John Deere 135D Excavator Operators Manual - OMT239673

OMT239673 - 135D Excavator Operator's Manual.pdf

Complete technical Operator's Manual for John Deere 135D Excavator. It's the same technical manual used by dealers that guaranteed to be fully functional and intact without any missing page.

John Deere 135D Excavator Operator's Manual (OMT239673) (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

Total Pages: 464 pages
File Format: PDF (Windows & Mac & Linux)
Language: English

Table of Contents (Exploded Views)
Forward . . . . . .7
1-1 Safety - Safety and Operator Conveniences . . . . . . 8
Safety and Operator Convenience Features . . . . 8
1-2 Safety - General Information. . . . .9
Wear Protective Equipment . . . . . .9
Avoid Unauthorized Machine Modifications . . . . .10
Add Cab Guarding for Special Uses . . . .11
Inspect Machine . . . . 12
Stay Clear of Moving Parts . . . .13
Avoid High-Pressure Fluids . . . . . .14
Avoid High-Pressure Oils . . . . .15
Work In Ventilated Area . . . . .16
Prevent Fires . . . . . .17
Prevent Battery Explosions . . . . . 18
Handle Chemical Products Safely . . . . .19
Dispose of Waste Properly . . . . . .20
Prepare for Emergencies . . . . 21
Clean Debris from Machine . . . . . 22
Recognize Safety Information . . . . 23
Follow Safety Instructions. . . . 24
Operate Only If Qualified . . . . 25
1-3 Safety - Operating Precautions . . . . .26
Avoid Backover Accidents . . . . . .26
Avoid Machine Tip Over . . . . 27
Use Special Care When Lifting Objects . . . .28
Add and Operate Attachments Safely . . . . . 29
Prevent Unintended Detonation of Explosive Devices. . . . 30
Use Steps and Handholds Correctly . . . . . .31
Start Only From Operator's Seat . . . . . 32
Use and Maintain Seat Belt. . . . . . 33
Prevent Unintended Machine Movement . . . . . .34
Avoid Work Site Hazards . . . . 35
Keep Riders Off Machine . . . . 36
1-4 Safety - Maintenance Precautions . . . . . .37
Drive Metal Pins Safely . . . . .37
Park and Prepare for Service Safely . . . . . .38
Service Cooling System Safely . . . . . . 39
Remove Paint Before Welding or Heating . . . . . .40
Make Welding Repairs Safely . . . . 41
1-5 Safety - Safety Signs . . . . . .42
Safety Signs . . . .42
Safety Signs Installed in Cab—Hydraulic Coupler—If Equipped . . . . . . 43
Safety Signs Installed on Hydraulic Coupler—If Equipped . . . .44
Replace Safety Signs . . . .46
2-1 Operation - Operator's Station. . . . . .47
Front Switch Panel Functions . . . . 47
Rear Switch Panel . . . . .49
Horn . . . . . .50
Pilot Shutoff Lever . . . . . .51
Travel Alarm and Travel Alarm Cancel Switch . . . . . .52
Seat Heater Switch—If Equipped . . . . .53
Cab Heater and Air Conditioner . . . . . .54
Selecting Display Between Celsius and Fahrenheit . . . . 56
FM Radio . . . . .57
Secondary Exit Tool . . . .58
Opening Upper Front (Secondary Exit) Window . . . . .59
Removing and Storing the Lower Front Window . . . .61
Opening Cab Door Window . . . . . 62
Opening and Closing the Polycarbonate Type Roof Exit Cover . . . . . . 63
Adjusting the Mechanical Suspension Seat . . . . .64
Adjusting the Air Suspension Seat—If Equipped . . . .65
Adjusting Pilot Control Lever Console Height . . . . . . 66
Pedals, Levers, and Panels . . . . . .68
Front Switch Panel . . . . . 69
2-2 Operation - Monitor Operation . . . . . .70
Monitor Start-Up . . . . . . 70
Main Menu . . . .71
Time Set Menu . . . . 72
Selecting an Attachment From Default Screen . . . . . 74
Selecting an Attachment From Main Menu . . . . 76
Attachment Specification Screen . . . . . 78
Pump 2 Flow Rate Adjustment . . . .79
Displaying Operating Conditions . . . . . .80
Maintenance Settings . . . .82
Screen Display When Scheduled Maintenance is Due . . . . . 85
No Display . . . . 87
Language Settings . . . . .89
Alarm Occurrence Screen . . . . . . 91
Monitor . . . .95
Monitor Functions . . . . . .96
2-3 Operation - Operating the Machine . . . . . .98
Travel Pedals and Levers . . . . . . 98
Locking the Hydraulic Coupler to the Attachment . . . . . . 100
Unlocking the Hydraulic Coupler From the Attachment . . . . . .102
Control Lever Pattern Operation . . . . . .104
Mechanical Control Lever Pattern Selector—If Equipped . . . . . . 106
Control Lever Pattern Conversion . . . . 108
Operating Blade—If Equipped . . . . . .110
Operating In Water and Mud . . . .111
Driving Up a Steep or Slippery Slope . . . .112
Lifting . . . .113
Lower Boom With Engine Stopped . . . . . .114
Parking Machine . . . . . 116
Loading and Unloading for Transport . . . . .117
Long Arm Setup for Transport or Operation—If Equipped . . . . . . 119
Towing Machine . . . . . .120
Lifting the Machine . . . . 121
Before Starting Work . . . . . .123
Operator's Daily Machine Check Before Starting . . . . . .124
Starting Engine . . . . 125
Cold Weather Warm-Up . . . .127
3-01 Maintenance - Machine . . . . . 129
Lubricity of Diesel Fuel . . . . 129
Handling and Storing Diesel Fuel . . . .130
BioDiesel Fuel . . . . 131
Testing Diesel Fuel . . . .133
Minimizing the Effect of Cold Weather on Diesel Engines . . . . . . 134
Alternative and Synthetic Lubricants . . . . .136
Diesel Engine Oil — Tier 3 and Stage III . . . . . 137
Diesel Engine Oil and Filter Service Intervals . . . . . 138
Hydraulic Oil . . . . .140
Swing Gear Case and Travel Gear Case Oils . . . . .142
Track Adjuster, Working Tool Pivot, Swing Bearing, and Swing Bearing Gear Grease . . . . . .144
Diesel Engine Coolant (engine with wet sleeve cylinder liners) . . . . . .145
Drain Intervals for Diesel Engine Coolant . . . . .147
John Deere COOL-GARD™ II Coolant Extender . . . . . .148
Supplemental Coolant Additives . . . . . 149
Operating in Warm Temperature Climates . . . .150
Additional Information About Diesel Engine Coolants and John Deere COOL-GARD™ II Coolant Ex1t5e1nder
Testing Diesel Engine Coolant. . . . . . 153
Diesel Fuel . . . .154
3-02 Maintenance - Periodic Maintenance . . . . .156
Open Engine Hood for Service . . . . . .156
Fuel Tank . . . . 157
Hydraulic Breaker and Crusher Attachments . . . . . 158
Fluid Analysis Program Test Kits and 3-Way Coolant Test Kit . . . . . .159
Periodic Maintenance Record Keeping System . . . .160
Service Machine at Specified Intervals . . . .163
Check the Hour Meter Regularly . . . . .164
Prepare Machine for Maintenance . . . . . . 165
Open Access Doors for Service . . . . .166
3-03 Maintenance - As Required . . . . . 167
Clean Air Cleaner Dust Unloader Valve . . . . . .167
Check Windshield Washer Fluid Level . . . . 168
Drain Fuel Tank Sump . . . . .169
3-04 Maintenance - Every 10 Hours or Daily . . . .170
Check Recovery Tank Coolant Level . . . . .170
Grease Hydraulic Coupler (If Equipped) . . . . . . 171
Check Hydraulic Tank Oil Level . . . . .172
Drain Water Separator . . . . .175
Check Engine Oil Level . . . .176
3-05 Maintenance - Initial Service - 50 Hours . . . . . .178
Inspect and Re-Torque Track Hardware . . . . . .178
3-06 Maintenance - Every 50 Hours . . . .179
Check and Adjust Track Sag . . . .179
3-08 Maintenance - Every 250 Hours . . . . . . 181
Grease Front End Pin Joints . . . . 181
Grease Working Tool Pivots . . . . 182
Check and Adjust Fan Belt Tension . . . . . .183
Check Travel Gear Case Oil Level . . . . . . 184
Check Battery Electrolyte Level and Terminals . . . . 185
Clean or Replace Primary Air Cleaner Element . . . .188
Inspect and Re-Torque Track Hardware . . . . . .190
Take Engine Oil Sample. . . . 192
Check Swing Gear Case Oil Level . . . . . . 193
Drain Hydraulic Tank Sump . . . . .194
3-09 Maintenance - Every 500 Hours . . . . . . 196
Check Cab Recirculating Air Filter . . . .196
Grease Swing Bearing . . . . .198
Take Fluid Samples . . . . . . 199
Grease Swing Bearing Gear . . . . 200
Replace Water Separator . . . . . .202
Replace Fuel Filter . . . . 204
Change Engine Oil and Replace Filter. . . . 206
Check Air Intake Hose . . . . .209
Clean Radiator Air Inlet Screen . . . . . 210
Check Cab Fresh Air Filter . . . . . 212
3-10 Maintenance - Every 1000 Hours. . . . . 215
Clean the Engine Crankcase Ventilation Tube . . . . .215
Adjust Engine Valve Clearance . . . . . 216
Replace Air Cleaner Elements and Dust Unloader Valve. . . . 217
Check Coolant . . . .220
Change Swing Gear Case Oil . . . . . . 221
Clean Fuel Tank Inlet Screen . . . . . .223
Replace Hydraulic Oil Tank Filter . . . .224
Replace Pilot Oil Filter . . . . .226
3-11 Maintenance - Every 2000 Hours. . . . . 228
Cooling System Fill and Deaeration Procedure . . . .228
Change Travel Gear Case Oil . . . . . . 229
Drain Cooling System . . . . . .230
Diesel Engine Coolant (engine with wet sleeve cylinder liners) . . . . . .234
3-12 Maintenance - Every 5000 Hours. . . . . 236
Change Hydraulic Tank Oil, Clean Suction Screen . . . . 236
4-1 Miscellaneous - Machine . . . . .240
Do Not Service Control Valves, Cylinders, Pumps, or Motors . . . .240
Precautions for Alternator and Regulator . . . . .241
Handling, Checking, and Servicing Batteries Carefully . . . . . 242
Using Booster Batteries—24-Volt System . . . . .245
Using Battery Charger . . . . . 246
Replacing Batteries . . . .248
Fluid Sampling Test Ports—If Equipped . . . . . . 249
Welding On Machine . . . . . .250
Clean the Machine Regularly . . . . 251
Adding 12-Volt Accessories . . . . .252
JDLink™ Machine Monitoring System (MMS)—If Equipped . . . . .253
Replacing Fuses. . . . . . 254
Replacing Bucket Tooth Tip—Heavy-Duty Bucket . . . . . 259
Replacing Bucket Teeth . . . .260
Replacing Bucket Teeth—TK Series . . . . .262
Removing Bucket . . . . . 263
Track Sag General Information . . . . . .264
Unified Inch Bolt and Screw Torque Values . . . . . .265
Metric Bolt and Screw Torque Values . . . . 267
Bleed Fuel System - Electric Priming Pump . . . . . . 269
Bleed Fuel System - Manual Pump. . . . . . 270
Check and Adjust A _ C Belt . . . .273
Do Not Service or Adjust Injection Nozzles or High Pressure Fuel Pump . . . . . .274
4-2 Miscellaneous - Machine . . . . .275
Operational Checkout . . . . . .275
4-3 Miscellaneous - Troubleshooting . . . . . .308
Using Troubleshooting Charts . . . . . .308
Engine . . . . . . 309
Electrical System . . . . .312
Hydraulic System . . . . . 314
4-4 Miscellaneous - Storage . . . . . .316
Prepare Machine for Storage . . . . 316
Monthly Storage Procedure . . . . . 318
4-5 Miscellaneous - Machine Numbers . . . . .320
Record Swing Motor Serial Number . . . . . 320
Record Hydraulic Pump Serial Number . . . . . .321
Hydraulic Coupler Serial Number—If Equipped . . . .322
Keep Proof of Ownership . . . . . . 323
Keep Machines Secure . . . . .324
Record Product Identification Number (PIN) . . . . . .325
Record Engine Serial Number . . . . . .326
Record Travel Motor Serial Numbers . . . .327
4-6 Miscellaneous - Specifications . . . . .328
135D Engine Specifications . . . . .328
135D Drain and Refill Capacities . . . . 329
135D Machine Specifications . . . .330
135D Working Ranges. . . . . 332
Lift Capacity—135D, Arm 2.52 m (8 ft 3 in.), 500 mm (20 in.) Rubber Pads . . . . . . 334
Lift Capacity—135D, Arm 2.52 m (8 ft 3 in.), Shoe 600 mm (24 in.) . . . . . .337
Lift Capacity—135D, Arm 2.52 m (8 ft 3 in.), Shoe 700 mm (28 in.) . . . . . .340
Lift Capacity—135D, Arm 3.01 m (9 ft 11 in.), 500 mm (20 in.) Rubber Pads . . . . . .343
Lift Capacity—135D, Arm 3.01 m (9 ft 11 in.), Shoe 600 mm (24 in.) . . . . . 346
Lift Capacity—135D, Arm 3.01 m (9 ft 11 in.), Shoe 700 mm (28 in.) . . . . . 349