PDF Service Manual John Deere 200D 200DLC Excavator - 1 MB
The complete service and repair technical manual for John Deere 200D and 200DLC excavators.
This guide provides in-depth instructions for diagnostics, disassembly, repair, and reassembly of all major components.
It is the same manual used by professional John Deere technicians.
Empower yourself to perform everything from routine maintenance to major overhauls with this detailed resource.
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--- Page 1 ---
200D and 200DLC
Excavator
Repair
REPAIR TECHNICAL MANUAL
200D and 200DLC Excavator
TM10079 14MAR19 (ENGLISH)
Worldwide Construction
And Forestry Division
PRINTED IN U.S.A.
--- Page 3 ---
Safety
Inspect Machine
Inspect machine carefully each day by walking around it
before starting.
Inspect and Clean the Polycarbonate Windows. See
Inspect and Clean Polycarbonate Windows. (Section 4-1.)
T6607AQ —UN—15APR13
Keep all guards and shields in good condition and properly
installed. Fix damage and replace worn or broken parts
immediately. Pay special attention to hydraulic hoses and
electrical wiring.
TX03679,0001734 -19-17DEC14-1/1
Stay Clear of Moving Parts
T133592 —UN—15APR13
Entanglements in moving parts can cause serious injury.
Stop engine before examining, adjusting or maintaining
any part of machine with moving parts.
Keep guards and shields in place. Replace any guard
or shield that has been removed for access as soon as
service or repair is complete.
TX03679,00016D2 -19-03JAN07-1/1
Avoid High-Pressure Fluids
Inspect hydraulic hoses periodically – at least once
per year – for leakage, kinking, cuts, cracks, abrasion,
blisters, corrosion, exposed wire braid or any other signs
of wear or damage.
X9811 —UN—23AUG88
Replace worn or damaged hose assemblies immediately
with John Deere approved replacement parts.
Escaping fluid under pressure can penetrate the skin
causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.
with this type of injury should reference a knowledgeable
Search for leaks with a piece of cardboard. Protect hands medical source. Such information is available in
and body from high-pressure fluids. English from Deere & Company Medical Department in
Moline, Illinois, U.S.A., by calling 1-800-822-8262 or +1
If an accident occurs, see a doctor immediately. Any fluid 309-748-5636.
injected into the skin must be surgically removed within
a few hours or gangrene may result. Doctors unfamiliar
DX,FLUID -19-12OCT11-1/1
TM10079 (14MAR19) 00-01-3 200D and 200DLC Excavator
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--- Page 4 ---
Group 0003
Torque Values
Metric Bolt and Cap Screw Torque Values
METRIC BOLT AND CAP SCREW TORQUE VALUES—Tolerance is ±10% unless otherwise specified
TORQ2 —UN—15APR13
Top—Property Class and Head Markings; Bottom—Property Class and Nut Markings
Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9
Thread Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb
Size N·m (lb-ft) N·m (lb-ft) N·m (lb-ft) N·m (lb-ft) N·m (lb-ft) N·m (lb-ft) N·m (lb-ft) N·m (lb-ft)
M6 4.7 (3.5) 6 (4.4) 9 (6.6) 11.5 (8.5) 13 (9.5) 16.5 (12.2) 15.5 (11.5) 19.5 (14.5)
M8 11.5 (8.5) 14.5 (10.7) 22 (16) 28 (20.5) 32 (23.5) 40 (29.5) 37 (27.5) 47 (35)
M10 23 (17) 29 (21) 43 (32) 55 (40) 63 (46) 80 (59) 75 (55) 95 (70)
M12 40 (29.5) 50 (37) 75 (55) 95 (70) 110 (80) 140 (105) 130 (95) 165 (120)
M14 63 (46) 80 (59) 120 (88) 150 (110) 175 (130) 220 (165) 205 (150) 260 (190)
M16 100 (74) 125 (92) 190 (140) 240 (175) 275 (200) 350 (255) 320 (235) 400 (300)
M18 135 (100) 170 (125) 265 (195) 330 (245) 375 (275) 475 (350) 440 (325) 560 (410)
M20 190 (140) 245 (180) 375 (275) 475 (350) 530 (390) 675 (500) 625 (460) 790 (580)
M22 265 (195) 330 (245) 510 (375) 650 (480) 725 (535) 920 (680) 850 (625) 1080 (800)
M24 330 (245) 425 (315) 650 (480) 820 (600) 920 (680) 1150 (850) 1080 (800) 1350 (1000)
M27 490 (360) 625 (460) 950 (700) 1200 (885) 1350 (1000) 1700 (1250) 1580 (1160) 2000 (1475)
M30 660 (490) 850 (625) 1290 (950) 1630 (1200) 1850 (1350) 2300 (1700) 2140 (1580) 2700 (2000)
M33 900 (665) 1150 (850) 1750 (1300) 2200 (1625) 2500 (1850) 3150 (2325) 2900 (2150) 3700 (2730)
M36 1150 (850) 1450 (1075) 2250 (1650) 2850 (2100) 3200 (2350) 4050 (3000) 3750 (2770) 4750 (3500)
a
"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
b
"Dry" means plain or zinc plated without any lubrication.
Fasteners should be replaced with the same or higher property class. If
CAUTION: Use only metric tools on metric hardware. Other higher property class fasteners are used, these should only be tightened
tools may not fit properly. Tool may slip and cause injury. to the strength of the original.
Make sure fastener threads are clean and that you properly start thread
DO NOT use these values if a different torque value or tightening engagement. This will prevent them from failing when tightening.
procedure is given for a specific application. Torque values listed are for
general use only. Check tightness of fasteners periodically. Tighten plastic insert or crimped steel-type lock nuts to approximately
50 percent of the dry torque shown in the chart, applied to the nut, not
Shear bolts are designed to fail under predetermined loads. Always to the bolt head. Tighten toothed or serrated-type lock nuts to the full
replace shear bolts with identical property class. torque value.
OUT3035,TORQUE2 -19-22MAR06-1/1
TM10079 (14MAR19) 00-0003-1 200D and 200DLC Excavator
031419
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--- Page 5 ---
Torque Values
O-Ring Face Seal Fittings With Metric Hex
Nut And Stud End For Standard Pressure
Service Recommendations
O-RING FACE SEAL AND FITTINGS WITH METRIC HEX NUT AND STUD END FOR STANDARD PRESSURE, BELOW 27 600
kPa (275.8 bar) (4,000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified
1 2 3 4
01
T196337 —UN—15APR13
7 9
11 8 11
6 6 5
01 11
01
8 8
733691T
1— 90° Swivel Elbow 4— Bulkhead Union and Nut 6— Tube Nut 11— Identification Groove
2— 90° Adjustable Stud Elbow 5— External Hex Stud End Plug 7— Swivel Nut
3— Stud Straight 8— Stud End
9— Hex Nut
10— O-Ring
Nominal Tube OD or Hose ID O-Ring Face Seal Hose or Tube Swivel Nut Bulkhead Nut
Metric Tube Inch Tube OD or Hose ID Thread Size Hex Size Torque Hex Size Torque
OD
mm Dash Size mm (in.) in. mm Nm (lb-ft) mm Nm (lb-ft)
4 -2 3.18 (0.125) — — — — —
5 -3 4.78 (0.188) — — — — —
6 -4 6.35 (0.250) 9/16-18 17 16 (12) 22 32 (24)
8 -5 7.92 (0.312) — — — — —
10 -6 9.53 (0.375) 11/16-16 22 24 (18) 27 42 (31)
12 -8 12.70 (0.500) 13/16-16 24 50 (37) 30 93 (69)
16 -10 15.88 (0.625 1-14 30 69 (51) 36 118 (87)
20 -12 19.05 (0.750) 1-3/16-12 36 102 (75) 41 175 (129)
22 -14 22.23 (0.875) 1-3/16-12 36 102 (75) 41 175 (129)
25 -16 25.40 (1.000) 1-7/16-12 41 142 (105) 46 247 (182)
28 — — — — — — —
32 -20 31.75 (1.250) 1-11/16-12 50 190 (140) 50 328 (242)
38 -24 38.10 (1.500) 2-12 60 217 (160) 60 374 (276)
50 -32 50.80 (2.000) — — — — —
O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH METRIC STUD END FOR STANDARD PRESSURE, BELOW
27 600 kPa (275.8 bar) (4,000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified
Thread Sizea Straight Hex Sizeb Adjustable Nut Hex Size Steel or Gray Iron Torque Aluminum or Brass Torque
mm. mm mm Nm (lb-ft) Nm (lb-ft)
M8 x 1 12 12 8 (6) 5 (4)
M10 x 1 14 14 15 (11) 10 (7)
M12 x 1.5 17 17 25 (18) 17 (12)
M14 x 1.5 19 19 40 (30) 27 (20)
M16 x 1.5 22 22 45 (33) 30 (22)
M18 x 1.5 24 24 50 (37) 33 (25)
M22 x 1.5 27 27 69 (51) 46 (34)
M27 x 2 32 32 100 (74) 67 (49)
M30 x 2 36 36 130 (96) 87 (64)
M33 x 2 41 41 160 (118) 107 (79)
M38 x 2 46 46 176 (130) 117 (87)
Continued on next page OUT3035,0000366 -19-28MAY09-1/2
TM10079 (14MAR19) 00-0003-11 200D and 200DLC Excavator
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--- Page 6 ---
Group 0130
Track System
Track Roller Remove and Install
1. Swing upperstructure 90° and lower bucket to raise
track off ground. Keep angle between boom and arm
90—110° and position round side of bucket on ground.
T7396DZ —UN—28NOV90
CAUTION: Prevent possible injury from
unexpected machine movement. Position
shop stands under frame to support machine
while removing lower track roller.
2. Put shop stands under machine.
Specification
200D Excavator—Weight
(approximate)........................................................................... 22 000 kg A—Grease Fitting C—Bleed Hole
49 000 lb B—Valve
Specification
200DLC Excava-
tor—Weight (approxi-
3. Loosen valve (B) one to two turns to release grease
mate)........................................................................................ 23 000 kg
through bleed hole (C).
50 000 lb
CAUTION: Prevent possible injury from high
pressure grease. Do not remove grease
fitting (A) from valve (B).
OUO6046,0002302 -19-27JUN08-1/2
CAUTION: Heavy component; use appropriate
lifting device.
Specification
Track Roller—Weight...................................................................... 35 kg
77 lb
T6585TN —UN—25OCT88
4. Attach appropriate lifting device to track roller (B).
Remove cap screws (A) and track roller (B).
5. Measure track roller tread diameter. See 200D
and 200DLC Track Roller Tread Diameter. (SP326
Undercarriage Appraisal Manual.)
6. Repair or replace parts as necessary. See Track
Roller Disassemble and Assemble. (Group 0130.)
A—Cap Screw (4 used) B—Track Roller
7. Install track roller and tighten cap screws to
specification.
Specification 9. Tighten valve on track adjuster to specification.
Roller-to-Frame Cap Specification
Screw—Torque............................................................................460 N·m Track Adjuster
340 lb-ft Valve—Torque...............................................................................88 N·m
8. If equipped, install track roller guard and tighten cap 65 lb-ft
screws to specification. 10. Check and adjust track sag. See Check and Adjust
Specification Track Sag. (Operator's Manual.)
Track Roller Guard Cap
Screw—Torque............................................................................460 N·m
340 lb-ft
OUO6046,0002302 -19-27JUN08-2/2
TM10079 (14MAR19) 01-0130-1 200D and 200DLC Excavator
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--- Page 7 ---
Track System
1— Track Link (200D, 45 used; 7— Master Pin 13— Shoe (200D, 46 used; 16— Master Bushing
200DLC, 48 used) 8— Spacer (2 used) 200DLC, 49 used) 17— Track Chain Without Shoes
2— Master Track Link 9— Snap Ring 14— Track Link (200D, 45 used;
3— Pin (200D, 45 used; 200DLC, 10— Cap Screw (200D, 184 used; 200DLC, 48 used)
48 used) 200DLC, 196 used) 15— Bushing (200D, 45 used;
5— Seal (200D, 90 used; 200DLC, 12— Nut (200D, 184 used; 200DLC, 48 used)
96 used) 200DLC, 196 used)
1. Measure track components (1—17). See 200D and 4. Apply grease to counterbore in track links, the seals,
200DLC Standard Bushing Outer Diameter. (SP326 and ends of bushings.
Undercarriage Appraisal Manual.)
5. For each joint, fill clearance between pin OD and
2. Turn pins (3 and 7) and bushings (15 and 16) as bushing ID with grease.
required.
6. Install seal (5) so tapered side is toward bushing.
3. Clean any dust or rust from surfaces of track link pin
bores, counterbores, and ends of bushings.
OUO6046,0002309 -19-26JUN08-2/2
Track Chain Repair
1. Remove track shoes from each side of broken link
assembly. See Track Shoe Remove and Install.
(Group 0130.)
IMPORTANT: When making cuts using cutting torch,
T5821AG —UN—26OCT88
be careful not to cut or gouge good parts.
2. Cut links, bushing, and pin at points (A) to remove
broken link (B).
A—Cut Locations B—Broken Link
OUO6046,000230A -19-05MAR07-1/4
3. Grind ends of bushing (A) even with links to make it
into a master bushing.
A—Bushing
T5821AH —UN—26OCT88
Continued on next page OUO6046,000230A -19-05MAR07-2/4
TM10079 (14MAR19) 01-0130-11 200D and 200DLC Excavator
031419
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--- Page 8 ---
Section 02
Axles, Differentials and Suspension Systems
Contents
Page
Group 0250—Axle Shaft, Bearings, and
Reduction Gears
Travel Gearbox Remove and
Install ..................................................... 02-0250-1
Travel Gearbox Disassemble and
Assemble............................................... 02-0250-3
Group 0260—Hydraulic System
Travel Motor and Park Brake
Remove and Install................................ 02-0260-1
Travel Motor and Park Brake
Disassemble and Assemble .................. 02-0260-6
Counterbalance Valve Remove
and Install .............................................. 02-0260-8
Crossover Relief Valve Remove
and Install ............................................ 02-0260-10
Make-Up Check Valve Remove
and Install ............................................ 02-0260-12
Travel Speed Selector Valve
Remove and Install.............................. 02-0260-13
Travel Motor and Park Brake
Start-Up Procedure.............................. 02-0260-14
Metal Face Seal Install ............................ 02-0260-15
TM10079 (14MAR19) 02-1 200D and 200DLC Excavator
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--- Page 9 ---
Group 0260
Hydraulic System
ESSENTIAL TOOLS
Travel Motor and Park Brake Remove and
JT01748 Lifting Brackets
Install
SPECIFICATIONS SERVICE EQUIPMENT AND TOOLS
Travel Motor and Gearbox Weight 310 kg DFT1036Aa Travel Gearbox Nut Wrench
683 lb DFT1109b Holding Bar
Ring Gear Approximate Weight 64 kg a
Fabricated tool, dealer made. (See Group 9900 for in-
141 lb structions to make tool.)
b
Third Stage Planetary Pinion 40 kg Fabricated too, dealer made. (See Group 9900 for in-
Carrier Approximate Weight 88 lb structions to make tool.)
Drum Approximate Weight 59 kg OTHER MATERIAL
130 lb
277 Loctite® Rigid Form-in-Plce Gasket
Bearing Cone Temperature 50—70°C
122—158°F 271 Loctite® Thread Lock and Sealer (high strength)
Bearing Nut Torque 800 N·m 242 Loctite® Thread Lock and Sealer (medium strength).
590 lb·ft
Ring Gear-to-Drum Cap Screw 265 N·m
Torque 195 lb·ft
Cover-to-Ring Gear Cap Screw 110 N·m
Torque 81 lb·ft
Continued on next page FS41334,0000171 -19-20FEB19-1/5
TM10079 (14MAR19) 02-0260-1 200D and 200DLC Excavator
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--- Page 10 ---
Hydraulic System
TX1020309 —UN—09MAR07
1— Travel Motor Cover 5— Valve (2 used) 9— Back-Up Ring (4 used) 13— Shim (2 used)
2— Sleeve (2 used) 6— Guide (2 used) 10— Plug (2 used)
3— O-Ring (2 used) 7— Spring (2 used) 11— O-Ring (2 used)
4— Back-Up Ring (4 used) 8— Piston (2 used) 12— Packing (2 used)
IMPORTANT: Disassembly of crossover relief new pump is installed or oil has been drained
valve will alter the set pressure. Adjust from the pump or hydraulic oil tank.
after repairs are made.
11. Fill pump housing with oil. See Pump 1 and 2 Start-Up
6. Disassemble crossover relief valves. Procedure. (Group 3360.)
7. Repair or replace parts as needed. Apply a film of 12. Connect battery ground (negative) cable.
clean hydraulic oil to parts before assembly.
13. Perform travel motor start-up procedure. See Travel
8. Assemble crossover relief valves. Motor and Park Brake Start-Up Procedure. (Group
0260.)
9. Install relief valves (10) and tighten to specification.
14. Install cover to track frame.
Specification
Relief Valve—Torque...................................................................450 N·m Specification
332 lb-ft Track Frame
Cover—Torque..............................................................................50 N·m
10. Fill hydraulic oil tank. See Check Hydraulic Tank Oil 37 lb-ft
Level. (Operator's Manual.)
15. Perform crossover relief valve test and adjustment.
IMPORTANT: Hydraulic pump will be damaged See Travel Motor Crossover Relief Valve Test and
if not filled with oil before starting engine. Adjustment. (9025-25.)
Procedure must be performed whenever a
FS41334,000015E -19-13APR07-3/3
TM10079 (14MAR19) 02-0260-11 200D and 200DLC Excavator
031419
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--- Page 11 ---
Group 0400
Removal and Installation
Engine Remove and Install
1. Disconnect battery ground (negative) cable.
CAUTION: Explosive release of fluids from
pressurized cooling system can cause
serious burns.
TS281 —UN—15APR13
Shut off engine. Remove filler cap when
cool to touch. Slowly loosen filler cap to
relieve pressure, then remove.
2. Drain coolant from radiator. Approximate capacity is
26 L (6.9 gal).
OUO6046,0002329 -19-10APR13-1/14
CAUTION: High pressure release of oil from
pressurized system can cause serious burns
or penetrating injury. Relieve pressure by
pushing pressure release button (1).
TX1020485A —UN—21MAR07
3. Push pressure release button (1).
4. Pull a vacuum in hydraulic oil tank using a vacuum
pump, or drain tank. See Apply Vacuum to Hydraulic
Oil Tank. (Group 3360.)
5. Close fuel supply valve on bottom of fuel tank.
1— Pressure Release Button 2— Hydraulic Oil Tank Cover
Continued on next page OUO6046,0002329 -19-10APR13-2/14
TM10079 (14MAR19) 04-0400-1 200D and 200DLC Excavator
031419