John Deere 120 Excavator Operator’s Manual – PDF DOWNLOAD

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John Deere 120 Excavator Operator’s Manual – PDF DOWNLOAD

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John Deere 120 Excavator Operator’s Manual – PDF DOWNLOAD

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TABLE OF CONTENTS:

John Deere 120 Excavator Operator’s Manual – PDF DOWNLOAD

Contents 7
Safety 11
John Deere Excavator Safety Features 11
Recognize Safety Information 12
Understand Signal Words 12
Follow Safety Instructions 12
Avoid Injury From: Loading Machine on a Trailer, fastening Machine to Trailer, Unloading Machine from Trailer Always Use Caution when Loading and Unloading Machines on a Trailer Always 13
Avoid Injury from Backover Accidents Before Moving Machine, be Sure All Persons are Clear of Area Always be Alert for Bystanders Moving into the Work Area Use Horn or Other Signal to W 14
Avoid Injury from Rollaway Accidents To Prevent Rollaway, Always Make Sure Machine is Properly Secured Before Leaving Operator’s Seat Death or Serious Injury may Result if You Attempt to Mo 15
Inspect Machine 15
Use Handholds and Steps 16
Use Seat Belt 16
Maintain Seat Belt 17
Move and Operate Machine Safely 17
Operate Only from Operator’s Seat 18
Secondary Exits 18
Operate Machine Safely 18
Dig with Caution 19
Operate with Caution 19
Avoid Tipping 19
Avoid Power Lines 20
Drive Machine Safely 20
Beware of Exhaust Fumes 20
Park Machine Safely 21
Keep Riders off Machine 21
Operate Attachment Safely 22
Handle Fluids Safely—Avoid Fires 22
Prepare for Emergencies 23
Handle Starting Fluid Safely 23
Clean Trash from Machine 23
Protect Against Flying Debris 24
Wear Protective Clothing 24
Protect Against Noise 24
Handle Chemical Products Safely 25
Warn Others of Service Work 25
Stay Clear of Moving Parts 26
Support Machine Properly 26
Service Cooling System Safely 26
Practice Safe Maintenance 27
Remove Paint Before Welding or Heating 28
Avoid Heating Near Pressurized Fluid Lines 28
Avoid High Pressure Fluids 29
Prevent Battery Explosions 29
Clean the Machine Regularly 30
Store Attachments Safely 30
Dispose of Waste Properly 31
Safety Signs 32
Safety Signs 32
Operator’s Station 39
Pedals, Levers, and Panels 39
Right Front Panel and Right Console Panel 40
Monitor Panel 41
Engine Coolant Temperature Gauge 41
Warm Up Indicator 41
Fuel Gauge 42
H/P (High Power) Mode Indicator 42
E (Economy) Mode Indicator 42
Auto Idle Indicator 42
Hydraulic Oil Level Indicator 43
Fuel Level Indicator 43
Air Filter Restriction Indicator 43
Engine Coolant Temperature Indicator 44
Engine Oil Pressure Indicator 44
Alternator Voltage Indicator 44
Engine Oil Level Indicator 45
Engine Coolant Level Indicator 45
Switch Panel 45
Buzzer and Buzzer Stop Switch 46
Wiper Switch 46
Washer Switch 47
Operating Lights Switch 47
Cab Light 48
Key Switch 48
Engine RPM Dial 48
Horn 48
Hour Meter 49
Heater 49
Control Panel Levers and Switches 50
Defroster Operation 50
Cab Heater and Air Conditioner—If Equipped 51
Control Panel Switches 52
Cab Heater Operation 53
Air Conditioner Operation 54
Defroster Operation 54
Front Console 55
Operating the AM/FM Radio 55
Setting the Clock 56
Cab Door Release Lever 56
Secondary Exit Tool 56
Opening Upper Front (Secondary Exit) Window 57
Closing Upper Front Window 57
Removing and Storing the Lower Front Window 58
Opening Side Windows 59
Opening and Closing the Roof Exit Cover 59
Adjusting the Seat 60
Adjusting the Armrest 60
Seat Belt 61
Operator’s Manual Compartment 61
Pre Start Inspection 62
Inspect Machine Daily Before Starting 62
Operating the Engine 63
Check Instruments Before Starting 63
Level Check 63
Starting the Engine 64
Using Booster Batteries—24 Volt System 65
Check Instruments After Starting 66
Warming the Machine 66
Cold Weather Warm Up 67
Stopping the Engine 68
Driving the Machine 69
Steering the Machine Using Pedals 69
Steering the Machine Using Levers 71
Removing Propel Levers 72
Propel Speed Switch 72
Travel Alarm and Travel Alarm Cancel Switch 73
Parking the Machine 73
Parking Machine During Freezing Weather 74
Lock All Compartments 74
Operating the Machine 75
ISO/SAE Excavator Control Pattern 75
Control Lever Pattern Conversion 76
Deere Backhoe Control Pattern 78
Pilot Control Shut Off Lever 79
Auto Idle Switch 80
Mode Selection Switch 81
E (Economy) Mode 82
H/P (High Power) Mode 83
Standard Mode 83
Operating Tips 84
Driving Machine 84
Driving on Slopes 85
Driving Down a Slope 85
Driving Up a Slope 85
Driving Up a Steep or Slippery Slope—Boom on Uphill End of Machine 86
Driving Up a Steep or Slippery Slope—Boom on Downhill End of Machine 86
Moving Machine off an Embankment 87
Leveling Machine 88
Using Bucket 88
Planning Spoil Piles 90
Trenching 90
Backfilling 91
Truck Loading 92
Operating in Water and Mud 93
Clean Track Frame Area 93
Lifting 94
Hydraulic Breaker and Crusher Attachments 96
Lower Boom with Engine Stopped 96
Transporting 99
Transporting 120 Excavator Equipped With Long Arm 99
Loading Machine on a Trailer 100
Fasten Machine to Trailer 101
Unloading Machine from Trailer 102
Towing Machine 103
Lifting the Machine 104
Fuels and Lubricants 105
Diesel Fuel 105
Lubricity of Diesel Fuels 105
Low Sulfur Diesel Fuel Conditioner 106
Diesel Fuel Storage 106
Fuel Tank 107
Do Not Use Galvanized Containers 107
Diesel Engine Oil 108
Hydraulic Oil 109
Swing Gearbox, Propel Gearbox and Pump Gearbox Oils 110
Track Roller, Front Idler, and Carrier Roller Oil 110
Track Adjuster, Working Tool Pivot, Swing Bearing, and Swing Bearing Gear Grease 111
Oil Filters 111
Lubricant Storage 112
Alternative and Synthetic Lubricants 112
Mixing of Lubricants 113
Periodic Maintenance 114
Service Your Machine at Specified Intervals 114
Check the Hour Meter Regularly 114
Use Correct Fuels and Lubricants 114
Prepare Machine for Maintenance 115
Open Access Doors for Service 115
Open Hood for Service 116
Maintenance and Repair Record Keeping System 117
OILSCAN Plus,® CoolScan Plus® and 3 Way Coolant Test Kit 118
Maintenance and Repair Record Keeping System 119
Maintenance—As Required 122
Clean Fuel Tank Inlet Screen 122
Drain Fuel Tank Sump 122
Clean Radiator Air Inlet Screen 123
Drain Water Separator 123
Clean Air Cleaner Dust Unloader Valve 124
Check Track Sag—Steel Shoe 124
Check Track Sag—Rubber Track, If Equipped 125
Adjusting Track Sag 126
Rubber Track Care 127
Removing Rubber Track 127
Installing Rubber Track 128
Check Windshield Washer Fluid Level 129
Maintenance—Every 10 Hours or Daily 130
Check Engine Oil Level 130
Check Recovery Tank Coolant Level 131
Check Hydraulic Oil Level 132
Maintenance—Every 50 Hours 134
Grease Working Tool Pivots 134
Maintenance—Every 250 Hours 136
Check Swing Gearbox Oil Level 136
Drain Hydraulic Tank Sump 136
Check Pump Drive Gearbox Oil Level 137
Change Engine Oil and Replace Filter 138
Check Radiator Coolant Level 140
Check Battery Electrolyte Level and Terminals 140
Check Propel Gearbox Oil Level 143
Clean Dusty Primary Element 144
Inspect Element 145
Maintenance—Every 500 Hours 146
Grease Swing Bearing 146
Grease Swing Bearing Gear 147
Replace Final Fuel Filter 148
Replace Primary Fuel Filter (Water Separator) 149
Check Air Intake Hoses 150
Replace Hydraulic Oil Filter 151
Check Coolant In Radiator 153
Maintenance—Every 1000 Hours 154
Change Swing Gearbox Oil 154
Change Pilot Control Oil Filter 154
Change Pump Drive Gearbox Oil 155
Change Air Cleaner Elements 156
Inspect Fan Belt 157
Replace Air Cleaner Dust Valve 157
Maintenance—Every 2000 Hours 158
Change Hydraulic Tank Oil 158
Drain Cooling System 161
Diesel Engine Coolant 163
Cooling System Fill and Deaeration 164
Change Propel Gearbox Oil 165
Clean the Engine Crankcase Ventilation Tube 166
Check and Adjust Engine Valve Lash (Clearance) 166
Firing Order 4—Cylinder Engine 168
Check Engine Speeds 169
Engine Control Motor and Sensor 169
Adjustment 169
Engine Speed Learning Procedure 171
Maintenance 172
Do Not Service Injection Nozzles 172
Do Not Adjust Injection Pump 172
Bleeding the Fuel System 173
Precautions for Alternator and Regulator 173
Service Batteries Carefully 174
Checking Electrolyte Specific Gravity 176
Using Battery Charger 177
Replacing Batteries 178
Removing Batteries 178
Welding on Machine 179
Adding 12—Volt Accessories 179
Replacing Fuses 180
Fuse (Blade Type) Color Codes 181
Checking Travel Alarm System 181
Replacing Bucket Teeth 182
Replacing Bucket Tooth Tip—Heavy Duty Bucket 183
Adjusting Bucket Linkage 183
Removing the Bucket 185
Do Not Service Control Valves, Cylinders, Pumps or Motors 185
Track Sag General Information 186
Hardware Torque Specifications 186
Check Track Shoe Torque 187
Unified Inch Bolt and Cap Screw Torque Values 188
Metric Bolt and Cap Screw Torque Values 189
Additional Metric Cap Screw Torque Values 190
Check Oil Lines And Fittings 192
Service Recommendations for O Ring Boss Fittings 193
Service Recommendations for Flat Face O Ring Seal Fittings 195
Service Recommendations for 37° Flare and 30° Cone Seat Connectors 196
Service Recommendations For Flared Connections—Straight or Tapered Threads 197
Service Recommendations For Inch Series Four Bolt Flange Fittings 198
Service Recommendations for Metric Series Four Bolt Flange Fitting 199
Operational Checkout 200
Operational Checkout 200
Operator Station Checks—Key Switch On, Engine Off 200
Operator Station Checks—Engine On 202
Hydraulic System Checks 205
Undercarriage Checks 212
Accessories Checks 215
Seat, Doors, Windows, Latches, and Locks Checks 217
Coolant Checks 222
Troubleshooting 225
Using Troubleshooting Charts 225
Engine 226
Electrical System 233
Hydraulic System 239
Storage 244
Prepare Machine for Storage 244
Monthly Storage Procedure 246
Machine Numbers 249
Record Product Identification Number (PIN) 249
Record Engine Serial Number 249
Record Propel Motor Serial Numbers 249
Record Swing Motor Serial Number 249
Record Hydraulic Pump Serial Number 250
Specifications 252
120 Excavator 252
120 Working Ranges 255
Engine Specifications 257
Drain and Refill Capacities 258
Lift Capacity—KG (LB) 259
Lift Capacity—KG (LB) 260
Lift Capacity—KG (LB) 261
Lift Capacity—KG (LB) 262
Lift Capacity—KG (LB) 263
Lift Capacity—KG (LB) 264
Crime Prevention Tips 265
Help Prevent Crime 265
Record Identification Numbers 265
Keep Proof of Ownership 265
Park Indoors Out of Sight 265
When Parking Outdoors 266
Reduce Vandalism 266
Report Thefts Immediately 267
Checklists 275
Maintenance and Repair Record Keeping System 275
John Deere Service Literature Available 279
Technical Information 279
John Deere Service Keeps You On The Job 281
AT YOUR SERVICE WHEN YOU NEED IT 281

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