John Deere 135G Excavator Repair Service Manual (TM14054X19)

tm14054x19 - 135G Excavator Technical Manual - Repair.pdf

Complete service repair manual for John Deere 135G Excavator, with all the shop information to maintain, diagnostic, repair, refurbish/rebuild like professional mechanics.

John Deere 135G Excavator workshop service & repair 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.
* 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.

PRODUCT DETAILS:
Total Pages: 836 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

tm14054x19 - 135G Excavator

Table of Contents

Foreword

Technical Information Feedback Form

Section 00: General Information

Group 0001: Safety

Recognize Safety Information

Follow Safety Instructions

Operate Only If Qualified

Wear Protective Equipment

Avoid Unauthorized Machine Modifications

Control Pattern Selector—If Equipped

Inspect Machine

Stay Clear of Moving Parts

Avoid High-Pressure Fluids

Avoid High-Pressure Oils

Work In Ventilated Area

Avoid Static Electricity Risk When Refueling

Prevent Fires

In Case of Machine Fire

Prevent Battery Explosions

Handle Chemical Products Safely

Handle Starting Fluid Safely

Decommissioning — Proper Recycling and Disposal of Fluids and Components

Exhaust Filter Ash Handling and Disposal

Prepare for Emergencies

Clean Debris from Machine

Add Cab Guarding for Special Uses

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

Inspect and Maintain ROPS

Travel Safely

Prevent Acid Burns

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

Clean Exhaust Filter Safely

Group 0003: Torque Values

Metric Bolt and Cap Screw Torque Values

Additional Metric Cap Screw Torque Values

Unified Inch Bolt and Cap Screw Torque Values

Service Recommendations for 37° Flare and 30° Cone Seat Connectors

Service Recommendations for O-Ring Boss Fittings

Service Recommendations for Flared Connections—Straight or Tapered Threads

Service Recommendations for Flat Face O-Ring Seal Fittings

O-Ring Boss Fittings In Aluminum Housing Service Recommendations—Excavators

O-Ring Face Seal Fittings With SAE Inch Hex Nut and Stud End for High-Pressure Service Recommendations

O-Ring Face Seal Fittings With Metric Hex Nut and Stud End for Standard Pressure Service Recommendations

O-Ring Face Seal Fittings With Metric Hex Nut and Stud End for High-Pressure Service Recommendations

Service Recommendations for Metric Series Four Bolt Flange Fitting

Service Recommendations For Inch Series Four Bolt Flange Fittings

Inch Series Four Bolt Flange Fitting for High-Pressure Service Recommendations

Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings

Service Recommendations For O-Ring Boss Fittings With Shoulder

Metric 24° O-Ring Seal DIN 20078 Service Recommendations

Section 01: Tracks

Group 0130: Track System

Track Roller Remove and Install

Track Roller Disassemble and Assemble

Track Roller Pressure Test

Track Carrier Roller Remove and Install

Metal Face Seals Repair

Track Shoe Remove and Install

Track Chain Remove and Install

Track Chain Disassemble and Assemble

Track Chain Repair to Replace Broken Part

Sprocket Remove and Install

Front Idler Remove and Install

Front Idler Disassemble and Assemble

Track Adjuster and Recoil Spring Remove and Install

Track Adjuster and Recoil Spring Disassemble and Assemble

Section 02: Axles, Differentials, and Suspension Systems

Group 0250: Axle Shaft, Bearings, and Reduction Gears

Travel Gear Case Remove and Install

Travel Gear Case Disassemble and Assemble

Group 0260: Hydraulic System

Travel Motor and Park Brake Remove and Install

Travel Motor and Park Brake Disassemble and Assemble

Park Brake Valve Disassemble and Assemble

Travel Motor and Park Brake Start-Up Procedure

Section 04: Engine

Group 0400: Removal and Installation

Engine Remove

Engine Install

Section 05: Engine Auxiliary System

Group 0510: Cooling Systems

Radiator Remove and Install

Hydraulic Oil Cooler Remove and Install

Charge Air Cooler Remove and Install

Fuel Cooler Remove and Install

Fan and Fan Guard Remove and Install

Coolant Surge Tank Remove and Install

Group 0530: External Exhaust Systems

Exhaust Tube Remove and Install

Exhaust Aftertreatment Assembly Remove and Install

Exhaust Aftertreatment Assembly Disassemble and Assemble

Diesel Exhaust Fluid (DEF) Tank Remove and Install

Diesel Exhaust Fluid (DEF) Tank Header Suction Screen Remove and Install

Diesel Exhaust Fluid (DEF) Header Remove and Install

Diesel Exhaust Fluid (DEF) Supply Module Remove and Install

Diesel Exhaust Fluid (DEF) Dosing Injector Remove and Install

Group 0560: External Fuel Supply Systems

Fuel Tank Remove and Install

Fuel Transfer Pump Install and Prime

Section 07: Damper Drive (Flex Coupling)

Group 0752: Elements

Damper Drive (Flex Coupling) Remove and Install

Section 17: Frame or Supporting Structure

Group 1740: Frame Installation

Welding on Machine

Group 1749: Chassis Weights

Counterweight Remove and Install

Section 18: Operator's Station

Group 1800: Removal and Installation

Cab Remove and Install

Group 1810: Operator Enclosure

Windshield Remove and Install

Windshield Disassemble and Assemble

Sliding Windows Remove and Install

Windowpane Dimensions

Windowpanes Remove and Install

Group 1821: Seat and Seat Belt

Seat Remove and Install

Seat Belt Remove and Install

Mechanical Suspension Seat Disassemble and Assemble

Air Suspension Seat Disassemble and Assemble

Group 1830: Heating and Air Conditioning

R134a Refrigerant Cautions and Proper Handling

R134a Refrigerant Oil Information

R134a Refrigerant Recovery, Recycling, and Charging Station Installation Procedure

Recover R134a Refrigerant

Flush and Purge Air Conditioning System

Evacuate R134a System

Charge R134a System

Air Conditioner Compressor Remove and Install

Condenser Remove and Install

Heater and Air Conditioner Remove and Install

Receiver-Dryer Remove and Install

Section 19: Sheet Metal

Group 1910: Hood and Engine Side Shields

Hood and Engine Side Shields Remove and Install

Section 32: Blade (If Equipped)

Group 3201: Blades

Blade Remove and Install

Group 3260: Hydraulic System

Blade Pump Remove and Install

Blade Pump Disassemble and Assemble

Blade Pump Pressure Relief Valve Remove and Install

Blade Control Valve Remove and Install

Blade Control Valve Disassemble and Assemble

Blade Cylinder Remove and Install

Blade Cylinder Disassemble and Assemble

Blade Pilot Control Valve Remove and Install

Blade Pilot Control Valve Disassemble and Assemble

Section 33: Excavator

Group 3302: Buckets

Bucket Remove and Install

Adjust Bucket Pivot End Play

Bucket Pin-Up Data

Group 3340: Frames

Bucket Links Remove and Install

Arm Remove and Install

Boom Remove and Install

Inspect Pins, Bushings, and Bosses—Front Attachment

Cylinder Specifications

Bushings and Seal Remove and Install

Group 3360: Hydraulic System

Apply Vacuum to Hydraulic Oil Tank

Pump 1 and 2 Remove and Install

Pump 1 and 2 Disassemble and Assemble

Pump 1 and 2 Inspection

Pump 1 and 2 Start-Up Procedure

Pump 1 and 2 Regulator Remove and Install

Pump 1 and 2 Regulator Disassemble and Assemble

Pilot Pump Remove and Install

Pilot Pump Disassemble and Assemble

Pilot Pressure Regulating Valve and Filter Remove and Install

Pilot Pressure Regulating Valve and Filter Disassemble and Assemble

Pilot Shutoff Solenoid Valve Remove and Install

Pilot Shutoff Solenoid Valve Disassemble and Assemble

Solenoid Valve Manifold Remove and Install

Solenoid Valve Remove and Install—Power Dig/Travel Speed (SG), Arm Regenerative (SC), Arm 2 Flow Control (SD), and Dig Regenerative (SF) Valves

Solenoid Valve Disassemble and Assemble—Power Dig/Travel Speed (SG), Arm Regenerative (SC), Arm 2 Flow Control (SD), and Dig Regenerative (SF) Valves

Pilot Valve (Left and Right) Remove and Install

Pilot Valve (Left and Right) Disassemble and Assemble

Travel Pilot Valve Remove and Install

Travel Pilot Valve Disassemble and Assemble

Pilot Signal Manifold Remove and Install

Pilot Signal Manifold Disassemble and Assemble

Control Valve Remove and Install

Control Valve Halves Disassemble and Assemble

Control Valve (Housing-A) Disassemble and Assemble

Control Valve (Housing-B) Disassemble and Assemble

Hydraulic Oil Tank Remove and Install

Restriction Valve Remove and Install

Hydraulic Oil Cooler Bypass Valve Remove and Install

Boom Cylinder Remove and Install

Boom Cylinder Disassemble and Assemble

Arm Cylinder Remove and Install

Arm Cylinder Disassemble and Assemble

Bucket Cylinder Remove and Install

Bucket Cylinder Disassemble and Assemble

Hydraulic Cylinder Bleed Procedure

Section 43: Swing or Pivoting System

Group 4350: Mechanical Drive Elements

Swing Gear Case Remove and Install

Swing Gear Case Disassemble and Assemble

Swing Gear Case Start-Up Procedure

Upperstructure Remove and Install

Swing Bearing Remove and Install

Swing Bearing Disassemble and Assemble

Swing Bearing Upper Seal Install

Swing Bearing Lower Seal Install

Group 4360: Hydraulic System

Center Joint Remove and Install

Center Joint Disassemble and Assemble

Center Joint Air Test

Swing Motor and Park Brake Remove and Install

Swing Motor and Park Brake Disassemble

Swing Motor and Park Brake Inspection

Swing Motor and Park Brake Assemble

Swing Motor and Park Brake Start-Up Procedure

Crossover Relief Valve and Make-Up Check Valve Remove and Install

Make-Up Check Valve Disassemble and Assemble

Section 99: Dealer Fabricated Tools

Group 9900: Dealer Fabricated Tools

DF1063 Lift Bracket

ST4920 Track Recoil Spring Disassembly and Assembly Tool

DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool

DFT1110 Spacer

DFT1130 Adapter

DFT1036A Travel Gear Case Nut Wrench

DFT1109 Holding Bar

Center Joint (Rotary Manifold) Lifting Tool

DFT1237 Swing Gear Case Nut Spanner Wrench