John Deere 120 Excavator Workshop Repair Service Manual TM1660 PDF - MJODTM1660.zip
This is a full workshop and repair guide for the John Deere 120 Excavator, offering the same detailed technical content professionals rely on to service, maintain, and fix the machine.
The John Deere 120 Excavator service repair manual contains:
* 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.
TM1660 - John Deere 120 Excavator Technical Manual (Repair).pdf
TM1660 - John Deere 120 Excavator Technical Manual (Repair).epub
Total Pages: 732 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English
MAIN SECTIONS
Foreword
Technical Information Feedback Form
General Information
Safety
General Specifications
Torque Values
Fuels and Lubricants
Tracks
Track System
Axles and Suspension Systems
Axle Shaft, Bearings, and Reduction Gears
Hydraulic System
Engine
Removal and Installation
Engine Auxiliary Systems
Cold Weather Starting Aids
Cooling System
Speed Controls
Intake System
External Fuel Supply Systems
Dampener Drive (Flex Coupling)
Elements
Electrical System
Batteries, Support, and Cables
Alternator, Regulator, and Charging System Wiring
Wiring Harness and Switches
System Controls
Instruments and Indicators
Frame or Supporting Structure
Frame Installation
Chassis Weights
Operator’s Station
Removal and Installation
Operator Enclosure
Seat and Seat Belt
Heating
Excavator
Buckets
Frames
Hydraulic System
Swing or Pivoting System
Mechanical Drive Elements
Hydraulic System
Dealer Fabricated Tools
tm1660 - 120 Excavator Repair
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 0002: General Specifications
120 Excavator Overview
120 Excavator
120 Working Ranges
Engine Specifications
Drain and Refill Capacities
Lift Capacity-KG (LB)
Lift Capacity-KG (LB)
Lift Capacity-KG (LB)
Lift Capacity-KG (LB)
Lift Capacity-KG (LB)
Lift Capacity-KG (LB)
Group 0003: Torque Values
Hardware Torque Specifications
Unified Inch Bolt and Cap Screw Torque Values
Metric Bolt and Cap 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
Group 04: Fuels and Lubricants
Diesel Fuel
Lubricity of Diesel Fuels
Low Sulfur Diesel Fuel Conditioner
Diesel Fuel Storage
Fuel Tank
Do Not Use Galvanized Containers
Diesel Engine Oil
Hydraulic Oil
Swing Gearbox, Propel Gearbox and Pump Gearbox Oils
Track Roller, Front Idler, and Carrier Roller Oil
Track Adjuster, Working Tool Pivot, Swing Bearing, and Swing Bearing Gear Grease
Oil Filters
Alternative and Synthetic Lubricants
Mixing of Lubricants
Section 01: Tracks
Group 0130: Track System
Essential Tools
Service Equipment and Tools
Other Material
Specifications
Measure Track Roller Wear
Remove and Install Track Roller
Disassemble and Assemble Track Roller
Test Track Roller for Oil Leakage
Measure Track Carrier Roller Wear
Remove and Install Track Carrier Roller
Disassemble and Assemble Track Carrier Roller
Inspect Metal Face Seals
Measure Track Shoe Grouser Wear
Remove and Install Track Shoe
Measure Track Chain Link Wear
Measure Track Chain Bushing Wear
Measure Track Chain Pitch
Remove Track Chain
Install Track Chain
Disassemble and Assemble Track Chain
Disassemble and Assemble Track Chain to Replace Broken Part
Adjust Track Sag
Remove and Install Sprocket
Measure Front Idler Wear
Remove and Install Front Idler
Disassemble Front Idler
Assemble Front Idler
Test Front Idler For Oil Leakage
Remove and Install Track Adjuster Cylinder and Recoil Spring
Disassemble and Assemble Track Adjuster Cylinder and Recoil Spring
Disassemble and Assemble Track Adjuster Cylinder
Section 02: Axles and Suspension Systems
Group 0250: Axle Shaft, Bearings, and Reduction Gears
Service Equipment and Tools
Other Material
Specifications
Towing Machine
Remove and Install Propel Gearbox
Disassemble Propel Gearbox
Inspect Metal Face Seals
Disassemble and Assemble First Planet Carrier
Disassemble and Assemble Second Planet Carrier
Assemble Propel Gearbox
Group 0260: Hydraulic System
Essential Tools
Service Equipment and Tools
Other Material
Specifications
Remove and Install Propel Motor and Brake
Disassemble Propel Motor and Brake
Assemble Propel Motor and Brake
Disassemble and Assemble Propel Motor Brake Valve Housing
Propel Motor Start-Up Procedure
Remove and Install Rotary Manifold
Disassemble and Assemble Rotary Manifold
Rotary Manifold Air Test
Section 04: Engine
Group 0400: Removal and Installation
POWERTECHPOWERTECH is a trademark of Deere & Company. 4.5 L (4045) John Deere Engine-Use CTM104
Essential Tools
Service Equipment and Tools
Other Material
Specifications
Remove Engine
Install Engine
Remove Oil Pan
Install Oil Pan
Remove In-Line Fuel Injection Pump
Repair In-Line Fuel Injection Pump
Install In-Line Fuel Injection Pump
Bleed Fuel System
Clean the Engine Crankcase Ventilation Tube
Check and Adjust Engine Valve Lash (Clearance)
Firing Order 4-Cylinder Engine
Remove and Install Starter (S.N. -030229)
Remove and Install Starter (S.N. 030230-)
Section 05: Engine Auxiliary Systems
Group 0505: Cold Weather Starting Aids
Other Material
Specifications
Remove and Install Starting Aid Solenoid and Nozzle
Remove and Install Engine Coolant Heater
Group 0510: Cooling System
Specifications
Remove and Install Fan, Shroud, and Guards
Remove and Install Radiator
Remove and Install Fan Belt
Group 0515: Speed Controls
Service Equipment and Tools
Specifications
Injection Pump Fast and Slow Idle Stops Adjustment
Remove and Install Engine Speed Control Cable
Remove and Install Engine Control Motor and Sensor
Engine Control Motor and Sensor Adjustment
Engine Speed Learning Procedure
Remove and Install Fuel Shut-Off Solenoid Linkage
Check and Adjust Fuel Shut-Off Solenoid Linkage
Group 0520: Intake System
Other Material
Specifications
Air Intake System Leakage Test
Remove and Install Air Cleaner
Group 0560: External Fuel Supply Systems
Other Material
Specifications
Remove and Install Fuel Tank
Remove and Install Primary Fuel Filter (Water Separator)
Disassemble and Assemble Primary Fuel Filter (Water Separator)
Remove and Install Final Fuel Filter
Remove and Install Final Fuel Filter Element
Bleed Fuel System
Section 07: Dampener Drive (Flex Coupling)
Group 0752: Elements
Service Equipment and Tools
Other Material
Specifications
Remove and Install Dampener Drive (Flex Coupling)
Section 16: Electrical System
Group 1671: Batteries, Support, and Cables
Service Equipment and Tools
Specifications
Handle Batteries Safely
Procedure for Testing Batteries
Checking Electrolyte Specific Gravity
Check Battery Electrolyte Level and Terminals
Using Booster Batteries-24 Volt System
Charge Battery
Engine Speed Learning Procedure
Remove and Install Batteries
Adding 12 or 24 Volt Accessories
Group 1672: Alternator, Regulator, and Charging System Wiring
Alternators and Starting Motors-Use CTM77
Specifications
Remove and Install Alternator
Group 1674: Wiring Harness and Switches
Essential Tools
Specifications
Front Chassis Electrical Component Identification
Cab Electrical Component Identification
Hydraulic Electrical Component Identification
Engine Electrical Component Identification
Connecting Engine and Pump Controller (EPC) Harness Connector
Disconnecting Spring Wire Clip Connectors
Disconnecting Tab Retainer Connectors
Replacing Fuses
Fuse (Blade-Type) Color Codes
Remove and Install Cab Ground Straps
Remove and Install Starter Switch
Engine Speed Learning Procedure
Remove and Install Dome Light Switch
Remove and Install Engine Overheat Alarm Switch
Remove and Install Coolant Level Switch
Remove and Install Engine Oil Pressure Switch
Remove and Install Engine Oil Level Switch
Remove and Install Engine Water Temperature Sensor
Remove and Install Fuel Level Switch
Remove and Install Travel Alarm
Changing Travel Alarm Volume
Remove and Install Dig Pressure Switch
Remove and Install Propel Pressure Switch
Remove and Install Front and Rear Pump Pressure Sensor
Remove and Install Front and Rear Pump Control Pressure Sensor
Remove and Install Proportional Solenoids
Remove and Install Windshield Wiper Enable Switch