Description
John Deere 200CLC, 230CLC, 270CLC Excavator Operator’s Manual (OMT187348)
John Deere 200CLC, 230CLC, 270CLC Excavator Index:
Safety—Safety Features Operation—Operator’s Station
Safety Features . . . . . . . . . . . . . . . . . . . . . . . . 1-1-1 Pedals, Levers, and Panels . . . . . . . . . . . . . . . 2-1-1
Monitor Panel . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-1
Safety—General Precautions Monitor Panel Functions. . . . . . . . . . . . . . . . . . 2-1-2
Recognize Safety Information. . . . . . . . . . . . . . 1-2-1 Front Switch Panel . . . . . . . . . . . . . . . . . . . . . . 2-1-3
Follow Safety Instructions. . . . . . . . . . . . . . . . . 1-2-1 Front Switch Panel Functions . . . . . . . . . . . . . . 2-1-4
Operate Only If Qualified . . . . . . . . . . . . . . . . . 1-2-1 Rear Switch Panel . . . . . . . . . . . . . . . . . . . . . . 2-1-5
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-5
Wear Protective Equipment . . . . . . . . . . . . . . . 1-2-2
Power Boost Switch . . . . . . . . . . . . . . . . . . . . . 2-1-5
Avoid Unauthorized Machine Modifications. . . . 1-2-2
Pilot Control Shut-Off Lever . . . . . . . . . . . . . . . 2-1-6
Add Cab Guarding for Special Uses. . . . . . . . . 1-2-3 Travel Alarm and Travel Alarm Cancel
Inspect Machine . . . . . . . . . . . . . . . . . . . . . . . . 1-2-3 Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-6
Stay Clear of Moving Parts. . . . . . . . . . . . . . . . 1-2-3 Cab Heater and Air Conditioner . . . . . . . . . . . . 2-1-7
Avoid High-Pressure Oils . . . . . . . . . . . . . . . . . 1-2-4 Operating the AM/FM Radio. . . . . . . . . . . . . . . 2-1-9
Beware of Exhaust Fumes . . . . . . . . . . . . . . . . 1-2-4 Secondary Exit Tool . . . . . . . . . . . . . . . . . . . . . 2-1-9
Prevent Fires . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-5 Opening Upper Front (Secondary Exit)
Prevent Battery Explosions. . . . . . . . . . . . . . . . 1-2-5 Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-9
Handle Chemical Products Safely. . . . . . . . . . . 1-2-6 Removing and Storing the Lower Front
Dispose of Waste Properly . . . . . . . . . . . . . . . . 1-2-6 Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-10
Prepare for Emergencies . . . . . . . . . . . . . . . . . 1-2-6 Opening Side Windows . . . . . . . . . . . . . . . . . 2-1-11
Opening and Closing the Roof Exit Cover . . . 2-1-12
Safety—Operating Precautions Adjusting the Seat . . . . . . . . . . . . . . . . . . . . . 2-1-13
Use Steps and Handholds Correctly. . . . . . . . . 1-3-1
Start Only From Operator’s Seat . . . . . . . . . . . 1-3-1 Operation—Operating the Machine
Use and Maintain Seat Belt . . . . . . . . . . . . . . . 1-3-1 Before Starting Work . . . . . . . . . . . . . . . . . . . . 2-2-1
Prevent Unintended Machine Movement . . . . . 1-3-2 Operator’s Daily Machine Check Before
Avoid Work Site Hazards . . . . . . . . . . . . . . . . . 1-3-3 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-1
Keep Riders Off Machine . . . . . . . . . . . . . . . . . 1-3-3 Starting Engine. . . . . . . . . . . . . . . . . . . . . . . . . 2-2-2
Avoid Backover Accidents . . . . . . . . . . . . . . . . 1-3-4 Cold Weather Warm-Up . . . . . . . . . . . . . . . . . . 2-2-4
Avoid Machine Tip Over . . . . . . . . . . . . . . . . . . 1-3-4 Using Booster Batteries—24 Volt System. . . . . 2-2-5
Use Special Care When Lifting Objects . . . . . . 1-3-5 Travel Pedals and Levers. . . . . . . . . . . . . . . . . 2-2-6
Add and Operate Attachments Safely. . . . . . . . 1-3-5 Control Lever Pattern Operation . . . . . . . . . . . . 2-2-7
Control Lever Pattern Conversion. . . . . . . . . . . 2-2-8
Operating In Water and Mud . . . . . . . . . . . . . . 2-2-9
Safety—Maintenance Precautions
Driving Up a Steep or Slippery Slope . . . . . . . 2-2-10
Park and Prepare for Service Safely . . . . . . . . 1-4-1 Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-10
Service Cooling System Safely. . . . . . . . . . . . . 1-4-1 Lower Boom With Engine Stopped. . . . . . . . . 2-2-11
Remove Paint Before Welding or Heating . . . . 1-4-2 Parking the Machine. . . . . . . . . . . . . . . . . . . . 2-2-12
Make Welding Repairs Safely. . . . . . . . . . . . . . 1-4-2 Loading and Unloading for Transport . . . . . . . 2-2-13
Drive Metal Pins Safely . . . . . . . . . . . . . . . . . . 1-4-3 Towing Machine . . . . . . . . . . . . . . . . . . . . . . . 2-2-14
Lifting the Machine . . . . . . . . . . . . . . . . . . . . . 2-2-14
Maintenance—Machine Maintenance—Every 250 Hours
Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-1 Check Swing Gearbox Oil Level . . . . . . . . . . . . 3-7-1
Low Sulfur Diesel Fuel Conditioner. . . . . . . . . . 3-1-2 Drain Hydraulic Tank Sump . . . . . . . . . . . . . . . 3-7-1
Testing Diesel Fuel. . . . . . . . . . . . . . . . . . . . . . 3-1-2 Check Pump Drive Gearbox Oil Level . . . . . . . 3-7-2
Handling and Storing Diesel Fuel . . . . . . . . . . . 3-1-3 Check Radiator Coolant Level . . . . . . . . . . . . . 3-7-3
Alternative and Synthetic Lubricants. . . . . . . . . 3-1-4 Check Battery Electrolyte Level and
Engine Break-In Oil . . . . . . . . . . . . . . . . . . . . . 3-1-5 Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7-4
Diesel Engine Oil . . . . . . . . . . . . . . . . . . . . . . . 3-1-6 Check Travel Gearbox Oil Level. . . . . . . . . . . . 3-7-6
Hydraulic Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-7 Clean or Replace Dusty Primary Element. . . . . 3-7-7
Swing Gearbox and Travel Gearbox Oils . . . . . 3-1-8
Pump Gearbox Oil . . . . . . . . . . . . . . . . . . . . . . 3-1-9 Maintenance—Every 500 Hours
Track Adjuster, Working Tool Pivot, Grease Working Tool Pivots. . . . . . . . . . . . . . . 3-8-1
Swing Bearing, and Swing Bearing Gear Grease Swing Bearing . . . . . . . . . . . . . . . . . . . 3-8-2
Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-10 Grease Swing Bearing Gear. . . . . . . . . . . . . . . 3-8-3
Replace Water Separator . . . . . . . . . . . . . . . . . 3-8-4
Maintenance—Periodic Maintenance Replace Final Fuel Filter. . . . . . . . . . . . . . . . . . 3-8-4
Service Your Machine at Specified Intervals. . . 3-2-1 Change Engine Oil and Replace Filter . . . . . . . 3-8-4
Check the Hour Meter Regularly . . . . . . . . . . . 3-2-1 Check Air Intake Hoses . . . . . . . . . . . . . . . . . . 3-8-5
Prepare Machine for Maintenance . . . . . . . . . . 3-2-1 Clean Cab Fresh Air and Recirculating
Open Access Doors for Service . . . . . . . . . . . . 3-2-2 Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8-6
Open Engine Hood for Service. . . . . . . . . . . . . 3-2-2
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-3 Maintenance—Every 1000 Hours
Hydraulic Breaker and Crusher Attachments . . 3-2-4 Change Swing Gearbox Oil . . . . . . . . . . . . . . . 3-9-1
Maintenance and Repair Record Replace Hydraulic Tank Oil Filter . . . . . . . . . . . 3-9-1
Keeping System . . . . . . . . . . . . . . . . . . . . . . 3-2-5 Replace Pilot System Oil Filter . . . . . . . . . . . . . 3-9-2
Fluid Analysis Program Test Kits and Change Pump Drive Gearbox Oil . . . . . . . . . . . 3-9-4
3-Way Coolant Test Kit . . . . . . . . . . . . . . . . . 3-2-6 Clean the Engine Crankcase Ventilation
Periodic Maintenance Record Keeping Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9-4
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-7 Inspect Fan Belt . . . . . . . . . . . . . . . . . . . . . . . . 3-9-5
Replace Air Cleaner Elements . . . . . . . . . . . . . 3-9-6
Replace Air Cleaner Dust Valve . . . . . . . . . . . . 3-9-6
Maintenance—As Required
Clean Fuel Tank Inlet Screen . . . . . . . . . . . . . . 3-3-1
Drain Fuel Tank Sump . . . . . . . . . . . . . . . . . . . 3-3-1 Maintenance—Every 2000 Hours
Drain Water Separator . . . . . . . . . . . . . . . . . . . 3-3-2 Drain Cooling System. . . . . . . . . . . . . . . . . . . 3-10-1
Bleed Fuel System. . . . . . . . . . . . . . . . . . . . . . 3-3-2 Diesel Engine Coolant . . . . . . . . . . . . . . . . . . 3-10-3
Cooling System Fill and Deaeration
Clean Radiator Air Inlet Screen . . . . . . . . . . . . 3-3-2
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10-4
Clean Air Cleaner Dust Unloader Valve . . . . . . 3-3-3
Adjust Engine Valve Clearance . . . . . . . . . . . 3-10-4
Windshield Washer Fluid Level. . . . . . . . . . . . . 3-3-3 Change Travel Gearbox Oil . . . . . . . . . . . . . . 3-10-5
Check and Adjust Track Sag . . . . . . . . . . . . . . 3-3-4
Maintenance—Every 4000 Hours
Maintenance—10 Hours or Daily Change Hydraulic Tank Oil, Clean
Check Engine Oil Level . . . . . . . . . . . . . . . . . . 3-4-1 Suction Screen . . . . . . . . . . . . . . . . . . . . . . 3-11-1
Check Recovery Tank Coolant Level . . . . . . . . 3-4-2
Check Hydraulic Tank Oil Level . . . . . . . . . . . . 3-4-3 Maintenance—Every 4500 Hours
Replace Engine Torsional Damper . . . . . . . . . 3-12-1
Maintenance—Every 100 Hours
Grease Working Tool Pivots. . . . . . . . . . . . . . . 3-5-1 Miscellaneous—Machine
Do Not Service or Adjust Injection
Maintenance—Initial Service – 250 Hours Nozzles or Injection Pump . . . . . . . . . . . . . . 4-1-1
Change Engine Break-In Oil and
Replace Filter . . . . . . . . . . . . . . . . . . . . . . . . 3-6-1 Continued on next page
ii 062906
PN=2
Contents
Page Page
Do Not Service Control Valves, 230CLC Engine Specifications . . . . . . . . . . . . 4-6-12
Cylinders, Pumps or Motors . . . . . . . . . . . . . 4-1-1 230CLC Drain and Refill Capacities . . . . . . . . 4-6-12
Precautions for Alternator and Regulator . . . . . 4-1-1 230CLC Machine Specifications . . . . . . . . . . . 4-6-13
Diagnostic Display Unit (DDU) Operation . . . . . 4-1-2 230CLC Working Ranges . . . . . . . . . . . . . . . . 4-6-15
Engine Service Codes . . . . . . . . . . . . . . . . . . . 4-1-8 230CLC Lift Capacity—KG (LB) . . . . . . . . . . . 4-6-17
Handling, Checking, and Servicing Batteries 270CLC Engine Specifications . . . . . . . . . . . . 4-6-23
Carefully . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-10 270CLC Drain and Refill Capacities . . . . . . . . 4-6-23
Using Battery Charger . . . . . . . . . . . . . . . . . . 4-1-11 270CLC Machine Specifications . . . . . . . . . . . 4-6-24
Replacing Batteries . . . . . . . . . . . . . . . . . . . . 4-1-12 270CLC Working Ranges. . . . . . . . . . . . . . . . 4-6-26
Welding on Machine. . . . . . . . . . . . . . . . . . . . 4-1-12 270CLC Lift Capacity—KG (LB) . . . . . . . . . . . 4-6-28
Clean the Machine Regularly . . . . . . . . . . . . . 4-1-12
Adding 12—Volt Accessories . . . . . . . . . . . . . 4-1-13
Replacing Fuses. . . . . . . . . . . . . . . . . . . . . . . 4-1-14
Replacing Bucket Teeth . . . . . . . . . . . . . . . . . 4-1-15
Replacing Bucket Tooth Tip—
Heavy-Duty Bucket . . . . . . . . . . . . . . . . . . . 4-1-16
Adjusting Bucket to Arm Joint. . . . . . . . . . . . . 4-1-16
Removing the Bucket . . . . . . . . . . . . . . . . . . . 4-1-17
Track Sag General Information. . . . . . . . . . . . 4-1-18
Check Track Shoe Hardware . . . . . . . . . . . . . 4-1-19
Unified Inch Bolt and Screw Torque Values . . 4-1-20
Metric Bolt and Screw Torque Values. . . . . . . 4-1-21
Miscellaneous—Operational Checkout
Operational Checkout. . . . . . . . . . . . . . . . . . . . 4-2-1
Operator Station Checks—Key Switch On,
Engine Off. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2-1
Operator Station Checks—Engine On . . . . . . . 4-2-2
Miscellaneous Checks . . . . . . . . . . . . . . . . . . . 4-2-9
Miscellaneous—Troubleshooting
Using Troubleshooting Charts . . . . . . . . . . . . . 4-3-1
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3-2
Electrical System . . . . . . . . . . . . . . . . . . . . . . . 4-3-6
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . 4-3-9
Miscellaneous—Storage
Prepare Machine for Storage . . . . . . . . . . . . . . 4-4-1
Miscellaneous—Machine Numbers
Record Product Identification Number (PIN) . . . 4-5-1
Record Engine Serial Number . . . . . . . . . . . . . 4-5-1
Record Travel Motor Serial Numbers . . . . . . . . 4-5-1
Record Swing Motor Serial Number . . . . . . . . . 4-5-1
Keep Proof of Ownership . . . . . . . . . . . . . . . . . 4-5-2
Keep Machines Secure . . . . . . . . . . . . . . . . . . 4-5-2
Miscellaneous—Specifications
200CLC Engine Specifications . . . . . . . . . . . . . 4-6-1
200CLC Drain and Refill Capacities . . . . . . . . . 4-6-1
200CLC Machine Specifications . . . . . . . . . . . . 4-6-2
200CLC Working Ranges. . . . . . . . . . . . . . . . . 4-6-4
200CLC Lift Capacity—KG (LB) . . . . . . . . . . . . 4-6-6
