250GLC Excavator Repair
REPAIR TECHNICAL MANUAL 250GLC (PIN: 1FF250GX_ _F608713- ) TM13209X19 21OCT15 (ENGLISH)
For complete service information also see: 250GLC Excavator Diagnostic
TM13208X19
JDLink (MTG) Technical Manual
TM114519
PowerTech 6068 OEM Diesel Engines (Final Tier 4/Stage IV Platform)
CTM120019
John Deere Construction and Forestry
250GLC Excavator Repair
(g) by Belgreen v2.1
Table of contents FOREWORD MANUAL IDENTIFICATION—READ THIS FIRST! TECHNICAL INFORMATION FEEDBACK FORM Section 00 - GENERAL INFORMATION Group 0001 - Safety Group 0003 - Torque Values Section 01 - TRACKS Group 0130 - Track System Section 02 - AXLES, DIFFERENTIALS AND SUSPENSION SYSTEMS Group 0250 - Axle Shaft, Bearings, and Reduction Gears Group 0260 - Hydraulic System Section 04 - ENGINE Group 0400 - Removal and Installation Section 05 - ENGINE AUXILIARY SYSTEM Group 0510 - Cooling Systems Group 0530 - External Exhaust Systems Group 0560 - External Fuel Supply Systems Section 07 - DAMPER DRIVE (FLEX COUPLING) Group 0752 - Elements Section 17 - FRAME OR SUPPORTING STRUCTURE Group 1740 - Frame Installation Group 1749 - Chassis Weights Section 18 - OPERATOR′S STATION Group 1800 - Removal and Installation Group 1810 - Operator Enclosure Group 1821 - Seat and Seat Belt Group 1830 - Heating and Air Conditioning Section 19 - SHEET METAL Group 1910 - Hood and Engine Side Shields Section 33 - EXCAVATOR Group 3302 - Buckets Group 3340 - Frames Group 3360 - Hydraulic System Section 43 - SWING OR PIVOTING SYSTEM Group 4350 - Mechanical Drive Elements Group 4360 - Hydraulic System Section 99 - DEALER FABRICATED TOOLS Group 9900 - Dealer Fabricated Tools
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250GLC Excavator Repair
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250GLC Excavator Repair
250GLC Excavator Repair
(g) by Belgreen v2.1
Foreword This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use. Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.
CAUTION: This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury. Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components. Operation and tests sections help you identify the majority of routine failures quickly. Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values. Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair. Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.
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250GLC Excavator Repair
250GLC Excavator Repair
(g) by Belgreen v2.1
Manual Identification—READ THIS FIRST! IMPORTANT: Use only supporting manuals designated for your specific machine. If incorrect manual is chosen, improper service may occur. Verify product identification number (PIN) when choosing the correct manual.
Choosing the Correct Supporting Manuals John Deere excavators are available in different machine configurations based on the various markets into which they are sold. Different supporting manuals exist for different machine configurations. When necessary, product identification numbers are listed on the front covers of excavator manuals. These numbers are used to identify the correct supporting manual for your machine. Product Identification Number
PIN Plate Location
Example of PIN Plate LEGEND: 1 PIN Plate 2 17-Character PIN The product identification number (PIN) plate (1) is located on the front, right corner of the cab. Each machine has a 17character PIN (2) shown on PIN plate. <- Go to Global Table of contents
250GLC Excavator Repair
250GLC Excavator Repair
(g) by Belgreen v2.1
The PIN identifies the producing factory, machine model number, machine option, year of manufacture, engine emission level, and machine serial number. The following is an example for a machine that meets Final Tier 4 and Stage IV emission levels: PIN Identification Table 17-Character PIN Examples 1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
1
F
F
2
5
0
G
X
_
_
F
6
0
8
7
1
3
(1—3) World Code: Identifies location where machine is manufactured.
(1—3) World Code 1FF ..........
World Code (manufacturing location)
1DW ..........
Davenport Works
1T8 ..........
Thibodaux Works
1T0 ..........
Dubuque Works
1FF ..........
Deere—Hitachi (Kernersville, NC, USA)
1F9 ..........
Deere—Hitachi (Indaiatuba, São Paulo, Brazil)
(4—8) Machine Model Identifier: Identifies model number.
(4—8) Machine Model Identifier 250G ..........
Machine Model Identifier
→NOTE: Characters 7—8 identify series and major machine configuration options. These characters will change from one machine to another.
(7—8) Machine Option Code X ..........
Machine Option Code X ..........
Base Machine
R ..........
HYEX Military Excavators
(9) Check Letter: This is a random character assigned by the factory. This is not used in machine identification.
(9) Check Letter _ ..........
Check Letter (variable)
(10) Manufacturing Year Code: Identifies year of machine manufacture.
(10) Manufacturing Year Code _ ..........
Manufacturing Year Code (variable) D ..........
2013
E ..........
2014
F ..........
2015
G ..........
2016
(11) Engine Emission Code: Represents engine emission certification.
(11) Engine Emission Code F ..........
Engine Emission Code C ..........
Tier 2 and Stage II
D ..........
Tier 3 and Stage III A
E ..........
Interim Tier 4 and Stage III B
F ..........
Final Tier 4 and Stage IV
(12—17) Machine Serial Number: Identifies machine serial number. This character will change from one machine to <- Go to Global Table of contents
250GLC Excavator Repair
250GLC Excavator Repair
(g) by Belgreen v2.1
another.
(12—17) Machine Serial Number 608713 ..........
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Machine Serial Number
250GLC Excavator Repair
GENERAL INFORMATION
(g) by Belgreen v2.0
Technical Information Feedback Form We need your help to continually improve our technical publications. Please copy this page and FAX or mail your comments, ideas and improvements.
Technical Manual Fax SEND TO:
John Deere Dubuque Works 18600 South John Deere Road Attn: Publications, Dept. 324 Dubuque, IA 52004-0538 USA
FAX NUMBER:
1-563-589-5800 (USA)
Publication Number:
Page Number:
Ideas, Comments:
Name:
Phone:
Email Address:
THANK YOU!
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Section 00 page 1
250GLC Excavator Repair
250GLC Excavator Repair
(g) by Belgreen v2.1
Section 00 - GENERAL INFORMATION Table of contents Group 0001 - Safety ................................................................................................................................. 1 Recognize Safety Information ............................................................................................................... 1 Follow Safety Instructions ..................................................................................................................... 1 Operate Only If Qualified ...................................................................................................................... 2 Wear Protective Equipment .................................................................................................................. 3 Avoid Unauthorized Machine Modifications .......................................................................................... 3 Control Pattern Selector—If Equipped .................................................................................................. 3 Add Cab Guarding for Special Uses ...................................................................................................... 4 Inspect Machine ................................................................................................................................... 4 Stay Clear of Moving Parts ................................................................................................................... 4 Avoid High-Pressure Fluids ................................................................................................................... 5 Avoid High-Pressure Oils ...................................................................................................................... 5 Work In Ventilated Area ........................................................................................................................ 6 Avoid Static Electricity Risk When Refueling ........................................................................................ 6 Prevent Fires ........................................................................................................................................ 7 In Case of Machine Fire ........................................................................................................................ 8 Prevent Battery Explosions ................................................................................................................... 9 Handle Chemical Products Safely ......................................................................................................... 9 Decommissioning: Proper Recycling and Disposal of Fluids and Components ................................... 11 Exhaust Filter Ash Handling and Disposal .......................................................................................... 11 Prepare for Emergencies .................................................................................................................... 11 Clean Debris from Machine ................................................................................................................ 12 Use Steps and Handholds Correctly ................................................................................................... 12 Start Only From Operator′s Seat ......................................................................................................... 13 Use and Maintain Seat Belt ................................................................................................................ 13 Prevent Unintended Machine Movement ............................................................................................ 14 Avoid Work Site Hazards .................................................................................................................... 15 Keep Riders Off Machine .................................................................................................................... 16 Avoid Backover Accidents .................................................................................................................. 16 Inspect and Maintain ROPS ................................................................................................................. 16 Avoid Machine Tip Over ...................................................................................................................... 17 Use Special Care When Lifting Objects ............................................................................................... 18 Travel Safely ....................................................................................................................................... 18 Add and Operate Attachments Safely ................................................................................................ 19 Park and Prepare for Service Safely ................................................................................................... 19 Service Cooling System Safely ........................................................................................................... 20 Remove Paint Before Welding or Heating ........................................................................................... 20 Make Welding Repairs Safely ............................................................................................................. 21 Drive Metal Pins Safely ....................................................................................................................... 21 Clean Exhaust Filter Safely ................................................................................................................. 22 Group 0003 - Torque Values ................................................................................................................. 24 Metric Bolt and Cap Screw Torque Values .......................................................................................... 24 Additional Metric Cap Screw Torque Values ....................................................................................... 25 Unified Inch Bolt and Cap Screw Torque Values ................................................................................. 27 Service Recommendations for 37° Flare and 30° Cone Seat Connectors ........................................... 28 Service Recommendations for O-Ring Boss Fittings ........................................................................... 29 Service Recommendations For Flared Connections—Straight or Tapered Threads ............................ 31 Service Recommendations For Flat Face O-Ring Seal Fittings ............................................................ 33 O-Ring Boss Fittings In Aluminum Housing Service Recommendations—Excavators ......................... 34 O-Ring Face Seal Fittings With SAE Inch Hex Nut And Stud End For High Pressure Service <- Go to Global Table of contents
250GLC Excavator Repair
250GLC Excavator Repair
(g) by Belgreen v2.1
Recommendations ....................................................................................................................... 36 O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For Standard Pressure Service Recommendations ....................................................................................................................... 38 O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For High Pressure Service Recommendations ....................................................................................................................... 40 Service Recommendations for Metric Series Four Bolt Flange Fitting ................................................. 42 Service Recommendations For Inch Series Four Bolt Flange Fittings ................................................. 43 Inch Series Four Bolt Flange Fitting For High Pressure Service Recommendations ............................ 44 Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings ........................................ 46 Service Recommendations For O-Ring Boss Fittings With Shoulder ................................................... 48 Metric 24° O-Ring Seal DIN 20078 Service Recommendations ........................................................... 51
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250GLC Excavator Repair