JCB 8020 Mini Excavator Service Manual – 9803/9600

(S/N: 1284000 to 1284999)
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This workshop repair service manual PDF download for the 8020 JCB Mini Excavator has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

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

– JCB Excavator 8020 serial number 1284000 to 1284999

TABLE OF CONTENTS :

Section 1 – General Information
Section 2 – Care and Safety
Section 3 – Maintenance
Section A – Attachments
Section B – Body and Framework
Section C – Electrics
Section D – Controls
Section E – Hydraulics
Section F – Gearboxes
Section J – Track and Running Gear
Section K – Engine

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9803/9600
Total Pages : 362

This JCB Mini Excavator service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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9803-9600
Section 1 – General Information
Introduction
About this Manual
Machine Model and Serial Number
Using this Manual
Units of Measurement
Left Side, Right Side
Using the Machine
Cross References
Section Numbering
Identifying Your Machine
Identification Plates
Data Plate
Typical Product Identification Number (PIN)
Typical Engine Identification Number
ROPS, TOPS and FOGS
Standard Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
Introduction
Bolts and Screws
Hydraulic Connections
‘O’ Ring Face Seal System
‘Torque Stop’ Hose System
Service Tools
Numerical List
Tool Detail Reference
Section B – Frame and Bodywork
Section C – Electrics
Section E – Hydraulics
Section K – Engine
Service Consumables
Sealing and Retaining Compounds
Terms and Definitions
Colour Coding
Hydraulic Schematic Colour Codes

Section 2 – Care and Safety
Safety Notices
Important Information
The Operator Manual
Safety Warnings
Safety Check List
Safety – Yours and Others
General Safety
Operating Safety
Maintenance Safety
Safety Decals
Introduction
Safety Decal Recognition

Section 3 – Maintenance
Routine Maintenance
Service Requirements
Introduction
Owner/Operator Support
Service/Maintenance Agreements
Obtaining Replacement Parts
Health and Safety
Lubricants
Battery
First Aid – Electrolyte
Service Schedules
Introduction
How to Use the Service Schedules
Pre Start Cold Checks, Service Points and Fluid Levels
Functional Test and Final Inspection
Fluids, Lubricants and Capacities
Coolant Mixtures
Fuels
Cleaning the Machine
Introduction
Preparing the Machine for Cleaning
Cleaning the Tracks
Checking for Damage
Seat Belt
Checking the Seat Belt Condition and Security
Checking the Cab/Canopy Frame
Greasing
Introduction
Pivot Pins
Every 50 Hours
Every 1000 Hours
Electrical System
Battery
Bulbs
Fuses
Engine
Checking the Oil Level
Changing the Oil and Filter
Changing the Air Filter Element
Checking the Coolant Level
Changing the Coolant
Adjusting the Fan Belt
Fuel System
Filling the Tank
Draining the Fuel Filter/Sedimenter
Replacing the Fuel Filter Element
Replacing the Fuel Pre Filter Element
Bleeding the System
Hydraulic System
Checking and Adjusting the Fluid Level
Replacing the Hydraulic Filter
Checking the Ram Piston Rods
Tracks and Running Gear
Checking the Track Gearbox Oil Level
Changing the Track Gearbox Oil
Checking the Track Tension

Section A – Attachments
Attachments
Introduction
Attachments for your Machine
Quick Release Couplings
Connecting and Disconnecting
Bucket
Bucket Selection
Removing a Bucket – Non Quickhitch Models
Installing a Bucket – Non Quickhitch Models
Removing a Bucket from a Quickhitch
Installing a Bucket on a Quickhitch
Replacing Bucket Teeth
JCB Hammermaster 100 Breaker
Operation
Quickhitch Rockbreaker
Removing a Quickhitch Rockbreaker
Installing a Quickhitch Rockbreaker
Operation
Hand Held Tools
Using Hand Held Tools

Section B – Body and Framework
Service Tools
Numerical List
Technical Data
General Description
Service Procedures
Rivet Nuts
Fitting Procedure
Glazing
Direct Glazing
Bucket Ram Pivot and Linkage
Removal and Replacement
Removal
Inspection
Replacement
Dipper
Removal and Replacement
Removal
Inspection
Replacement
Boom
Removal and Replacement
Removal
Inspection
Replacement
Kingpost
Removal and Replacement
Removal
Inspection
Replacement
Cab Tilting
Procedure
Prepare the Machine
Removing Floor Controls
Tilting the Cab
Securing the Cab

Section C – Electrics
Service Tools
Numerical List
Technical Data
General Electrical Data
Service Procedures
Using a Multimeter
Measuring DC Voltage
Measuring Resistance
Measuring Continuity
Measuring Frequency
Testing a Diode or a Diode Wire
Alternator
General Description
Service Precautions
Charging Circuit Test
Alternator Charging Test
Starter Motor
Starting Circuit Test
Battery
Maintenance
First Aid – Electrolyte
Testing
Specific Gravity Testing
Wiring Harness Repair
Introduction
Repair Procedure
Starter Motor
Removal and Replacement
Removal
Replacement
Alternator
Removal and Replacement
Removal
Replacement
Schematic Circuits
8020
Harness Data
Wire and Harness Number Identification
Introduction
Wire Numbers and Functions
Drawings and Interconnection
Harnesses
Drawings

Section D – Controls
Controls
Controls Identification
Servo Hand Controllers
Introduction
Operation
Inspection
Leakage Amount
Spool
Plunger
Loose Movement in the Operating Controls
Actuation Stability
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Dismantling
Assembly
Assembly
Fault Finding
Track Levers
Operation
Track Controls
Removal and Replacement
Removal
Replacement
Dozer Lever
Operation
Dozer Controls
Removal and Replacement – Lever
Removal
Replacement
Removal and Replacement – Cable
Removal
Replacement
Engine Throttle
Operation
Engine Control
Removal, Replacement and Adjustment
Removal
Replacement
Adjustment
Control Bar
Operation
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Dismantling
Assembly

Section E – Hydraulics
Service Tools
Numerical List
Technical Data
8020
Basic System Operation
Introduction to Hydraulic Schematic Symbols
General (Basic and Functional Symbols)
Control Valves
Example of Schematic Circuit
Hydraulic Circuit
Neutral Pressure Circuit
Servo Circuit
Schematic Circuits
8020
Component Key
Hose Colour Data
Fault Finding
Hydraulic System
General Fault Diagnosis
Slew Motor and Gearbox
Service Procedures
Hydraulic Contamination
Hydraulic Fluid Quality
Effects of Contamination
Cleaning Operation
Contaminant Standards
Filters
Pressure Testing
Main Relief Valves
Auxiliary Relief Valves
Servo Pressure
Cross Line Relief Valves
Control Valve
Description
Component Locations
Control Valve Sections
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Dismantling
Inspection
Assembly
Hydraulic Pump
General Description
Removal and Replacement
Removal
Replacement
Pump Flow Testing
Troubleshooting
Main Relief Valve
Removal and Replacement
Removal
Replacement
Auxiliary Relief Valves
Removal, Dismantling, Inspection and Assembly
Removal
Dismantling
Inspection
Assembly
Pressure Maintenance Valve and Dual Solenoid Valve
Removal and Replacement
Removal
Replacement
Track Motor
General Description
Normal Operation
Braking
Counterbalance Operation
Motor Low Speed, High Traction Selected (where applicable)
Motor High Speed, Low Traction Selected (where applicable)
Auto Kick Down Function (where applicable)
Track Motor Dismantling and Assembly
Dismantling
Assembly
Brake Valve Dismantling and Assembly
Dismantling
Assembly
Slew Motor
General Description
Hydraulic Motor Section
Cross Line Relief Valve Section
Anti Cavitation Valve Section
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Dismantling
Assembly
Rotary Coupling
Two Speed Extending Undercarriage Machines
Removal
Replacement
Dismantling
Inspection
Assembly
Hydraulic Rams
Precautions During Use
Installation
Caution During Use
Maintenance, Inspection Points
Removal and Replacement
Boom, Dipper and Bucket Rams
Dozer Ram
Swing Ram
Dismantling and Assembly
All Rams

Section F – Gearboxes
Technical Data
General Description
Basic Operation
Track Gearbox
Track Gearbox
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Dismantling
Inspection
Assembly
Slew Gearbox
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Dismantling
Inspection
Assembly

Section J – Track and Running Gear
Technical Data
General Description
Rubber Track
Removal and Replacement
Removal
Replacement
Steel Track
Removal and Replacement
Removal
Replacement
Track Guides
Removal and Replacement
Removal
Replacement
Track Rollers (Lower)
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Dismantling
Inspection
Assembly
Track Rollers
Track Roller Metallic Face Seals
When Removing
Inspection
When Replacing
Driven Sprocket
Removal and Replacement
Removal
Inspection
Replacement
Idler and Recoil Unit
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Dismantling
Assembly

Section K – Engine
Service Tools
Numerical List
Technical Data
General

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