Part of the JCB Repair Manuals.
This is the JCB service manual for the 805, 805B, 806B, 807B, and 808 tracked excavators, publication 9803/3150. It covers the full machine and the Perkins 4.248 and 6.354 series diesel engines, including turbocharged T6.354 units, along with the 2700 Series engines fitted to some builds.
The 242 page manual is organised by system: general lubricants and service schedules, a large hydraulics section covering pumps, motors, and filtration, attachments, body and framework with the slew ring, track and slew gearboxes, tracks and running gear, the engine, and the electrical system with full circuit diagrams.
Use it to service filters and belts on schedule, set track tension, torque the slew ring, trace hydraulic faults through the pumps and motors, and work through the wiring using the circuit diagrams for each model.
What's Inside This JCB 805–808 Manual
| System | Pages | Key Topics |
|---|---|---|
| General | 16-23 | Lubricants and Capacities, Service Schedule, Grease Points (All Pivot Pins, Each Slewing Ring Nipple and Rotary Coupling, Slewing Ring Teeth) |
| Pumps and Motors (Commercial) | 24-39 | Hydraulic Filter (Early Type), Technical Data (Continued), Technical Data, Relief Valve Operating Pressures, River Maintenance Rig, Rams, Filtration, Filter Operation |
| Jcb 805B From M/C No. 200607 | 40-61 | Motor Spool (Husco) with Brake Vent Valve, Circuit Operation, Standard Spool Operation, Example, Method of Operation, Non-Return Valves, Typical Spool-Track, Excavator & Attachment Service Valves |
| Offloading Valve (in Valve Block-Pilot Operated) | 62-77 | Auxiliary Relief Valves (Rubery Owen and Husco), Relief Valves - Excavator & Attachment Service Valves, Excavator Relief Valve Operation, Auxiliary Relief Valve Operation, Operation, Valve Closed, Pilot Valve Opens, Dump Valve Opens |
| Pressure Testing | 78-93 | Offloading Valve Operation (Commercial), Operation, Off Loading Valve (Commercial), Dismantling and Assembly, When Assembling, Main Relief Valves-Track Block (Jcb 805, 806B |
| Track & Slew Valve (Hamworthy) | 94-109 | Hydraulic Circuit - Excavator Operating, Track/Slew Valve Block - Slew Operating, Track/Slew Valve Block - Neutral Circuit, Hydraulic Circuit - Neutral, Hydraulic Circuit - Slew Operating, Track/Slew Valve Block - One Track Operating, Hydraulic Circuit - Tracks Operating, Track/Slew Valve Block - Two Tracks Operating |
| Variable Boom Drop Restrictor (From M/C No. 77307) | 110-125 | Pressure Testing (Hamworthy), Excavator Valve (Hamworthy), Track & Slew Valve (Hamworthy), Slew Relief Valve (a), When Dismantling, When Assembling, Offloading Valve (B), Non-Return Valves (C |
| Circuit Diagram Jcb 805B (to M/C No. 200147) | 126-141 | Rotary Coupling, Beam Clamp Control Valve (to M/C No. 200297), Beam Clamp Cylinder, Beam Clamp Operation, Dismantling and Assembly, When Dismantling, When Assembling, Port Connections |
| Fault Finding (Continued) | 142-149 | Circuit Diagram Jcb 805B (From M/C No. 200148 to 200205), Neutral Circuit (Bold Line), Boom, Dipper and Bucket Services, Off-Loading Valve, Track Service, Slew Service, Beam Clamp |
| Attachments | 150-155 | Attachment Service Valve, Hose Connections, Grab Gearbox (Rotating Head) |
| Body & Framework | 156-167 | Cab (Glazing), Hydraulic Tilt Cab (System Bleeding), Slew Ring (When Replacing), Slew Ring Seal (Replacement) |
| Gearboxes | 168-188 | Track Gearbox, Slew Gearbox, Slew Gearbox Oil Level 805B, Track Gearbox (Primary Reduction), Track Gearbox (Secondary Reduction) |
| Track & Running Gear | 189-200 | Tracks (Inspect, Clean, Check, Adjust), Track (Removal and Replacement, When Removing, When Replacing), Rollers (Dismantling and Assembly) |
| Engine | 201-216 | Technical Data, Engine Oil Perkins, Engine Oil 2700 Series, Engine Oil Filter, Engine Fuel Filters, Engine Fuel Sediment Bowl, Engine Fuel Lift Pump, Engine Fuel System Perkins |
| Electrics | 217-236 | Technical Data, Circuit Diagram, Circuit Diagram 805, 806B, 807B, 808 (Main Components, Warning Lights, Lights, Cable Colour Code, Switches) |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Hydraulic Fault Reset Procedure | Not specified; manual provides fault finding checks and actions, not a general reset procedure. | p. 145 |
| Slew Ring Bolts Torque | 405 Nm (300 lbf ft) | p. 163 |
| Engine Oil Filter Replacement Interval | Every 200 Hours | p. 204 |
| Hydraulic Filter (Early Type) Replacement Interval | Every 400 Hours | p. 31 |
| Hydraulic Filter (Later Type) Replacement Interval | Every 400 Hours | p. 32 |
| Engine Fuel Filter Replacement Interval | Every 400 Hours | p. 205 |
| Engine Fuel Sediment Bowl Drain Interval | Every 50 Hours | p. 206 |
| Fan Belt Check Tension Interval | 50 Hours | p. 212 |
| Fan Belt Deflection | approximately 10mm (0.4in.) | p. 212 |
| Track Tension | 25mm (1in.) | p. 189 |
| Battery Voltage | 12 volt | p. 217 |
| Battery Capacity | 128 Amp hour | p. 217 |
