John Deere Excavators 600CLC & 800C Service Repair Manual (TM1923)

TM1923 - John Deere 600CLC and 800C Excavators Technical Manual - Repair.PDF

Complete service repair manual for Excavators 600CLC & 800C, with all the service information to maintain, repair, rebuild like professional mechanics.

John Deere Excavators 600CLC & 800C workshop service repair manual includes:
* 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.

Total Pages: 733 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

MAIN SECTIONS
 Foreword
   Technical Information Feedback Form
   General Information
      Safety
      Torque Values
   Tracks
      Track System
   Axles and Suspension Systems (Propel)
      Axle Shaft, Bearings and Reduction Gears
      Hydraulic System
   Engine
      Removal and Installation
   Engine Auxiliary System
      Cooling Systems
      Speed Controls
      Intake System
      External Fuel Supply Systems
   Connector Drive
      Elements
   Splitter Drive
      Gears, Shafts and Bearings
   Frame or Supporting Structure
      Frame Installation
   Operator`s Station
      Removal and Installation
      Operator Enclosure
      Seat and Seat Belt
      Heating and Air Conditioning
   Excavator
      Buckets
      Frames
      Hydraulic System
   Swing or Pivoting System
      Mechanical Drive Elements
      Hydraulic System
   Dealer Fabricated Tools

tm1923 - 600CLC and 800CExcavatorRepair

Table of Contents

Foreword

Technical Information Feedback Form

Section 00: General Information

Group 0001: 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 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

Park and Prepare for Service Safely

Service Cooling System Safely

Remove Paint Before Welding or Heating

Make Welding Repairs Safely

Drive Metal Pins Safely

Group 0003: Torque Values

Hardware Torque Specifications

Unified Inch Bolt and Screw Torque Values

Metric Bolt and 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

Section 01: Tracks

Group 0130: Track System

Track Roller, Front Idler and Carrier Roller Oil

Track Roller Repair

Metal Face Seals Repair

Track Carrier Roller Repair

Track Shoe Repair

Track Chain Repair

Sprocket Repair

Front Idler Repair

Track Adjuster Cylinder and Recoil Spring Repair

Section 02: Axles and Suspension Systems (Propel)

Group 0250: Axle Shaft, Bearings and Reduction Gears

Propel Gearbox Repair

Group 0260: Hydraulic System

Propel Motor and Park Brake Repair

Propel Speed Change Solenoid Valve Repair

Propel Flow Regulator Repair

Propel Motor Start-Up Procedure

Rotary Manifold Repair

Section 04: Engine

Group 0400: Removal and Installation

Engine Repair

Turbocharger Repair

Exhaust Manifold Repair

Intake Manifold Repair

Water Pump Repair

Cylinder Head Repair

Cylinder Block Repair

Rocker Arm Assembly Repair

Camshaft Repair

Flywheel Repair

Oil Pan Repair

Crankshaft Repair

Piston and Connecting Rod Repair

Oil Pump Repair

Fuel Injection Pump Repair

Fuel Injection Pump Coupling Assembly Repair

Fuel Injection Pump Timing

Starter Repair

Oil Cooler Repair

Thermostat Repair

Fuel Bleed Procedure

Section 05: Engine Auxiliary System

Group 0510: Cooling Systems

Fan, Shroud and Guard Repair

Radiator, Hydraulic Oil Cooler and Charge Air Cooler Repair

Group 0515: Speed Controls

Speed Control Linkage Repair

Engine Stop Cable Repair

Engine Control (EC) Motor and Sensor Repair

Engine Speed Programming Procedure After Battery Disconnection

Group 0520: Intake System

Air Cleaner Repair

Air Intake Leakage Check

Group 0560: External Fuel Supply Systems

Fuel Tank Repair

Section 07: Connector Drive

Group 0752: Elements

Connector Drive Coupling Repair

Section 08: Splitter Drive

Group 0851: Gears, Shafts and Bearings

Pump Drive Gearbox Repair

Section 17: Frame or Supporting Structure

Group 1740: Frame Installation

Welding On Machine

Welding Repair of Major Structure

Section 18: Operator's Station

Group 1800: Removal and Installation

Cab Repair

Group 1810: Operator Enclosure

Windowpane and Two Piece Molding Repair

Windowpane and One Piece Molding Repair

Sliding Windows Repair

Windowpanes Repair

Group 1821: Seat and Seat Belt

Seat Belt Repair

Group 1830: Heating and Air Conditioning

Refrigerant Cautions and Proper Handling

R134a Compressor Oil Charge Check

R134a Compressor Oil Removal

R134a Refrigerant Oil Information

R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure

Recover R134a Refrigerant

Evacuate R134a System

Charge R134a System

Compressor Repair

Receiver-Dryer Repair

Air Conditioner and Heater Repair

Condenser Repair

Section 33: Excavator

Group 3302: Buckets

Bucket Repair

Bucket Links Repair

Adjusting Bucket Linkage—600CLC

Adjusting Bucket Linkage—800C

Bucket Pin-Up Data—600CLC

Bucket Pin-Up Data—800C

Group 3340: Frames

Arm Repair

Boom Repair

Inspect Boom, Arm and Bucket Pins, Bushings and Bosses

Bushings and Seals Repair

Group 3360: Hydraulic System

Hydraulic Oil Tank Vent Procedure

Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy

Hydraulic Pump Repair

Hydraulic Pump Regulator Repair

Hydraulic Pump Start-Up Procedure

Hydraulic Pump Angle Sensor (A Sensor) Repair

Hydraulic Pump Pressure Sensor Repair

Hydraulic Pump Displacement Solenoid Valve Repair

Pilot Pump Repair

Pilot Filter Repair

Hydraulic Oil Filter Inspection Procedure

Solenoid Valve Manifold and Pilot Pressure Regulating Valve Repair

Pilot Shut-Off Valve Repair

Pilot Check Valve Manifold Repair

Pilot Signal Manifold Repair

Swing Priority Solenoid Valve Repair

Boom Down Flow Regulator Valve Repair

Pilot Controller Repair

Propel Pilot Controller Repair

Counterweight Pilot Controller Repair

Control Valve Repair

Boom Cylinder Repair

Arm Cylinder Repair

Bucket Cylinder Repair

Boom, Arm and Bucket Cylinder Repair

Counterweight Lift Cylinder Repair

Hydraulic Cylinder Bleeding Procedure

Hydraulic Oil Cooler Bypass Valve Repair

Restriction Valve Repair

Hydraulic Oil Tank Repair

Section 43: Swing or Pivoting System

Group 4350: Mechanical Drive Elements

Swing Gearbox Repair

Swing Gearbox Start-Up Procedure

Upperstructure

Swing Bearing Repair

Group 4360: Hydraulic System

Swing Motor and Park Brake Repair

Swing Motor Start-Up Procedure

Section 99: Dealer Fabricated Tools

Group 9900: Dealer Fabricated Tools

Rotary Manifold Lifting Tool

DFT1075 Propel Gearbox Nut Wrench

DFT1077 Spool Holding Fixture

DFT1220 Swing Gearbox Nut Spanner Wrench