Part of the JCB Repair Manuals.
Looking for the exact factory procedures for your JCB Workmax 800D utility vehicle? This 329-page service manual (OEM #9813/0450-1) covers the complete engine, transmission, and suspension rebuild process. Inside you get full electrical circuits to trace wiring faults, exploded views of the CVT gearbox, and step-by-step procedures for pulling the A-arm and suspension struts. Open to the troubleshooting section to quickly diagnose transmission slipping or steering rack wear before tearing anything apart. Verify the CVT pulley alignment to exactly 45-46 mm and refill the gearbox with exactly 1.0 litres of approved fluid at your next service. Stop hunting down obscure numbers online. Download this bookmarked PDF to your phone, walk right up to your machine, and start turning wrenches.
Complete the set for your Workmax 800D
- Operator Manual: JCB Workmax 800D Operator Manual
What's Inside This Manual
| System | Pages | Key Topics |
|---|---|---|
| General Information | 1-19 | Introduction, Machine Description, Identifying Your Machine, Fastener Torque Chart, Service Tools, Consumables |
| Care and Safety | 20-37 | Safety Notices, Safety Check List, Safety Labels |
| Maintenance | 38-95 | Routine Maintenance, Fluids, Lubricants and Capacities, Service Schedules, Prepare the Machine for Maintenance, Cleaning the Machine, Checking for Damage, Greasing |
| Body and Framework | 96-123 | General Description, Load Bay, Chassis Panels, Fuel Tank, Cab |
| Electrics | 124-159 | Service Tools, Fault Finding, Harness System, Circuits, Battery, Alternator |
| Controls | 160-171 | Adjustments, Differential Lock, Four Wheel Drive Selector, Forward/Reverse Selector, Throttle, Park Brake, Service Brake Pedal |
| Transmission | 172-251 | Technical Data, CVT, Fault Finding, Gearbox, Speed Sensors, Front Differential, Rear Differential, Propshafts |
| Brakes | 252-285 | System Description, Fault Finding, Rear Brakes, Front Brakes, Park Brake, Brake Bleeding |
| Steering | 286-295 | System Description, Steering Rack, Wheel Alignment |
| Engine | 296-313 | Technical Data, Fault Finding, Exhaust, Starter Motor |
| Suspension | 314-329 | A Arm (Removal, Replacement), Suspension Strut (Removal, Ball Joint (Removal |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Wheel nut torque | 66 Nm | p. 93 |
| CVT Pulley Alignment Difference (dimensions E and F) | 45-46 mm | p. 181 |
| Engine (Coolant) Capacity | 2.8 Litres | p. 48 |
| Gearbox Capacity | 1.0 Litres | p. 48 |
| Antifreeze Concentration (Standard) | 50% | p. 49 |
| Brake Pad Minimum Thickness | 1 mm | p. 68 |
| Rear Axle Speed Sensor Operating Distance | 1 to 2.5 mm | p. 196 |
| Wheel Alignment (Front Wheel Toe-in) | 3 to 6 mm | p. 294 |
| Maximum Travel Speed | 40 kph | p. 176 |
| UNF Grade 'S' Fasteners (Condition 1) - 1/4 inch bolt torque | 11.2 Nm | p. 13 |
