TM 5-3805-280-24-2

TM 5-3805-280-24-2

TECHNICAL MANUAL

UNIT, DIRECT SUPPORTAND GENERAL SUPPORT MAINTENANCE MANUAL

HYDRAULIC EXCAVATORJOHN DEERE

MODEL 230LCRNSN 3805-01-463-0804

AND

MODEL 230LCRD WITH ROCK DRILLNSN 3805-01-463-0806

DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited.

Reproduced by permission of Deere & Company, Moline, IL 2000.All rights reserved.

HEADQUARTERS, DEPARTMENT OF THE ARMY

15 FEBRUARY 2000

A

TM 5-3805-280-24-2

INSERT LATEST UPDATED PAGES. DESTROY SUPERSEDED DATA.

LIST OF EFFECTIVE PAGES

Note: The portion of text or illustration affected by the updates is indicated by a vertical line in the outer margins ofthe page. Updates to wiring diagrams are indicated by shaded areas.

Dates of issue for original and updated pages are:

Original .. 0 .. 15 February 2000

TOTAL NUMBER OF PAGES IN THIS VOLUME IS 1451 CONSISTING OF THE FOLLOWING:

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TM 5-3805-280-24-2Technical ManualNo. 5-3805-280-24-2 HEADQUARTERS,

DEPARTMENT OF THE ARMY Washington, DC, 15 February 2000

UNIT, DIRECT SUPPORTAND GENERAL SUPPORTMAINTENANCE MANUAL

HYDRAULIC EXCAVATORJOHN DEERE

MODEL 230LCRNSN 3805-01-463-0804

AND

MODEL 230LCRD WITH ROCK DRILLNSN 3805-01-463-0806

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this publication. If you find any mistakes or if you know of a way to improve the procedures,please let us know. Submit your DA Form 2028-2 (Recommended Changes to Equipment Technical Publications),through the Internet, on the Army Electronic Product Support (AEPS) website. The Internet address ishttp://aeps.ria.army.mil. If you need a password, scroll down and click on ACCESS REQUEST FORM. The DAForm 2028 is located in the ONLINE FORMS PROCESSING section of the AEPS. Fill out the form and click onSUBMIT. Using this form on the AEPS will enable us to respond quicker to your comments and better manage theDA Form 2028 program. You may also mail, fax or email your letter, DA Form 2028, or DA Form 2028-2 directto: Commander, U.S. Army Tank-automotive and Armaments Command, ATTN: AMSTA-LC-CI, Rock Island, IL61299-7630. The email address is [email protected]. The fax number is DSN 793-0726 orCommercial (309) 782-0726.

DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited.

TABLE OF CONTENTS

TM 5-3805-280-24-1

Chapter 1 Section 9000 General Information

Chapter 2 Section 9005 Operational Checkout Procedure

Chapter 3 Section 9010 Engine

Chapter 4 Section 9015 Electrical System

Chapter 5 Section 9020 Power Train

Chapter 6 Section 9025 Hydraulic System

TM 5-3805-280-24-2

TABLE OF CONTENTS (Continued)Page

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Chapter 7 Section 9031 Air Conditioning System

Chapter 8 Section 9035 Arctic/Cold Weather Heater

Chapter 9 Section 9040 Air Compressor

Chapter 10 Section 9045 Rock Drill Attachment

Chapter 11 Section 01 Tracks Repair

Chapter 12 Section 02 Axles and Suspension Systems (Propel) Repair

TM 5-3805-280-24-2

Chapter 13 Section 04 Engine Repair0400 Removal and Installation .............................................................................13-1

Essential Tools .......................................................................................13-1Service Equipment and Tools.................................................................13-2Other Material ........................................................................................13-2Specifications .........................................................................................13-3Engine

Remove...............................................................................................13-4Install ..................................................................................................13-8

Oil PanRemove...............................................................................................13-10Install ..................................................................................................13-11

In-Line Fuel Injection PumpRemove...............................................................................................13-11Repair .................................................................................................13-14Install ..................................................................................................13-14

Bleed Fuel System..................................................................................13-18Engine Crankcase Ventilation Tube, Clean............................................13-19Engine Valve Lash (Clearance), Check and Adjust ...............................13-19Firing Order, 6-Cylinder Engine ............................................................13-22Starter, Remove and Install ....................................................................13-23PowerTech 4.5 L Engine ......................................................................13-24PowerTech 6.8 L Engine ......................................................................13-25

General Information ....................................................................................13-26Unified Inch Bolt and Cap Screw Torque Values ..................................13-26Metric Bolt and Cap Screw Torque Values............................................13-27Engine Model Designation.....................................................................13-28Engine Serial Number Plate Information ...............................................13-29General OEM Engine Specifications......................................................13-30

Fuels, Lubricants and Coolant .....................................................................13-31Diesel Fuel .............................................................................................13-31Lubricity of Diesel Fuels........................................................................13-31Engine Break-In Oil ...............................................................................13-32Diesel Engine Oil ...................................................................................13-33Alternative and Synthetic Lubricants .....................................................13-34Mixing of Lubricants..............................................................................13-34Grease.....................................................................................................13-35Diesel Engine Coolant Recommendations .............................................13-36Engine Coolant Specifications ...............................................................13-37Testing Diesel Engine Coolant...............................................................13-40

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Replenishing Supplemental Coolant Additives (SCAs)Between Coolant Changes ..................................................................13-41

Operating in Warm Temperature Climates ............................................13-42Flush and Service Cooling System.........................................................13-43Disposing of Coolant..............................................................................13-44

Engine Mounting .........................................................................................13-45Engine Repair Stand...............................................................................13-45Safety Precautions ..................................................................................13-46Install Adapters on Engine Repair Stand................................................13-47Engine Lifting Procedure .......................................................................13-48Clean Engine ..........................................................................................13-49Disconnect Turbocharger Oil Inlet Line.................................................13-50Mount Engine on Repair Stand ..............................................................13-51Engine Mounted on Repair Stand...........................................................13-52

Engine Rebuild Guide .................................................................................13-53Engine Disassembly Sequence ...............................................................13-53Sealant Application Guidelines ..............................................................13-55Engine Assembly Sequence ...................................................................13-57

Cylinder Head and Valves ...........................................................................13-59Essential Tools .......................................................................................13-59Service Equipment and Tools.................................................................13-62Other Material ........................................................................................13-64Cylinder Head and Valves Specifications ..............................................13-65Valve Clearance, Check and Adjust .......................................................13-68Valve Lift, Measure................................................................................13-71Cylinder Head, Remove .........................................................................13-73Rocker Arm Shaft Assembly, Disassemble and Inspect ........................13-79Rocker Arm Assembly, Assemble .........................................................13-80Fuel Supply Pump Push RodIf Applicable

Inspect, Measure, and Install ..............................................................13-80Camshaft FollowersInspect, Measure, and Assemble ........................13-82Valve Recess in Cylinder Head, Measure ..............................................13-83Preliminary Cylinder Head and Valve Checks.......................................13-84Valve Assembly, Remove ......................................................................13-85Valve Springs, Inspect and Measure ......................................................13-86Valve Rotators, Inspect ..........................................................................13-86Valves

Clean...................................................................................................13-87Inspect and Measure ...........................................................................13-87Grind...................................................................................................13-88

Cylinder HeadInspect and Clean................................................................................13-89Check Flatness ....................................................................................13-89Measure Thickness .............................................................................13-90

Clean Injection Nozzle Bores.................................................................13-90Valve Guides

Clean...................................................................................................13-91Measure ..............................................................................................13-91Knurl...................................................................................................13-92

Valve SeatsClean and Inspect................................................................................13-92Grind...................................................................................................13-93Remove Inserts ...................................................................................13-96Measure Bore in Cylinder Head .........................................................13-99Install Inserts.......................................................................................13-100

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Valves, Install.........................................................................................13-100Cylinder Head Cap Screws, Clean and Inspect ......................................13-101Exhaust Manifold, Inspect and Clean.....................................................13-101Top Deck of Cylinder Block, Clean and Inspect....................................13-102Cylinder Liner Standout (Height Above Block), Measure .....................13-103Cylinder Head, Install.............................................................................13-104Torque-Turn Method for Proper Torque ................................................13-106Rocker Arm Assembly, Install ...............................................................13-107Ventilator Outlet Hose, Inspect and Clean .............................................13-107Rocker Arm Cover, Install .....................................................................13-108Complete Final Assembly ......................................................................13-109Perform Engine Break-In .......................................................................13-113

Cylinder Block, Liners, Pistons and Rods ...................................................13-114Essential Tools .......................................................................................13-114Service Equipment and Tools.................................................................13-117Other Material ........................................................................................13-118Cylinder Block, Liners, Pistons and Rods Specifications ......................13-119Connecting RodsGeneral Information................................................13-125Pistons and Connecting Rods, Remove..................................................13-126Cylinder Liners, Remove .......................................................................13-129Complete Disassembly of Cylinder Block (If Required) .......................13-131Preliminary Liner, Piston and Rod Checks ............................................13-132Piston and Rod Assembly, Disassemble.................................................13-133Pistons

Clean...................................................................................................13-134Visually Inspect ..................................................................................13-135

Cylinder LinersClean...................................................................................................13-136Visually Inspect ..................................................................................13-137

PistonCheck Ring Groove Wear...................................................................13-139Measure Pin Bore ...............................................................................13-140Measure Skirt......................................................................................13-140Measure Height...................................................................................13-140

Determine Piston-to-Liner Clearance.....................................................13-141Cylinder Liners, Deglaze........................................................................13-142Piston and Liner Sets, Replace ...............................................................13-143Inspect and Measure Connecting Rod Bearings

(Rods Removed From Engine) ...........................................................13-143(Rod and Crankshaft in Engine) .........................................................13-144

Rod and Cap, Inspect .............................................................................13-145Piston Pins and Bushings, Inspect ..........................................................13-147Piston Pin Bushing, Remove ..................................................................13-148Connecting Rod Pin Bore, Clean and Inspect ........................................13-150Piston Pin Bushing in Connecting Rod, Install ......................................13-151Rod Center-to-Center Bores, Measure ...................................................13-152Cylinder Block, Inspect and Clean.........................................................13-153Cylinder Liner O-Ring Bore, Clean .......................................................13-155Measure

Cylinder Block Main Bearing Bore ....................................................13-155Camshaft Follower Machined Bore in Block .....................................13-156Camshaft Bushing Bores in Block......................................................13-156Balancer Shaft Bushing ID in Block4-Cylinder Engines................13-158Cylinder Liners and Block Bores........................................................13-159Liner Flange Counterbore Depth in Block..........................................13-160

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Liner Flange Thickness.......................................................................13-160Cylinder Block Top Deck Flatness .....................................................13-161

Piston Cooling Orifices Remove, Inspect, and Install ........................13-162Fuel Supply Pump Push Rod Bore and Push Rod OD, Measure............13-163Cylinder Liner Standout (Height Above Block), Measure .....................13-164Install Packing on Cylinder Liner and O-Rings in Block.......................13-166Install Cylinder Liner in Block...............................................................13-167Piston and Connecting Rod, Assemble ..................................................13-168Piston Rings, Install................................................................................13-170Piston and Connecting Rod Assembly, Install .......................................13-171Torque-Turn Connecting Rod Cap Screws ............................................13-175Check Engine Rotation for Excessive Tightness....................................13-176Piston Protrusion, Measure.....................................................................13-177Complete Final Assembly ......................................................................13-178

Crankshaft, Main Bearings and Flywheel....................................................13-179Essential Tools .......................................................................................13-179Service Equipment and Tools.................................................................13-182Other Material ........................................................................................13-184Crankshaft, Main Bearings and Flywheel Specifications.......................13-185Crankshaft and Main Bearing Failure Analysis .....................................13-187Vibration Damper (6-Cylinder Engine), Inspect ....................................13-188Pulley or Vibration Damper and Pulley, Remove .................................. 13-189Pulley or Vibration Damper Pulley, Install ............................................ 13-191Checking Vibration Damper or Pulley ................................................... 13-193Front Crankshaft Oil Seal and Wear Sleeve, Replace ............................ 13-193Crankshaft End Play, Check................................................................... 13-198Flywheel, Inspect ................................................................................... 13-199Flywheel Face, Check Flatness .............................................................. 13-200Pilot Bearing Bore, Check Concentricity ............................................... 13-200Flywheel

Check Housing Face Runout .............................................................. 13-201Remove............................................................................................... 13-202Replace Ring Gear .............................................................................. 13-202Replace Pilot BearingIf Equipped .................................................. 13-204Install .................................................................................................. 13-205

Crankshaft Rear Oil Seal and Wear SleeveHandling Precautions.......................................................................... 13-206Remove............................................................................................... 13-206

Crankshaft Flange, Clean and Inspect .................................................... 13-209Crankshaft Rear Oil Seal and Wear Sleeve, Install ................................ 13-210Flywheel Housing, Remove ................................................................... 13-213Crankshaft Main Bearings, Remove....................................................... 13-213Check Main Bearing Oil Clearance........................................................ 13-215Crankshaft Gear (Crankshaft Installed in Engine)

Remove and Install ............................................................................. 13-216Crankshaft, Remove ............................................................................... 13-218Crankshaft, Inspect................................................................................. 13-219Crankshaft Journals and Main Bearing ID, Measure.............................. 13-220Main Thrust Journal and Thrust Bearing, Measure Width ..................... 13-221Crankshaft Grinding Guidelines............................................................. 13-222Crankshaft Grinding Specifications ....................................................... 13-223Main Bearing Caps, Measure Assembled ID ......................................... 13-224Piston Cooling OrificesRemove, Inspect, and Install ......................... 13-225Main and Thrust Bearing Inserts, Install in Block.................................. 13-226Crankshaft, Install .................................................................................. 13-228

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Flywheel Housing, Install....................................................................... 13-231Complete Final Assembly ...................................................................... 13-232

Camshaft, Balancer Shafts and Timing Gear Train .....................................13-233Essential Tools .......................................................................................13-233Service Equipment and Tools.................................................................13-236Other Material ........................................................................................13-237Camshaft, Balancer Shafts and Timing Gear Train Specifications ........13-238Measure Valve Lift.................................................................................13-243Timing Gear Cover, Remove .................................................................13-245Camshaft Bushing With Front Plate Installed, Remove and Install .......13-248Camshaft Gear-Driven Auxiliary Drive, Remove and Install ................13-251Measure End Play

Camshaft .............................................................................................13-252Balancer Shaft (4-Cylinder Engines) ..................................................13-252Idler Gear............................................................................................13-253

Timing Gear, Measure Backlash ............................................................13-254Camshaft

Remove...............................................................................................13-255Visually Inspect ..................................................................................13-257Measure Thrust Plate Clearance and Thickness .................................13-258Inspect and Measure Bushing ID and Journal OD..............................13-259Measure Lobe Height .........................................................................13-260Remove and Install Gear.....................................................................13-260Inspect Followers................................................................................13-262

Fuel Supply Pump Push RodInspect, Measure, and Install ................13-263Electronic Tachometer (Magnetic Pick-Up) Sensor, Replace ................13-264Mechanical Tachometer Adapter, Replace.............................................13-265Balancer Shaft

RemoveIf Equipped (4-Cylinder Engines) .....................................13-266Inspect and Measure Bushings and Journals.......................................13-267Remove and Install Bushings (4-Cylinder Engines)...........................13-268Inspect Gears and Thrust Plates..........................................................13-268Remove and Install Gears ...................................................................13-269

Cylinder Block Front Plate, Remove......................................................13-270Idler Gear Bushings

Measure Bushing and Shaft ................................................................13-272Remove...............................................................................................13-273Install ..................................................................................................13-274

Lower and Upper Idler Shafts, Remove .................................................13-275Front Plate, Clean and Inspect................................................................13-275Transfer Fuel Injection Pump Timing Mark

Onto Replacement Front Plate ............................................................13-276Idler Shaft Spring Pins (If Equipped), Install .........................................13-277Upper Idler Shaft, Install in Front Plate .................................................13-277Lower Idler Shaft, Install in Front Plate .................................................13-278Engine Front Plate, Install ......................................................................13-278Balancer Shafts (4-Cylinder Engines), Install and Time ........................13-280Camshaft and Rotary Fuel Injection Pump, Install and Time.................13-284Timing Gear Cover, Clean and Inspect ..................................................13-287Timing Gear Cover, Install.....................................................................13-288Crankshaft Front Wear Sleeve and Oil Seal, Install ...............................13-290Complete Final Assembly ......................................................................13-293

Lubrication System......................................................................................13-294Essential Tools .......................................................................................13-294Service Equipment and Tools.................................................................13-296

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Other Material ........................................................................................13-297Lubrication System Specifications .........................................................13-298General Lubrication System Information...............................................13-300Remove, Inspect, and Install

Oil Filter Base.....................................................................................13-300Oil Cooler ...........................................................................................13-303Oil Bypass Valve ................................................................................13-307

Remove and InstallOil Pressure Regulating Valve and Seat .............................................13-307Oil Fill Tube .......................................................................................13-309Dipstick Tube With Oil Pan Installed.................................................13-310Dipstick Tube With Fitting .................................................................13-311

Oil Pump Pick-Up Tube AssemblyRemove, Inspect, and Install.......13-312Engine Oil Pump Assembly ...................................................................13-313Engine Oil Pump, Remove.....................................................................13-313Inspect and Measure Clearances ............................................................13-315Complete Oil Pump Disassembly...........................................................13-318Engine Oil Pump, Assemble ..................................................................13-318Engine Oil Pump, Install ........................................................................13-319Oil Pan, Install........................................................................................13-322

Cooling System............................................................................................13-324Essential Tools .......................................................................................13-324Service Equipment and Tools.................................................................13-324Other Material ........................................................................................13-325Cooling System Specifications...............................................................13-326Diagnosing Cooling System Malfunctions.............................................13-328Water Manifold/Thermostat Cover and Thermostat, Remove ...............13-329Water Manifold/Thermostat Cover and Thermostat, Install...................13-330Water Manifold and Thermostats

(Dual Thermostats), Remove and Install ............................................13-332Test Thermostat(s)..................................................................................13-333Water Pump

Remove...............................................................................................13-334Assembly ............................................................................................13-335Disassemble ........................................................................................13-335Inspect, Clean, and Measure Parts ......................................................13-338Assemble ............................................................................................13-339Install ..................................................................................................13-341

Cooling System Deaeration....................................................................13-343Automatic (Spring) Belt Tensioner, Remove and Install .......................13-343Checking Belt Tensioner Spring Tension and Belt Wear.......................13-344Manual Belt Tensioner Adjustment........................................................13-346Fan Assembly, Inspect and Install..........................................................13-347Fan Drive Assembly, Remove and Inspect ............................................13-347Adjustable Fan Drive Assembly, Replace Bearings...............................13-350Fan Drive Assembly, Install ...................................................................13-353Coolant HeaterIf Equipped, Remove and Install................................13-355Temperature Switch (Cold Start Advance), Remove and Install............13-356

Air Intake and Exhaust System....................................................................13-357Other Material ........................................................................................13-357Air Intake and Exhaust System Specifications.......................................13-358Turbocharger

Extending Life ....................................................................................13-359Remove...............................................................................................13-361

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Failure Analysis ..................................................................................13-362Seven-Step Inspection ........................................................................13-364

Perform Radial Bearing Clearance Test .................................................13-370Perform Axial Bearing End Play Test ....................................................13-371Turbocharger

Adjust Wastegate Actuator .................................................................13-372Repair .................................................................................................13-373Prelube................................................................................................13-373Install ..................................................................................................13-374Break-In ..............................................................................................13-375Recommendations for Use..................................................................13-376

Exhaust ManifoldRemove, Inspect, and Install..................................13-376Air-to-Air Aftercooler, Remove and Install ...........................................13-378Air Intake Pipe, Remove and Install.......................................................13-378Air Heater, Remove and Install ..............................................................13-379

Fuel System .................................................................................................13-380Essential Tools .......................................................................................13-380Service Equipment and Tools.................................................................13-383Other Material ........................................................................................13-384Fuel System Specifications ....................................................................13-385Fuel SystemGeneral Information .......................................................13-388Relieve Fuel System Pressure ................................................................13-389Final Fuel Filter and/or Primary Fuel

Filter/Water Separator Base, Remove.................................................13-390Primary Fuel Filter/Water Separator Assembly .....................................13-392Final Fuel Filter Assembly .....................................................................13-393Final Fuel Filter and Primary Fuel Filter/Water Separator, Replace......13-394Fuel Supply Pump

Remove...............................................................................................13-396Bench Test ..........................................................................................13-397Install ..................................................................................................13-399Remove on In-Line Fuel Injection Pump............................................13-400Test In-Line Pump for Leaks ..............................................................13-401Disassemble ........................................................................................13-402Inspect and Repair Components .........................................................13-405Assemble ............................................................................................13-407Install on In-Line Fuel Injection Pump...............................................13-408

Service Injection Pump Overflow Valve................................................13-408Fuel Shutoff Solenoid, Remove and Install............................................13-410Rotary Fuel Injection Pump Timing.......................................................13-411In-Line Fuel Injection Pump Timing......................................................13-412Stanadyne Model DB2 and DB4 Injection Pump, Remove....................13-413Injection Pump Drive Gear I.D. and Shaft O.D., Inspect .......................13-415Stanadyne Fuel Injection Pump, Repair .................................................13-416Stanadyne Model DB2 and DB4 Injection Pump, Install.......................13-417Lucas Fuel Injection Pump

Remove...............................................................................................13-420Repair .................................................................................................13-423Install ..................................................................................................13-423

In-Line Fuel Injection PumpRemove...............................................................................................13-427Repair .................................................................................................13-430Install ..................................................................................................13-430

Repair Aneroid .......................................................................................13-435

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Transfer Fuel Injection Pump Timing MarkOnto Replacement Front Plate ............................................................13-436

Fuel Injection NozzlesRemove...............................................................................................13-437Clean Nozzle Bore..............................................................................13-438Clean...................................................................................................13-439Diagnose Malfunction ........................................................................13-440Test .....................................................................................................13-441Disassemble ........................................................................................13-446Inspect and Clean Nozzle Body.......................................................... 13-449

Valve and Valve Seat, Inspect and Clean...............................................13-450Valve Adjusting Mechanism, Inspect.....................................................13-452Fuel Injection Nozzles

Assemble ............................................................................................13-453Adjust..................................................................................................13-454Install Seals.........................................................................................13-458Install ..................................................................................................13-459

Starting and Charging Systems....................................................................13-461Essential Tools .......................................................................................13-461Starting and Charging System Specifications ........................................13-461Starter, Remove and Install ....................................................................13-462Alternator, Remove and Install...............................................................13-463

Engine Tune-Up and Break-In.....................................................................13-464Effects of Altitude and Temperature on Engine Performance................13-464Preliminary Engine Testing....................................................................13-465General Tune-Up Recommendations .....................................................13-466Dynamometer Test .................................................................................13-467Dynamometer Test Specifications..........................................................13-467Engine Break-In Guidelines ...................................................................13-470Perform Engine Break-In .......................................................................13-471Engine Oil Consumption ........................................................................13-472Crankcase Ventilation System, Check ...................................................13-473Air Intake System, Check.......................................................................13-474Exhaust System, Check ..........................................................................13-475Cooling System, Check and Service ......................................................13-476Electrical System, Check........................................................................13-478

Engine System Operation and Tests ............................................................13-479Essential Tools .......................................................................................13-479Engine Test Specifications .....................................................................13-480EngineSectional View ........................................................................13-481General Engine Description ...................................................................13-482How the Engine Lubrication System Works ..........................................13-483How the Cooling System Works ............................................................13-485Head Gasket Joint Construction and Operation .....................................13-487Diagnosing Head Gasket Joint Failures..................................................13-489Head Gasket Inspection and Repair Sequence .......................................13-493Diagnosing Engine Malfunctions ...........................................................13-495Test Engine Compression Pressure ........................................................13-498Check Engine Oil Pressure.....................................................................13-500Check for Excessive Engine Crankcase Pressure (Blow-By).................13-502Pressure Test Cooling System and Radiator Cap ...................................13-503Inspect Thermostat and Test Opening Temperature...............................13-505Engine Cranking Speed Test ..................................................................13-506

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Air Intake and Exhaust System Operation and Tests...................................13-507Essential Tools .......................................................................................13-507Service Equipment and Tools.................................................................13-507Diagnosing Air Intake Malfunctions ......................................................13-509How the Air Intake and Exhaust System Works ....................................13-510Air Cleaner Operation ............................................................................13-511Air Filter Restriction Indicator Switch Test ...........................................13-512Intake Air Leak Test...............................................................................13-513Exhaust Leak Check (Turbocharged Engines) .......................................13-514Intake and Exhaust Restriction Check....................................................13-515Diagnosing Turbocharger Malfunctions.................................................13-516Turbocharger Operation .........................................................................13-517How the Turbocharger is Lubricated......................................................13-517Check Intake Manifold Pressure (Turbocharger Boost).........................13-518Intake Manifold Pressure (Turbocharger Boost) Specifications.............13-520Turbocharger Wastegate Test.................................................................13-526Turbocharger Oil Seal Leak Test ...........................................................13-527

Fuel System Operation and Tests ................................................................13-528Essential Tools .......................................................................................13-528Service Equipment and Tools.................................................................13-529Fuel System Test Specifications.............................................................13-531Rotary Fuel Injection Pump Specifications ............................................13-532Fuel Injection PumpGeneral Information...........................................13-542Using TIME TRAC as a Tachometer ...................................................13-543Rotary Injection Pump Dynamic Timing, Check and Adjust.................13-543In-Line Injection Pump Static Timing, Check and Adjust .....................13-550Fuel System OperationRotary Fuel Injection Pump...........................13-551Fuel System OperationIn-Line Fuel Injection Pump..........................13-553Diagnose Fuel System Malfunctions......................................................13-555Fuel Supply Quality Check ....................................................................13-559Air in Fuel Test ......................................................................................13-560Restricted Fuel Return Line Check ........................................................13-561Rotary Injection Pump

Fuel Supply Pump Operation..............................................................13-562Diagnose Fuel Supply Pump Malfunctions ........................................13-563Measure Fuel Supply Pump Pressure .................................................13-564

In-Line Injection PumpFuel Supply Pump Operation..............................................................13-565Measure Fuel Supply Pump Pressure .................................................13-567Diagnose Fuel Supply Pump Malfunctions ........................................13-568Test Fuel Supply Pump for Leaks.......................................................13-569Check Fuel Supply Pump Operation...................................................13-570

Service Fuel Supply Pump .....................................................................13-572Rotary Pumps

Cold Start Advance System Operation ...............................................13-573Cold Start Switch Operational Check .................................................13-574Cold Start Advance System Operational Check .................................13-575Light Load Advance Operation ..........................................................13-577Light Load Advance Operational Checkout .......................................13-577

Fuel Shut-Off Solenoid Operational Check(In-Line Injection Pumps)...................................................................13-578

Fuel Shut-Off Solenoid Resistance Test (Nippondenso Pump)..............13-579Fuel Shut-Off Solenoid Resistance Test (Lucas Pump) .........................13-580Fuel Shut-Off Solenoid Linkage Adjustment

(In-Line Injection Pumps)...................................................................13-581

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Final Fuel Filter/Water Separator Operation..........................................13-582Bleed the Fuel System............................................................................13-583Stanadyne Rotary Fuel Injection Pump Operation .................................13-587Lucas Rotary Fuel Injection Pump Operation ........................................13-589Diagnose Rotary Fuel Injection Pump Malfunctions .............................13-591Check and Adjust Engine Speeds on Lucas Pump .................................13-592Adjust Variable Speed on Generator Set Engines

(Lucas Pumps Only) ...........................................................................13-593Check and Adjust Engine Speeds on Stanadyne Pump ..........................13-594Adjust Variable Speed (Droop) on Generator Set Engines (35%

Governor Regulation)Stanadyne DB2 and DB4 Injection Pumps ..13-595In-Line Fuel Injection Pump Operation..................................................13-596Diagnose In-Line Fuel Injection Pump Malfunctions ............................13-597Check Fast Idle SpeedIn-Line Fuel Injection Pump...........................13-598Check and Adjust Slow Idle SpeedIn-Line Fuel Injection Pump.......13-599Change Engine Rated Speed and Adjust

DroopIn-Line Injection Pumps .......................................................13-601How the Aneroid Works (If Equipped) ..................................................13-603Diagnose Aneroid Malfunctions.............................................................13-604Fuel Injection NozzlesGeneral Information and Operation................13-605Diagnose Fuel Injection Nozzle Malfunctions .......................................13-607Test Fuel Injection Nozzles (Engine Running) ......................................13-608Fuel Drain Back Test Procedure ............................................................13-609

Dealer Fabricated Tools...............................................................................13-610How to Make Tools................................................................................13-610DFRG3Cylinder Liner Holding Fixture .............................................13-610DFRG5Injection Pump Front Plate Timing Mark Transfer Tool .......13-611Engine Oil Dipstick Tube Driver

(60106910 Series Tractor Engines) ................................................13-612

Chapter 14 Section 05 Engine Auxiliary System Repair0505B Cold Weather Starting Aids.........................................................................14-1

Engine Coolant HeaterRemove and Install .............................................................................14-1Disassemble and Assemble.................................................................14-3

0510 Cooling System............................................................................................14-5Specifications .........................................................................................14-5Radiator, Oil Cooler, and Fan ShroudRemove and Install .................14-5Fan and Fan Guard, Remove and Install ................................................14-7Fan Belt, Remove and Install .................................................................14-8Thermostats, Remove and Install ...........................................................14-9Cooling System Fill and Deaeration.......................................................14-11

0515 Speed Controls.............................................................................................14-12Service Equipment and Tools.................................................................14-12Specifications .........................................................................................14-13Injection Pump Fast and Slow Idle Stops Adjustment ...........................14-14Engine Speed Control Cable, Remove and Install..................................14-17Engine Control Motor and Sensor

Remove and Install .............................................................................14-18Adjustment..........................................................................................14-19

Engine Speed Learning Procedure .........................................................14-20Fuel Shut-Off Solenoid Linkage

Remove and Install .............................................................................14-22Check and Adjust................................................................................14-23

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0520 Intake System ..............................................................................................14-25Essential Tools .......................................................................................14-25Service Equipment and Tools.................................................................14-25Specifications .........................................................................................14-26Air Intake System Leakage Test.............................................................14-27Air Cleaner

Remove and Install .............................................................................14-28Disassemble and Assemble.................................................................14-29

Charge Air Cooler, Remove and Install .................................................14-310560 External Fuel Supply System.......................................................................14-33

Other Material ........................................................................................14-33Specifications .........................................................................................14-33Fuel Tank, Remove and Install...............................................................14-34Primary Fuel Filter (Water Separator)

Remove and Install .............................................................................14-36Element, Remove and Install ..............................................................14-38

Final Fuel FilterRemove and Install .............................................................................14-40Element, Remove and Install ..............................................................14-41

Bleed Fuel System..................................................................................14-43Arctic/Cold Weather Heater Fuel Supply Pump, Remove and Install....14-44

Chapter 15 Section 07 Dampener Drive (Flex Coupling) Repair0752 Elements ......................................................................................................15-1

Service Equipment and Tools.................................................................15-1Other Material ........................................................................................15-1Specifications .........................................................................................15-2Dampener Drive (Flex Coupling), Remove and Install..........................15-2

Chapter 16 Section 16 Electrical System Repair1671 Batteries, Support, and Cables.....................................................................16-1

Service Equipment and Tools.................................................................16-1Specifications .........................................................................................16-2Batteries

Handle Safely......................................................................................16-3Procedure for Testing .........................................................................16-4

Check Battery Electrolyte Level and Terminals.....................................16-5Using Booster Batteries24-Volt System.............................................16-6Battery, Charge.......................................................................................16-8Engine Speed Learning Procedure .........................................................16-10Batteries, Remove and Install.................................................................16-12Adding 12-Volt Accessories ..................................................................16-1324-Volt Slave Receptacle, Remove and Install ......................................16-14

1672 Alternator, Regulator, and Charging System Wiring...................................16-15Service Equipment and Tools.................................................................16-15Specifications .........................................................................................16-15Fan BeltInspect, Remove, and Install.................................................16-16Alternator, Remove and Install...............................................................16-17Function of Alternator ............................................................................16-19Special or Essential Tools ......................................................................16-21Robert Bosch Charging Circuit Specifications.......................................16-22Alternator, Section View........................................................................16-23AlternatorRemoval .............................................................................16-23Removing Brush Holder With Regulator ...............................................16-24AlternatorDisassembly .......................................................................16-24

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StatorRemoval....................................................................................16-24Diode PlateRemoval...........................................................................16-24Alternator, Exploded View.....................................................................16-25Testing Rotor for Short Circuit...............................................................16-26Testing Rotor for Ground .......................................................................16-26Testing Slip Rings and Rotor Shaft for Radial Runout ..........................16-26Turning Down Slip Rings.......................................................................16-27Testing Stator Coil for Short Circuit ......................................................16-27Testing Stator Coil for Grounds .............................................................16-27Replacing Carbon Brushes .....................................................................16-28Replacing Ball Bearings.........................................................................16-28Checking Positive Diodes ......................................................................16-28Checking Negative Diodes.....................................................................16-29Testing Exciting Diodes .........................................................................16-29Diode Plate Installation ..........................................................................16-30Soldering Stator Coils ............................................................................16-30Pressing Ball Bearing Onto Rotor Shaft.................................................16-30Pressing Rotor Into Drive End Frame ....................................................16-31AlternatorAssembly............................................................................16-31Installing Brush Holder With Regulator.................................................16-31Fan and Belt PulleyInstallation ..........................................................16-31

1674 Wiring Harness and Switches ......................................................................16-32Excavator Overview............................................................................... 16-32Component Location Drawing

Legend ................................................................................................ 16-33Cab...................................................................................................... 16-37Engine and Frame Harness ................................................................. 16-38Air Compressor and Rock Drill Harness ............................................ 16-40

FusesReplacing ............................................................................................ 16-41(Blade-Type) Color Codes.................................................................. 16-43

Remove and InstallControl Panel Switches....................................................................... 16-44Dome Light Switch............................................................................. 16-45Propel Alarm Cancel Switch and Start Aid Switch ............................ 16-46Starter Switch...................................................................................... 16-46Cab Ground Straps.............................................................................. 16-47Engine Temperature Switch................................................................ 16-48Charge Air Temperature Switch ......................................................... 16-48Coolant Level Switch ......................................................................... 16-49Engine Oil Pressure Switch ................................................................ 16-49Engine Oil Level Switch..................................................................... 16-50Engine Coolant Temperature Sensor .................................................. 16-50Fuel Level Switch ............................................................................... 16-51Fuel Level Sensor ............................................................................... 16-51

Travel AlarmRemove and Install ............................................................................. 16-52Changing Volume............................................................................... 16-52

Remove and InstallPropel Pressure Switch ....................................................................... 16-53Dig Pressure Switch............................................................................ 16-54Rear Pump Pressure Sensor ................................................................ 16-54Front Pump Pressure Sensor ............................................................... 16-55Engine Speed Sensor .......................................................................... 16-55Pump Control Pressure Sensor ........................................................... 16-56

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Proportional Solenoids........................................................................ 16-56Engine Hourmeter Switch................................................................... 16-57Windshield Wiper Enable Switch....................................................... 16-57Air Cleaner Restriction Indicator Switch............................................ 16-58

Engine and Pump Controller (EPC)Connecting Harness Connector .......................................................... 16-58Remove and Install ............................................................................. 16-59

Monitor Panel and Switch Panel Bulb, Replace..................................... 16-60Monitor Panel, Remove and Install ........................................................ 16-60Hour Meter, Remove and Install ............................................................ 16-62Propel Alarm Volume, Changing ........................................................... 16-62Spring Wire Retainer Connectors, Disconnecting.................................. 16-63Tab Retainer Connectors, Disconnecting ............................................... 16-63Remove and Install

Battery Relay ...................................................................................... 16-64Starter Relay ....................................................................................... 16-65Fuel Shutoff Relay.............................................................................. 16-66Hydraulic Oil Filter Restriction Switch (230LCRD).......................... 16-67Overload Alarm Relay........................................................................ 16-68Overload Alarm Pressure Switch........................................................ 16-69Overload Alarm Proximity Switch ..................................................... 16-70

1675 System Controls...........................................................................................16-71Specifications .........................................................................................16-71Welding on Machine ..............................................................................16-71Engine and Pump Controller (EPC)

Connecting Harness Connector ..........................................................16-73Remove and Install .............................................................................16-73

Engine Speed Learning Procedure .........................................................16-74Remove and Install

Monitor Controller..............................................................................16-76Rockdrill Control Console ..................................................................16-77Rock Drill StartStop Selector Control Box.....................................16-79Compressor Remote Control Panel..................................................... 16-80

1677 Starting Motors ............................................................................................16-81General Information ...............................................................................16-81Typical Starting Circuit Operation .........................................................16-81Typical Starting Motor Operation ..........................................................16-82Special or Essential Tools ......................................................................16-83Robert Bosch Starting Motor Specifications ..........................................16-84Make No-Load Test ...............................................................................16-85Diagnosing Starting Motor Malfunctions...............................................16-86Robert Bosch Starting Motor .................................................................16-87Starting Motor, Exploded View .............................................................16-88Disassembly ...........................................................................................16-89Solenoid SwitchRemoval ...................................................................16-89Carbon Brush PlateRemoval ..............................................................16-89ArmatureRemoval ..............................................................................16-90Snap RingRemoval.............................................................................16-90Cleaning Parts ........................................................................................16-90Testing Armature for Grounds ...............................................................16-90Testing Armature for Short Circuit ........................................................16-91Testing Armature for Open Circuit ........................................................16-91Turning Commutator Down ...................................................................16-92Testing Commutator for Out-of-Roundness...........................................16-92Testing Field Winding for Ground Circuits ...........................................16-93

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Field WindingRemoval ......................................................................16-93Make Open Circuit Test for Field Windings ..........................................16-94Lubrication of Starting Motor (Before and During Assembly) ..............16-94Field WindingInstallation...................................................................16-95Checking Carbon Brush Plate for Grounds ............................................16-95Testing Carbon Brushes .........................................................................16-96Replace Carbon Brushes ........................................................................16-96Engaging LeverInstallation ................................................................16-96Testing Armature End Play ....................................................................16-97Installing Starting Motor ........................................................................16-97

Chapter 17 Section 17 Frame or Supporting Structure Repair1740 Frame Installation ........................................................................................17-1

Specifications .........................................................................................17-1Welding on Machine ..............................................................................17-1Welding Repair of Major Structure........................................................17-3

1749 Chassis Weights...........................................................................................17-4Service Equipment and Tools.................................................................17-4Specifications .........................................................................................17-4Counterweight, Remove and Install (Model 230LCR)...........................17-5Compressor, Remove and Install (Model 230LCRD) ............................17-6

Chapter 18 Section 18 Operators Station Repair1800 Operators Station........................................................................................18-1

Specifications .........................................................................................18-1Cab, Remove and Install ........................................................................18-1

1810 Operator Enclosure ......................................................................................18-6Service Equipment and Tools................................................................. 18-6Other Material ........................................................................................ 18-6Windowpane

Remove and Install Two Piece Molding............................................. 18-7Remove and Install One Piece Molding ............................................. 18-8

Sliding Windows, Remove and Install ................................................... 18-9Windowpane Dimensions....................................................................... 18-10

1821 Seat and Seat Belt ........................................................................................18-12Specifications .........................................................................................18-12Seat

Check Adjustments.............................................................................18-12Remove and Install .............................................................................18-13

Seat BeltRemove and Install .............................................................................18-19Inspect.................................................................................................18-20

1830 Heating and Air Conditioning .....................................................................18-21Essential Tools .......................................................................................18-21Service Equipment and Tools.................................................................18-22Other Material ........................................................................................18-22Specifications .........................................................................................18-23R134a Refrigerant

Proper Handling..................................................................................18-23Cautions ..............................................................................................18-24

R134a Compressor OilCharge Check......................................................................................18-25Removal..............................................................................................18-25

R134a Component Oil Charge ...............................................................18-26

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R134a Refrigerant Recovery, Recycling and ChargingStation Installation Procedure.............................................................18-27

R134a SystemRecover...............................................................................................18-28Evacuate..............................................................................................18-29Charge.................................................................................................18-30

Air Conditioning CompressorCheck and Adjust Belt Tension ..........................................................18-31Remove and Install .............................................................................18-32Disassemble and Inspect.....................................................................18-33Assemble ............................................................................................18-44Inspect Manifolds ...............................................................................18-47

Remove and InstallReceiver Dryer....................................................................................18-48Evaporator ..........................................................................................18-50Condenser ...........................................................................................18-52Heater CoreMachine With Air Conditioning..................................18-54Heater Core and Blower Motor ..........................................................18-56Heater Hoses.......................................................................................18-58

Chapter 19 Section 19 Sheet Metal and Styling Repair1910 Hand Rails, Remove and Install ..................................................................19-11919 Boom Cylinder Guard, Remove and Install.................................................19-2

Chapter 20 Section 22 Compressor Repair2200 Disassembly and Assembly .........................................................................20-1

Separator TankSeparator Tank....................................................................................20-1Remove and Install .............................................................................20-3Disassemble and Assemble.................................................................20-4

Disassemble and Assemble Cooling System..........................................20-5Unloader Valve Assembly


Oil Temperature Bypass Valve AssemblyRemove and Install .............................................................................20-11Disassemble and Assemble.................................................................20-14

Oil Filter AssemblyRemove and Install .............................................................................20-14Disassemble and Assemble.................................................................20-16

Minimum Pressure ValveRemove and Install .............................................................................20-17Disassemble and Assemble.................................................................20-19

Air IntakeRemove and Install .............................................................................20-20Disassemble and Assemble.................................................................20-22

Disassemble and Assemble Air Cleaner Assembly................................20-23Instrument Panel Assembly


Disassemble and Assemble Air Piping...................................................20-28Disassemble and Assemble Oil Piping...................................................20-31

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Chapter 21 Section 33 Excavator Repair3302 Buckets ........................................................................................................21-1

Specifications .........................................................................................21-1Bucket Tooth, Replace ...........................................................................21-1Bucket Tooth TipHeavy-Duty Bucket, Replace.................................21-3Welding on Machine ..............................................................................21-3Tooth Shank, Remove and Install ..........................................................21-5Cutting Edge

Replace Welded..................................................................................21-8Repair Cracked ...................................................................................21-9

Bucket, Disassemble and Assemble .......................................................21-10Hydraulic Thumb

Remove and Install (Model 230LCR).................................................21-12Lock-Up Procedure.............................................................................21-14

Quick-Disconnect HitchRemove and Install (Model 230LCRD)..............................................21-15Remove and Install (Model 230LCR).................................................21-17Disassemble ........................................................................................21-19Assemble ............................................................................................21-21

3340 Frames .........................................................................................................21-23Service Equipment and Tools.................................................................21-23Other Material ........................................................................................21-23Specifications .........................................................................................21-24Remove and Install

Bucket Links.......................................................................................21-27Arm.....................................................................................................21-29Boom ..................................................................................................21-31

Boom, Arm, and Bucket Pins, Bushings and BossesInspect ..............21-36Bushings and Seals, Remove and Install ................................................21-39

3360 Hydraulic System ........................................................................................21-40Essential Tools .......................................................................................21-40Service Equipment and Tools.................................................................21-41Other Material ........................................................................................21-45Specifications .........................................................................................21-46Control Lever Pattern Conversion..........................................................21-56Hydraulic System Warm-Up Procedure.................................................21-57Lower Boom With Engine Stopped (Using Boom Cylinder

Load Lowering Valve)........................................................................21-59Lower Boom With Engine Stopped (When Not Equipped With

Boom Cylinder Load Lowering Valve) ..............................................21-60Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy.............21-62Hydraulic Pump and Drive Gearbox

Remove and Install .............................................................................21-63Start-Up Procedure .............................................................................21-65Disassemble ........................................................................................21-66

Pilot Pump Drive Shaft and Gear, Disassemble and Assemble..............21-79Hydraulic Pump and Drive Gearbox, Assemble.....................................21-80Hydraulic Pump Regulator, Disassemble and Assemble .......................21-88Pilot Pump


Pilot Pressure Regulating Valve and FilterRemove and Install .............................................................................21-94Disassemble and Assemble.................................................................21-96

Pilot Shut-Off Valve

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Remove and Install .............................................................................21-96Linkage Adjustment............................................................................21-98Disassemble and Assemble.................................................................21-99

Proportional Solenoid ValveManifold, Remove and Install ............................................................21-100Disassemble and Assemble.................................................................21-103

Dig Function Pilot ControllerRemove and Install .............................................................................21-106Disassemble and Assemble.................................................................21-109

Propel Pilot ControllerRemove and Install .............................................................................21-112Disassemble and Assemble.................................................................21-114

Flow Regulator ValveRemove and Install .............................................................................21-117Disassemble and Assemble.................................................................21-119

Control ValveRemove and Install .............................................................................21-120Disassemble and Assemble.................................................................21-128

System Relief Valve, Disassemble and Assemble .................................21-145Circuit Relief and Anti-Cavitation Valve, Disassemble

and Assemble......................................................................................21-147Hydraulic Oil Tank


Return Filter and Bypass Valve, Remove and Install.............................21-155Suction Strainer, Remove and Install .....................................................21-158Hydraulic Oil Tank Relief Valve and Breather Filter Cap

Disassemble and Assemble.................................................................21-162Remove and Install

Swing Motor Make-Up Oil Restriction Valve....................................21-163Oil Cooler Bypass Valve ....................................................................21-165Oil Cooler ...........................................................................................21-167230 Left Boom Cylinder Controlled Load Lowering Valve ...............21-171230 Right Boom Cylinder Controlled Load Lowering Valve.............21-173Boom Cylinder ...................................................................................21-175Arm Cylinder ......................................................................................21-179Bucket Cylinder ..................................................................................21-182

Hydraulic Cylinder Bleed Procedure......................................................21-187Boom, Arm or Bucket Cylinder

Disassemble ........................................................................................21-188Assemble ............................................................................................21-198

Hydraulic Thumb CylinderRemove and Install .............................................................................21-212Disassemble and Assemble.................................................................21-214

Hydraulic Hose Reel, Remove and Install..............................................21-215

Chapter 22 Section 43 Swing or Pivoting System Repair4350 Mechanical Drive Elements.........................................................................22-1

Service Equipment and Tools.................................................................22-1Other Material ........................................................................................22-3Specifications .........................................................................................22-4Swing Gearbox

Remove and Install .............................................................................22-5Start-Up Procedure .............................................................................22-8Disassemble and Assemble.................................................................22-9

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UpperstructureRemove...............................................................................................22-18Install ..................................................................................................22-24

Swing BearingRemove and Install .............................................................................22-28Disassemble and Assemble.................................................................22-30Install Upper Seal ...............................................................................22-34Install Lower Seal ...............................................................................22-35

4360 Hydraulic System ........................................................................................22-36Specifications .........................................................................................22-36Swing Motor and Park Brake

Remove and Install .............................................................................22-36Start-Up Procedure .............................................................................22-38Disassemble ........................................................................................22-39Assemble ............................................................................................22-45

Swing Motor Make-Up and Crossover Relief ValvesDisassemble and Assemble.................................................................22-52

Swing Park Brake Orifice and Check Valve, Remove and Install .........22-54Swing Park Brake Release Valve, Remove and Install ..........................22-55

Chapter 23 Section 44 Rock Drill Repair4400 Rock Drill ....................................................................................................23-1

Service Equipment and Tools.................................................................23-1Other Material ........................................................................................23-5Torque Specifications..........................................

Documents

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