JCB 8080 Midi Excavator Repair Service Manual

(S/N: 1024000 Onwards)
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This service manual PDF download for the 8080 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 8080
From S/N: 1024000 Onwards


TABLE OF CONTENTS :

General Information
Care & Safety
Routine Maintenance
Body and Framework
Electrics
Controls
Hydraulics
Transmission
Track and Running Gear
Engine


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Publication No. : 9803/9330 Issue 3
Total Pages : 401


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
Colour Coding

General Information
Identifying your Machine
Identification Plates
Operation
Introduction
Before Entering the Cab
Entering/Leaving the Cab
Opening and Closing the Door
Opening and Closing the Front Upper Window
Opening and Closing the Front Lower Window
Emergency Exit
Door Sliding Window
Opening and Closing the Sunblind
Seat
Seat Belt
Location of Controls and Components
Switches and Controls
Right Console
Underseat Tool Box and Cool Box
Heater/Air Conditioning Controls
Left Console
EMS Panel
Facia Panel
Redundancy Switch
Mechanical Engine Speed Override
Servo Controls Immobilisation
Cab Interior Light
Radio (Optional)
Travel Levers
Travel Speed Change Button
Excavating Controls
Operation
Slewing
Boom Swing
Boom Swing Stop
Boom Raise/Lower
Dipper In/Out
Bucket Close/Open
Refuelling
Fuel Level
Filling the Tank
Refuelling Pump (optional)
Before Starting the Engine
Starting the Engine
Jump-Starting the Engine
Warming Up
Operating in Cold Climates
Operating in High Temperatures
Operating in Dusty or Sandy Areas
Operating in Coastal Regions
Operating on Wet or Soft Ground
Preparing for Travel
Stopping and Parking the Machine
Working on Slopes
Digging Near Walls
Dumping into a Truck
Dozing and Grading
Scraping and Cutting
Backfilling
Pulling out of Soft Ground
Installing and Removing a Bucket
Replacing Bucket Teeth
Bucket Selection
JCB Mechanical Quickhitch
Lifting (Craning) Regulations and Safe Working Loads
Overload Warning System (Optional)
Operating Attachments
Moving a Disabled Machine
Transporting the Machine
Preparing the Transporting Vehicle
Driving a Machine onto the Transporting Vehicle
Securing the Machine
Unloading a Machine from the Transporting Vehicle
Sealing and Retaining Compounds

Care & Safety
Safety Notices
General Safety
Operating Safety
Maintenance Safety

Routine Maintenance
Lubricants and Capacities
Coolant Mixtures
Torque Settings
Hydraulic Fittings and Torque Settings
Service Schedules
Revised Service Schedules - Rockbreaker Usage
Lubricants - Health and Safety
Cleaning the Machine
Checking for Damage
Greasing
Slew Ring Teeth and Slew Pinion
Slew Ring Bearing
Excavator End (Standard Boom)
Engine Air Filter
Changing the Elements
Engine Oil and Filter
Checking the Oil Level
Changing the Oil and Filter
Engine Cooling System
Checking the Coolant Level
Coolant Mixtures
Changing the Coolant
Cleaning the Radiator and Oil Cooler
Air Conditioning
Checking Compressor Belt Tension
Engine
Checking Fan Belt Tension
Fitting a New Fan Belt
Fuel System
Types of Fuel
Advice
Filling the Tank
Draining Fuel Tank Impurities
Draining the Water Separator
Cleaning the Water Separator
Changing the Filter Element
Bleeding the Fuel System
Hydraulic System
Checking the Fluid Level
Topping-up the Fluid Level
Replacing the Hydraulic Filter
Gearboxes
Checking the Track Gearbox Oil Level
Changing the Track Gearbox Oil
Tracks and Running Gear
Clean the Tracks
Inspection
Checking/Adjusting the Track Tension
Checking the Track Shoes
Checking the Rollers and Idler Wheels for Oil Leaks
Electrical System
Fuses
Relays
Battery
First Aid - Electrolyte
Checking the Electrolyte Level
Warning Symbols
Windscreen Washer

Body and Framework
Service Tools
Technical Data
General Description
Weights and Dimensions
Basic Operation
Air Conditioning
Fault Finding
Air Conditioning
Service Procedures
Air Conditioning
Cab
Direct Glazing
Removal and Replacement
Upper Structure
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
Fuel Tank
Removal and Replacement

Electrics
Service Tools
Technical Data
General
Fuses
Relays
Basic System Operation
Switches and Controls
Component Identification
Schematic Diagrams
AMS (Advanced Management System)
System Overview
Circuit Concepts
Pulse Width Modulation (PWM)
Functional Description
Engine Throttle Control
Throttle Control
Throttle Control Auto Idle
One Touch Idle
Power Modes
Pre Heating and Auto Warm
Engine Emergency Stop
Redundancy System
Lever Lock/Servo Isolator
Wiper
Washer
Horn
Travel Alarm (Optional)
Slew Brake
Slew lock (100% Slew Brake)
High Speed Travel
High Flow
Double Acting High Flow (Optional)
Work Lights (Boom Light and Optional Work Lights)
Engine Oil Pressure Warning
Fuel Level Sensor/Warning
Engine Temperature Sensor/Warning
Hydraulic Temperature Sensor/Warning
Alternator Charging
Air Filter Blocked
Quick hitch (Optional)
Overload Caution (Optional)
Beacon
Refuelling Pump (Optional)
Interior Light
Service Required Warning
Text Messages
Types of Message Displayed of EMS
Menu Messages
Repetitive Messages
One Time Messages
Error Codes
Service Procedures
Engine Throttle Calibration
Electrical Testing Methods
Using a Multimeter
Measuring DC Voltage
Measuring Resistance
Measuring Continuity
Testing a Diode
Testing of ECU-MIDI (Electronic Control Unit)
Wiring Harness
Introduction
Tools Required
Repair Procedure
Battery
Maintenance
Safety
Testing
Alternator
Starter Motor
Starting Circuit Test
Alternator
Removal and Replacement
Starter Motor
Removal and Replacement
Beacon
Mounting
Bulb Change
Harness Data
Slewpan Harness Drawing
Slewpan Harness Connector Locations - right side
Slewpan Harness Connector Locations - left side
Main Cab Harness Drawing
Main Cab Harness Connector Locations
Upper Cab Harness Drawing
Upper Cab Harness Connector Locations
Boom Light Harness
Refuel Pump Harness

Hydraulics
Service Tools
Technical Data
Hydraulic Contamination
Introduction to Hydraulic Schematic Symbols
Schematics
Schematic Hydraulic Circuit
Spool in Neutral
Single Spool Operation (Arm/Boom/Bucket/Offset)
Two Spool Operation - Multi Functioning
Travel Operation
100% Slew Brake
50% Slew Brake
Slew Operation
Cross Line Relief Valve
Slew Reduction Gearbox Lubrication
Dozer Operation
Pump Theory
Anti Cavitation
Pressure Testing - General
Main Relief Valve (MRV) Pressure
Servo Relief Pressure
Fault Finding
Hydraulic Pump
Removal and Replacement
Dismantling and Assembly
Location of Main Hydraulic Components
Joystick Controllers
Introduction
Specification
Operation
Dismantling and Assembly
Maintenance Specifications
Control Valve
Control Valve (10 - Section)
Removal and Replacement
Hose Connections
Pilot Supply Valve
Dismantling and assembly
Hydraulic Rams
Boom, Dipper and Bucket Rams
Removal and Replacement
Dozer Ram
Removal and Replacement
Swing Ram
Removal and Replacement
Dismantling and Assembly
Typical Ram
JCB Ram Sealing Procedure
Precautions During Use
Rotary Coupling
Description
Operation
Removal and Replacement
Dismantling and Assembly
Slew Motor
Hydraulic Motor Components
Reduction Gear Components
Hydraulic Circuit
Operation
Maintenance Specifications
Motor Assembly/Cylinder Assembly
Dismantling
Assembly
Fault Finding

Transmission
Technical Data
Traction Motor/Reduction Gear
Fault Finding
Removal and Replacement
Motor Bleeding

Track and Running Gear
Technical Data
Tracks
Removal
Replacement
Replacing the Shoe Plate
Replacing the Track Link
Changing from Steel to Rubber Tracks
Changing from Rubber to Steel Tracks
Idler Wheel and Recoil Unit
Removal
Replacement
Idler Wheel
Dismantling
Assembly
Recoil Unit
Dismantling
Assembly
Grease Cylinder
Dismantling and Assembly
Drive Sprocket
Removal
Replacement
Top Roller
Removal
Replacement
Dismantling
Assembly
Bottom Roller
Removal
Replacement
Dismantling
Assembly

Engine
Routine Maintenance
Technical Data

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