JCB Hydrapower 801.4, 801.5, 801.6 Mini Excavators Service Manual PDF

Maintenance is a set of technical measures aimed at creating the most favorable working conditions for excavator parts, timely warning of malfunctions and detection of defects. Technical service helps to increase the inter-repair periods and the overall service life of the machine, reduce downtime due to technical malfunctions, and therefore increase the productivity of the excavator.

Therefore, in order to carry out competent and proper maintenance of the JCB Mini Excavators 801.4, 801.5, 801.6, you should purchase this PDF service manual.

This service manual contains a description of organizational and technical measures to ensure reliable operation of the machine, recommendations for troubleshooting, safe operation rules, and other service information.

This manual is a PDF document that you can print in full and use it as a handbook. In order for the service repair manual to open without errors and you can view and copy all the pictures and schemes, we recommend using Adobe PDF Reader.

Publication No. 9803/3130 Issue 1

Models covered:
JCB JZ235/255 from serial number 1234500 to 1235499.

Contents:

• Section 1 - General Information
  • Identification
  • *Preparation for Storage
  • *Preparation after Storage
• Section 2 - Care & Safety
  • Safety Notices
  • General Safety
  • Operating Safety
  • Maintenance Safety
• Section 3 - Routine Maintenance
  • Lubricants and Capacities
  • Service Schedule
  • Greasing
  • Cooling System
  • Torque Settings
  • Hydraulic Fittings & Torque Settings
• Section B - Body & Framework
  • *Technical Data
  • General Description
  • Bucket Ram Pivot and Linkage
  • *Dipper
  • Boom
  • Kingpost
  • Upper Structure
• Section C - Electrics
  • Technical Data
  • Battery
  • Alternator
  • Voltage Regulator Operation
  • Charging System Testing 
  • Starter Motor
  • Circuit Diagram
  • Wiring Harness
  • *Beacon
• Section D - Controls
  • *Technical Data
  • *Control Cables
  • Servo Hand Controllers
  • Hand Controller Handles
  • Engine Throttle Cable
• Section E - Hydraulics
  • Technical Data
  • General Description
  • Hydraulic Circuit
  • Checking the Fluid Level
  • Hydraulic Pump
  • Track Motor
  • Slew Motor - Description
  • Slew Gearbox - Removal & Replacement
  • Slew Motor
  • Slew Gearbox Motor - Removal & Replacement
  • Fault Finding
  • Control Valve
  • Main Relief Valve
  • Rams
  • *Rotary Coupling
  • *Pressure Testing
• Section J - Track & Running Gear
  • Technical Data
  • General Description
  • Tracks
  • Track Rollers - Dismantling & Assembly
  • Idler & Recoil Unit
  • Changing from Rubber to Steel Tracks
• Section L - Engine
  • Technical Data
  • Engine Oil - Draining & Filling
  • Oil Pressure Relief Valve - Removing & Fitting
  • Oil Sump Suction Pipe & Strainer
  • Fuel Filter - Renewing
  • Fuel Lift Pump - Removing, Inspecting & Fitting
  • Fuel Injection Pump Assembly
  • Fuel Injection Timing - Checking & Adjusting
  • Fuel Injectors & Fuel Pipe Assembly
  • Fuel System - Bleeding
  • Air Filter
  • Engine Coolant - Draining & Filling
  • Water Pump Assembly
  • Fan Belt
  • Alternator
  • Starter Motor
  • *Engine
  • Cylinder Head
  • Piston & Connecting Rods
  • Timing Gear Case
  • Idler Gear & Oil Pump Assembly
  • Crankshaft Assembly & Tachometer Drive
  • Crankshaft
  • *Exhaust Emissions