JCB 8018 Excavator Workshop Repair Service Manual

World Class Customer Support 9803/9350-4 Publication No. Service Manual 717260 JCB 8014, 8016, 8018, 8020 S/N: 1156000 Onwards (8014) S/N: 1155000 Onwards (8016) S/N: 1046000 Onwards (8018) S/N: 1284000 Onwards (8020)

Section 0 - Service Manual 0-0 0-0 9803/9350-4 Notes:

Page No. Contents Section 1 - General Information 1-i 1-i Introduction 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 ........................................................................... 1-3 Machine Identification Plate .................................................................. 1-3 Component Identification Plates ............................................................ 1-4 Standard Torque Settings Zinc Plated Fasteners and Dacromet Fasteners ....................................... 1-6 Introduction ............................................................................................ 1-6 Bolts and Screws ................................................................................... 1-6 Hydraulic Connections ............................................................................. 1-10 'O' Ring Face Seal System .................................................................. 1-10 'Torque Stop' Hose System ................................................................. 1-13 O-Ring Face Seal .................................................................................... 1-14 Introduction .......................................................................................... 1-14 Machines Affected ............................................................................... 1-14 Procedure ............................................................................................ 1-15 Key Points ........................................................................................... 1-15 General ................................................................................................ 1-17 Service Tools Numerical List .......................................................................................... 1-18 Tool Detail Reference .............................................................................. 1-21 Section B - Frame and Bodywork ........................................................ 1-21 Section C - Electrics ............................................................................ 1-25 Section E - Hydraulics ......................................................................... 1-26 Section K - Engine ............................................................................... 1-31 Service Consumables Sealing and Retaining Compounds ......................................................... 1-32 Terms and Definitions Colour Coding .......................................................................................... 1-33 Hydraulic Schematic Colour Codes ..................................................... 1-33

Page No. Contents Section 1 - General Information 1-ii 1-ii

Section 1 - General Information 1-1 1-1 9803/9350-4 Introduction About this Manual Machine Model and Serial Number This manual provides information for the following model(s) in the JCB machine range: – 8014 from serial number 1156000 – 8016 from serial number 1155000 – 8018 from serial number 1046000 – 8020 from serial number 1284000 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. Finally, please remember above all else safety must come first! Section Numbering T11-005 The manual is compiled in sections, the first three are numbered and contain information as follows: The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for example: Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of each alphabetically coded section. 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. A Attachments B Body and Framework, etc.

Section 1 - General Information Introduction About this Manual 1-2 1-2 9803/9350-4 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. 731911-3 Fig 1. Cross References 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 ( T 1-2) .

Section 1 - General Information Introduction Identifying Your Machine 1-3 1-3 9803/9350-4 Identifying Your Machine Machine Identification Plate Your machine has an identification plate mounted as shown. The Product Identification Number (PIN), weight, engine power, year of manufacture and serial number of the machine are shown on the plate. Note: The machine model and build specification is indicated by the PIN. Refer to Typical Product Identification Number (PIN). If the engine is replaced by a new one, the serial number on the identification plate will be wrong. Either get a replacement identification plate from your JCB Dealer or simply remove the old number. This will prevent the wrong unit number being quoted when replacement parts are ordered. The machine and engine serial numbers can help identify exactly the type of equipment you have. 772890-3 Fig 2. Typical Product Identification Number (PIN) 1 World Manufacturer Identification (3 Digits). JCB = UK Build. 2 Machine Type and Model (5 Digits). 08014 = 8014. 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. 1 2 3 4 JCB 08014 L 01156000

Section 1 - General Information Introduction Identifying Your Machine 1-4 1-4 9803/9350-4 Component Identification Plates Typical Engine Identification Number The engine data label is located on the cylinder block as shown. The data label includes the engine identification number. A typical engine identification number is: 1 Engine Type (2 Digits) GJ = Naturally aspirated, 13.8kW (18.5Hp) 2 Country of Manufacture (1 Digit) U = United Kingdom 3 Build Number (5 Digits) 4 Engine Serial Number (6 Digits) 5 Year of Manufacture (1 Digit) T017650-2 Fig 3. GJ U 65692 500405 P 1 2 3 4 5

Section 1 - General Information Introduction Identifying Your Machine 1-5 1-5 9803/9350-4 ROPS, TOPS and FOGS ! WARNING 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. ( T 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. ( T 1-5) When a machine is used in an application with the risk of falling objects, the machine must be equipped with the optional FOGS guard. This guard is compliant to ISO10262 level 1 and is intended for protection from small objects, e.g. small rocks, small debris and other small objects encountered in operations such as highway maintenance, landscaping and other construction site services. Fig 4. Fig 5. FOPS Data Plate ! WARNING Do not use the machine if the falling objects protection level provided by the structure is not sufficient for the application. Falling objects can cause serious injury. 8-2-8-17 If the machine is used in any application where there is a risk of falling objects then a falling-objects protective structure (FOPS) must be installed. For further information contact your JCB Dealer The falling objects protection structure (FOPS) is fitted with a dataplate. The dataplate indicates what level protection the structure provides. There are two levels of FOPS: – Level I Impact Protection - impact strength for protection from small falling objects (e.g. bricks, small concrete blocks, hand tools) encountered in operations such as highway maintenance, landscaping and other construction site services. – Level II Impact Protection - impact strength for protection from heavy falling objects (e.g. trees, rocks) for machines involved in site clearing, overhead demolition or forestry.

Section 1 - General Information Standard Torque Settings Zinc Plated Fasteners and Dacromet Fasteners 1-6 1-6 9803/9350-4 Standard Torque Settings Zinc Plated Fasteners and Dacromet Fasteners T11-002 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 ( T 1-6) . 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. 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. Fastener Type Colour Part No. Suffix Zinc and Yellow Golden finish 'Z' (e.g. 1315/3712Z) Dacromet Mottled silver finish 'D' (e.g. 1315/3712D)

JCB 8018 Excavator Workshop Repair Service Manual

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