Worldwide Construction And Forestry Division 135D User manual

135D
Excavator
OperationandTest
OPERATION&TESTTECHNICAL
MANUAL
135DExcavator
TM1074216AUG19(ENGLISH)
WorldwideConstruction
AndForestryDivision
PRINTEDINU.S.A.

Introduction
DX,TMIFC-19-15APR14-1/1
Foreword
Thismanualiswrittenforanexperiencedtechnician.
Essentialtoolsrequiredinperformingcertainservicework
areidentifiedinthismanualandarerecommendedforuse.
Livewithsafety:Readthesafetymessagesinthe
introductionofthismanualandthecautionspresented
throughoutthetextofthemanual.
Thisisthesafety-alertsymbol.Whenyouseethis
symbolonthemachineorinthismanual,bealerttothe
potentialforpersonalinjury.
Technicalmanualsaredividedintwoparts:repairand
operationandtests.Repairsectionstellhowtorepair
thecomponents.Operationandtestssectionshelpyou
identifythemajorityofroutinefailuresquickly.
Informationisorganizedingroupsforthevarious
componentsrequiringserviceinstruction.Atthe
beginningofeachgrouparesummarylistingsofall
applicableessentialtools,serviceequipmentandtools,
othermaterialsneededtodothejob,servicepartskits,
specifications,weartolerances,andtorquevalues.
TechnicalManualsareconciseguidesforspecific
machines.Theyareon-the-jobguidescontainingonlythe
vitalinformationneededfordiagnosis,analysis,testing,
andrepair.
Fundamentalserviceinformationisavailablefromother
sourcescoveringbasictheoryofoperation,fundamentals
oftroubleshooting,generalmaintenance,andbasictype
offailuresandtheircauses.
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Introduction
TX,TM,FAX-19-03JUL01-1/1
TechnicalInformationFeedbackForm
Weneedyourhelptocontinuallyimproveourtechnical
publications.PleasecopythispageandFAXormailyour
comments,ideasandimprovements.
SENDTO:JohnDeereDubuqueWorks
18600SouthJohnDeereRoad
Attn:Publications,Dept.324
Dubuque,IA52004-0538
USA
FAXNUMBER:1-563-589-5800(USA)
PublicationNumber:
PageNumber:
Ideas,Comments:
Name:
Phone:
EmailAddress:
THANKYOU!
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Introduction
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Contents
Section9000—GeneralInformation
Group01—Safety
Section9001—Diagnostics
Group10—MainController(MCF)DiagnosticTrouble
Codes
Group20—EngineControlModule(ECM)Diagnostic
TroubleCodes
Group30—InformationController(ICF)Diagnostic
TroubleCodes
Group40—AirConditionerController(ACF)Diagnostic
TroubleCodes
Group50—MonitorController(MON)Diagnostic
TroubleCodes
Section9005—OperationalCheckout
Procedure
Group10—OperationalCheckoutProcedure
Section9010—Engine
Group05—TheoryofOperation
Group15—DiagnosticInformation
Group25—Tests
Section9015—ElectricalSystem
Group05—SystemInformation
Group10—SystemDiagrams
Group15—Sub-SystemDiagnostics
Group16—MonitorOperation
Group20—References
Section9020—PowerTrain
Group05—TheoryofOperation
Group15—DiagnosticInformation
Section9025—HydraulicSystem
Group05—TheoryofOperation
Group15—DiagnosticInformation
Group25—Tests
Section9031—HeatingandAirConditioning
Group05—TheoryofOperation
Group15—DiagnosticInformation
Group25—Tests
Section9050—ReferenceMaterial
Group05—TerminologyCrossReferenceChart
Section9900—DealerFabricatedTools
Group99—DealerFabricatedT ools
OriginalInstructions.Allinformation,illustrationsandspecificationsinthis
manualarebasedonthelatestinformationavailableatthetimeofpublication.
Therightisreservedtomakechangesatanytimewithoutnotice.
COPYRIGHT©2019
DEERE&COMPANY
Moline,Illinois
Allrightsreserved.
AJohnDeereILLUSTRUCTION™Manual
PreviousEditions
Copyright©2008,2010,2011,2012,2013,2014,2015,2016,2017,2018
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Contents
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Section9000
GeneralInformation
Contents
Page
Group01—Safety
RecognizeSafetyInformation...................9000-01-1
FollowSafetyInstructions..........................9000-01-1
OperateOnlyIfQualified...........................9000-01-1
WearProtectiveEquipment.......................9000-01-1
AvoidUnauthorizedMachine
Modifications..........................................9000-01-2
AddCabGuardingforSpecial
Uses......................................................9000-01-2
InspectMachine........................................9000-01-2
StayClearofMovingParts........................9000-01-2
AvoidHigh-PressureFluids.......................9000-01-3
AvoidHigh-PressureOils..........................9000-01-3
BewareofExhaustFumes........................9000-01-4
PreventFires.............................................9000-01-4
PreventBatteryExplosions.......................9000-01-4
HandleChemicalProductsSafely..............9000-01-5
DisposeofWasteProperly........................9000-01-5
PrepareforEmergencies...........................9000-01-5
UseStepsandHandholds
Correctly................................................9000-01-5
StartOnlyFromOperator'sSeat...............9000-01-6
UseandMaintainSeatBelt.......................9000-01-6
PreventUnintendedMachine
Movement..............................................9000-01-6
AvoidWorkSiteHazards...........................9000-01-7
KeepRidersOffMachine..........................9000-01-7
AvoidBackoverAccidents.........................9000-01-8
AvoidMachineTipOver............................9000-01-8
UseSpecialCareWhenLifting
Objects..................................................9000-01-9
AddandOperateAttachments
Safely.....................................................9000-01-9
PreventUnintendedDetonationof
ExplosiveDevices.................................9000-01-9
ParkandPrepareforService
Safely...................................................9000-01-10
ServiceCoolingSystemSafely...............9000-01-10
RemovePaintBeforeWeldingor
Heating................................................9000-01-11
MakeWeldingRepairsSafely.................9000-01-11
DriveMetalPinsSafely...........................9000-01-11
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Contents
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Group01
Safety
TX03679,00016CC-19-03JAN07-1/1
TX14740,0000019-19-10JAN07-1/1
TX03679,00016FA-19-03JAN07-1/1
TX03679,00016D0-19-03JAN07-1/1
RecognizeSafetyInformation
Thisisthesafetyalertsymbol.Whenthissymbolis
noticedonthemachineorinthismanual,bealertfor
thepotentialofpersonalinjury.
Followtheprecautionsandsafeoperatingpractices
highlightedbythissymbol.
Asignalword—DANGER,WARNING,orCAUTION—
isusedwiththesafetyalertsymbol.DANGERidentifies
themostserioushazards.
Onthemachine,DANGERsignsareredincolor,
WARNINGsignsareorange,andCAUTIONsignsare
yellow.DANGERandWARNINGsignsarelocatednear
specifichazards.GeneralprecautionsareonCAUTION
labels.
T133555—UN—15APR13T133588—19—28AUG00
FollowSafetyInstructions
Readthesafetymessagesinthismanualandonthe
machine.Followthesewarningsandinstructionscarefully.
Reviewthemfrequently.
Keepsafetysignsingoodcondition.
Besurenewequipmentcomponentsandrepairparts
includethecurrentsafetysigns.
Besurealloperatorsofthismachineunderstandevery
safetymessage.Replaceoperator'smanualandsafety
signsimmediatelyifmissingordamaged.Replacement
safetysignsareavailablefromyourauthorizeddealer.
OperateOnlyIfQualified
Donotoperatethismachineunlesstheoperator'smanual
hasbeenreadcarefully,andyouhavebeenqualifiedby
supervisedtrainingandinstruction.
Operatorshouldbefamiliarwiththejobsiteand
surroundingsbeforeoperating.Tryallcontrolsand
machinefunctionswiththemachineinanopenarea
beforestartingtowork.
Knowandobserveallsafetyrulesthatmayapplytoevery
worksituationandworksite.
WearProtectiveEquipment
Guardagainstinjuryfromflyingpiecesofmetalordebris;
weargogglesorsafetyglasses.
Wearclosefittingclothingandsafetyequipment
appropriatetothejob.
Prolongedexposuretoloudnoisecancauseimpairment
orlossofhearing.Wearsuitablehearingprotectionsuch
asearmuffsorearplugstoprotectagainstobjectionable
oruncomfortableloudnoises.
TS206—UN—15APR13
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Safety
AM40430,00000A9-19-01JUL15-1/1
TX03679,00016CE-19-03JAN07-1/1
TX03679,0001734-19-17DEC14-1/1
TX03679,00016D2-19-03JAN07-1/1
AvoidUnauthorizedMachineModifications
JohnDeererecommendsusingonlygenuineJohnDeere
replacementpartstoensuremachineperformance.
NeversubstitutegenuineJohnDeerepartswithalternate
partsnotintendedfortheapplicationasthesecan
createhazardoussituationsorhazardousperformance.
Non-JohnDeereparts,oranydamageormalfunctions
resultingfromtheiruse,arenotcoveredbyanyJohn
Deerewarranty.
Modificationsofthismachine,oradditionofunapproved
productsorattachments,mayaffectmachinestabilityor
reliability,andmaycreateahazardfortheoperatoror
othersnearthemachine.Theinstallerofanymodification
whichmayaffecttheelectroniccontrolsofthismachineis
responsibleforestablishingthatthemodificationdoesnot
adverselyaffectthemachineoritsperformance.
Alwayscontactanauthorizeddealerbeforemaking
machinemodificationsthatchangetheintendeduse,
weightorbalanceofthemachine,orthataltermachine
controls,performance,orreliability.
AddCabGuardingforSpecialUses
Specialworksituationsormachineattachmentsmay
createanenvironmentwithfallingorflyingobjects.
Workingnearanoverheadbank,doingdemolitionwork,
usingahydraulichammer,orworkinginawoodedarea,
forexample,mayrequireaddedguardingtoprotectthe
operator.
FOPS(fallingobjectprotectivestructures)andspecial
screensorguardingshouldbeinstalledwhenfallingor
flyingobjectsmayenterordamagethemachine.Contact
yourauthorizeddealerforinformationondevicesintended
toprovideprotectioninspecialworksituations.
T133733—UN—15SEP00
InspectMachine
Inspectmachinecarefullyeachdaybywalkingaroundit
beforestarting.
InspectandCleanthePolycarbonateWindows.See
InspectandCleanPolycarbonateWindows.(Section4-1.)
Keepallguardsandshieldsingoodconditionandproperly
installed.Fixdamageandreplacewornorbrokenparts
immediately.Payspecialattentiontohydraulichosesand
electricalwiring.
T6607AQ—UN—15APR13
StayClearofMovingParts
Entanglementsinmovingpartscancauseseriousinjury.
Stopenginebeforeexamining,adjustingormaintaining
anypartofmachinewithmovingparts.
Keepguardsandshieldsinplace.Replaceanyguard
orshieldthathasbeenremovedforaccessassoonas
serviceorrepairiscomplete.
T133592—UN—15APR13
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