
Engine Speed Check
Injection Pump Fast and Slow Idle Stops
Engine Speed Control Motor
Engine Speed Learning Procedure
Cooling System Fill and Deaeration
Tests
Fuel Line Leakage
Air Filter Restriction Indicator Switch
Air Intake System Leakage
Radiator Air Flow
Engine Power Test Using Turbocharger Boost Pressure
Torsional Dampener
Electrical System
System Information
Electrical System
Electrical Circuit
Circuit Malfunction
Using Test Equipment
Schematic, Wiring Diagram, and Component Location Information
Reading a System Functional Schematic
Reading a Wiring Diagram
Reading a Component Location Diagram
Reading a Connector End View Diagram
Electrical Schematic Symbols
System Diagrams
Fuse Specifications
Fuse
Component Identification Table
Functional Schematic and Component Location
System Functional Schematic
System Functional Schematic (SE1—SE3)
System Functional Schematic (SE4—SE6)
System Functional Schematic (SE7—SE9)
System Functional Schematic (SE10—SE12)
System Functional Schematic (SE13—SE15)
System Functional Schematic (SE16—SE18)
Engine and Frame Harness (W1)
Cab Harness (W2)
Monitor and Relay Harness (W3)
Air Conditioner Harness (W9)
Sub-System Diagnostics
Power Circuit
Power Circuit Diagnostic Procedures
Charging Circuit
Charging Circuit Diagnostic Procedures
Starting and Fuel Shutoff Circuit
Starting Circuit and Fuel Shutoff Circuit
Starting and Fuel Shutoff Circuit Diagnostic Procedures
Windshield Wiper and Washer Circuit
Windshield Wiper and Washer Circuit Diagnostic Procedures
Light Circuit
Work and Drive Light Circuit
Work and Drive Light Circuit Diagnostic Procedures
Accessory Circuits
Accessory Circuits Diagnostic Procedures
Heater Circuit (Machines Without Air Conditioner)
Heater Circuit (Machines With Air Conditioner)
Monitor Controller and Display Circuit
Monitor Controller and Display Circuit Diagnostic Procedures
Engine and Pump Controller Circuit
Engine and Pump Controller Circuit Diagnostic Procedures
Travel Alarm Circuit
Travel Alarm Circuit Diagnostic Procedures
References
Battery
Batteries
Travel Alarm
Proportional Solenoid
Pump Control
Pump Pressure Sensor
Power Train
Track Adjuster
Propel Gearbox
Undercarriage Components
Track Chain
Track Shoe
Track Roller
Track Carrier Roller
Front Idler
Measure Wear
Track Sag
Hydraulic System
Hydraulic System Diagram
Pilot Pump Operation
Pilot Pressure Regulating Valve and Filter Operation
Pilot Shut-Off Valve Operation
Pilot Controller
Propel Pilot Controller
Flow Regulator Valve
Hydraulic Pump and Drive Gearbox
Hydraulic Pump
Hydraulic Pump Regulator
Proportional Solenoid Valve
Engine Speed Sense Control Circuit
Control Valve
System Releif Valve and Power Boost
Power Boost Control Circuit
Circuit Relief Valve
Pump Control Valve
Flow Combiner Valve
Arm Regenerative Valve
Boom and Arm Reduced Leakage Valve
Bucket Flow Control Valve
Propel Flow Control Valve
Propel-Boom Down Selector Valve
Boom Regenerative Valve
Propel and Arm In Combined
Swing and Boom Up Combined
Swing Gearbox
Swing Motor
Rotary Manifold
Propel Motor
Cylinder
Return Filter
Hydraulic System Circuit Symbols
Schematic
Diagnostic Procedure
Diagnose Malfunctions
Hydraulic System Malfunctions
Pilot Circuit Malfunctions
Dig Circuit Malfunctions
Swing Circuit Malfunctions
Propel System Malfunctions
Control Lever Pattern Conversion
Component Location
Adjustment
Pilot Shut-Off Valve Linkage
Laptop Computer
Excavator Diagnostics Program
Engine and Pump Controller
JT05800 Digital Thermometer Installation
JT02156 Digital Pressure and Temperature Analyzer
Start-Up Procedure
Hydraulic Oil Filter Inspection Procedure
Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy
Hydraulic System Warm-Up Procedure
Lower Boom with Engine Stopped
Harness Test
Cycle Time
Swing Dynamic Braking
Pilot Pressure Regulating Valve
Valve Spool Actuating Pilot Pressure
System Relief Valve
Swing Motor Crossover Relief Valve
Propel Motor Crossover Relief Valve
Hydraulic Pump Flow
Pilot Pump Flow
Propel System Tracking
Cylinder Drift
Swing Motor Leakage
Propel Motor Leakage
Air Conditioning System
Proper Refrigerant Handling
R134a Refrigerant Cautions
Refrigerant Theory of Operation
Heater and Air Conditioner Circuit Operational Information
Heater and Air Conditioner Circuit Theory of Operation
Heater and Air Conditioner Circuit
Receiver/Dryer Operation
Expansion Valve Operation
Compressor Relief Valve Operation
Temperature Control (Early Models)
Heater and Air Conditioner Controller Operation (Later Models)
Heating and Air Conditioning
Visual Inspection of Components
System Operating Checks
Heater Circuit Checks (Machines Equipped with Heater Only)
Heater and Air Conditioner Circuit Checks
Air Conditioning
Refrigerant
Compressor
Oil Charge
Recover
Evacuate
Charge
Operating Pressure
Switch
Leak Testing
Page Numbers