John Deere 120C Excavator Repair Technical Manual (TM1935)

TM1935 - John Deere 120C Excavator Technical Manual (Repair).pdf

Complete service repair manual for John Deere 120C Excavator, with all the service information to maintain, diagnostic, repair, refurbish/rebuild like professional mechanics.

John Deere 120C 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.

Total Pages: 515 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

tm1935 - 120C Excavator

Table of Contents

Foreword

Technical Information Feedback Form

Section 00: General Information

Group 0001: Safety

Follow Safe Procedures

Prepare for Emergencies

Prevent Acid Burns

Handle Chemical Products Safely

Handle Fluids Safely—Avoid Fires

Avoid High-Pressure Fluids

Warn Others of Service Work

Support Machine Properly

Operate Only from Operator's Seat

Park Machine Safely

Stay Clear of Moving Parts

Avoid Power Lines

Use Handholds and Steps

Keep Riders Off Machine

Move and Operate Machine Safely

Wear Protective Clothing

Protect Against Flying Debris

Protect Against Noise

Illuminate Work Area Safely

Service Machines Safely

Remove Paint Before Welding or Heating

Avoid Heating Near Pressurized Fluid Lines

Beware of Exhaust Fumes

Use Proper Lifting Equipment

Service Cooling System Safely

Dispose of Waste Properly

Work in a Clean Area

Use Tools Properly

Replace Safety Signs

Live With Safety

Group 0003: Torque Values

Unified Inch Bolt and Screw Torque Values

Metric Bolt and Screw Torque Values

Additional Metric Cap Screw Torque Values

Check Oil Lines And Fittings

Service Recommendations for O-Ring Boss Fittings

Service Recommendations For Flat Face O-Ring Seal Fittings

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

Service Recommendations For Flared Connections—Straight or Tapered Threads

Service Recommendations For Inch Series Four Bolt Flange Fittings

Service Recommendations for Metric Series Four Bolt Flange Fitting

Section 01: Tracks

Group 0130: Track System

Track Roller, Front Idler, and Carrier Roller Oil

Track Roller Repair

Track Carrier Roller Repair

Metal Face Seals Repair

Track Shoe Repair

Track Chain Repair

Broken Track Chain Part Repair

Sprocket Repair

Front Idler Repair

Track Adjuster and Recoil Spring Repair

Track Adjuster Cylinder Repair

Section 02: Axles and Suspension Systems

Group 0250: Axle Shaft, Bearings, and Reduction Gears

Propel Gearbox Repair

Group 0260: Hydraulic System

Propel Motor Repair

Propel Motor Start-Up Procedure

Rotary Manifold Repair

Section 04: Engine

Group 0400: Removal and Installation

Engine Repair

Fuel Injection Pump Repair

Starter Repair

Section 05: Engine Auxiliary Systems

Group 0510: Cooling System

Radiator Repair

Fan, Fan Guard, and Fan Shroud Repair

Fan Belt Repair

Group 0520: Intake System

Air Intake System Leakage Test

Air Cleaner Repair

Group 0560: External Fuel Supply Systems

Fuel Tank Repair

Primary Fuel Filter (Water Separator) Repair

Final Fuel Filter Repair

Section 07: Dampener Drive (Flex Coupling)

Group 0752: Elements

Dampener Drive (Flex Coupling) Remove and Install (S.N. —034261)

Dampener Drive (Flex Coupling) Repair (S.N. 034262— )

Section 17: Frame or Supporting Structure

Group 1740: Frame Installation

Welding On Machine

Welding Repair of Major Structure

Group 1749: Chassis Weights

Counterweight Repair

Section 18: Operator’s Station

Group 1800: Removal and Installation

Cab Repair

Group 1810: Operator Enclosure

Windowpane and Two Piece Molding Repair

Windowpane and One Piece Molding Repair

Sliding Windows Repair

Windowpanes Repair

Group 1821: Seat and Seat Belt

Seat Belt Repair

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 Repair

Receiver-Dryer Repair

Air Conditioner and Heater Repair

Condenser Repair

Section 32: Bulldozers (Backfill Blade)

Group 3201: Blades

Backfill Blade Repair

Group 3260: Hydraulic System

Backfill Blade Pump Repair

Backfill Blade Control Valve Repair

Backfill Blade Pilot Controller Repair

Backfill Blade Pilot Valve Repair

Backfill Blade Cylinder Repair

Section 33: Excavator

Group 3302: Buckets

Bucket Repair

Adjust Bucket Pivot End Play

Bucket Pin-Up Data

Group 3340: Frames

Bucket Links Repair

Arm Repair

Boom Repair

Inspect Boom, Arm, and Bucket Pins, Bushings and Bosses

Bushings and Seals Repair

Group 3360: Hydraulic System

Hydraulic Oil Tank Vent Procedure

Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy

Hydraulic Pump Repair

Hydraulic Pump Start-Up Procedure

Hydraulic Pump Regulator Repair

Pilot Pump Repair

Pilot Pressure Regulating Valve and Filter Repair

Pilot Shut-Off Valve Repair

Propel Speed and Arm Regenerative Solenoid Valve Repair

Pilot Controller Repair

Propel Pilot Controller Repair

Pilot Signal Manifold Repair

Control Valve Repair

Hydraulic Oil Tank Repair

Restriction Valve Repair

Oil Cooler Bypass Valve Repair

Oil Cooler Repair

Boom Cylinder Repair

Arm Cylinder Repair

Bucket Cylinder Repair

Boom, Arm, or Bucket Cylinder Repair

Hydraulic Cylinder Bleed Procedure

Section 43: Swing or Pivoting System

Group 4350: Mechanical Drive Elements

Swing Gearbox Repair

Swing Gearbox Start-Up Procedure

Upperstructure

Swing Bearing Repair

Group 4360: Hydraulic System

Swing Motor and Park Brake Repair

Swing Motor and Park Brake Start-Up Procedure

Section 99: Dealer Fabricated Tools

Group 9900: Dealer Fabricated Tools

ST4920 Track Recoil Spring Disassembly and Assembly Tool

DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool

DFT1112 Spacer

DF1036A Propel Gearbox Nut Wrench

DFT1109 Holding Bar

Rotary Manifold Lifting Tool

DFT1089 Barrel Support

DFT1113 Guide Pin

DFT1119 Pump Support

DFT1237 Swing Gearbox Nut Spanner Wrench