Complete Operation and Test manual with electrical wiring diagrams for John Deere 80 Min Excavator, with technical information to maintain, diagnose, and service like professional mechanics.

John Deere 80 Excavator workshop Operation and Test 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.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* 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.

TM1655 - John Deere 80 Midi Excavator Operation and Test Manual - Operation and Test.PDF

PRODUCT DETAILS:
Total Pages: 1,101 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
   Operational Checkout Procedure
      Operational Checkout Procedure
   Engine
      Theory of Operation
      Diagnostic Information
      Adjustments
      Tests
   Electrical System
      System Information
      System Diagrams
      Sub-System Diagnostics
      References
   Power Train
      Theory of Operation
      Diagnostic Information
      Adjustments
   Hydraulic System
      Theory of Operation
      Diagnostic Information
      Adjustment
      Tests

tm1655 - 80 Excavator Operation and Tests

Table of Contents

Foreword

Technical Information Feedback Form

Section 9000: General Information

Group 01: 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 02: 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 03: 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 04: 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 9005: Operational Checkout Procedure

Group 10: Operational Checkout Procedure

Operational Checkout

Section 9010: Engine

Group 05: Theory of Operation

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

Engine Speed Control System Operation

Engine RPM Dial Speed Control Circuit Operation

E (Economy) Mode Speed Control Circuit Operation

Auto-Idle Mode Speed Control Circuit Operation

Engine Speed Learning Control Circuit Operation

Cooling System Operation

Engine Lubrication System Operation

Air Cleaner Operation

Fuel Supply System Operation

Fuel Injection Pump Operation

Fuel Injection Nozzle Operation

Group 15: Diagnostic Information

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

Diagnose Engine Malfunctions

Group 20: Adjustments

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

JT05801 Clamp-On Electronic Tachometer Installation

Fuel Shut-Off Solenoid Linkage Adjustment

Engine Speed Check

Injection Pump Fast and Slow Idle Stops Adjustment

Engine Speed Control Cable Adjustment

Engine Control Motor and Sensor Adjustment

Engine Speed Learning Procedure

Fan Belt Tension Adjustment

Injection Pump Static Timing Adjustment

Check and Adjust Engine Valve Lash (Clearance)

Cooling System Fill and Deaeration

Group 25: Tests

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

JT05801 Clamp-On Electronic Tachometer Installation

Valve Lift Check

Compression Pressure Test

Engine Oil Pressure Test

Fuel Transfer Pump Pressure Test

Cooling System Test

Air Filter Restriction Indicator Switch Test

Air Intake System Leakage Test

Radiator Air Flow Test

Section 9015: Electrical System

Group 05: System Information

Electrical System Visual Inspection

Electrical Circuit Malfunctions

High Resistance Circuit

Open Circuit

Grounded Circuit

Shorted Circuit

Sensor Circuit Shorted to Power

Sensor Circuit Shorted to Itself

Sensor Circuit Shorted to Ground

Multimeter

Seven Step Electrical Test Procedure

Schematic, Wiring Diagram and Component Location Information

Reading a System Functional Schematic

Reading a Wiring Diagram

Reading a Component Location Diagram

Reading a Connector End View Diagram

Electrical Schematic Symbols

Group 10: System Diagrams

Component Identification Table

Fuse Specifications

Fuse (Blade-Type) Color Codes

Functional Schematic and Component Location Drawing Legend

System Functional Schematic Section Legend

System Functional Schematic (SE1-SE4)

System Functional Schematic (SE5-SE6)

System Functional Schematic (SE7-SE9)

System Functional Schematic (SE10-SE11)

Engine and Frame Harness (W1) Component Location Drawing

Engine and Frame Harness (W1) Component Location-Detail A (Harness Mating Connectors)

Engine and Frame Harness (W1) Connectors, Wire and Pin Locations

Cab Harness (W2) Component Location Drawing

Cab Harness (W2) Component Location-Detail A (Harness Mating Connectors)

Cab Harness (W2) Connectors, Wire and Pin Locations

Group 15: Sub-System Diagnostics

Power Circuit Operational Information

Power Circuit Theory of Operation

Power Circuit Schematic

Charging Circuit Operational Information

Charging Circuit Theory of Operation

Charging Circuit Schematic

Alternator Theory of Operation

Starting Circuit Operational Information

Starting Circuit Theory of Operation

Starting Circuit Schematic

Starter Operation

Windshield Wiper and Washer Circuit Operational Information

Windshield Wiper and Washer Circuit Continuous Theory of Operation

Windshield Wiper Park Position Theory of Operation

Windshield Wiper and Washer Circuit Schematic

Work and Drive Light Circuit Operational Information

Work and Drive Light Circuit Theory of Operation

Work and Drive Light Circuit Schematic

Accessory Circuits Operational Information

Accessory Circuits Theory of Operation

Accessory Circuits Schematic

Heater Circuit Operational Information

Heater Circuit Theory of Operation

Heater Circuit Schematic

Monitor Controller and Display Circuit Specifications

Monitor Controller and Display Circuit Operational Information

Monitor Controller and Display Circuit Theory of Operation

Monitor Controller and Display Circuit Schematic

Engine and Pump Control Circuit Operational Information

Engine and Pump Control Circuit Theory of Operation

Engine and Pump Controller Circuit Schematic

Travel Alarm Circuit Operational Information

Travel Alarm Circuit Theory of Operation

Travel Alarm Circuit Schematic

Group 20: References

Battery Operation

Battery Specifications

Diagnose Battery Malfunctions

Check Battery Electrolyte Level and Terminals

Procedure For Testing Batteries

Using Booster Batteries-24 Volt System

Replacing Batteries

Adding 12 or 24 Volt Accessories

Changing Travel Alarm Volume

Windshield Wiper Circuit Test Harness

Section 9020: Power Train

Group 05: Theory of Operation

Track Adjuster and Recoil Spring Operation

Propel Gearbox Operation

Group 15: Diagnostic Information

Diagnose Undercarriage Components Malfunctions

Measure Track Chain Bushing Wear

Measure Track Chain Link Wear

Measure Track Chain Pitch

Measure Track Shoe Grouser Wear

Measure Track Roller Wear

Measure Track Carrier Roller Wear

Measure Front Idler Wear

Measure Swing Bearing Wear

Group 20: Adjustments

Adjust Track Chain Sag

Section 9025: Hydraulic System

Group 05: Theory of Operation

Hydraulic System Diagram

Pilot Pump Operation

Backfill Blade and Pilot Pump Operation

Pilot Pressure Regulating Valve and Filter Operation

Pilot Shut-Off Valve Operation

Pilot Controller Operation-Neutral

Pilot Controller Operation-Metering and Full Stroke

Offset Boom Pilot Controller Operation

Pilot Controller Operation of Control Valve

Flow Regulator Valve Operation

Main Hydraulic Pump Operation

Main Hydraulic Pump High and Low Maximum Displacement Control Circuit Operation

Main Hydraulic Pump Displacement Circuit Operation

Control Valve Operation

Control Valve Circuit Schematic

Control Valve Pilot Pressure Signal Passages Operation

Control Valve Neutral and Power Passages Operation

System Relief Valve Operation

Circuit Relief and Anti-Cavitation Valve Operation

Flow Combiner Valve Operation

Boom Reduced Leakage Valve Operation

Swing Gearbox Operation

Swing Motor Operation

Swing Crossover Relief and Make-Up Valves Operation

Swing Park Brake Release Valve Operation

Rotary Manifold With Backfill Blade Function Operation

Propel Motor Operation

Propel Motor Park Brake Operation

Propel Motor Brake Valve Operation

Propel Motor Crossover Relief Valve Operation

Backfill Blade Hydraulic System Operation

Hydraulic Cylinder Operation

Hydraulic Oil Return Filter Operation

Hydraulic System Circuit Symbols

Controllers and Pilot Shut-Off Valve Schematic

Flow Regulator Valve Schematic

Control Valve Schematic

Pumps and Pilot Pressure Regulating Valve Schematic

Swing Motor Schematic

Propel Motor Schematic

Group 15: Diagnostic Information

Diagnostic Procedure

Diagnose Electronic and Control Valve Component Malfunctions

Diagnose Hydraulic System Malfunctions

Diagnose Pilot Circuit Malfunctions

Diagnose Dig Circuit Malfunctions

Diagnose Swing Circuit Malfunctions

Diagnose Propel System Malfunctions

Control Lever Pattern Conversion

Control Valve Line Identification-Left Front

Control Valve Line Identification-Right Rear

Control Valve Line Identification-Bottom

Control Valve Component Identification-Left Front

Control Valve Component Identification-Right Rear

Control Valve Component Identification-Bottom

Main Hydraulic System Component Location

Main Hydraulic System With Offset Boom Component Location

Backfill Blade Hydraulic System Component Location

Pilot System-Controllers-To-Flow Regulator Valve Component Location-SAE Pattern

Pilot System-Controllers-To-Flow Regulator Valve Component Location-John Deere Pattern

Pilot System-Flow Regulator Valve-To-Control Valve Component Location

Propel Hydraulic System Component Location

Pressure and Return Hydraulic System Component Location

Group 20: Adjustment

Pilot Shut-Off Valve Linkage Adjustment

Group 25: Tests

Laptop Computer General Description

Excavator Diagnostics Program-Overview

Excavator Diagnostics Program-Install

Excavator Diagnostics Program-Uninstall

Excavator Diagnostics Program-Starting

Excavator Diagnostics Program Feature-Service Codes

Excavator Diagnostics Program Feature-Monitor Data

Excavator Diagnostics Program Feature-Saving Monitor Data

Excavator Diagnostics Program Special Function-Engine Speed Adjustment

Excavator Diagnostics Program-Service Codes List

Excavator Diagnostics Program-Monitor Data Items

Excavator Diagnostics Program Special Function-Engine Speed Factory Settings Parameters

Pump Flow Rate to Engine Speed Chart

Excavator Diagnostics Program Troubleshooting

Reading Service Codes Without Excavator Diagnostics Program

Engine and Pump Controller Function

JT05801 Clamp-On Electronic Tachometer Installation

JT05800 Digital Thermometer Installation

JT02156A Digital Pressure and Temperature Analyzer Installation

Hydraulic Pump Start-Up Procedure

Swing Motor Start-Up Procedure

Swing Gearbox Start-Up Procedure

Propel Motor Start-Up Procedure

Propel Gearbox Start-Up Procedure

Hydraulic Oil Filter Inspection Procedure

Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy

Hydraulic System Warm-Up Procedure

Lower Boom With Engine Stopped

Engine Control Sensor (EC Sensor) Harness Test

Engine Control Motor (EC Motor) Harness Tests

Miscellaneous Component Harness Test

Cycle Time Test

Swing Dynamic Braking (Drift) Test

Pilot Pressure Regulating Valve Test and Adjustment

Control Valve Spool Pilot Actuation Pressure Test

Dig and Propel System Relief Valve Test and Adjustment

Circuit Relief Valve Test and Adjustment

Swing Motor Crossover Relief Valve Test and Adjustment

Propel Motor Crossover Relief Valve Test and Adjustment

Backfill Blade System Relief Valve Test and Adjustment

Backfill Blade Circuit Relief Valve Test

Main Hydraulic Pump Regulating Test and Adjustment (Engine Pulldown)

Main Hydraulic Pump Flow Test

Pilot Pump Flow Test

Backfill Blade Pump Flow Test

Propel System Tracking Test

Cylinder Drift Test-Boom, Arm, and Bucket

Swing Motor Leakage Test

Propel Motor Leakage Test

John Deere 80 Excavator Operation and Test Service Manual (TM1655)