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John Deere 300GLC Excavator Repair Technical Manual TM13264X19 – PDF DOWNLOAD
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John Deere 300GLC Excavator Repair Technical Manual TM13264X19 – PDF DOWNLOAD
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Description
John Deere 300GLC Excavator Repair Technical Manual TM13264X19 – PDF DOWNLOAD
FILE DETAILS:
John Deere 300GLC Excavator Repair Technical Manual TM13264X19 – PDF DOWNLOAD
Language : English
Pages : 464
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
John Deere 300GLC Excavator Repair Technical Manual TM13264X19 – 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:
Contents.................................................................................................................................... 5 General Information..................................................................................................................... 7 Safety.............................................................................................................................. 9 Recognize Safety Information.................................................................................................... 9 Follow Safety Instructions...................................................................................................... 9 Operate Only If Qualified....................................................................................................... 9 Wear Protective Equipment....................................................................................................... 10 Avoid Unauthorized Machine Modifications........................................................................................ 10 Control Pattern Selector—If Equipped............................................................................................ 10 Add Cab Guarding for Special Uses............................................................................................... 10 Inspect Machine................................................................................................................. 11 Stay Clear of Moving Parts...................................................................................................... 11 Avoid High-Pressure Fluids...................................................................................................... 11 Avoid High-Pressure Oils........................................................................................................ 12 Work In Ventilated Area......................................................................................................... 12 Avoid Static Electricity Risk When Refueling.................................................................................... 13 Prevent Fires................................................................................................................... 13 In Case of Machine Fire......................................................................................................... 14 Prevent Battery Explosions...................................................................................................... 14 Handle Chemical Products Safely................................................................................................. 14 Decommissioning — Proper Recycling and Disposal of Fluids and Components........................................................ 15 Exhaust Filter Ash Handling and Disposal........................................................................................ 15 Prepare for Emergencies......................................................................................................... 15 Clean Debris from Machine....................................................................................................... 16 Use Steps and Handholds Correctly............................................................................................... 16 Start Only From Operator's Seat................................................................................................. 16 Use and Maintain Seat Belt...................................................................................................... 16 Prevent Unintended Machine Movement............................................................................................. 17 Avoid Work Site Hazards......................................................................................................... 17 Keep Riders Off Machine......................................................................................................... 18 Avoid Backover Accidents........................................................................................................ 18 Inspect and Maintain ROPS....................................................................................................... 18 Avoid Machine Tip Over.......................................................................................................... 19 Use Special Care When Lifting Objects........................................................................................... 19 Travel Safely................................................................................................................... 20 Add and Operate Attachments Safely.............................................................................................. 20 Park and Prepare for Service Safely............................................................................................. 20 Service Cooling System Safely................................................................................................... 21 Remove Paint Before Welding or Heating.......................................................................................... 21 Make Welding Repairs Safely..................................................................................................... 21 Drive Metal Pins Safely......................................................................................................... 22 Clean Exhaust Filter Safely..................................................................................................... 23 Torque Values....................................................................................................................... 25 Metric Bolt and Cap Screw Torque Values......................................................................................... 25 Additional Metric Cap Screw Torque Values....................................................................................... 26 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................................................................................ 28 Service Recommendations for Flared Connections—Straight or Tapered Threads...................................................... 30 Service Recommendations for Flat Face O-Ring Seal Fittings...................................................................... 31 O-Ring Boss Fittings In Aluminum Housing Service Recommendations—Excavators..................................................... 32 O-Ring Face Seal Fittings With SAE Inch Hex Nut and Stud End for High-Pressure Service Recommendations.......................... 33 O-Ring Face Seal Fittings With Metric Hex Nut and Stud End for Standard Pressure Service Recommendations........................ 35 O-Ring Face Seal Fittings With Metric Hex Nut and Stud End for High-Pressure Service Recommendations............................ 37 Service Recommendations for Metric Series Four Bolt Flange Fitting.............................................................. 39 Service Recommendations For Inch Series Four Bolt Flange Fittings............................................................... 40 Inch Series Four Bolt Flange Fitting for High-Pressure Service Recommendations.................................................. 41 Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings.......................................................... 42 Service Recommendations For O-Ring Boss Fittings With Shoulder.................................................................. 43 Metric 24° O-Ring Seal DIN 20078 Service Recommendations........................................................................ 45 Tracks.................................................................................................................................. 47 Track System........................................................................................................................ 49 Track Roller Remove and Install................................................................................................. 49 Track Roller Disassemble and Assemble........................................................................................... 51 Track Roller Pressure Test...................................................................................................... 53 Track Carrier Roller Remove and Install......................................................................................... 55 Metal Face Seals Repair......................................................................................................... 57 Track Shoe Remove and Install................................................................................................... 58 Track Chain Remove and Install.................................................................................................. 59 Track Chain Disassemble and Assemble............................................................................................ 64 Track Chain Repair to Replace Broken Part....................................................................................... 66 Sprocket Remove and Install..................................................................................................... 72 Front Idler Remove and Install.................................................................................................. 73 Front Idler Disassemble and Assemble............................................................................................ 74 Track Adjuster and Recoil Spring Remove and Install............................................................................. 76 Track Adjuster and Recoil Spring Disassemble and Assemble....................................................................... 77 Axles, Differentials, and Suspension Systems............................................................................................ 85 Axle Shaft, Bearings, and Reduction Gears........................................................................................... 87 Travel Gear Case Remove and Install............................................................................................. 87 Travel Gear Case Disassemble and Assemble....................................................................................... 90 Hydraulic System.................................................................................................................... 97 Travel Motor and Park Brake Remove and Install.................................................................................. 97 Travel Motor and Park Brake Disassemble and Assemble............................................................................ 98 Park Brake Valve Disassemble and Assemble.......................................................................................106 Travel Motor and Park Brake Start-Up Procedure..................................................................................108 Engine..................................................................................................................................109 Removal and Installation............................................................................................................111 Engine Remove...................................................................................................................111 Engine Install..................................................................................................................117 Engine Auxiliary System.................................................................................................................119 Cooling Systems.....................................................................................................................121 Radiator Remove and Install.....................................................................................................121 Hydraulic Oil Cooler Remove and Install.........................................................................................122 Charge Air Cooler Remove and Install............................................................................................124 Fuel Cooler Remove and Install..................................................................................................125 Cooling Package Remove and Install..............................................................................................126 Fan and Fan Guard Remove and Install............................................................................................131 Coolant Surge Tank Remove and Install...........................................................................................134 External Exhaust Systems............................................................................................................137 Exhaust Tube Remove and Install.................................................................................................137 JDG11335 Bellows Alignment Fixture..............................................................................................138 Exhaust Bellows Alignment Procedure.............................................................................................143 Diesel Particulate Filter (DPF) Remove and Install..............................................................................146 Selective Catalyst Reduction (SCR) Remove and Install...........................................................................149 Diesel Oxidation Catalyst (DOC) Remove and Install..............................................................................152 Exhaust Aftertreatment Assembly Remove and Install..............................................................................155 Diesel Exhaust Fluid (DEF) Tank Remove and Install..............................................................................157 Diesel Exhaust Fluid (DEF) Tank Header Remove and Install.......................................................................160 Diesel Exhaust Fluid (DEF) Tank Header Disassemble and Assemble.................................................................161 Diesel Exhaust Fluid (DEF) Tank Cleaning Procedure..............................................................................162 Diesel Exhaust Fluid (DEF) Dosing Unit Remove and Install.......................................................................163 Diesel Exhaust Fluid (DEF) Dosing Injector Remove and Install...................................................................172 Diesel Exhaust Fluid (DEF) Decomposition Tube Remove and Install................................................................173 External Fuel Supply Systems........................................................................................................175 Fuel Tank Remove and Install....................................................................................................175 Damper Drive (Flex Coupling)............................................................................................................179 Elements............................................................................................................................181 Damper Drive (Flex Coupling) Remove and Install.................................................................................181 Frame or Supporting Structure...........................................................................................................183 Frame Installation..................................................................................................................185 Welding on Machine..............................................................................................................185 Chassis Weights.....................................................................................................................187 Counterweight Remove and Install................................................................................................187 Operator's Station......................................................................................................................189 Removal and Installation............................................................................................................191 Cab Remove and Install..........................................................................................................191 Operator Enclosure..................................................................................................................199 Windshield Remove and Install...................................................................................................199 Windshield Disassemble and Assemble.............................................................................................200 Sliding Windows Remove and Install..............................................................................................205 Windowpanes Remove and Install..................................................................................................205 Windowpanes Dimensions..........................................................................................................206 Seat and Seat Belt..................................................................................................................215 Seat Remove and Install.........................................................................................................215 Seat Belt Remove and Install....................................................................................................216 Mechanical Suspension Seat Disassemble and Assemble.............................................................................219 Air Suspension Seat Disassemble and Assemble....................................................................................224 Premium Air Suspension Seat Disassemble and Assemble............................................................................228 Heating and Air Conditioning........................................................................................................235 R134a Refrigerant Cautions and Proper Handling..................................................................................235 R134a Refrigerant Oil Information...............................................................................................236 R134a Refrigerant Recovery, Recycling, and Charging Station Installation Procedure..............................................237 Recover R134a Refrigerant.......................................................................................................237 Flush and Purge Air Conditioning System.........................................................................................238 Evacuate R134a System...........................................................................................................240 Charge R134a System.............................................................................................................241 Air Conditioner Compressor Remove and Install...................................................................................242 Condenser Remove and Install....................................................................................................243 Heater and Air Conditioner Remove and Install...................................................................................244 Receiver-Dryer Remove and Install...............................................................................................247 Sheet Metal and Styling.................................................................................................................249 Hood or Engine Enclosure............................................................................................................251 Hood and Engine Side Shields Remove and Install.................................................................................251 Excavator...............................................................................................................................255 Buckets.............................................................................................................................257 Bucket Remove and Install.......................................................................................................257 Adjust Bucket Pivot End Play....................................................................................................257 Bucket Pin-Up Data..............................................................................................................258 Frames..............................................................................................................................261 Bucket Links Remove and Install.................................................................................................261 Arm Remove and Install..........................................................................................................263 Boom Remove and Install.........................................................................................................265 Inspect Pins, Bushings, and Bosses—Front Attachment.............................................................................271 Cylinder Specifications.........................................................................................................273 Bushings and Seal Remove and Install............................................................................................274 Hydraulic System....................................................................................................................275 Apply Vacuum to Hydraulic Oil Tank..............................................................................................275 Pump 1 and 2 Remove and Install.................................................................................................276 Pump 1 and 2 Disassemble and Assemble...........................................................................................279 Pump Gear Case Disassemble and Assemble.........................................................................................286 Pump 1 and 2 Inspection.........................................................................................................288 Pump 1 and 2 Start-Up Procedure.................................................................................................291 Pump 1 and 2 Regulator Remove and Install.......................................................................................292 Pump 1 and 2 Regulator Disassemble and Assemble.................................................................................294 Pilot Pump Remove and Install...................................................................................................296 Pilot Pump Disassemble and Assemble.............................................................................................298 Pilot Pressure Regulating Valve and Filter Remove and Install...................................................................300 Pilot Pressure Regulating Valve and Filter Disassemble and Assemble.............................................................301 Pilot Shutoff Solenoid Valve Remove and Install.................................................................................302 Pilot Shutoff Solenoid Valve Disassemble and Assemble...........................................................................303 Fan Drive Pump Remove and Install...............................................................................................305 Fan Drive Motor Remove and Install..............................................................................................306 Fan Drive Motor Disassemble and Assemble........................................................................................307 Fan Drive Motor Solenoid Valves Remove and Install..............................................................................310 Solenoid Valve Remove and Install—Power Dig/Travel Speed (SG), Arm Regenerative (SC), and Dig Regenerative (SF) Valves..........311 Solenoid Valve Disassemble and Assemble—Power Dig/Travel Speed (SG), Arm Regenerative (SC), and Dig Regenerative (SF) 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 Single Pedal Travel Pilot Valve Remove and Install..............................................................................327 Single Pedal Travel Pilot Valve Disassemble and Assemble........................................................................329 Pilot Signal Manifold Remove and Install........................................................................................330 Pilot Signal Manifold Disassemble and Assemble..................................................................................332 Control Valve Remove and Install................................................................................................335 Control Valve Halves Disassemble and Assemble...................................................................................339 Control Valve (5-Spool) Disassemble and Assemble................................................................................341 Control Valve (4-Spool) Disassemble and Assemble................................................................................355 Hydraulic Oil Tank Remove and Install...........................................................................................367 Restriction Valve Remove and Install............................................................................................371 Hydraulic Oil Cooler Bypass Valve Remove and Install............................................................................372 Boom Cylinder Remove and Install................................................................................................373 Boom Cylinder Disassemble and Assemble..........................................................................................376 Arm Cylinder Remove and Install.................................................................................................379 Arm Cylinder Disassemble and Assemble...........................................................................................381 Bucket Cylinder Remove and Install..............................................................................................384 Bucket Cylinder Disassemble and Assemble........................................................................................386 Hydraulic Cylinder Bleed Procedure..............................................................................................389 Swing or Pivoting System................................................................................................................391 Mechanical Drive Elements...........................................................................................................393 Swing Gear Case Remove and Install..............................................................................................393 Swing Gear Case Disassemble and Assemble........................................................................................395 Swing Gear Case Start-Up Procedure..............................................................................................406 Upperstructure Remove and Install...............................................................................................407 Swing Bearing Remove and Install................................................................................................410 Swing Bearing Disassemble and Assemble..........................................................................................412 Swing Bearing Upper Seal Install................................................................................................416 Swing Bearing Lower Seal Install................................................................................................417 Hydraulic System....................................................................................................................419 Center Joint Remove and Install.................................................................................................419 Center Joint Disassemble and Assemble...........................................................................................422 Center Joint Air Test...........................................................................................................423 Swing Motor and Park Brake Remove and Install...................................................................................424 Swing Motor and Park Brake Disassemble..........................................................................................426 Swing Motor and Park Brake Inspection...........................................................................................428 Swing Motor and Park Brake Assemble.............................................................................................432 Swing Motor and Park Brake Start-Up Procedure...................................................................................434 Crossover Relief Valve and Make-Up Check Valve Remove and Install...............................................................435 Make-Up Check Valve Disassemble and Assemble....................................................................................437 Swing Park Brake Check Valve and Orifice Remove and Install.....................................................................438 Dealer Fabricated Tools.................................................................................................................439 Dealer Fabricated Tools.............................................................................................................441 DF1037 Hydraulic Pump Torque Adapter............................................................................................441 DF1063 Lift Bracket.............................................................................................................442 ST4920 Track Recoil Spring Disassembly and Assembly Tool........................................................................444 DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool.................................................................448 DFT1110 Spacer..................................................................................................................449 DFT1130 Adapter.................................................................................................................450 DFT1036A Travel Gearbox Nut Wrench..............................................................................................451 DFT1109 Holding Bar.............................................................................................................452 DFT1119 Pump Support............................................................................................................453 DFT1351 Swing Gear Case Nut Spanner Wrench......................................................................................454 Center Joint (Rotary Manifold) Lifting Tool.....................................................................................455 DF1038 Torque Adapter...........................................................................................................456 DFT1144 Guide Pin...............................................................................................................456 Page Number................................................................................................................................. 5 Section 00.............................................................................................................................. 7 Group 0001.......................................................................................................................... 9 Group 0003.......................................................................................................................... 25 Section 01.............................................................................................................................. 47 Group 0130.......................................................................................................................... 49 Section 02.............................................................................................................................. 85 Group 0250.......................................................................................................................... 87 Group 0260.......................................................................................................................... 97 Section 04..............................................................................................................................109 Group 0400..........................................................................................................................111 Section 05..............................................................................................................................119 Group 0510..........................................................................................................................121 Group 0530..........................................................................................................................137 Group 0560..........................................................................................................................175 Section 07..............................................................................................................................179 Group 0752..........................................................................................................................181 Section 17..............................................................................................................................183 Group 1740..........................................................................................................................185 Group 1749..........................................................................................................................187 Section 18..............................................................................................................................189 Group 1800..........................................................................................................................191 Group 1810..........................................................................................................................199 Group 1821..........................................................................................................................215 Group 1830..........................................................................................................................235 Section 19..............................................................................................................................249 Group 1910..........................................................................................................................251 Section 33..............................................................................................................................255 Group 3302..........................................................................................................................257 Group 3340..........................................................................................................................261 Group 3360..........................................................................................................................275 Section 43..............................................................................................................................391 Group 4350..........................................................................................................................393 Group 4360..........................................................................................................................419 Section 99..............................................................................................................................439 Group 9900..........................................................................................................................441
S.S 24/02/2025
