JCB 801.4, 801.5, 801.6 Mini Excavator Repair Service Manual

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This service manual PDF download for the 801.4, 801.5, 801.6 JCB Mini 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 Mini Excavator

JCB Excavator 801.4 – From S/N: 720001 Onwards
JCB Excavator 801.5 – From S/N: 730001 to 730614
JCB Excavator 801.6 – From S/N: 728750 to 729999

TABLE OF CONTENTS :

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

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9803/3130 Issue 1
Total Pages : 199

This JCB Mini 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 !!!!

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail! You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

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Cover
Contents

General Information
Identification
Preparation for Storage
Preperation after Storage

Care and Safety
Safety Notices
General Safety
Operating Safety
Maintenance Safety

Routine Maintenance
Lubricants and Capacities
Service Schedule
Greasing
Cooling System
Torque Settings
Hydraulic Fittings & Torque Settings

Attachments
Front Attachment

Body and Framework
Technical Data
Front attachment
General Description
Bucket Ram Pivot and Linkage
Dismantling and Assembly
Dipper
Removal and Replacement
Boom
Removal and Replacement
Kingpost
Removal and Replacement
Upper Structure
Dismantling and Assembly

Electrics
Technical Data
Battery
Alternator
Removal and Replacement
Dismantling
Inspection & Testing
Assembly
Voltage Regulator operation
Charging System Testing
Starter Motor
Removal and Replacement
Disassembly
Inspection
Assembly
Circuit Diagram
Wiring Harness
Beacon
Mounting
Bulb Change

Controls
Technical Data
Control Cables
Removal
Replacement
Excavator Control Cables
Swing Control Cable
Auxiliary Control Cable
Servo Hand Controllers
Removal
Replacement
Engine Throttle Cable
Removal and Replacement

Hydraulics
Technical Data
General Description
Hydraulic Circuit
Description
Servo Circuit Description
Checking the Fluid Level
Hydraulic Pump
Description
Dismantling and Assembly
Track Motor
Operation
Dismantling & Assembly
Slew Motor – Description
Slew Gearbox – Removal and replacement
Slew Motor
Dismantling and Assembly
Operation
Slew Gearbox Motor – Removal and replacement
Fault Finding
Control Valve
Forward Valve
Rear Valve
Dismantling and Assembly
Main Relief Valve
Operation
Removal
Dismantling and Assembly
Rams
Boom, Dipper and bucket – Removal & Replacement
Dozer – Removal & Replacement
Swing – Removal & Replacement
Typical – Dismantling and Assembly
Typical – Inspection
Rotary Coupling
Removal, Dismantling, Assembly & Replacement
Pressure Testing
Main Relief Valves
Auxiliary Relief Valves
Servo Relief Valves
Crossline Relief Valves

Gearboxes
Technical Data
General Description
Track Gearbox
Check Level
Drain & Refill
Dismantling and Assembly
Slew Gearbox (early types)
Operation
Removal & Replacement
Dismantling
Assembly
Slew gearbox (later types)
Check Level
Removal and replacement
Dismantling and Assembly

Track and Running Gear
Technical Data
General Description
Tracks
Clean
Inspect
Removal and Replacement – Steel Track
Removal and Replacement – Rubber Track
Track Tensioning
Track Rollers – Dismantling & Assembly
Idler & Recoil Unit
Dismantling
Assembly
Changing from rubber to Steel Tracks

Engine
Technical Data
Engine Oil – Drainging and Filling
Oil Pressure Relief Valve – Removing & Fitting
Oil Sump, Suction Pipe & Strainer – Removal and Fitting
Fuel Filter – Renewing
Fuel Lift Pump – Removing, Inspecting and Fitting
Fuel injection Pump Assembly – Removal and Fitting
Fuel Injection timing – Checking and Adjusting
Fuel Injectors & Fuel Pipe Assembly
Removing, Dismantling/Inspecting
Reassembling/Adjusting & Fitting
Fuel System – Bleeding
Air Filter
Renew Outer Element
Renew inner Element
Engine Coolant – Draining & Filling
Water Pump assembly – Removing, Inspecting and Fitting
Fan Belt – Removing, Inspection and Fitting
Alternator – removing and fitting
Starter Motor – Removing and Fitting
Engine – Removal and Replacement
Cylinder Head – Removing, Inspecting and Fitting
Piston and Connecting rods – Removing, Inspecting and Fitting
Timer Gear Case – Removal and Replacement
Idler Gear and Oil Pump Assembly – Removing, Dismantling and Fitting
Camshaft Assembly and Tachometer Drive – Removal, Inspecting and Fitting
Crankshaft
Removing
Dismantling and Inspecting
Assembling
Exhaust Emissions

 

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JCB 801.4, 801.5, 801.6 Mini Excavator Repair Service Manual.pdf

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