John Deere 120D Excavator Repair Technical Manual (TM10737)

TM10737 - John Deere 120D Excavator Technical Manual (Repair).pdf

Complete service repair manual for John Deere 120D Excavator, with all the workshop information to maintain, repair, rebuild like professional mechanics.

John Deere 120D 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.
* 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: 623 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

MAIN SECTIONS
Foreword
   Technical Information Feedback Form
   General Information
      Safety
      Torque Values
   Tracks
      Track System
   Axles and Suspension Systems
      Axle Shaft, Bearings, and Reduction Gears
      Hydraulic System
   Engine
      Removal and Installation
   Engine Auxiliary Systems
      Cooling System
      Intake System
      External Fuel Supply Systems
   Dampener Drive (Flex Coupling)
      Elements
   Frame or Supporting Structure
      Frame Installation
      Chassis Weights
   Operator’s Station
      Removal and Installation
      Operator Enclosure
      Seat and Seat Belt
      Heating and Air Conditioning
   Bulldozers (Backfill Blade)
      Blades
      Hydraulic System
   Excavator
      Buckets
      Frames
      Hydraulic System
   Swing or Pivoting System
      Mechanical Drive Elements
      Hydraulic System
   Dealer Fabricated Tools

tm10737 - 120D 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

Add Cab Guarding for Special Uses

Inspect Machine

Stay Clear of Moving Parts

Avoid High-Pressure Fluids

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

Prevent Unintended Detonation of Explosive Devices

Park and Prepare for Service Safely

Service Cooling System Safely

Remove Paint Before Welding or Heating

Make Welding Repairs Safely

Drive Metal Pins 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

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

Service Recommendations for Flared Connections—Straight or Tapered Threads

Service Recommendations for Flat Face O-Ring Seal Fittings

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

Inspect Metal Face Seals

Track Shoe Remove and Install

Track Chain Remove and Install

Track Chain Disassemble and Assemble

Track Chain Repair

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

Track Adjuster Cylinder Disassemble and Assemble

Section 02: Axles and Suspension Systems

Group 0250: Axle Shaft, Bearings, and Reduction Gears

Travel Gearbox Remove and Install

Travel Gearbox Disassemble and Assemble

Group 0260: Hydraulic System

Travel Motor and Park Brake Remove and Install

Travel Motor and Park Brake Disassemble and Assemble

Travel Motor Cover Disassemble and Assemble

Travel Motor Crossover Relief Valve Disassemble and Assemble

Travel Speed Change Solenoid Valve Remove and Install

Travel Motor and Park Brake Start-Up Procedure

Section 04: Engine

Group 0400: Removal and Installation

PowerTech E™ 4.5 L and 6.8 L (4045 and 6068) John Deere Engines

Engine Remove and Install

Section 05: Engine Auxiliary Systems

Group 0510: Cooling System

Radiator Remove and Install

Hydraulic Oil Cooler Remove and Install

Intercooler Remove and Install

Fuel Cooler Remove and Install

Fan, Fan Guard, and Fan Shroud Remove and Install

Coolant Surge Tank Remove and Install

Group 0520: Intake System

Air Cleaner Remove and Install

Group 0560: External Fuel Supply Systems

Fuel Tank Remove and Install

Primary Fuel Filter (Water Separator) Remove and Install

Final Fuel Filter Remove and Install

Section 07: Dampener Drive (Flex Coupling)

Group 0752: Elements

Dampener Drive (Flex Coupling) Remove and Install

Section 17: Frame or Supporting Structure

Group 1740: Frame Installation

Welding On Machine

Welding Repair of Major Structure

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

Sliding Window Remove and Install

Windowpanes Remove and Install

Windowpanes Dimensions

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

Left and Right Console Covers Remove and Install

Group 1830: Heating and Air Conditioning

Refrigerant Cautions and Proper Handling

Flush and Purge Air Conditioner System

R134a Refrigerant Oil Information

R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure

Recover R134a Refrigerant

Evacuate R134a System

Charge R134a System

Compressor Remove and Install

Condenser Remove and Install

Heater and Air Conditioner Remove and Install

Receiver-Dryer Remove and Install

Section 32: Bulldozers (Backfill Blade)

Group 3201: Blades

Blade Remove and Install

Group 3260: Hydraulic System

Blade Pump Remove and Install

Blade Pump Pressure Relief Valve Remove and Install

Blade Control Valve Remove and Install

Blade Control Valve Disassemble and Assemble

Blade Pilot Controller Remove and Install

Blade Pilot Controller Disassemble and Assemble

Blade Cylinder Remove and Install

Blade Cylinder Disassemble and Assemble

Section 33: Excavator

Group 3302: Buckets

Bucket Remove and Install

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

Bushings and Seal Remove and Install

Group 3360: Hydraulic System

Apply Vacuum to Hydraulic Oil Tank

Hydraulic Oil Cleanup Procedure With Portable Filter Caddy

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

Fan Drive Pump Remove and Install

Fan Drive Motor Remove and Install

Fan Drive Standard Control Valve Remove and Install

Fan Drive Reversing Control Valve Remove and Install

Fan Drive Reversing Control Valve Disassemble and Assemble

Solenoid Valve Manifold Remove and Install

Travel Speed and Arm Regenerative Solenoid Valve Disassemble and Assemble

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 Separation

Control Valve (5-Spool) Disassemble and Assemble

Control Valve (4-Spool) Disassemble and Assemble

Hydraulic Oil Tank Remove and Install

Hydraulic Oil Tank Disassemble and Assemble

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 Gearbox Remove and Install

Swing Gearbox Disassemble and Assemble

Swing Gearbox 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 and Assemble

Swing Motor and Park Brake Inspection

Swing Motor and Park Brake Start-Up Procedure

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

Swing Park Brake Release Valve Remove and Install

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

DFT1112 Spacer

DFT1130 Adapter

DFT1036A Travel Gear Case Nut Wrench

DFT1109 Holding Bar

Center Joint (Rotary Manifold) Lifting Tool

DFT1304 Guide Pin

DFT1119 Pump Support

DFT1237 Swing Gear Case Nut Spanner Wrench