jcb 8080 User manual

Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
World Class
Customer Support
S2-eng
Publication No.
Issued by JCB Technical Publications, JCB Service, World Parts Centre, Beamhurst, Uttoxeter, Staffordshire, ST14 5PA, England. Tel [phone] Fax [phone]
Service Manual
Midi Excavator
9803/9330 8080 1024000 Onwards

General Information 1
Care & Safety 2
Routine Maintenance 3
Body and Framework B
Electrics C
Controls D
Hydraulics E
Transmission F
Track and Running Gear J
Engine K
Steeriteering H
Service
Manual
8080
PUBLISHED BY THE
TECHNICAL PUBLICATIONS DEPARTMENT
OF JCB SERVICE; © WORLD PARTS CENTRE,
WATERLOO PARK, UTTOXETER, ST14 5PA
ENGLAND
Tel. ROCESTER [phone]
PRINTED IN ENGLAND
Publication No. 9803/9330 Issue 3
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Introduction
This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training
by JCB Technical Training Department.
These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques
associated with the maintenance and repair of hydraulic earthmoving equipment.
Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of
course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe
connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt. Finally, please remember above all
else SAFETY MUST COME FIRST!
The manual is compiled in sections, the first three are numbered and contain information as follows:
1=General Information - includes torque settings and service tools.
2=Care & Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc.
3=Routine Maintenance - includes service schedules and recommended lubricants for all the
machine.
The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for
example:
A=Attachments
B=Body & Framework ...etc.
The page numbering in each alphabetically coded section is not continuous. This allows for the insertion of new items in later
issues of the manual.
Section contents, technical data, circuit descriptions, operation descriptions etc are inserted at the beginning of each
alphabetically coded section.
All sections are listed on the front cover; tabbed divider cards align directly with individual sections on the front cover for rapid
reference.
Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry
threads, hence for lubricated threads may be reduced by one third.
With the exception of slewing operations 'Left Hand' and 'Right Hand' are as viewed from the rear of the machine facing
forwards.
9803/9330 Issue 1
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Colour Coding
The following colour coding, used on illustrations to denote various conditions of oil pressure and flow, is standardised
throughout JCB Service publications.
9803/9330 Issue 1
A390940
Full Pressure
Pressure generated from operation of a service. Depending on application this may
be anything between neutral circuit pressure and M.R.V. operating pressure.
Pressure
Pressure that is above neutral circuit pressure but lower than that denoted by red.
Servo
Oil pressure used in controlling a device (servo).
Neutral
Neutral circuit pressure.
Exhaust
Cavitation
Oil subjected to a partial vacuum due to a drop in pressure (cavitation).
Lock Up
Oil trapped within a chamber or line, preventing movement of components (lock up).
Red
Pink
Orange
Blue
Green
Light
Green
Yellow
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i
Section 1 General Information
9803/9330
Section 1
i
Issue 1
Contents Page No.
Identifying your Machine
Identification Plates 1 - 1
Operation
Introduction 2 - 1
Before Entering the Cab 2 - 2
Entering/Leaving the Cab 2 - 3
Opening and Closing the Door 2 - 4
Opening and Closing the Front Upper Window 2 - 4
Opening and Closing the Front Lower Window 2 - 5
Emergency Exit 2 - 5
Door Sliding Window 2 - 5
Opening and Closing the Sunblind 2 - 5
Seat 2 - 6
Seat Belt 2 - 6
Location of Controls and Components 3 - 1
Switches and Controls 4 - 1
Right Console 4 - 1
Underseat Tool Box and Cool Box 4 - 2
Heater/Air Conditioning Controls 4 - 3
Left Console 4 - 4
EMS Panel 4 - 5
Facia Panel 4 - 9
Redundancy Switch 4 - 10
Mechanical Engine Speed Override 4 - 10
Servo Controls Immobilisation 4 - 10
Cab Interior Light 4 - 11
Radio (Optional) 4 - 11
Travel Levers 4 - 12
Travel Speed Change Button 4 - 12
Excavating Controls 5 - 1
Operation 5 - 1
Slewing 5 - 2
Boom Swing 5 - 3
Boom Swing Stop 5 - 3
Boom Raise/Lower 5 - 4
Dipper In/Out 5 - 5
Bucket Close/Open 5 - 6
Refuelling 6 - 1
Fuel Level 6 - 1
Filling the Tank 6 - 1
Refuelling Pump (optional) 6 - 2
Before Starting the Engine 6 - 3
Starting the Engine 6 - 4
Jump-Starting the Engine 6 - 5
Warming Up 6 - 6
Operating in Cold Climates 6 - 7
Operating in High Temperatures 6 - 7
Operating in Dusty or Sandy Areas 6 - 7
Operating in Coastal Regions 6 - 7
Operating on Wet or Soft Ground 6 - 7
Preparing for Travel 6 - 8
Stopping and Parking the Machine 6 - 9
Working on Slopes 7 - 1
Digging Near Walls 7 - 1
Dumping into a Truck 7 - 1
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ii
Section 1 General Information
9803/9330
Section 1
ii
Issue 1
Contents Page No.
Dozing and Grading 7 - 2
Scraping and Cutting 7 - 2
Backfilling 7 - 2
Pulling out of Soft Ground 7 - 2
Installing and Removing a Bucket 7 - 3
Replacing Bucket Teeth 7 - 4
Bucket Selection 7 - 4
JCB Mechanical Quickhitch 8 - 1
Lifting (Craning) Regulations and Safe Working Loads 10 - 1
Overload Warning System (Optional) 10 - 2
Operating Attachments 11 - 1
Moving a Disabled Machine 12 - 1
Transporting the Machine
Preparing the Transporting Vehicle 12 - 2
Driving a Machine onto the Transporting Vehicle 12 - 2
Securing the Machine 12 - 3
Unloading a Machine from the Transporting Vehicle 12 - 4
Sealing and Retaining Compounds 15 - 1
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1 - 1
Identification Plates
Machine Identification Number
Your machine has a Data Plate Alocated on the right hand
side of the kingpost. The VIN number is also stored in the
machine’s EMS Panel (see EMS Panel).
Engine Identification Number
The engine number is located at C. If the engine is replaced
by a new one, the data plate serial number will be wrong.
Either stamp the new number on the plate or stamp out the
old one. This will prevent the wrong number being quoted
when you order replacement parts.
Section 1 General Information
9803/9330
Section 1
1 - 1
Issue 2*
Identifying your Machine
JS06061
A404220
AA
C*
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2-1
Introduction
This chapter is arranged to guide you step-by-step through
the task of learning how to operate the machine. Read it
through from beginning to end. By the end of the chapter
you should have a good understanding of the machine and
how to operate it.
Pay particular attention to all safety messages. They are to
warn you of possible danger. Do not just read them; think
about what they mean. Understand the dangers and how to
avoid them. If there is anything you do not understand, ask
your JCB distributor. He will be pleased to advise you.
When you have learned where the track driving controls are
and what they do, practice using them. Practice driving the
machine in a safe, open space clear of other people. Get to
know the ‘feel’ of the machine and its track controls.
Move on to the boom and dipper controls only when you
can drive the machine confidently and safely. When you
have learned where the boom and dipper controls are and
what they do, practice using them but take great care at the
same time. Practice in an open space clear of other people.
Do not jerk the controls; operate them slowly until you
understand the effect they have on the machine.
Finally, do not rush the job of learning. Take your time and
take it safely.
Remember
BE CAREFUL
BE ALERT
BE SAFE
INT-1-3-1/1
Section 1 General Information
9803/9330
Section 1
2-1
Issue 1
Operation
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2-2
Before Entering the Cab
The following checks should be made each time you return
to the machine after leaving it for any period of time. We
advise you also to stop the machine occasionally during
long work sessions and do the checks again. All these
checks concern the serviceability of the machine. Some
concern your safety. Get your service engineer to check and
correct any defects.
!WARNING
Walking or working under a raised boom and dipper is
hazardous. You could be crushed by the boom and
dipper or get caught in the linkages. Lower the boom
and dipper before doing these checks. If you are new to
this machine, get an experienced operator to lower the
boom and dipper for you.
If there is nobody to help you, study this handbook until
you have learned how to lower the boom and dipper.
8-2-1-1
!CAUTION
On machines fitted with hose burst protection valves, the
attachments cannot be lowered with the engine stopped.
On these machines start the engine and lower the
attachments before doing the walk round inspection.
2-2-3-5
!CAUTION
The hydraulic oil filler cap may be hot if the machine has
recently been used. If this is the case, wear suitable
gloves when tightening or loosening this cap.
1 Check for Cleanliness
aClean the windows, light lenses and rear view
mirrors.
bRemove dirt and debris, especially from around the
linkages, rams, pivot pins and radiator grille.
cMake sure the cab step and handholds are clean
and dry.
dClean all safety decals. Replace any that are missing
or cannot be read.
2 Check for Damage
aInspect the machine generally for damaged and
missing parts.
bMake sure that all pivot pins are secured in place.
cInspect the windows for cracks and other damage.
dCheck for oil, fuel and coolant leakages beneath the
machine.
eCheck the tracks (rubber). Check for cut rubber and
penetration by sharp objects. Do not use a machine
with damaged tracks.
3 Check for Security
aCheck the security of the hinged covers on the
engine compartment and hydraulic compartment.
bMake sure that the hydraulic oil and diesel fuel filler
caps are both tightly closed. REMEMBER THAT THE
HYDRAULIC FILLER CAP MAY BE HOT IF THE
MACHINE HAS RECENTLY BEEN USED. (We also
recommend that you lock the fuel filler cap.)
Section 1 General Information
9803/9330
Section 1
2-2
Issue 1
Operation
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2-3
!!CAUTION
Always face the machine when entering (and leaving) the
cab. Make sure your shoes and hands are clean and dry.
Otherwise you could slip and fall.
2-2-1-3
Entering the Cab
1Open the cab door and, if necessary, secure it in the
fully open position (see Doors and Windows, Opening
and Closing the Door).
2 Check that the Controls Lock Lever (see Switches
and Controls) is raised.
3Holding the two handrails (one each side of the cab
entrance), climb onto the top of the track (as at A). Do
not use the skirt 1as a step.
4Retaining hold of the left handrail, step into the cab and
swing yourself into the operator’s seat (as at B).
!!WARNING
Do not use the machine controls as handholds when
entering (or leaving) the machine.
2-2-1-4
Leaving the Cab
1Stop the engine and, with the Starter Switch set to ON,
operate the hydraulic controls several times to release
any residual hydraulic pressure in the system. Turn the
Starter Switch OFF.
2Open the cab door and, if necessary, secure it in the
fully open position (see Doors and Windows, Opening
and Closing the Door).
3Press the Servo Isolator Switch (see Facia Panel)to
isolate the controls.
4Raise the Controls Lock Lever (see Switches and
Controls).
5Leave the cab by reversing instructions 3and 4of
Entering the Cab. Do not use the skirt 1as a step.
Section 1 General Information
9803/9330
Section 1
2-3
Issue 1
Operation
AABB
1111
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