JCB 801.4, 801.5 & 801.6 Mini Crawler Excavators Service Manual (9803/3130-01)

JCB 801.4, 801.5 & 801.6 Mini Crawler Excavators Service Manual (9803/3130-01)

This official JCB workshop manual provides comprehensive repair, maintenance, and diagnostic information for the JCB 801.4, 801.5, and 801.6 Mini Crawler Excavators. It includes detailed mechanical, electrical, and hydraulic system data designed to ensure precise servicing and reliable performance of compact excavators operating under a wide range of job site conditions.

Model Covers:

JCB 801.4 Mini Crawler Excavator
JCB 801.5 Mini Crawler Excavator
JCB 801.6 Mini Crawler Excavator

Note: Applicable to all JCB 801 Series Mini Excavators equipped with JCB powertrain and hydraulic systems. Includes model-specific component data and maintenance procedures.

File Format: PDF

Size: 4.28 MB

No. of pages: 188

Language: English

Delivery Method: Instant Download – Access your file immediately after purchase.

📑 Included Sections:

Section 1 – General Information

• Identification plate and serial number locations
• Preparation for storage and post-storage maintenance
• Torque settings for both metric and imperial fasteners
• Service tools index for all subassemblies
• Approved sealing and retaining compounds
• Towing procedures and safety precautions
• Hydraulic hose handling, cleanliness, and contamination standards

Section 2 – Care and Safety

• Safety notices (Danger, Warning, and Caution categories)
• Operator, maintenance, and lifting safety
• Fire safety, hazardous material handling, and PPE requirements
• Electrical and hydraulic system isolation procedures
• Battery, welding, and high-pressure hydraulic safety guidelines
• Coolant and anti-freeze handling standards

Section 3 – Routine Maintenance

• Comprehensive service schedule: 10h, 50h, 100h, 250h, 500h, 1000h, 2000h intervals
• Lubricant charts for engine, hydraulic, transmission, and slew systems
• JCB-approved lubricant grades based on temperature range
• Greasing points and service intervals (daily to 1000h)
• Cooling system draining, refilling, and coolant mixture ratios
• Torque settings for major subassemblies (engine, hydraulics, rams)
• SAE ‘O’-Ring Face Seal fitting torque specifications

Section A – Attachments

• Front attachment overview and component breakdown
• Bucket dismantling and assembly instructions
• Wear limits for bucket teeth, pins, and bushings
• Pivot pin and bush tolerances

Section B – Body & Framework

• Machine technical data and general description
• Bucket ram pivot and linkage assembly
• Dipper, boom, and kingpost removal and replacement procedures
• Upper structure dismantling and reassembly

Section C – Electrics

• 12V negative earth electrical system overview
• Battery testing, charging, and inspection
• Alternator removal, inspection, and testing
• Starter motor disassembly and reassembly
• Voltage regulator operation and diagnostics
• Complete electrical circuit diagram and harness layout
• Beacon and work light installation procedures

Section E – Hydraulics

• Hydraulic circuit schematics and flow diagrams
• Component servicing for pumps, valves, and rams
• Hydraulic filtration and contamination prevention standards
• Pressure testing and relief valve adjustment procedures

Section F – Gearboxes

• Transmission assembly, disassembly, and inspection
• Lubrication procedures and torque data

Section G – Track & Running Gear

• Track tensioning and alignment procedures
• Idler, sprocket, and roller service instructions
• Final drive maintenance and testing

Section K – Engine

• Engine servicing and configuration overview
• Fuel, air intake, and cooling system specifications
• Mounting and vibration isolation data
• Electrical sensor and control system diagnostics

Section L – Attachments & Ancillary Equipment

• Optional accessory and attachment compatibility
• Hydraulic auxiliary line connection and testing

This JCB 801.4, 801.5 & 801.6 Mini Excavator Service Manual is essential for workshop engineers performing repair, maintenance, and overhaul operations on compact crawler excavators, ensuring long-term durability and optimal performance in demanding working environments.