John Deere 120C Excavator Technical Manual - Operation & Test (TM1934)

TM1934 - John Deere 120C Excavator Operation & Test Service Manual.pdf

Complete Technical Diagnostic, Operation and Test Manual with Electrical Wiring Diagrams for John Deere 120C Excavators, with all the shop information to maintain, diagnose, service, rebuild like professional mechanics.

John Deere Excavator 120C workshop Diagnosis & Test manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

Total Pages: 629 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

MAIN SECTIONS
Foreword
   Technical Information Feedback Form
   General Information
      Safety
   Diagnostics
      Main Controller (MCZ) Diagnostic Trouble Codes
      Engine Control Unit (ECU) Diagnostic Trouble Codes
      Monitor Controller (DSZ) Diagnostic Trouble Codes
      Air Conditioner Controller (ACF) Diagnostic Trouble Codes
   Operational Checkout Procedure
      Operational Checkout Procedure
   Engine
      Theory of Operation
      Diagnostic Information
      Adjustments
      Tests
   Electrical System
      System Information
      System Diagrams
      Sub-System Diagnostics
      Monitor Operation
      References
   Power Train
      Theory of Operation
      Diagnostic Information
   Hydraulic System
      Theory of Operation
      Diagnostic Information
      Tests
   Heating and Air Conditioning
      Theory of Operation
      Diagnostic Information
      Tests
   Dealer Fabricated Tools

tm1934 - 120C Excavator

Table of Contents

Foreword

Technical Information Feedback Form

Section 9000: General Information

Group 01: Safety

Recognize Safety Information

Follow Safety Instructions

Operate Only If Qualified

Wear Protective Equipment

Avoid Unauthorized Machine Modifications

Add Cab Guarding for Special Uses

Inspect Machine

Stay Clear of Moving Parts

Avoid High-Pressure Oils

Beware of Exhaust Fumes

Prevent Fires

Prevent Battery Explosions

Handle Chemical Products Safely

Dispose of Waste Properly

Prepare for Emergencies

Use Steps and Handholds Correctly

Start Only From Operator's Seat

Use and Maintain Seat Belt

Prevent Unintended Machine Movement

Avoid Work Site Hazards

Keep Riders Off Machine

Avoid Backover Accidents

Avoid Machine Tip Over

Use Special Care When Lifting Objects

Add and Operate Attachments Safely

Park and Prepare for Service Safely

Service Cooling System Safely

Remove Paint Before Welding or Heating

Make Welding Repairs Safely

Drive Metal Pins Safely

Section 9005: Operational Checkout Procedure

Group 10: Operational Checkout Procedure

Operational Checkout

Section 9010: Engine

Group 05: Theory of Operation

Engine Speed Control System Operation

Group 15: Diagnostic Information

Diagnose Engine Malfunctions

Group 25: Tests

Engine Speed Test

Fuel Line Leakage Test

Engine Power Test Using Turbocharger Boost Pressure

Section 9015: Electrical System

Group 05: System Information

Electrical Diagram Information

Group 10: System Diagrams

Explanation of Wire Markings

Fuse Specifications

Functional Schematic, Wiring Diagram, and Component Location Master Legend

System Functional Schematic

Overall Machine Harnesses Component Location

Cab Harness (W1) Component Location

Cab Harness (W1) Wiring Diagram

Machine Harness (W2) Component Location

Machine Harness (W2) Wiring Diagram

Monitor Harness (W3) Component Location

Monitor Harness (W3) Wiring Diagram

Air Conditioner Harness (W9) Component Location

Air Conditioning Harness (W9) Wiring Diagram

Pump Harness (W12) Component Location

Pump Harness (W12) Wiring Diagram

Engine Control Unit Harness (W19) Component Location

Engine Control Unit Harness (W19) Wiring Diagram

Engine Harness (W20) Component Location

Engine Harness (W20) Wiring Diagram

Group 15: Sub-System Diagnostics

Starting and Charging Circuit Theory of Operation

Monitor Controller and Display Circuit Theory of Operation

Engine Control Unit Circuit Theory of Operation

Propel Alarm Circuit Theory of Operation

Pump and Valve Controller Circuit Theory of Operation

Windshield Wiper and Washer Circuit Theory of Operation

Air Conditioner Controller Circuit Theory of Operation

Group 20: References

Excavator Diagnostic Program General Description and Overview

Monitor Data Items

Reading Pump and Valve Controller Diagnostic Trouble Codes Without Laptop Computer

Pump and Valve Controller Diagnostic Trouble Codes

Reading Engine Diagnostic Trouble Codes Without Laptop Computer

Engine Diagnostic Trouble Codes

Monitor Controller And Display Diagnostic System Operation

Alternator Test Procedure

Fuse Test

Relay Test

Pressure Sensor Test

Solenoid Test

Temperature Sensor Test

Speed Sensor Test

Electrical Component Checks

Engine Control Unit Remove and Install

Pump and Valve Controller Remove and Install

Battery Remove and Install

Propel Alarm Cancel Switch Remove and Install

Key Switch Remove and Install

Propel Alarm Remove and Install

Windshield Wiper Enable Switch Remove and Install

Rear Cover Remove and Install

Switch Panel (A4) Remove and Install

Monitor Controller and Display (A5) Remove and Install

Disconnect Tab Retainer Connectors

Disconnecting Spring Wire Clip Connectors

Replace DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Connectors

Install DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Contacts

Replace WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Connector

Install WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Contacts

Remove Connector Body from Blade Terminals

Section 9020: Power Train

Group 05: Theory of Operation

Track Adjuster and Recoil Spring Operation

Propel Gearbox Operation

Group 15: Diagnostic Information

Diagnose Undercarriage Components Malfunctions

Measure Swing Bearing Wear

Section 9025: Hydraulic System

Group 05: Theory of Operation

Hydraulic System Diagram and Operation

Pilot System Diagram and Operation

Pilot Pump, Pressure Regulating Valve, and Filter Operation

Pilot Shut-Off Valve Operation

Pilot Controller Operation

Propel Pilot Controller Operation

Pilot Operation of Control Valve Operation

Pilot Signal Manifold Operation

Hydraulic Pump Operation

Hydraulic Pump Regulator Operation

Engine Speed Sensing Control Circuit Operation

Control Valve Operation

Control Valve Check Valves Identification and Operation

System Relief Valve Operation

Circuit Relief and Anti-Cavitation Valve Operation

Propel Flow Combiner Valve Operation

Auxiliary Flow Combiner Valve and Bypass Shut-Off Valve Operation

Arm Regenerative Valve Circuit Operation

Bucket and Boom Regenerative Valve Circuit Operation

Boom and Arm Reduced Leakage Valves Operation

Bucket and Auxiliary Flow Rate Valve Circuit Operation

Propel and Arm In Combined Operation

Swing and Boom Up Combined Operation

Swing Gearbox Operation

Swing Motor, Crossover Relief, Cushion, and Make-Up Valve Operation

Swing Motor Park Brake Release Circuit Operation

Backfill Blade Circuit Operation

Rotary Manifold With Backfill Blade Function Operation

Rotary Manifold Operation

Propel Motor and Valve Housing Operation

Propel Motor Speed Circuit Operation

Hydraulic Cylinder Operation

Hydraulic System Circuit Symbols

Hydraulic System Schematic

Group 15: Diagnostic Information

Diagnose Hydraulic System Malfunctions

Diagnose Pilot Circuit Malfunctions

Diagnose Dig Circuit Malfunctions

Diagnose Swing Circuit Malfunctions

Diagnose Propel System Malfunctions

Control Valve and Solenoid Valve Manifold Line Identification

Swing Motor Line Identification

Pump 1, Pump 2, and Pilot Pump Line Identification

Propel Hydraulic System Line Identification

Pilot Controllers-to-Pilot Signal Manifold Component Location—Excavator Pattern

Pilot Controllers-to-Pilot Signal Manifold Component Location—Backhoe Pattern

Pilot Signal Manifold-to-Control Valve Component Location

Backfill Blade Hydraulic System Component Location

Group 25: Tests

JT05801 Clamp-On Electronic Tachometer Installation

JT05800 Digital Thermometer Installation

JT02156A Digital Pressure/Temperature Analyzer Installation

Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy

Hydraulic System Warm-Up Procedure

Cylinder Drift Test—Arm, Boom, and Bucket

Pilot Pressure Regulating Valve Test and Adjustment

Control Valve Spool Actuating Pilot Pressure Test

System Relief Valve Test and Adjustment

Circuit Relief Valve Test and Adjustment

Backfill Blade System Relief Valve Test and Adjustment

Backfill Blade Circuit Relief Valve Test and Adjustment

Swing Motor Crossover Relief Valve Test and Adjustment

Propel Motor Crossover Relief Valve Test and Adjustment

Propel Speed and Arm Regenerative Solenoid Valve Test and Adjustment

Hydraulic Pump Regulator Test and Adjustment—Minimum Flow

Hydraulic Pump Regulator Test and Adjustment—Maximum Flow

Hydraulic Pump Regulator Test and Adjustment—Engine Pulldown

Hydraulic Pump Flow Test

Swing Motor Leakage Test

Propel Motor Leakage Test

Section 9031: Heating and Air Conditioning

Group 05: Theory Of Operation

Air Conditioning System Cycle Of Operation

Group 15: Diagnostic Information

Diagnose Air Conditioning System Malfunctions

Diagnose Heater System Malfunctions

Diagnose Air Conditioning Diagnostic Trouble Codes

Heating and Air Conditioning Component Location Diagram

Group 25: Tests

Heating and Air Conditioning System Checks

R134a Air Conditioning System Test

Air Conditioning Compressor Clutch Test

Refrigerant Leak Test

Refrigerant Hoses and Tubing Inspection

Air Conditioner Compressor Belt Test and Adjustment

Fresh Air Filter and Recirculating Air Filter Remove and Install

Section 9900: Dealer Fabricated Tools

Group 99: Dealer Fabricated Tools

DFT1236 Split Flange Hose Cap