John Deere 120D Excavator Service Repair Manual - TM10737

John Deere 120D Excavator Service Repair Manual - TM10737

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This Technical Manual offers all the service and repair data. With this in-depth & very detailed manual you will be able to work on your vehicle with the absolute best resources available, which will not only save you money in repair bills but will also help you to look after your bussiness. The information on this manual covered everything you need to know when you want to repair or service your device.

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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