John Deere 80C Excavator Repair Technical Manual TM1939

[Martin Welker]

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John Deere 80C Excavator Repair Technical Manual TM1939
Size: 13.68 MB
Format: PDF
Language: English
Brand: John Deere
Type of Machine: Excavator
Type of Manual: Repair Technical Manual
Model: John Deere 80C Excavator
Part Number: TM1939
Publication Date: 2012
Number of Pages: 522 Pages

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
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 Remove and Install
Track Roller Disassemble and Assemble
Track Roller Oil Leakage Test
Track Carrier Roller Remove and Install
Track Carrier Roller Disassemble and Assemble
Metal Face Seals Inspection
Track Shoe Remove and Install
Track Chain Remove and Install
Track Chain Disassemble and Assemble
Broken Track Chain Repair
Sprocket Remove and Install
Front Idler Remove and Install
Front Idler Disassemble
Front Idler Assemble
Front Idler Oil Leakage Test
Track Adjuster Cylinder and Recoil Spring Remove and Install
Track Adjuster and Recoil Spring Disassemble and Assemble
Track Adjuster Cylinder Disassemble and Assemble
Section 02 - AXLES AND SUSPENSION SYSTEMS
Group 0250 - Axle Shaft, Bearings, and Reduction Gears
Propel Gearbox Remove and Install
Propel Gearbox Disassemble and Assemble
Group 0260 - Hydraulic System
Propel Motor Remove and Install
Propel Motor Disassemble and Assemble
Propel Motor Valve Housing Disassemble and Assemble
Propel Motor Start-Up Procedure
Rotary Manifold Remove and Install
Rotary Manifold Disassemble and Assemble
Rotary Manifold Bench Test
Section 04 - ENGINE
Group 0400 - Removal and Installation
Engine Remove and Install
Exhaust Manifold Remove and Install
Valve Cover Remove and Install
Valve Cover Disassemble and Assemble
Rocker Arm Assembly Remove and Install
Rocker Arm Assembly Disassemble and Assemble
Rocker Arm Assembly Inspection
Intake Manifold Remove and Install
Intake Manifold Disassemble and Assemble
Water Pump Remove and Install
Cylinder Head Remove and Install
Cylinder Head Disassemble and Assemble
Cylinder Head Inspection
Timing Gear Case Remove and Install
Cylinder Block Disassemble and Assemble
Cylinder Block Inspection
Rear Oil Seal Installation
Camshaft Remove and Install
Camshaft Disassemble and Assemble
Camshaft Inspection
Flywheel Remove and Install
Flywheel Disassemble and Assemble
Flywheel Housing Remove and Install
Oil Pan Remove and Install
Crankshaft Remove and Install
Crankshaft Disassemble and Assemble
Crankshaft Inspection
Piston and Connecting Rod Remove and Install
Piston and Connecting Rod Disassemble and Assemble
Piston and Connecting Rod Inspection
Oil Pump Remove and Install
Oil Pump Disassemble and Assemble
Oil Pump Inspection
Thermostat Housing Remove and Install
Thermostat Housing Disassemble and Assemble
Thermostat Inspection
Fuel Injection Pump Remove and Install
Fuel Injection Nozzle Remove and Install
Fuel Injection Nozzle Disassemble and Assemble
Starter Remove and Install
Alternator Remove and Install
Section 05 - ENGINE AUXILIARY SYSTEMS
Group 0510 - Cooling System
Radiator and Oil Cooler Remove and Install
Fan, Shroud, and Guards Remove and Install
Fan Belt Remove And Install
Group 0515 - Speed Controls
Speed Control Linkage Remove and Install
Engine Control (EC) Motor and Sensor Remove and Install
Group 0560 - External Fuel Supply Systems
Fuel Tank Remove And Install
Water Separator Remove and Install
Section 17 - FRAME OR SUPPORTING STRUCTURE
Group 1740 - Frame Installation
Welding On Machine
Welding Repair of Major Structure
Group 1749 - Chassis Weights
Counterweight Remove and Install
Section 18 - OPERATOR’S STATION
Group 1800 - Removal and Installation
Cab Remove and Install
Group 1810 - Operator Enclosure
Bonded Windowpane Remove and Install
Sliding Window Remove and Install
Group 1821 - Seat and Seat Belt
Seat Remove and Install
Seat Belt Remove and Install
Group 1830 - Heating and Air Conditioning
Refrigerant Cautions and Proper Handling
Flush and Purge Air Conditioner System
R134a Refrigerant Oil Information
R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure
Recover R134a Refrigerant
Evacuate R134a System
Charge R134a System
Compressor Remove and Install
Receiver-Dryer Remove and Install
Air Conditioner and Heater Remove and Install
Condenser Remove and Install
Section 32 - BULLDOZERS (BLADE)
Group 3201 - Blades
Blade Remove and Install
Group 3260 - Hydraulic System
Blade Cylinder Remove and Install
Blade Cylinder Disassemble and Assemble
Blade Pilot Controller Remove and Install
Blade Pilot Controller Disassemble and Assemble
Section 33 - EXCAVATOR
Group 3302 - Buckets
Tooth Shank Remove and Install
Welded Cutting Edge Replacement
Cracked Cutting Edge Repair
Bucket Repair
Bucket Pin-Up Data
Group 3340 - Frames
Bucket Links Remove and Install
Arm Remove and Install
Boom Remove and Install
Offset Boom Remove and Install
Boom, Arm, Bucket and Blade Pins, Bushings and Bosses Inspection
Bushing and Seal Remove and Install
Group 3360 - Hydraulic System
Hydraulic Oil Tank Pressure Release Procedure
Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy
Hydraulic Pump Remove and Install
Hydraulic Pumps 1 and 2 Disassemble and Assemble
Hydraulic Pump 3 and Pilot Pump Remove and Install
Hydraulic Pump 3 Disassemble and Assemble
Pilot Pump Disassemble and Assemble
Hydraulic Pump Start-Up Procedure
Dampener Drive (Flex Coupling) Remove and Install
Pilot Pressure Regulating Valve and Filter Remove and Install
Pilot Pressure Regulating Valve Disassemble and Assemble
Drain Filter and Bypass Valve Remove and Install
Pilot Control Shut-Off Valve Remove and Install
Pilot Control Shut-Off Valve Disassemble and Assemble
Propel Speed Solenoid Valve Remove and Install
Proportional Solenoid Valve Disassemble and Assemble
Pilot Controller Remove and Install
Pilot Controller Disassemble and Assemble
Propel Pilot Controller Remove and Install
Propel Pilot Controller Disassemble and Assemble
Offset Boom Pilot Controller Remove and Install
Offset Boom Pilot Controller Disassemble and Assemble
Flow Regulator Valve Manifold Remove and Install (S.N. —011047)
Flow Regulator Valve Manifold Disassemble and Assemble (S.N. —011047)
Flow Regulator Valve Manifold Remove and Install (S.N. 011048— )
Control Valve Remove and Install
Control Valve Disassemble
Control Valve Assemble
Hydraulic Oil Tank Remove and Install
Oil Cooler Bypass Valve Remove and Install
Boom Cylinder Remove and Install
Boom Cylinder Disassemble and Assemble
Arm Cylinder Remove and Install
Arm Cylinder Disassemble and Assemble
Bucket Cylinder Remove and Install
Bucket Cylinder Disassemble and Assemble
Offset Boom Cylinder Remove and Install
Offset Boom Cylinder Disassemble and Assemble
Offset Boom Arm Cylinder Remove and Install
Hydraulic Cylinder Bleed Procedure
Section 43 - SWING OR PIVOTING SYSTEM
Group 4350 - Mechanical Drive Elements
Swing Gearbox Remove and Install
Swing Gearbox Disassemble and Assemble
Upperstructure Remove And Install
Swing Bearing Remove and Install
Swing Bearing Disassemble and Assemble
Swing Bearing Upper Seal Install
Swing Bearing Lower Seal Install
Group 4360 - Hydraulic System
Swing Motor and Park Brake Remove and Install
Swing Motor and Park Brake Disassemble
Swing Motor and Park Brake Inspection
Swing Motor and Park Brake Assemble
Swing Motor Crossover Relief Valve and Make-Up Valve Remove and Install
Swing Motor And Gearbox Start-Up Procedure
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 Travel and Swing Gearbox Nut Wrench
Rotary Manifold Lifting Tool
DFT1119 Pump Support