John Deere 80 Excavator Service Repair Manual (TM1656)
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.
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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)