John Deere 80 Excavator Workshop Repair Service Manual (TM1656) PDF Download - MJODTM1656.zip
The full workshop repair guide for the John Deere 80 Excavator, containing every detail you need to service, maintain, and fix the machine just like a trained technician.
Inside the John Deere 80 Excavator service and repair manual you'll find:
* 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