JCB 805, 805B, 806B, 807B, 808 Tracked Excavator Service Repair Manual – PDF DOWNLOAD

SERVICE MANUAL

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Contents

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General

1

Hydraulics

2

Attachments

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Body & Framework

4

Gearboxes

5

Track & Running Gear

6

Engine

7

Electrics

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805,8058 8068,8078 808

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Publication No. 9803/3150

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Introduct¡on {

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This publication

is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received training by the JCB Technical Training Department.

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It is assumed that such personnel have at least a sound knowledge of workshop practice, safety procedures and general techniques assoc¡ated with the maintenance and repair of hydraulic earthmoving equipment. Details of such are therefore generally omitted from this manual, the intention being to convey only the more specialised information concerning particular aspects of the machine or component in question.

For example, renewal of oil seals, gaskets etc. and any component showing obvious wear or damage is expected as a matter of course and information on these matters is therefore only included where a specialised procedure or range of wear tolerances is required. Similarly, it is expected that components will be thoroughly cleaned and lubricated where appropriate, also that any opened hose or pipe connections will be blanked to prevent entry of dirt and excessive loss of hydraulic fluid.

For convenience the manual is compiled in sections, e.g. "Hydraulics", "Gearboxes" etc., but to find details of specific component, reference should be made to the alphabet¡cal index at the back of the book.

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1.

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lllustrations showing a dismantled component are numbered as a guide to the dismantling sequence which can generally be reversed for assembly.

Torque settings quoted are given as'mean'figures which may be varied by as viewed from the rear of the machine.

i gø. 'Left Hand'and 'Right Hand'are

i

Replacement or additional pages for this manual will be issued from t¡me to time and should be inserted in place of the existing pages which should be removed and destroyed.

Where possible, revised pages

will

bear an asterisk

(*)

against the new information, the page issue number in the

bottom right hand corner being similarly marked.

A Service Tools Catalogue, detailing special tools required,

is available separately

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SERVICE

CATALOGUE

/NINUAL - REPTACETEI{T PAGES

805,8058,8068,8078,808

Publication No. 9803/3150

4th SetJuly 1981

Service Manual

These pagesshould be inserted immediately in their correct positions, and pages of a lower issue No. removed and destroyed. The total contents of this publication can be checked using the index below. Retain index at front of book. Replaoement pages issued in thisset are indicated by an asterisk *

Page

No.

lssue

1

1

Page No.

8-1

8-2

2 2

8-3

1

1-1 2-1 2-2 3-1

4*

84

2 2

3-2

3

8-5 8-6 8-7 9-1

2

Section 2 3

10-2

Deleted

10-3 10-4 10-5 11-1 11-2 1 1-3 12-1 12-2 12-3 13-1 13-2 14-1

1-4

1*

1-5 2-1 2-2

1* 3 3

2-3

I

'3-1

3-2 3-3

3-4 3-5 3-6 3-7 3-8 3-9 4-1 4-2 4-3 5-1

5-2 à-s

54

5-5 6-1 6-2 6-3 6-4 6-5 6-6 6-7 6-8 6-9 7-1 7-2

Date

2 Deleted Deleted Deleted Deleted Deleted Deleted Deleted Deleted 2 Deleted Deleted

17-11

1*

17-12 17-13 17-14 18-1 18-2 18-3 19-1 20-1

1* 1

1

1-2 1-2A

3*

1

9-3 10-1

2 2 1

1 1 1 1 1

16-1

1*

1*

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16-2 16-3 16-4 16-5 16-6 16-7 16-8 16-9 16-10

1

16-11

2 1

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17-1 17-2 17-3

1

174

1

17-5

2

174

of lnærporation

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24

1

2-5

1

1

3-1

1

3-2 3-3 4-1

1

2 2 3 2

1-3 2-1 2-2 2-3

1

1

1

1

21.-3

154

I

1

1-2

1

2 2

1

1-1

1* 1* 1* 1* 1* 1*

1

15-2 15-3

1

Section 5

6-2

2*

2

1*

2

1

1

22-1 22-2 22-3 22-4 22-5 22-6 22-7 22-8 22-9 22-10 22-11 23-1 23-2 23-3 Section 3

1* 1*

1-1

1* 1*

2-1 2-2

1* 1* 1* 1* 1* 1* 1*

I 2 1 1

2

6-1

1

1

6-2

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1 1 1 1 1 1

1

1 1 1 1

I 1 1 1

Section 7

1-1

2-1 2-2 3-1 4-1 4-2 4-3

44

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1

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4-1 4-2 4-3 4-4

1

1

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1-1 2-1

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5-1 6-1 7-1 8-1

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JCB SERVICE CATALOGUE /il,âJ'J|UAL 805,8058,8068,8078,808

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Service Manual

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REPLACETE]IT PAGES

-

Publication No. 9803/3150

March 19Bl

These pages should be inserted immediately in their correct positions, and pages of a lower issue No. removed and destroyed. The total contents of this publication can be checked using the index below. Retain index at front of book. Replacement pages issued in this set are indicated by an asterisk *

Page

No.

lssue

Contents

Section

1

Page No.

8-2

2*

8-3

1*

84

1

lssue

1*

1-1 2-1 2-2 3-1

9-2

1

2

9-3

1

3-2

3*

10-1

3* 2 2

10-2 10-3

Section 2

1-1 1-2 1-2A 1-3 2-1 2-2 2-3

1

3

2* 2

3* 3* 1*

3-1

2*

3-2

Deleted Deleted Deleted Deleted Deleted Deleted Deleted Deleted 2x Deleted Deleted

3-3 3-4 3-5 3-6 3-7 3-8 3-9 4-1 4-2 4-3 5-1

1

5-2

2

5-3 5-4 5-5

2

6-1

1

6-2 6-3 6-4 6-5 6-6 6-7 6-8 6-9 7-1 7-2 8-1

8-5 9-1

1

104 10-5 11-1 11-2 11-3 12-1 12-2 12-3 13-1 13-2 14-1 14-2 14-3 15-1 15-2 15-3

154 16-1 18-1

18-2 18-3 19-1 20-1

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20-2 20-3 21-1 21-2 21-3 22-1 22-2 22-3

1

224

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44

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1 1

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7-1 8-1

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1* 1 1

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2* 1 1 1

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1 1 1

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4-1 5-1 6-1

2

6-1

1

6-2

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1 1

1 1

7-1 7-2 8-1

1

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1

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Section 6

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Section 5

1-1 1-2 1-3 2-1 2-2

1 L

2*

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4* 1

Section 7

1

1

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1* 1*

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1

1

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5-1 6-1

1-1 2-1 2-2 3-1 4-1 4-2 4-3 4-4 4-5 5-1

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No.

4-2

1{ß

Section 3

1-1 2-1 2-2

Page

Signature

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JCB SERVIGE CATALOGUE

/

N¡NUAL

805,8058,8068,807 8,808

-

REPLACETIEI{T PAGES

2nd Set January 1980

Service Manual

Publication No. 9803/3150

These pages should be inserted immediately in their correct positions, and pages of a lower issue No. removed and destroyed. The total contents of this publication can be checked using the index below. Retain index at front of book. Replacement pages issued in this set are indicated by an asterisk *

Page

No.

lssue

Page No,

9-3 10-1

10-2 10-3 10-4 10-s 11-1 11-2 11-3 12-1 12-2 12-3

Page No.

lssue

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Section 5

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13-2 14-1 14-2 14-3

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2-4 2-5 3-1 3-2

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3-3 4-1 5-1 6-1

2' 1'/ 1/

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Section 6

15-2 15-3 15-4

2

1-1 2-1 2-2 3-1 4-1 4-2 5-1

18-3 19-1 20-1

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CATALOGUE /NÂffTUAL 805,8058,8068,807 8,808

-

REPTACETEI{T PAGES

lst Set Nov 1979

Se¡uice Manual

Publication No. 9803/3150

These pages should be inserted immediately in their correct positions, and pages of a lower issue No. removed and destroyed. The total contents of this publication cao be checked using the index below. Retain index at front of book. Replacement pages issued in thisset are indicated by an asterisk *

Page

No.

lssue

Contents

I

Page No.

9-3 10-1

Section

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1-1 2-1 2-2 3-1

3-2

10-2

1-2

(

3-3 3-4 3-5 3-6 3-7 3-8 3-9 4-1 4-2 4-3

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1*

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3-1 4-1 5-1

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Page No.

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2* 2* 2* 2* 2*

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1-1

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4-2 4-3 4-4

8-2 9-1

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Signature

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E Sheet 1 of 1 March 1985

E12O/H

8116/E

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Gear Pumps and Motors (

Service Procedure

( lnstances have occurred where dealers have changed pumps and motors under warranty due

to 'scuffing' of the body at relatívely low hours. (

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The scuff ing of the housing of gear pumps and motors is an essential part of their performance.

Allowing the gear tips to cut into the housing ensures tr," rinir..¡¡n;i;¡t i..ìi;;; across the teeth under pressure. initial cutt¡ng occùrs during manufactü?e, the amorn-t of scuffing .The can vary from assembly to assembly bui on average ¡sb.OZS to 0.lmm. (0.OOl to 0.004in.).

These markings are of no detriment to the performance necessary part of their design.

of pumps or motors but are

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T.P.D. E85/O9

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General

1

1

1-1

1-1

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LUBRICANTS AND CAPACITI ES

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CAPACITY

Litres

(Ullgal)

Perkins 4.248 Perkins 6.354 Perkins 6.3544

16

25

(3.5) (5.5)

13.5 14.0 27.3 14.5 12.5

(3.0) (3.1) (6.0) (3.2) (2.751

20.0 25.5

(5.5)

JCB 'special' Gear Oil (4000/0501ì

6.8

(1.5)

JCB Slew O¡l (4000/0701)

"t5.4

(3.4)

805 8058

254 409

(56) (e0)

8068.8078,808

339

(74.51

LUBRICANT

ITEM * Engine

(Also Fuel lnjection Pump on 2700 Series)

(

-18 to

a

-l

Mobil Delvac 1310 JCB Super X Universal (20W20) or Mobil Delvac 1320 Mobil Delvac 1330

deg C

-1 to 27 deg c Above 27 degC

( ( (

-8058 -8068,8078 Perkins T6.354 Perkins T6.3544

27128 4Cvl. 2715E 6 Cvl-

-To mlc77891 -From 77892 *

Irack Gearbox

*Slew Gearbox

JCB'Special' Hydraulic Fluid

Hydraulic Tank

( Track ldler Wheels

Mobil Delvac 1330

Track Rollers (Top & Bottom)

Mobil Delvac 1330

Slew Ring-Bearings

û4pb¡'l{.lcn',4r¡- SC'ß Mobiltac E (SeeWARNING below)

\n¡i"'å frPr-

-Gear Teeth

All Other

Grease Points

Mobiltac E has a lead content of 1.53% Contaminated materials, e.g. rags, containers etc., must only be disposed of in accordance with regulations governing the disposal of toxic waste.

Fuel Tank Capacity

*Coolant Capacity

9803/31 50

+¡qc¡¡þ¡cx-+7, JCB'Special' MPL Grease or Mobilgrease Super JCB'Special' Slide Lubricant

Sliding Beam WARNING:

14.41

Litres

(UK gal)

-805 -8058 -8068,8078,808

291 323 482

64

-Perkins 4.248 -Perkins 6.354 (8058) -Perkins 6.3544 (8068,8078 ) -Perkins 6.3544 (to m/c 76160) -Perkins T6.354 (from m/c 76161 -Perkins T6.354 -Perkins 16.3544

26 28 26 26.8 32 28 27.5

5.75

)

71

106

6.25

5.75 5.9 7

6.25 6.1

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General

1

1

2-1

2-1

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SERVICE SCHEDUTE

I

Free Service

Every Every Every Every Every Every Every 10 50 100 200 400 800 1600 Hours Hours Hours Hours Hours Hours Hours

Check

_1

Hydraulic fluid level Hose and pipework

for

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lea

Tightness of ram end ca

Condition of ram piston

Operation of services

Main relief valve pressure(s

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7

slew)-

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-Excavator-Transmission -Brakes (track &

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pressure_1 Auxiliary relief valve pressures-l All grease seals-l3

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Off loading valve

nt

1

2

nt

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load_20 Gearbox oil (track & slew) levels_21 Track roller levels-22 Track plate condition 23

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Track adjustment

oil

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condition.-25

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level-3O

Fuel injection pump oil (2700

Series)-3,l

(anti-freeze)_ Fuel system for leaks--33 Valve clearance and lubrication _34 Engine coolant

Engine mounting bol

T T

+ê

32

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smoke)-36 Max, governed engine speed-37

nt

NT n

35

Exhaust (excessive

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Trl

Slewing ring bolts torque

Track and running gear

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rods-4

Pump drive

Engine

Routine Service

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NT

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ldling speed Turbocharger boost pressure

Air cleaner

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hose security

security-4l Fan belt adjustment-42 -39 Exhaust system

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gear_b0 Operation of electrical equipment _ 5l

Starter motor/alternator brush

* Battery electrolyte

level

(8058 Fulmen Battery 9803/3150

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52

Ar 1600 hours or yearly)

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SERVICE SGHEDULE

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oil-60

T1

Engine oil f ilter element

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Engine

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Free Service

Air cleaner element (outer)

A'

(inner)-63 Fuel filter element

64

t I

Gearbox oil (track &

TII NI

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Air cleaner element

* Fuel injection pump oil (2700

Routine Service

Every Every Every Every Every Every Every 1600 800 10 200 400 50 100 Hours Hours Hours Hours Hours Hours Hours

Change

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1

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Series)-65

nl

I

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tr

slew)_--66

Hydraulic fluid and clean suction strainer 67

* Hydraulic fluid f ilter

n

element--68

Clean Fuel

lift

n

pump-75

Drain fuel filters Drain fuel sediment

trap--

lnjectors and test

78

Battery terminals

79

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Radiator matrix

80

(\

Grease Rotary Coupling

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nipples-91 Slewing ring teeth-92 All pivot pins-93

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77

nl

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nl

90

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Slewing ring grease

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9803/31 50

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General

1

1

3-1

3-1 \

)

GREASE POINTS

ALL PIVOT PINS

10 Hours

EACH SLEWING

RING NIPPLE AND ROTARY COUPLING * 4 shots 50 Hours

)

)

SLEW]NG RING TEETH

Repack

1600 Hours

0

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3-2

3-2 GREASE POINTS

ALL PIVOT 10 Hours

PI NS

EACH SLEWING RING NIPPLE AND ROTARY COUPLING 50 Hours 4 shots SLEWING TEETH

R

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Repack

1600 Hours

SLIDING BEAM Grease as required

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