Complete service repair manual for John Deere 80 Excavator, with all the workshop information to maintain, repair, and service like professional mechanics.

John Deere 80 Excavator 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.
...
TM1656 - John Deere 80 Midi Excavator Technical Manual - Repair.PDF

PRODUCT DETAILS:
Total Pages: 978 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

MAIN SECTIONS
 Foreword
   Technical Information Feedback Form
   General Information
      Safety
      General Specifications
      Torque Values
      Fuels and Lubricants
   Tracks
      Tracks System
   Axles and Suspension Systems
      Axle Shaft, Bearings, and Reduction Gears
      Hydraulic System
   Engine
      Removal and Installation
   Engine Auxiliary Systems
      Cold Weather Starting Aids
      Cooling System
      Speed Controls
      Intake System
      External Exhaust Systems
      External Fuel Supply Systems
   Dampener Drive (Flex Coupling)
      Elements
   Electrical System
      Batteries, Support, and Cables
      Alternator, Regulator, and Charging System Wiring
      Wiring Harness and Switches
      System Controls
      Instruments and Indicators
   Frame or Supporting Structure
      Frame Installation
      Chassis Weights
   Operator’s Station
      Removal and Installation
      Operator Enclosure
      Seat and Seat Belt
      Heating
   Bulldozers (Backfill Blade)
      Blades
      Control Linkage
      Hydraulic System
   Excavator
      Bucket
      Frames
      Hydraulic System
   Swing Rotation or Pivoting System
      Mechanical Drive Elements
      Hydraulic System
   Dealer Fabricated Tools

tm1656 - 80 Excavator Repair

Table of Contents

Foreword

Technical Information Feedback Form

Section 00: General Information

Group 0001: Safety

Follow Safe Procedures

Prepare for Emergencies

Prevent Acid Burns

Handle Chemical Products Safely

Handle Fluids Safely-Avoid Fires

Avoid High-Pressure Fluids

Warn Others of Service Work

Support Machine Properly

Operate Only from Operator's Seat

Park Machine Safely

Stay Clear of Moving Parts

Avoid Power Lines

Use Handholds and Steps

Keep Riders Off Machine

Move and Operate Machine Safely

Wear Protective Clothing

Protect Against Flying Debris

Protect Against Noise

Illuminate Work Area Safely

Service Machines Safely

Remove Paint Before Welding or Heating

Avoid Heating Near Pressurized Fluid Lines

Beware of Exhaust Fumes

Use Proper Lifting Equipment

Service Cooling System Safely

Dispose of Waste Properly

Work in a Clean Area

Use Proper Tools

Replace Safety Signs

Live With Safety

Group 0002: General Specifications

80 Excavator Overview

80 Excavator

Working Ranges

Engine Specifications

Drain and Refill Capacities

Lift Capacity-KG (LB) (without blade and with standard boom)

Lift Capacity-KG (LB) (without blade and with standard boom)

Lift Capacity-KG (LB) (without blade and with standard boom)

Lift Capacity-KG (LB) (without blade and with standard boom)

Lift Capacity-KG (LB) (blade off the ground with standard boom)

Lift Capacity-KG (LB) (blade off the ground with standard boom)

Lift Capacity-KG (LB) (blade off the ground with standard boom)

Lift Capacity-KG (LB) (blade off the ground with standard boom)

Lift Capacity-KG (LB) (without blade and with offset boom)

Lift Capacity-KG (LB) (without blade and with offset boom)

Lift Capacity-KG (LB) (blade off the ground and with offset boom)

Lift Capacity-KG (LB) (blade off the ground and with offset boom)

Group 0003: Torque Values

Hardware Torque Specifications

Unified Inch Bolt and Cap Screw Torque Values

Metric Bolt and Cap 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

Group 0004: Fuels and Lubricants

Diesel Fuel

Lubricity of Diesel Fuels

Low Sulfur Diesel Fuel Conditioner

Diesel Fuel Storage

Fuel Tank

Do Not Use Galvanized Containers

Diesel Engine Oil

Hydraulic Oil

Swing Gearbox and Propel Gearbox Oils

Track Roller, Front Idler, and Carrier Roller Oil

Track Adjuster, Working Tool Pivot, Swing Bearing, and Swing Bearing Gear Grease

Oil Filters

Lubricant Storage

Alternative and Synthetic Lubricants

Mixing of Lubricants

Section 01: Tracks

Group 0130: Tracks System

Service Equipment and Tools

Other Material

Specifications

Measure Track Roller Wear

Remove and Install Track Roller

Disassemble Track Roller

Assemble Track Roller

Test Track Roller for Oil Leakage

Measure Track Carrier Roller Wear

Remove and Install Track Carrier Roller

Disassemble and Assemble Track Carrier Roller

Inspect Metal Face Seals

Measure Track Shoe Grouser Wear

Remove and Install Track Shoe

Measure Track Chain Bushing Wear

Measure Track Chain Link Wear

Measure Track Chain Pitch

Remove Track Chain

Install Track Chain

Disassemble and Assemble Track Chain

Disassemble and Assemble Track Chain to Replace Broken Part

Adjust Track Chain Sag

Remove and Install Sprocket

Measure Front Idler Wear

Remove and Install Front Idler

Disassemble Front Idler

Assemble Front Idler

Test Front Idler for Oil Leakage

Remove and Install Track Adjuster Cylinder and Recoil Spring

Disassemble and Assemble Track Adjuster Recoil Spring

Disassemble and Assemble Track Adjuster Cylinder

Section 02: Axles and Suspension Systems

Group 0250: Axle Shaft, Bearings, and Reduction Gears

Service Equipment and Tools

Other Material

Specifications

Towing Machine

Remove and Install Propel Gearbox

Disassemble Propel Gearbox

Inspect Metal Face Seals

Disassemble and Assemble First Planet Pinion Carrier

Disassemble and Assemble Second Planet Pinion Carrier

Assemble Propel Gearbox

Propel Gearbox Start-Up Procedure

Group 0260: Hydraulic System

Essential Tools

Service Equipment and Tools

Other Material

Specifications

Remove and Install Propel Motor and Park Brake

Propel Motor Start-Up Procedure

Disassemble and Assemble Propel Motor and Park Brake

Disassemble and Assemble Propel Motor Brake Valve

Remove and Install Rotary Manifold

Disassemble and Assemble Rotary Manifold

Bench Test Rotary Manifold

Section 04: Engine

Group 0400: Removal and Installation

YANMAR 4TNE98-JCF (CH4033D) Diesel Engine Repair-Use CTM119

Service Equipment and Tools

Other Material

Specifications

Remove and Install Engine

Bleeding the Fuel System

Remove and Install Oil Pan

Remove and Install Starter

Section 05: Engine Auxiliary Systems

Group 0505: Cold Weather Starting Aids

Remove and Install Air Heater

Group 0510: Cooling System

Specifications

Remove and Install Fan, Shroud, and Guards

Cooling System Fill and Deaeration

Remove and Install Radiator

Remove and Install Fan Belt

Group 0515: Speed Controls

YANMAR 4TNE98-JCF (CH4033D) Diesel Engine Repair-Use CTM119

Service Equipment and Tools

Specifications

JT05801 Clamp-On Electronic Tachometer Installation

Engine Speed Check

Engine Speed Control Cable Adjustment

Engine Control Motor and Sensor Adjustment

Engine Speed Learning Procedure

Injection Pump Fast and Slow Idle Stops Adjustment

Remove and Install Engine Speed Control Cable

Remove and Install Engine Control (EC) Motor and Sensor

Fuel Shut-Off Solenoid Linkage Adjustment

Group 0520: Intake System

Service Equipment and Tools

Specifications

Remove and Install Air Cleaner

Air Intake System Leakage Test

Group 0530: External Exhaust Systems

Remove and Install Muffler

Group 0560: External Fuel Supply Systems

Other Material

Specifications

Remove and Install Fuel Tank

Remove and Install Primary Fuel Filter (Water Separator)

Disassemble and Assemble Primary Fuel Filter (Water Separator)

Remove and Install Final Fuel Filter

Replace Fuel Filter Element

Bleeding the Fuel System

Section 07: Dampener Drive (Flex Coupling)

Group 0752: Elements

Other Material

Specifications

Remove and Install Dampener Drive (Flex Coupling)

Section 16: Electrical System

Group 1671: Batteries, Support, and Cables

Service Equipment and Tools

Specifications

Service Batteries Carefully

Procedure for Testing Batteries

Checking Electrolyte Specific Gravity

Check Battery Electrolyte Level and Terminals

Using Booster Batteries-24-Volt System

Charge Battery

Engine Speed Learning Procedure

Remove and Install Batteries

Adding 12-Volt Accessories

Group 1672: Alternator, Regulator, and Charging System Wiring

Alternators and Starting Motors-Use CTM77

Specifications

Remove and Install Alternator

Group 1674: Wiring Harness and Switches

Specifications

Front Chassis Electrical Component Identification

Frame and Engine Electrical Component Identification

Front Cab Electrical Component Identification

Rear Cab Electrical Component Identification

Connect Engine and Pump Controller (EPC)

Engine Speed Learning Procedure

Disconnecting Spring Wire Retainer Connectors

Disconnecting Tab Retainer Connectors

Fuse Specifications

Fuse (Blade-Type) Color Codes

Remove and Install Cab Ground Straps

Remove and Install Starter Switch

Remove and Install Dome Light Switch

Remove and Install Travel Alarm Cancel Switch

Group 1675: System Controls

Specifications

Welding on Machine

Connecting Engine and Pump Controller (EPC) Harness Connector

Remove and Install Engine and Pump Controller (EPC)

Remove and Install Monitor Controller

Engine Speed Learning Procedure

Group 1676: Instruments and Indicators

Replace Monitor Panel Bulbs

Remove and Install Travel Alarm

Changing Travel Alarm Volume

Section 17: Frame or Supporting Structure

Group 1740: Frame Installation

Specifications

Welding on Machine

Welding Repair of Major Structure

Group 1749: Chassis Weights

Service Equipment and Tools

Specifications

Remove and Install Counterweight

Section 18: Operator’s Station

Group 1800: Removal and Installation

Specifications

Remove and Install Cab

Group 1810: Operator Enclosure

Other Material

Remove and Install Windowpane and Two Piece Molding

Remove and Install Windowpane and One Piece Molding

Remove and Install Bonded Windowpane

Remove and Install Sliding Windows

Windowpane Dimensions

Group 1821: Seat and Seat Belt

Specifications

Check Seat Adjustments

Remove and Install Seat

Remove and Install Seat Belt

Inspect Seat Belt

Group 1830: Heating

Remove and Install Heater Core and Blower Motor

Remove and Install Heater Hoses

Section 32: Bulldozers (Backfill Blade)

Group 3201: Blades

Remove and Install Backfill Blade

Disassemble and Assemble Backfill Blade

Group 3215: Control Linkage

Remove and Install Backfill Blade Control Lever and Linkage

Adjust Backfill Blade Control Lever and Linkage

Group 3260: Hydraulic System

Specifications

Remove and Install Backfill Blade Hydraulic Pump

Disassemble and Assemble Backfill Blade Hydraulic Pump

Remove and Install Backfill Blade Control Valve

Disassemble and Assemble Backfill Blade Control Valve

Remove and Install Backfill Blade Cylinder

Disassemble and Assemble Backfill Blade Cylinder

Section 33: Excavator

Group 3302: Bucket

Specifications

Replacing Bucket Teeth

Replace Bucket Tooth Tip-Heavy-Duty Bucket

Welding on Machine

Remove and Install Tooth Shank

Replace Welded Cutting Edge

Repair Cracked Cutting Edge

Remove and Install Bucket

Adjust Bucket Pivot End Play

Disassemble and Assemble Bucket

Bucket Pin-Up Data

Group 3340: Frames

Service Equipment and Tools

Other Material

Specifications

Remove and Install Bucket Links

Remove and Install Standard or Long Arm

Remove and Install Offset Arm

Remove and Install Boom

Remove and Install Offset Boom

Inspect Arm and Boom Pins and Bushings

Remove and Install Bushings and Seals

Group 3360: Hydraulic System

Service Equipment and Tools

Other Material

Specifications

Control Lever Pattern Conversion

Lower Boom With Engine Stopped

Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy

Remove and Install Main Hydraulic Pump

Hydraulic Pump Start-Up Procedure

Disassemble Main Hydraulic Pump

Assemble Main Hydraulic Pump

Remove and Install Main Hydraulic Pump Displacement Valve

Disassemble and Assemble Main Hydraulic Pump Displacement Valve

Remove and Install Pilot Pump

Disassemble and Assemble Pilot Pump

Remove and Install Pilot Pressure Regulating Valve and Filter

Disassemble and Assemble Pilot Pressure Regulating Valve and Filter

Remove and Install Pilot Shut-Off Valve

Disassemble and Assemble Pilot Shut-Off Valve

Pilot Shut-Off Valve and Propel Control Lever Lock Linkage Adjustment

Remove and Install Dig Function Pilot Controller

Disassemble and Assemble Dig Function Pilot Controller

Remove and Install Flow Regulator Valve

Disassemble and Assemble Flow Regulator Valve

Remove and Install Propel Control Valve Linkage

Remove and Install Main Control Valve

Disassemble and Assemble Main Control Valve

Remove and Install Offset Boom Pilot Controller

Disassemble and Assemble Offset Boom Pilot Controller

Disassemble and Assemble System Relief Valve

Disassemble and Assemble Circuit Relief and Anti-Cavitation Valve

Disassemble and Assemble Boom Reduced Leakage Valve

Remove and Install Boom Cylinder

Remove and Install Offset Boom Cylinder

Remove and Install Offset Boom Arm Cylinder

Remove and Install Arm Cylinder

Remove and Install Bucket Cylinder

Hydraulic Cylinder Bleed Procedure

Disassemble Boom, Bucket and Arm Cylinders

Assemble Boom, Bucket and Arm Cylinders

Remove and Install Hydraulic Oil Cooler

Remove and Install Hydraulic Oil Cooler Bypass Valve

Remove and Install Return Filter and Bypass Valve

Remove and Install Hydraulic Oil Tank

Disassemble and Assemble Hydraulic Oil Tank

Remove and Install Suction Filter (Screen)

Disassemble and Assemble Hydraulic Oil Tank Relief Valve and Breather Filter Cap

Section 43: Swing Rotation or Pivoting System

Group 4350: Mechanical Drive Elements

Service Equipment and Tools

Other Material

Specifications

Remove and Install Swing Gearbox

Swing Gearbox Start-Up Procedure

Disassemble and Assemble Swing Gearbox

Remove Upperstructure

Install Upperstructure

Remove and Install Swing Bearing

Disassemble and Assemble Swing Bearing

Install Swing Bearing Upper Seal

Install Swing Bearing Lower Seal

Group 4360: Hydraulic System

Other Material

Specifications

Remove and Install Swing Motor and Park Brake

Swing Motor Start-Up Procedure

Disassemble Swing Motor and Park Brake

Assemble Swing Motor and Park Brake

Disassemble and Assemble Cover For Swing Motor and Park Brake

Disassemble and Assemble Swing Motor Crossover Relief Valve

Remove and Install Swing Park Brake Release Valve

Disassemble and Assemble Swing Brake Valve

Section 99: Dealer Fabricated Tools

Group 9900: Dealer Fabricated Tools

ST4920 Track Recoil Spring Disassembly and Assembly Tool

DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool

DFT1112A Spacer

DFT1169 Propel and Swing Gearbox Nut Wrench

Rotary Manifold Lifting Tool

DFT1119 Pump Support

DFT1089 Barrel Support

DFT1077 Spool Holding Fixture

John Deere 80 Excavator Service Repair Manual (TM1656)