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Service Manual JCB 8085 Section 1 - General Information Section 2 - Care & Safety Section 3 - Routine Maintenance Section B - Body & Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section J - Tracks Section K - Engine
Publication No.
9803/9990-1
World Class Customer Support 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. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
Section 1 - General Information Contents Page No. Introduction About this Manual ...................................................................................... 1-1 Machine Identification Identifying Your Machine ........................................................................... 1-3 Service Tools Numerical List Section B - Body and Framework ...................................... 1-5 Tool Detail Reference Section B - Body and Framework .......................... 1-6 Numerical List Section C - Electrics ........................................................ 1-10 Tool Detail Reference Section C - Electrics ............................................. 1-11 Numerical List Section E- Hydraulics ...................................................... 1-12 Tool Detail Reference Section E- Hydraulics ........................................... 1-15 Torque Settings Zinc Plated Fasteners and Dacromet Fasteners ..................................... 1-19 Hydraulic Connections ............................................................................. 1-23 Service Consumables Sealing and Retaining Compounds ......................................................... 1-27 Terms and Definitions Colour Coding .......................................................................................... 1-29
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Section 1 - General Information
Introduction About this Manual Machine Model and Serial Number
Finally, please remember above all else safety must come first!
This manual provides information for the following model(s) in the JCB machine range:
Section Numbering T11-005
The manual is compiled in sections, the first three are numbered and contain information as follows:
JCB 8085 from serial number 1071500.
Using the Service Manual T11-004
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. The illustrations in this publication are for guidance only. Where the machines differ, the text and/or the illustration will specify. General warnings in Section 2 are repeated throughout the manual, as well as specific warnings. Read all safety statements regularly, so you do not forget them. 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. 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. The manufacturer's policy is one of continuous improvement. The right to change the specification of the machine without notice is reserved. No responsibility will be accepted for discrepancies which may occur between specifications of the machine and the descriptions contained in this publication.
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1
General Information - includes torque settings and service tools.
2
Care and Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc.
3
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 and Framework, etc.
Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of each alphabetically coded section.
Units of Measurement T1-001_2
In this publication, the S.I. system of units is used. For example, liquid capacities are given in litres. The Imperial units follow in parentheses ( ) eg 28 litres (6 gal).
Cross References T1-004_2
In this publication, page cross references are made by presenting the subject title printed in bold, italic and underlined. It is preceeded by the 'go to' symbol. The number of the page upon which the subject begins, is indicated within the brackets. For example: K Cross References ( T 1-1).
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Section 1 - General Information Introduction About this Manual
Left Side, Right Side In this manual, `left' A and `right' B mean your left and right when you are seated correctly in the machine.
B
A T011800
Fig 1.
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Section 1 - General Information Machine Identification Identifying Your Machine
Machine Identification Identifying Your Machine Machine Identification Plate
Typical Product Identification Number (PIN)
Your machine has an identification plate A attached to the right hand side of the kingpost.
1
2
3
4
5
JCB
08085
L
7
1071500
1
World Manufacturer Identification (3 Digits). JCB = UK Build.
2
Machine Type and Model (5 Digits). 08085 = 8085.
3
Random Check Letter (1 Digit).
4
Year of Manufacture (1 Digit).
5
Machine Serial Number (8 Digits).
A
Each machine has a unique serial number.
JCB COMPACT PRODUCTS LIMITED HAREWOOD ESTATE, LEEK ROAD, CHEADLE, STOKE ON TRENT, UNITED KINGDOM, ST10 2JU
817/17768
Fig 1.
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Section 1 - General Information Machine Identification Identifying Your Machine
Component Identification Plates
ROPS, TOPS and FOGS
!MWARNING
Typical Engine Identification Number If the engine is replaced by a new one, the data plate serial number B 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. a
b
c
d
e
LE
50316
J
000001
Y
Modified and wrongly repaired ROPS, TOPS & FOGS Structures are dangerous. Do not modify the TOPS Structure. Do not attempt to repair the ROPS, TOPS & FOGS Structure. If the ROPS, TOPS & FOGS Structure has been in an accident, do not use the machine until the structure has been inspected and repaired. This must be done by a qualified person. For assistance, contact your JCB dealer. Failure to take precautions could result in death or injury to the operator. 5-3-1-7_2
a
Engine Type A bolt on Falling Object Guard Structure (FOGS) is available which also carries a certified label. This label certifies the cab to a FOGS standard. K Fig 3. ( T 1-4).
b Engine Part number c
Country of Manufacture When a machine is used in an application with the risk of falling objects, the machine must be equipped with an optional FOGS. There are two guard options available depending on the application:
d Engine Serial Number e
Year of Manufacture
– Level 1 (ISO10262). Is intended for protection from small objects for example small rocks, small debris and other small objects found in operations such as highway maintenance, landscaping and other construction site services. – Level 2. Is intended for protection from large objects for example large rocks, large debris and other large objects encountered in operations such as construction and demolition.
B Fig 3. T049100
Fig 2.
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Section 1 - General Information
Service Tools Numerical List Section B - Body and Framework The tools listed in the table are special tools required for removal and replacement of Body and Framework parts. These tools are available from JCB Service.
Note: Tools other than those listed will be required. It is expected that such general tools will be available in any well equipped workshop or be available locally from any good tool supplier.
Part Number
Description
Tool Detail Reference
4104/1310
Hand Cleaner
K Fig 1. ( T 1-6)
826/01099
Rivet Nut
K Fig 15. ( T 1-9)
826/01101
Rivet Nut
K Fig 15. ( T 1-9)
826/01102
Rivet Nut
K Fig 15. ( T 1-9)
826/01103
Rivet Nut
K Fig 15. ( T 1-9)
826/01104
Rivet Nut
K Fig 15. ( T 1-9)
826/01105
Rivet Nut
K Fig 15. ( T 1-9)
892/00842
Glass Lifter
K Fig 6. ( T 1-6)
892/00843
Folding Stand
K Fig 4. ( T 1-6)
892/00844
Long Knife
K Fig 12. ( T 1-8)
892/00845
Cartridge Gun
K Fig 2. ( T 1-6)
892/00846
Glass Extractor (Handles)
K Fig 9. ( T 1-7)
892/00847
Nylon Spatula
K Fig 13. ( T 1-8)
892/00848
Wire Starter
K Fig 7. ( T 1-7)
892/00849
Braided Cutting Wire
K Fig 11. ( T 1-8)
926/15500
Rubber Spacer Blocks
K Fig 14. ( T 1-8)
992/12300
12V Mobile Oven
K Fig 3. ( T 1-6)
992/12400
Static Oven - 2 Cartridge
K Fig 5. ( T 1-6)
992/12600
Static Oven - 6 Cartridge
K Fig 5. ( T 1-6)
992/12800
Cut-Out Knife
K Fig 8. ( T 1-7)
992/12801
"L" Blades
K Fig 10. ( T 1-7)
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Section 1 - General Information Service Tools Tool Detail Reference Section B - Body and Framework
Tool Detail Reference Section B - Body and Framework
Fig 1. Hand Cleaner - special blend for the removal of polyurethane adhesives. JCB part number - 4104/1310 (454g; 1 lb tub)
Fig 2. Cartridge Gun - hand operated - essential for the application of sealants, polyurethane materials etc. JCB part number - 892/00845
Fig 3.
Fig 4. 12V Mobile Oven - 1 cartridge capacity - required to pre-heat Folding Stand for holding glass - essential for preparing adhesive prior to use. It is fitted with a male plug (703/23201) new glass prior to installation. which fits into a female socket (715/04300). JCB part number - 992/12300 JCB part number - 892/00843
Fig 5. Fig 6.
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Section 1 - General Information Service Tools Tool Detail Reference Section B - Body and Framework 240V Static Oven - available with 2 or 6 cartridge capacity - Glass Lifter - minimum 2 off - essential for glass installation, required to pre-heat adhesive prior to use. No plug supplied. 2 required to handle large panes of glass. Ensure suction Note: 110V models available upon request - contact JCB cups are protected from damage during storage. Technical Service. JCB part number: JCB part number - 892/00842 992/12400 - 2 Cartridge x 240V9 992/12600 - 6 Cartridge x 240V
Fig 8. Fig 7. Wire Starter - used to access braided cutting wire (below) Cut-Out Knife - used to remove broken glass. through original polyurethane seal. JCB part number - 892/00848 JCB part number - 992/12800
Fig 10.
Fig 9. Glass Extractor (Handles) - used with braided cutting wire 'L' Blades - 25 mm (1 in) cut - replacement blades for cut-out (below) to cut out broken glass. knife (above). JCB part number - 892/00846 JCB part number - 992/12801 (unit quantity = 5 off)
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Section 1 - General Information Service Tools Tool Detail Reference Section B - Body and Framework
Fig 11.
Fig 12. Braided Cutting Wire - consumable heavy duty cut-out wire Long Knife - used to give extended reach for normally used with the glass extraction tool (above). inaccessible areas. JCB part number - 892/00849 (approx 25 m length) JCB part number - 892/00844
Fig 13.
Fig 14. Nylon Spatula - general tool used for smoothing sealants - Rubber Spacer Blocks - used to provide the correct set also used to re-install glass in rubber glazing because metal clearance between glass edge and cab frame. tools will chip the glass edge. JCB part number - 892/00847 JCB part number - 926/15500 (unit quantity = 500 off)
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Section 1 - General Information Service Tools Tool Detail Reference Section B - Body and Framework
Fig 15. Rivet Nuts 826/01099 M6 x 16mm Rivet Nut 826/01101 M6 x 19mm Rivet Nut 826/01103 M8 x 18mm Rivet Nut 826/01102 M8 x 21mm Rivet Nut 826/01104 M10 x 23mm Rivet Nut 826/01105 M10 x 26mm Rivet Nut Installation Tool Available from: Bollhoff Fastenings Ltd. Midacre The Willenhall Estate Rose Hill Willenhall West Midlands, WV13 2JW
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Section 1 - General Information Service Tools Numerical List Section C - Electrics
Numerical List Section C - Electrics The tools listed in the table are special tools required for testing electrics. These tools are available from JCB Service.
Note: Tools other than those listed will be required. It is expected that such general tools will be available in any well equipped workshop or be available locally from any good tool supplier.
Part Number
Description
Tool Detail Reference
721/10885
Interconnecting Cable (part of 892/01033)
K Fig 17. ( T 1-11)
892/01033
Electronic Service Tool Kit
K Fig 16. ( T 1-11)
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Section 1 - General Information Service Tools Tool Detail Reference Section C - Electrics
Tool Detail Reference Section C - Electrics
3 D
C
B
A
J
E F
H
D
C
B
G
A
J
E F
H
G
4 A408030
Fig 17. Interconnecting Cable 721/10885
Interconnecting cable, DLA to machine ECU diagnostics socket (part of 892/ 01033 Kit).
1 2
A406130-1
Fig 16. Electronic Service Tool Kit 892/01033 Tool Kit comprises: 1
Data Link Adaptor (DLA), enables data exchange between the machine ECU (Electronic Control Unit) and a laptop PC loaded with the applicable diagnostics software.
2
Interconnecting cable, DLA to laptop PC. Several cables are included to enable compatibility with different PC port types.
3
Interconnecting cable, DLA to machine ECU diagnostics socket.
4
Kit carrying case.
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Section 1 - General Information Service Tools Numerical List Section E- Hydraulics
Numerical List Section E- Hydraulics The tools listed in the table are special tools required for testing, removing and replacing hydraulics. These tools are available from JCB Service.
Note: Tools other than those listed will be required. It is expected that such general tools will be available in any well equipped workshop or be available locally from any good tool supplier.
Part Number
Description
Tool Detail Reference
1406/0011
Bonded Washer
K Fig 23. ( T 1-16)
1406/0018
Bonded Washer
K Fig 23. ( T 1-16)
1406/0021
Bonded Washer
K Fig 23. ( T 1-16)
1406/0029
Bonded Washer
K Fig 23. ( T 1-16)
1604/0003
Adapter
K Fig 24. ( T 1-16)
1604/0004
Adapter
K Fig 24. ( T 1-16)
1604/0006
Adapter
K Fig 24. ( T 1-16)
1606/0003
Adapter
K Fig 24. ( T 1-16)
1606/0004
Adapter
K Fig 24. ( T 1-16)
1606/0007
Adapter
K Fig 24. ( T 1-16)
1606/0008
Adapter
K Fig 24. ( T 1-16)
1606/0009
Adapter
K Fig 24. ( T 1-16)
1612/0006
Adapter
K Fig 21. ( T 1-15)
816/00189
Blanking Cap
K Fig 26. ( T 1-16)
816/00190
Blanking Cap
K Fig 26. ( T 1-16)
816/00193
Blanking Cap
K Fig 26. ( T 1-16)
816/00196
Blanking Cap
K Fig 26. ( T 1-16)
816/00197
Blanking Cap
K Fig 26. ( T 1-16)
816/00294
Blanking Cap
K Fig 26. ( T 1-16)
816/15118
Pressure Test Adapter
K Fig 20. ( T 1-15)
816/50043
'T' Adapter
K Fig 27. ( T 1-17)
816/55038
Pressure Test 'T' Adapter
K Fig 19. ( T 1-15)
816/55040
Pressure Test 'T' Adapter
K Fig 19. ( T 1-15)
816/60096
'T' Adapter
K Fig 27. ( T 1-17)
892/00047
'T' Adapter
K Fig 27. ( T 1-17)
892/00048
'T' Adapter
K Fig 27. ( T 1-17)
892/00055
Blanking Plug
K Fig 25. ( T 1-16)
892/00056
Blanking Plug
K Fig 25. ( T 1-16)
892/00057
Blanking Plug
K Fig 25. ( T 1-16)
892/00059
Blanking Plug
K Fig 25. ( T 1-16)
892/00060
Blanking Plug
K Fig 25. ( T 1-16)
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