Part of the JCB Repair Manuals.
Looking for a reliable JCB 801 service manual pdf? This 216-page factory reference (OEM #9803/3161) breaks down the complete hydraulic, engine, and track running gear procedures for your Tracked Excavator. Clear hydraulic schematics, complete wiring diagrams, and exploded views covering the track gearboxes and slew motors are all included. Open the troubleshooting charts to run continuity tests on the alternator, or consult the dedicated torque tables before rebuilding the Sundstrand hydraulic pump. Adjust the main relief valve until the gauge reads exactly 207 bar, and tighten the SAE Size 4 hydraulic outer sleeve nut to 20-30 Nm. Guessing kills pumps and wastes your shop hours. Download this bookmarked file, jump straight to the exact spec, and get the machine digging again today.
What's Inside This Manual
| System | Pages | Key Topics |
|---|---|---|
| General | 7-13 | Lubricants & Capacities, Torque Settings, Service Schedules |
| Greasing | 16-20 | |
| Hydraulic Circuit | 21-30 | |
| Track Motor Operation | 31-40 | |
| Hydraulic Pump | 41-57 | |
| Slew Motor | 58-63 | |
| Slew Motor Brake Valve | 64-82 | |
| Control Valve | 83-90 | |
| Rams | 91-101 | |
| Attachments | 102 | |
| Body and Framework | 103-112 | Front Attachment, Upper Structure |
| Engine | 113-152 | Technical Data, Fuel System, Cylinder Head, Piston and Connecting Rods, Crankshaft |
| Gearboxes | 153-170 | Track Gearbox, Slew Gearbox |
| Track & Running Gear | 171-185 | Tracks, Track Rollers, Idler and Recoil Unit |
| Electrics | 186-216 | Alternator, Voltage Regulator Operation, Continuity Tests, Starter Motor |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Main Relief Valve Adjustment | Adjust the M.R.V. by means of the screw D until the gauge reads 207 bar (3000 lbf/in2) | p. 100 |
| Hydraulic Pump Drive Coupling Torque (Sundstrand) | 44 Nm (4.5 kgf m, 32 lbf ft) | p. 10 |
| Hydraulic Pump Tie Bolts Torque (Sundstrand) | 54-61 Nm (5.5-6.2 kgf m, 40-45 lbf ft) | p. 10 |
| Hydraulic Fitting Adapter (A) Torque (SAE Tube Size 4) | 20-28 Nm (16.5-18.5 lbf ft) | p. 11 |
| Hydraulic Fitting Outer Sleeve Nut (B) Torque (SAE Tube Size 4) | 20-30 Nm (15-21 lbf ft) | p. 11 |
| Fuel Filter Canister Tightening | hand tight and then one quarter turn | p. 121 |
| Inner Air Filter Element Replacement Interval | every third time the outer element is changed | p. 128 |
| Fan Belt Deflection | 5 mm (0.2 in) with 50 N (5 kgf, 11 lbf) finger force | p. 131 |
| Track Gearbox Oil Capacity | 1.6 litres (0.4 UK gal) | p. 153 |
| Track Gearbox Plug Torque | 20-30 Nm (2.0-3.0 kgf m, 15-22 lbf ft) | p. 165 |
| Rubber Track Tension | 10-15 mm (0.4-0.6 in) | p. 174 |
| Battery Voltage | 12V | p. 186 |
