John Deere 135G Excavator Operator's Manual (OMT382334X19)

omt382334x19 - 135G Excavator Operator's Manual.pdf

Complete Operator's Manual for John Deere 135G Excavator, with all the shop information to maintain & operate your Excavator.

Total Pages: 649 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

omt382334x19 - 135G Excavator

Table of Contents

Foreword

Manual Identification—READ THIS FIRST!

IMPORTANT

License Agreement for John Deere Software

Non-Road Diesel Engine Emission Control System Warranty Statement

Off-Road Compression-Ignition Engines CALIFORNIA EMISSIONS CONTROL WARRANTY STATEMENT

FCC Notifications to User

John Deere Online Bookstore

Technical Information Feedback Form

Section 1-1: Safety—Safety and Operator Conveniences

Safety and Operator Convenience Features

Section 1-2: Safety—General Precautions

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

Section 1-3: Safety—Operating Precautions

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

Section 1-4: Safety—Maintenance Precautions

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

Section 1-5: Safety—Safety Signs and Other Instructions

Safety Signs and Other Instructions

Safety Signs Installed on Hydraulic Coupler—If Equipped

Section 2-1: Operation—Operator's Station

Pedals, Levers, and Panels

Switch Panel

Switch Panel Functions

Rear Left Panel

Rear Right Panel

Horn

Power Dig Button

Pilot Shutoff Lever

Engine Stop Switch

Left Console

Travel Alarm and Travel Alarm Cancel Switch

Auxiliary Function Enable Switch

Rear Light Switch—If Equipped

Right Console

Aftertreatment Device Regeneration Switch

Right Enable Switch

Cab Heater and Air Conditioner

Selecting Display Between Celsius and Fahrenheit

Operating the AM/FM Radio

Fire Extinguisher Mounting Location

Alternative Exit Tool

Cab Dome Light Switch

Opening Upper Front (Alternative Exit) Window

Removing and Storing the Lower Front Window

Opening Cab Door Window

Opening and Closing the Polycarbonate-Type Roof Exit Cover

Adjusting the Mechanical Suspension Seat

Adjusting the Air Suspension Seat—If Equipped

Adjusting Pilot Control Lever Console Height

Section 2-2: Operation—Monitor Operation

Monitor

Monitor Functions

Aftertreatment Indicators Overview

Monitor Start-Up

Main Menu

Main Menu—Alarm List

Main Menu—Air Conditioner

Main Menu—Radio

Main Menu—Work Mode

Main Menu—Setting Menu

Main Menu—Setting Menu—Date and Time

Main Menu—Setting Menu—Attachment Name Input

Main Menu—Setting Menu—Auto-Shutdown

Main Menu—Setting Menu—Aftertreatment Device Regeneration Inhibit

Main Menu—Setting Menu—Sub Meter Selection

Main Menu—Setting Menu—Rear View Camera Monitor

Main Menu—Setting Menu—Display Item Selection

Main Menu—Setting Menu—Brightness Adjustment

Main Menu—Setting Menu—Language

Main Menu—Setting Menu—Unit Selection

Main Menu—Setting Menu—Main Menu Sequence Change

Main Menu—Information Menu

Main Menu—Information Menu—Operation

Main Menu—Information Menu—Maintenance

Main Menu—Information Menu—Troubleshooting

Main Menu—Information Menu—Monitoring

Section 2-3: Operation—Operating the Machine

Before Starting Work

Inspect Machine Daily Before Starting

Battery Disconnect Switch

Engine Break-In Period

Starting Engine

Cold Weather Start Aid

Cold Weather Warm-Up

Required Machine Stop Warning

Travel Pedals and Levers

Auxiliary Function Lever (AFL)—If Equipped

Aftertreatment Device

Aftertreatment Device Regeneration

Selective Catalytic Reduction (SCR) System Overview

Locking the Hydraulic Coupler to the Attachment—If Equipped

Unlocking the Hydraulic Coupler From the Attachment—If Equipped

Control Lever Pattern Operation

Mechanical Control Lever Pattern Selector—If Equipped

Control Lever Pattern Conversion

Operating Blade—If Equipped

Operating in Water and Mud

Driving Up a Steep or Slippery Slope

Lifting With Bucket Loop

Lifting With John Deere Quick Coupler

Lower Boom With Engine Stopped

Parking the Machine

Loading and Unloading for Transport

Long Arm Setup for Transport or Operation—If Equipped

Towing Machine a Short Distance

Lifting the Machine

Section 3-1: Maintenance—Machine

Required Emission-Related Information

Diesel Fuel

Diesel Fuel Specifications

Lubricity of Diesel Fuel

Handling and Storing Diesel Fuel

Biodiesel Fuel

Testing Diesel Fuel

Supplemental Diesel Fuel Additives

Fuel Filters

Diesel Exhaust Fluid (DEF) — Use in Selective Catalytic Reduction (SCR) Equipped Engines

Refilling Diesel Exhaust Fluid (DEF) Tank

Testing Diesel Exhaust Fluid (DEF)

Storing Diesel Exhaust Fluid (DEF)

Disposal of Diesel Exhaust Fluid (DEF)

Minimizing the Effect of Cold Weather on Diesel Engines

John Deere Break-In Plus™ Engine Oil—Interim Tier 4, Final Tier 4, Stage IIIB, and Stage IV

Diesel Engine Oil — Interim Tier 4, Final Tier 4, Stage IIIB, and Stage IV

Engine Oil and Filter Service Intervals — Interim Tier 4, Final Tier 4, Stage IIIB, and Stage IV Engines

Diesel Engine Oil Service Interval for Operation at High Altitude

Oil Filters

Diesel Engine Coolant (engine with wet sleeve cylinder liners)

Water Quality for Mixing with Coolant Concentrate

Operating in Warm Temperature Climates

Testing Coolant Freeze Point

Disposing of Coolant

Alternative and Synthetic Lubricants

Lubricant Storage

Mixing of Lubricants

Hydraulic Oil

Swing Gear Case and Travel Gear Case Oils

Track Adjuster, Working Tool Pivot, Swing Bearing, and Swing Bearing Gear Grease

Section 3-2: Maintenance—Periodic Maintenance

Service Machine at Specified Intervals

Check the Hour Meter Regularly

Prepare Machine for Maintenance

Open Access Doors for Service

Open Engine Cover for Service

Fuel Tank

Hydraulic Breaker and Crusher Attachments

Fluid Analysis Program Test Kits and 3-Way Coolant Test Kit

Service Intervals

Required Parts

Section 3-3: Maintenance—As Required

Remove and Clean Fuel Tank Inlet Screen

Clean Rear Camera Lens

Inspect Belts

Clean or Replace Diesel Exhaust Fluid (DEF) Tank Fill Screen

Check and Clean Radiator Air Inlet Screen

Check Windshield Washer Fluid Level

Check and Adjust Track Sag

Drain Water and Sediment From Fuel Tank Sump

Section 3-4: Maintenance—10 Hours or Daily

Check Hydraulic Tank Oil Level

Check Engine Oil Level

Check Engine Coolant Level

Lubricate Hydraulic Coupler—If Equipped

Section 3-5: Maintenance—50 Hours or Weekly

Drain Primary Fuel Filter and Water Separator

Section 3-6: Maintenance—Initial Service—100 Hours

Inspect and Re-Torque Track Hardware

Section 3-7: Maintenance—Every 100 Hours

Lubricate Working Tool Pivots

Section 3-8: Maintenance—Every 250 Hours

Check Swing Gear Case Oil Level

Drain Water and Sediment From Hydraulic Tank Sump

Check Travel Gear Case Oil Level

Check Battery Electrolyte Level and Terminals

Lubricate Blade Pivots—If Equipped

Inspect and Re-Torque Track Hardware

Take Engine Oil Sample

Section 3-9: Maintenance—Every 500 Hours

Lubricate Swing Bearing

Lubricate Swing Bearing Gear

Lubricate Front End Pin Joints

Drain and Refill Engine Oil and Replace Filter

Check Air Intake Hoses

Clean Cab Fresh Air and Cab Recirculating Air Filters

Take Fluid Samples

Section 3-10: Maintenance—Every 1000 Hours

Drain and Refill Swing Gear Case Oil

Replace Hydraulic Tank Oil Filter

Replace Primary Fuel Filter and Water Separator

Replace Final Fuel Filter

Replace Pilot Oil Filter

Check and Adjust Engine Valve Lash

Replace Air Cleaner Elements

Replace Air Cleaner Dust Unloader Valve

Section 3-11: Maintenance—Every 2000 Hours

Drain and Refill Travel Gear Case Oil

Section 3-12: Maintenance—Every 2500 Hours

Replace Oil Separator Filter Element

Section 3-13: Maintenance—Every 4000 Hours

Drain, Flush, and Refill Engine Cooling System

Section 3-14: Maintenance—Every 4500 Hours

Access Diesel Exhaust Fluid (DEF) Dosing Unit Filter

Changing Diesel Exhaust Fluid (DEF) Dosing Unit Filter

Section 3-15: Maintenance—Every 5000 Hours

Drain and Refill Hydraulic Tank Oil and Clean Suction Screen

Replace Hydraulic Tank Vent Cap Filter

Section 4-1: Miscellaneous—Machine

Bleed Fuel System

Bleed Hydraulic System

Clean Radiator, Oil Cooler, Charge Air Cooler, and Fuel Cooler

Do Not Service or Adjust Injection Nozzles or High-Pressure Fuel Pump

Do Not Service Control Valves, Cylinders, Pumps, or Motors

Precautions for Alternator and Regulator

Handling, Checking, and Servicing Batteries Carefully

Using Battery Charger

Using Booster Batteries—24-Volt System

Replacing Batteries

Welding on Machine

Clean the Machine Regularly

Adding 12-Volt Accessories

Keep Electronic Control Unit Connectors Clean

JDLink™ Machine Monitoring System (MMS)

Replacing Fuses

Replacing Bucket Teeth

Replacing Bucket Tooth Tip—Heavy-Duty Bucket

Replacing Bucket Teeth—TK Series

Removing the Bucket

Track Sag General Information

Check Track Shoe Hardware

Hardware Torque Specifications

Unified Inch Bolt and Screw Torque Values

Metric Bolt and Screw Torque Values

Section 4-2: Miscellaneous—Operational Checkout

Operational Checkout

Section 4-3: Miscellaneous—Troubleshooting

Troubleshooting Procedure

Engine

Hydraulic System

Electrical System

Section 4-4: Miscellaneous—Storage

Monthly Storage Procedure

Prepare Machine for Storage

Preparing Engine for Long-Term Storage

Removing Engine From Long-Term Storage

Section 4-5: Miscellaneous—Machine Numbers

Record Product Identification Number (PIN)

Record Engine Serial Number

Record Travel Motor Serial Numbers

Record Swing Motor Serial Number

Record Hydraulic Coupler Serial Number—If Equipped

Record Hydraulic Pump Serial Number

Keep Proof of Ownership

Keep Machines Secure

Section 4-6: Miscellaneous—Specifications

135G Engine Specifications

135G Drain and Refill Capacities

135G Machine Specifications

135G Working Ranges

135G Lift Capacity—Rubber Track; Without Blade; Arm: 2.52 m (8 ft 3 in); Bucket: 414 kg (913 lb); Shoe: 500 mm (20 in)

135G Lift Capacity—Rubber Track; Blade on Ground; Arm: 2.52 m (8 ft 3 in); Bucket: 414 kg (913 lb); Shoe: 500 mm (20 in)

135G Lift Capacity—Without Blade; Arm: 2.52 m (8 ft 3 in); Bucket: 414 kg (913 lb); Shoe: 600 mm (24 in)

135G Lift Capacity—Blade on Ground; Arm: 2.52 m (8 ft 3 in); Bucket: 414 kg (913 lb); Shoe: 600 mm (24 in)

135G Lift Capacity—Without Blade; Arm: 2.52 m (8 ft 3 in); Bucket: 414 kg (913 lb); Shoe: 700 mm (28 in)

135G Lift Capacity—Blade on Ground; Arm: 2.52 m (8 ft 3 in); Bucket: 414 kg (913 lb); Shoe: 700 mm (28 in)

135G Lift Capacity—Rubber Track; Without Blade; Arm: 3.01 m (9 ft 11 in); Bucket: 414 kg (913 lb); Shoe: 500 mm (20 in)

135G Lift Capacity—Rubber Track; Blade on Ground; Arm: 3.01 m (9 ft 11 in); Bucket: 414 kg (913 lb); Shoe: 500 mm (20 in)

135G Lift Capacity—Without Blade; Arm: 3.01 m (9 ft 11 in); Bucket: 414 kg (913 lb); Shoe: 600 mm (24 in)

135G Lift Capacity—Blade on Ground; Arm: 3.01 m (9 ft 11 in); Bucket: 414 kg (913 lb); Shoe: 600 mm (24 in)

135G Lift Capacity—Without Blade; Arm: 3.01 m (9 ft 11 in); Bucket: 414 kg (913 lb); Shoe: 700 mm (28 in)

135G Lift Capacity—Blade on Ground; Arm: 3.01 m (9 ft 11 in); Bucket: 414 kg (913 lb); Shoe: 700 mm (28 in)