TECHNICAL MANUAL UNIT, DIRECT SUPPORT AND GENERAL …tm 5-3805-280-24-2 technical manual no. 5-3805-280-24-2 headquarters, department of the army washington, dc, 15 february 2000 unit,
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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.
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.
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
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
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
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 Rod—If Applicable
Inspect, Measure, and Install ..............................................................13-80Camshaft Followers—Inspect, 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
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 Rods—General 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
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 Block—4-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 Bearing—If 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 Orifices—Remove, 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
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
Remove—If 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
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
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 Heater—If 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
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 Manifold—Remove, 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 System—General Information .......................................................13-388Relieve Fuel System Pressure ................................................................13-389Final Fuel Filter and/or Primary Fuel
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
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 .....................................................................13-480Engine—Sectional 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 Pump—General 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 Operation—Rotary Fuel Injection Pump...........................13-551Fuel System Operation—In-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
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 (3—5%
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 Speed—In-Line Fuel Injection Pump...........................13-598Check and Adjust Slow Idle Speed—In-Line Fuel Injection Pump.......13-599Change Engine Rated Speed and Adjust
Droop—In-Line Injection Pumps .......................................................13-601How the Aneroid Works (If Equipped) ..................................................13-603Diagnose Aneroid Malfunctions.............................................................13-604Fuel Injection Nozzles—General 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................................................................................13-610DFRG3—Cylinder Liner Holding Fixture .............................................13-610DFRG5—Injection Pump Front Plate Timing Mark Transfer Tool .......13-611Engine Oil Dipstick Tube Driver
(6010—6910 Series Tractor Engines) ................................................13-612
Engine Coolant HeaterRemove and Install .............................................................................14-1Disassemble and Assemble.................................................................14-3
0510 Cooling System............................................................................................14-5Specifications .........................................................................................14-5Radiator, Oil Cooler, and Fan Shroud—Remove 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
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
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 Batteries—24-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 Belt—Inspect, 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........................................................................16-23Alternator—Removal .............................................................................16-23Removing Brush Holder With Regulator ...............................................16-24Alternator—Disassembly .......................................................................16-24
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Stator—Removal....................................................................................16-24Diode Plate—Removal...........................................................................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 ....................................................16-31Alternator—Assembly............................................................................16-31Installing Brush Holder With Regulator.................................................16-31Fan and Belt Pulley—Installation ..........................................................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
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 Start—Stop 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 Switch—Removal ...................................................................16-89Carbon Brush Plate—Removal ..............................................................16-89Armature—Removal ..............................................................................16-90Snap Ring—Removal.............................................................................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 Winding—Removal ......................................................................16-93Make Open Circuit Test for Field Windings..........................................16-94Lubrication of Starting Motor (Before and During Assembly) ..............16-94Field Winding—Installation...................................................................16-95Checking Carbon Brush Plate for Grounds ............................................16-95Testing Carbon Brushes .........................................................................16-96Replace Carbon Brushes ........................................................................16-96Engaging Lever—Installation ................................................................16-96Testing Armature End Play ....................................................................16-97Installing Starting Motor ........................................................................16-97
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 Operator’s Station Repair1800 Operator’s 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
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 Core—Machine 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
Remove and Install .............................................................................20-8Disassemble and Assemble.................................................................20-10
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
Remove and Install .............................................................................20-24Disassemble and Assemble.................................................................20-26
Disassemble and Assemble Air Piping...................................................20-28Disassemble and Assemble Oil Piping...................................................20-31
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
Boom, Arm, and Bucket Pins, Bushings and Bosses—Inspect ..............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
Remove and Install .............................................................................21-91Disassemble and Assemble.................................................................21-92
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
Remove and Install .............................................................................21-148Disassemble and Assemble.................................................................21-154
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
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
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.............................................................................23-6Rock Drill, Disassemble.........................................................................23-7Hydraulic Drifter, Disassemble and Assemble.......................................23-28HP Accumulator
Central, Disassemble and Assemble ...................................................23-46Disassemble and Assemble.................................................................23-47
LP Accumulator, Disassemble and Assemble........................................23-48Hydraulic Drifter Inspection ..................................................................23-49Disassemble and Assemble
GCX 14/12 Feed.................................................................................23-74Rod Changer .......................................................................................23-96Cradle and Articulation.......................................................................23-109Cross-Tilting Cylinder ........................................................................23-111Electro-Hydraulic Equipment .............................................................23-112Dust Collector.....................................................................................23-160Hydraulic Drifter Control ...................................................................23-165Remote Control Assembly..................................................................23-185
Rock Drill, Assemble .............................................................................23-190
Appendix A Unit Preventive Maintenance Checks and Services (PMCS) ...................A-1
Appendix B Maintenance Allocation Chart for Hydraulic Excavator230LCR and 230LCRD..........................................................................B-1
Appendix C References ....................................................................................................C-1
CHAPTER 13
SECTION 04
ENGINE REPAIR
TM 5-3805-280-24-2
Group 0400Removal and Installation
0404001CED,OUOE003,1159 –19–18SEP98–1/6
ESSENTIAL TOOLS
NOTE: Order tools according to information given in theU.S. SERVICEGARD Catalog or from theEuropean Microfiche Tool Catalog (MTC).
NOTE: Order tools according to information given in theU.S. SERVICEGARD Catalog or from theEuropean Microfiche Tool Catalog (MTC). Sometools may be available from a local supplier.
To support main hydraulic pump when engine is removed.
1Fabricated tool, dealer made. (See Section 99 for instructions to maketool.)
CED,OUOE003,1160 –19–18SEP98–1/1
OTHER MATERIAL
Number Name Use
TY6304 (U.S.) Flexible Sealant Apply to oil pan rail where flywheelTY9484 (Canadian) housing, front plate, and timing gear515 (LOCTITE) cover contact cylinder block.
CAUTION: Explosive release of fluids frompressurized cooling system can cause seriousburns
Shut off engine. Only remove filler cap whencool enough to touch with bare hands. Slowlyloosen cap to first stop to relieve pressurebefore removing completely.
1. Disconnect negative (-) battery cable.
2. Drain coolant. Cooling capacity is approximately 28.4 L(30 qt).
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A—Hood Support
3. Remove hood and hood support (A).
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13-4
Removal and Installation
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B—Coupling
4. Remove air intake hoses and coupling (B) above therocker arm cover.
5. Remove fan guard.
6. Remove upper and lower radiator hoses.
7. Remove fan and fan spacer.
8. Remove muffler and muffler bracket.
9. Disconnect wiring harnesses.
10. Disconnect fuel lines. Plug openings.
11. Disconnect heater hoses. Plug openings.
12. Remove air conditioner compressor and bracket fromengine. It is not necessary to discharge the airconditioning system.
13. Secure compressor so it does not interfere whenremoving the engine.
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Removal and Installation
040400
6
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A—DFT1119 Pump SupportB—Winch Hoist
CAUTION: The approximate weight of hydraulicpump and gearbox is 167 kg (370 lb).
Hydraulic Pump and Gearbox—Specification
Weight 167 kg (370 lb) approximate............................................................
14. Support main hydraulic pump and gearbox usingDFT1119 Pump Support (A) and a small winch hoist(B). (See Section 99 for instructions to make tool.)
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13-6
Removal and Installation
0404007
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A—JDG23 Lifting Sling
CAUTION: The approximate weight of engine is954 kg (2100 lb).
The recommended method for lifting the engineis using the JDG23 Lifting Sling. The liftingforce must be at 90° at the lifting points.
Engine—Specification
Weight 954 kg (2100 lb) approximate..........................................................
15. Attach JDG23 lifting sling (A) to engine as shown.