8055, 8065
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
Publication No. 9803/9890-3
		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.

General Information
Service Manual - 8055, 8065
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
Publication No. 9803/9890-2
		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.

Notes:

Contents Introduction

Page No.

About this Manual 1-1

Machine Model and Serial Number 1-1

Using the Service Manual 1-1

Section Numbering 1-1

Left Side, Right Side 1-2

Cross References 1-2

Identifying Your Machine

Identification Plates 1-3

Data Plate 1-3

Typical Vehicle Identification Number (VIN) 1-3

Typical Product Identification Number (PIN) 1-3

Typical Engine Identification 1-4

ROPS, TOPS and FOGS 1-5

Standard Torque Settings

Zinc Plated Fasteners and Dacromet Fasteners 1-7

Introduction 1-7

Bolts and Screws 1-7

Hydraulic Connections 1-11

'O' Ring Face Seal System 1-11

'Torque Stop' Hose System 1-14

Service Tools

Numerical List 1-15

Tool Detail Reference 1-18

Section B - Frame and Bodywork 1-18

Section C - Electrics 1-22

Section E - Hydraulics 1-23

Section K - Engine 1-28

Service Consumables

Sealing and Retaining Compounds 1-29

Terms and Definitions

Colour Coding 1-31

Hydraulic Schematic Colour Codes 1-31

Contents Page No.

Introduction

About this Manual

About this Manual

Machine Model and Serial Number

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

Finally, please remember above all else safety must come first!

Section Numbering

JCB 8055 from serial number 1536000 Onwards JCB 8065 from serial number 1537500 Onwards

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.

T11-005

The manual is compiled in sections, the first three are numbered and contain information as follows:

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:

   
   

   1. Attachments

   2. Body and Framework, etc.

      
      

      Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of each alphabetically coded section.

      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

      
      

      Cross References

      A

      Fig 1.

      
      

      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 (    1-2).

      Identifying Your Machine

      Identification Plates

      
      

      Data Plate

      Your machine has a Data Plate either attached to the left hand front face of the machine or behind the front face of the machine, next to the swing ram.

      Typical Product Identification Number (PIN)

      
      

      1 2 3 4

      JCB 08055 L 01536000

      
      

      
      

      JCB COMPACT PRODUCTS LIMITED HAREWOOD ESTATE, LEEK ROAD, CHEADLE, STOKE ON TRENT, UNITED KINGDOM, ST10 2JU.

      
      

      WEIGHT Kg ENGINE POWER kW @ RPM

      YEAR OF MANUF.

      VIN Vehicle Ident. No. PIN Prod.Ident. No.

R

M

1. World Manufacturer Identification (3 Digits).

   
   

   R

   E

   T

   S

   I

   G

   E

   R

   I

   F

   D

   E

   JCB = UK Build.

   
   

2. Machine Type and Model (5 Digits).

   
   

   08055 = 8055.

   
   

3. Random Check Letter (1 Digit).

   
   

   The Check Letter is used to verify the authenticity of a machine’s PIN.

   
   

4. Machine Serial Number (8 Digits).

Each machine has a unique serial number.

Fig 1.

Typical Vehicle Identification Number (VIN)

1. World Manufacturer Identification (JCB)

   
   

2. Machine Type and Model (08055 = 8055)

   
   

3. Random Check Letter

   
   

4. Year of Manufacture ( 6 = 2006, 7 = 2007, 8 = 2008,

   9 = 2009)

   
   

5. Product Identification Number (1226501)

Identification Plates

Typical Engine Identification

The engine model decal is located on top of the rocker cover. K Fig 2. (    1-4)

Fig 3.

Fig 2.

The engine serial number is stamped in front of cylinder number 1 injection pump.K Fig 3. (    1-4)

ROPS, TOPS and FOGS

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

Machines built to ROPS and TOPS standards have an identification label fitted to the cab. K Fig 4. (    1-5).

A bolt on falling object guard is available which also carries a certified label. This label certifies the cab to FOGS standard. K Fig 5. (    1-5)

Fig 4.

Fig 5.

V019006

V019007

Page left intentionally blank

Zinc Plated Fasteners and Dacromet Fasteners

Standard Torque Settings

Zinc Plated Fasteners and Dacromet Fasteners

Introduction

Some external fasteners on JCB machines are manufactured using an improved type of corrosion resistant finish. This type of finish is called Dacromet and replaces the original Zinc and Yellow Plating used on earlier machines.

The two types of fasteners can be readily identified by colour and part number suffix. K Table 1. Fastener Types (    1-7).

Table 1. Fastener Types

Note: As the Dacromet fasteners have a lower torque setting than the Zinc and Yellow fasteners, the torque figures used must be relevant to the type of fastener.

Note: A Dacromet bolt should not be used in conjunction with a Zinc or Yellow plated nut, as this could change the torque characteristics of the torque setting further. For the same reason, a Dacromet nut should not be used with a Zinc or Yellow plated bolt.

Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification.

Note: Dacromet bolts, due to their high corrosion resistance are used in areas where rust could occur. Dacromet bolts are only used for external applications. They are not used in applications such as gearbox or engine joint seams or internal applications.

T11-002

Bolts and Screws

Use the following torque setting tables only where no torque setting is specified in the text.

Note: Dacromet fasteners are lubricated as part of the plating process, do not lubricate.

Torque settings are given for the following conditions:

Condition 1

• Un-lubricated fasteners

• Zinc fasteners

• Yellow plated fasteners

  
  

  Condition 2

  
  

• Zinc flake (Dacromet) fasteners

• Lubricated zinc and yellow plated fasteners

• Where there is a natural lubrication. For example, cast iron components

Verbus Ripp Bolts

Fig 1.

Torque settings for these bolts are determined by the application. Refer to the relevant procedure for the required settings.

Zinc Plated Fasteners and Dacromet Fasteners

Table 2. Torque Settings - UNF Grade 'S' Fasteners

Table 3. Torque Settings - Metric Grade 8.8 Fasteners

Zinc Plated Fasteners and Dacromet Fasteners

Table 4. Metric Grade 10.9 Fasteners

Table 5. Metric Grade 12.9 Fasteners

Zinc Plated Fasteners and Dacromet Fasteners

Table 6. Torque Settings - Rivet Nut Bolts/Screws

Table 7. Torque Settings - Internal Hexagon Headed Cap Screws (Zinc)

'O' Ring Face Seal System

Hydraulic Connections

T11-003

Hydraulic Connections

Adaptors Screwed into Valve Blocks

Adaptor screwed into valve blocks, seal onto an 'O' ring which is compressed into a 45° seat machined into the face of the tapped port.

Table 8. Torque Settings - BSP Adaptors

Table 9. Torque Settings - SAE Connections

Hydraulic Connections

Hoses Screwed into Adaptors

Fig 2.

Hoses 2-B screwed into adaptors 2-A seal onto an `O' ring 2-C which is compressed into a 45° seat machined into the face of the adaptor port.

Note: Dimension 2-D will vary depending upon the torque applied.

Table 10. BSP Hose - Torque Settings

Hydraulic Connections

Adaptors into Component Connections with Bonded Washers

Table 11. BSP Adaptors with Bonded Washers - Torque Settings

Hydraulic Connections

'Torque Stop' Hose System

Fig 3.

`Torque Stop' Hoses 3-B screwed into adaptors 3-A seal onto an 'O' ring 3-C which is compressed into a 45° seat machined in the face of the adaptor port. To prevent the 'O' ring being damages as a result of over tightening, 'Torque

Stop' Hoses have an additional shoulder 3-D, which acts as a physical stop.

Note: Minimum dimension 3-E fixed by shoulder 3-D.

Table 12. BSP `Torque Stop' Hose - Torque Settings

Service Tools

Numerical List

Numerical List

The tools listed in the table are special tools required for carrying out the procedures described in this manual. These tools are available from JCB Service.

Some tools are available as kits or sets, the part numbers for parts within such kits or sets are not listed here. For full details of all tools, including the content of kits and sets, refer to Tool Detail Reference, Section 1.

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.

Numerical List

Numerical List

Tool Detail Reference

Section B - Frame and Bodywork

Fig 1. 993/68100 Slide Hammer Kit
1	993/68101	Slide Hammer	7	993/68107	Bar - M20 x M20 X 800 mm
2	993/68102	End Stops	8	993/68108	Adaptor - M20 x 7/8" UNF
3	993/68103	Adaptor - M20 x 5/8" UNF	9	993/68109	Adaptor - M20 x M12
4	993/68104	Adaptor - M20 x 1" UNF	10	993/68110	Adaptor - M20 x 5/8" UNF (Shoulder)
5	993/68105	Adaptor - M20 x M20	11	993/68111	Adaptor - M20 x 1/2" UNF
6	993/68106	Adaptor - M20 x M24

Fig 2. Rivet Nut Tool	1	826/01099	M6 x 16 mm Rivet Nut
		826/01101	M6 x 19 mm Rivet Nut
		826/01102	M8 x 18 mm Rivet Nut
		826/01103	M8 x 21 mm Rivet Nut
		826/01104	M10 x 23 mm Rivet Nut
		826/01105A	M10 x 26 mm Rivet Nut
	2	-	Installation Tool available from: Bollhoff Fastenings Ltd (www.bollhof.com)

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