JOHN DEERE C120 COMBINE TM703019 PDF MANUAL

C120 Combines (Asian Edition)

TECHNICAL MANUAL C120 Combines (Asian Edition) TM703019 01DEC18 (ENGLISH)

John Deere

Introduction Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service This manual is written for an experienced technician. Essential equipment and tools, other materials needed to do the job, tools required in performing certain service work are identified in service parts kits, specifications, wear tolerances, and torque values. this manual and are recommended for use.

Foreword

Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.

Technical Manuals are concise guides for specific machines.

They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair.

This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury.

Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.

Technical manuals tell how to repair the components and help you identify the majority of routine failures quickly.

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Contents Section 10 - General

Group 05 - Safety Group 10 - Identification Views and Serial Numbers Group 15 - Specifications Group 20 - Fuels, Lubricants, and Coolants Group 25 - Dimensions Group 30 - Delivery and Storage Instructions

Section 20 - Engine

Group 05 - Engine Cooling System Group 10 - Engine

Section 30 - Fuel and Air Group 05 - Components Group 10 - Intake and Exhaust System

Section 40 - Electrical System Group 05 - Battery

Group 10 - Electrical Components Group 15 - Alternator Group 20 - Starting Motor and Starting Relay Group 25 - Sensors

Section 50 - Ground Drive Group 05 - Variable Speed

Group 10 - Clutch Group 15 - Transmission and Differential Group 20 - Final Drive

Section 60- -Brakes Brakes and Rear Axle Group 05

Group 15 - Chain

Section 90 - Operator Station Group 05 - Cab Group 20 - Windshield Wiper Group 30 - Operating Platform Levers Group 40 - Operator Seat Group 50 - Steering Column

Section 110 - Feeder House

Group 05 - Feeder House-Removing and Installing Group 10 - Feeder House-Adjustments

Section 120 - Threshing Separation and Grain Cleaning Group 05 - Cylinder and Concave Group 10 - Separator Drive Group 15 - Rotor Group 20 - Cleaning

Section 130 - Elevator, Grain Tank and Group 05 - Elevators and Augers Unloading Group 10 - General References Section 240 - Electrical Diagnostic Group 20 - Theory of Operation Group 30 - Schematics Group 50 - Diagnostics

Group 10 - Rear Axle Group 15 - Brake Valve and Brake Fluid Reservoir

Group 40 249 - Electrical Connectors Components/ Section - Electrical Connectors

Group 05 - Hydraulic Lines and Connections

Section 270 - Hydraulic Diagnostics Group 20 - Theory of Operation

Section 70 - Hydraulic System

Group 10 - Hydraulic Reservoir Group 15 - Hydraulic Pump Group 20 - Hydraulic Control Valve Group 25 - Hydraulic Cylinders Group 30 - Accumulator Group 70 - Hydrostatic Motor

Group 10 - Hydraulic System Specification Group 30 - Schematics Group 50 - Diagnostics

Group 10 - Hydraulic System Components Group 20 - Hydraulic Sub-System Components Section 279 - Hydraulic Components Group 30 - Hydraulic System Sub-Components

Section 80 - Miscellaneous

Group 05 - Shafts and Bearings Group 10 - Belts

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Section 10

General Page

Contents

Page

Service combine harvester safely.........................10-05-12 Support harvester properly....................................10-05-12 Maintenance of electrical parts..............................10-05-12 Prevent battery explosions....................................10-05-12 Handle batteries safely..........................................10-05-12 Service engine.......................................................10-05-13 Remove accumulated crop debris.........................10-05-13 Service cooling system safely...............................10-05-13 Service tires safely................................................10-05-14 Retighten Front and Rear Wheel Nuts..................10-05-14 Lock the cutter fuel tank........................................10-05-15 Safety regulations for unattended combine 10-05-15 harvester........................................................

Group 05 - Safety Be familiar with safety information.........................10-05-1 Understand relevant safety instructions................10-05-1 Understand sign words..........................................10-05-1 Use proper tools....................................................10-05-2 Practise safe maintenance....................................10-05-2 Handle chemical products safely...........................10-05-2 Remove paint before welding or heating...............10-05-2 Avoid heating near pressurized fluid lines.............10-05-3 Avoid injury caused by pressurized fluids..............10-05-3 Work in clean area.................................................10-05-3 Dispose of waste properly.....................................10-05-4 Avoid harmful asbestos dust.................................10-05-4

Park the combine harvester safely........................10-05-15 Protect against noise.............................................10-05-15 Use and precautions of hydraulic jacks.................10-05-16

Avoid hot exhaust..................................................10-05-4 Handle starting fluid safely....................................10-05-5 Handle fluids safely - Prevent Fire.........................10-05-5

Support front axle..................................................10-05-16 Support rear axle...................................................10-05-17

Illuminate working area safely...............................10-05-5 Install various guards.............................................10-05-5 Use lifting equipment properly...............................10-05-6

Safety signs...........................................................10-05-18 Group 10 - Identification Views and Serial Numbers

Safety first..............................................................10-05-6 Support machine properly.....................................10-05-6 Prevent acid burns.................................................10-05-7 Replace safety signs.............................................10-05-7

Identification Numbers...........................................10-10-1 Group 15 - Specifications C120 self-propelled Combine Specifications.........10-15-1 Metric Bolt and Screw Torque Values....................10-15-3

Service accumulator system safely.......................10-05-7 Do not open pressurized fuel system....................10-05-8 Waiting period before opening pressurized fuel 10-05-8 system ........................................................... .

Use steps and handrails correctly.........................10-05-8

Unified Inch Bolt and Screw Torque Values..........10-15-4 Keep Hydraulic System Clean...............................10-15-4 Face Seal Fittings Assembly and Installation-All 10-15-5 Pressure Applications....................................

Driving combine harvester.....................................10-05-8 Riders are not allowed to get on the machine.......10-05-9 Avoid cables..........................................................10-05-9 Park the harvester safely.......................................10-05-9 Handle fuel safely - Prevent fire............................10-05-9 Prepare for emergencies.......................................10-05-9 Wear protective clothing........................................10-05-10 Transport harvester with cutter safely....................10-05-10 Transport harvester without cutter safely...............10-05-10 Transport position of steps....................................10-05-10 Transport Position of Unloading Auger Tube.........10-05-10 Transport lights......................................................10-05-11 Drive on a slope.....................................................10-05-11 Use safety signal lights and safety signs...............10-05-11 Do not get close to the cutter.................................10-05-11 Keep hands away from blades..............................10-05-11 General maintenance............................................10-05-11 Avoid touching moving parts.................................10-05-11 Cleaning grain tank................................................10-05-11 Stay away from the chopper..................................10-05-12

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Metric Face Seal Fitting Torque Chart Standard 10-15-6 Pressure Applications....................................

Group 20 - Fuels, Lubricants, and Coolants Diesel Fuel............................................................10-20-1 Engine Oil..............................................................10-20-1 Hydraulic Oil..........................................................10-20-1 Gear Oil.................................................................10-20-2 Transmission......................................................... 10-20-3 Gear Oil Information..............................................10-20-3 Grease................................................................... 10-20-4 Coolants................................................................ 10-20-5 Group 25 - Dimensions Dimensions of Cutting Platform.............................10-25-1 Group 30 - Delivery and Storage Instructions Combine Temporary Storage Instructions.............10-30-1 Prepare Combine For Railroad Delivery...............10-30-1 Pre-Delivery Inspection.........................................10-30-2 Delivery Instructions and Inspection......................10-30-3

C120 Combines

Safety

Group 05 Safety Be familiar with safety information

T81389-UN: Safety alert signs

This is a safety alert sign. When you see this sign on your machine or in this manual, beware of the possibility of personal injury.

Follow recommended precautions and safe operating practices.

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the latest safety signs are included. You may buy safety signs Understand relevant safety instructions thatfrom the dealers of John Deere for replacement. Know how to

operate the machine and to properly use control devices.

YC1281-UN: Safety instructions

on roads.

Drivers must be trained and qualified by the Deere dealer, and fully understand the operator′s manual; otherwise, they do not have the qualification to operate the harvester. Persons who are not trained by Deere dealers, drunken people, non-adults, pregnant or sick people are strictly prohibited to operate the machine. Each user must strictly abide by the technical safety instructions and strictly observe traffic regulations when driving

Keep the machine in good working condition. If the machine is modifiedwithoutauthorization,theperformanceandsafetyofthe machine will be weakened, and the service life of the machine will be affected. If you do not understand any content in this manual Carefullyreadallsafetyinformationinthemanualandtheand need help, please contact John Deere dealer. machine safety alerts. Keep the safety signs in good condition.

OUYC401,0000376-19-20120322 Replace lost or damaged safety signs. When buying new equipment components and repair parts, you should make sure

Understand sign wordsTS187-19: Sign words Sign words DANGER, WARNING or CAUTION are to be used togetherwithsafetyalertsigns.DANGERindicatesaveryserious

injury may occur.

DANGER or WARNING sign appears in certain particularly dangerous places. General precautions are listed in CAUTION safety signs. In this manual, CAUTION also reminds us to pay

attention to some safety information.

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Safety

Use proper tools

TS779-UN: Proper tools

Tools should be in accordance with operating requirements.

Makeshift tools and incorrect procedures may induce safety hazards.

Powered tools are used only to loosen threaded parts and fasteners.

Use correct size tools to loosen and tighten fasteners. Using imperial unit tools on metric unit fasteners is prohibited. Beware of wrench slippage which may result in personal injury.

Only use repair parts that meet the specifications of John Deere.

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Before work, understand the maintenance procedures and keep the working environment clean and dry.

Practise safe maintenance YC1282-UN: Safe maintenance

Do not lubricate, repair or calibrate the machine when it is running. Keep your hands, feet and clothing away from the movingparts.Separatealldrivesandcontrolstorelievepressure.

Lower the cutter to the ground, switch off the engine and get the key out. Let the machine cool down.

Machine parts that are lifted for maintenance purpose should be well supported.

Keep all parts in good condition and install them in the correct positions. Carry out troubleshooting timely, replace worn or broken parts. Clear the grease, oil and dust accumulated on the machine.

Beforecalibratingtheelectricalsystemofthemachineandbefore welding, disconnect the battery grounding wire.

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Dangerous chemical products can cause serious personal injury.

Handle chemical products safely YC1283-UN: Chemical products

Related chemical products with potential danger are: lubricants, refrigerants, paints and adhesives.

Read relevant instructions before using dangerous chemical products. You can then know the risks exactly and complete all tasks safely. Comply with relevant procedures and use equipment as recommended.

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Remove paint before welding or heating YC1284-UN: Welding

Clearatleast76mm(3inches)paintfromthepartstobeheated.

If you′re using sand paper or other materials to clear paint, avoid breathing in the dust. When working, wear an approved antidust mask. If you use solvents or paint strippers to remove paint, before welding, first use soap and water to clear the solvents or paint strippers. Remove solvent or paint stripper containers and other flammable materials from the work site. Wait for at least 15 minutestillthesmokedissipates,andcarryoutweldingorheating afterwards.

Avoid potentially toxic gases and dust that are generated.

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Toxic fumes may be generated when the paint is heated during welding, brazing, or blast-burning.

Work in outdoor environment or in a well-ventilated place. Handle paints and solvents properly.

Remove paint before heating:

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For the full PDF version of this manual, Please click on the above download PDF button.

Safety

Avoid heating near pressurized fluid TS953-UN: Flammable spray Flammable spray can be generated by heating near pressurized lines fluid lines, resulting in severe burns to yourself and bystanders.

Welding, brazing, or blast-burning is prohibited near pressurized fluid lines or other combustible materials. Heating beyond the allowed area can lead to burst of pressurized fluid lines.

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Immediately replace the torn or worn hose assembly with the

injury by pressurized Avoid parts approved

by Johncaused Deere. fluids

Leaked pressurized fluid can penetrate skin and cause serious

injury.

Avoid hazards by relieving pressure before disconnecting hydraulic or other lines. Tighten all the joints before pressurizing.

Use cardboards to check for leaks. Protect hands and body from pressurized fluids.

Seek for medical treatment immediately in case of injury. Any fluid penetrated into skin must be removed, within a few hours, by means of surgery. Otherwise, it may lead to skin damage.

Doctors who are not familiar with how to deal with such injury should refer to relevant medical books or consult related personnel.SuchinformationinEnglishcanbeobtainedbycalling 1-800-822-8262 or +1 309-748-5636 from the Deere Medical

Centre, Moline, Illinois, United States.

X9811-UN: PressurizedOUYC401,000037E-19-20120313

Regularly, at least once a year, check the hydraulic hoses for oil leakage, kinks, cuts, cracks, abrasions, blisters, rust, exposed wire or any other tear or wear.

Work in clean areaT6642EJ-UN: Clean working area Before working:

Clean the working area and machine.

Make sure that you have all necessary tools to do your job.

Get the parts ready.

Read all instructions thoroughly, not only skimming.

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Safety Inappropriate disposal of waste harms the environment and the ecological balance. Potentially harmful waste used in the John Deere equipment include: lubricants, fuel, coolant, brake fluid, filters and batteries, etc.

Dispose of waste properly

Use leak-proof containers when draining fluids away. Using food orbeveragecontainersisprohibited,soastopreventothersfrom drinking mistakenly.

Do not pour waste onto the ground, down to sewage, or into any water source.

Air-conditioning refrigerant, when spilled into the air, may damage the atmosphere. Government regulations may require a certified air-conditioning service centre to recover and recycle used airconditioning refrigerants.

Please inquire on the proper way to recycle or dispose of waste from your local environmental or recycling centre, or from your John Deere dealer.

TS1133-UN: Recycle waste

Avoid harmful asbestos dust

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Avoid breathing in asbestos dust that may be generated when handling components containing asbestos fibers. Breathing in asbestos dust can lead to lung cancer.

Components containing asbestos fibers include brake pads, brake band and lining, clutch discs and some gaskets. Asbestos used in these components is usually in the resin or sealed in certain forms. Normal contact with the components is harmless because that does not release asbestos dust.

Avoid generating asbestos dust. Cleaning with compressed air is prohibited. Brushing, rubbing or polishing materials that contain asbestos is prohibited. When carrying out maintenance, wear a qualified breathing mask. Using a specialized vacuum cleaner to clean the asbestos is recommended. If not, oil mist, or water mist should be sprayed on the materials which contain asbestos.

TS220-UN: Asbestos dust

Keep bystanders away from this area.

Avoid hot exhaust

RG17488-UN: Safety — Hot parts

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When the engine is running, servicing the machine or accessories can result in serious personal injury. Avoid exposure to hot exhaust or skin contact with these hot exhaust parts.

When the machine is at work, exhaust parts and gases are of hightemperature.Exhaustgasesandcomponentsmayreachthe temperature hot enough to burn people, ignite, or melt general materials.

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Safety

Handle starting fluid safely

TS1356-UN: Store safely

Starting fluid is highly flammable.

Keep all sparks and flame away when using it. Starting fluid should be kept away from batteries and cables.

To prevent accidental discharge when storing the pressurized can, keep the cap on the container, and store it in a cool and secured location.

Do not incinerate or puncture a starting fluid container.

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Handle fluids safely — Prevent Fire

TS227-UN: Prevent fire

When you work around fuel, do not smoke or work with fuel near heaters or other fire hazards.

Keep flammable fluids away from fire hazards. Do not incinerate or puncture a pressurized container.

Make sure that the machine is clear of trash, grease and debris.

Do not store oily rags because they can be ignited and burn spontaneously.

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Illuminate working area safely

TS223-UN: Safe working area

Illumination in working area should be appropriate and safe. To workinorunderthemachine,useportablesafelights.Ensurethat the bulb is enclosed in wire cage. A hot filament which suddenly breaks will set the leaked fuel on fire.

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Install various guards

TS677-UN: Safety fan

Rotating cooling system fans, belts, pulleys, and drives can cause serious injury.

Keep all guards in place at all times when the engine is running.

Wear tight fitting clothes. Stop the engine and ensure that the fans, belts, pulleys and drives are stopped before calibrating, connecting or cleaning near fans and the drive components.

Install guards properly when the combine harvester operates.

Before removing the guards, separate the threshing clutch and switch off the engine.

Caution: Keep the hands, feet and clothing away from the moving parts.

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Safety

Use lifting equipment properly

TS226-UN: Proper lifting equipment

Lifting heavy components incorrectly can cause severe injury or machine damage.

Please follow the recommended procedures in this manual to dismount and install components.

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Safety first

TS231-19: Safety system

Before returning the machine to a customer, make sure that all parts of the machine function properly, especially the safety system. Install all fences and guards properly.

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Support machine properly

TS229-UN: Support properly

Before working on the machine, always lower the accessories or implements to the ground. If the work requires lifting machine or implements, you must support them safely. If they are lifted for a long time, hydraulic support devices may subside or leak.

Using cinder bricks, hollow bricks or other materials that may collapse under sustained loading to support the machine is prohibited. Using only one jack to support the machine is prohibited.Pleasefollowtherecommendedoperatingprocedures in this manual.

When implements or accessories are used with a machine, always follow safety precautions listed in the implement or accessory operator′s manual.

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Safety

Prevent acid burns

TS203-UN: Acid burns

Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, corrode clothes, and cause blindness if splashed into eyes.

Avoid the hazard by:

Filling batteries in a well-ventilated area.

Wearing eye protection and rubber gloves Avoiding breathing in fumes when electrolyte is added.

Avoiding spilling or dripping electrolyte.

Using proper jump start procedure.

If you spill acid on yourself:

Flush your skin with water.

Apply baking soda or lime to help neutralize the acid.

Flush your eyes with water for 15 - 30 minutes. Get medical attention immediately.

If acid is swallowed:

Do not induce vomiting.

Drink large amount of water or milk, but do not exceed 2 L (2 quarts).

Get medical attention immediately.

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Replace safety signs

TS201-UN: Safety signs

If safety signs are missing or damaged, replace them immediately. Use this operator’s manual for the correct placement of safety signs.

Therecanbeadditionalsafetyinformationcontainedonpartsand components sourced from suppliers that isnot reproduced in this operator′s manual.

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Service accumulator system safely

TS281-UN: Hydraulic accumulator

Leaked fluid or gas from the pressurized accumulators that are used in air-conditioning, hydraulic, and air braking systems can cause serious injury. Excessively high temperature can cause accumulator explosion and accidental rupture of pressurized pipes. Welding or blast-burning near pressurized accumulator or pressurized pipes is prohibited.

Relieve pressure from the pressurized system before dismounting accumulator.

Relieve pressure from the pressurized system before dismounting accumulator. Never attempt to relieve hydraulic system or accumulator pressure by loosening a fitting.

Accumulators cannot be repaired.

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Safety

Do not open pressurized fuel system

TS1343-UN: Pressurized fuel lines

Pressurized fuel in the fuel lines can cause serious injury. Do not disconnect or attempt to repair fuel lines, sensors, or any other components between the pressurized fuel pump and nozzles on engines with High Pressure Common Rail (HPCR) fuel system.

Only technicians who are familiar with this type of system can repair. (Please contact your John Deere dealer.)

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Waiting period before pressurized fuel system

opening TS1343-UN: Pressurized fuel lines

Pressurized fuel in the fuel lines can cause serious injury. Only technicians who are familiar with this type of system can repair.

Before disconnecting fuel lines, sensors, or any other components between the pressurized fuel pump and nozzles on engines with High Pressure Common Rail (HPCR) fuel system, wait a minimum of 15 minutes after the engine is stopped.

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Use steps and handrails correctly

T133468-UN: Use Handrails and steps

Prevent falls by facing the machine when you get on and off.

Keep three points of contact with step, handrail and railing.

Pay extra attention when mud, snow, or water causes slippery conditions on the steps. Keep the steps clean and free from any grease or lubricant oil. When getting out of the machine, do not jump. When the machine isoperating, do not mount ordismount.

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Driving combine harvester YC1285-UN: Driving

When the harvester is at work, all guards should have been installed properly. The harvester must be driven by a qualified driver. Before starting the machine, operator should note if there are any bystanders around. Honk the horn to alert them. Be particularly cautious when mounting the cutter to the machine.

Before starting the engine, the shift lever should be in neutral positionandthethreshingclutchmustbeintheseparateposition.

Caution: Keep the hands, feet and clothing away from the moving parts. Never run the engine in a closed room.

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Safety the operator is allowed to drive the machine. Riders should Riders are not allowed to get on the Only be kept away from the machine. machine Riders may be injured, for example, being thrown out of the machine. Meanwhile, the riders may hinder the view of the operator, leading to unsafe driving of the machine.

YC1286-UN: Riders

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Avoid cables YC1287-UN: Cables

Before riding on the road, set the grain unloading cylinder to the transport state and lock it firmly.

When riding through the low-hanging cables in the transport state, ensure that a safe distance is kept between the highest point of the machine and the cables. Absolutely avoid scratching and electric shock.

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Before leaving the harvester, you should:

Park the harvester safely

-lower the cutter on the ground.

YC1288-UN: Park safely

-switch off the engine and get the key out.

-park the hand brake and disconnect the battery grounding line.

-hang NOT TO BE USED sign in the cab.

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Please handle fuel carefully: Fuel is highly flammable. Do not refuel the machine when smoking or staying near open flame or sparks.

Handle fuel safely — Prevent fire

Switch off the engine before refueling. Always refuel the oil tank outdoor.

Prevent fire by keeping the machine clear of accumulated trash, grease, and debris. Always wipe away fuel spills.

Useonlyapprovedfuelcontainerstotransportflammableliquids.

Never refuel the fuel container on a truck with plastic flooring.

Before refueling, always place the fuel container on the ground.

Before removing the container lid, put the fuel dispenser nozzle into contact with the fuel container. Maintain contact of the fuel dispenser nozzle and the fuel containers during refueling.

Donotstorefuelcontainersinaplacewithopenflame,sparksor spot lights, such as in water heaters or other devices.

TS202-UN: Prevent fire

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Prepare for emergencies

TS291-UN: First-aid kit

Be prepared to prevent fire at any time.

Keep a first-aid kit and fire extinguisher nearby.

Keep emergency numbers of doctors, ambulance service, hospital and fire department near your telephone.

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For the full PDF version of this manual, Please click on the above download PDF button.