Part of the John Deere Repair Manuals.
This 408-page John Deere 200D, 200DLC Repair Manual (OEM #TM10079) walks you through every system on your excavator, from tracks and travel gearboxes to the swing bearing and boom hydraulics. You get a full torque values section covering metric and inch bolt specs plus O-ring boss fitting charts, exploded views for parts identification, and step-by-step procedures for pump, control valve, and travel motor work. Torque the O-ring boss straight fitting stud end nut to 39 N-m in aluminum housing, and set the pump regulator-to-housing cap screws to 49 N-m. No more flipping through a shop binder trying to find the right spanner wrench spec for the swing gearbox nut. This PDF carries bookmarks for every section and a real text layer, so you search by keyword, jump straight to the procedure, and get your 200D or 200DLC back to work instead of guessing.
What's Inside This John Deere 200D, 200DLC Repair Manual
| System | Pages | Key Topics |
|---|---|---|
| General Information | 9-44 | Safety, Torque Values, Metric Bolt and Cap Screw Torque Values, Unified Inch Bolt and Cap Screw Torque Values, O-Ring Boss Fittings, O-Ring Face Seal Fittings |
| Tracks | 45-78 | Track Roller, Track Carrier Roller, Metal Face Seals, Track Shoe, Track Chain, Sprocket |
| Axles, Differentials and Suspension Systems | 79-112 | Travel Gearbox, Travel Motor and Park Brake, Counterbalance Valve, Crossover Relief Valve, Make-Up Check Valve, Travel Speed Selector Valve |
| Engine | 113-124 | Engine Remove and Install |
| Engine Auxiliary System | 125-158 | Radiator, Hydraulic Oil Cooler, Intercooler, Fuel Cooler, Cooling Package, Air Cleaner |
| Dampener Drive (Flex Coupling) | 159-162 | - |
| Frame or Supporting Structure | 163-170 | Welding on Machine, Welding Repair of Major Structure, Counterweight |
| Operator's Station | 171-212 | Cab, Sliding Windows, Windowpanes, Seat, Seat Belt, Heating and Air Conditioning |
| Excavator | 213-340 | Buckets, Frames, Hydraulic System |
| Swing or Pivoting System | 341 | Mechanical Drive Elements, Hydraulic System |
| Dealer Fabricated Tools | 8 | DF1063 Lift Bracket, ST4920 Track Recoil Spring Disassembly and Assembly Tool, DFT1110 Spacer, DFT1130 Adapter, DFT1119 Pump Support, DFT1220 Swing Gearbox Nut Spanner Wrench |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Torque for Straight Fitting or Special Nut | 8 N·m (6 lb-ft) | p. 32 |
| O-RING BOSS STRAIGHT OR ADJUSTABLE FITTING STUD END NUT WITH METRIC THREAD IN ALUMINUM HOUSING TORQUE VALUES | 39 N·m (29 lb-ft) | p. 32 |
| TORQUE CHART Straight Thread | 15 N·m (11 lb-ft) | p. 36 |
| Pump 1 (Front) and Pump 2 (Rear) Regulator-to-Pump Housing Cap Screw-Torque | 49 N•m 36 lb-ft | p. 259 |
| Plug-to-housing-Torque | 50 N•m 37 lb-ft | p. 268 |
| Pilot Shutoff Valve Housing-to-Cab Platform Cap Screw-Torque | 50 N•m 37 lb-ft | p. 269 |
| Metric Bolt and Cap Screw Torque (M6, Class 12.9, Lubricated) | 15.5 N•m (11.5 lb-ft) | p. 25 |
| Metric Bolt and Cap Screw Torque (M10, Class 12.9, Lubricated) | 75 N•m (55 lb-ft) | p. 25 |
| Metric Bolt and Cap Screw Torque (M16, Class 12.9, Lubricated) | 320 N•m (235 lb-ft) | p. 25 |
| Track Roller Oil Cavity Pressure | 110 ± 28 kPa (16 ± 4 psi) | p. 51 |
John Deere 200D, 200DLC Common Problems This Manual Covers
John Deere 200D hydraulic oil leak from flared fitting that worsens after tightening
Inspect the O-ring boss seat for damage. Replace the defective fitting immediately rather than overtightening. Install the new straight thread fitting and torque it to exactly 15 N·m (11 lb-ft) as detailed on page 36. Clean the surrounding area and recheck for leaks.
Manual Section: General Information p. 36Boom cylinder hydraulic hose leaking oil heavily during operation
Remove the damaged line immediately per safety protocols. Install the replacement 36mm boom cylinder hose fitting. Torque the connection to 175 N·m (130 lb-ft) using a calibrated wrench as specified on page 319. Check the hydraulic tank capacity and top off if necessary.
Manual Section: Excavator p. 319Pilot control shutoff valve leaking fluid into the cab platform area
Check the shutoff solenoid valve housing plug for signs of fluid bypass. Remove the plug and inspect the threads. Install a new plug and torque it to 28 N·m (246 lb-in) as directed on page 271. Verify the housing is dry before returning to service.
Manual Section: Excavator p. 271Spongy boom operation or uncommanded drift after hydraulic cylinder replacement
Bleed air from the hydraulic cylinders following the procedure on page 340. Run the engine at slow idle. Slowly extend and retract the cylinder several times to approximately 100 mm (4 in) from the end of its stroke before operating to full stroke.
Manual Section: Excavator p. 340Frequently Asked Questions
What are the torque specifications for John Deere 200D engine mounting bolts?
The manual provides specific torque values for engine mounting hardware. For engine mount cap screws, the torque is 108 N•m (80 lb-ft). For engine isolator cap screws, the torque is 392 N•m (289 lb-ft). These values are for general use unless a different procedure is specified for a particular application. p. 123
What is the approximate capacity of the hydraulic oil tank for the John Deere 200D excavator?
The approximate capacity of the hydraulic oil tank is 135 L (36 gal). This information is relevant for draining and refilling the tank during various service procedures, such as when removing the travel gearbox or hydraulic pump. p. 81
What is the approximate capacity of the cooling system for the John Deere 200D excavator?
The approximate capacity of the cooling system is 26 L (6.9 gal). This specification is important for proper coolant draining and refilling procedures, such as during engine removal or radiator service. p. 115
What is the approximate weight of the swing bearing for the John Deere 200D excavator?
The approximate weight of the swing bearing is 226 kg (500 lb). This weight specification is important for using appropriate lifting devices during removal and installation to prevent injury. p. 356
What is the torque specification for the cap screws connecting the swing bearing to the upperstructure?
The cap screws connecting the swing bearing to the upperstructure should be tightened to a torque of 510 N•m (380 lb-ft). This ensures proper installation and secure fastening of the swing bearing during reassembly. p. 355
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