John Deere 240DLC 270DLC Excavator Repair Technical Manual TM2323 25MAY21

Section 00
General Information
Contents
Page
Group 01—Safety ………………………………….00­01­1
Group 0003—Torque Values
Torque Value
Metric Bolt and Cap Screw………………..00­0003­1
Additional Metric Cap Screw
Torque Values…………………………………. 00­0003­2
Unified Inch Bolt and Cap Screw ……….00­0003­3
Service Recommendations for
37° Flare and 30° Cone Seat
Connectors …………………………………….. 00­0003­4
Service Recommendations for
O­Ring Boss Fittings………………………… 00­0003­4
Service Recommendation
O­Ring Boss Fittings In Aluminum HousingExcavators…………………………………………………….00­0003­6
Service Recommendations For
Flared Connections—Straight or
Tapered Threads …………………………….. 00­0003­7
Service Recommendations For
Flat Face O­Ring Seal Fittings ………….. 00­0003­8
O­Ring Face Seal Fittings with SAE Inch Hex Nut and
Stud End for High Pressure…………………..00­0003­9
O­Ring Face Seal Fittings with Metric Hex Nut and
Stud End for Standard Pressure…………..00­0003­11
O­Ring Face Seal Fittings with Metric Hex Nut and
Stud End for High Pressure…………………00­0003­13
Service Recommendations for
Metric Series Four Bolt Flange
Fitting…………………………………………… 00­0003­15
Service Recommendations For
Inch Series Four Bolt Flange
Fittings …………………………………………. 00­0003­16
Inch Series Four Bolt Flange Fitting
For High Pressure Service
Recommendations…………………………. 00­0003­17
Service Recommendations
For Non­Restricted Banjo
(Adjustable) Fittings……………………….. 00­0003­18
Service Recommendations For
O­Ring Boss Fittings With
Shoulder ………………………………………. 00­0003­19
Metric 24 O­Ring Seal DIN 20078…….00­0003­21
Section 01
Tracks
Contents
Page
Group 0130—Track System
Track Roller Remove and Install …………… 01­0130­1
Track Roller Disassemble and
Assemble……………………………………….. 01­0130­3
Track Roller Pressure Test …………………… 01­0130­4
Track Carrier Roller Remove and
Install …………………………………………….. 01­0130­4
Metal Face Seals Repair ……………………… 01­0130­6
Track Shoe Remove and Install ……………. 01­0130­7
Track Chain Remove and Install …………… 01­0130­8
Track Chain Disassemble and
Assemble……………………………………… 01­0130­10
Track Chain Repair……………………………. 01­0130­13
Sprocket Remove and Install………………. 01­0130­15
Front Idler Remove and Install ……………. 01­0130­15
Front Idler Disassemble and
Assemble……………………………………… 01­0130­16
Track Adjuster and Recoil Spring
Remove and Install………………………… 01­0130­18
Track Adjuster and Recoil Spring
Disassemble and Assemble ……………. 01­0130­19
Track Adjuster Cylinder
Disassemble and Assemble ……………. 01­0130­23
Section 02
Axles, Differentials and Suspension Systems
Contents
Page
Group 0250—Axle Shaft, Bearings, and
Reduction Gears
Travel Gearbox Remove and
Install …………………………………………….. 02­0250­1
Travel Gearbox Disassemble and
Assemble—240DLC ………………………… 02­0250­2
Travel Gearbox Disassemble and
Assemble—270DLC ………………………… 02­0250­6
Group 0260—Hydraulic System
Travel Motor and Park Brake
Remove and Install—240DLC …………… 02­0260­1
Travel Motor and Park Brake
Remove and Install—270DLC …………… 02­0260­4
Travel Motor and Park
Brake Disassemble and
Assemble—240DLC ………………………… 02­0260­8
Travel Motor and Park
Brake Disassemble and
Assemble—270DLC ………………………. 02­0260­10
Travel Motor Cover Disassemble
and Assemble—240DLC ………………… 02­0260­12
Travel Motor Cover Disassemble
and Assemble—270DLC ………………… 02­0260­14
Travel Motor Start­Up Procedure ………… 02­0260­15
Section 04
Engine
Contents
Page
Group 0400—Removal and Installation
Engine Remove and Install…………………… 04­0400­1
Fuel Injection Pump Remove and
Install …………………………………………….. 04­0400­9
Starter Motor Remove and Install………….. 04­0400­9
Section 05
Engine Auxiliary System
Contents
Page
Group 0510—Cooling System
Radiator Remove and Install ………………… 05­0510­1
Oil Cooler Remove and Install………………. 05­0510­4
Charge Air Cooler Remove and
Install …………………………………………….. 05­0510­7
Fan Drive Motor Remove and
Install …………………………………………….. 05­0510­8
Fan, Fan Guard, and Fan Shroud
Remove and Install………………………… 05­0510­10
Serpentine Belt Remove and
Install …………………………………………… 05­0510­12
Coolant Surge Tank Remove and
Install …………………………………………… 05­0510­12
Fan Drive Pump Remove and
Install …………………………………………… 05­0510­13
Fan Speed Solenoid Valve Remove
and Install …………………………………….. 05­0510­14
Group 0520—Intake System
Air Cleaner Remove and Install…………….. 05­0520­1
Group 0560—External Fuel Supply System
Fuel Tank……………………………………………05­0560­1
Primary Fuel Filter (Water
Separator) Remove and Install………….. 05­0560­2
Final Fuel Filter Remove and
Install …………………………………………….. 05­0560­3
Section 07
Dampener Drive (Flex Coupling)
Contents
Page
roup 0752—Elements
ampener Drive (Flex Coupling)
Remove and Install………………………….. 07­0752­1
Section 17
Frame or Supporting Structure
Contents
Page
Group 1740—Frame Installation
Welding On Machine …………………………… 17­1740­1
Welding Repair of Major Structure………….. 17­1740­2
Group 1749—Chassis Weights
Counterweight …………………………………….17­1749­1
Section 18
Operator’s Station
Contents
Page
Group 1800—Removal and Installation
Cab Remove and Install ………………………. 18­1800­1
Group 1810—Operator Enclosure
Windowpane and One Piece
Molding Remove and Install ……………… 18­1810­1
Sliding Windows Remove and
Install …………………………………………….. 18­1810­2
Windowpanes Remove and
Install …………………………………………….. 18­1810­2
Group 1821—Seat and Seat Belt
Seat Remove and Install ……………………… 18­1821­1
Seat Belt Remove and Install ……………….. 18­1821­4
Mechanical Suspension Seat
Disassemble and Assemble ……………… 18­1821­5
Air Suspension Seat Disassemble
and Assemble…………………………………. 18­1821­6
Group 1830—Heating and Air Conditioning
Refrigerant Cautions and Proper
Handling ………………………………………… 18­1830­1
R134a Compressor Oil Charge
Check ……………………………………………. 18­1830­1
R134a Compressor Oil Removal…………… 18­1830­2
R134a Refrigerant Oil Information………….. 18­1830­2
R134a Refrigerant
Recovery/Recycling and
Charging Station Installation
Procedure ………………………………………. 18­1830­3
Recover R134a Refrigerant………………….. 18­1830­3
Evacuate R134a System……………………… 18­1830­4
Charge R134a System ………………………… 18­1830­5
Compressor Remove and Install …………… 18­1830­5
Receiver­Dryer Remove and
Install …………………………………………….. 18­1830­6
Air Conditioner and Heater Remove
and Install ………………………………………. 18­1830­8
Condenser Remove and Install …………….. 18­1830­9
Section 33
Excavator
Contents
Page
Group 3302—Buckets
Bucket Remove and Install…………………… 33­3302­1
Bucket
Adjust Pivot End Play……………………….33­3302­3
Bucket Pin­Up Data…………………………….. 33­3302­4
Group 3340—Frames
Bucket Links Remove and Install ………….. 33­3340­1
Arm……………………………………………………33­3340­3
Boom …………………………………………………33­3340­6
Inspect Pins, Bushings and
Bosses—Front Attachment……………… 33­3340­10
Bushings and Seal Remove and
Install …………………………………………… 33­3340­13
Group 3360—Hydraulic System
Apply Vacuum to Hydraulic Oil
Tank………………………………………………. 33­3360­1
Hydraulic Oil Cleanup Procedure
Using Portable Filter Caddy………………. 33­3360­2
Pump 1 and 2 Remove and Install………….. 33­3360­3
Pump 1 and 2 Disassemble and
Assemble……………………………………….. 33­3360­6
Pump 1 and 2 Inspection……………………. 33­3360­13
Pump 1 and 2 Start­Up Procedure………… 33­3360­16
Pump 1 and 2 Regulator Remove
and Install …………………………………….. 33­3360­17
Pump 1 and 2 Regulator
Disassemble and Assemble ……………. 33­3360­18
Pilot Pump Remove and Install …………… 33­3360­20
Pilot Pump Disassemble and
Assemble……………………………………… 33­3360­22
Pilot Pump Drive Shaft Remove
and Install …………………………………….. 33­3360­24
Pilot Pressure Regulating Valve
and Filter Remove and Install………….. 33­3360­24
Pilot Pressure Regulating Valve
and Filter Disassemble and
Assemble……………………………………… 33­3360­25
Pilot Shut­Off Solenoid Valve
Remove and Install………………………… 33­3360­26
Pilot Shut­Off Solenoid Valve
Disassemble and Assemble ……………. 33­3360­28
Solenoid Valve Remove and
Install—Power Digging (Port
SG), Travel Speed (Port SI), Arm
Regenerative (Port SC) and Dig
Regenerative (Port SF) Valves ………… 33­3360­29
Solenoid Valve Disassemble and
Assemble—Power Digging (Port
SG), Travel Speed (Port SI), Arm
Regenerative (Port SC) and Dig
Regenerative (Port SF) Valves ………… 33­3360­31
Page
Torque Control and Pump Flow
Rate Limit Solenoid Valve
Remove and Install………………………… 33­3360­32
Pilot Valve…………………………………………33­3360­32
Left and Right Pilot Valve
Disassemble and Assemble ……………. 33­3360­38
Travel Pilot Control Valve Remove
and Install …………………………………….. 33­3360­40
Travel Pilot Control Valve
Disassemble and Assemble ……………. 33­3360­41
Pilot Signal Manifold Remove and
Install …………………………………………… 33­3360­43
Pilot Signal Manifold Disassemble
and Assemble……………………………….. 33­3360­44
Control Valve Remove and Install………… 33­3360­47
Left Control Valve (5­Spool)
Disassemble and Assemble ……………. 33­3360­49
Right Control Valve (4­Spool)
Disassemble and Assemble ……………. 33­3360­56
Hydraulic Oil Tank Remove and
Install …………………………………………… 33­3360­62
Hydraulic Oil Tank Disassemble
and Assemble……………………………….. 33­3360­64
Oil Cooler Bypass Valve Remove
and Install …………………………………….. 33­3360­65
Boom Cylinder Remove and
Install …………………………………………… 33­3360­67
Boom Cylinder Disassemble and
Assemble—240DLC ………………………. 33­3360­70
Boom Cylinder Disassemble and
Assemble—270DLC ………………………. 33­3360­72
Arm Cylinder Remove and Install………… 33­3360­74
Arm Cylinder Disassemble and
Assemble—240DLC ………………………. 33­3360­78
Arm Cylinder Disassemble and
Assemble—270DLC ………………………. 33­3360­81
Bucket Cylinder Remove and
Install …………………………………………… 33­3360­83
Bucket Cylinder Disassemble and
Assemble—240DLC ………………………. 33­3360­86
Bucket Cylinder Disassemble and
Assemble—270DLC ………………………. 33­3360­88
Hydraulic Cylinder Bleed
Procedure …………………………………….. 33­3360­90
ection 43
Swing or Pivoting System
Contents
Page
Group 4350—Mechanical Drive Elements
Swing Gearbox Remove and
Install …………………………………………….. 43­4350­1
Swing Gearbox Disassemble and
Assemble……………………………………….. 43­4350­4
Swing Gearbox Start­Up
Procedure ………………………………………. 43­4350­8
Swing Bearing Remove and
Install …………………………………………….. 43­4350­9
Swing Bearing Disassemble and
Assemble……………………………………… 43­4350­10
Swing Bearing Upper Seal Install………… 43­4350­13
Swing Bearing Lower Seal Install………… 43­4350­13
Upperstructure Remove and
Install …………………………………………… 43­4350­14
Group 4360—Hydraulic System
Center Joint Remove and Install …………… 43­4360­1
Center Joint Disassemble and
Assemble……………………………………….. 43­4360­3
Center Joint Air Test ……………………………. 43­4360­4
Swing Motor and Park Brake
Remove and Install………………………….. 43­4360­4
Swing Motor and Park Brake
Disassemble—240DLC ……………………. 43­4360­6
Swing Motor and Park Brake
Assemble—240DLC ………………………… 43­4360­8
Swing Motor and Park Brake
Disassemble—270DLC ………………….. 43­4360­10
Swing Motor and Park Brake
Assemble—270DLC ………………………. 43­4360­12
Swing Motor and Park Brake
Inspection …………………………………….. 43­4360­14
Swing Motor and Park Brake
Start­Up Procedure………………………… 43­4360­17
Crossover Relief Valve and
Make­Up Check Valve Remove
and Install …………………………………….. 43­4360­17
Make­Up Check Valve
Disassemble and Assemble ……………. 43­4360­18
Swing Dampener Valve Remove
and Install …………………………………….. 43­4360­19
Swing Park Brake Check Valve
and Orifice Remove and
Install—270DLC ……………………………. 43­4360­22
Section 99
Dealer Fabricated Tools
Contents
Page
Group 9900—Dealer Fabricated Tools
DF1063 Lift Bracket…………………………….. 99­9900­1
ST4920 Track Recoil Spring
Disassembly and Assembly
Tool……………………………………………….. 99­9900­3
DFT1087 Track Recoil Spring
Disassembly and Assembly
Guard Tool ……………………………………… 99­9900­7
DFT1110 Spacer…………………………………. 99­9900­8
DFT1130 Adapter ……………………………….. 99­9900­9
Center Joint Lifting Tool……………………… 99­9900­10
DFT1119 Pump Support …………………….. 99­9900­11
DFT1220 Swing Gearbox Nut
Spanner Wrench……………………………. 99­9900­12
DFT1305 Travel Gearbox Nut
Wrench ………………………………………… 99­9900­13