JCB 805 & 806 Excavators Tier 1 Service Manual (9803/9290)

JCB 805 & 806 Excavators Tier 1 Service Manual (9803/9290)

This Tier 1 Service Manual provides an in-depth technical reference for JCB 805 and 806 excavators, delivering system architecture overviews, factory-approved servicing procedures, diagnostic workflows, pressure setting data, and step-by-step repair instructions. Designed for pre-emission models, it covers all major assemblies including hydraulics, drivetrain, electrics, engine systems, controls, framework, and running gear—ensuring precise maintenance and long-term machine reliability.

Model Covers:

JCB 805 Excavator

JCB 806 Excavator

Applicable Models: Tier 1 / Pre-Emission

Note: All technical procedures, component specifications, and system diagrams apply to Tier 1 machines only. Always verify compatibility against serial identification plates before servicing.

File Format: PDF

Size: 15.49 MB

No. of pages: 313

Language: English

Delivery Method: Instant Download - Immediate access after purchase.

📑 Included Sections:

Section 1 - General Information

• Machine identification, serial number locations, and specification data
• Comprehensive torque settings for structural and hydraulic fasteners
• Service tools, adapters, sealing compounds, and retaining agents
• Hydraulic hose handling procedures and contamination control
• Towing instructions, lifting points, and workshop safety
• Recommended lubricants and maintenance consumables

Section 2 - Care and Safety

• Safety regulations for machine operation and maintenance
• Electrical and fire safety protocols
• Personal protective equipment and hazard identification
• Warning decals, safety labels, and machine risk zones

Section 3 - Routine Maintenance

• Maintenance intervals from daily inspections to 2000-hour service
• Lubrication charts, fluid capacities, and grease point distribution
• Battery care, filter changes, and operational checks
• Cold and hot climate service considerations

Section B - Body and Framework

• Chassis frame, structural body components, and counterweights
• Superstructure layout, access covers, and cab mounting systems
• Boom, dipper, kingpost, and swing frame assemblies
• ROPS-compliant cab structures and operator protection systems

Section C - Electrics

• Electrical system descriptions and full circuit diagrams
• Battery, starter motor, alternator, and charging systems
• Lighting circuits, indicators, fuses, relays, and harness routing
• Electrical troubleshooting logic and component location charts

Section D - Controls

• Control levers, pedals, and hydraulic pilot arrangements
• Travel and slew control mechanisms
• Servo control valve operations and linkage assemblies
• Hydraulic command interfaces for boom, dipper, and bucket

Section E - Hydraulics

• Hydraulic system overview and diagnostic circuit diagrams
• Main pump specifications, flow control, and valve block layouts
• Boom, dipper, bucket, and blade ram servicing
• Slew motor, slew brake, and dozer blade hydraulic circuits
• Pressure testing, relief valve settings, and adjustment procedures
• Hydraulic tank components, filtration, and contamination control

Section F - Gearboxes

• Slew reduction gearbox servicing and diagnostics
• Track drive gearbox removal, overhaul, and lubrication requirements

Section J - Track and Running Gear

• Track frames, idlers, rollers, and sprocket assemblies
• Track chains, pads, and wear component inspection
• Track tensioning procedure and alignment guidelines
• Travel motor mounting details and fastener specifications

Section L - Engine

• Engine identification and plate locations
• Engine mounting, removal, and installation procedures
• Cooling circuit, radiator group, and airflow management
• Fuel delivery system, filtration, and injector servicing
• Air intake and exhaust routing including silencer assemblies
• Engine electrical components and maintenance procedures

This Tier 1 Service Manual is an indispensable technical resource for technicians servicing JCB 805 and 806 excavators, providing precise data, schematics, and procedures needed for expert diagnostics, efficient repairs, and long-term operating reliability.