JCB 805 Excavator Service Repair Manual

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Transcript of JCB 805 Excavator Service Repair Manual

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    SERVICE MANUAL

    JCB SERVICE @ ROCESTER, STAFFORDSHIRE,

    ST14 5LS. ENGLAND.

    TEL. AOCESTER (0889) 590312

    Printed 'in England.

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  • Contents

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    General

    Hydraulics

    Attachments

    Body & Framework

    Gearboxes

    Track & Running Gear

    Engine

    Electrics

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    805,80588068,8078

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    Introduct¡on

    This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have receivedtraining by the JCB Technical Training Department.

    It is assumed that such personnel have at least a sound knowledge of workshop practice, safety procedures andgeneral techniques assoc¡ated with the maintenance and repair of hydraulic earthmoving equipment. Details of suchare therefore generally omitted from this manual, the intention being to convey only the more specialised informationconcerning particular aspects of the machine or component in question.

    For example, renewal of oil seals, gaskets etc. and any component showing obvious wear or damage is expected as amatter of course and information on these matters is therefore only included where a specialised procedure or rangeof wear tolerances is required. Similarly, it is expected that components will be thoroughly cleaned and lubricatedwhere appropriate, also that any opened hose or pipe connections will be blanked to prevent entry of dirt andexcessive loss of hydraulic fluid.

    For convenience the manual is compiled in sections, e.g. "Hydraulics", "Gearboxes" etc., but to find details of aspecific component, reference should be made to the alphabet¡cal index at the back of the book.

    lllustrations showing a dismantled component are numbered as a guide to the dismantling sequence which cangenerally be reversed for assembly.

    Torque settings quoted are given as'mean'figures which may be varied by i gø. 'Left Hand'and 'Right Hand'areas viewed from the rear of the machine.

    Replacement or additional pages for this manual will be issued from t¡me to time and should be inserted in place ofthe existing pages which should be removed and destroyed.

    Where possible, revised pages will bear an asterisk (*) against the new information, the page issue number in thebottom right hand corner being similarly marked.

    A Service Tools Catalogue, detailing special tools required, is available separately

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  • 1 General 1

    3-1

    GREASE POINTS

    ALL PIVOTPINS 10 Hours

    EACH SLEWINGRING NIPPLE ANDROTARYCOUPLING

    * 4 shots 50 HoursSLEW]NG RINGTEETHRepack 1600 Hours

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    GREASE POINTS

    ALL PIVOTPI NS 10 Hours

    EACH SLEWINGRING NIPPLE ANDROTARYCOUPLING4 shots 50 Hours

    SLEWING R INGTEETHRepack 1600 Hours

    SLIDING BEAMGrease as required

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    FILTER OPERATION

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    HYDRAULIC FITTER(Early Type)

    RENEW EveTyELEMENT 400 Hours1

    2

    3

    4

    5

    6

    Carefully removehydraulic oil filler cap4

    Remove plug B toprevent excess loss off luid.

    Remove U-bolt C.

    Note:

    Unscrew bolt D untilbody can be withdrawn.

    A considerableamount of fluid willflow from the filter atthis stage.

    Remove bolt Ð, body,and element F.

    Wash all metal parts inJCB'Special' HydraulicFluid.

    Re-assemble using newelement and seal F.

    Repeat for second filter

    Top up at filler cap.

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    HYDRAULIC FILTER(Later Type)

    ( Renew Element EverY 400 Hours.

    To prevent siphoning of tankwhen draining filter, removetank filler cap and filter PlugA.

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    2. Drain filter at plug C.

    Note: On 805,8068,8078 and 808Remove access plate B.

    Unscrew bolt D (nut D onlater 8058) and element E

    Wash all metal parts in JCB'Special' Hydraulic Fluid.

    Reassemble using new element

    and seal F which should belu bricated before f itting.

    6. Top up hydraulic tank.

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    PUMP OPERATION

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    MOTOR OPERATION

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    PUMPS & MOTORS (HAMWORTHY)

    Dismantling and Assembly

    * NOTE: Main illustration showsa typical three sectíon pumpwith alternative later type wearplates at A. For clarity, pipeconnections have been omittedfrom centre pump section 25.Motors have only one pair ofgears with the wear plate andseal arrangement shown at B;otherwise construction issimilar.

    When Dismantling

    Mark housings and end coversto ensure correct re-assembly.Use a soft faced hammer to partcomponents. Do not use leversor machined surfaces may bedamaged.

    Mark adjacent teeth of gearswith indelible ink beforeremoval. Retain gears in pairs.

    Use Service Tool 8T2464 towithdraw bearings 12, 21,35,45, 58 and 65.

    Remove sharp edges, burrs andlight scoring from gears, shaftsand housings. Use a fineabrasive stone. Wash off anygrit or metal particles with cleanhydraulic fluid.

    When Assembling

    Renew any pair of gears if:-

    a) Journal area of shaft ispitted or worn in excessof 0.025mm. (0.001 in.).

    b) Keyway, splines or gearsare badly worn or cracked

    Renew bearings if worn or ifgears are renewed. They must fitflush with or not more than

    0.05mm. (0.002in.) below faceof bearing bore.

    Renew wear plates 5,9,26,30,49 and 53 if scored or eroded.

    Ensure that all wear plates aref¡tted with their slots correctlypositioned relative to the gearsand to the suction and pressureports as shown. Plates 9, 30and 53 must fit fully home inthe housings and move freely.

    Ensure that seal supports 7, 11,28,32,51 and 55 also seals6, 10, 27,31,50 and 54 arecorrectly trimmed and do notbecome trapped between wearplates and housing wall.

    lf the original gears are refitted,align the marks made duringdismantling.

    Torque Settings

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    *PUMPS & MOTORS {COMMERCIAL}

    Dismantling and Assembly

    *NOTE: lllustration shows an805/8068 pump. Other pumpshave an additional bearinghousing 10 in place of adapterflanges 18 and 20. Motorshave only one pair of gears,otherwise construct¡on is similar

    When Dismantling

    Mark housings and end covers toensu re correct replacement.When separat¡ng these components,take care to avoid damage to themachined faces.

    Before removing gears, markadjacent teeth with indelibleink to ensure correctreplacement. Do not centrepunch or stamp. Retain gearsin pairs.

    Check gear housings 5, 13 and29 for wear as at B. lf gearcut-out exceeds 0.1 2mm.(0.005in.), the housing must berenewed.

    Use extractor MD956 (seeService Tools catalogue) toremove bearings 38. Bearingsshould bea light press fitin theirbores. Loose bearings mayindicate worn bores.

    *Check security of plug(s) 40.Only remove if damaged, notingposition for re-assemblY.

    When Assembling

    Remove burrs and sharp edgesfrom splines, shafts and housings,using a fine abrasive stone.

    Renew wear plates 3,9,11,16,28 and 33 if worn to a thicknessof less than 9.47mm.(0.373in.),or if scored, eroded or pitted.

    *On pumps, Posit¡on the Presurerelief groove towards the highpressure side (see page2/5-51.

    Renew gears if pitted, scored orchipped or if wear on shaftdiameter exceeds 0.05mm.(0.002in.). Shaft wear is mostlikely on the contact area ofring seals 39. Wear on gearteeth width must not exceed0.025mm. (0.001 in.) belowthe nominal size of 1.000in.(25.40mm), 1.250in. (31.75mm)or 1.500in, (38.1Omm). Whenrenewing gears, fit in matchedpairs and renew the bearings.

    lnstall new ring seals 39 withnotched faces towards thebearings. See page 2/5-5 forinstallation of pocket seals A.lnstall lip seal 37 (also 23 and26 where fitted) facing in thedirection shown. Press items23 and 26 to the bottom ofrecess and item 37 flush withsurface. Secure with Loctite222.

    5-4

    Torque Settings

    Item Nm. kgf m1t

    Tfll 27o 2srle I

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    200

    tNote: ltems 17 and 19 arenot used on 8078 and 808.

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    5-5

    PUMPS AND MOTORS(Commercial)

    Pocket Seal Fitting

    The following instructions applywhen fitting seals to all thrustplates.

    Cut two centre-seals to alength of 5.5mm. (O.22in.l

    Coat the seals with grease andinsert into the centre slots of thethrust plate as at A.

    Place thrust plate,seals facingdownwards, into position overthe bearings as at B and tap witha soft hammer until clearancebetween thrust plate and housingis approximately 0.8mm (0.030 in.).Note: On pumps the pressure reliefgroove X must be towards the highpressure side,

    Cut four seals to an approximatelength of 6.5mm. (0.25in.).

    Push the seals into the radial slotsas at C until contact is made withthe bearings. Tap the thrust platefirmly down against the machinedsurface. Use a sharp razor bladeto trim the exposed ends of theseals until they are square andflush with the thrust plates.

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    CIRCUIT OPERATION

    When the spool is in the neutralposition oil from the pump passesthrough the centre or neutral circuitof the valve.

    lf a service is selected bY movingthe spool either up or down, theneutral circuit is blocked bY thespool. The oil then f lows into theparallel gallery, past the non-returnvalve'Aand through the open portto the ram or motor.

    Simultaneously, oi I returning f rom

    the ram or motor enters the valveblock, passes into the exhaustgallery and so back to tank.

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    CIRCUIT OPERATION

    The illustration on the previouspage shows the parallel gallery feddirectly from the neutral gallery.Where several spools are housedwithin one block however, eachspool is supplied by a commonparallel gallery A running the lengthof the valve block. The parallelgallery itself is fed from the neutralgallery upstream of the first spoolas shown. Alternatively it may befed from outside the block bymeans of a High Pressure Carry-overline as described later. More thanone spool may thus be operated atany one time.

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  • 2Hydraulics2

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    f, 6-3STANDARD SPOOL OPE RATION

    The standard spool is used inconjunction with a non"return valveto operate a service where back-pressure in the service line willoccur due to a gravity loadingopposing the action of the ram.

    Example:ln the upper illustration the dipperram spool is being selected but, due

    to the loaded bucket Ã, the back-pressure in the ram feed line isgreater than the PumP outputpressure in the parallel gallery at'B'.

    This higher pressure causes the non-

    return valve'C'to remain closed,preventing the possibility of reverseoil flow which would allow theload to drop.

    When the spool is fullY selected,the neutral circuit'D' is ccmpletelycut off and the pressure rises in theparal lel gallery'E'until it exceedsthat in the ram feed line. At thispoint the non-return valve 'F'oPens,permitting oil to flow to the ramand so raise the load.

    The use of non-return valves alsoprevents interaction between spools.For example, if non-return valveswere not f¡ttd and two loads werebeing raised simultaneouslY, the

    heavier of the two loads would falland oil from that ram would flow

    to the more lightlY loaded ram andincrease its lifting speed. Withnon-return valves in the system

    however, the oil ¡s Prevented fromflowing from one service to another.

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    MOTOR SPOOL (HUSCO}WITH BRAKEVENT VALVE

    Motor circuits are subject to 'reversepressure' hydraulic conditions createdby the tendency of the driven loadto'overrun'. The control valve spoolis therefore designed such that, whenset to the neutral position, bothmotor ports are vented to low pressure.

    Example

    Under slewing conditions, thesuperstructure of an excavatorattains considerable momentum.This causes the mass to 'run on'after the control lever has beenreset to neutral. When this occursthe motor'A' acts as a pump (beingdriven by the load through theslewing gears) and excessively highpressure would be developed if theoil could not escape to exhaust.The pressure would also tend tohold off the automat¡c brake 'B'.

    Method of Operation

    When a service is selected, the mainspool blocks the neutral circuitand diverts oil into the parallelgallery, through the open port toone side of motor, a reduced f lowalso passes through restrictor'E'to release the automat¡c brake.Shuttle valve 'C' prevents shortcircuiting of the motor by thebrake supply.

    Exhaust oil from the motor returnsto the valve block low pressuregallery.

    As the control lever is returned toneutral, both motor ports areopened to exhaust. Any pressurewhich might be generated by themotor ¡s therefore safely dissipated.Brake Vent valve 'D' also opens toprovide a direct route to tank foroil from the brake, thus ensuringrapid brake application.

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