Complete Technical Diagnostic, Operation and Test Manual with Electrical Wiring Diagrams for John Deere 120D Excavators, with workshop information to maintain, diagnose, and service like professional mechanics.

John Deere Excavator 120D 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.

TM10736 - John Deere 120D Excavator Operation & Test Service Manual.pdf

Total Pages: 1,137 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

tm10736 - 120D 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 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

Section 9001: Diagnostics

Group 10: Main Controller (MCF) Diagnostic Trouble Codes

Main Controller (MCF) Diagnostic Trouble Codes

11000.02 - Abnormal EEPROM

11001.02 - Abnormal RAM

11002.02 - Abnormal A/D Conversion

11003.03 - Abnormal Sensor Voltage

11004.02 - Abnormal CAN Communication

11100.02 - Abnormal Engine Speed

11101.03 - Engine Control Dial Voltage High

11101.04 - Engine Control Dial Sensor Voltage Low

11200.03 - Pump 1 Delivery Pressure Sensor Voltage High

11200.04 - Pump 1 Delivery Pressure Sensor Voltage Low

11202.03 - Pump 2 Delivery Pressure Sensor Voltage High

11202.04 - Pump 2 Delivery Pressure Sensor Voltage Low

11206.03 - Pump 1 Control Pressure Sensor Voltage High

11206.04 - Pump 1 Control Pressure Sensor Voltage Low

11208.03 - Pump 2 Control Pressure Sensor Voltage High

11208.04 - Pump 2 Control Pressure Sensor Voltage Low

11301.03 - Swing Pilot Pressure Sensor Voltage High

11301.04 - Swing Pilot Pressure Sensor Voltage Low

11302.03 - Boom Up Pilot Pressure Sensor Voltage High

11302.04 - Boom Up Pilot Pressure Sensor Voltage Low

11303.03 - Arm In Pilot Pressure Sensor Voltage High

11303.04 - Arm In Pilot Pressure Sensor Voltage Low

11304.03 - Travel Pilot Pressure Sensor Voltage High

11304.04 - Travel Pilot Pressure Sensor Voltage Low

11307.03 - Front Attachment Pilot Pressure Sensor Voltage High

11307.04 - Front Attachment Pilot Pressure Sensor Voltage Low

11400.02 - Pump 2 Flow Rate Limit Solenoid Current Feedback Abnormal

11400.03 - Pump 2 Flow Rate Limit Solenoid Current Feedback Abnormal

11400.04 - Pump 2 Flow Rate Limit Solenoid Feedback Current Low

11401.02 - Torque Control Solenoid Feedback Current Abnormal

11401.03 - Torque Control Solenoid Feedback Current High

11401.04 - Torque Control Solenoid Feedback Current Low

11403.02 - Arm Regenerative Solenoid Feedback Current Abnormal

11403.03 - Arm Regenerative Solenoid Feedback Current High

11403.04 - Arm Regenerative Solenoid Feedback Current Low

11405.02 - Travel Speed Solenoid Feedback Current Abnormal

11405.03 - Travel Speed Solenoid Feedback Current High

11405.04 - Travel Speed Solenoid Feedback Current Low

11410.02 - Pump 1 Flow Rate Limit Solenoid Current Feedback Abnormal

11410.03 - Pump 1 Flow Rate Limit Solenoid Feedback Current High

11410.04 - Pump 1 Flow Rate Limit Solenoid Feedback Current Low

11901.03 - Hydraulic Oil Temperature Sensor Voltage High

11901.04 - Hydraulic Oil Temperature Sensor Voltage Low

11910.02 - Actual Engine Speed Message Error

11911.02 - Security Signal Received from Monitor

11914.02 - Radiator Coolant Temperature Message Error

11918.02 - Work Mode Received Message Error

11920.02 - Fuel Flow Rate Message Error

Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes

Engine Control Unit (ECU) Diagnostic Trouble Codes

171.03 - Intake Air Temperature Sensor Out of Range High

171.04 - Intake Air Temperature Sensor Out of Range Low

647.05 - Proportional Fan Speed Solenoid Driver Open

647.31 - Fan Manual Reverse Mode Input Active Too Long

898.09 - Engine Speed Request Not Received or Timed Out

1638.09 - Hydraulic Oil Temperature Message Not Received or Timed Out

Group 30: Information Controller (ICF) Diagnostic Trouble Codes

Information Controller (ICF) Diagnostic Trouble Codes

14000.02 - Abnormal CAN Communication

14001.02 - ICF: Flash Memory: Read/Write Error

14002.02 - ICF: External RAM: Read/Write Error

14003.02 - ICF: EEPROM: Sum Check Error

14006.02 - ICF: Satellite Communication Terminal: Communication Error

14008.02 - ICF: Abnormal Internal RAM

14100.02 - Satellite Communication Terminal: Abnormal EEPROM

14101.02 - Satellite Communication Terminal: Abnormal IB/OB Queue

14102.02 - Satellite Communication Terminal: Abnormal Local Loop Back

14103.02 - Satellite Communication Terminal: The Satellite is not found

14104.02 - Satellite Communication Terminal: Fail 1 of Remote Loop Back

14105.02 - Satellite Communication Terminal: Tail 2 of Remote Loop Back

14106.02 - Satellite Communication Terminal: Sending and Receiving Data are Mismatched

Group 40: Air Conditioner Controller (ACF) Diagnostic Trouble Codes

Air Conditioner Controller (ACF) Diagnostic Trouble Codes

21 - Mix Door Open Circuit

-21 - Mix Door Short Circuit

22 - Mode Encoder Open Circuit

23 - In-Cab Ambient Temperature Sensor Open Circuit

-23 - In-Cab Ambient Temperature Sensor Short Circuit

24 - Outdoor Ambient Temperature Sensor Open Circuit

-24 - Outdoor Ambient Temperature Sensor Short Circuit

25 - Coolant Temperature Sensor Open Circuit

-25 - Coolant Temperature Sensor Short Circuit

26 - Solar Radiation Sensor Open Circuit

-26 - Solar Radiation Sensor Short Circuit

Group 50: Monitor Controller (MON) Diagnostic Trouble Codes

Monitor Controller (MON) Diagnostic Trouble Codes

13303.02 - Abnormal Thermister Temperature

13304.02 - Abnormal REG Input H Level

13306.02 - Abnormal EEPROM

13308.02 - Abnormal CAN Communication

13310.02 - Shorted Circuit in Coolant Temperature Sensor

13311.03 - Fuel Level Sensor Short Circuit

13311.04 - Fuel Level Sensor Open Circuit

13334.2 - Radiator Coolant Error

20105.2 - Hydraulic Oil Filter Restriction Alarm

20106.2 - Air Cleaner Restriction Alarm

Section 9005: Operational Checkout Procedure

Group 10: Operational Checkout Procedure

Operational Checkout

Section 9010: Engine

Group 05: Theory of Operation

Engine Fuel System Component Location

Engine Cooling System Component Location

Cold Weather Starting Aid

Engine Speed Control System Operation

Group 15: Diagnostic Information

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

Group 25: Tests

Radiator Temperature Differential Check

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 and Relay Specifications

System Functional Schematic, Component Location, and Wiring Diagram Master Legend

System Functional Schematic

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

Engine Harness (W4) Component Location

Engine Harness (W4) Wiring Diagram

Engine Interface Harness (W5) Component Location

Engine Interface Harness (W5) Wiring Diagram

Right Console Harness (W7) Component Location

Right Console Harness (W7) Wiring Diagram

Pump Harness (W8) Component Location

Pump Harness (W8) Wiring Diagram

Auxiliary Fuse Box Harness (W9) Component Location

Auxiliary Fuse Box Harness (W9) Wiring Diagram

Pilot Shutoff Switch Harness (W11) Component Location

Pilot Shutoff Switch Harness (W11) Wiring Diagram

Air Suspension Seat Harness (W12) Component Location

Air Suspension Seat Harness (W12) Wiring Diagram

Seat Heater Switch Harness (W13) Component Location

Seat Heater Switch Harness (W13) Wiring Diagram

Multi-Function Pilot Control Lever Harness (W14) Component Location

Multi-Function Pilot Control Lever Harness (W14) Wiring Diagram

Travel Alarm Cancel Switch Harness (W15) Component Location

Travel Alarm Cancel Switch Harness (W15) Wiring Diagram

Fan Reversing Switch Harness (W16) Component Location

Fan Reversing Switch Harness (W16) Wiring Diagram

Pilot Shutoff Valve Harness (W17) Component Location

Pilot Shutoff Valve Harness (W17) Wiring Diagram

Attachment Harness (W20) Component Location

Attachment Harness (W20) Wiring Diagram

2-Speed Harness (W21) Component Location

2-Speed Harness (W21) Wiring Diagram

Alternator Harness (W22) Component Location

Alternator Harness (W22) Wiring Diagram

Attachment Pressure Sensor Harness (W23) Component Location—Except 2-Speed

Attachment Pressure Sensor Harness (W23) Wiring Diagram—Except 2-Speed

12-Volt Power Converter Harness (W24) Component Location

12-Volt Power Converter Harness (W24) Wiring Diagram

Travel Alarm Harness (W26) Component Location

Travel Alarm Harness (W26) Wiring Diagram

Starter Harness (W27) Component Location

Starter Harness (W27) Wiring Diagram

Start Aid Switch Harness (W28) Component Location

Start Aid Switch Harness (W28) Wire Diagram

Auxiliary Solenoid Harness (W61) Component Location

Auxiliary Solenoid Harness (W61) Wiring Diagram

JDLink™ Modular Telematics Gateway (MTG) Harness (W6002) Component Location—If Equipped

JDLink™ Modular Telematics Gateway (MTG) Harness (W6002) Wiring Diagram—If Equipped

Group 15: Sub-System Diagnostics

Controller Area Network (CAN) Theory of Operation

Starting and Charging Circuit Theory of Operation

Monitor Controller Circuit Theory of Operation

Engine Control Unit (ECU) Circuit Theory of Operation

Main Controller (MCF) Circuit Theory of Operation

Information Controller (ICF) Circuit Theory of Operation

Travel Alarm Circuit Theory of Operation

Windshield Wiper and Washer Circuit Theory of Operation

Pilot Shutoff Circuit Theory of Operation

Attachment Control Circuit Theory of Operation

JDLink™ Circuit Theory of Operation—If Equipped

Group 16: Monitor Operation

Monitor Menu Operation

Monitor Service Menu Operation

Group 20: References

Monitor Data Items

Reading Diagnostic Trouble Codes With Monitor Display

Service ADVISOR™ Diagnostic Application

Service ADVISOR™ Connection Procedure

Reading Diagnostic Trouble Codes With Service ADVISOR™ Diagnostic Application

JDLink™ Connection Procedure—If Equipped

Information Controller (ICF) Recorded Data

Fuse Test

Relay Test

Pressure Sensor Test

Solenoid Test

Proportional Solenoid Test

Temperature Sensor Test

Alternator Test

Electrical Component Checks

Battery Remove and Install

Rear Cover Remove and Install

Main Controller (MCF) Remove and Install

Engine Control Unit (ECU) Remove and Install

Information Controller (ICF) Remove and Install

Monitor Controller Remove and Install

Key Switch Remove and Install

Switch Panel Remove and Install

Travel Alarm Remove and Install

Left Console Switch Remove and Install

Disconnect Tab Retainer Connectors

Disconnecting Spring Wire Clip Connectors

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

Replace DEUTSCH DEUTSCH is a trademark of Deutsch Co. Rectangular or Triangular Connectors

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

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

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

Replace (Pull Type) Metri-Pack™ Connectors

Replace (Push Type) Metri-Pack™ Connectors

Replace CINCH CINCH is a trademark of the Cinch Co. Connectors

Install CINCH CINCH is a trademark of the Cinch Co. Contact

Repair 32 and 48 Way CINCH CINCH is a trademark of the Cinch Co. Connectors

Remove Connector Body from Blade Terminals

Section 9020: Power Train

Group 05: Theory of Operation

Track Adjuster and Recoil Spring Operation

Travel 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 Operation

Fan Drive Hydraulic System Operation—If Equipped

Pilot System Operation

Pilot Pump, Pressure Regulating Valve and Filter Operation

Pilot Shutoff Solenoid Valve Operation

Pilot Control Valve Operation

Travel Pilot Control Valve Operation

Pilot Operation of Control Valve Operation

Pilot Signal Manifold Operation

Pump 1, Pump 2 and Drive Gearbox Operation

Pump 1 and Pump 2 Regulator Operation

Engine Speed Sensing Control Circuit Operation

Control Valve Operation

Control Valve Check Valves Identification and Operation

Main Relief Valve Circuit Operation

Circuit Relief and Anticavitation Valve Operation

Flow Combiner Valve Operation

Auxiliary Flow Combiner Valve and Bypass Shut-Off Valve Operation

Boom Regenerative Valve Circuit Operation

Arm Regenerative Valve Circuit Operation

Bucket Regenerative Valve Circuit Operation

Boom and Arm Reduced Leakage Valves Operation

Bucket Flow Rate Control Valve Circuit Operation

Auxiliary Flow Rate Control Valve Circuit Operation

Blade Circuit Operation—If Equipped

Swing Reduction Gearbox Operation

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

Swing Motor Park Brake Release Circuit Operation

Center Joint Operation

Travel Motor and Park Brake Valve Operation

Travel Motor Speed Circuit Operation

Cylinder Operation

Return Filter Operation

Auxiliary System Operation

Auxiliary Pilot Control Valve Operation

Flow Rate Select Solenoid Valve Operation

Flow Rate Pressure Reducing Valve Operation

Selector Valve Solenoid Valve Operation

Selector Valve Operation

Auxiliary Shuttle Valve Operation

Auxiliary High Flow Line Kit Operation

Two Way Solenoid Kit Operation

Two Pump Combined Flow Kit Operation

Group 15: Diagnostic Information

All Hydraulic Functions Slow

Hydraulic Oil Overheats

No Hydraulic Functions

No Hydraulic Functions—Electrical Checks

Function Does Not Stop When Control Lever Released

Load Drifts Down When Control Lever is in Neutral Position

Load Falls When Control Valve is Actuated To Raise Load

H/P (High Power) Function Does Not Operate, PWR (Power) Mode is Normal

Boom Down Does Not Function, Moves Slowly, or is Erratic, All Other Functions Normal

Arm In Does Not Function, Moves Slowly, or is Erratic, All Other Functions Normal

Swing Speed Slow During Arm In Function

Boom Cannot Raise Track Off Ground

Swing Function Does Not Operate in Both Directions

Swing Speed Slow in Both Directions

Swing Speed Slow or Does Not Operate in One Direction

Upperstructure Drift With Swing Valve in Neutral

Machine Freewheels Down an Incline

Track Will Not Move in Either Direction

Machine Mistracks

Machine Mistracks Left During Combined Travel and Dig Functions

Machine Will Not Shift Into Fast (Rabbit) Speed

Pump 1, Pump 2, and Pilot Pump Line Identification

Control Valve Line Identification

Swing Motor Line Identification

Pilot Control Valve-to-Pilot Signal Manifold Component Location—Excavator Pattern

Pilot Control Valve-to-Pilot Signal Manifold Component Location—Backhoe Pattern

Pilot Signal Manifold-to-Control Valve Line Connection

Travel System Component Location

Travel Hydraulic System Line Connection

Blade Hydraulic System Component Location

Auxiliary Attachment Schematic

Auxiliary System Line Connections

Hydraulic System Schematic

Hydraulic System Component Location

Hydraulic System Line Connections

Fan Drive Hydraulic System Schematic

Fan Drive Hydraulic System Component Location

Group 25: Tests

JT05800 Digital Thermometer Installation

JT02156A Digital Pressure/Temperature Analyzer Installation

General Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy

Hydraulic Component Failure Cleanup Procedure Using Portable Filter Caddy

Hydraulic Oil Warm-Up Procedure

Pilot Pressure Regulating Valve Test and Adjustment

Control Valve Spool Actuating Pilot Pressure Test

Arm Regenerative Solenoid Valve Test and Adjustment

Travel Speed Solenoid Valve Test and Adjustment

Torque Control Solenoid Valve Test and Adjustment

Pump Control Pilot Pressure Signal Test

Main Relief Valve Test and Adjustment

Circuit Relief Valve Test and Adjustment

Blade Main Relief Valve Test and Adjustment

Swing Motor Crossover Relief Valve Test and Adjustment

Travel Motor Crossover Relief Valve Test and Adjustment

Pump Regulator Test and Adjustment—Minimum Flow

Pump Regulator Test and Adjustment—Maximum Flow

Pump Flow Test

Swing Motor Leakage Test

Travel Motor Leakage Test

Cylinder Drift Test—Boom, Arm, and Bucket

Fan Drive Pump Flow Test

Fan Speed 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 Heating System Malfunctions

Heater and Air Conditioner Diagnostic Trouble Code Check

Heater and Air Conditioner Component Location

Group 25: Tests

Refrigerant Cautions and Proper Handling

Heater and Air Conditioner Operational Checks

Air Conditioner Compressor Clutch Test

Refrigerant Leak Test

Refrigerant Hoses and Tubing Inspection

Air Conditioner Compressor Belt Check and Adjustment

Operating Pressure Diagnostic Chart

Section 9050: Reference Material

Group 05: Terminology Cross Reference Chart

Terminology Cross Reference Chart

Section 9900: Dealer Fabricated Tools

Group 99: Dealer Fabricated Tools

DFT1218 Split Flange Hose Cap

John Deere 120D Excavator Technical Manual - Operation & Test (TM10736)