200lc technical manual operation and tests tm1663.pdf

8/19/2019 200LC TECHNICAL MANUAL OPERATION AND TESTS TM1663.pdf

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200LCExcavator

Operation and Tests

TECHNICAL MANUAL

200LC Excavator Operation andTests

TM1663 28NOV01 (ENGLISH)

For complete service information also see:

200LC Excavator Repair . . . . . . . . . . . . . . . . TM1664POWERTECH 4.5 L & 6.8 L (4045 and 6068)Diesel Engines. . . . . . . . . . . . . . . . . . . . . . . . CTM104Alternators and Starting Motors . . . . . . . . . . CTM77Undercarriage Appraisal Manual . . . . . . . . . SP326

Worldwide ConstructionAnd Forestry Division

LITHO IN U.S.A.


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Introduction

DX,TMIFC –19–29SEP98–1/1

Foreword

This manual is written for an experienced technician.Essential tools required in performing certain servicework are identified in this manual and arerecommended for use.

Live with safety: Read the safety messages in the

introduction of this manual and the cautions presentedthroughout the text of the manual.

This is the safety-alert symbol. When you see this

symbol on the machine or in this manual, be alert tothe potential for personal injury.

Technical manuals are divided in two parts: repair andoperation and tests. Repair sections tell how to repairthe components. Operation and tests sections help you

identify the majority of routine failures quickly.

Information is organized in groups for the variouscomponents requiring service instruction. At thebeginning of each group are summary listings of allapplicable 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 specificmachines. They are on-the-job guides containing onlythe vital information needed for diagnosis, analysis,testing, and repair.

Fundamental service information is available fromother sources covering basic theory of operation,fundamentals of troubleshooting, general maintenance,

and basic type of failures and their causes.

TM1663 (28NOV01) 200LC Excavator Operation & Tests101603

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Introduction

TX,TM,FAX –19–28NOV01–1/1

Technical Information Feedback Form

We need your help to continually improve our technicalpublications. Please copy this page and FAX or mail yourcomments, ideas and improvements.

SEND TO: John Deere Dubuque WorksP.O. Box 538

Attn: Publications Supervisor, Dept. 303

Dubuque, IA 52004-0538

FAX NUMBER: 563-589-5800

Ideas, Comments (Please State Page Number):

OVERALL, how would you rate the quality of this publication? (Check one)

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THANK YOU!


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Introduction


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Contents9

SECTION 9000—General Information

Group 01—SafetyGroup 02—General SpecificationsGroup 03—Torque ValuesGroup 04—Fuels and Lubricants

9

SECTION 9005—Operational Checkout ProcedureGroup 10—Operational Checkout Procedure

SECTION 9010—EngineGroup 05—Theory of OperationGroup 10—System Operational ChecksGroup 15—Diagnostic InformationGroup 20—AdjustmentsGroup 25—Tests

9

SECTION 9015—Electrical System

Group 05—System InformationGroup 10—System Diagrams

Group 15—Sub-System DiagnosticsGroup 20—References

SECTION 9020—Power TrainGroup 05—Theory of OperationGroup 15—Diagnostic Information

Group 20—Adjustments

9

SECTION 9025—Hydraulic SystemGroup 05—Theory of OperationGroup 15—Diagnostic InformationGroup 20—AdjustmentGroup 25—Tests

SECTION 9031—Air Conditioning SystemGroup 05—Theory of OperationGroup 10—System Operational ChecksGroup 15—Diagnostic InformationGroup 20—Adjustments

9

Group 25—Tests

All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice.

9

COPYRIGHT 2002DEERE & COMPANY

Moline, IllinoisAll rights reserved

A John Deere ILLUSTRUCTION ManualPrevious Editions

Copyright 2000, 1998, 1996

9

I

TM1663 (28NOV01) i 200LC Excavator Operation & Tests101603

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Contents

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9

Section 9000

General InformationContents

PagePage

Track Adjuster, Working Tool Pivot, SwingGroup 01—Safety . . . . . . . . . . . . . . . . . . . .9000-01-1Bearing, and Swing Bearing Gear

Grease. . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-7Group 02—General SpecificationsOil Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9000-04-7Excavator Overview . . . . . . . . . . . . . . . . . . .9000-02-1Lubricant Storage . . . . . . . . . . . . . . . . . . . . .9000-04-8200LC Specifications. . . . . . . . . . . . . . . . . . .9000-02-2Alternative and Synthetic Lubricants . . . . . . .9000-04-8

200LC Working Ranges . . . . . . . . . . . . . . . .9000-02-4Mixing of Lubricants . . . . . . . . . . . . . . . . . . .9000-04-9

200LC Engine Specifications. . . . . . . . . . . . .9000-02-6

200LC Drain and Refill Capacities. . . . . . . . .9000-02-6

Group 03—Torque ValuesUnified Inch Bolt and Cap Screw Torque

Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-03-1

Metric Bolt and Cap Screw Torque

Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-03-2

Additional Metric Cap Screw Torque

Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-03-3

Check Oil Lines And Fittings . . . . . . . . . . . . .9000-03-5

Service Recommendations for O-Ring

Boss Fittings . . . . . . . . . . . . . . . . . . . . . . .9000-03-6

Service Recommendations For Flat Face

O-Ring Seal Fittings. . . . . . . . . . . . . . . . . .9000-03-8

Service Recommendations for 37° Flareand 30° Cone Seat Connectors . . . . . . . . .9000-03-9

Service Recommendations For Flared

Connections—Straight or Tapered

Threads . . . . . . . . . . . . . . . . . . . . . . . . . . 9000-03-10

Service Recommendations For Inch

Series Four Bolt Flange Fittings. . . . . . . .9000-03-11

Service Recommendations for Metric

Series Four Bolt Flange Fitting . . . . . . . . 9000-03-12

Group 04—Fuels and Lubricants

Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . 9000-04-1

Lubricity of Diesel Fuels . . . . . . . . . . . . . . . .9000-04-1Low Sulfur Diesel Fuel Conditioner . . . . . . . .9000-04-2

Diesel Fuel Storage. . . . . . . . . . . . . . . . . . . .9000-04-2

Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-3

Do Not Use Galvanized Containers. . . . . . . .9000-04-3

Diesel Engine Oil . . . . . . . . . . . . . . . . . . . . . 9000-04-4

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . .9000-04-5

Swing Gearbox, Propel Gearbox and Pump

Gearbox Oils . . . . . . . . . . . . . . . . . . . . . . .9000-04-6

Track Roller, Front Idler, and Carrier

Roller Oil . . . . . . . . . . . . . . . . . . . . . . . . . . 9000-04-6

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Group 01Safety

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TX,05,FF1611 –19–14JUN90–1/1

Follow Safe Procedures

T S 2 3 1

– 1 9 – 0 7 O C T 8 8

Unsafe work practices are dangerous. Understand serviceprocedure before doing work; do not attempt shortcuts.

DX,FIRE2 –19–03MAR93–1/1

Prepare for Emergencies

T S 2 9 1

– U N – 2 3 A U G 8 8

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.

TX,05,FF1622 –19–14JUN90–1/2

Handle Fluids Safely—Avoid Fires

T S 2 0 2

– U N – 2 3 A U G 8 8

Handle fuel with care; it is highly flammable. Do not refuel

the machine while smoking or when near open flame orsparks. Always stop engine before refueling machine. Fillfuel tank outdoors.

TX,05,FF1622 –19–14JUN90–2/2

T S 2 2 7

– U N – 2 3 A U G 8 8

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.

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Safety

DX,SPARKS –19–03MAR93–1/1

Prevent Battery Explosions

T S 2 0 4

– U N – 2 3 A U G 8 8

Keep sparks, lighted matches, and open flame away fromthe top of battery. Battery gas can explode.

Never check battery charge by placing a metal object

across the posts. Use a volt-meter or hydrometer.

Do not charge a frozen battery; it may explode. Warmbattery to 16°C (60°F).

DX,MSDS,NA –19–03MAR93–1/1

Handle Chemical Products Safely

T S 1 1 3 2

– U N – 2 6 N O V 9 0

Direct exposure to hazardous chemicals can causeserious injury. Potentially hazardous chemicals used with

John Deere equipment include such items as lubricants,coolants, paints, and adhesives.

A Material Safety Data Sheet (MSDS) provides specific

details on chemical products: physical and health hazards,safety procedures, and emergency response techniques.

Check the MSDS before you start any job using ahazardous chemical. That way you will know exactly whatthe risks are and how to do the job safely. Then followprocedures and recommended equipment.

(See your John Deere dealer for MSDS’s on chemical

products used with John Deere equipment.)


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Safety

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DX,POISON –19–21APR93–1/1

Prevent Acid Burns

T S 2 0 3

– U N – 2 3 A U G 8 8

Sulfuric acid in battery electrolyte is poisonous. It is strongenough to burn skin, eat holes in clothing, and causeblindness if splashed into eyes.

Avoid the hazard by:

1. Filling batteries in a well-ventilated area.2. Wearing eye protection and rubber gloves.3. Avoiding breathing fumes when electrolyte is added.4. Avoiding spilling or dripping electrolyte.5. Use proper jump start procedure.

If you spill acid on yourself:

1. Flush your skin with water.

2. Apply baking soda or lime to help neutralize the acid.3. Flush your eyes with water for 15—30 minutes. Get

medical attention immediately.

If acid is swallowed:

1. Do not induce vomiting.2. Drink large amounts of water or milk, but do not

exceed 2 L (2 quarts).3. Get medical attention immediately.


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Safety

DX,FLUID –19–03MAR93–1/1

Avoid High-Pressure Fluids

X 9 8 1 1

– U N – 2 3 A U G 8

8

Escaping fluid under pressure can penetrate the skincausing serious injury.

Avoid the hazard by relieving pressure before

disconnecting hydraulic or other lines. Tighten allconnections before applying pressure.

Search for leaks with a piece of cardboard. Protect handsand body from high pressure fluids.

If an accident occurs, see a doctor immediately. Any fluidinjected into the skin must be surgically removed within afew hours or gangrene may result. Doctors unfamiliar withthis type of injury should reference a knowledgeablemedical source. Such information is available from Deere

& Company Medical Department in Moline, Illinois, U.S.A.

TX,05,RR,566 –19–23JUL91–1/1

Warn Others of Service Work

T 7 2 7 3 A P

– U N – 0 8 J U N 9 0

Unexpected machine movement can cause serious injury.

Before performing any work on the machine, attach a “DoNot Operate” tag on the right control lever.


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Safety

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TX,05,DH5002 –19–28MAY96–1/1

Park Machine Safely

Before working on the machine:

• Park machine on a level surface.• Lower bucket to the ground.

• Turn auto-idle switch off.• Run engine with engine RPM dial at 1/3 position for 2

minutes.• Move engine RPM dial to slow idle position.• Turn key switch to OFF. Remove key from switch.• Pull pilot control shut-off lever to locked position.• Allow engine to cool.

DX,LOWER –19–24FEB00–1/1

Support Machine Properly

T S 2 2 9

– U N – 2 3 A U G 8 8

Always lower the attachment or implement to the ground

before you work on the machine. If the work requires thatthe machine or attachment be lifted, provide securesupport for them. If left in a raised position, hydraulicallysupported devices can settle or leak down.

Do not support the machine on cinder blocks, hollow tiles,or props that may crumble under continuous load. Do not

work under a machine that is supported solely by a jack.Follow recommended procedures in this manual.

When implements or attachments are used with amachine, always follow safety precautions listed in theimplement or attachment operator’s manual.

TX,05,FF1615 –19–14JUN90–1/1

Operate Only from Operator’s Seat

T 6 6 0 7 A O

– U N – 1 8 O C T 8 8

Avoid possible injury or machine damage. Do not startengine by shorting across starter terminals.

NEVER start engine while standing on ground. Start

engine only from operator’s seat.


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Safety

TX,05,RR,572 –19–12JUN90–1/1

Stay Clear of Moving Parts

T 7 2 7 3 A S

– U N – 0 8 J U N

9 0

Entanglements in moving parts can cause serious injury.

To prevent accidents, use care when working aroundrotating parts.

TX,05,RR,594 –19–12JUN90–1/1

Avoid Power Lines

T 7 2 7 3 A D

– U N – 0 8 J U N 9 0

Serious injury or death can result from contact withelectric lines.

Never move any part of the machine or load closer toelectric line than 3 m (10 ft) plus twice the line insulatorlength.

TX,05,DH832 –19–16MAR92–1/1

Use Handholds and Steps

T 6 9 8 1 A N

– U N – 1 5 J U N 8 9

Falling is one of the major causes of personal injury.

When you get on and off the machine, always maintain athree point contact with the steps and handrails and facethe machine. Do not use any controls as handholds.

Never jump on or off the machine. Never mount ordismount a moving machine.

Be careful of slippery conditions on platforms, steps, andhandrails when leaving the machine.


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Safety

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TX,05,RR,560 –19–05OCT90–1/1

Keep Riders Off Machine

T 7 2 7 3 A H

– U N – 0 8 J U N

9 0

Only allow the operator on the machine. Keep riders off.

Riders on machine are subject to injury such as beingstruck by foreign objects and being thrown off the

machine. Riders also obstruct the operator’s view resultingin the machine being operated in an unsafe manner.

TX,05,FF1806 –19–05OCT90–1/1

Move and Operate Machine Safely

T 7 2 7 3 A L

– U N – 0 8 J U N 9 0

Bystanders can be run over. Know the location ofbystanders before moving, swinging, or operating the

machine.

Always keep the travel alarm in working condition. Itwarns people when the machine starts to move.

Use a signal person when moving, swinging, or operatingthe machine in congested areas. Coordinate hand signalsbefore starting the machine.

DX,WEAR2 –19–03MAR93–1/1

Wear Protective Clothing

T S 2 0 6

– U N

– 2 3 A U G 8 8

Wear close fitting clothing and safety equipment

appropriate to the job.

Operating equipment safely requires the full attention ofthe operator. Do not wear radio or music headphoneswhile operating machine.


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Safety

TX,05,FF1613 –19–14JUN90–1/1

Protect Against Flying Debris

T 6 6 4 2 D K

– U N – 1 8 O C T

8 8

Guard against injury from flying pieces of metal or debris;wear goggles or safety glasses.

DX,NOISE –19–03MAR93–1/1

Protect Against Noise

T S 2 0 7

– U N – 2 3 A U G 8 8

Prolonged exposure to loud noise can cause impairmentor loss of hearing.

Wear a suitable hearing protective device such asearmuffs or earplugs to protect against objectionable oruncomfortable loud noises.

DX,LIGHT –19–04JUN90–1/1

Illuminate Work Area Safely

T S 2 2 3

– U N – 2 3 A U G 8 8

Illuminate your work area adequately but safely. Use a

portable safety light for working inside or under themachine. Make sure the bulb is enclosed by a wire cage.The hot filament of an accidentally broken bulb can ignitespilled fuel or oil.

DX,LOOSE –19–04JUN90–1/1

Service Machines Safely

T S 2 2 8

– U N – 2 3 A U G 8 8

Tie long hair behind your head. Do not wear a necktie,scarf, loose clothing, or necklace when you work nearmachine tools or moving parts. If these items were to getcaught, severe injury could result.

Remove rings and other jewelry to prevent electricalshorts and entanglement in moving parts.


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Safety

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DX,PAINT –19–22OCT99–1/1

Remove Paint Before Welding or Heating

T S 2 2 0

– U N – 2 3 A U G 8 8

Avoid potentially toxic fumes and dust.

Hazardous fumes can be generated when paint is heatedby welding, soldering, or using a torch.

Remove paint before heating:

• Remove paint a minimum of 76 mm (3 in.) from area tobe affected by heating.

• If you sand or grind paint, avoid breathing the dust.Wear an approved respirator.

• If you use solvent or paint stripper, remove stripper withsoap and water before welding. Remove solvent orpaint stripper containers and other flammable materialfrom area. Allow fumes to disperse at least 15 minutes

before welding or heating.

Do all work in an area that is ventilated to carry toxicfumes and dust away.

Dispose of paint and solvent properly.

DX,TORCH –19–03MAR93–1/1

Avoid Heating Near Pressurized Fluid Lines

T S 9 5 3

– U N – 1 5 M A Y 9 0

Flammable spray can be generated by heating near

pressurized fluid lines, resulting in severe burns toyourself and bystanders. Do not heat by welding,soldering, or using a torch near pressurized fluid lines orother flammable materials. Pressurized lines can be

accidentally cut when heat goes beyond the immediateflame area.

02T,05,J9 –19–07JAN91–1/1

Beware of Exhaust Fumes

T 6 4 5 8 A O

– U N – 1 8 O C T 8 8

Prevent asphyxiation. Engine exhaust fumes can causesickness or death.

If you must operate in a building, be positive there is

adequate ventilation. Either use an exhaust pipe extensionto remove the exhaust fumes or open doors and windowsto bring enough outside air into the area.


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Safety

DX,LIFT –19–04JUN90–1/1

Use Proper Lifting Equipment

T S 2 2 6

– U N – 2 3 A U G 8 8

Lifting heavy components incorrectly can cause severeinjury or machine damage.

Follow recommended procedure for removal and

installation of components in the manual.

DX,RCAP –19–04JUN90–1/1

Service Cooling System Safely

T S 2 8 1

– U N – 2 3 A U G 8 8

Explosive release of fluids from pressurized coolingsystem can cause serious burns.

Shut off engine. Only remove filler cap when cool enoughto touch with bare hands. Slowly loosen cap to first stopto relieve pressure before removing completely.

DX,DRAIN –19–03MAR93–1/1

Dispose of Waste Properly

T S 1 1 3 3

– U N – 2 6 N O V 9 0

Improperly disposing of waste can threaten the

environment and ecology. Potentially harmful waste usedwith John Deere equipment include such items as oil, fuel,coolant, brake fluid, filters, and batteries.

Use leakproof containers when draining fluids. Do not usefood or beverage containers that may mislead someoneinto drinking from them.

Do not pour waste onto the ground, down a drain, or intoany water source.

Air conditioning refrigerants escaping into the air can

damage the Earth’s atmosphere. Government regulationsmay require a certified air conditioning service center torecover and recycle used air conditioning refrigerants.

Inquire on the proper way to recycle or dispose of wastefrom your local environmental or recycling center, or fromyour John Deere dealer.


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Safety

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TX,05,FF1624 –19–14JUN90–1/1

Work in a Clean Area

Before starting a job, clean the work area. Removeobjects that may be a safety hazard to the mechanic orbystanders.

TX,05,FF1614 –19–14JUN90–1/1

Use Tools Properly

T S 7 7 9

– U N – 0 8 N O V 8 9

Use tools appropriate to the work. Makeshift tools, parts,and procedures can create safety hazards.

Use power tools only to loosen threaded tools andfasteners.

For loosening and tightening hardware, use the correctsize tools. DO NOT use U.S. measurement tools onmetric fasteners. Avoid bodily injury caused by slippingwrenches.

Use only recommended replacement parts. (See PartsCatalog.)

DX,SIGNS1 –19–04JUN90–1/1

Replace Safety Signs

T S 2 0 1

– U N

– 2 3 A U G 8 8

Replace missing or damaged safety signs. See the

machine operator’s manual for correct safety signplacement.


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Safety

DX,LIVE –19–25SEP92–1/1

Live With Safety

T S 2 3 1

– 1 9 – 0 7 O C T 8 8

Before returning machine to customer, make suremachine is functioning properly, especially the safetysystems. Install all guards and shields.


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Group 02General Specifications

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CED,TX08227,2993 –19–10FEB98–1/1

Excavator Overview

T 1 1 5 6 8 3

– U N – 0 2 J U N 9 8


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General Specifications

CED,TX14740,6954 –19–07SEP00–1/2

200LC Specifications

T 1 1 3 2 1 5

– U N – 0 3 F E B 9 8

A—Sprocket Center To Idler D—Rear End Swing Radius H—Center Of Sprocket To J—Undercarriage Width

Center E—Overall Width Center Of Sprocket K—Overall Length

B—Undercarriage Length F—Cab Height I—Track Shoe Width L—Transport Height

C—Counterweight Clearance G—Minimum Ground

Clearance

NOTE: Specifications and design subject to change

without notice. Wherever applicable,specifications are in accordance with PCSAand SAE standards. Except where otherwise noted these specifications are based on a

machine equipped with 800 mm (32 in.) shoes,

counterweight, 2.91 m (9 ft 7 in.) arm, 723 kg (1590 lb) 0.86 m 3 (1.12 yd 3 ) bucket, full fuel tank, 79 kg (175 lb) operator and standard equipment.

Item Measurement Specification

A—Sprocket Center To Idler Center Distance 3660 mm (12 ft 0 in.)

B—Undercarriage Length 4460 mm (14 ft 8 in.)

C—Counterweight Clearance Distance 1030 mm (3 ft 5 in.)

D—Rear End Swing Radius Distance 2720 mm (8 ft 11 in.)

E—Overall Width (Excluding Back Distance 2720 mm (8 ft 11 in.)Mirrors)

F—Cab Height 2720 mm (8 ft 11 in.)


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CED,TX14740,6954 –19–07SEP00–2/2


G—Minimum Ground Clearance Distance 450 mm (1 ft 6 in.)

H—Center Of Sprocket To Center Of Distance 2390 mm (7 ft 10 in.)Sprocket

I—Track Shoe Width 600 mm (24 in.) or 700 mm (28 in.)

or 800 mm (32 in.)

J—Undercarriage Width With 600 mm (24 in.) shoes: 2990mm (9 ft 10 in.)

Width With 700 mm (28 in.) shoes: 3090mm (10 ft 2 in.)

Width With 800 mm (32 in.) shoes: 3190mm (10 ft 6 in.)

K—Machine Overall Length With 2220 mm (7 ft 3 in.) Arm: 9620mm (31 ft 7 in.)

Overall Length With 2910 mm (9 ft 7 in.) Arm: 9500mm (31 ft 2 in.)

L—Machine Transport Height With 2220 mm (7 ft 3 in.) Arm: 3090mm (10 ft 2 in.)

Transport Height With 2910 mm (9 ft 7 in.) Arm: 2970

mm (9 ft 9 in.)

Machine Operating Weight 20 298 kg (44,750 lb)


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TX,115,DH5117 –19–15JUL96–1/2

200LC Working Ranges

T 1 0 2 3 8 9

– U N – 2 4 M A R 9 7

A—Maximum Digging Reach B—Maximum Digging Depth E—Maximum Cutting Height G—Minimum Swing Radius

A1—Maximum Digging Reach C—Maximum Vertical Wall F—Maximum Dumping Height

At Ground Level D—Maximum Digging Depth(Flat Bottom)


A—Maximum Digging Reach Distance With 2220 mm (7 ft 3 in.) Arm: 9250mm (30 ft 4 in.)

Distance With 2910 mm (9 ft 7 in.) Arm: 9910mm (32 ft 6 in.)


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TX,115,DH5117 –19–15JUL96–2/2


A1—Maximum Digging Reach At Distance With 2220 mm (7 ft 3 in.) Arm: 9080Ground Level mm (29 ft 9 in.)

Distance With 2910 mm (9 ft 7 in.) Arm: 9750mm (32 ft 0 in.)

B—Maximum Digging Depth Depth With 2220 mm (7 ft 3 in.) Arm: 5980

mm (19 ft 7 in.)Depth With 2910 mm (9 ft 7 in.) Arm: 6670

mm (21 ft 11 in.)

C—Maximum Vertical Wall Depth With 2220 mm (7 ft 3 in.) Arm: 5140mm (16 ft 10 in.)

Depth With 2910 mm (9 ft 7 in.) Arm: 6050mm (19 ft 10 in.)

D—Maximum Digging Depth (Flat Depth With 2220 mm (7 ft 3 in.) Arm: 5740Bottom) mm (18 ft 10 in.)

Depth With 2910 mm (9 ft 7 in.) Arm: 6490mm (21 ft 4 in.)

E—Maximum Cutting Height Height With 2220 mm (7 ft 3 in.) Arm: 9170mm (30 ft 1 in.)

Height With 2910 mm (9 ft 7 in.) Arm: 9600

mm (31 ft 6 in.)

F—Maximum Dumping Height Height With 2220 mm (7 ft 3 in.) Arm: 6390mm (21 ft 0 in.)

Height With 2910 mm (9 ft 7 in.) Arm: 6780mm (22 ft 3 in.)

G—Minimum Swing Radius Radius With 2220 mm (7 ft 3 in.) Arm: 3540

mm (11 ft 7 in.)Radius With 2910 mm (9 ft 7 in.) Arm: 3540

mm (11 ft 7 in.)


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CED,TX14740,6956 –19–07SEP00–1/1

200LC Engine Specifications


John Deere POWERTECH 6.8 Type 4-Stroke Cycle, Turbocharged,Aftercooled

Bore And Stroke 106 x 127 mm (4.17 x 5.0 in.)Cylinders 6

Displacement 6.785 L (414 cu in.)Net Torque @ 1300 RPM 579 N•m (427 lb-ft)Compression Ratio 17:1Power At 2150 RPM 104 kW (140 hp) Net SAELubrication Pressure System With Full-Flow

FilterCooling Fan SuctionElectrical system 24 VoltBatteries (2) 12 volt 180 Minutes Reserve Capacity:

POWERTECH is a trademark of Deere & Company.

TX,115,DH5114 –19–15JUL96–1/1

200LC Drain and Refill Capacities


Fuel Tank Capacity 303 L (80 gal)

Cooling System Capacity 28.4 L (7.5 gal)

Engine Oil Capacity, Including Filter Change 19 L (5.0 gal)

Hydraulic System Capacity 250 L (66 gal)

Hydraulic Tank Capacity 130 L (34 gal)

Swing Gearbox Capacity 4.7 L (5.0 qt)

Propel Gearbox (Each) Capacity 5.2 L (5.5 qt)

Pump Drive Gearbox Capacity 1.0 L (1.1 qt)


PN=26


27/694

Group 03Torque Values

9

0

1

DX,TORQ1 –19–01OCT99–1/1

Unified Inch Bolt and Cap Screw Torque Values

T O R Q 1 A

– U N – 2 7 S E P 9 9

Top, SAE Grade and Head Markings; Bottom, SAE Grade and Nut Markings

Grade 1 (No Mark) Grade 2a (No Mark) Grade 5, 5.1 or 5.2 Grade 8 or 8.2

Size Lubricatedb Dryc Lubricatedb Dryc Lubricatedb Dryc Lubricatedb Dryc

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)

1/4 3.8 (2.8) 4.7 (3.5) 6 (4.4) 7.5 (5.5) 9.5 (7) 12 (9) 13.5 (10) 17 (12.5)

5/16 7.7 (5.7) 9.8 (7.2) 12 (9) 15.5 (11.5) 19.5 (14.5) 25 (18.5) 28 (20.5) 35 (26)3/8 13.5 (10) 17.5 (13) 22 (16) 27.5 (20) 35 (26) 44 (32.5) 49 (36) 63 (46)

7/16 22 (16) 28 (20.5) 35 (26) 44 (32.5) 56 (41) 70 (52) 80 (59) 100 (74)

1/2 34 (25) 42 (31) 53 (39) 67 (49) 85 (63) 110 (80) 120 (88) 155 (115)

9/16 48 (35.5) 60 (45) 76 (56) 95 (70) 125 (92) 155 (115) 175 (130) 220 (165)

5/8 67 (49) 85 (63) 105 (77) 135 (100) 170 (125) 215 (160) 240 (175) 305 (225)

3/4 120 (88) 150 (110) 190 (140) 240 (175) 300 (220) 380 (280) 425 (315) 540 (400)

7/8 190 (140) 240 (175) 190 (140) 240 (175) 490 (360) 615 (455) 690 (510) 870 (640)

1 285 (210) 360 (265) 285 (210) 360 (265) 730 (540) 920 (680) 1030 (760) 1300 (960)

1-1/8 400 (300) 510 (375) 400 (300) 510 (375) 910 (670) 1150 (850) 1450 (1075) 1850 (1350)

1-1/4 570 (420) 725 (535) 570 (420) 725 (535) 1280 (945) 1630 (1200) 2050 (1500) 2600 (1920)

1-3/8 750 (550) 950 (700) 750 (550) 950 (700) 1700 (1250) 2140 (1580) 2700 (2000) 3400 (2500)1-1/2 990 (730) 1250 (930) 990 (730) 1250 (930) 2250 (1650) 2850 (2100) 3600 (2650) 4550 (3350)

a Grade 2 applies for hex cap screws (not hex bolts) up to 6 in. (152 mm) long. Grade 1 applies for hex cap screws over 6 in. (152 mm) long,

and for all other types of bolts and screws of any length.

b "Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.

c "Dry" means plain or zinc plated without any lubrication.

DO NOT use these values if a different torque value or tightening Make sure fastener threads are clean and that you properly start

procedure is given for a specific application. Torque values listed are thread engagement. This will prevent them from failing when

for general use only. Check tightness of fasteners periodically. tightening.

Shear bolts are designed to fail under predetermined loads. Always Tighten plastic insert or crimped steel-type lock nuts to approximately

replace shear bolts with identical grade. 50 percent of the dry torque shown in the chart, applied to the nut,

not to the bolt head. Tighten toothed or serrated-type lock nuts to the

full torque value.

Fasteners should be replaced with the same or higher grade. If

higher grade fasteners are used, these should only be tightened to

the strength of the original.


PN=27


28/694

Torque Values

DX,TORQ2 –19–01OCT99–1/1

Metric Bolt and Cap Screw Torque Values

T O R Q 2

– U N – 0 7 S E P 9 9

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

Size Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb

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.

DO NOT use these values if a different torque value or tightening Make sure fastener threads are clean and that you properly start

procedure is given for a specific application. Torque values listed are thread engagement. This will prevent them from failing when

for general use only. Check tightness of fasteners periodically. tightening.

Shear bolts are designed to fail under predetermined loads. Always Tighten plastic insert or crimped steel-type lock nuts to approximately

replace shear bolts with identical property class. 50 percent of the dry torque shown in the chart, applied to the nut,

not to the bolt head. Tighten toothed or serrated-type lock nuts to the

full torque value.

Fasteners should be replaced with the same or higher property class.

If higher property class fasteners are used, these should only betightened to the strength of the original.


PN=28


29/694

Torque Values

9

0

3

04T,90,M170 –19–29SEP99–1/2

Additional Metric Cap Screw Torque Values

T 6 8 7 3 A

A

– U N – 1 8 O C T 8 8

T 6 8 7 3 A B

– U N – 1 8 O C T 8 8

T 6 8 7 3 A C

– U N – 1 8 O C T 8 8

CAUTION: Use only metric tools on metrichardware. Other tools may not fit properly. They

may slip and cause injury.

Check tightness of cap screws periodically. Torque valueslisted are for general use only. Do not use these values ifa different torque value or tightening procedure is listedfor a specific application.

Shear bolts are designed to fail under predetermined

loads. Always replace shear bolts with identical grade.

Fasteners should be replaced with the same or highergrade. If higher grade fasteners are used, these shouldonly be tightened to the strength of the original.

Make sure fastener threads are clean and you properlystart thread engagement. This will prevent them from

failing when tightening.

Tighten cap screws having lock nuts to approximately 50percent of amount shown in chart.



PN=29


30/694

Torque Values

04T,90,M170 –19–29SEP99–2/2

METRIC CAP SCREW TORQUE VALUESa

T-Bolt H-Bolt M-Bolt

Nominal

Dia N•m lb-ft N•m lb-ft N•m lb-ft

8 29 21 20 15 10 7

10 63 46 45 33 20 15

12 108 80 88 65 34 25

14 176 130 137 101 54 40

16 265 195 206 152 78 58

18 392 289 294 217 118 87

20 539 398 392 289 167 125

22 735 542 539 398 216 159

24 931 687 686 506 274 202

27 1372 1012 1029 759 392 289

30 1911 1410 1421 1049 539 398

33 2548 1890 1911 1410 735 542

36 3136 2314 2401 1772 931 687

aTorque tolerance is ±10%.


PN=30


31/694

Torque Values

9

0

5

TX,90,DH1559 –19–01AUG94–1/1

Check Oil Lines And Fittings

X 9 8 1 1

– U N – 2 3 A U G 8

8

CAUTION: Escaping fluid under pressure canpenetrate the skin causing serious injury. Avoid

the hazard by relieving pressure beforedisconnecting hydraulic or other lines. Tightenall connections before applying pressure.Search for leaks with a piece of cardboard.Protect hands and body from high pressurefluids.

If an accident occurs, see a doctor immediately.

Any fluid injected into the skin must besurgically removed within a few hours organgrene may result. Doctors unfamiliar withthis type of injury may call the Deere &Company Medical Department in Moline, Illinois,or other knowledgeable medical source.

Check all oil lines, hoses, and fittings regularly for leaks or

damage. Make sure all clamps are in position and tight.Make sure hoses are not twisted or touching movingmachine parts. If abrasion or wear occurs, replaceimmediately.

Tubing with dents may cause the oil to overheat. If youfind tubing with dents, install new tubing immediately.

IMPORTANT: Tighten fittings as specified in torquechart.

When you tighten connections, use two wrenches toprevent bending or breaking tubing and fittings.


PN=31


32/694

Torque Values

04T,90,K66 –19–29SEP99–1/2

Service Recommendations for O-Ring BossFittings

T 6 2 4 3 A E

– U N – 1 8 O C T

8 8

Straight Fitting

1. Inspect O-ring boss seat for dirt or defects.

2. Lubricate O-ring with petroleum jelly. Place electricaltape over threads to protect O-ring. Slide O-ring overtape and into O-ring groove of fitting. Remove tape.

3. Tighten fitting to torque value shown on chart.



PN=32


33/694

Torque Values

9

0

7

04T,90,K66 –19–29SEP99–2/2

T 6 5 2 0 A B

– U N – 1 8 O C T

8 8

Angle Fitting

1. Back-off lock nut (A) and back-up washer (B)completely to head-end (C) of fitting.

2. Turn fitting into threaded boss until back-up washer

contacts face of boss.

3. Turn fitting head-end counterclockwise to proper index(maximum of one turn).

NOTE: Do not allow hoses to twist when tightening fittings.

4. Hold fitting head-end with a wrench and tighten locknutand back-up washer to proper torque value.

STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART

Thread Size N•m lb-ft

3/8-24 UNF 8 6

7/16-20 UNF 12 9

1/2-20 UNF 16 12

9/16-18 UNF 24 18

3/4-16 UNF 46 34

7/8-14 UNF 62 46

1-1/16-12 UN 102 75

1-3/16-12 UN 122 90

1-5/16-12 UN 142 105

1-5/8-12 UN 190 140

1-7/8-12 UN 217 160

NOTE: Torque tolerance is ± 10%.


PN=33


34/694

Torque Values

04T,90,K67 –19–02MAR00–1/1

Service Recommendations For Flat Face O-Ring Seal Fittings

1. Inspect the fitting sealing surfaces and O-ring. Theymust be free of dirt or defects.

2. Lubricate O-rings and install into grove using

petroleum jelly to hold in place.

3. Index angle fittings and tighten by hand pressing joint together to insure O-ring remains in place.

4. Tighten fitting or nut to torque value shown on thechart. Do not allow hoses to twist when tightening

fittings, use backup wrench on straight hosecouplings.

IMPORTANT: Tighten fittings to 150% of listed

torque value if indexing is necessaryor if fitting is attached to anactuating devise.

Tighten fittings to 50% of listedtorque value if used in aluminumhousing.

FLAT FACE O-RING SEAL FITTING TORQUE*

Nominal Tube O.D. Thread Size Swivel Nut Bulkhead Nut

mm in. in. N•m lb-ft N•m lb-ft

6.35 0.250 9/16-18 16 12 12 9

9.52 0.375 11/16-16 24 18 24 1812.70 0.500 13/16-16 50 37 46 34

15.88 0.625 1-14 69 51 62 46

19.05 0.750 1 3/16-12 102 75 102 75

22.22 0.875 1 3/16-12 102 75 102 75

25.40 1.000 1 7/16-12 142 105 142 105

31.75 1.250 1 11/16-12 190 140 190 140

38.10 1.500 2-12 217 160 217 160

*Torque tolerance is +15 -20% unless otherwise specified.

Stud End O-ring Seal Torque for Straight and Adjustable Fittings*

Thread Size Straight Hex Size Locknut Hex Size Straight Fitting or Locknut Toque

Inch Inch Inch N•m lb-ft3/8-24 5/8 9/16 12 9

7/16-20 5/8 5/8 21 15

1/2-20 3/4 11/16 26 19

9/16-18 3/4 3/4 34 25

3/4-16 7/8 15/16 73 55

7/8-14 1 1/16 1 1/16 104 76

1 1/16-12 1 1/4 1 3/8 176 130

1 3/16-12 1 3/8 1 1/2 230 170

1 5/16-12 1 1/2 1 5/8 285 210

*Torque tolerance is +15 -20% unless otherwise specified.


PN=34


35/694

Torque Values

9

0

9

T82,BHMA,EL –19–29SEP99–1/1

Service Recommendations for 37° Flare and30° Cone Seat Connectors

T 6 2 3 4 A C

– U N – 1 8 O C T

8 8

1. Inspect flare and flare seat. They must be free of dirtor obvious defects.

2. Defects in tube flare cannot be repaired.Overtightening a defective flared fitting will not stopleaks.

3. Align tube with fitting before attempting to start nut.

4. Lubricate male threads with hydraulic fluid or petroleum jelly.

5. Index angle fittings and tighten by hand.

6. Tighten fitting or nut to torque value shown on torquechart. Do not allow hoses to twist when tightening

fittings.

STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART

Thread Size N•m lb-ft

3/8 - 24 UNF 8 6

7/16 - 20 UNF 12 9

1/2 - 20 UNF 16 12

9/16 - 18 UNF 24 18

3/4 - 16 UNF 46 34

7/8 - 14 UNF 62 46

1-1/16 - 12 UN 102 75

1-3/16 - 12 UN 122 90

1-5/16 - 12 UN 142 105

1-5/8 - 12 190 140

1-7/8 - 12 UN 217 160

NOTE: Torque tolerance is ± 10%.


PN=35


36/694

Torque Values

04T,90,M171 –19–28JAN92–1/1

Service Recommendations For FlaredConnections—Straight or Tapered Threads

T 6 8 7 3 A E

– U N – 1 8 O C T

8 8

Straight Thread

T 6 8 7 3 A D

– U N – 1 8 O C T 8 8

Tapered Thread

1. Inspect flare and flare seat. They must be free of dirtor obvious defects.

2. Defects in the tube flare cannot be repaired.Overtightening a defective flared fitting will not stopleaks.

3. Align the tube with the fitting before attempting to start

the nut.

4. Lubricate the male threads with hydraulic fluid orpetroleum jelly.

5. Index angle fittings and tighten by hand.

6. Tighten fitting or nut to torque value shown on the

chart. Do not allow hoses to twist when tighteningfittings.

TORQUE CHART a

Straight Thread b Tapered Thread

Thread

Size N•m lb-ft N•m lb-ft

1/8 15 11

1/4 20 15 45 33

3/8 29 21 69 51

1/2 49 36 93 69

3/4 69 51 176 130

1 157 116 343 253

1-1/2 196 145 539 398

2 255 188 588 434

aTorque tolerance is ±10%.

bWith seat face.

NOTE: If female thread is cast iron (control valves, brake valves motors, etc.), torque must be reduced

approximately 10%.


PN=36


37/694

Torque Values

9

0

1

04T,90,K174 –19–01AUG94–1/1

Service Recommendations For Inch Series Four Bolt Flange Fittings

T 6 8 9 0 B B

– U N – 0 1 M A R 9 0

A—Sealing Surface B—Split Flange C—Pinched O-Ring D—Single Piece Flange

1. Clean sealing surfaces (A). Inspect. Scratchescause leaks. Roughness causes seal wear.

Out-of-flat causes seal extrusion. If defects cannotbe polished out, replace component.

2. Install O-ring (and backup washer if required) intogroove using petroleum jelly to hold it in place.

3. Split flange: Loosely assemble split flange (B)halves. Make sure split is centrally located andperpendicular to port. Hand tighten cap screws tohold parts in place. Do not pinch O-ring (C).

4. Single piece flange (D): Place hydraulic line incenter of flange and install cap screws. Flange

must be centrally located on port. Hand tighten capscrews to hold flange in place. Do not pinch O-ring.

5. Tighten one cap screw, then tighten the diagonallyopposite cap screw. Tighten two remaining capscrews. Tighten all cap screws as specified in thechart below.

DO NOT use air wrenches. DO NOT tighten onecap screw fully before tightening the others. DONOT over tighten.

TORQUE CHART

N•m lb-ft

Nominal Cap Screw

Flange Size

Size Min Max Min Max

1/2 5/16-18 20 31 15 23

UNC

3/4 3/8-16 UNC 28 54 21 40

1 3/8-16 UNC 37 54 27 40

1-1/4 7/16-14 47 85 35 63

UNC

1-1/2 1/2-13 UNC 62 131 46 97

2 1/2-13 UNC 73 131 54 97

2-1/2 1/2-13 UNC 107 131 79 97

3 5/8-11 UNC 158 264 117 195

3-1/2 5/8-11 UNC 158 264 117 195

4 5/8-11 UNC 158 264 117 195

5 5/8-11 UNC 158 264 117 195


PN=37


38/694

Torque Values

04T,90,K175 –19–29SEP99–1/1

Service Recommendations for Metric Series Four Bolt Flange Fitting

T 6 8 9 0 B B

– U N – 0 1 M A R 9 0

A—Sealing Surface B—Split Flange C—Pinched O-Ring D—Single Piece Flange

1. Clean sealing surfaces (A). Inspect. Scratchescause leaks. Roughness causes seal wear.

Out-of-flat causes seal extrusion. If defects cannotbe polished out, replace component.

2. Install the correct O-ring (and backup washer ifrequired) into groove using petroleum jelly to hold itin place.

3. Split flange: Loosely assemble split flange (B)halves. Make sure split is centrally located andperpendicular to the port. Hand tighten cap screwsto hold parts in place. Do not pinch O-ring (C).

4. Single piece flange (D): Place hydraulic line in

center of flange and install four cap screws. Flangemust be centrally located on port. Hand tighten capscrews to hold flange in place. Do not pinch O-ring.

5. After components are properly positioned and capscrews are hand tightened, tighten one cap screw,

then tighten the diagonally opposite cap screw.Tighten two remaining cap screws. Tighten all cap

screws as specified in the chart below.

DO NOT use air wrenches. DO NOT tighten one

cap screw fully before tightening the others. DONOT over tighten.

TORQUE CHARTa

Threadb N•m lb-ft

M6 12 9

M8 30 22

M10 57 42

M12 95 70

M14 157 116

M16 217 160

M18 334 246

M20 421 318

aTolerance ± 10%. The torques given are enough for the given

size connection with the recommended working pressure.

Increasing cap screw torque beyond these amounts will result in

flange and cap screw bending and connection failures.

bMetric standard thread.


PN=38


39/694

Group 04Fuels and Lubricants

9

0

1

TX,45,JC1132 –19–22MAY96–1/1

Diesel Fuel

Consult your local fuel distributor for properties of thediesel fuel available in your area.

In general, diesel fuels are blended to satisfy the low

temperature requirements of the geographical area inwhich they are marketed.

Diesel fuels specified to EN 590 or ASTM D975 arerecommended.

In all cases, the fuel shall meet the followingproperties:

• Cetane Number 40 minimum. Cetane numbergreater than 50 is preferred, especially for

temperatures below -20°C (-4°F) or elevations above1500 m (5000 ft).

• Cold Filter Plugging Point(CFPP) below theexpected low temperature OR Cloud Point at least5°C (9°F) below the expected low temperature.

• Fuel Lubricity should pass a minimum of 3100gram load level as measured by the BOCLE scuffingtest.

• Sulfur content:

– Sulfur content should not exceed 0.5% Sulfurcontent less than 0.05% is preferred.

– If diesel fuel with sulfur content greater than 0.5%sulfur content is used, reduce the service intervalfor engine oil and filter by 50%.

– DO NOT use diesel fuel with sulfur contentgreater than 1.0%.

Bio-diesel fuels with properties and meeting DIN 51606or equivalent specifications may be used.

DO NOT mix used engine oil or any other type of

lubricant with diesel fuel.

TX,45,JC1771 –19–08JAN97–1/1

Lubricity of Diesel Fuels

Diesel fuel must have adequate lubricity to ensure

proper operation and durability of fuel injection systemcomponents.

Diesel fuels for highway use in the United States and

Canada now require sulfur content less than 0.05%.Diesel fuel in the European Union require sulfurcontent less than 0.05% as of 1 October 1996.

Experience shows that some low sulfur diesel fuelsmay have inadequate lubricity and their use mayreduce performance in fuel injection systems due toinadequate lubrication of injection pump components.

The lower concentration of aromatic compounds inthese fuels also adversely affects injection pump sealsand may result in leaks.

Use of low lubricity diesel fuels may also causeaccelerated wear, injection nozzle erosion or corrosion,

engine speed instability, hard starting, low power, and

engine smoke.

Fuel lubricity should pass a minimum of 3100 gramload level as measured by the BOCLE scuffing test.

ASTM D975 and EN 590 specifications do not requirefuels to pass a fuel lubricity test.

If fuel of low or unknown lubricity is used, add JohnDeere PREMIUM DIESEL FUEL CONDITIONER (orequivalent) at the specified concentration. John DeerePREMIUM DIESEL FUEL CONDITIONER is available

in winter and summer formulas. Consult your JohnDeere engine distributor or servicing dealer for moreinformation.


PN=39


40/694

Fuels and Lubricants

TX,45,DH5857 –19–15AUG97–1/1

Low Sulfur Diesel Fuel Conditioner

When possible, use existing fuel formulations for enginesused off-highway. This fuel will not require any additivesto provide good performance and engine reliability.However, many local fuel distributors will not carry both

low and regular sulfur diesel fuels.

If the local fuel distributor will supply only low sulfur fuel,order and use John Deere PREMIUM DIESEL FUELCONDITIONER. It provides lubricating properties alongwith other useful benefits, such as cetane improver,anti-oxidant, fuel stabilizer, corrosion inhibitor and others.John Deere PREMIUM DIESEL FUEL CONDITIONER isspecifically for use with low sulfur fuels. Nearly all otherdiesel fuel conditioners only improve cold weather flowand stabilize long-term fuel storage. They do not contain

the lubrication additives needed by rotary fuel injectionpumps.

TX,45,JC1772 –19–08JAN97–1/1

Diesel Fuel Storage

Proper fuel storage is critically important. Use clean

storage and transfer tanks. Periodically drain waterand sediment from bottom of tank. Store fuel in aconvenient place away from buildings.

IMPORTANT: DO NOT store diesel fuel ingalvanized containers. Diesel fuelstored in galvanized containersreacts with zinc coating on containerto form zinc flakes. If fuel containswater, a zinc gel will also form. Thegel and flakes will quickly plug fuelfilters, damage injection nozzles andinjection pump.

DO NOT use brass-coated containersfor fuel storage. Brass is an alloy ofcopper and zinc.

Store diesel fuel in plastic, aluminum, and steel

containers specially coated for diesel fuel storage.

Avoid storing fuel over long periods of time. If fuel isstored for more than a month prior to use, or there is a

slow turnover in fuel tank or supply tank, add a fuelconditioner such as John Deere PREMIUM DIESELFUEL CONDITIONER or equivalent to stabilize the fueland prevent water condensation. John DeerePREMIUM DIESEL FUEL CONDITIONER is availablein winter and summer formulas. Fuel conditioner alsoreduces fuel gelling and controls wax separation duringcold weather.

Consult your John Deere engine distributor or servicingdealer for recommendations and local availability.Always follow manufacturer’s directions on label.


PN=40


41/694


9

0

3

TX,45,DH5077 –19–01JUL96–1/1

Fuel Tank

CAUTION: Handle fuel carefully. If the engine ishot or running, do not fill the fuel tank. Do not

smoke while you fill fuel tank or work on fuelsystem.

To avoid condensation, fill the fuel tank at the end of eachday’s operation. Capacity is 303 L (80 gal).

MX,FLBT,C –19–04JUN90–1/1

Do Not Use Galvanized Containers

IMPORTANT: Diesel fuel stored in galvanizedcontainers reacts with zinc coating

on the container to form zinc flakes.If fuel contains water, a zinc gel willalso form. The gel and flakes willquickly plug fuel filters and damage

fuel injectors and fuel pumps.

DO NOT USE a galvanized container to store dieselfuel.

Store fuel in:

•

plastic containers.• aluminum containers.• specially coated steel containers made for diesel

fuel.

DO NOT USE brass-coated containers: brass is analloy of copper and zinc.


PN=41


42/694


DX,ENOIL –19–10OCT97–1/1

Diesel Engine Oil

T S

1 6 6 1

– U N – 1 0 O C T 9 7

Use oil viscosity based on the expected air temperaturerange during the period between oil changes.

The following oil is preferred:

• John Deere PLUS-50

The following oil is also recommended:

• John Deere TORQ-GARD SUPREME

Other oils may be used if they meet one or more of thefollowing:

• API Service Classification CG-4

• API Service Classification CF-4• ACEA Specification E3

• ACEA Specification E2

Multi-viscosity diesel engine oils are preferred.

If diesel fuel with sulfur content greater than 0.5% is used,reduce the service interval by 50%.

Extended service intervals may apply when John Deerepreferred engine oils are used. Consult your John Deeredealer for more information.

PLUS-50 is a registered trademark of Deere & Company.

TORQ-GARD SUPREME is a trademark of Deere & Company


PN=42


43/694


9

0

5

CED,TX14740,6951 –19–07JAN00–1/1

Hydraulic Oil

T S

1 6 6 0

– U N – 1 0 O C T 9 7


The following oils are preferred:

• John Deere HY-GARD

• John Deere Low Viscosity HY-GARD

Other oils may be used if they meet one of the following:

• John Deere Standard JDM J20C• John Deere Standard JDM J20D

Use the following oil when a biodegradable fluid isrequired:

• John Deere1BIO-HY-GARD

Manufacturer Oil

Mobil DTE 25

Shell Tellus 46

Caltex Oil Rando Oil HD46

Texaco Inc. Rando Oil HD46

Chevron U.S.A. Inc. Chevron AW46

Esso Standard Oil NUTO H46

HY-GARD is a trademark of Deere & Company

BIO-HY-GARD is a trademark of Deere & Company

1

BIO-HY-GARD meets or exceeds the minimum biodegradability of 80% within 21 days according to CEC-L-33-T-82 test method. BIO-HY-GARD

should not be mixed with mineral oils because this reduces the

biodegradability and makes proper oil recycling impossible.


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OUOE003,0005424 –19–07SEP00–1/1

Swing Gearbox, Propel Gearbox and PumpGearbox Oils

T S 1 6 5 3

– U N – 1 4 M A R 9 6


The following oils are preferred:

• John Deere GL-5 GEAR LUBRICANT• John Deere EXTREME-GARD

Other oils may be used if they meet API ServiceClassification GL-5.

EXTREME-GARD is a trademark of Deere & Company.

TX,45,DH5142 –19–09AUG96–1/1

Track Roller, Front Idler, and Carrier RollerOil

Use SAE 30 oil meeting API Service GL-5 (MIL-L-2105Bor MIL-L-2105C).


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CED,TX14740,6952 –19–07JAN00–1/1

Track Adjuster, Working Tool Pivot, SwingBearing, and Swing Bearing Gear Grease

T S

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– U N – 3 0 J U N 9 9

Use grease based on NLGI consistency numbers and theexpected air temperature range during the service interval.

The following greases are preferred:

• John Deere SD POLYUREA GREASE

The following greases are also recommended:

• John Deere HD MOLY GREASE• John Deere HD LITHIUM COMPLEX GREASE• John Deere HD WATER RESISTANT GREASE• John Deere GREASE-GARD

Other greases may be used if they meet the following:

• NLGI Performance Classification GC-LB

IMPORTANT: Some types of grease thickener are notcompatible with others.

DX,FILT –19–18MAR96–1/1

Oil Filters

Filtration of oils is critical to proper operation and

lubrication. Always change filters regularly as specified inthis manual.

Use filters meeting John Deere performance

specifications.


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DX,LUBST –19–18MAR96–1/1

Lubricant Storage

Your equipment can operate at top efficiency onlywhen clean lubricants are used.

Use clean containers to handle all lubricants.

Whenever possible, store lubricants and containers in

an area protected from dust, moisture, and othercontamination. Store containers on their side to avoidwater and dirt accumulation.

Make certain that all containers are properly marked toidentify their contents.

Properly dispose of all old containers and any residual

lubricant they may contain.

DX,ALTER –19–18MAR96–1/1

Alternative and Synthetic Lubricants

Conditions in certain geographical areas may require

lubricant recommendations different from those printed inthis manual. Some John Deere brand coolants andlubricants may not be available in your location. Consultyour John Deere dealer to obtain information andrecommendations.

Synthetic lubricants may be used if they meet the

performance requirements as shown in this manual.

The temperature limits and service intervals shown in thismanual apply to both conventional and synthetic oils.

Re-refined base stock products may be used if thefinished lubricant meets the performance requirements.


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DX,LUBMIX –19–18MAR96–1/1

Mixing of Lubricants

In general, avoid mixing different brands or types of oil.Oil manufacturers blend additives in their oils to meetcertain specifications and performance requirements.Mixing different oils can interfere with the proper

functioning of these additives and degrade lubricantperformance.

Consult your John Deere dealer to obtain specificinformation and recommendations.


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Section 9005

Operational Checkout ProcedureContents 9

Page

Group 10—Operational Checkout ProcedureOperational Checkout . . . . . . . . . . . . . . . . . .9005-10-1

Operator Station Checks—Key Switch On,Engine Off . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-1

Operator Station Checks—Engine On . . . . . . 9005-10-4Hydraulic System Checks . . . . . . . . . . . . . . .9005-10-9Undercarriage Checks. . . . . . . . . . . . . . . . .9005-10-16Accessories Checks . . . . . . . . . . . . . . . . . .9005-10-18Heating and Air Conditioning Checks . . . . . 9005-10-20Seat, Doors, Windows, Latches, and

Locks Checks . . . . . . . . . . . . . . . . . . . . . 9005-10-23Engine Cooling System Checks . . . . . . . . . 9005-10-28Air Intake System Checks . . . . . . . . . . . . . . 9005-10-33Fuel System Checks . . . . . . . . . . . . . . . . . . 9005-10-36Visual Inspection. . . . . . . . . . . . . . . . . . . . .9005-10-38


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Contents


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Group 10Operational Checkout Procedure

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TX,9005,GG2241 –19–07SEP00–1/1

Operational Checkout

Use this procedure to check all systems and functions onthe machine. It is designed so you can make a quickcheck of machine operation while doing a walk aroundinspection and performing specific checks from the

operator’s seat.

Should you experience a problem with your machine, youwill find helpful diagnostic information in this checkout thatwill pinpoint the cause. This information may allow you toperform a simple adjustment yourself which will reducethe down time of your machine. Use the table of contentsto help find adjustment procedures.

The information you provide after completing theoperational checkout will allow you or your authorized

dealer to pinpoint a specific test or repair needed torestore the machine to design specifications.

A location will be required which is level and hasadequate space to complete the checks. No tools orequipment are needed to perform the checkout.

Complete the necessary visual checks (oil levels, oil

condition, external leaks, loose hardware, linkage, wiring,etc.) prior to doing the checkout. The machine must be atoperating temperature for many of the checks.

Start at the top of the left column and read completelydown column before performing check. Follow thissequence from left to right. In the far right column, if noproblem is found, you will be instructed to go to next

check. If a problem is indicated, you will be referred toeither a section in this manual or to your authorized dealerfor repair.

– – –1/1

1 Operator Station Checks—Key Switch On, Engine Off


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Operational Checkout Procedure

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Gauges, Monitor, and

Battery Disconnect Relay

Checks

T102096 –UN–26JUL96

A—Temperature Gauge

B—Fuel Gauge

NOTE: Monitor buzzer is not checked during this

procedure.

If engine coolant temperature is below 30 °C (86 °F)

engine temperature gauge needle may not move to the right. Run engine a few minutes to warm coolant before

check.

Key switch ON.

Engine OFF.

Does battery relay click?

Do engine temperature gauge (A) and fuel gauge (B)

needles move to the right?

Do all eight monitor lights come on and after 2—3

seconds only the alternator indicator and engine oil

pressure indicator remain on?

YES: Go to next check.

NO: Check monitor fuse.

NO: Check and replace

bulb if any bulb fails to

come on. Go to Group

9015-15.

– – –1/1

Fluid Level (Coolant,

Hydraulic Oil, and

Engine Oil) Indicator

Circuit Checks

T102097 –UN–26JUL96

A—Level Check Switch

B—Engine Oil Level Indicator

C—Engine Coolant Level Indicator

D—Hydraulic Oil Level Indicator

Key switch ON.

Engine OFF.

Push and hold level check switch (A).

Are the hydraulic oil level (B), coolant level (C), and

engine oil level (D) indicator lights ON?


NO: Check monitor fuse.

If OK, check fluid levels in

radiator, recovery tank,

hydraulic oil tank, or

engine. If OK, check fluid

level switch or wiring. Go

to Group 9015-15.


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Engine Oil Level and

Condition Check

T6488GH –19–23FEB89

T103525 –UN–10SEP96

A—Pre-Operation Level Check Switch

B—Engine Oil Level Indicator

Engine OFF.

Remove dipstick and check oil level and condition.

Is oil above “full” mark or below “add” mark on dipstick.

Does the oil look milky or grainy?

If oil level is high, check for fuel or anti-freeze. Drain a small amount of engine oil into

a clear container. Watch oil in container to see if anti-freeze or water accumulates at

the bottom. If oil is milky, moisture or anti-freeze may be present.

If oil is grainy, carbon may be present. Carbon in oil may result when engine runs at

slow idle too long.

If oil level is low, check for oil leaks or oil seal problems in engine.

Adjust oil level to between “add” and “full” marks on dipstick.

Key switch ON.

Push pre-operation level check switch (A).

Is green light for engine oil level indicator (B) ON?

YES: Add oil if low.

Change oil and filter if too

high, milky or grainy. Go

to Group 9000-04. Check

oil level after a few hours

operation to determine if

a problem exists. Go toDiagnose Engine

Malfunctions Group

9010-15.

NO: If engine oil level

indicator does not come

ON, go to Monitor

Diagnostic Information in

Group 9015-15.

If oil level is OK, go to

next check.


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Propel Lever and Pedal

Dampener Checks

T7531AO –UN–07JUN91

A—Propel Lever and Pedal Forward

B—Propel Lever and Pedal Rearward

Engine OFF.

Push each propel lever and pedal forward (A), then

release.

Pull each propel lever and pedal rearward (B), then

release.

Does each lever and pedal have equal effort to operate

forward and reverse?

Does each lever and pedal return to neutral at the same

time when released?


NO: Repair or replace

propel pedal dampeners.

Go to Group 3360.

– – –1/1

2 Operator Station Checks—Engine On

– – –1/1

Monitor Circuit and

Gauge Checks

T102096 –UN–26JUL96

A—Coolant Temperature Gauge

B—Fuel Gauge

Start engine.

IMPORTANT: Stop the engine if alternator or engine

oil pressure indicators do not go OFF or a monitor

indicator comes ON after engine starts.

Do alternator and engine oil pressure indicators go OFF

after engine starts?

Do all monitor indicators remain OFF after engine starts?

The buzzer will sound if engine oil pressure is low.

Is coolant temperature gauge needle (A) in normal

operating zone after a few minutes?

Does fuel gauge (B) indicate fuel level?

Stop engine.


NO: Check engine

lubrication system if

engine oil pressure

indicator is on after

engine starts. Go to

Group 9010-10 or

CTM104.

Check alternator belt if

alternator indicator is on

after engine starts. Go to

Group 0510. If OK, check

fuses and alternator. Go

to Group 9015-15.

Check switches, sensors,

and gauges. Go to Group

9015-15.

Check fluid levels.


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Power Mode Circuit

Checks

T7351CC –UN–22AUG90

LOCKED

T102098 –UN–26JUL96

A—HP (High Power) Mode Switch

B—E (Economy) Mode Switch

Start engine.

Auto-idle switch OFF.

Pilot shut-off lever in LOCKED position.

Push power mode HP mode (A) and E mode (B) select switches one at a time.

Do corresponding indicator lights come on as each switch is pushed?


NO: Check controller

fuse. Go to Group

9015-15.

– – –1/1

Work Mode Circuit

Checks

T102099 –UN–26JUL96

A—Work Mode Switch

B—Dig Mode Indicator

C—Grading Mode Indicator

D—Precision Mode Indicator

E—Attachment Mode Indicator

Start engine.

Turn engine rpm dial to fast idle.



Push work mode select switch (A) to select desired work

mode.

Do corresponding indicator lights (B—E) come on as

each switch is pushed?

Does engine speed decrease when precision mode is

selected?


NO: Check fuse. If OK,

check monitor and wiring

harness. Go to Group

9015-15.


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Engine RPM Dial Checks

T102100 –UN–26JUL96

A—Engine RPM Dial

Start engine.



Turn engine rpm dial (A) clockwise.

Does engine speed increase?

Turn engine rpm dial counterclockwise.

Does engine speed decrease?


NO: Check dial and

wiring harness. Go to

Group 9015-15. If OK,

check for control signal to

EC motor. Go to harness

test in Group 9025-25.Check that cable from EC

motor to injection pump

lever moves freely. Go to

Group 0515.

– – –1/1

Auto-Idle Circuit Check

T102101 –UN–26JUL96

A—Auto Idle Switch

B—Auto Idle Indicator

Engine at fast idle.

HP (High Power) and E (Economy) mode switches OFF.


Pilot shut-off lever in UNLOCKED position.

Push auto-idle switch (A) to ON.

Does auto-idle indicator (B) come on?

Does engine speed decrease after 4—6 seconds?

Slowly actuate any dig function control lever.

Does engine speed return to fast idle?


NO: Check fuse. Check

switches and wiring

harness. Go to Group

9015-15.


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E (Economy) Mode

Check

T103545 –UN–09SEP96 T103546 –UN–09SEP96

A—E (Economy) Mode Switch

B—E (Economy) Mode Indicator

Start the engine.


Turn engine rpm dial clockwise to fast idle.

Push E (Economy) mode switch (A) on.

Does engine speed decrease?

Does E mode indicator (B) come on?

Push E mode switch again to turn it OFF.

Does E mode indicator go out and engine speed increase to fast idle?


NO: Check switch,

indicator, and harness.

Go to Group 9015-15.

– – –1/1

HP (High Power) Mode

Check

T111983 –UN–27OCT97T112183 –UN–13NOV97

A—HP (High Power) Mode Switch

B—HP (High Power) Mode Indicator

Start the engine.


Turn engine rpm dial clockwise to fast idle

200lc technical manual operation and tests tm1663.pdf

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