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JCB 8055, 8065 Service Repair Manual

 Machine Model and Serial Number

This manual provides information for the following model(s) in the JCB machine range:

  • JCB 8055 from serial number 1536000 to 1537499

  • JCB 8065 from serial number 1537500 to 1538999

 

JCB 8055, 8065 Service Repair Manual

This is Manual Covers:

Section 1 – General Information

  • Contents Page No. Introduction
  • About this Manual 1-1
  • Machine Model and Serial Number .1-1
  • Using the Service Manual .1-1
  • Section Numbering 1-1
  • Units of Measurement .1-1
  • Left Side, Right Side 1-2
  • Cross References 1-2
  • Identifying Your Machine
  • Identification Plates . 1-3
  • Data Plate 1-3
  • Typical Vehicle Identification Number (VIN) 1-3
  • Typical Engine Identification Number 1-3
  • ROPS, TOPS and FOGS 1-4
  • Standard Torque Settings
  • Zinc Plated Fasteners and Dacromet Fasteners . 1-5
  • Introduction 1-5
  • Bolts and Screws .1-5
  • Hydraulic Connections . 1-9
  • Tool Detail Reference
  • Section B – Frame and Bodywork 1-16
  • Section C – Electrics 1-20
  • Section E – Hydraulics .1-21
  • Section K – Engine .1-26
  • Service Consumables
  • Sealing and Retaining Compounds . 1-27
  • Terms and Definitions
  • Colour Coding 1-29
  • Hydraulic Schematic Colour Codes .1-29

Section 2 – Care and Safety

  • Safety Notices
  • Important Information 2-1
  • The Operator Manual 2-1
  • Safety Warnings 2-1
  • Safety Check List . 2-2
  • Safety – Yours and Others .2-2
  • General Safety 2-2
  • Operating Safety .2-4
  • Maintenance Safety .2-8
  • Safety Decals 2-12
  • Safety Decal Recognition 2-13

Section 3 – Maintenance

  • Routine Maintenance Service Requirements . 3-1
  • Introduction 3-1
  • Owner/Operator Support .3-1
  • Service/Maintenance Agreements 3-1
  • Obtaining Replacement Parts 3-1
  • Health and Safety 3-3
  • Lubricants 3-3
  • Battery .3-5
  • First Aid – Electrolyte .3-5
  • Service Schedules . 3-7
  • Introduction 3-7
  • How to Use the Service Schedules .3-7
  • Pre Start Cold Checks, Service Points and Fluid Levels .3-8
  • Functional Test and Final Inspection .3-10
  • Fluids, Lubricants and Capacities 3-11
  • Coolant Mixtures . 3-11
  • Fuels 3-13
  • Cleaning the Machine 3-16
  • Introduction 3-16
  • Cleaning the Tracks .3-17
  • Checking for Damage 3-18
  • Seat Belt 3-19
  • Checking the Seat Belt Condition and Security .3-19
  • Checking the Cab/Canopy Frame . 3-20
  • Greasing 3-21
  • Introduction 3-21
  • Pivot Pins 3-21
  • Every 50 Hours 3-23
  • Every 1000 Hours 3-23
  • Electrical System . 3-25
  • Battery .3-25
  • Fuses .3-27
  • Bulbs .3-28
  • Engine and Hydraulic Bay Covers . 3-29
  • Opening the Engine Cover 3-29
  • Closing the Engine Cover 3-29
  • Opening the Hydraulic Bay Cover .3-29
  • Closing the Hydraulic Bay Cover .3-30
  • Engine . 3-31
  • Checking the Oil Level 3-31
  • Changing the Oil and Filter 3-32
  • Air Filter .3-33
  • Checking the Coolant Level 3-34
  • Changing the Coolant 3-34
  • Adjusting the Fan Belt .3-35
  • Adjusting the HVAC Compressor Pump Belt .3-36
  • Fuel System . 3-37
  • Filling the Tank 3-37
  • Draining the Fuel Filter/Sedimenter .3-38
  • Replacing the Fuel Pre-Filter Element 3-39
  • Replacing the Fuel Filter Element .3-40
  • Bleeding the System .3-41
  • Contents Page No.
  • Hydraulic System . 3-43
  • Checking and Adjusting the Fluid Level 3-43
  • Replacing the Hydraulic Filter .3-43
  • Checking the Ram Piston Rods 3-43
  • Tracks and Running Gear . 3-44
  • Checking the Track Gearbox Oil Level 3-44
  • Changing the Track Gearbox Oil .3-44
  • Checking the Track Tension 3-45

Section A – Attachments

  • Attachments for your Machine . 1-1 Introduction 1-1
  • Installing the Quickhitch 1-2
  • Removing the Quickhitch 1-2
  • Maintenance 1-3
  • Installing Excavator Quickhitch Attachments .1-3
  • Removing Excavator Quickhitch Attachments .1-4
  • Quick Release Couplings 1-6
  • Connecting and Disconnecting 1-6
  • Buckets 1-8
  • Bucket Selection 1-8
  • Removing a Bucket – Non Quickhitch Models .1-9
  • Installing a Bucket – Non Quickhitch Models .1-10
  • Removing a Bucket from a Quickhitch 1-10
  • Installing a Bucket on a Quickhitch .1-12
  • Replacing Bucket Teeth .1-13
  • Quickhitch Rockbreaker 1-14
  • Removing a Quickhitch Rockbreaker 1-14
  • Installing a Quickhitch Rockbreaker 1-16
  • Operation .1-16

Section B – Body and Framework

  • Service Procedures Rivet Nuts . B-1
  • Fitting Procedure B-2
  • Glazing . B-3
  • Direct Glazing . B-3
  • Kingpost
  • Removal and Replacement B-9
  • Removal . B-9
  • Replacement .B-11
  • Dipper
  • Removal and Replacement B-13
  • Removal . B-13
  • Inspection . B-14
  • Replacement B-14
  • Bucket Ram Pivot and Linkage
  • Removal and Replacement B-15
  • Removal . B-15
  • Inspection . B-15
  • Replacement B-15
  • Boom
  • Removal and Replacement B-17
  • Removal . B-17
  • Inspection . B-17
  • Replacement B-17
  • Slew Ring
  • Removal and Replacement B-19
  • Removal . B-19
  • Checking Slew Bearing Backlash . B-21
  • Checking Slew Bearing Vertical Lift B-22

Section C – Electrics

  • Technical Data General Electrical Data . C-1
  • Service Procedures
  • Using a Multimeter C-3
  • Measuring DC Voltage . C-4
  • Measuring Resistance C-4
  • Measuring Continuity C-5
  • Measuring Frequency . C-5
  • Testing a Diode or a Diode Wire . C-6
  • Alternator C-7
  • General Description C-7
  • Service Precautions . C-7
  • Charging Circuit Test C-7
  • Alternator Charging Test . C-8
  • Starter Motor . C-10
  • Starting Circuit Test C-10
  • Battery C-12
  • Maintenance .C-12
  • First Aid – Electrolyte C-12
  • Testing C-13
  • Specific Gravity Testing C-14
  • Wiring Harness Repair . C-15
  • Introduction .C-15
  • Repair Procedure .C-15
  • Alternator
  • Removal and Replacement C-19
  • Removal .C-19
  • Replacement C-19
  • Starter Motor
  • Removal and Replacement C-21
  • Removal .C-21
  • Replacement C-21
  • Schematic Circuits
  • All Machines . C-23
  • .C-23
  • Harness Data
  • Wire and Harness Number Identification C-31
  • Introduction .C-31
  • Wire Numbers and Functions .C-32
  • Mainframe Harness C-33
  • Drawings C-33

Section D – Controls

  • Controls Identification . D-1 Fault Finding
  • Servo Hand Controllers D-3
  • Servo Hand Controllers
  • Introduction . D-5
  • Operation D-6
  • Inspection . D-7
  • Leakage Amount D-7
  • Spool D-7
  • Plunger . D-7
  • Loose Movement in the Operating Controls . D-7
  • Actuation Stability . D-7
  • Dismantling and Assembly . D-8
  • Dismantling . D-8
  • Assembly D-10
  • Fault Finding . D-11
  • Track Levers
  • Operation D-13
  • Track Controls D-13
  • Dozer Lever
  • Operation D-15
  • Dozer Controls .D-15
  • Engine Throttle
  • Cable Adjustment and Calibration D-17
  • Cable Adjustment .D-17
  • System Calibration .D-19

Section E – Hydraulics

  • Basic System Operation
  • Introduction to Hydraulic Schematic Symbols E-4
  • General (Basic and Functional Symbols) .E-4
  • Control Valves E-8
  • Example of Schematic Circuit E-9
  • Service Procedures
  • Hydraulic Contamination E-10
  • Hydraulic Fluid Quality .E-10
  • Effects of Contamination E-10
  • Cleaning Operation E-10
  • Contaminant Standards .E-11
  • Filters .E-11
  • Schematic Circuits
  • All Machines . E-12
  • Component Key E-12
  • Hose Colour Data .E-14
  • Neutral Circuit .E-15
  • Main Services Circuit E-16
  • Traction Circuit .E-17
  • Slew Circuit E-18
  • Fault Finding
  • Hydraulic System E-20
  • General Fault Diagnosis .E-20
  • Slew Motor and Gearbox E-22
  • Main Relief Valve
  • Removal and Replacement E-24
  • Removal .E-24
  • Replacement E-24
  • Testing and Setting . E-25
  • Auxiliary Relief Valves
  • Removal and Inspection . E-26
  • Removal .E-26
  • Inspection .E-26
  • Testing and Setting . E-28
  • Pressure Maintenance Valve
  • Description E-30
  • Removal and Replacement E-31
  • Removal .E-31
  • Replacement E-31
  • Testing and Setting . E-32
  • Setting Servo Pressure E-32
  • Testing the P.M.V. .E-32
  • Hydraulic Pump
  • Description E-38
  • Testing and Setting . E-41
  • Setting the Pressure Control Valve E-41
  • Setting the Flow Control Valve .E-43
  • Removal and Replacement E-45
  • Removal .E-45
  • Replacement E-46
  • Dismantling and Assembly . E-47
  • External Components .E-47
  • Internal Components E-51
  • Track Motor/Gearbox
  • Description E-55
  • Component Key E-57
  • Hydraulic Motor Section .E-58
  • Two Speed Motor Operation .E-59
  • Hydraulic Valve Section E-60
  • Parking Brake Section E-61
  • Removal and Replacement – 8055 . E-62
  • Removal .E-62
  • Replacement E-62
  • Dismantling and Assembly – 8055 E-63
  • Track Motor E-64
  • Track Gearbox E-66
  • Brake Valve E-69
  • Dismantling and Assembly – 8065 E-70
  • Slew Motor/Gearbox
  • Description – 8055 E-71
  • Component Key E-72
  • Component Key E-74
  • Hydraulic Motor Section .E-75
  • Parking Brake Section E-76
  • Shockless Relief Valve Section E-77
  • Check Valve Section E-78
  • Parking Brake Timer Valve Section E-78
  • Removal and Replacement – 8055 . E-79
  • Removal .E-79
  • Replacement E-80
  • Dismantling and Assembly – 8055 E-81
  • Slew Motor .E-82
  • Slew Gearbox .E-84
  • Parking Brake Timer Valve .E-86
  • Cross Line Relief Valve E-86
  • Dismantling and Assembly – 8065 E-87
  • Control Valve
  • Description E-89
  • Component Locations E-89
  • Schematics .E-91
  • Regeneration E-93
  • Removal and Replacement E-97
  • Removal .E-97
  • Replacement E-97
  • Dismantling, Inspection and Assembly . E-99
  • Dismantling .E-99
  • Inspection .E-99
  • Assembly E-100
  • Control Valve Sections . E-101
  • Inlet/Outlet E-101
  • Slew E-103
  • Boom E-105
  • Auxiliary E-107
  • Bucket E-109
  • Dipper E-111
  • Dozer .E-113
  • Swing .E-115
  • Low Flow .E-117
  • Track Right E-119
  • Track Left E-121
  • Rotary Coupling
  • Removal and Replacement E-124
  • Removal .E-124
  • Replacement E-124
  • Dismantling, Inspection and Assembly . E-125
  • Dismantling .E-125
  • Inspection .E-125
  • Assembly E-125
  • Hydraulic Rams
  • Precautions During Use E-128
  • Installation E-128
  • Caution During Use E-128
  • Maintenance, Inspection Points .E-128
  • Removal and Replacement E-130
  • Boom, Dipper and Bucket Rams E-131
  • Dozer Ram .E-132
  • Swing Ram .E-133
  • Dismantling and Assembly . E-134
  • All Rams .E-134

Section F – Gearboxes
Section J – Track and Running Gear

  • Tracks and Running Gear General Description . J-1
  • Technical Data . J-2
  • Major Component Torque Settings J-2
  • Steel Track
  • Removal and Replacement . J-3
  • Rubber Track
  • Removal and Replacement . J-5
  • Track Guides
  • Introduction J-7
  • Removal and Replacement . J-8
  • Removal J-8
  • Replacement . J-8
  • Track Rollers
  • Removal and Replacement . J-9
  • Removal J-9
  • Replacement .J-10
  • Dismantling and Assembly J-11
  • Lower Rollers J-11
  • Upper Rollers J-12
  • Idler and Recoil Unit
  • Removal and Replacement . J-15
  • Removal J-15
  • Replacement .J-15
  • Dismantling, Inspection and Assembly J-16
  • Dismantling J-17
  • Inspection J-17
  • Assembly .J-18
  • Track Rollers
  • Track Roller Metallic Face Seals . J-19
  • When Removing J-19
  • Inspection J-19
  • When Replacing J-19
  • Driven Sprocket
  • Removal and Replacement . J-21
  • Removal J-21
  • Inspection J-21
  • Replacement .J-21

Section K – Engine

 
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