JCB 8052, 8060 Midi Excavator Service Manual – 9803/9290-4

This workshop repair service manual PDF download for the 8052, 8060 JCB Midi 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 :

JCB Midi Excavator

JCB Excavator 8052 – From S/N: 802000 – 803999
JCB Excavator 8052 – From S/N: 1178000 Onwards
JCB Excavator 8060 – From S/N: 883000 – 884999
JCB Excavator 8060 – From S/N: 1236000 Onwards

TABLE OF CONTENTS :

General Information
Care and Safety
Routine Maintenance
Optional Equipment
Body and Framework
Electrics
Controls
Hydraulics
Gearboxes
Track and Running Gear
Engine

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9803/9290 Issue 4
Total Pages : 297

This JCB Midi 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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Cover
Contents
Introduction

General Information
Identification
Explanation of Vehicle Identification Number (VIN)
Explanation of Engine Identification Number
Storing your Machine
ROPS, TOPS and FOGS
Operation
Introduction
Before Entering the Cab
Machine Walk Round Inspection
Cab
Opening and Closing the Cab Door
Securing the Door in the Open Position
Entering/Exiting the Cab
Opening the Windscreen
Opening the Side Window
Adjusting the Seat
Heater Controls
Fastening the Seat Belt
Cab Radio (Optional)
Engine and Track Controls, Switches and Instruments
Track controls
Engine Controls
Switches
Instruments
Digital LCD Fuel Gauge
Dozer Controls
Excavator Controls
Changing the Control Pattern (ISO/SAE)
Slew Cab
Swing Boom
Raise/Lower Boom
Dipper
Bucket
Refuelling the Machine
Before Starting the Engine
Starting the Engine
Jump Starting the Engine
Cold Climate Warm Up
Operating in High/Low Temperatures
Stopping and Parking the machine
Preparing for road/stie Travel
Getting the Machine Moving
Working with the Dozer
Working with the Excavator
Working on a Slope
Digging
Moving the Machine While Digging on the Level
Digging Near Walls
Lifting (Craning) Regulations and Safe Working Loads
Using the attachments and site safety
Moving a Disabled Machine
Transporting the Machine
Preparing for Road Travel
Before using the transporting vehicle
Loading – Preparing the transporting vehicle
Loading a machine onto the transporting vehicle
Securing the machine
Unloading a machine from the transporting vehicle
Service Tools
Numerical List
Section B – Body and Framework
Section C – Electrics
Section E – Hydraulics
Section K – Engine
Sealing and Retaining Compounds

Care and Safety
Safety Notices
General Safety
Operating Safety
Maintenance Safety

Routine Maintenance
Fluids, Lubricants, Capacities and Specifications
Engine Lubrication Chart
Lubricants – Health and Safety
Hygiene
Storage
Waste Disposal
Handling
First Aid – Oil
Torque Settings
Introduction – Zinc Plated Fasteners and Dacromet Fasteners
Hydraulic Fittings and Torque Settings
‘O’ Ring Face Seal System
Torque Stop’ Hose System
Fuel System
Bleeding the Fuel System – 8052
Bleeding the Fuel System – 8060
Draining the Filter Element – 8052
Changing the Filter Element – 8052
Draining the Sediment Bowl
Changing the Filter Element – 8060
Cleaning the Lift Pump Strainer – 8060
Service Schedules
Every 10 Operating hours (or daily)
Every 50 operating hours (or weekly)
First 100 hours only
Every 100 operating hours (or 2 weeks)
First 250 operating hours
Every 250 operating hours (or monthly)
First 500 operating hours (8060 only)
Every 500 operating hours (or 6 months)
Every 1000 operating hours (or yearly)
Every 2000 operating hours (or 2 years)
Greasing
Greasing (every 250 hours) Slew Ring Bearings
Greasing (every 1000 hours) Slew Ring Gear Teeth
Hydraulic System
Checking and adjusting the Fluid level
Replacing the hydraulic filter
Checking the Ram Piston Rods
Track Gearbox
Engine Air Filter
Changing the Element
Engine
Checking the Oil Level
Changing the Oil and Filter
Engine Cooling System
Coolant Mixtures
Checking the Coolant Level
Changing the Coolant
Adjusting the Fan Belt
Battery
Warning Symbols
First Aid – Electrolyte
Checking the Electrolyte Level

Optional Equipment
Available Attachments
Buckets
Bucket Selection
Removing a Bucket
Installing a Bucket
Replacing Bucket Teeth
Quickhitch
Installing
Removing
Installing Excavator Quickhitch Attachments
Removing Excavator Quickhitch Attachments
Hydraulic Attachment Circuits
Single Acting Hydraulic Circuit
Making the Machine Ready
Installing the Boom and Dipper Pipes and Hoses
Installing the Boom to Mainframe Hoses
Fitting the Auxiliary Pedal and Cable
Installing the Mainframe Pipes and Hoses
Double Acting Hydraulic Circuit
Making the Machine Ready
Installing the Boom and Dipper Pipes and Hoses
Installing the Boom to Mainframe Hoses
Fitting the Auxiliary Pedal and Cable
Installing the Mainframe Pipes and Hoses
Hydraulic Breakers
Removing a Quickhitch Rockbreaker
Installing a Quickhitch Rockbreaker
Hydraulic Tool Kit
Making the Machine Ready
Assembly/Installation
Using Hand Held Tools

Body and Framework
General Description
Bucket Linkage – Removal and Replacement
Bucket Ram pivot and Linkage – Removal and Replacement
Dipper – Removal and Replacement
Boom – Removal and Replacement
Kingpost – Removal and Replacement
Dozer – Removal and Replacement
Glazing – Removal and replacement
Seat Base Installation
Slew Ring – Setting Up

Electrics
Technical Data
Fuses – 8052
Fuses – 8060
Battery
Fan Belt
Alternator
Starter Motor
Beacon
Mounting
Bulb Change
Schematic Diagrams
8052 machines from 0802000 upto 0803370
8052 machines from 0803371
8060 machines from 0883000
Harness Data
Wiring Harness Repair
Wire Identification
Introduction
Harness Locations and Connections – 8052
Main Harness
8052 machines upto 0803370
8052 machines from 0803371
8060 machines from 0883000
Cab Harness
8052 machines from 0802000 upto 0803370
8060 machines from 0883000
8052 machines from 0803371
Canopy Harness
8052 machines from 0802000 upto 0803370
8052 machines from 0803371
Optional Working Lights Harness
8052 machines from 0803370
8060 machines from 0883000
Boom Working Light Harness
8052 machines from 0802000 upto 0803370
8060 machines from 0883000
8052 machines from 0803371

Controls
Servo Hand Controllers
Description and Operation
Port Identification
Track Levers – Removal and Replacement
Dozer Control Lever – removal and Replacement
Control Cables – Inspection

Hydraulics
Technical Data – 8052
Technical Data – 8060
Hydraulic Circuit (Schematic) – 8052
Hydraulic Circuit (Schematic) – 8060
Hydraulic Destinations
Main Circuit
Servo Circuit
Hydraulic System – General Fault Diagnosis
Hydraulic Pump
Description
Load Sensing – Maximum Flow
Load Sensing – Standby
Load Sensing – Maximum Pressure (No Flow)
Initial Build Performance Checks
Removal and Replacement
Pump Drive – Removal and replacement
Renewing Pump Drive Seal
Pump – Dismantling and Assembly
Track Motor
Description and Operation – 8052
Removal and Replacement – 8052
Dismantling and Assembly – 8052
Description and Operation – 8060
Removal and replacement – 8060
Dismantling and Assembly – 8060
Slew Motor
Description – 8052
Crossline Relief Valve
Port Identification
Description – 8060
Removal and replacement
Control Valve
Descripiton
Testing Compensator Shettle Signal Network
Removal and Replacement
Dismantling and Assembly
Load Sense Relief Valves – Removal and Replacement
Servo Relief Valve – Removal and Replacement
Auxiliary Relief Valve – Removal and Replacement
Anti-Cavitation Valve
Load Sense Flow Control Valve – Removal and Replacement
Rams
Boom, Dipper and Bucket – Removal and Replacement
Dozer – Removal and Replacement
Swing
Removal and Replacement
Dismantling and Assembly
Rotary Coupling
Description and Operation
Removal and Replacement
Dismantling and Assembly
Pressure testing
Pressure Maintenance Valve
Slew Crossline relief Valves
Hydraulic Oil Cooler – Removal and Replacement

Gearboxes
Technical Data
Track Gearbox
Removal and Replacement
Dismantling and Assembly – 8052
Dismantling and Assembly – 8060
Slew Gearbox
Removal and Replacement
Dismantling and ASsembly

Track and Running Gear
General Description
Tracks
Clean and Inspection
Removal and Replacement
Converting Tracks
Track Rollers
Removal and Replacement
Dismantling and Assembly
Track Idler and Recoil Unit
Dismantling and Assembly
Driven Sprocket – Dismantling and Assembly
Track Roller Metallic Face Seals – Removal and Replacement

Engine
Technical Data
Fuel System Layout

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