JCB 8085 Midi Excavator Service Manual – 9803/9990-1

(S/N: 1071500 Onwards)
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This workshop repair service manual PDF download for the 8085 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 :

This manual provides information for the following model(s) in the JCB machine range:
– JCB Excavator 8085 from S/N: 1071500.

TABLE OF CONTENTS :

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

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9803/9990-1
Total Pages : 480

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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9803-9990

Section 1 – General Information
Introduction
About this Manual
Machine Model and Serial Number
Using the Service Manual
Section Numbering
Units of Measurement
Cross References
Left Side, Right Side
Machine Identification
Identifying Your Machine
Machine Identification Plate
Typical Product Identification Number (PIN)
Component Identification Plates
Typical Engine Identification Number
ROPS, TOPS and FOGS
Service Tools
Numerical List Section B – Body and Framework
Tool Detail Reference Section B – Body and Framework
Numerical List Section C – Electrics
Tool Detail Reference Section C – Electrics
Numerical List Section E- Hydraulics
Tool Detail Reference Section E- Hydraulics
Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
Introduction
Bolts and Screws
Condition 1
Condition 2
Verbus Ripp Bolts
Hydraulic Connections
‘O’ Ring Face Seal System
Adaptors Screwed into Valve Blocks
Hoses Screwed into Adaptors
Adaptors into Component Connections with Bonded Washers
‘Torque Stop’ Hose System
Service Consumables
Sealing and Retaining Compounds
Terms and Definitions
Colour Coding
Hydraulic Schematic Colour Codes

Section 2 – Care & Safety
Safety Notices
Important Information
The Operator Manual
Safety Warnings
Safety Checklist
Safety – Yours and Others
General Safety
Maintenance Safety
Safety Decals
Introduction
Safety Label Identification

Section 3 – Routine Maintenance
Routine Maintenance
Health and Safety
Lubricants
Introduction
Hygiene
Storage
Waste Disposal
Handling
New Oil
Used Oil
First Aid – Oil
Eyes
Swallowing
Skin
Spillage
Fires
Battery
First Aid – Electrolyte
GETS INTO YOUR EYES
IS SWALLOWED
GETS ONTO YOUR SKIN
Warning Symbols
Service Schedules
Introduction
How to Use the Service Schedules
Pre-Start Cold Checks, Service Points and Fluid Levels
Functional Test and Final Inspection
Service Intervals for Attachments
Periodic Replacement of Safety Related Components
Fluids, Lubricants and Capacities
Coolant Mixtures
Cleaning the Machine
Preparing the Machine for Cleaning
Introduction
Detergents
Pressure Washing and Steam Cleaning
Cleaning the Radiator and Air Cooler
Cleaning the Tracks
Inspection
Checking for Damage
Check the Machine Body and Structure
Check the Hydraulic Hoses and Fittings
Seat Belt
Checking the Seat Belt Condition and Security
Checking the ROPS/FOPS Structure
Greasing
Introduction
Grease Points
Slew Ring Bearings
Slew Ring Teeth and Slew Pinion
Electrical System
Battery
Battery Disconnection/Connection
Disconnection
Connection
Checking the Electrolyte Level
Jump Starting the Engine
Windscreen Washer
Engine
Checking the Oil Level
Changing the Oil and Filter
Air Filter
Changing the Elements
Checking the Coolant Level
Changing the Coolant
Adjusting the Fan Belt
Fitting a New Fan Belt
Adjusting the Compressor Pump Belt
Fuel System
Types of Fuel
Cetane Number
Viscosity
Density
Sulphur
Distillation
Low Temperature Fuels
Fatty Acid Methyl Ester Fuels as a replacement for Diesel Fuels
Advice
Filling the Tank
Sedimenter and Engine Fuel Filter
Draining the Fuel Pre-Filter/Sedimenter
Replacing the Fuel Pre-Filter Element
Replacing the Fuel Filter
Bleeding the Fuel System
Refuelling
Filling the Tank
Draining Fuel Tank Impurities
Hydraulic System
Introduction
Checking the Fluid Level
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 / Adjusting the Track Tension
Checking the Track Shoes
Checking the rollers and Idler Wheels for Oil Leaks
Fault Finding
Engine and Related Area
Operating Controls
Hydraulic Pump
Working Attachments
Travelling
Slewing
Hydraulic Rams

Section B – Body & Framework
Technical Data
General Description, Weights and Torque Settings
General Description
Weights and Dimensions
Major Component Torque settings
Air Conditioning
Basic Operation
Heater/Air Conditioning Controls
Heater Controls
Air Conditioning Control
Air Distribution
Control
Pressures Switch Settings
Safety Procedures
Inspection
Condenser
Receiver Drier
Compressor and Drive Belt
Hoses and Fittings
Fault Finding
General Fault Indications
Sight Glass Indications
Clear
Foam or Bubbles
Clear
Fault Finding – No Air Conditioning
System Diagnosis
Normally Functioning A/C System
Low R-134a Charge
Poor Refrigerant Circulation
No Refrigerant Circulation
Insufficient Cooling of Condenser or Refrigerant Overcharge
Air in System
Expansion Valve Improperly Mounted or Heat Sensing Tube Defective (Opening Too Wide)
Compressor Malfunction
Some Moisture in the System
Service Procedures
Checking Refrigerant Charge Level
Leak Testing
Tightening Leaking Hoses
Condenser
Condenser Cleaning
Cab
Direct Glazing
Direct Glazing
Removing the Broken Glass and Old Sealant
Preparing the Cab Frame Aperture
Preparing the New Glass
Installing the New Glass
Upper Structure
Removal and Replacement
Removal
Replacement
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
Dozer
Removal and Replacement
Removal
Inspection
Replacement
Fuel Tank
Removal and Replacement
Removal
Replacement

Section C – Electrics
Technical Data
General Data
Fuses and Relays
Fuses
Relays
Basic System Operation
Switches and Controls
Location of Controls and Components
Right Console
Left Console
Switches
Control Lock Lever
Heater/Air Conditioning Controls
Using the Air Conditioning
EMS Panel
LCD Display Icons
Indication Lamps
Menu Modes
Set Mode
Monitor Messages (Repetitive Messages)
Diagnostic Mode
Facia Panel
Redundancy Switch
Servo Controls Immobilisation
Cab Interior Light
Track Controls
Travel Speed Change Button
Schematic Diagrams
Component Identification
Component Key
Harness Data
Wire and Harness Number Identification
Introduction
Wire Numbers and Functions
Wires 000-199
Wires 200-399
Wires 400-599
Wires 600-799
Wires 800-999
Wires In Splices
General Points
Harness Drawings
Harness Key
Service Procedures
Using a Multimeter
Measuring DC Voltage
Measuring Resistance
Measuring Continuity
Measuring Frequency
Testing a Diode or a Diode Wire
Fault Finding
Testing of ECU Inputs + Outputs
Testing Low Side Input
Testing High Side Input
Testing Low Side Output
Testing High Side Output
Battery
Maintenance
Testing
Specific Gravity Testing
Wiring Harness Repair
Introduction
Repair Procedure
AMS (Advanced Management System)
System Overview
Operation
Circuit Concepts
Inputs
Digital Inputs (on/off switch type inputs)
Analogue Input (i.e. sensor type inputs)
Outputs
Pulse Width Modulation (PWM)
Functional Description
Inputs and Outputs
Engine Throttle Control
Throttle Control System
Throttle Control Circuit
Throttle Control
Operation
Throttle Control Auto Idle
Operation
One Touch Idle
Operation
Power Modes
Operation
Mode Definition
Changing Modes
Pre-heating and Auto Warm
Pre-heat Operation
Auto Warm Operation
Engine Emergency Stop
Operation
Normal Mode
Redundancy Mode
Redundancy System
Operation
Normal Mode
Redundancy Mode
Lever Lock/Servo Isolator
Operation
Lever Lock
Servo Isolator
Wiper
Operation
Washer
Operation
Horn
Operation
Travel Alarm (Optional)
Operation
High Speed Travel
Operation
Swing Auxiliary Changeover
Operation
Electro-proportional Auxiliary Status (Optional)
Operation
Work Lights (Boom Light and Optional Work Lights)
Operation
No Options Installed
Options Installed
Engine Oil Pressure Warning
Operation
Fuel Level Sensor/Warning
Operation
Engine Temperature Sensor/Warning
Operation
Hydraulic Temperature Sensor/Warning
Operation
Alternator Charging
Operation
Alternator Excitation
Input
Output
Alternator
Battery
Sensor Voltage
Air Filter Blocked
Operation
Quick Hitch (Optional)
Operation
Overload Caution (Optional)
Operation
Beacon
Operation
Refuelling Pump (Optional)
Operation
Automatic Mode
Manual Mode
Interior Light
Operation
Turning On
Turning Off
Service Required Warning
Operation
Cancellation of the Service Indicator
Text Messages
Types of Messages Displayed on EMS
Menu Messages
Repetitive Messages
One Time Messages
Error Codes
Engine Throttle Calibration
Calibration Procedure
Alternator
Service Procedures
General
Service Precautions
Charging Test
Removal and Replacement
Removal
Replacement
Starter
Service Procedures
Starting Circuit Test
Test 1
Test 2
Test 3
Test 3a
Test 3b
Test 4
Test 5
Test 5a
Removal and Replacement
Removal
Replacement
Beacon
Mounting and Bulb Changing
Mounting
Bulb Change

Section E – Hydraulics
Technical Data
Description and General Data
Pumps
Control valve
Relief Valve Settings
Hydraulic Cylinders
Filtration
Cooling
Controls
Service Capacities
Swing System
Excavator End
Service Procedures
Hydraulic Contamination
Hydraulic Fluid Quality
Effects of Contamination
Cleaning Operation
Procedure
Contaminant Standards
Filters
Cleaning Operation
Procedure
Circuit Diagrams
Introduction to Hydraulic Schematic Symbols
General (Basic and Functional Symbols)
Control Valves
Example of Schematic Circuit
Example Circuit Key
Schematic Diagrams
Schematic Hydraulic Circuits – Upper Structure
Key – Main Components (Upper Structure)
Schematic Hydraulic Circuit- Undercarriage
Key – Main Components
Pump Theory
Key
Services not selected
Services selected
Anti Cavitation
Pressure Testing
General
Confirmation of Oil Temperature
Warming-up Procedure
Main Relief Valve (MRV) Pressure
Servo Relief Pressure
Fault Finding
Hydraulic System
Hydraulic Pump
Control Valve
Main Relief Valve
Pressure/flow Curve for Hydraulic Pump
Hydraulic Pump
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Dismantling
Assembling
Joystick Controllers
Introduction
Specification
Key
Operation
Function
Dismantling and Assembly
Notes
Dismantling
Assembly
Control Valve
Control Valve (10 Section)
Key
Removal and Replacement
Removal
Replacement
Hose Connections
Other Connections
Pilot Supply Valve
Dismantling and Assembly
Cartridge Details
Hydraulic Rams
Precautions During Use
Installation
Caution During Use
Maintenance, Inspection Points
Boom, Dipper and Bucket Rams
Removal and Replacement
When Removing
When Replacing
Dozer Ram
Removal and Replacement
When Removing
When Replacing
Swing Ram
Removal and Replacement
When Removing
When Replacing
Dismantling and Assembly – Typical Ram
When Dismantling
Boom Ram
Dozer Ram
Swing Ram
Bucket Ram
Dipper Ram
When Assembling
New rod and piston head
New piston head fitted to a pre-drilled piston rod
New piston rod fitted to a pre-drilled piston head
JCB Ram Sealing Procedure
Rotary Coupling
Description
Operation
Removal and Replacement
Removal
Replacement
Hose Connections
Dozer Ram
L.H. Track Motor
R.H. Track Motor
Dismantling and Assembly
Dismantling
Assembly
Slew Motor
Hydraulic Circuit
Key
Operation
Slew Motor Configuration
Hydraulic Motor Components
Reduction Gear Components
Maintenance Specifications
Motor Assembly/Cylinder Assembly
Dismantling
Assembly
Fault Finding

Section F – Transmission
Technical Data
General Data
Traction Motor/Reduction Gear
Fault Finding
Removal and Replacement
Removal
Replacement
Motor Bleeding
Method 1
Method 2
Method 3

Section J – Tracks
Technical Data
General Data
Tracks
Track Removal and Replacement
Track Removal
Track Replacement
Replacing a Shoe Plate
Replacing a Track Link
Changing Tracks
Changing from Steel to Rubber Tracks
Changing from Rubber to Steel Tracks
Idler Wheel and Recoil Unit
Unit Removal and Replacement
Removal
Replacement
Idler Wheel
Dismantling and Assembly
Dismantling
Assembly
Recoil Unit
Dismantling and Assembly
Dismantling
Assembly
Grease Cylinder
Dismantling and Assembly
Dismantling
Assembly
When Assembling
Drive Sprocket
Removal and Replacement
Sprocket Removal
Sprocket Replacement
Top Roller
Removal and Replacement
Roller Removal
Roller Replacement
Dismantling and Assembly
Dismantling
Assembly
Bottom Roller
Removal and Replacement
Roller Removal
Roller Replacement
Dismantling and Assembly
Dismantling
Assembly

Section K – Engine
Technical Data
General Data

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