John Deere 245GLC Excavator Repair Technical Manual TM12663 – PDF DOWNLOAD

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John Deere 245GLC Excavator Repair Technical Manual TM12663 – PDF DOWNLOAD

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John Deere 245GLC Excavator Repair Technical Manual TM12663 – PDF DOWNLOAD

Language : English
Pages : 464
Downloadable : Yes
File Type : PDF

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John Deere 245GLC Excavator Repair Technical Manual TM12663 – PDF DOWNLOAD

• 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.
• Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components. Operation and test sections help to quickly 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.

TABLE OF CONTENTS:

John Deere 245GLC Excavator Repair Technical Manual TM12663 – PDF DOWNLOAD

Contents.........................................................................................................................................................................  3
	General Information..........................................................................................................................................................  5
		Safety...................................................................................................................................................................  7
			Recognize Safety Information.........................................................................................................................................  7
			Follow Safety Instructions...........................................................................................................................................  7
			Operate Only If Qualified............................................................................................................................................  7
			Wear Protective Equipment............................................................................................................................................  8
			Avoid Unauthorized Machine Modifications.............................................................................................................................  8
			Control Pattern Selector—If Equipped.................................................................................................................................  9
			Add Cab Guarding for Special Uses....................................................................................................................................  9
			Inspect Machine......................................................................................................................................................  9
			Stay Clear of Moving Parts...........................................................................................................................................  9
			Avoid High-Pressure Fluids........................................................................................................................................... 10
			Avoid High-Pressure Oils............................................................................................................................................. 10
			Work In Ventilated Area.............................................................................................................................................. 11
			Prevent Fires........................................................................................................................................................ 11
			Prevent Battery Explosions........................................................................................................................................... 12
			Handle Chemical Products Safely...................................................................................................................................... 12
			Decommissioning — Proper Recycling and Disposal of Fluids and Components............................................................................................. 13
			Exhaust Filter Ash Handling and Disposal............................................................................................................................. 13
			Prepare for Emergencies.............................................................................................................................................. 13
			Clean Debris from Machine............................................................................................................................................ 14
			Use Steps and Handholds Correctly.................................................................................................................................... 14
			Start Only From Operator's Seat...................................................................................................................................... 14
			Use and Maintain Seat Belt........................................................................................................................................... 14
			Prevent Unintended Machine Movement.................................................................................................................................. 15
			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................................................................................................................................ 17
			Add and Operate Attachments Safely................................................................................................................................... 18
			Park and Prepare for Service Safely.................................................................................................................................. 19
			Service Cooling System Safely........................................................................................................................................ 19
			Remove Paint Before Welding or Heating............................................................................................................................... 20
			Make Welding Repairs Safely.......................................................................................................................................... 20
			Drive Metal Pins Safely.............................................................................................................................................. 20
			Clean Exhaust Filter Safely.......................................................................................................................................... 21
		Torque Values............................................................................................................................................................ 23
			Metric Bolt and Cap Screw Torque Values.............................................................................................................................. 23
			Additional Metric Cap Screw Torque Values............................................................................................................................ 24
			Unified Inch Bolt and Cap Screw Torque Values........................................................................................................................ 25
			Service Recommendations for 37° Flare and 30° Cone Seat Connectors................................................................................................... 26
			Service Recommendations for O-Ring Boss Fittings..................................................................................................................... 26
			Service Recommendations For Flared Connections—Straight or Tapered Threads........................................................................................... 28
			Service Recommendations For Flat Face O-Ring Seal Fittings........................................................................................................... 29
			O-Ring Boss Fittings In Aluminum Housing Service Recommendations—Excavators.......................................................................................... 30
			O-Ring Face Seal Fittings With SAE Inch Hex Nut And Stud End For High Pressure Service Recommendations............................................................... 32
			O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For Standard Pressure Service Recommendations............................................................. 34
			O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For High Pressure Service Recommendations................................................................. 36
			Service Recommendations for Metric Series Four Bolt Flange Fitting................................................................................................... 38
			Service Recommendations For Inch Series Four Bolt Flange Fittings.................................................................................................... 39
			Inch Series Four Bolt Flange Fitting For High Pressure Service Recommendations....................................................................................... 40
			Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings............................................................................................... 41
			Service Recommendations For O-Ring Boss Fittings With Shoulder....................................................................................................... 42
			Metric 24° O-Ring Seal DIN 20078 Service Recommendations............................................................................................................. 44
	Tracks....................................................................................................................................................................... 45
		Track System............................................................................................................................................................. 47
			Track Roller Remove and Install...................................................................................................................................... 47
			Track Roller Disassemble and Assemble................................................................................................................................ 49
			Track Roller Pressure Test........................................................................................................................................... 50
			Track Carrier Roller Remove and Install.............................................................................................................................. 52
			Metal Face Seals Repair.............................................................................................................................................. 54
			Track Shoe Remove and Install........................................................................................................................................ 55
			Track Chain Remove and Install....................................................................................................................................... 56
			Track Chain Disassemble and Assemble................................................................................................................................. 61
			Track Chain Repair to Replace Broken Part............................................................................................................................ 64
			Sprocket Remove and Install.......................................................................................................................................... 70
			Front Idler Remove and Install....................................................................................................................................... 72
			Front Idler Disassemble and Assemble................................................................................................................................. 73
			Track Adjuster and Recoil Spring Remove and Install.................................................................................................................. 75
			Track Adjuster and Recoil Spring Disassemble and Assemble............................................................................................................ 76
	Axles, Differentials, and Suspension Systems................................................................................................................................. 83
		Axle Shaft, Bearings, and Reduction Gears................................................................................................................................ 85
			Travel Gear Case Remove and Install.................................................................................................................................. 85
			Travel Gear Case Disassemble and Assemble............................................................................................................................ 88
		Hydraulic System......................................................................................................................................................... 95
			Travel Motor and Park Brake Remove and Install....................................................................................................................... 95
			Travel Motor and Park Brake Disassemble and Assemble................................................................................................................. 96
			Park Brake Valve Disassemble and Assemble............................................................................................................................100
			Travel Motor and Park Brake Start-Up Procedure.......................................................................................................................102
	Engine.......................................................................................................................................................................103
		Removal and Installation.................................................................................................................................................105
			Engine Remove and Install............................................................................................................................................105
	Engine Auxiliary System......................................................................................................................................................115
		Cooling Systems..........................................................................................................................................................117
			Radiator Remove and Install..........................................................................................................................................117
			Hydraulic Oil Cooler Remove and Install..............................................................................................................................122
			Charge Air Cooler Remove and Install.................................................................................................................................130
			Fuel Cooler Remove and Install.......................................................................................................................................131
			Cooling Package Remove and Install...................................................................................................................................133
			Fan, Fan Guard, and Fan Shroud Remove and Install....................................................................................................................142
			Serpentine Belt Remove and Install...................................................................................................................................143
			Coolant Recovery Tank Remove and Install.............................................................................................................................144
		Intake System............................................................................................................................................................145
			Air Cleaner Remove and Install.......................................................................................................................................145
		External Exhaust Systems.................................................................................................................................................147
			Exhaust Tube Remove and Install......................................................................................................................................147
			Diesel Particulate Filter (DPF) Remove and Install...................................................................................................................147
			Exhaust Filter Remove and Install....................................................................................................................................148
			Exhaust Filter Disassemble and Assemble..............................................................................................................................151
		External Fuel Supply Systems.............................................................................................................................................155
			Fuel Tank Remove and Install.........................................................................................................................................155
			Primary Fuel Filter and Water Separator Remove and Install...........................................................................................................159
			Final Fuel Filter Remove and Install.................................................................................................................................161
			Auxiliary Fuel Filter Remove and Install (If Equipped)...............................................................................................................163
	Damper Drive (Flex Coupling).................................................................................................................................................165
		Elements.................................................................................................................................................................167
			Damper Drive (Flex Coupling) Remove and Install......................................................................................................................167
	Frame or Supporting Structure................................................................................................................................................169
		Frame Installation.......................................................................................................................................................171
			Welding on Machine...................................................................................................................................................171
		Chassis Weights..........................................................................................................................................................173
			Counterweight Remove and Install.....................................................................................................................................173
	Operator's Station...........................................................................................................................................................175
		Removal and Installation.................................................................................................................................................177
			Cab Remove and Install...............................................................................................................................................177
			Monitor Remove and Install...........................................................................................................................................186
		Operator Enclosure.......................................................................................................................................................189
			Windshield Remove and Install........................................................................................................................................189
			Windshield Disassemble and Assemble..................................................................................................................................190
			Sliding Windows Remove and Install...................................................................................................................................195
			Windowpanes Remove and Install.......................................................................................................................................195
			Windowpanes Dimensions...............................................................................................................................................196
		Seat and Seat Belt.......................................................................................................................................................205
			Seat Remove and Install..............................................................................................................................................205
			Seat Belt Remove and Install.........................................................................................................................................206
			Mechanical Suspension Seat Disassemble and Assemble..................................................................................................................210
			Air Suspension Seat Disassemble and Assemble.........................................................................................................................212
			Left and Right Console Covers Remove and Install.....................................................................................................................213
		Heating and Air Conditioning.............................................................................................................................................221
			Refrigerant Cautions and Proper Handling.............................................................................................................................221
			Flush and Purge Air Conditioning System..............................................................................................................................222
			R134a Refrigerant Oil Information....................................................................................................................................224
			R134a Refrigerant Recovery, Recycling, and Charging Station Installation Procedure...................................................................................225
			R134a Compressor Oil Charge Check....................................................................................................................................226
			R134a Compressor Oil Removal.........................................................................................................................................226
			Recover R134a Refrigerant............................................................................................................................................227
			Evacuate R134a System................................................................................................................................................228
			Charge R134a System..................................................................................................................................................229
			Air Conditioner Compressor Remove and Install........................................................................................................................229
			Condenser Remove and Install.........................................................................................................................................231
			Heater and Air Conditioner Remove and Install........................................................................................................................232
			Heater and Air Conditioner Blower Motor Remove and Install...........................................................................................................238
			Receiver-Dryer Remove and Install....................................................................................................................................244
	Sheet Metal..................................................................................................................................................................245
		Hood and Engine Side Shield Remove and Install...........................................................................................................................247
			Hood Remove and Install..............................................................................................................................................247
			Engine Side Shield Remove and Install................................................................................................................................247
	Excavator....................................................................................................................................................................251
		Buckets..................................................................................................................................................................253
			Bucket Remove and Install............................................................................................................................................253
			Adjust Bucket Pivot End Play.........................................................................................................................................253
			Bucket Pin-Up Data...................................................................................................................................................254
		Frames...................................................................................................................................................................257
			Bucket Links Remove and Install......................................................................................................................................257
			Arm Remove and Install...............................................................................................................................................259
			Boom Remove and Install..............................................................................................................................................261
			Inspect Pins, Bushings, and Bosses—Front Attachment..................................................................................................................266
			Cylinder Specifications..............................................................................................................................................268
			Bushings and Seal Remove and Install.................................................................................................................................269
		Hydraulic System.........................................................................................................................................................271
			Apply Vacuum to Hydraulic Oil Tank...................................................................................................................................271
			General Hydraulic Oil Cleanup Procedure..............................................................................................................................271
			Hydraulic Component Failure Cleanup Procedure........................................................................................................................271
			Pump 1, 2, and 3 Remove and Install..................................................................................................................................272
			Pump 1, 2, and 3 Disassemble and Assemble............................................................................................................................278
			Pump 1, 2, and 3 Inspection..........................................................................................................................................293
			Pump 1, 2, and 3 Start-Up Procedure..................................................................................................................................296
			Pump 1, 2, and 3 Regulator Remove and Install........................................................................................................................297
			Pump 1, 2, and 3 Regulator Disassemble and Assemble..................................................................................................................298
			Pilot Pump Remove and Install........................................................................................................................................300
			Pilot Pump Disassemble and Assemble..................................................................................................................................302
			Pilot Pressure Regulating Valve and Filter Remove and Install........................................................................................................304
			Pilot Pressure Regulating Valve and Filter Disassemble and Assemble..................................................................................................305
			Pilot Shutoff Solenoid Valve Remove and Install......................................................................................................................306
			Pilot Shutoff Solenoid Valve Disassemble and Assemble................................................................................................................308
			Solenoid Valve Manifold Remove and Install...........................................................................................................................311
			Solenoid Valve Remove and Install—Power Dig (SG), Arm Regenerative (SC), Dig Regenerative (SF), Arm 1 Flow Control (SE), and Arm 2 Flow Control (SD) Valves..........312
			Solenoid Valve Disassemble and Assemble—Power Dig (SG), Arm Regenerative (SC), Dig Regenerative (SF), Arm 1 Flow Control (SE), and Arm 2 Flow Control (SD) Valves....313
			Pilot Valve (Left and Right) Remove and Install......................................................................................................................314
			Pilot Valve (Left and Right) Disassemble and Assemble................................................................................................................316
			Travel Pilot Valve Remove and Install................................................................................................................................322
			Travel Pilot Valve Disassemble and Assemble..........................................................................................................................324
			Pilot Signal Manifold Remove and Install.............................................................................................................................326
			Pilot Signal Manifold Disassemble and Assemble.......................................................................................................................328
			Control Valve Remove and Install.....................................................................................................................................331
			Control Valve Halves Disassemble and Assemble........................................................................................................................337
			Control Valve Front (6-Spool) Disassemble and Assemble...............................................................................................................340
			Control Valve Rear (6-Spool) Disassemble and Assemble................................................................................................................359
			Hydraulic Oil Tank Remove and Install................................................................................................................................373
			Hydraulic Oil Tank Disassemble and Assemble..........................................................................................................................378
			Restriction Valve Remove and Install.................................................................................................................................381
			Hydraulic Oil Cooler Bypass Valve Remove and Install.................................................................................................................383
			Boom Cylinder Remove and Install.....................................................................................................................................384
			Boom Cylinder Disassemble and Assemble...............................................................................................................................387
			Arm Cylinder Remove and Install......................................................................................................................................389
			Arm Cylinder Disassemble and Assemble................................................................................................................................391
			Bucket Cylinder Remove and Install...................................................................................................................................393
			Bucket Cylinder Disassemble and Assemble.............................................................................................................................395
			Hydraulic Cylinder Bleed Procedure...................................................................................................................................398
	Swing or Pivoting System.....................................................................................................................................................399
		Mechanical Drive Elements................................................................................................................................................401
			Swing Gear Case Remove and Install...................................................................................................................................401
			Swing Gear Case Disassemble and Assemble.............................................................................................................................403
			Upperstructure Remove and Install....................................................................................................................................408
			Swing Bearing Remove and Install.....................................................................................................................................411
			Swing Bearing Disassemble and Assemble...............................................................................................................................413
			Swing Bearing Upper Seal Install.....................................................................................................................................415
			Swing Bearing Lower Seal Install.....................................................................................................................................416
		Hydraulic System.........................................................................................................................................................417
			Center Joint Remove and Install......................................................................................................................................417
			Center Joint Disassemble and Assemble................................................................................................................................419
			Center Joint Air Test................................................................................................................................................420
			Swing Motor and Park Brake Remove and Install........................................................................................................................421
			Swing Motor and Park Brake Disassemble...............................................................................................................................424
			Swing Motor and Park Brake Inspection................................................................................................................................426
			Swing Motor and Park Brake Assemble..................................................................................................................................430
			Swing Motor and Park Brake Start-Up Procedure........................................................................................................................432
			Crossover Relief Valve and Make-Up Check Valve Remove and Install....................................................................................................432
			Make-Up Check Valve Disassemble and Assemble.........................................................................................................................434
			Swing Park Brake Check Valve and Orifice Remove and Install..........................................................................................................435
	Dealer Fabricated Tools......................................................................................................................................................439
		Dealer Fabricated Tools..................................................................................................................................................441
			DF1063 Lift Bracket..................................................................................................................................................441
			ST4920 Track Recoil Spring Disassembly and Assembly Tool.............................................................................................................443
			DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool......................................................................................................447
			DFT1110 Spacer.......................................................................................................................................................448
			DFT1130 Adapter......................................................................................................................................................449
			DFT1036A Travel Gear Case Nut Wrench.................................................................................................................................450
			DFT1109 Holding Bar..................................................................................................................................................451
			Center Joint (Rotary Manifold) Lifting Tool..........................................................................................................................452
			DFT1119 Pump Support.................................................................................................................................................453
			DFT1220 Swing Gear Case Nut Spanner Wrench...........................................................................................................................454
Page Number......................................................................................................................................................................  3
	Section 00...................................................................................................................................................................  5
		Group 0001...............................................................................................................................................................  7
		Group 0003............................................................................................................................................................... 23
	Section 01................................................................................................................................................................... 45
		Group 0130............................................................................................................................................................... 47
	Section 02................................................................................................................................................................... 83
		Group 0250............................................................................................................................................................... 85
		Group 0260............................................................................................................................................................... 95
	Section 04...................................................................................................................................................................103
		Group 0400...............................................................................................................................................................105
	Section 05...................................................................................................................................................................115
		Group 0510...............................................................................................................................................................117
		Group 0520...............................................................................................................................................................145
		Group 0530...............................................................................................................................................................147
		Group 0560...............................................................................................................................................................155
	Section 07...................................................................................................................................................................165
		Group 0752...............................................................................................................................................................167
	Section 17...................................................................................................................................................................169
		Group 1740...............................................................................................................................................................171
		Group 1749...............................................................................................................................................................173
	Section 18...................................................................................................................................................................175
		Group 1800...............................................................................................................................................................177
		Group 1810...............................................................................................................................................................189
		Group 1821...............................................................................................................................................................205
		Group 1830...............................................................................................................................................................221
	Section 19...................................................................................................................................................................245
		Group 1910...............................................................................................................................................................247
	Section 33...................................................................................................................................................................251
		Group 3302...............................................................................................................................................................253
		Group 3340...............................................................................................................................................................257
		Group 3360...............................................................................................................................................................271
	Section 43...................................................................................................................................................................399
		Group 4350...............................................................................................................................................................401
		Group 4360...............................................................................................................................................................417
	Section 99...................................................................................................................................................................439
		Group 9900...............................................................................................................................................................441

S.S 25/02/2025