John Deere 80C Excavator Repair & Technical Manual TM1939 – PDF DOWNLOAD

Description

John Deere 80C Excavator Repair & Technical Manual TM1939 – PDF DOWNLOAD

FILE DETAILS:

John Deere 80C Excavator Repair & Technical Manual TM1939 – PDF DOWNLOAD

Language : English
Pages :478
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Foreword

• This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use.
• Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual. This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury. Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components.
• Operation and tests sections help you identify the majority of routine failures quickly. Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits,
• specifications, wear tolerances, and torque values. Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair. Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.

TABLE OF CONTENTS:

Contents 5
General Information 9
Safety 11
Recognize Safety Information 11
Follow Safety Instructions 11
Operate Only If Qualified 11
Wear Protective Equipment 12
Avoid Unauthorized Machine Modifications 12
Add Cab Guarding For Special Uses 12
Inspect Machine 13
Stay Clear of Moving Parts 13
Avoid High-Pressure Fluids 13
Beware of Exhaust Fumes 14
Prevent Fires 14
Prevent Battery Explosions 14
Handle Chemical Products Safely 15
Dispose of Waste Properly 15
Prepare for Emergencies 15
Use Steps and Handholds Correctly 16
Start Only From Operator’s Seat 16
Use and Maintain Seat Belt 16
Prevent Unintended Machine Movement 17
Avoid Work Site Hazards 17
Keep Riders Off Machine 18
Avoid Backover Accidents 18
Avoid Machine Tip Over 19
Use Special Care When Lifting Objects 19
Add And Operate Attachments Safely 20
Park And Prepare For Service Safely 20
Service Cooling System Safely 21
Remove Paint Before Welding or Heating 21
Make Welding Repairs Safely 21
Drive Metal Pins Safely 22
Torque Values 23
Unified Inch Bolt and Screw Torque Values 23
Metric Bolt and Screw Torque Values 24
Additional Metric Cap Screw Torque Values 25
Check Oil Lines And Fittings 27
Service Recommendations for O-Ring Boss Fittings 28
Service Recommendations For Flat Face O-Ring Seal Fittings 30
Service Recommendations for 37° Flare and 30° Cone Seat Connectors 31
Service Recommendations For Flared Connections—Straight or Tapered Threads 32
Service Recommendations For Inch Series Four Bolt Flange Fittings 33
Service Recommendations for Metric Series Four Bolt Flange Fitting 34
Tracks 35
Track System 37
Track Roller, Front Idler, and Carrier Roller Oil 37
Track Roller Remove and Install 37
Track Roller Disassemble and Assemble 39
Track Roller Oil Leakage Test 41
Track Carrier Roller Remove and Install 42
Track Carrier Roller Disassemble and Assemble 44
Metal Face Seals Inspection 45
Track Shoe Remove and Install 47
Track Chain Remove and Install 47
Track Chain Disassemble and Assemble 51
Broken Track Chain Repair 52
Sprocket Remove and Install 54
Front Idler Remove and Install 55
Front Idler Disassemble 56
Front Idler Assemble 57
Front Idler Oil Leakage Test 59
Track Adjuster Cylinder and Recoil Spring Remove and Install 60
Track Adjuster and Recoil Spring Disassemble and Assemble 61
Track Adjuster Cylinder Disassemble and Assemble 65
Axles and Suspension Systems 69
Axle Shaft, Bearings, and Reduction Gears 71
Propel Gearbox Remove and Install 71
Propel Gearbox Disassemble and Assemble 74
Hydraulic System 85
Propel Motor Remove and Install 85
Propel Motor Disassemble and Assemble 86
Propel Motor Valve Housing Disassemble and Assemble 89
Propel Motor Start-Up Procedure 91
Rotary Manifold Remove and Install 92
Rotary Manifold Disassemble and Assemble 94
Rotary Manifold Bench Test 95
Engine 97
Removal and Installation 99
Engine Remove and Install 99
Exhaust Manifold Remove and Install102
Valve Cover Remove and Install103
Valve Cover Disassemble and Assemble103
Rocker Arm Assembly Remove and Install103
Rocker Arm Assembly Disassemble and Assemble105
Rocker Arm Assembly Inspection106
Intake Manifold Remove and Install108
Intake Manifold Disassemble and Assemble108
Water Pump Remove and Install109
Cylinder Head Remove and Install111
Cylinder Head Disassemble and Assemble115
Cylinder Head Inspection117
Timing Gear Case Remove and Install125
Cylinder Block Disassemble and Assemble129
Cylinder Block Inspection131
Rear Oil Seal Installation135
Camshaft Remove and Install136
Camshaft Disassemble and Assemble136
Camshaft Inspection137
Flywheel Remove and Install140
Flywheel Disassemble and Assemble140
Flywheel Housing Remove and Install141
Oil Pan Remove and Install141
Crankshaft Remove and Install142
Crankshaft Disassemble and Assemble147
Crankshaft Inspection148
Piston and Connecting Rod Remove and Install155
Piston and Connecting Rod Disassemble and Assemble159
Piston and Connecting Rod Inspection162
Oil Pump Remove and Install166
Oil Pump Disassemble and Assemble167
Oil Pump Inspection167
Thermostat Housing Remove and Install168
Thermostat Housing Disassemble and Assemble170
Thermostat Inspection171
Fuel Injection Pump Remove and Install172
Fuel Injection Nozzle Remove and Install173
Fuel Injection Nozzle Disassemble and Assemble175
Starter Remove and Install176
Alternator Remove and Install177
Engine Auxiliary Systems179
Cooling System181
Radiator and Oil Cooler Remove and Install181
Fan, Shroud, and Guards Remove and Install184
Fan Belt Remove And Install188
Speed Controls189
Speed Control Linkage Remove and Install189
Engine Control (EC) Motor and Sensor Remove and Install190
External Fuel Supply Systems191
Fuel Tank Remove And Install191
Water Separator Remove and Install196
Frame or Supporting Structure199
Frame Installation201
Welding On Machine201
Welding Repair of Major Structure202
Chassis Weights203
Counterweight Remove and Install203
Operator’s Station205
Removal and Installation207
Cab Remove and Install207
Operator Enclosure213
Bonded Windowpane Remove and Install213
Sliding Window Remove and Install214
Seat and Seat Belt217
Seat Remove and Install217
Seat Belt Remove and Install217
Heating and Air Conditioning219
Refrigerant Cautions and Proper Handling219
Flush and Purge Air Conditioner System221
R134a Refrigerant Oil Information224
R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure225
Recover R134a Refrigerant226
Evacuate R134a System227
Charge R134a System228
Compressor Remove and Install229
Receiver-Dryer Remove and Install230
Air Conditioner and Heater Remove and Install230
Condenser Remove and Install235
Bulldozers (Blade)237
Blades239
Blade Remove and Install239
Hydraulic System241
Blade Cylinder Remove and Install241
Blade Cylinder Disassemble and Assemble244
Blade Pilot Controller Remove and Install250
Blade Pilot Controller Disassemble and Assemble252
Excavator255
Buckets257
Tooth Shank Remove and Install257
Welded Cutting Edge Replacement260
Cutting Edge261
Repair Crack261
Bucket Repair262
Bucket Pin-Up Data263
Frames265
Bucket Links Remove and Install265
Arm Remove and Install268
Boom Remove and Install272
Offset Boom Remove and Install276
Boom, Arm, Bucket and Blade Pins, Bushings and Bosses Inspection280
Bushing and Seal Remove and Install285
Hydraulic System287
Hydraulic Oil Tank Pressure Release Procedure287
Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy288
Hydraulic Pump Remove and Install289
Hydraulic Pumps 1 and 2 Disassemble and Assemble292
Hydraulic Pump 3 and Pilot Pump Remove and Install303
Hydraulic Pump 3 Disassemble and Assemble306
Pilot Pump Disassemble and Assemble314
Hydraulic Pump Start-Up Procedure315
Dampener Drive (Flex Coupling) Remove and Install316
Pilot Pressure Regulating Valve and Filter Remove and Install317
Pilot Pressure Regulating Valve Disassemble and Assemble318
Drain Filter and Bypass Valve Remove and Install319
Pilot Control Shut-Off Valve Remove and Install320
Pilot Control Shut-Off Valve Disassemble and Assemble323
Propel Speed Solenoid Valve Remove and Install325
Proportional Solenoid Valve Disassemble and Assemble326
Pilot Controller Remove and Install327
Pilot Controller Disassemble and Assemble329
Propel Pilot Controller Remove and Install331
Propel Pilot Controller Disassemble and Assemble332
Offset Boom Pilot Controller Remove and Install335
Offset Boom Pilot Controller Disassemble and Assemble336
Flow Regulator Valve Manifold Remove and Install (SN —011047)338
Flow Regulator Valve Manifold Disassemble and Assemble (SN —011047)340
Flow Regulator Valve Manifold Remove and Install (SN 011048— )342
Control Valve Remove and Install343
Control Valve Disassemble348
Control Valve Assemble358
Hydraulic Oil Tank Remove and Install367
Oil Cooler Bypass Valve Remove and Install375
Boom Cylinder Remove and Install376
Boom Cylinder Disassemble and Assemble380
Arm Cylinder Remove and Install388
Arm Cylinder Disassemble and Assemble392
Bucket Cylinder Remove and Install398
Bucket Cylinder Disassemble and Assemble402
Offset Boom Cylinder Remove and Install408
Offset Boom Cylinder Disassemble and Assemble412
Offset Boom Arm Cylinder Remove and Install414
Hydraulic Cylinder Bleed Procedure424
Swing or Pivoting System425
Mechanical Drive Elements427
Swing Gearbox Remove and Install427
Swing Gearbox Disassemble and Assemble430
Upperstructure Remove And Install437
Swing Bearing Remove and Install440
Swing Bearing Disassemble and Assemble441
Swing Bearing Upper Seal Install443
Swing Bearing Lower Seal Install443
Hydraulic System445
Swing Motor and Park Brake Remove and Install445
Swing Motor and Park Brake Disassemble448
Swing Motor and Park Brake Inspection451
Swing Motor and Park Brake Assemble452
Swing Motor Crossover Relief Valve and Make-Up Valve Remove and Install456
Swing Gearbox458
Start-Up Procedure458
Dealer Fabricated Tools459
Dealer Fabricated Tools461
ST4920 Track Recoil Spring Disassembly and Assembly Tool461
DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool465
DFT1112A Spacer466
DFT1169 Travel and Swing Gearbox Nut Wrench467
Rotary Manifold Lifting Tool468
DFT1119 Pump Support469
Page Numbers 5
Section 00 9
Group 0001 11

S.M 6/1/25