John Deere 230LC Excavator Workshop Repair Manual TM1666 PDF Download - MJODTM1666.zip
John Deere 230LC Excavator Repair Service Manual (TM1666)
This is the full workshop service manual for the John Deere 230LC Excavator, packed with every detail a trained technician needs to service, troubleshoot, fix, and overhaul/rebuild the machine like a pro.
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