Service Manual: Super Plus

General Information 1
Care & Safety 2

Routine Maintenance 3
A
Service
Optional Equipment
Manual Body & Framework B

Electrics C
Plus
Super
Controls
D
Plus Hydraulics E
Super
Plus
Gearboxes F
Super Track & Running Gear J
Published by the
TECHNICAL PUBLICATIONS DEPARTMENT
Engine L
of
JCB COMPACT PRODUCTS LTD;
Harewood Estate
Leek Road, Cheadle
Stoke-on Trent
Staffordshire, England
ST10 2JU
Tel: 01538 757500, Fax: 01538 757590
Publication No. 9803/3145 Issue 3
Section 1 General Information Section 1
Introduction
This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received,
training by JCB Technical Training Department.
It is assumed that these personnel have a sound knowledge of workshop practice, safety procedures and general
techniques associated with the maintenance and repair of hydraulic earthmoving equipment. Therefore, these basic
subjects generally are omitted from this manual, the intention being to convey only more specialised information
concerning particular aspects of a machine or component.
For example, renewal of oil seals, gaskets etc., and any component showing obvious signs of wear or damage is
expected as a matter of course and, therefore, information of this nature is included only in the context of specialised
procedures or where a range of wear tolerances is required. Similarly, it is expected that components will be cleaned
and lubricated where appropriate, also that any opened hose or pipe connections will be blanked to prevent excessive
loss of hydraulic fluid and ingress of dirt. Finally, please remember above all SAFETY MUST COME FIRST!
The manual is compiled in sections, the first three are numbered and contain information as follows:
1 = General Information - includes torque settings and service tools

2 = Care & Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc.
3 = Routine Maintenance - includes service schedules and recommended lubricants for the
machine.
The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components,
for example:
A = Optional Equipment
B = Body & Framework ... etc.
The page numbering in each alphabetically coded section may not be continuous. This allows for the insertion of new
items in later issues of the manual.
Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of each
alphabetically coded section.
All sections are listed on the front cover; tabbed divider cards align directly with individual sections on the front cover
for rapid reference.
Illustrations which show a dismantled component are numbered as a guide to the dismantling sequence, which
generally can be reversed for assembly.
Torque settings are given as a 'mean' figure which may be varied by plus or minus 3%. Torque figures indicated are
for dry threads, hence for lubricated threads may be reduced by one third.
'Left Hand' and 'Right Hand' are as viewed from the rear of the machine.
References to alternative servicing intervals are to be treated on a 'whichever occurs first' basis.
9803/3145 Issue 1
i i
Contents Page No.
Identification ............................................................................................ 1 - 1
Storing your machine .............................................................................. 2 - 1
Operation
Introduction ................................................................................................ B1
Before entering the cab ....................................................................... B2 - B3
Entering/exiting the cab ...................................................................... B4 - B5
Cab ..................................................................................................... B6 - B7
Opening the windscreen ............................................................................. B8
Opening the side window ........................................................................... B9
Heater controls ................................................................................ B10 - B11
Seat .......................................................................................................... B12
Seat belt (when fitted) .............................................................................. B13
Engine and track controls
Switches and instruments ............................................................... B14 - B15
Track controls ........................................................................... B16 - B17
Engine controls ................................................................................. B19
Switches ................................................................................... B20 - B21
Instruments .............................................................................. B24 - B25
Dozer controls ................................................................................. B26 - B27
Excavator controls .......................................................................... B28 - B23
Slew cab ............................................................................................ B30
Swing boom ...................................................................................... B31
Boom swing stop ........................................................................ B32-B33
Raise / Lower boom ................................................................... B34-B35
Dipper................................................................................................ B36
Bucket ............................................................................................... B37
Refuelling the machine ............................................................................ B39
Before starting the engine ............................................................... B40 - B41
Starting the engine .......................................................................... B42 - B43
Jump starting the engine ................................................................. B44 - B46
Cold climate warm up .............................................................................. B47
Operating in high / low temperatures ....................................................... B48
Stopping and parking the machine .................................................. B50 - B51
Preparing for road / site travel ......................................................... B52 - B53
Getting the machine moving ........................................................... B54 - B55
Working with the dozer .................................................................... B56 - B57
Working with the excavator ............................................................. B58 - B43
Installing a bucket - non Quickhitch models ............................. B58 - B59
Replacing bucket teeth...................................................................... B59
Removing a bucket ........................................................................... B37
Bucket selection ................................................................................ B60
Removing a bucket - non Quickhitch models ................................... B61
Installing a bucket on a Quickhitch .......................................... B62 - B63
Removing a bucket from a Quickhitch ..................................... B64 - B65
Working on a slope ......................................................................... B66 - B67
Digging ..................................................................................... B68 - B69
Moving the machine while digging on the level ................................ B70
Digging near walls ............................................................................. B71
Lifting ................................................................................................ B72
Safe working loads ............................................................................ B73
Using the attachments and site safety ............................................ B74 - B77
Single/double acting circuits .................................................... B78 - B79
Removing a Quickhitch Rockbreaker ....................................... B80 - B83
Using hand held tools ............................................................... B84 - B85
Moving a disabled machine ............................................................ B86 - B87
Transporting the machine ................................................................ B88 - B89
Securing for Transport ..................................................................... B90 - B91
9803/3145 Issue 3*
1-1 1-1
Identifting Your Machine

The machine has a Data Plate attached to the left hand
front face of the machine.
The serial numbers of the machine, engine and
gearboxes are stamped on this plate.
If the engine is replaced, stamp the new serial number
in place of the old one.
Explanation of Vehicle Identification Explanation of Engine Identification

Number (VIN) Number
Code SLP 0803 T E 0765607 Code A B C D E

Example A B C D E Example KE 50390 J 000001 y
A World Manufacturer Identification SLP = JCB A Engine Type

B Machine Model 0803 = 803 B Engine Parts List
C Country of Manufacture
C Year of Manufacture D Engine Serial Number
R = 1994 W = 1998 2 = 2002 E Year of Manufacture
S = 1995 X = 1999 3 = 2003
T = 1996 Y = 2000 4 = 2004
V = 1997 1 = 2001 5 = 2005
D Manufacturers Location E = England

E Machine Serial Number 0765607
OSEN ISO9001
J C BAMFORD EXCAVATORS LTD
ROCESTER, STAFFS, ENGLAND
CONSTRUCTOR
FM 14063
Product
Identification
VIN Vehicle Identification Number Number
ENGINE SERIAL NUMBER LH TRACK GEARBOX SERIAL NUMBER
SLEW GEARBOX SERIAL NUMBER RH TRACK GEARBOX SERIAL NUMBER
WEIGHT kg ENGINE POWER kW @ RPM

YEAR OF MANUFACTURE
H04343
9803/3145 Issue 1
2-1 2-1
Preparation for Storage Preparation after Storage

The operations to place a machine into storage (-15°C The operations to remove a machine from storage (-
to 44° C) are given below. 15°C to 44°C) and prepare it for use are given below.
1 Park the machine safely with the bucket and dipper 1 Lower the fuel level to ensure that sufficient air
rams retracted and the dig end outstretched. Lower space exists in the tank.
the boom until the bucket rests on the ground.
Lower the dozer to the ground. 2 Check all oil and water levels, adjust contents to
correct levels as necessary.
2 Switch off the engine. Operate controls to release
pressure from the rams. 3 Ensure the battery is fully charged.
3 Disconnect battery to prevent discharge. 4 Reconnect battery.
4 Ensure the fuel tank is filled to a maximum, leaving 5 Remove electrical contact from fuel injection pump
no air space. solenoid.
5 Ensure hydraulic tank is filled to maximum on the 6 Crank engine for 20 seconds or until oil pressure
sight gauge. warning light goes out.
6 Spray exposed ram rods with Waxoyl. 7 Reconnect electrical supply to the fuel injection
pump solenoid.
7 Slacken off rubber tracks until no visible spring
tension exists. 8 Start the engine. If the engine fails to start after
several attempts, bleed the fuel system.
9 Adjust track tensions.
10 Grease all lubrication points.
9803/3145 Issue 1
B1 OPERATION B1
Introduction
This chapter is arranged to guide you step-by-step Move on to the attachment controls only when you can
through the task of learning how to use the machine. drive the machine confidently and safely.
Read it through from beginning to end. By the end of
the chapter you should have a good understanding of Take great care when practising with the attachment
the machine and how to operate it. controls. Practise in an open space, keep people clear.
Do not jerk the controls: operate them slowly until you
Pay particular attention to all safety messages. They understand the effect they have on the machine.
are there to warn you of possible hazards. Do not just
read them-think about what they mean. Understand Finally, do not rush the job of learning. Take you time
the hazards and how to avoid them. and take it safely.
If there is anything you do not understand, ask your

JCB dealer, he will be pleased to advise you. Remember BE CAREFUL
BE ALERT
SAFE
When you have learned where the driving controls are
and what they do, practise using them. Practise driving
the machine in a safe, open space clear of other people.
Get to know the "feel" of the machine and its driving

controls.
B2 BEFORE ENTERING THE CAB B2
WARNING
Walking or working under raised attachments The following checks should be made each time you
can be hazardous. You could be crushed by the return to the machine after leaving it for any period
attachments or get caught in the linkages. of time. We advise you also to stop the machine
occasionally during long work sessions and do the
checks again.
All these checks concern the serviceability of the

machine. Some concern your safety. Get your
service engineer to check and correct any defects.
Lower the attachments to the ground before doing

these checks. If you are new to his machine, get
an experienced operator to lower them for you.
If there is nobody to help you, study this handbook

until you have learned how to lower the
attachments. Also make sure that the swing lock
is fitted before doing these checks.
HOP26
9803/3145 Issue 3*
B3 BEFORE ENTERING THE CAB B3
Machine walk round inspection d Inspect the windows for cracks and damage
1 Check for cleanliness: e Check for oil, fuel and coolant leakages
beneath the machine.
a Clean the windows and light lenses.
b Remove dirt and debris, especially from WARNING

around the linkages, rams, pivot points and You could be killed or injured with damaged
radiator. tracks. Do not use the machine with damaged or
excessively worn tracks.
c Make sure the cab and handrails are clean HOP27
and dry.
3 Check the Tracks (Rubber)
d Clean all safety decals. Replace any that are Check for cut rubber and penetration by sharp
missing or cannot be read. objects. Do not use a machine with damaged tracks.
2 Check for damage: 4 Check the engine cover/panels and fuel filler
a Inspect the machine generally for damaged cap
and missing parts. a Make sure the engine cover / panels are fitted
and securely locked.
b Make sure that the bucket teeth are secure
and in good condition b Make sure the fuel filler cap is tightly closed
(we also recommend that you lock it).
c Make sure that all the pivot pins are secured
correctly in place
9803/3145 Issue 3*
B4 ENTERING/EXITING THE CAB B4
B5 ENTERING/EXITING THE CAB B5
WARNING WARNING
Do not enter or exit the cab unless the arm rest Always face the machine when entering or leaving
or lever lock is fully engaged. the cab. Use the step(s) and handrails. Make sure
the step(s), handrails and your boot soles are
To give sufficient clearance to enter or leave the cab, clean and dry. Do not jump from the machine. Do
the left lock must be raised. not use the machine controls or lever locks as
handholds, use the handrails. Failure to follow
When the lock is in the raised position the excavator these instructions could result in unexpected
controls cannot be operated. Lowering the lock to movement of the machine.
the normal position connects the excavator controls
and allows the normal operation of the levers.
Note: When entering or leaving a canopy machine,

both LH and RH locks must be raised.
9803/3145 Issue 3*
B6 CAB B6
F E
H50250
B7 CAB B7
The cab is bolted on top of the mainframe and is a Opening and closing the door
welded steel construction. The cab has a sliding
To open a door from the outside, unlock it with the
window on the right side, a hinged door and an up
key provided and press the lock barrel to release the
and over windscreen. All windows are of toughened
catch. To open a door from inside, push lever A Close
glass. The cab is fitted with a windscreen wiper,
the door from the inside by pulling it firmly, it will
heater fan, seat and all operating controls and
latch itself.
instruments.
Securing the door in the open position
CAUTION
Do not drive the machine with the door unlatched. Swing the door fully open until the spigot E on the
It must be correctly closed or secured fully open. side of the cab locates securely in the socket F on
HOP29 the door.
To release the door when it is secured fully open,

operate the button G on the inside of the door.
9803/3145 Issue 3*
B8 OPENING THE WINDSCREEN B8
To open the up and over window, disengage the latch

pins A on both handles and lift the screen to a position
parallel with the roof. Secure in place with the latch
pins A.
Note: Care must be taken when lowering the window

not to bump the top edge of the lower front window. A
H14080
B9 OPENING THE SIDE WINDOW B9
The side window is held closed by catch A operated

from inside the cab.
To open the window, operate the catch A and slide

the window to the desired position.
To close the window, slide the window fully shut and

check that the catch A has located on the frame.
H50260
9803/3145 Issue 3*
B10 HEATER CONTROLS B10
H14041
B11 HEATER CONTROLS B11
Hot air can be directed to the cab floor by closing /

opening flap A. Hot air is directed to the windscreen
via. a fixed vent system B.
For the summer use, the heater element can be

turned off at the water valve C on the engine.
WARNING
Stop the engine before lifting the engine cover to
operate valve C. HOP30
Heater fan
Press the rocker switch D located on the right hand
instrument console, down to switch the fan on. Return
the switch to the first position to turn the fan off.
9803/3145 Issue 3*
B12 SEAT CONTROL B12
WARNING Suspension seat - when fitted

Do not adjust the seat with the engine running
otherwise your legs could knock the control WARNING
levers. HOP31
Whilst seated, adjust the dial below the seat until
your weight in kgs. appears in the red shaded
Depending on the type of machine various
area. Failure to set the weight adjustment dial
adjustments can be made to the positions of the
will reduce the beneficial isolation effect of the
control levers and the seat consoles/armrests.
seat suspension and may result in personal
discomfort or injury.
The operators seat can be adjusted for your comfort. 2-2-1-12
A correctly adjusted seat will reduce operator fatigue.
Position the seat so that you can comfortably reach
the controls with your feet on the cab floor. The seat
is adjustable for height and reach.
CAUTION
Having adjusted the seat position, ensure the
seat locking lever has engaged fully.
B13 SEAT BELT - when fitted B13
Fasten the seat belt

Sit correctly in the seat. Make sure the belt is not
twisted. Push the male fitting A into the buckle B
until it latches.
Release the seat belt

Press button C and pull the recoil side of the belt
outwards.
A
B
Note: If your machine is fitted with a seat belt, USE
IT.
H26160
9803/3145 Issue 3*
B14 ENGINE AND TRACK CONTROLS, SWITCHES AND INSTRUMENTS B14
1 2
13
16
12
7
8
3
9
10
6 5
11
H50810
4 15
B15 ENGINE AND TRACK CONTROLS, SWITCHES AND INSTRUMENTS B15
1 Left Track Control Lever

2 Right Track Control Lever
3 Hand Throttle Lever
4 Starter Switch
5 Working Lights Switch
6 Windscreen Wiper Switch
7 Horn Button
8 Warning Lights
9 Hourmeter
10 Fuel Gauge
11 Heater Fan
12 Two Speed Tracking Switch
13 Slew Switches
15 Beacon Socket
16 Boom Boost Switch (optional)
9803/3145 Issue 3*
B16 ENGINE AND TRACK CONTROLS, SWITCHES AND INSTRUMENTS - continued B16
H50280
Track controls Forward

The two tracks are controlled by a pair of control To move the machine forward, push both levers
levers A in front of the seat. Each lever controls one forward. Release the levers to stop.
track and is spring loaded to a central position. In
this position the track does not operate. The left side Reverse
lever controls the left track. The right side lever
To move the machine backward, pull both levers
controls the right track. The two levers can be
backward. Release the levers to stop.
operated individually or together as necessary to
move the machine as required. This can be done
using one hand or both. An increase in speed can be
Turn
achieved by operating the push button switch C To turn the machine whilst travelling, move the lever
located in the dozer lever if fitted. back towards the central position on the side towards
which you want to go e.g. move the left lever back to
turn left. This causes one of the tracks to move
WARNING slower than the other. The faster moving track will
Make sure that all persons are clear before push the machine around. Release the lever to stop.
moving.
Spin
WARNING To spin the machine around though 360º, without
The track controls operate as described when the moving it, operate one lever, in a forward position
dozer is located in front of the windscreen. If the and the other in a reverse position. This will cause
dozer is positioned behind the cab, the lever the tracks to drive in opposite directions and hence
operation will be reversed. It is advisable when push the machine around.
tracking to always position the dozer to the front
of the machine.
9803/3145 Issue 3*
Engine Controls
Engine speed
A hand operated throttle lever in the cab, controls
the speed of the engine.
Move the lever to increase or decrease the engine

speed. The lever can be left in any position between
idle and maximum as required.
Engine start / stop

To start and stop the engine use the starter switch,
see Switches on the following page.
H50290
9803/3145 Issue 3*
D E
C A
H50300
9803/3145 Issue 3*
Switches
Starter Switch A
This is operated by the starter key. It has four
positions. The key can only be removed when in the
'O' position.
O Off/Stop Engine II Heat Position

Turn the key to this position to stop the engine. Holding the key in this position switches on the
Make sure the controls are in neutral and the glow plugs. The glow plugs warm the engine
excavator and dozer are lowered before stopping combustion chambers for cold weather starting.
the engine. Do not hold in this position for more than 15
seconds. The key will spring back to O when
I On released.
Turning the key in this position connects the
battery to the electrical circuits The key will spring lll Start
back to this position when released from ll. Operates the starter motor to turn the engine.
Note: Do not operate the starter for more than 20

seconds at one time.
Switches - continued
Working Light Switch B Horn Button D

Press the switch down to switch the working lights on. This is a push button switch located in the R.H.
Press the switch again to switch the working lights off. excavator control lever or positioned in the instrument
console. Press the switch to activate the horn.
Windscreen Wiper Switch C
Press the switch down once to switch the windscreen Cab Light E
wiper on to the slower speed. A cab light is situated on the right side of the cab,
Press the switch down again to switch the windscreen above the rear window. It is operated by pressing
wiper on to the fast speed. Put the switch to the off either end of the light lens.
position to switch off the windscreen wiper, which will
then self park.
Functions only with the starter switch at I.
9803/3145 Issue 3*
E C
B
F
G A
H50860
Instrument cluster
Indicators for the engine and related systems are
mounted in the instrument cluster in the R.H. console.
Hourmeter (A) Glow Plug (E)

Indicates the accumulative machine operating hours. Illuminated with the starter key at positions II and III.
Extinguished at all other times.
Blocked Air Cleaner (B) Optional
Illuminated when the air flow through air cleaner is Engine Oil Pressure (F)
restricted Illuminated when the pressure of the oil in the engine
is too low, and initially with the starter at position I
Coolant Temperature (C) before the engine is cranked.
Illuminated when the engine coolant becomes
overheated. Fuel Gauge (G)
Indicates the amount of fuel in the tank.
Alternator (D)
Illuminated when the alternator supply current to the
battery is defective and/or the fan belt is broken. It
will also illuminate initially with the starter key at
position I before the engine is cranked.
9803/3145 Issue 3*
B26 DOZER CONTROLS B26
B
H50310
B27 DOZER CONTROLS B27
The dozer is operated by a single control lever on Raise dozer 'A'

the right side of the cab. This lever is spring loaded
To raise the dozer pull the lever backward. At the
to the central position. In this position the dozer will
required position release the lever.
not move.
Lower dozer 'B'
CAUTION
Before operating the dozer, make sure that large To lower the dozer push the lever forward until an
rocks or other objects are not between it and the increased resistance is felt and the blade moves. At
tracks that can jam the mechanism. HOP34 the required position release the lever.
CAUTION Dozer float position 'C'

Before stopping the engine lower the dozer blade The float operation is selected by pushing and holding
to the ground. HOP35 the lever fully forward.
9803/3145 Issue 3*
B28 EXCAVATOR CONTROLS B28
B29 EXCAVATOR CONTROLS B29
The slew lock is situated forward of the seat. Lift Most excavating movements are achieved using a
and turn it through 90º to unlock. Ensure it is combination of both controllers at the same time.
UNLOCKED before operating the excavator controls. Practise such movements until you are familiar with
the operations that can be achieved safely.
The excavator controls consist of those levers which
operate the boom, dipper and bucket and swing the
WARNING
machine.
When using the boom and dipper fully extended,
There are two excavator controllers A and B which take the following precautions, otherwise the
control all the functions. The controls are situated in machine could get damaged or become unstable
the operators seat armrests. Raising the left armrest and a danger to you and other people.
when leaving the cab prevents the services operating. Make sure you do not exceed the working capacity
When re-entering the cab, ensure the armrest is of the boom at maximum reach.
replaced firmly to ensure correct operation. Swing the boom slowly to prevent any chance of
the machine becoming unstable. For the same
The left side controller A controls swing, and dipper reason avoid dumping downhill if possible.
HOP36
functions. The right side controller B controls boom
and bucket functions as standard. CAUTION
Do not excavate on hard or rocky ground with the
It is possible to specify SAE style operating functions boom set diagonally across the undercarriage.
i.e. left controller A controlling swing and boom. The This induces a rocking motion that can cause
right hand controller B controlling dipper and bucket damage to the track gearbox sprockets and tracks.
operation. Both controllers are spring loaded to the HOP37
central position. In this position related services will
not operate.
9803/3145 Issue 3*
B30 EXCAVATORS CONTROLS - continued B30
Before slewing the cab ensure the slew lock D is The machine should be set for slew operation. Ensure
disengaged, (the up position). you are in slew mode by carefully operating the left
hand control lever and noting the movement.
Select Slew on the Slew/Swing switch A on the left
hand controller.
D
Slew cab left
To slew the cab to your left, move the left controller
to the left B. Release the controller when you have
moved to the desired position.
Slew cab right A

To slew the cab to your right, move the left controller
to the right C. Release the controller when you have
moved to the desired position.
B C
B C
H50820
B31 EXCAVATORS CONTROLS - continued B31
Select Swing on the Slew/Swing switch A on the left CAUTION

hand controller. When the requirement for boom swing has
finished, position boom to the straight ahead
Swing boom left configuration and reset machine to 360 deg. slew
by operating switch A.
To swing the boom to your left, move the left controller
to the left B. Release the controller when you have
reached the desired position.
Swing boom right

To swing the boom to your right, move the left A
controller to the right C. Release the controller when
you have reached the desired position.
B C
B C
H50820
9803/3145 Issue 3*
B32 EXCAVATOR CONTROLS - continued B32
A B H24230
WARNING CAUTION
Before repositioning swing stop, lower the boom With certain digging configurations with the boom
until the bucket is on the ground. Stop the stop set to 90º the bucket can contact the cab.
engine. Care should be taken whenever operating with
the boom stop set to 90º especially at the extremes
of position. The machine can become unstable
Boom swing stop with a fully laden bucket.
HOP39
The boom swing can be adjusted to allow an increased
swing to the left from 60º to 90º by repositioning the
swing stop. CAUTION
The boom stop should only be used in the 90º
position for the duration of the job. Return the
60º Operation (normal operation) boom stop to the 60º position for normal
Set the swing stop to position A this enables the operating.
machine to operate in an arc of 60º to the left and 50º
to the right.
90º Operation (for specific jobs only)

Set the swing stop to position B this enables the
machine to operate in an arc of 90º to the left and 50º
to the right.
9803/3145 Issue 3*
B B
SAE ISO
A A
H50340
WARNING Raise boom

Thoroughly warm the hydraulic oil before To raise the boom pull the respective controller
operating the excavator services. To ensure backwards A. Release the controller when the boom
smooth boom operation damping is incorporated has reached the desired position. The boom ram
into the boom lift circuit, this means when boom incorporates damping at the limit of boom raise,
raise is released, the boom may continue to rise reducing the speed of the ram, eliminating shock
for a fraction of a second. Before selecting boom loadings.
up, check there are no overhead obstructions or
electric power cables. Boom boost
HOP40
Partial selection of the controller will limit the speed
Note: Boom damping is an option and not fitted as of boom raise. Boom Boost is automatically engaged
standard. when controller is fully selected. An optional switch is
available on the LH controller which will disable the
CAUTION boom boost operation.
The boom service is operated by the R.H.
controller on standard ISO control machines or Lower boom
by the L.H. controller on the optional SAE control To lower the boom, push the respective controller
pattern machines. forwards B. Release the controller when the boom
HOP41
has reached the desired position.
9803/3145 Issue 3*
CAUTION
The dipper service is operated by the L.H.
controller on standard ISO control machines or B B
by the R.H. controller on the optional SAE control
pattern machines. HOP42
ISO SAE
Dipper In
To bring the dipper in, pull the respective controller A A
backward A. Release the controller when the dipper
is at the desired position.
Dipper Out
To push the dipper out, push the respective controller
forward B. Release the controller when the dipper is
at the desired position. B
A
H50350
Close bucket
To close the bucket (to gather a load), move the right
controller to the left A. Release the controller when
the bucket is closed sufficiently.
A B
Open bucket
To open the bucket (to dump a load), move the right
controller to the right B. Release the controller when
the bucket is open far enough.
B H50360
9803/3145 Issue 3*
B39 REFUELLING THE MACHINE B39
WARNING
Diesel fuel is flammable. Keep flames away from
the machine. DO NOT smoke while fuelling the
machine or working on the engine. Do not refuel
with the engine running. There could be a fire
and injury if you do not follow these precautions.
INT-3-2-2
CAUTION
Spilt fuel may cause skidding and therefore
accidents. Clean any spilt fuel immediately.
Do not use fuel to clean the machine.
When filling with fuel, choose a well aired and

ventilated area.
At the end of every working day, fill the tank with the
correct type of fuel. This will prevent overnight
condensation from developing in the fuel. Do not fill
the tank completely, leave some space to allow the
fuel to expand
9803/3145 Issue 3*
B40 BEFORE STARTING THE ENGINE B40
Note: Read Operating in Low Temperatures or 2 Do a pre-start inspection.

Operating in High Temperatures in operation section For your own safety (and others) and for a
if you will be using the machine in very hot or cold maximum service life of your machine, do a pre-
climates. start inspection before starting the engine.
WARNING a If you haven't already done it, do a walkround

inspection of the outside of the machine. See
Before lowering the attachments to the ground, before entering the cab in operation section
make sure that the machine and the area around
it are clear of other people. Anyone on or close to b Remove dirt and rubbish from the cab interior,
the machine could fall and be crushed by the especially round the pedal and control levers.
attachments, or get caught in the linkages.
HOP43
c Remove oil, grease and mud from the pedals
1 Lower the attachments to the ground. and control levers.
Lower the excavator bucket and dozer to the
ground, if they are not already there. They will
lower themselves under their own weight when
WARNING
you operate the controls. Operate the controls Keep the machine controls clean and dry. Your
carefully to control the rate of descent. hands and feet could slide off slippery controls.
If that happens you will lose control of the
machine. HOP44
d Make sure that your hands and shoes are

clean and dry
B41 BEFORE STARTING THE ENGINE - continued B41
WARNING
Loose articles can fall and strike you or roll on the
floor. You could be knocked unconscious, or the
controls could get jammed. If that happens you
will lose control of the machine.
HOP45
e Remove or secure all loose articles in the cab, 3 Adjust the Seat
such as lunch boxes, tools etc. Adjust the seat so that you can comfortably reach
all driving controls. You should be able to
f Check round the cab for loose or missing operate the control pedal with your back against
bolts, screws etc. Fit new ones or tighten the seat back.
where necessary. Ensure the seat locking lever has engaged fully.
g Inspect the seat belt (if fitted) and its 4 Set the hand Throttle Lever
mountings for damage and excessive wear.
Set the hand throttle lever to idle.
h Check that the following are in working order:
Lights, Horns all Switches and Wiper
j Check the excavator lever gaiters are not

damaged or loose, replace or secure as
required with new fasteners.
9803/3145 Issue 3*
B42 STARTING THE ENGINE B42
817
/ 03310 H04431
B43 STARTING THE ENGINE B43
1 Start the engine CAUTION

Move the throttle lever to full speed position. Once the engine has started, move the throttle
Turn the starter key to the glow plug position A lever to the idle position. Check that all the
for approximately 6 seconds to warm the engine warning lights have gone out. Do not race the
combustion chambers. engine until the oil pressure low light has
extinguished.
Note: outside temperatures below 32°F (0°C) will If any indicator fails to extinguish, or if they
require extended times. illuminate while the engine is running, make the
machine safe, stop the engine and investigate
Turn the starter key further to position lll and the cause. HOP46
hold it there until the engine starts; do not exceed
20 seconds. If the engine does not start, turn the 3 Warm up the engine and hydraulics
starter switch to position A and repeat step 1. Allow the engine to warm up at idle speed for
five minutes. If the engine has been jump-
2 Check the indicators started, remove the booster cables (see jump
starting the engine). Operate the excavator a
few times to help warm up the hydraulic system.
9803/3145 Issue 3*
B44 JUMP STARTING THE ENGINE B44
9803/3145 Issue 3*
B45 JUMP STARTING THE ENGINE B45
Note: Read battery pages in section C of this 1 Lower the Attachments to the Ground
handbook before carrying out any work with the Lower the excavator bucket and dozer to the ground.
battery. If they are not already there. They will lower
themselves under their own weight when you operate
Follow the instructions on this and the following page the control. Operate the control carefully to control
to start the engine using booster cables. Your the rate of descent.
machine has a 12V starting system. The negative
(-) terminal on the battery is connected to frame 2 Set all switches in the cab to off
earth.
CAUTION
WARNING The booster supply should not be higher than
12V. Using a welder or higher voltage supply will
If you try to charge a frozen battery, or jump start
damage your machine's electrical system.
and run the engine, the battery could explode.
Do not use a battery if its electrolyte is frozen. To
CAUTION
prevent the battery electrolyte from freezing, keep
Do not connect two batteries together to give
the battery at full charge.
24V. This could burn out the glow plugs and
damage the starter motor.
WARNING
Before lowering the attachments to the ground 3 Open the engine cover
make sure the machine and the area around it are
clear of people. Anyone on or close to the machine
could fall and be crushed by the attachments, or
get caught in the linkages.
HOP43
B46 JUMP STARTING THE ENGINE - continued B46
4 Connect the Booster Cables 7 Disconnect the Booster Cables

a Remove battery cover if fitted. a Disconnect the cable from the machine frame
earth, then disconnect if from the booster
b Connect the positive booster cable to the supply.
positive (+) terminal on the machine battery.
Connect the other end of this cable to the b Disconnect the positive booster cable from
positive (+) terminal of the booster supply. the positive (+) terminal on the battery, then
disconnect it from the booster supply.
c Connect the negative (-) booster cable to a
good frame earth on the machine, away from 8 Fit battery cover (if required).
and below the battery.
9 Refit items removed to gain access to the battery.
Note: A good frame earth is part of the machine
frame, free from paint and dirt. Do not use a pivot
WARNING
pin for an earth.
Keep metal watch straps and any metal fasteners
d Connect the other end of this cable to the on your clothes, clear of the positive (+) battery
negative (-) terminal on the booster supply. terminal. Such items can short between the
terminals and nearby metal work. If this hapens
5 Do the pre-start checks you can get burned.
See before starting the engine
Make sure that the fuel filler cap is tightly fitted.
6 Start the engine - see starting the engine Make sure that all spilt fuel is cleaned away from
the battery area.
HOP48
9803/3145 Issue 3*
B47 COLD CLIMATE WARM UP B47
Before starting work in temperatures below -15°C,

hydraulic fluid must be warmed.
1 Warm up Engine 3 Warm up Hydraulic Circuit

After starting the engine (see starting engine) set a Reduce engine speed by moving throttle lever
the throttle lever to mid position and run for 10 to mid position.
minutes.
DO NOT operate any services. After the warm b Raise and lower boom from ground level to
up period make sure that everyone is clear of full height five times.
the machine.
c Stroke the dipper fully in both directions, five
2 Warm up Hydraulic Oil times
a Increase engine speed to maximum. Warm
the hydraulic oil by repeatedly selecting d Rotate the bucket fully in both directions, five
bucket crowd by moving the right hand lever times
to the left for 5 seconds. Repeat for several
minutes. e Swing the upper structure clockwise for one
revolution and stop. Swing the upper structure
b Select dozer up by moving dozer control lever anti-clockwise for one revolution and stop.
backwards, keep selected for one minute.
f Repeat step 3c three times
4 The machine should now operate correctly.

Should operation still appear slow, then steps 3b
and 3c may be repeated.
9803/3145 Issue 3*
B48 OPERATING IN LOW TEMPERATURES B48
In low temperature situations, take the following

precautions. They will make for easier starting and
prevent possible damage to your machine.
1 Use the correct viscosity engine lubricating 7 Install cold weather starting aids
oil In very low temperatures, say -18°C and below,
See fluids and lubricants - Capacities and additional starting aids may be needed.
Specifications in Maintenance section Examples are fuel, oil and coolant heaters and
extra batteries.
2 Use a low temperature diesel fuel Ask your JCB Dealer for advice
If available. See fuel system in Maintenance
section Note: Do not connect two batteries in series to give
24 volts for starting. This could burn out the glow
3 Use the correct coolant mixture plugs and starter motor.
See Coolant Mixture in Maintenance section
8 Remove snow from around the engine cover
before starting
4 Keep the battery at full charge
Otherwise snow could get into the air filter.
5 Fill the fuel tank at the end of each work
period
6 Protect the machine when not in use

Park the machine inside a building or cover it
with a tarpaulin.
B49 OPERATING IN HIGH TEMPERATURES B49
In high temperature situations, take the following

precautions to prevent possible damage to the
machine.
1 Use the correct viscosity engine oil

See Fluids and Lubricants-Capacities and
Specification in Maintenance section.
2 Use the correct coolant mixture

See coolant mixtures in Maintenance Publication
3 Check the coolant system regularly

Keep the coolant at the correct level. Make sure
there are no leaks.
4 Keep the radiator/oil cooler clean.

Regularly remove dirt and debris from between
the radiator /oil cooler and the engine.
5 Check ventilation grilles

Ensure the ventilation grilles to and from the
engine compartment are not blocked.
9803/3145 Issue 3*
B50 STOPPING AND PARKING THE MACHINE B50
C C
H27190
B51 STOPPING AND PARKING THE MACHINE B51
Whenever possible, stop the machine on dry and

level ground.
1 Stop the machine 6 Switch off all unnecessary Switches

Release the two track levers A then push the If you are leaving the machine, make sure that
hand throttle lever B to the idle position. all switches are set to off.
2 Lower the Bucket and Dozer to the ground.

WARNING
3 Stop the Engine and reset ignition key to Ensure that the excavator is in a safe condition
HOP49
position I,
7 Leave and Secure the machine
4 Vent the Hydraulic System
Raise the left armrest or engage the lever
Note: Hydraulic pressure is retained in an lock(s).Use the handrail to leave the cab. If you
accumulator which must be vented when leaving the are leaving the machine for a long period, close
machine. and latch the window and lock the door. Make
sure that the fuel filler cap is locked.
Operate the control levers C to vent the hydraulic
system residual pressure.
5 Remove the Starter Key

Ensure the waterproof cover is closed on canopy
machines.
9803/3145 Issue 3*
B52 PREPARING FOR SITE TRAVEL B52
150mm
(6 in.)
H50390
B53 PREPARING FOR SITE TRAVEL B53
CAUTION
Always travel the machine with the excavator
positioned at the same end as the dozer, especially
on hard and rocky ground.
Travelling position (level site conditions) Travelling position (uneven site conditions)
(Activate warning beacon if fitted) (Activate warning beacon if fitted)
Cab facing forward over dozer, excavator as shown, Lower the boom so that the bucket or attachment is
dozer blade fully up. approximately 150mm (6in) from the ground.
Position boom fully up, operate dipper fully in and

bucket fully crowded, i.e. bucket rotated fully towards
cab.
9803/3145 Issue 3*
B54 GETTING THE MACHINE MOVING B54
After you have warmed up the engine, move off as

described below. Read Operating Hints and Warnings
first.
Operating hints WARNING

The machine does not have gears. Do not overwork You and others could be killed or injured if you
the engine unnecessarily. Operate at an engine reverse direction on the move, because the change
speed suitable for the duty being carried out. in direction will be sudden and without warning
to others.
Note: Too low an engine speed may result in lack of
dipper control. Always stop the machine and drop engine speed
to idle before changing from forward to reverse
When moving the machine, keep it under control at or vice versa.
all times. Stay alert for obstructions and possible HOP51
hazards.
Approach deep mud slowly.
B55 GETTING THE MACHINE MOVING B55
1 Check your seat. 4 Move the machine

Make sure that the seat is secure and correctly a Check that the attachments are in the travel
adjusted. position. Make sure that it is safe to move
Fasten the seat belt if fitted. off.
2 Cab Swing Lock b Take hold of both track control levers in one
Make sure that the cab swing lock is disengaged hand
and the swing switch is pressed.
c Move the levers forward or backward as
3 Start the Engine required and pull the throttle lever slowly
See starting the engine in Operation section backward until the desired speed is attained.
To increase tracking speed operate the two
speed tracking switch. See 'Engine and Track
Controls' page.
9803/3145 Issue 3*
B56 WORKING WITH THE DOZER B56
H50400
B57 WORKING WITH THE DOZER B57
Remember that you will be driving the machine while

you are using the dozer. Keep alert for bystanders,
animals and possible hazards.
Ensure the slew lock is engaged when working with

the dozer.
Dozing and Grading Backfilling

Keep the bottom of the dozer parallel to the ground. When backfilling on a slope, pile the material on the
When grading a site remove high spots first, then use high side of the trench whenever possible.
this soil to fill in troughs. Do not use excessive Set the dozer level to the ground. Work at right
downward pressure on the dozer or machine traction angles to the trench filling a dozer's width at a time.
could be lost. When working with the dozer, set the Leave any spillage until the trench is filled. Use the
excavator straight with the machine, as for road spillage to finish the job by driving the length of the
travel. Keep the dozer high when travelling as this trench with the dozer low to the ground.
increases the machines ground clearance.
Scraping and Cutting

If a deep cut is to be made, do it in steps of about
50mm (2in). Do not forget to adjust the dozer height
when the machines tracks enter the cut.
9803/3145 Issue 3*
B58 WORKING WITH THE EXCAVATOR B58
B59 WORKING WITH THE EXCAVATOR B59
Installing a bucket - non Quickhitch Replacing bucket teeth

models
(See Bucket Selection) 1 Position the Bucket
Make sure that the bucket is resting flat on the
Note: This job is easier done by two people - one to ground.
operate the controls and one to line up the pivots.
2 Switch off the Engine
1 Position the Bucket Remove the starter key.
Set the bucket flat on level ground, using a
suitable lifting device. 3 Remove a Tooth
Remove the nut and bolt C and the tooth D.
WARNING
4 Install a Tooth
DO NOT use your fingers through the holes to
align the links Position the tooth D and fit the bolts C.
HOP65
2 Engage the Dipper

If necessary move the machine to align the pivot
pin holes. Carefully align the holes in the dipper
and bucket link with the bucket. Fit the pivot
pins B and lynch pin A.
9803/3145 Issue 3*
B60 WORKING WITH THE EXCAVATOR - continued B60
Bucket selection
WARNING
The bucket selected should be the correct width to
suit the hole/trench to be excavated. However, if the
hole width demands the larger bucket, consideration
should be given to the density/weight of the material
to be moved affecting the stability of the machine
especially if working on a slope. If there is danger of
the machine's stability being compromised, then select
a smaller bucket or reposition the machine.
Use the 300mm (12 in.) wide bucket for narrow

excavations or for maximum penetration when digging
in hard, rocky or clay soils.
Larger buckets are ideally suited to bulk shifting light

or loose materials.
WARNING
When buckets 750mm or wider are fitted to the machine,
use extreme caution in operation to avoid contact with
the cab.
Removing a bucket - non Quickhitch

models
1 Position the Boom WARNING

Swing the boom so that it is straight in front of If two people are doing this job, make sure that
the machine. Rest the bucket on level ground, the person working the controls is competent. A
with the dipper approximately vertical and the person can be killed or seriously injured if the
bucket flat to the ground. Block the bucket to controls are moved violently or incorrectly.
prevent its movement. HOP64
3 Withdraw the Dipper

WARNING
Using the controls, carefully lift the dipper clear
Stand clear and to one side of the bucket while of the bucket.
the pivot pins are removed: the bucket could roll
over.
HOP63
2 Detach the Bucket

Remove the lynch pin A and the pivot pins B.
9803/3145 Issue 3*
Installing a bucket on a Quickhitch

(See Bucket Selection)
1 Position the Bucket

G Set the bucket on firm level ground. Use safe
and correct lifting equipment to move the bucket
F .
2 Position the Machine
B a Position the machine so that the Quickhitch
and bucket are correctly aligned for
A connection as shown.
D
b Use the excavator controls to engage jaw A
C of the quickhitch with the pivot pin B of the
E bucket.
H25960
c Use the excavator controls to roll the

Quickhitch in the direction of arrow C until
WARNING
the latch hook D has fully engaged the pivot Always fit the Quickhitch latch hook locking pin.
pin E on the bucket . Due to the light weight Failure to fit the pin will result in possible failure
of some bucket it may be necessary to apply of the latching mechanism. Such a failure would
a load on the bucket teeth to achieve result in the sudden release of an attachment
Quickhitch connection. from the machine, you or others could be killed or
Alternatively, use the tommy bar to lever the seriously injured.
latch off, allowing the attachment pivot pin
E, to locate in jaw D of the Quickhitch. CAUTION
When the Quickhitch is installed and its
CAUTION attachment fitted, there is a danger of the
Make sure that the latch hook has fully engaged. attachment hitting the underside of the boom.
2-4-4-3
Operate the boom and dipper carefully when the
Quickhitch and its attachment are fitted.
2-4-4-2
d Fit the latch hook locking pin F and secure
with lynch pin G.
9803/3145 Issue 3*
H
F
J
Z
K
H25970
Removing a bucket from a Quickhitch
Note: Deposit Quickhitch attachments on firm level

ground whenever possible. This will make later
refitting easy and safe.
1 Park the machine on firm level ground. 5 Apply a downward pressure on the bar to release
the buckets’ rear pivot pin from the latch hook,
2 Position the bucket so that it is approximately as shown at Z. Remove the tommy bar from the
150mm (6 in) above the ground. Quickhitch.
6 Rest the bucket on the ground.

WARNING
The attachment will roll forward when released. 7 Slowly roll the Quickhitch back and
Stand clear and to one side when releasing the simultaneously raise the dipper arm to release
attachment. the buckets’ front pivot pin, as shown at Y.
2-4-4-1
Note: Quickhitch procedure applies to most

3 Remove lynch pin H, and locking pin F. attachments. See your attachments instructions for
specific procedures.
4 Insert the tommy bar J into the hole K of the
latch hook.
9803/3145 Issue 3*
25°
10°
9
H05500
Working on slopes
WARNING CAUTION
Failure to observe these precautions may cause the When excavating on level ground, the dozer may be
machine to become unstable and in extreme positioned at either end of the machine to improve
circumstances will overturn with potential serious stability. Always lower the dozer blade to the ground.
injury to the operator.
HOP64
The machine can operate without detriment to its
systems on inclines of up to 25º. However, on slopes
greater than 10º the operator must use his discretion
and proceed with extreme caution.
When working on inclines, position the dozer for

maximum stability. This may mean the dozer and
the boom are at the same end of the machine,
especially if digging down hill, lower the dozer
sufficiently to bring the machine level. If necessary,
to prevent an instability problem, cut a level platform
for the machine to stand on.
If your machine is fitted with a seat belt, USE IT.
9803/3145 Issue 3*
2
3
H50410
Digging
It is possible when excavating, to use either full Start dumping as the bucket approaches the pile. Do
machine slew when discharging a loaded bucket, or not waste time by dumping too far from the
if conditions dictate, swinging the excavator end only excavation. Dump close to the start dig position.
to the required dumping area. Swing the bucket back to the excavation and start
the next dig.
1 To start the dig, reach out with the boom and
dipper and position the bucket as shown. CAUTION
If machines are fitted with the extra long dipper
Slowly close the bucket at the same time bring the (1660mm) option or long dozer (standard on 804
dipper in. Make sure the bucket stays at the same machines) then care must be taken when digging
angle to the ground while it travels. If necessary, at up to machine as it is possible for the dig end to
the same time apply a downward pressure on the contact the dozer.
boom, to increase the digging force on the bucket.
CAUTION
2 When the bucket is full, close it fully and at the
Do not use the side of the excavation to stop the
same time move the dipper out a little way. This
bucket. This could damage the machine and
will keep soil from building up under the machine.
cause the sides of the trench to collapse.
3 Slew the machine or swing the bucket to the Backfill the excavation by loading the bucket with
dump area. soil from the pile. Do not push the soil with the side
of the bucket.
Note: Take extra care if extended swing is utilised

(see Excavator Controls - Extended Operation).
9803/3145 Issue 3*
Moving the machine while digging on the

level
When digging a trench or hole which is longer than
the excavator's reach, dig to the required depth and
width A until it is not possible to dig any closer without
contacting the machine.
When this position is reached, move the machine a

suitable distance away from the excavation.
Lower the dozer blade until the machine is level, then B

continue digging B.
A
Tracking on uneven ground
As for the travelling position, except that the bucket
should be lowered to approximately 150 mm (6 in.)
above ground.
150mm
(6in)
H05370
Digging near walls Digging up against obstructions
1 Swing left or right as required

WARNING
When digging near a wall, take care not to 2 Position the machine so that the bucket is up
undermine the foundations. The wall could against the obstruction when fully rotated.
collapse. HOP66
3 When swinging away from the obstruction the
Position the machine close to the wall as shown. Set rear of the machine may contact the obstruction
the machine at an approximate angle of 45° to the if care is not taken.
wall.
H50830
9803/3145 Issue 3*
Lifting (Craning) regulations and safe WARNING

working loads Do not use the Excavator as a 'Crane'. Consult
National Lifting Regulations.
Lifting regulations
The factories Act Construction (Lifting Operations)
Regulations 1961 defines 'Excavators' as 'Lifting
Appliances'. As such the JCB Mini Excavators are
subject to these regulations.
The owner and/or operator must make sure that he

fully understands the laws and regulations concerning
the use of the JCB Excavator. Consult your JCB Note: The machine is fitted with an eye on the tipping
dealer for further information. link. This is for securing the machine for transport or
lifting buckets and attachments for safe storage only.
Safe working loads
WARNING
The safe working load indicated on lifting
accessories such as cranes etc. is not the safe
working load of the machine.
When loads are to be lifted by the excavator, a

bucket must be fitted.
The maximum load which may be lifted depends

on the equipment fitted to the excavator and the
laws and regulations in force at the time and in
the country in which the excavator is being used.
If your machine is equipped to be operated under

'Exemption Certificate' rules, your Exemption
Certificate will specify the Safe Working Loads.
Note: In certain countries Safety Regulations in force

call for the application of specific safety factors.
Consult your dealer for information.
9803/3145 Issue 3*
B74 USING THE ATTACHMENTS AND SITE SAFETY B74
This section explains some techniques for efficient Choose the correct attachment for the job. Do not
and safe use of the machine and its attachments. use an oversize bucket for rocky material. It could
Attention is also drawn to the various safety aspects overload the system and shorten service life.
of operating on site. Read and understand this
section before you start working with the machine.
Practice using the attachments until you are
WARNING
completely familiar with the controls and what they General site safety
do. Before you start using this machine, inspect the job
sites. You could be killed or injured if the ground
Before using the attachments, study the lifting and gives way under your machine or if piled material
digging diagrams in the Specification section of the collapses onto it. Check for potholes and hidden
maintenance publication. debris, logs, ironwork etc. Any of these could cause
you to lose control of your machine.
Before you start using the machine, tell your HOP52
workmates what you will be doing and where you will

be working. On a busy site, use a signalman. CAUTION
Legal liability
Remember that your machine is mobile. Whenever You and/or your company could be legally liable for
possible, manoeuvre your machine into a position any damage you cause to public utilities. Make sure
which combines safety with efficiency. If you have to that you know the locations of all public utility cables
choose remember that or pipes on the site which could be damaged by your
machine.
SAFETY MUST COME FIRST! HOP53
B75 USING THE ATTACHMENTS AND SITE SAFETY - continued B75
WARNING WARNING
Electrical power cables Overhead electric power cables
You could be electrocuted or badly burned if you get There is a minimum clearance required for working
the machine or its attachments to close to electrical beneath overhead power cables. You must obtain
power cables. details from you local electric company. HOP56
You are strongly advised to make sure that the safety
arrangements on site comply with the local laws and WARNING
regulations concerning work near electric power lines. If you will be working with a labourer, make sure that
HOP54
you both understand what each other will be doing.
WARNING Learn and use the recognised signalling procedures.
Buried electric power cables Do not rely on shouting he will not hear you! HOP58
Before you start using the machine, check with your
electricity supplier if there are any buried power cables
on the site. HOP55
9803/3145 Issue 3*
WARNING
Underground gas pipes
Before you start using the machines, find out from If a gas leak is suspected, contact the local gas
your local gas company if there are any buried gas company immediately and warn everyone on the site.
pipes on the site. Ban smoking, ensure that all naked lights are
extinguished and switch off any engines which may
Some modern gas pipes cannot be detected by metal be running.
detectors. So it is essential that you get an accurate
map of buried gas pipes before you begin any You are strongly advised to make sure that the safety
excavation work. arrangements on site comply with the local laws and
regulations concerning work near buried gas pipes.
Hand-dig trial holes to obtain precise pipe locations. HOP57
If you find any cast iron pipes, assume they are gas
pipes until you can prove otherwise.
Older gas pipes can be damaged by heavy vehicles

driving over this ground above them. Mechanical
digging must not take place within 500mm (20in) of
a gas pipe. Leaking gas is highly explosive.
CAUTION WARNING
Do not travel with the track motors leading particularly Reworking old sites
on hard and rocky ground. The recoil units will not There could be hazardous materials such as
absorb the shocks and damage could result to the asbestos, poisonous chemicals or other harmful
track running gear. substances buried on the site. If you uncover any
Do not excavate on hard or rocky ground with the containers or if you see any signs of toxic waste,
boom positioned diagonally across the undercarriage. stop the machine and inform the site manager
This can produce a rocking motion that could cause immediately.
damage to the track gearbox sprockets.
WARNING
WARNING Water supplies and drains
Hill sides Before you start using the machine, check with your
Operating on hillsides can be hazardous, especially local public water company if there are buried pipes
moving across a slope. If the slope is too steep, and drains on the site. If there are, obtain a map of
your machine could roll over. If you must drive across their locations and follow the advice given by the
a slope keep the attachments close to the ground. water supplier.
Remember that loose surface material and mud will You are strongly advised to make sure that the safety
change the ground conditions. In any event do not arrangements on site comply with the local laws and
drive across a slope of greater than 17 deg. regulations concerning work near buried water pipes
and drains.
HOP62
9803/3145 Issue 3*
B78 USING THE ATTACHMENTS - continued B78
H20170
There are two types of hydraulic attachment circuits

available. Single acting or double acting. Both types
WARNING
are operated by a floor mounted pedal. Hydraulic Fluid
Fine jets of hydraulic fluid at high pressure can
Single acting circuit penetrate the skin. Do not use your fingers to
check for hydraulic fluid leaks. Do not put your
This type powers a dipper mounted breaker A.
face close to suspected leaks. Hold a piece of
cardboard close to suspected leaks and then
Double acting circuit inspect the cardboard for signs of hydraulic fluid.
This type powers reversible attachments such as an If hydraulic fluid penetrates your skin, get medical
auger B. The double acting circuit can be switched help immediately.
to single acting operation by means of a valve C INT-3-1-10/1
located to the right of the radiator in the engine

compartment. Rotate the valve fully anti-clockwise
for single acting operation or fully clockwise for
double acting operation.
Operate the pedal in the required direction for correct
tool operation. In non-operating conditions the pedal
must be locked in position D.
9803/3145 Issue 3*
J
K
H27200
Removing a Quickhitch Rockbreaker WARNING

Hydraulic Fluid
Note: Deposit Quickhitch attachments on firm level Fine jets of hydraulic fluid at high pressure can
ground whenever possible. This will make later penetrate the skin. Do not use your fingers to
refitting easy and safe. check for hydraulic fluid leaks. Do not put your
face close to suspected leaks. Hold a piece of
1 Park the machine on firm level ground.
cardboard close to suspected leaks and then
inspect the cardboard for signs of hydraulic fluid.
CAUTION
If hydraulic fluid penetrates your skin, get medical
The rockbreaker must be positioned correctly
help immediately .
before attempting to release it from the quickhitch. INT-3-1-10/1
if incorrectly positioned, the rockbreaker could
swing or fall suddenly from the machine when 3 Stop the Engine.
releasing the quickhitch latch
hook. 4 Operate the auxiliary attachment control pedal, this
will release any hydraulic pressure trapped in the
2 Position the rockbreaker just clear of the ground system.
and at an angle such that the rockbreaker does
not detatch from the front pivot pin when the 5 Disconnect the hydraulic hoses.
Quickhitch is unlatched. Typically shown at V.
WARNING
The attachment will roll forward when released.
Stand clear and to one side when releasing the
attachment. 2-4-4-1
9803/3145 Issue 3*
J
K
H27200
Removing a Quickhitch Rockbreaker -

continued
6 Remove lynch pin H, and locking pin F. 11 Slowly roll the Quickhitch back and
simultaneously raise the dipper arm to release
7 Insert the tommy bar J into the hole K of the the rockbreakers’ front pivot pin, as shown at Y.
latch hook.
12 Remember to remove the lynch pin H and locking
8 Apply a downward pressure on the bar to release pin F before fitting another attachment.
the rockbreakers’ rear pivot pin from the latch
hook, allowing the attachment to swing forward
as shown at Z. Remove the tommy bar from the
Installing a Quickhitch Rockbreaker
Quickhitch. Procedure is as installing a bucket.
9 Refit the locking pin F and lynch pin H. Failure

to refit the pin will result in the rockbreaker re-
latching as it is lowered to the ground. Make sure
that the hydraulic hoses do not become trapped
under the attachment.
10 Start the engine and carefully lower the

attachment to the ground as shown at Y.
9803/3145 Issue 3*
A
C
H26040
Using hand held tools

Hand held tools operate from the machines auxiliary 1 Stop the Engine.
circuit via a valve A.
2 Operate the auxiliary attachment control pedal,
this will release any hydraulic pressure trapped
WARNING in the system.
Hydraulic Fluid
Fine jets of hydraulic fluid at high pressure can 3 Attach the valve A to the bucket ram protection
penetrate the skin. Do not use your fingers to plate B.
check for hydraulic fluid leaks. Do not put your
face close to suspected leaks. Hold a piece of 4 Connect the hydraulic hoses C to the auxiliary
cardboard close to suspected leaks and then connectors D, making sure they are clean.
inspect the cardboard for signs of hydraulic fluid.
If hydraulic fluid penetrates your skin, get medical 5 Connect the hand held attachment to the
help immediately. connectors E, making sure they are clean.
INT-3-1-10/1
6 Lock the auxiliary pedal F in the operating

position.
9803/3145 Issue 3*
B86 MOVING A DISABLED MACHINE B86
H50420
B87 MOVING A DISABLED MACHINE B87
CAUTION
Do not tow a disabled machine. Permanent Lifting points have been provided on the machine as
damage to the track motors will occur if the follows:
machine is towed.
HOP68 1 On each end of the dozer blade at points A.
If the machine becomes disabled, it must not be 2 On the boom at point C.

towed or otherwise moved on its tracks.The machine
should be made safe, lifted onto a transporter and The correct method for 3-point lifting is shown in the
moved to a location where maintenance can be illustration opposite.
carried out.
When the machine is totally disabled, the boom
should be set to the fully raised position and lifted
using the 3-point lifting method.
9803/3145 Issue 3*
B88 TRANSPORTING THE MACHINE B88
Preparing for road travel

Before loading the machine on to its trailer (see Note: The transport position height does not include
transporting the machine), remove all loose dirt that the truck/trailer height, add the two figures together
may otherwise come off and obstruct the highway for the clearance height.
and damage other vehicles.
CAUTION
Note: Before transporting the machine make sure Make sure that the two speed tracking selector is
you will be obeying the local rules and laws regarding set to low speed before loading or unloading the
machine transportation of all the areas that the machine.
machine will be carried through.
Make sure that the transporting vehicle is suitable.

See Maintenance section for the dimensions and
weight of your machine. There is a travel height label
fitted to the cab.
Try to make sure that the truck driver knows the

clearance height before he drives away. See section
D for machine height figures.
B89 BEFORE USING THE TRAILER B89
WARNING WARNING
Before moving the machine onto the trailer, make The safe transit of the load is the responsibility of
sure that the trailer and ramp are free from oil, the transport contractor and driver. Any machine,
grease and ice. Remove oil, grease and ice from attachment or parts that may move during transit
the machine tracks. Make sure the machine will must be adequately secured. 5-2-5-3
not foul on the ramp angle. HOP69
1 Remove any dirt or debris from the trailer.
2 Check the operation of the parking brake.
3 Check the trailer bodywork for signs of damage.
4 Check the tyre pressures are correct (consult the

Manufacturer's handbook).
5 Check the lights are working and are the correct

voltage for the towing vehicle (consult the
Manufacturer's handbook).
6 Check the breakaway cable is serviceable.
9803/3145 Issue 3*
B90 SECURING THE MACHINE B90
A D
D
B C B
H27220
B91 SECURING THE MACHINE B91
WARNING
The machine must be securely tied down to the
trailer to prevent lateral movement, fore-and-aft
movement, and slewing of the superstructure.
Failure to do so could cause injury to yourself or
others.
1 Engage slew lock. Ensure by operating the slew 4 Place skids B under each track at front and rear
control that the slew lock is engaged. to prevent movement of the machine in the fore-
and-aft direction.
2 Close the bucket. Position the dipper vertically
and lower the boom until the bucket rests on a 5 Position a wire rope C of suitable breaking strain
wooden block on the trailer bed. around each track at front and rear and secure
to the trailer shackles to prevent lateral
3 Position a wire rope A of suitable breaking strain movement of the machine.
over the bucket and secure to the trailer
shackles. 6 Attach wire ropes D of suitable breaking strain
to the lifting points on the superstructure and
secure to the trailer shackles to prevent the
superstructure from swinging.
9803/3145 Issue 3*
Section 3 Routine Maintenance Section 3
i i
Contents Page No.
Fluids, Lubricants, Capacities and Specifications ......................... 1 - 1
Engine Lubrication Chart ............................................................... 1 - 2
Torque Settings ............................................................................. 1 - 3
Hydraulic Fittings .......................................................................... 1 - 5
Fuel Systems ................................................................................ 1 - 6
Coolant Mixtures ........................................................................... 1 - 7
Service Schedules ........................................................................ 2 - 1
Greasing ........................................................................................ 3 - 1
Hydraulic Fluid Level .................................................................... 4 - 1
Track Gearbox .............................................................................. 5 - 1
9803/3145 Issue 1
1-1 Fluids, Lubricants, Capacities and Specifications 1-1
Note: New engines DO NOT require a running-in period. The engine should be used in a normal work cycle immediately;
glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no
circumstances should the engine be allowed to idle for extended periods (e.g. warming-up without load).
ITEM CAPACITY FLUID/LUBRICANT INTERNATIONAL

Litres (UK/US Gal) SPECIFICATION
* Engine Oil 4.5 (1.0) [1.2] JCB 10W/30 Multigrade MIL-L-46152, API CC/SF
100 Series KR Builds above - 15OC (5OF)
First 100 hours only JCB 5W/20 Multigrade API CC/SE (recommended)
-15OC to - 25OC (5 OF to - 13OF)
Engine Oil 4.5 (1.0) [1.2] JCB Extreme Performance CH4/SJ (ACEA E5-B3-A3)
400 Series HP Builds Engine Oil 15W/40
* -10°C to +50°C (14°F to 122°F)
Engine (Coolant)
Canopy 4.5 (1.0) [1.2] JCB Universal Antifreeze/water ASTM D3306-74
Cab 5.0 (1.1) [1.3] ( See Coolant Mixtures)
Track Gearbox (each) 1.2 (0.26) [0.3] JCB SAE 30 Engine Oil API CD/SF, MIL-L-46152B
( NOT Multigrade ) MIL-L-2104B
Slew Gearbox Lubricated from hydraulic system
Track Idler Wheels Sealed Unit JCB HD90 Gear Oil API-GL-5, MIL-L-2105D
Track Rollers
(bottom) Sealed Unit JCB HD90 Gear Oil API-GL-5, MIL-L-2105D
(top) Sealed Unit JCB HD90 Gear Oil API-GL-5, MIL-L-2105D
Hydraulic Tank
802.7 48 (10.6) [12.7] JCB Hydraulic fluid 46
803 48 (10.6) [12.7] -10°C to +40°C (14°F to 104°F)
804 to M734833 46 (10.1) [12.2] JCB Special Hydraulic fluid
804 M734834 on 48 (10.6) [12.7] -10°
JCB Hydraulic fluid 68
Hydraulic System Above +40°C (Above 104°F)
802.7 to M747210 81 (18.0) [21.5]
802.7 M747211 on 70 (15.7) [18.6]
803 to M827239 81 (18.0) [21.5]
803 M827240 on 70 (15.7) [18.6]
804 to M734833 81 (18.0) [21.5]
804 M734834 on 70 (15.7) [18.6]
Fuel Tank
802.7 to M747210 43 (9.5) [11.4] Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D
802.7 M747211 on 48 (10.6) [12.7]
803 to M827239 43 (9.5) [11.4]
803 M827240 on 48 (10.6) [12.7]
804 to M734833 42 (9.25) [11.0]
804 M734834 on 48 (10.6) [12.7]
#Slew Ring
Bearings JCB MPL Grease Lithium based,
Gear Teeth JCB Slew Pinion Grease ## No. 2 consistency.
All Other Grease JCB MPL Grease Lithium based,

Points No. 2 consistency.
## WARNING
JCB Slew Pinion Grease is harmful. It contains bitumen compounds 2811 with possible risks of irreversible effects. Excessive
contact may lead to dermatitis or skin cancer. Always use a barrier cream or wear gloves.
Wash contaminated skin thoroughly with soap and water. In the event of contact with the eye, immediately wash with plenty
of water and seek medical advice.
9803/3145 Issue 3
1-2 Fluids, Lubricants, Capacities and Specifications 1-2
Engine Lubrication Chart
JCB Super Universal Agricultural

First 100 Hours only
100 SERIES ENGINE
JCB Extreme Performance Engine Oil

15W/40
5W/20
-30 -20 -10 0 10 20 30 40 50

AMBIENT TEMPERATURE (DEGREES C)
Safety Notice
Care must be taken when handling fluids and lubricants. Refer to Product Safety Information (COSHH) leaflet.
9803/3145 Issue 2
1-3 1-3
Torque settings
Only use following when no setting is specified in text of manual.
CAUTION: All bolts used on JCB equipment are high tensile and must not under any circumstances be replaced with
bolts of a lesser tensile specification.
Metric Grade 8.8 Bolts
Bolt Size Hexagon (A/F) Torque Settings

(mm) mm Nm kgf m lbf ft
M5 (5) 8 7 0.7 5
M6 (6) 10 12 1.2 9
M8 (8) 13 28 3.0 21
M10 (10) 17 56 5.7 42
M12 (12) 19 98 10 72
M16 (16) 24 244 25 180
M20 (20) 30 476 48 352
M24 (24) 36 822 84 607
M30 (30) 46 1633 166 1205
M36 (36) 55 2854 291 2105
Table of important tightening torques
Tightening Points Tightening Torque

Nm kgf m lbf ft
Track motor to undercarriage 113 11.5 83
Retaining bolts 250 25.5 184
Track roller 244 25 180
Idler yoke 98 10 72
Rotary coupling mounting 56 5.7 41
Rotary coupling torque arm 35 3.6 26
Slew ring 120 12.3 89
Slew gearbox case 244 25 180
Hydraulic oil tank 56 5.7 41
Fuel tank 56 5.7 41
Hydraulic filter cover 28 3.0 21
Rod end - controls 56 5.7 41
Silencer bolt 28 3.0 21
Exhaust tail pipe 56 5.7 41
Engine shock absorber (to slew frame) 56 5.7 41
Engine shock absorber (to engine) 98 10 72
Engine bracket 118 12 87
Engine support (to bell housing) 98 10 72
Counterweight 98 10 72
Track gearbox cover 56 5.7 41
Slew ring to superstructure (802.7 / 803) 100 10.2 74
Slew ring to superstructure (804) 160 16.3 118
Rams: See Section E
9803/3145 Issue 1
1-4 1-4
Table of important tightening torques (cont'd)
Tightening Points
Tightening Torque Nm kgf m lbf ft
Valve Block
Tie rod (large diameter) 45 4.6 33
Tie rod (small diameter) 19 2.0 14
Spool spring retainer TBA TBA TBA
End cap screw 7 0.7 5
Servo retaining cap screws TBA TBA TBA
Track Motor
Motor to undercarriage bolts 98 10 72
Drive sprocket to motor bolts 98 10 72
Pump 802.7 - 803
Drive coupling 54 5.5 40

Tie bolts (main) 43-46 4.4-4.7 32-34
Tie bolts (servo) 24-27 2.4-2.8 18-20
Engine
Bearing holder bolts 49-54 5.0-5.5 36-40
Rear plate Bolts 13-18 1.4-2.4 10-13
Flywheel Housing bolts 24-28 2.5-2.9 18-21
Flywheel bolts 58-68 6.0-7.0 43-51
Connecting rod nuts 49-54 5.0-5.5 36-40
Oil suction filter bolts 9-12 1.0-1.2 7-9
Sump bolts 9-12 1.0-1.2 7-9
Crankshaft pulley nut 275-333 28-46 203-246
Cylinder head bolts (oiled) 88-93 9.0-9.5 65-69
Injection pump bolts 9-12 1.0-1.2 7-9
Injection pump nuts 9-12 1.0-1.2 7-9
Rocker arm nuts 20-24 2.0-2.5 14.5-18.1
Head cover nuts 8-12 0.8-1.2 6-9
Cooling fan bolts 9-12 1.0-1.2 7-9
Oil pipe banjo bolt 10-13 1.0-1.3 7.2-9.4
Oil sump drain bolt 30-39 3.1-4.0 22-29
Injector nozzle 59-69 6.0-7.0 44-51
Injector nozzle clamp 20-24 2.0-2.5 14.5-18.1
Injector pipe 15-24 1.5-2.5 11-18
Thermo switch 26-30 2.6-3.1 19-22
Oil pressure switch 15-20 1.5-2.0 11-15
Glow plug 15-20 1.5-2.0 11-15
Stop solenoid 15-20 1.5-2.0 11-15
Oil relief valve 57-69 6.0-7.0 44-51
Adjusting screw nut 6-16 1.0-1.6 7-12
9803/3145 Issue 1
1-5 1-5
Hydraulic fittings & torque settings
O-ring Face Seal

All the hydraulic fittings on the JCB Plus Series of Tracked Excavators use the O-ring face seal system which achieves
a leakproof, non loos-ening connection.
Adapters screwed to valve blocks etc. seal onto an O-ring which is compressed into a 45O seal machined in the face
of the tapped port.
Adaptor (A)
SAE SAE Port A/F Tightening Torque

Tube Size Thread Size mm in Nm lbf ft
4 7/16 - 20 15.9 0.625 20-28 16.5 - 18.5

6 9/16 - 18 19.1 0.750 46-54 34 - 40
8 3/4 - 16 22.2 0.875 95-105 69-77
10 7/8 - 14 27.0 1.063 130-140 96 - 104
12 1.1/16 - 12 31.8 1.250 190 - 210 141-155
16 1.5/16 - 12 38.1 1.500 290 - 310 216 - 230
20 1.5/8 - 12 47.6 1.875 280 - 380 210 - 280
Outer sleeve nut (B)
SAE Hose/pipe A/F Tightening Torque

Tube Size Thread Size mm in Nm lbf ft
4 9116 - 18 17.5 0.688 20-30 15-21

6 11/16 - 16 20.6 0.813 31-39 23-29
8 13116 - 16 23.8 0.937 45 - 55 33 - 41
10 1-14 28.6 1.125 80 - 90 59-67
12 1.3/16 - 12 35.0 1.375 105-125 77 - 93
16 1.7/16 - 12 41.5 1.625 155-175 114 - 130
9803/3145 Issue 1
1-6 1-6
Fuel system
Types of Fuel Fuel Standards

Use good quality diesel fuel to get the correct power and Consult your fuel supplier, JCB distributor or Perkins
performance from your engine. The recommended fuel dealer about the suitability of any fuel you are unsure of.
specification for Perkins engines is given below.
Low Temperature Fuels
Cetane Number: 45(minimum) Special winter fuels may be available for engine opera-
Viscosity: 2.5/4.5 centistokes at 40OC(104OF) tion at temperatures below 0OC (32OF). These fuels have
Density: 0.835/0.855 kg/litre a lower viscosity. They also limit wax formation in the
(0.872/0.904 lb./pint) fuel at low temperatures. (Wax forming in the fuel can
Sulphur: 0.5% of mass (maximum) stop the fuel flowing through the filter).
Distillation: 85% at 350OC (662OF)
Flow improvers may also be available. These can be
Cetane Number added to the fuel to reduce wax formation.
Indicates ignition performance. Fuel with a low cetane
number can cause cold start problems and affect com- Petrol
bustion
WARNING
Viscosity Do not use petrol in this machine. Do not mix petrol
Is the resistance to flow. If this is outside limits, the with the diesel fuel. In storage tanks the petrol could
engine performance can be affected. rise to the top and form flammable vapours.
INT3-1-6
Density
Lower power will reduce engine power. Higher density Advice
will increase both engine power and exhaust smoke. If you have to use nonstandard fuels, contact your JCB
distributor for advice on engine adjustments and oil
Sulphur change periods.
High sulphur content can cause engine wear, (High
sulphur fuel is not normally found in North America, WARNING
Europe or Australia). If you have to use high sulphur fuel
Diesel fuel is flammable; keep naked flames away
you must also use a highly alkaline engine lubricating oil:
from the machine. Do not smoke while refuelling the
or change the normal oil more frequently.
machine or working on the engine. Do not refuel
with the engine running. There could be a fire and
Distillation
injury if you do follow these precautions
This indicates the mixture of different hydrocarbons in INT3-2-2
the fuel. A high ratio of lightweight hydrocarbons can
affect the combustion characteristics.
9803/3145 Issue 1
1 - 6A 1 - 6A
Fuel system (cont'd)
Bleeding the Fuel System
802.7 to M747158
803 to M766870
804 to M734750
WARNING WARNING
Air in the fuel system can cause misfiring or When you turn the engine to bleed the fuel lines,
failure to start. Air will enter the system if any do not operate any of the hydraulic control levers.
part of it is disconnected or emptied.
4 Loosen the unions at C, D and E. If you are working
WARNING with an assistant warn him that you are about to
turn the engine.
To bleed the air from the system, the engine must
be turning. When the engine is turning, there are 5 Open the throttle a little and turn the starter key to
parts rotating in the engine compartment. Before rotate the engine.
starting this job, make sure you have no loose
clothing (cuffs, ties etc.) which could get caught 6 When air-free fuel flows from all three points, tighten
in rotating parts. Keep clear of rotating parts. the unions.
1 Raise the engine cover.
2 To bleed air from the filter, slacken bleed screw A.

Operate lift pump lever B until air-free fuel flows
from the union.
3 The fuel injection pump is self bleeding as the

engine is cranked.
9803/3145 Issue 1*
1 - 6B 1 - 6B
Fuel system (cont'd)

Bleeding the Fuel System (cont'd)
802.7 M747159 on
803 M766871 on
804 M734751 on
WARNING WARNING
Air in the fuel system can cause misfiring or When you turn the engine to bleed the fuel lines,
failure to start. Air will enter the system if any do not operate any of the hydraulic control levers.
part of it is disconnected or emptied.
4 Loosen the unions at C, D and E. If you are working
WARNING with an assistant warn him that you are about to
turn the engine.
To bleed the air from the system, the engine must
be turning. When the engine is turning, there are 5 Open the throttle a little and turn the starter key to
parts rotating in the engine compartment. Before rotate the engine.
starting this job, make sure you have no loose
clothing (cuffs, ties etc.) which could get caught 6 When air-free fuel flows from all three points, tighten
in rotating parts. Keep clear of rotating parts. the unions.
1 Raise the engine cover.
2 To bleed air from the filter, slacken bleed screw A.

Squeeze the priming bulb B repeatedly until air-
free fuel flows from the union.
3 The fuel injection pump is self bleeding as the

engine is cranked.
Note: The illustration shows a typical model; your

machine may look different from the model shown.
9803/3145 Issue 1*
1-7 1-7
Coolant mixtures
The protection provided by JCB Universal Antifreeze is
shown below. If any other antifreeze is used, refer to
the manufacturers' instructions and ensure that a
corrosion inhibitor is included.
DO NOT use solutions of more than 60% or less than

50% or damage to the cooling system will occur.
Solution Maintains circulation Protects

down to against damage
down to
deg C deg F deg C deg F
55% -36 -33 -41 -42
The strength of the antifreeze solution must be checked

at least once a year, preferably at the beginning of the
cold period.
It is an advantage to leave the antifreeze in all the year

round as it gives continued protection against corrosion.
Always renew the antifreeze every two years.
A 50% antifreeze mixture must be used even if frost

protection is not needed. This gives protection against
corrosion and raises the coolant's boiling point.
Note: In climates where antifreeze is not necessary, a

reputable inhibitor must be used. Renew the mixture
every 6 months.
WARNING
Antifreeze can be harmful. Obey the manufacturers
instructions when handling neat or diluted antifreeze.
7-3-4-4
9803/3145 Issue 1*
2-1 SERVICE SCHEDULES 2-1
Every 10 operating hours or daily Every 50 operating hours or weekly

whichever occurs first whichever occurs first
Clean Do the daily jobs plus:

1 Machine generally
Clean
Check and adjust where necessary (engine stopped) 1 Drain and clean fuel filter
2 Generally for damage 2 Drain fuel sediment bowl
3 Hydraulic oil level 3 Radiator matrix
4 Engine oil level
5 Engine coolant Check and adjust where necessary (engine stopped)
6 Fuel system for leaks 4 Fan belt adjustment
7 Engine air filter pre-cleaner
8 Track adjustment Note: Failure to maintain correct fan belt adjustment
can result in damage to timing case cover.
Check and adjust where necessary (engine running)
9 Operation of horn
10 Operation of all other electrical equipment First 100 hours only
11 Exhaust (excessive smoke) Do the jobs listed in 50 hours (above) plus:
12 Dozer operation
13 Excavator operation Change
14 Track and running gear operation 1 Engine oil and filter canister
15 Hourmeter operation
Check
2 Track tension (rubber tracks only)
9803/3145 Issue 1
Every 100 operating hours or 2 weeks Every 250 operating hours or monthly
Do the daily jobs through to 50 hours plus: Do the daily jobs through to 100 hours plus:
Clean Change
1 Battery terminals 1 Engine oil
2 Engine oil filter canister
Check and adjust where necessary (engine stopped)
2 Hose and pipework for security and damage Grease
3 Condition of ram piston rods 3 Slew ring grease nipples
4 All grease seals
5 Track, plate condition/rubber condition Every 500 operating hours or 6 months
6 Engine mounting bolts whichever occurs first
7 Air cleaner hose security
8 Wiring for damage Do the daily jobs through to 250 hours plus:
9 Track tension
Clean
First 250 operating hours only
1 Fuel lift pump
Do the daily jobs through to 100 hours plus:
Change
Change
2 Fuel filter element
1 Track gearbox oil 3 Hydraulic fluid return filter element
4 Outer air cleaner element (very dusty conditions
Check only)
2 Kingpost pivot pins retaining bolt torque.
Check and adjust where necessary
(engine stopped)
5 Exhaust system security
6 Track gearbox oil levels
7 Injectors and test
8 Tighten cylinder head
9 Valve clearances
10 Engine mounting bolts
Check and adjust where necessary

(engine running)
11 Main relief valve pressure
12 Auxiliary relief valve pressure
13 Slew crossline relief valve
14 Engine idle speed
15 Engine maximum speed
9803/3145 Issue 1
Every 1000 operating hours or yearly Every 2000 operating hours or 2 years
Do the daily jobs through to 500 hours plus: Do the daily jobs through to 1000 hours plus:
Clean Change
1 Air filter dust valve 1 Air cleaner element (inner)
2 Hydraulic fluid and clean suction strainer
Change 3 Engine coolant
2 Air filter element (outer)
3 Track gearbox oil Check (engine stopped)
4 Idler wheel and track rollers, oil and seals 5 Battery electrolyte level (low maintenance)
6 Starter motor and alternator brush gear
Check 7 Valve clearance and lubrication
5 Cab frame
6 Check security of all major component mounting
bolts, gearboxes, slew motor, track motors, rotary
joint etc.
7 Check, clean and replace if damaged, filter adaptors
fitted in pressure maintenance valve
Grease
8 Slew pinion and slew ring gear teeth
9803/3145 Issue 1
3-1 3-1
Greasing
WARNING
You will be working close into the machine for these For the types of grease to use at each point, see the
jobs. Lower the attachments if possible. Remove Lubricants and Capacities chart at the start of the
the starter key. This will prevent the engine being Routine Maintenance section.
started. Do not mix different types of grease, keep them separate.
8-3-1-3
You must grease the machine regularly to keep it

working efficiently. Regular greasing will also lengthen
the machine's working life.
Greasing should be done with a grease gun. Normally

two strokes of the gun should be enough. Stop greasing
when fresh grease appears at the joint.
H23630
9803/3145 Issue 2*
3-2 3-2
Greasing - every 250 hours
Slew Ring Bearings

Ensure the slew ring is kept full of grease.
Grease point on left hand side of mainframe.
To ensure distribution of grease, use the following

procedure:
1 Grease, rotate 180°
2 Grease, rotate 180°
3 Grease.
H23640
9803/3145 Issue 2*
3-3 3-3
Greasing - every 1000 hours
Slew Ring Gear Teeth
WARNING
JCB Slew Pinion Grease Is harmful as It contains
bitumen compounds 2811. Excessive contact may
lead to dermatitis or skin cancer. Always use a
barrier cream or wear gloves; wash contaminated
skin thoroughly with soap and water. In the event of
eye contact, Immediately wash with plenty of water
and seek medical advice.
8-1-1-2
WARNING
A machine can sink Into soft ground. Never work
under a machine on soft ground.
INT-3-2-1
WARNING
A machine can roll off jacks and crush you. Do not
work under a machine supported only by jacks.
MD-1-6-1
1 Raise machine and support the undercarriage.
2 Stop the engine and remove the starter key.
3 Remove the bolts A and plate B in the underside of

the undercarriage.
4 Apply the grease to the pinion using an applicator.
5 Insert the starter key and start the engine.
6 Rotate the main frame twice fully.
8 Repeat step 4 as necessary.
9 Refit the plate B and bolts A.
10 Put the machine back on the ground.
A B
H23650
9803/3145 Issue 2*
4-1 4-1
Hydraulic fluid level

Check Level - For interval see Service Schedule.
WARNING
B
Fine jets of hydraulic oil at high pressure can
penetrate the skin. Do not use your fingers to check
for hydraulic oil leaks. Do not put your face close to
suspected leaks. Hold a piece of cardboard close to
suspected leak and then inspect the cardboard for C
signs of hydraulic oil. If hydraulic oil penetrates
your skin, get medical help immediately.
HYD-001 D
Position the machine on firm level ground with the rams
half extended. Check that the hydraulic level is to the E
correct mark A (804) A1 (802.7 / 803 / 804 Super*).
Remove hydraulic tank cover, unscrew cap B1 from
return filter and top up tank as necessary. Replace cap
and cover.HYDRAULIC FILTER A
Renew Filter - For interval see Service Schedule.
1 Remove hydraulic tank cover B (and filter cap B1

802.7 / 803 / 804 Super*).
2 Withdraw spring C, filter element D and seal E from

body.
3 Clean all metal parts. Reassemble using new filter

element D and seal E.
4 Replace and secure filler cap B1 and hydraulic tank A1

cover
B
B1
9803/3145 Issue 2*
5-1 5-1
Track Gearbox
Check Level - For interval see Service Schedule Drain& Refill - For interval see Service Schedule
1 Position the machine on firm level ground with the 1 Position the machine on firm level ground with safe
drain plug B at the lowest point and with safe access access to the level plug A, and the drain plug B at
to the level plug A and filler plug C. the lowest point.
2 Remove the level plug A. Oil should flow from the 2 Remove plugs B and C and allow oil to drain
hole. completely.
3 If necessary, remove filler plug C and top up the 3 Fit the drain plug B.
oil.
4 Fill the gearbox through the filler hole at C to the
4 Refit the filler plug C. correct level at A.
5 Fit the level plug A. 5 Fit the plugs A and C.
Note: There is a track gearbox on each track. Note: There is a track gearbox on each track.
9803/3145 Issue 1
Section A Optional Equipment Section A
1-1 1-1
General Description
This section lists the options available on the Mini-Excavators and, where appropriate, details the procedures necessary
to carry out the installations or conversions.
Options
Cab Working Lights

Twin roof-mounted working lights.
Double Acting Auxiliary Pipework

Enables forward or reverse operation of various hydraulic
attachments.
3CX Hand Controller Pattern

To change the standard ISO hand controller pattern to
the 3CX pattern.
Hose Burst protection Valves

To fit lock valves to both the dipper ram and the boom
ram to prevent uncontrolled descent if an hydraulic hose fails.
Radio Kit
Radio cassette, twin speakers and antenna.
Long, Standard or Short Dipper

Refer to Section B, Body and Framework for dismantling
and assembly of Dipper.
Long or Short Dozer

Dozer blade length conversion.
Rubber or Steel Tracks

Refer to Section J, Track and Running Gear for removal
and replacement of tracks.
9803/3145 Issue 1
Section B Body & Framework Section B
i i
Contents Page No.
General Description .................................................................... 1 - 1
Bucket Linkage
- Removal and Replacement ........................................... 2 - 1
Bucket Ram Pivot and Linkage

Dipper
Boom
Upper Structure
- Dismantling and Assembly ............................................ 6 - 1
Kingpost
9803/3145 Issue 1
1-1 1-1
General Description
The Mini-Excavator body and framework is of fabricated steel construction and comprises the upper structure
and front attachment. The upper structure comprises a fabricated steel base that provides housing and mounting
for the machine controls and services above and below a floorplate. The machine cab is mounted on the
floorplate. The engine is mounted behind the cab. The front attachment comprises a bucket, dipper and boom
assembly attached to the front of the upper structure through a kingpost. The front attachment is pivoted on the
kingpost enabling movement right and left. The bucket dipper and boom are connected through pivots enabling
a full range of bucket, or other attachment operations
9803/3145 Issue 1
2-1 2-1
Front attachment
Bucket
Removal and Replacement
When Removing
1 Set up the machine in the posture shown, with the
bucket lightly grounded.
2 Shut down the machine and post WARNING notices

to prevent operation during maintenance.
3 Remove the lynch pins A. Drive out the bucket pivot

pins B.
4 Separate the bucket from the machine.
5 Check the wear on the bucket teeth. Remove and

renew as necessary.
9803/3145 Issue 1
2-2 2-2
Front attachment - cont.
Bucket
When Replacing
1 Check the bucket pivot pins and the bushing in the
bucket linkage are within the permitted tolerances.
Renew the pivot pins as necessary. Remove and
inspect the bucket ram pivot linkage before refitting
the bucket.
Tolerances - Pivot Pin/Pivot Bush
Pin Bush
Reference value 35mm 35mm I/D
Allowable limit 34mm 36mm I/D
2 Locate the bucket onto the dipper arm and adjust

to align the bores of the bucket bosses, the dipper
arm end boss and link.
WARNING
DO NOT align pivot pin holes with your fingers.
3 Fit the bucket pivot pins B and secure by fitting the

lynch pins A.
9803/3145 Issue 1
3-1 3-1
Bucket - Ram pivot and linkage
Removal
1 Remove the bucket.
2 Remove the self-locking nut C and the bolt D.

Support the link H. Drive out the pivot pin E and
remove the link H. Lower the piston rod end of the
bucket ram F clear of the link G.
3 Clean all old grease from the links G and H and

pivot pin E.
Inspection
1 Check that the link bushes and the pivot pin are
within permitted tolerances. Renew pivot pin and/
or remove and replace link bushes as necessary.
Tolerances - Pivot Pin/Pivot Bush

Pin Bush
Reference value 30 mm dia. 30 mm I/D

Allowable limit 29 mm dia. 31 mm I/D
Replacement
WARNING
DO NOT align pivot pin holes with your fingers.
1 Locate the fork end of the link H into the fork of the
dipper end link G. Locate the rod end of the bucket
ram F into the fork of the link H.
2 Fit the pivot pin E through both links and the ram
end. Secure using bolt D and new self-locking nut
C.
3 Grease the linkage through the grease nipple on

the ram end boss, for grease specification and
quantity see Section 3 1-2.
9803/3145 Issue 1
4-1 4-1
Dipper
Removal
1 Remove the bucket.
2 If necessary remove the bucket ram.
3 Remove the locknut A and bolt B. Drive out the
dipper ram pivot pin C. Separate the dipper ram
eye end D from the dipper pivot E. Position a block
of timber on which to rest the dipper ram eye end.
Note: The machine will be fitted with one of the three

dipper options. Apart from dimensions and weight the C A
removal/replacement sequence is identical.
4 Attach suitable lifting equipment through the dipper

ram pivot pin location and support the dipper J.
5 Remove the locknut F and the bolt G. Drive out the E B
pivot pin H.
6 Using suitable lifting equipment, remove the dipper
from the machine. D
Inspection
1 Check that the dipper pivot bushes and the pivot
pin are within permitted tolerances. Renew pivot
pin and/or remove and replace dipper pivot bushes
as necessary.
Tolerances
Pivot pin Pivot bush

Reference value 30mm dia. 30mm I/D
Allowable limit 29mm dia. 31mm I/D H
F
Overall Length Weight
802.7 1100 mm 55 kg
803 1400 mm 74 kg G
J
804 1400 mm 74 kg
804 1660 mm 84 kg
Replacement
1 Using suitable lifting equipment, locate the dipper
J onto the boom.
2 Fit the pivot pin H and secure with bolt G and a
new locknut F.
3 Locate the dipper ram end D into the dipper pivot H15680
E. Fit the pivot pin C and secure with the bolt B and
new locknut A.
4 Fit the bucket ram.
5 Fit the bucket.
9803/3145 Issue 2*
5-1 5-1
9803/3145 Issue 1
5-2 5-2
Boom
Removal Replacement
1 Remove the bucket, bucket link and dipper. Note: The boom weighs 100kg.
2 Remove the dipper and boom rams. 1 Using suitable lifting equipment, locate the boom
D onto the kingpost E.
3 Disconnect the hydraulic hoses at the base of the
boom. Blank off the open ends of hoses and pipes. 2 Fit the pivot pin C and secure with the bolt B and a
new locknut A.
4 Disconnect the boom working light harness.
3 Fit the dipper and boom rams.
Note: The boom weighs 100kg.
4 Fit the dipper, bucket link and bucket.
5 Attach suitable lifting equipment to the boom D and
take up the slack. 5 Remove the blanks and connect the hydraulic hoses
at the base of the dipper.
6 Remove the locknut A. Remove the bolt B and drive
out the pivot pin C. Remove the boom from the 6 Restore the hydraulic supply and set up the
machine. hydraulic circuit.
Inspection 7 Connect the boom working lights.

1 Check that the boom pivot bushes and the pivot
pin are within permitted tolerances. Renew pivot
pin and/or boom pivot bushes as necessary.
Tolerances
Pivot Pin Pivot Bush

Reference value 30 mm dia. 30 mm I/D
Allowable limit 29 mm dia. 31 mm I/D
2 Examine the boom structure for wear, damage or

corrosion. Renew as necessary.
9803/3145 Issue 1
6-1 6-1
Upper structure - all machines
Dismantling and Assembly
When Dismantling
Note: The upper structure encompasses all equipment
and structure located above the track and running gear
with the exception of the front end attachment.
1 Remove the excavator assembly. 11 Remove the track control lever(s), see B/6-3, step
2.
2 Disconnect the interior light and windscreen wiper
motor in the cab/canopy structure. 12 Remove the slew motor and gearbox and the valve
blocks, if required.
3 Remove the cab/canopy floor.
13 Remove the hydraulics from the rotary coupling.
4 Disconnect all electrical cables and hydraulic pipes
to the seat. 14 Remove the bolts from the rotary joint.
5 Remove the seat. 15 Remove the engine assembly, if necessary.
6 Drain and remove the fuel tank. 16 Attach lifting equipment to the upper structure
frame. Take up slack in the slings 17. Remove the
7 Remove the dozer control lever, see B/6-3, step 1. nuts A securing the upper structure frame to the
slew ring. Lift the upper structure frame clear of the
8 Drain the hydraulic system. Remove the hydraulic machine. Take care not to foul the rotary coupling.
pipework.
18 Remove the rotary coupling, if necessary. Remove
9 Remove the hydraulic tank. dowels D.
10 Disconnect the instrument panel electrical cables. 19 Remove the nuts B and the bolts E securing the
slew ring C to the machine undercarriage.
20 Remove the slew ring from the machine.
9803/3145 Issue 1
6-2 6-2
Upper Structure (cont'd)
Dismantling and Assembly (cont'd)
When Assembling
1 Fit the bolts F into the slew ring from below and fit
the slew ring to the machine, ensuring that the soft
spot (marked 'S') is towards the right hand side of
the machine. Line up dowel holes and fit dowels D.
2 Secure the slew ring using the nuts B and bolts E.
3 Fit the rotary coupling.
4 Refit the hydraulics to the rotary coupling if

necessary.
5 Refit and secure the upper structure.
6 If necessary, refit the engine assembly.
7 Refit the slew motor and gearbox. Refill the gearbox

with oil.
8 Refit the valve blocks if necessary.
9 Refit the hydraulic tank. Fit the hydraulic hoses as

necessary. Remake all hydraulic connections.
10 Top up the hydraulic tank.
11 Reconnect the machine electrics.
12 Refit the dozer control lever.
13 Refit the track control levers.
14 Refit the floor plate.
15 Refit and fill the fuel tank.
16 Refit and secure the seat assembly.
17 Connect the seat equipment electrical connections.
18 Refit the cab/canopy.
19 Connect the cab/canopy electrical cables.
20 Refit the excavator assembly.
9803/3145 Issue 1
6-3 6-3
Upper Structure, Control Mechanism -

all machines
When Removing When Replacing

1 Remove bolt H and nut J. Remove the dozer control 1 Replace the controls in reverse order of
lever G. disassembly
2 Remove bolts K and nuts L. Remove bolts N and 2 Set up the hydraulic system.
M.
3 Set up the control system by slackening locknuts
3 Remove the track control levers Q and P. R and adjusting rods S until all control levers are
set at 90O in both planes, to the line of the floor.
Inspection
1 Check all linkages for security and excessive 4 Fit and secure the floor plate(s) and seat.
movement.
2 Remove and replace defective components.
9803/3145 Issue 1
7-1 7-1
C
A
J
A
G
9803/3145 Issue 1
7-2 7-2
Kingpost
Removal Replacement
1 Remove the boom, ensure the boom working light 1 Clean paint and loose scale from the pin abutment
is disconnected. area J on both the upper and lower kingpost pivot
pins and from the kingpost abutment areas.
2 Remove both outer hose clamps A.
2 Using suitable lifting equipment, locate the kingpost
3 Remove the bolts securing the central hose clamp onto the mainframe, threading the hoses through
B. the centre of the kingpost.
4 Remove the swing ram locking plate C and drive 3 Fit both the lower and upper pivot pins, locating
out the rod side pivot pin. the abutment areas into the kinpost.
4 Fit the attaching parts to the upper and lower pivot

WARNING pins and torque tighten to 250 Nm (26 kgf m, 184
The kingpost weighs 42 kg. Take care when lift- lbf ft).
ing or handling it.
5 Fit the swing ram pivot pin and secure with the
5 Support the weight of the kingpost with suitable locking plate.
lifting equipment.
6 Arrange the boom hoses in the central kingpost
6 Undo the top mounting securing bolt D and washer clamp and tighten the clamp.
and remove them; drive out the upper pivot pin E
in a downward movement, avoiding contact with 7 Fit both the outer hose clamps.
the hydraulic hoses.
8 Fit the boom and working light.
7 Remove the king pin lower protective cap F.
8 Undo the lower mounting securing bolt and washer

G and remove; drive out lower pivot pin H in an
upward movement, avoiding contact with the
hydraulic hoses.
9803/3145 Issue 1
Section C Electrics Section C
i i
Contents Page No.
Technical Data .............................................................................. 1 - 1
Battery ........................................................................................... 2 - 1
Fan Belt ......................................................................................... 3 - 1
Alternator ...................................................................................... 4 - 1
Starter Motor ................................................................................. 5 - 1
Beacon .......................................................................................... 8 - 1
Circuit Diagram ........................................................................... 10 - 3
Wiring Harness (802.7 / 803) ...................................................... 10 - 5
Wiring Harness (804) .................................................................. 10 - 7
Harness Specifications ............................................................... 10 - 9
- Main Harness .................................................................. 10 - 10
- Radio Harness ................................................................ 10 - 16
- Cab Harness ................................................................... 10 - 17
- Instrument Panel Adaptor Harness ................................ 10 - 18
- Fuel Sender Adaptor Harness ........................................ 10 - 19
- Slew Frame to Cab Adaptor Harness ............................. 10 - 20
- Slew/Swing Change-over Harness ................................. 10 - 21
9803/3145 Issue 1
1-1 1-1
Technical Data
System Type 12Volt negative earth
Battery - Type 058, (802.7 / 803)

Type 643, (804)
Voltage 12V
Capacity 75 ampere/hour (Wet charged) 802.7 / 803
60 ampere/hour (Dry charged) 802.7 / 803
103 ampere/hour (Wet charged) 804
96 ampere/hour (Dry charged) 804
Specific Gravity (fully charged) Between 1.285 and 1.310 at 15°C
Bulbs
Function Rating
Cab lights 18W
Working lights 55W
Indicator N/A
Power N/A
Glowplug N/A
Working lights on/off (indication at switch ) 1.2W
Circuit Protection
The electrical circuits are protected by fuses located in a fuse box below the instrument panel, with an extra main
harness protection line mounted 50A fuse (clipped to the top of the engine rocker cover).
Fuse Circuit Rating

A Main harness (not shown) 50A
6 Horn, Beacon (optional), Radio (optional) 15A
5 Seat Microswitch, Slew/Swing,
Servo Supply Solenoid 5A
4 Working Lights 10A
Working Lights plus Cab Lights (optional) 20A 6
3 Wipers, Heater 15A 5
2 Instrument Panel (Hourmeter,
Engine Oil Pressure Switch, 4
Coolant Temperature Switch, 3
Blocked Air Filter Switch),
Two Speed Switch/Solenoid, 2
Auxiliary Power Socket (optional) 10A 1
1 Cab Light RADIO removed 5A
H50770
9803/3145 Issue 2*
2-1 2-1
Battery
Negative Earth Electrical System High Rate Discharge Test

1 Always connect the negative terminal of the battery This test is to determine the electrical condition of the
to EARTH. battery and to give an indication of the remaining useful
2 When connecting the battery, connect the earth lead ‘life’
LAST.
3 When disconnecting the battery, disconnect the Before testing, ensure that the battery is at least 75%
earth lead FIRST. charged.
Inspection 1 Disconnect both terminals of the battery.

Check the level of the electrolyte (low maintenance).
Make sure that the terminals are tight and clean. Coat 2 Adjust the discharge tester to 3 x amp/hour rating
them with petroleum jelly to prevent corrosion. of the battery.
Testing the Specific Gravity 3 Connect the tester to the battery terminals,
observing the polarity.
The specific gravity of the electrolyte gives an indication
of the state of charge of the battery. Readings should be
4 Note the voltmeter reading. The battery should be
taken using a hydrometer, when the electrolyte
capable of maintaining at least 9 volts for 1 0
temperature is 15°C (60°F). If the battery has recently
seconds. A rapidly falling voltage indicates a fault
been charged, wait approximately one hour, to dissipate
in one or more of the battery cells.
the ‘surface charge’ before testing.
Note: Do not leave the discharge tester connected to the
Readings should not vary between cells by more than
battery for longer than is necessary to complete the test.
0.04. A greater variation indicates an internal fault on
that particular cell.
If the electrolyte temperature is other than 15°C (60°F)

a 'correction factor’ must be applied to the reading
obtained. Add 0.0007 per 1°C higher than 15°C, and
subtract the same if the temperature is lower.
9803/3145 Issue 1
3-1 3-1
Fan belt
Removing, Inspection and Fitting
Removing Fitting
1 Park the machine on firm, level ground and remove 1 Install the fan belt so that it passes around the fan,
the starter key. crankshaft, water pump and alternator pulleys.
2 Open the engine cover. 2 Use a wooden lever and move the alternator away
from the engine block. Apply pressure at the drive
3 Remove the engine access panel. end bracket only.
3 Adjust the position of the alternator, so that when

WARNING
the belt is depressed at the mid-point C between
Make sure that the engine cannot be started. the crankshaft and alternator pulleys, the deflection
Disconnect the battery. Disconnect the earth lead is 5 mm (0.2 in). Use a finger force of approximately
first. 10 N (1 kgf, 0.51 lbf) for this check.
ENG 6-3
4 Tighten the mounting bolts A and the adjusting bolt

4 Loosen the alternator mounting bolts A and the
B.
adjusting bolt B.
5 Reconnect the battery. Connect the earth lead
5 Move the alternator towards the engine block.
last.
6 Remove the fan belt from the alternator pulley,
water pump pulley and the crankshaft pulley.
7 Remove the fan belt over the fan.
Inspection
1 Examine the fan belt and pulleys for damage.
Renew as necessary.
9803/3145 Issue 1
4-1 4-1
Alternator
Removing and Fitting
Removing Fitting
1 Raise the engine cover. 1 Put the alternator in position and align with the fan
belt.
2 Remove the interior access panel.
2 Fit the mounting nut A and bolt B and the adjusting
3 Disconnect the battery. Disconnect the earth lead bolts C.
first.
3 Adjust the fan belt tension, see page 5/7 - 3, and
4 Disconnect the electrical connections. tighten the mounting nut A and bolt B, and the
adjusting bolt C.
5 Support the alternator and remove the mounting
nut A and bolt B. 4 Connect the electrical connections.
6 Remove the adjusting bolt C. 5 Reconnect the battery. Connect the earth load
last.
7 Remove the alternator.
6 Refit the interior access panel.
7 Close the engine cover.
9803/3145 Issue 1
5-1 5-1
Starter Motor
Removing Refitting
1 Raise the engine cover. 1 Engage the starter pinion with the engine flywheel
Remove the interior access panel. gear teeth.
3 Disconnect the battery. Disconnect the earth lead 2 Support the starter A motor while refitting and
first. tightening the securing bolts B.
4 Disconnect the starter electrical connections. 3 Reconnect the starter motor electrical
connections.
5 Support the starter motor A, loosen and remove
the securing bolts B. 4 Refit and secure the access panel behind the driver’s
seat in the rear of the cab.
6 Disengage the pinion from the flywheel gear teeth
and remove the starter motor. 5 Reconnect the battery terminals.
Fitting 6 Close the rear engine cover.

1 Put the starter motor in position and align the pinion
in the flywheel gear teeth.
2 Fit and tighten the securing bolts B.
3 Connect the electrical connections.
4 Connect the battery terminals. Connect the earth

terminal last.
5 Fit the interior access panel.
6 Close the engine cover.
9803/3145 Issue 2*
5-2 5-2
Starter Motor (cont'd)
Inspection and Testing

1 Check torque settings for all connections, and
connections are free from contamination caused
by arcing or sparking, Clean and re-torque as
required.
Note: Do not over tighten connections, this could result

in damaged threads or internal damage to the starter
motor. B
CAUTION
Never remove the inner lock nut on either the Starter
Motor A or Solenoid B. Removal will cause permanent
internal damage to the Starter Motor and Solenoid.
2 If the starter will still not start, disconnect electrical

connections and remove the starter from the engine.
For the following tests, a 12V battery, (in a good state of

charge), two heavy duty battery jump leads fitted with
crocodile clips and a 5 amp lead, with open circuit in line A
push button switch are required.
H28000
3 Secure the motor in a vice or similar.
4 Connect the battery positive lead to the heavy duty

solenoid connection, using one of the battery jump
C
leads. Connect the second jump lead to the starter
motor case terminal and battery negative pole.
There should be NO operation of the starter motor,
if there is any buzzing, smoking or sparking from
the starter motor it is faulty and should be replaced.
5 With the existing connections in place, connect the

5 amp capacity wire between battery positive and
solenoid lucar blade.
Operate the push button switch C, the solenoid
should engage moving the starter pinion out.
The starter motor will rotate, releasing the push
button will allow the pinion to retract and the starter
to stop rotating.
If there is any abnormal noise, electrical buzzing,
smoke, the starter does not rotate or the pinion does
not move forward or back, the starter motor is faulty
and should be replaced.
If the starter motor operates correctly investigate the

machine electrical system.
H28010
9803/3145 Issue 2*
8-1 8-1
Beacon
Mounting
The rotating beacon relies on the force of a magnet to
hold it in position on the machine. A cable and plug from
the beacon fits into a socket located on a panel in the cab
of the machine. The panel is wired to provide a beacon
operating switch and warning light.
The intended beacon mounting position must be flat,

clean and dry. When mounted, particularly ensure beacon
positioning conforms to the following:
- Is in accordance with National and local legal
requirements.
- The light is visible from any point at a reasonable
distance from the machine.
- Beacon base parallel to the ground and on the
machine longitudinal centre line.
- If radio equipment is fitted to the machine, there
should be a minimum distance of 500 mm (20
in.) between the beacon and the radio antenna.
CAUTION
The beacon must be removed before the machine is
towed or loaded onto a trailer for towing. The
beacon must not be fitted if the machine is moved at
speeds exceeding 80 kph (50 mph).
Bulb Change
1 Remove the lens latch locking screw A.
2 Push down the lens latch B. Turn lens C anti-

clockwise to release and remove it.
3 Taking care not to touch the bulb glass, release the

bulb retaining clip D and lift bulb E and attached
clip from the connector F. Disconnect bulb E.
4 Remove the unserviceable bulb from clip D.
5 Fit a new bulb and assemble the beacon in reverse

order of dismantling. Do not tighten the lens latch
locking screw A to more than 0.65Nm (5.75 lbf in.).
Note: Ensure the drive motor is fitted with the red pulley
for correct operation on 12V systems.
9803/3145 Issue 1
10 - 3 10 - 3
1 35 36
34
9 10
3
51
2 7 11
5B
40 12
6
52
41 13
4
42 14
43 15
8 8 8
44
5
45 16
17
F1
F2
F3
19
F4
F5 18
F6 M
22 21
20
23
48
46
47
49
50
25 26
27 28A
30 28B
29
32
31 H03661
9803/3145 Issue 1
10 - 4 10 - 4
Circuit diagram
Main Components Lamps

1 Battery 40 Alternator Warning
2 Alternator 41 Engine Oil Pressure Warning
3 Starter Motor 42 Engine Coolant Temperature Warning
4 Starter Switch 43 Blocked Air Filter Warning
5 Fuse Block 44 Glowplug Warning
5B 50 amp Main Harness Fuse 45 Interior
6 Warning Buzzer 46 Boom
7 Diode Bank 47 Mainframe working (if fitted)
8 Glow Plugs 48 Working Light Switch
9 Fuel Gauge 49 Cab Roof - Optional
10 Fuel Gauge Sender 50 Cab Roof - Optional
11 Fuel Solenoid 51 Fuel Gauge
12 Hourmeter 52 Hourmeter
13 Engine Oil Pressure Switch 53 Low hydraulic temperature warning (804 m/c
14 Engine Coolant Temperature Switch only)
15 Blocked Air Filter Switch
16 Radio - Optional
17 Interior Light Switch
18 Windscreen Wiper Motor
19 Wiper Motor Parking Switch
20 Heater Motor
21 Resistor
22 Heater Switch
23 Working Light Switch
25 Seat Microswitch
26 Servo Supply Solenoid
27 Slew/Swing Switch
28A Swing Solenoid
28B Swing Solenoid
29 Horn Switch
30 Horn
31 Low hydraulic oil temperature sender (804 m/c only)
32 Beacon
34 Cigarette Lighter
35 Two Speed Switch
36 Two Speed Solenoid
9803/3145 Issue 1
10 - 5 10 - 5
22 124 R CAB CONNECTOR

45 39B 22 BL
45 R/GN
35 65 35 R/BL
40 R/BN
40 70 124 GN
39B BL/BK
65 BK
70 BK
34 41 61
63 8
39
44
SP11 39B 69
41
71 66A
81 82
32, 33 19
36 18
31 17
23, 24 16
SP8 25, 37 15
POSITION 1, 42 GR/BK SP5 13, 15, 16, 17 22 5
POSITION 2, 64 BK 10, 60, 61, 62 18, 19, 20, 21
63, 64, 65, 66
66A, 67, 68, 70,
46/47 GN/BL
73, 74, 260, 262,
48/49 W/BN 272
50 BN/PK
51/52 LT.GN/R
66 BK 43 W/OR
67 BK 53 BN/BK
54 GN 32 262
8 BL/BK 48 51 56 59 74 82
26 GN 49 52 53 80
20 43 73
66,67,54,8,42,26
46 50 43
SP7 35, 36
47
SP9 38 272
25, 26 138 60 138
54, 80 238 38
34
81
SP10
33 7,7a,9 260 238
12,12a
55 56
13
52,72,9,47,-,49,-,50 4
12
AIR CLEANER 52 LT.GN/RED 6 4a
GLOW PLUG 72 BK 12a
GLOW PLUG 9 BN/BL 14
WATER TEMP 47 GN/BL 14a
ENGINE OIL 49W/GN
ALTERNATOR WARNING 50 BN/PK 3
23 45 3a
44 24/124
71 68 69 35 SP1
31 39 1,2,4,4a
72 40
45 R/GN 5,14,14a
71 BL/BK 24/124 GN
39 BL/BK 68/72 BK 69 GN/GY
35 R/BL
23 GN
40 R/GN
44 GN/Y
46
48
10
7 3 1, 2
58
7a 3a 53 21
59 6
58
37 H18560
51
9803/3145 Issue 2*
10 - 6 10 - 6
Wiring Harness - 802.7 / 803
1 Starter Motor Feed to SP1 46 Engine Coolant Temperature Switch to Diode

2 Starter Motor Feed to SP1 Connector
3 Starter Solenoid to Fuse 47 Engine Coolant Warning Lamp to Diode
3a Starter Solenoid to Fuse Connector
4 Ignition Switch to SP1 48 Engine Oil Pressure Switch to Diode Connector
4a Ignition Switch to SP1 49 Engine Oil Pressure Warning Lamp to Diode
5 Fuse Block to SP1 Connector
6 Ignition Switch to Starter Solenoid 50 Alternator Warning Lamp to Diode
7 Glow Plug to SP10 Connector
7a Glow Plug to SP10 51 Blocked Air Filter Switch to Diode
8 SP11 to Instrumentation Illumination Connector
9 Glow Plug Warning Lamp to SP10 52 Blocked Air Filter Warning Lamp to Diode
10 Earth to SP5 Connector
12 Ignition Switch to SP10 53 Alternator to Diode Connector
12a Ignition Switch to SP10 54 Hour Meter to SP9
13 Ignition Switch to SP8 55 Slew/Swing Switch to Seat Micro - Switch
14 Fuse to SP1 56 Seat Micro - Switch to Servo Supply Solenoid
14a Fuse to SP1 58 Blocked Air Filter Switch to Earth
15 Fuse Block to SP8 59 Pilot Solenoid to Earth
16 Fuse Block to SP8 60 Swing Solenoid to SP5
17 Fuse Block to SP8 61 Boom Lamp to SP5
18 Fuse Block to SP8 62 Tube to Earth
19 Fuse Block to SP8 63 Horn to SP5
20 Warning Buzzer to SP8 64 Fuel Gauge Sender to SP5
21 Alternator to SP8 65 Cab Connector to SP5
22 Fuse Block to Cab Connector 66 Hour Meter to SP5
23 Fuse Block to Blower Motor 66A Heater to SP5
24 Fuse Block to Wiper Motor 67 SP5 to Instruments
25 Fuse Block to SP9 68 SP5 to Boom Lamp Warning System
26 Fuel Gauge to SP9 69 Heater to Blower Motor
31 Boom Lamps To Fuse Block 70 Cab Connector to SP5
32 Fuse Block to Beacon Feed 71 Boom Lamp Warning System to Boom Lamp
33 Fuse Block to Horn Feed Relay
34 Horn to Horn Switch 72 Glow Plug Lamp to Boom Lamp Warning
35 Wiper Motor to Cab Connector System
36 Fuse Block to Slew/Swing Switch 73 Cigarette Lighter to SP5
37 Fuse Block to Fuel Solenoid 74 2 - Speed Solenoid to SP5
38 Slew/Swing Switch to SP7 80 Cigarette Lighter to SP9
39 Boom lamps to SP11 81 2 - Speed Switch to SP9
39B SP11 to Cab Connector 82 2 - Speed Switch to 2 - Speed Solenoid
40 Wiper to Cab Connector 124 Cab Connector to Wiper Motor
41 Boom Lamps to SP11 138 Swing Solenoid to SP7
42 Fuel Gauge to Fuel Gauge Sender 238 Swing Solenoid to SP7
43 Diode Connector to Warning Buzzer 260 Swing Solenoid to SP5
44 Blower Motor to Heater 262 Beacon Feed to SP5
45 Windscreen Wiper Motor to Cab Connector 272 Slew Swing Switch to SP5
9803/3145 Issue 1
10 - 7 10 - 7
9803/3145 Issue 1
10 - 8 10 - 8
Wiring Harness - 804
1 Starter Motor Feed to SP1 44 Blower Motor to Heater

2 Starter Motor Feed to SP1 45 Windscreen Wiper Motor to Cab Connector
3 Starter Solenoid to Fuse 46 Engine Coolant Temperature Switch to Diode
3a Starter Solenoid to Fuse Connector
4 Ignition Switch to SP1 47 Engine Coolant Warning Lamp to Diode
4a Ignition Switch to SP1 Connector
5 Fuse Block to SP1 48 Engine Oil Pressure Switch to Diode Connector
6 Ignition Switch to Starter Solenoid 49 Engine Oil Pressure Warning Lamp to Diode
7 Glow Plug to SP10 Connector
8 Glow Plug to SP10 50 Alternator Warning Lamp to Diode Connector
9 Glow Plug Warning Lamp to SP10 51 Blocked Air Filter Switch to Diode Connector
10 Earth to SP5 52 Blocked Air Filter Warning Lamp to Diode
11 Fuse to SP1 Connector
11a Fuse to SP1 53 Alternator to Diode Connector
12 Ignition Switch to SP10 54 Hour Meter to Alternator Warning Lamp
12a Ignition Switch to SP10 55 Slew/Swing Switch to Seat Micro - Switch
13 Ignition Switch to SP8 56 Seat Micro - Switch to Servo Supply Solenoid
14 Ignition Switch to SP8 58 Blocked Air Filter Switch to Earth
15 Fuse Block to SP8 59 Pilot Solenoid to Earth
16 Fuse Block to SP8 60 Swing Solenoid to SP5
17 Fuse Block to SP8 61 Boom Lamp to SP5
18 Fuse Block to SP8 62 Tube to Earth
19 Fuse Block to SP8 63 Horn to SP5
20 Warning Buzzer to SP8 64 Fuel Gauge Sender to SP5
21 Alternator to SP8 65 Cab Connector to SP5
22 Fuse Block to Cab Connector 66 Hour Meter to SP5
23 Fuse Block to Blower Motor 66A Heater to SP5
24 Fuse Block to Wiper Motor 67 Fuel Gauge to Hour Meter
25 Fuse Block to SP9 68 Fuel Gauge to Boom Lamp Warning System
26 Fuel Gauge to SP9 69 Heater to Blower Motor
27 Water Temperature Lamp to SP9 70 Cab Connector to SP5
28 Engine Oil Lamp to SP9 71 Boom Lamp Warning System to Boom Lamp
29 Alternator Warning Lamp to SP9 Relay
30 Air Cleaner Lamp to SP9 72 Glow Plug Lamp to Boom Lamp Warning
31 Boom Lamps To Fuse Block System
32 Fuse Block to Beacon Feed 73 Cigarette Lighter to SP5
33 Fuse Block to Horn Button 74 2 - Speed Solenoid to SP5
34 Horn to Horn Button 80 Cigarette Lighter to SP9
35 Wiper Motor to Cab Connector 81 2 - Speed Switch to SP9
36 Fuse Block to Slew/Swing Switch 82 2 - Speed Switch to 2 - Speed Solenoid
37 Fuse Block to Fuel Solenoid 124 Cab Connector to Wiper Motor
38 Slew/Swing Switch to SP7 138 Swing Solenoid to SP7
39 Boom lamps to SP11 238 Swing Solenoid to SP7
39B SP11 to Cab Connector 260 Swing Solenoid to SP5
40 Wiper to Cab Connector 262 Beacon Feed to SP5
41 Boom Lamps to SP11 270 Boom Boost Switch to SP5
42 Fuel Gauge to Fuel Gauge Sender 271 Boom Boost Switch to SP12
43 Diode Connector to Warning Buzzer 272 Slew Swing Switch to SP5
273 SP12 to Fuse Block
9803/3145 Issue 1
10 - 9 10 - 9
8 4 2
MZ 7 3 MN
NF MP 6 2
1
5 1
NH
NJ
2
1
MY
NA 1
1 2
2 3 MR
3 4
4 5 2
2
5 6 1
1
6 7
8
MM
NC
2
8 6 42
NE 1
MT 7 5 31 ML
8 6 42
MU 7 5 31
NB
10 8 6 42
6 3
9 7 5 31
5 2
4 1
MV
1 1U
MX 2 2U
3 3U
4 4U
5 5U
ND 6 6U
B
NM A
MS
NL
B
A
3
2
1
MD
MF
ME
MC
B B 1
A A MB 60A
2
NR NK
MA
MJ
MG
MH
2
1 NS
H27570
9803/3145 Issue 1*
10 - 10 10 - 10
Harness specifications
Main Harness
Refer to the Reference Tables on Page 10-14 for the Unit Items, Related Items and wire colour information.
Unit Wire ID No Plug Plug Wire Wire Related

(Unit Items) (Colour) ID Terminal Size Destination Items
Maxi-Fuse 3 (N) MA 1 6.0 MB1 -

(AY) 14 (N/R) 2 6.0 S1 -
Starter Solenoid 3 (N) MB 1 6.0 MA1 M,BP
Starter Solenoid 6 (W/R) MC 1 3.0 MX4 C

(D, E)
Alternator (N, P) 1 (N) MD 1 4.0 S1 R

2 (N) 2 4.0 S1 R
53 (N/B) 3 1.0 NB6 S
Temp Sender 46 (G/U) ME 1 1.0 S8 BG

(BH)
Earth Ring 10 (B) MF 1 6.0 S5 M,K
Fuel Cut-off 37 (W/G) MG 1 1.0 S12 A,D,E
Glow Plug 7 (N/R) MH 1 4.0 S9 L,K
Oil Pressure 48 (W/N) MJ 1 1.0 S10 G,H
Fuel Sender 42 (G/B) ML 1 1.0 NA2 AW,AX

(AV) 64 (B) 2 1.0 S5 AW,AX
Boom Light 41 (U/B) MM 1 1.4 S7 Z,AA

(AB, AC) 61 (B) 2 1.4 S5 Z,AA
Horn (AZ,BA) 34 (P/B) MN 1 1.4 MZ2 BB,BC

63 (B) 2 1.4 S5 BB,BC
Cab Connector 22 (U) MP 1 1.4 MS1U Z,AA

(X,Y) 45 (R/G) 2 1.4 MT1 Z,AA
35 (R/U) 3 1.4 MT5 Z,AA
40 (R/N) 4 1.4 MT7 Z,AA
124 (G) 5 1.4 S13 Z,AA
39B (U/B) 6 1.4 S7 Z,AA
65 (B) 7 2.0 S5 Z,AA
70 (B) 8 2.0 S5 Z,AA
Dozer Lever MR 1 1.0 S12 V,W

(2 Speed) 2 1.0 NKA V,W
(AB, AC)
9803/3145 Issue 1*
10 - 11 10 - 11
Main Harness - cont'd

Fuse Box 5 (N) MS 1 1.4 S1 BE

(AG, AH) 22 (U) 1U 1.4 MP1 BE
15 (W) 2 1.0 S6 BD
25 (G) 2U 1.0 S12 BD
16 (W) 3 2.0 S6 BE
24A (G) 3U 2.0 S13 BE
17 (W) 4 2.0 S6 BD
31 (P) 4U 2.0 MV5 BD
18 (W) 5 2.0 S6 BE
36A (W/G) 5U 2.0 S4 BE
19 (W) 6 2.0 S6 BE
32 (P) 6U 1.0 ND1 BF
33 (P) 1.4 MZ1 BF
Wiper Switch 45 (R/G) MT 1 1.4 MP2 AP

(AM) - 2 - - -
24 (G) 3 1.4 S13 AP
- 4 - - -
35 (R/U) 5 1.4 MP3 AP
- 6 - - -
40 (R/N) 7 1.4 MP4 AP
- 8 - - -
Blower Switch 69 (G/S) MU 1 1.4 NE2 AP

(AM) - 2 - - -
23 (G) 3 1.4 S13 AP
- 4 - - -
44 (G/Y) 5 1.4 NE3 AP
- 6 - - -
- 7 - - -
- 8 - - -
Boom Lights 39 (U/B) MV 1 2.0 S7 AP

(AM) - 2 - - -
- 3 - - -
- 4 - - -
31 (P) 5 2.0 MS4U AP
- 6 - - -
- 7 - - -
- 8 - - -
Boom Lights 71 (U/B) 9 0.6 S7 AN

(Warning) (AL) 68 (B) 10 0.6 S5 AN
Ignition Switch 4 (N) MX 1 6.0 S1 J,K

13 (W) 2 3.0 S6 C,D
12 (N/R) 3 4.0 S9 J,K
6 (W/R) 4 3.0 MC1 C,D
9803/3145 Issue 1*
10 - 12 10 - 12
Refer to the Reference Tables on Page 10-14 for the Unit Items, Related Items and Wire Colour information.

Indicator Lamps 50 (N/K) MY 1 0.6 NB3 AU

(AT) - 2 - - -
49 (W/N) 3 0.6 S10 AU
- 4 - - -
47 (G/U) 5 0.6 S8 AU
9 (N/R) 6 0.6 S9 AU
72 (B) 7 0.6 S5 AU
52 (LG/R) 8 0.6 S11 AU
Horn Button 33 (P) MZ 1 1.4 MS6U B

(D) 34 (P/B) 2 1.4 MN2 B
Fuel Gauge/ 26 (G) NA 1 0.6 S12 AU

Hourmeter (AS) 42 (G/B) 2 1.0 ML1 AU
8 (U/B) 3 0.6 S7 AU
54 (G) 4 0.6 S12 AU
67 (B) 5 0.6 S5 AU
66 (B) 6 0.6 S5 AU
Diode Connector 46A (G/U) NB 1 0.6 S8 V,W

(T, U) 48A (W/N) 2 0.6 S10 V,W
50 (N/K 3 0.6 MY1 V,W
51A (LG/R) 4 0.6 S11 V,W
43 (W/O) 5 0.6 NC1 V,W
53 (N/B) 6 1.0 MD3 V,W
Buzzer 43 (W/O) NC 1 0.6 NB5 E,F

20 (G/N) 2 0.6 S12 A,D
Beacon Feed 32 (P) ND 1 1.0 MS6U A,D

262 (B) 2 1.0 S5 A,D
Heater 66A (B) NE 1 1.4 S5 B,D

69 (G/S) 2 1.4 MU1 B,D
44 (G/Y) 3 1.4 MU5 B,D
Cigarette Lighter 73 (B) NF 1 1.4 S5 B,D

80 (G) 2 1.4 S4 B,D
Slew Swing Switch 36 (W/G) NH 1 1.0 S4 B,D,E

38 (W/G) 2 1.0 S3 B,D,E
272 (B) 3 1.0 S5 A,D,E
Micro Switch 55 (B/R) NJ 1 1.0 S4 V,W

(AB, AC) 56 (B/R) 2 1.0 NRA V,W
Solenoid (2 Speed) 82 (W/U) NK A 1.0 MR2 BJ,BK

(AF) 74 (B) B 1.0 S5 BJ,BK
Swing Solenoid 138 (W/G) NL A 1.0 S3 BJ,BK

(AF) 60 (B) B 1.0 S5 BJ,BK
Swing Solenoid 238 (W/G) NM A 1.0 S3 BJ,BK

(AF) 260 (B) B 1.0 S5 BJ,BK
9803/3145 Issue 1*
10 - 13 10 - 13

Pilot Solenoid (AF) 56 (B/R) NR A 1.0 NJ2 BJ,BK

59 (B) B 1.0 S5 BJ,BK
Air Filter (AV) 51 (LG/R) NS 1 1.0 S11 AW,AX

58 (B) 2 1.0 S5 AW,AX
9803/3145 Issue 1*
10 - 14 10 - 14

Reference Table - Unit and Related Items
Item Description Item Description

Ref. Ref.
A Faston Terminal, 6.35 mm (0.35 - 1.0 mm²) BA Econoseal Socket Housing Retainer,
B Faston Terminal, 6.35 mm (1.0 - 3.0 mm²) Two Way
C Faston Terminal, 6.35 mm (3.0 - 5.0 mm²) BB Econoseal Socket Terminal,
D Individual Faston Housing Block (0.75 - 2.0 mm²)
E Cover for 6.35 mm Tab BC Econoseal Cable Seal, 2.0 mm²,
F Male Tab Terminal, 6.35 mm (0.6 - 3.0 mm²) Max Ins, 2.7 mm dia.
G Ring, 4.3 mm dia. 0.5 - 1.0 mm² CSA BD Fusebox Terminal, 6.35 mm
H Heatshrink Sleeve, 30 mm x 6.4 mm BE Fusebox Terminal, 6.35 mm
J Fastin Terminal, 9.5 mm (2.0 - 6.0 mm²) BF Fusebox Terminal, 6.35 mm
K Heatshrink Sleeve, 12/4 x 40 mm BG Socket Terminal, 4.0 mm
L Ring, 5.4 mm dia. 2.5 - 6.0 mm² CSA BH Socket Terminal Cover, 4.0 mm
M Ring, 10.5 mm dia. 6.0 - 10.0 mm² CSA BJ W/pack Cable Entry Seal, 1.0 - 2.0 mm
N Alternator Housing, Left Hand, Three Way BK W/pack Pin Terminal, 1.0 - 3.0 mm
P Alternator Housing Cover BP Heatshrink Sleeve, Red, 12/4 x 40 mm
R Fastin-Faston Terminal, 90 deg., 9.5 mm
(3.0 - 4.5 mm²) Reference Table - Wire Colours
S Fastin-Faston Terminal, 90 deg., 6.3 mm
(0.65 - 1.0 mm²) Wire Code Wire Colour
T Socket Housing, Six Way, HW090
U Socket Retainer, Six Way, HW090 N Brown
V Socket Terminal, HW090, 0.3 - 1.25 mm N/R Brown/Red
W Blue Cable Seal, 1.4 - 2.2 mm OD N/B Brown/Black
X Socket Housing, Eight Way, HW090 N/K Brown/Pink
Y Socket Retainer, Eight Way, HW090 G Green
Z Socket Terminal, HW090, 1.4 - 2.0 mm G/ Green/Black
AA Brown Cable Seal, 2.2 - 2.9 mm OD G/U Green/Blue
AB Socket Housing, Two Way, HW090 G/S Green/Slate (Grey)
AC Socket Retainer, Two Way, HW090 G/Y Green/Yellow
AF W/Pack Shd Housing 10, Two Way G/N Green/Brown
AG Fusebox Housing, Six Way LG/R Light Green/Red
AH Fusebox Cover, Six Way U Blue
AL Illumination Housing, Two Way U/B Blue/Black
AM Switch Base, Eight Way W White
AN Fastin-Faston Terminal, 6.35 mm W/G White/Green
0.5 - 1.0 mm², LIF W/N White/Brown
AP Fastin-Faston Terminal, 6.35 mm W/U White/Blue
0.8 - 2.0 mm², LIF W/R White/Red
AS PCB 3.96 mm Pitch Connector, W/N White/Brown
Female, Six Way W/O White/Orange
AT PCB 3.96 mm Pitch Connector, P Purple
Female, Eight Way P/B Purple/Black
AU Terminal, Female, 3.96 and 5.08 Pitch B Black
AV Junior Timer Socket Housing with A/B Block, B/R Black/Red
Two Way R/G Red/Green
AW Junior Timer Socket Terminal R/U Red/Blue
AX Cable Entry Seal, Junior Timer R/N Red/Brown
AY Maxi-Fuse Kit, 60 Amp
AZ Econoseal Socket Housing, Two Way
9803/3145 Issue 1*
10 - 15 10 - 15
8 7 8 7
AD 6 5
3
6 5
AC AA BEACON POWER
4 4 3
2 1 2 1
TERM WIRE SIZE DEST TYPE
1 32P 1,0 AC7 L,M
32AP 1,0 AB1
2 262B 1,0 AC8 L,M
262AB 1,0 AB2
AB BEACON
1 32AP 1,0 AA1 N,P
AA 2 262AB 1,0 AA2 N,P
AC RADIO POWER A
1 - - - -
2 - - - -
3 - - - -
AB 4 - - - -
5 - - - -
4 2
AE 6 - - - -
3 1
7 32P 1,0 AA1 C
8 262B 1,0 AA2 C
3 1 AD RADIO SPEAKERS B
4 2
AF
1 - - - -
2 - - - -
3 860 1,0 AE1 C
4 602 1,0 AE2 C
5 859 1,0 AE3 C
6 601 1,0 AE4 C
7 - - - -
AG 8 - - - -
AE SPEAKER SOCKET D,E

1 860 1,0 AD3 H,K
2 602 1,0 AD4 H,K
3 859 1,0 AD5 H,K
4 601 1,0 AD6 H,K
AF SPEAKER PLUG F,G

AH 1 860 1,0 AG1 J,K
2 602 1,0 AG2 J,K
3 859 1,0 AH1 J,K
RHS LHS
SPEAKER SPEAKER 4 601 1,0 AH2 J,K
AG RHS SPEAKER
860 602 859 601
1 860 1,0 AF1 N,P
32P 262B 2 602 1,0 AF2 N,P
32AP 262AB
32P 262B 32AP 262AB
AH LHS SPEAKER
3 4 5 6 7 8 1 2 1 2
RADIO RADIO BEACON BEACON
SPEAKER POWER POWER 1 859 1,0 AF3 N,P
CIRCUIT DIAGRAM 2 601 1,0 AF4 N,P
9803/3145 Issue 1*
10 - 16 10 - 16
Harness Specifications
Radio Harness
Item Reference Table
Item Ref. Description
A Radio Power Plug

B Radio Speaker Plug
C Socket Terminal
D Socket Housing, Four Way
E Socket Retainer, Four Way
F Pin Housing, Four Way
G Pin Retainer, Four Way
H Socket Terminal, 0.3 - 1.25 mm
J Pin Terminal, 0.3 - 1.25 mm
K Wire Seal (Blue)
L Faston Tab Terminal, 6.3 mm
M Housing Shroud
N Pos-Lok Receptacle, 6.3 mm
(0.6 - 2.0 mm)
P Pos-Lok Sleeve
9803/3145 Issue 1*
10 - 17 10 - 17
Harness Specifications - cont'd

Cab Harness
DC
2 1
DD 4 3 DE
DA
DB 12 3 4
56 7 8
H27580
DE WIPER MOTOR DD WORKLIGHT CONN.

TERM WIRE SIZE DEST TYPE TERM WIRE SIZE DEST TYPE
1 600T 1,0 SA K,N 1 225C 2,0 DA5 J,M
2 600R 2,0 DA8 J,M
DB INTERIOR LIGHT DA UPPER CAB CONN. A,B

1 208 1,0 DA1 H,J 1 208 1,0 DB1 C,D
2 600P 1,0 SA H,J 2 832 1,0 DC2 C,D
3 217 1,0 DC1 C,D
DC WIPER MOTOR 4 833 1,0 DC3 C,D
TERM WIRE SIZE DEST TYPE 5 225C 2,0 DD1 E,F
1 217 1,0 DA3 L 6 45 1,0 DC4 C,D
2 832 1,0 DA2 L 7 600N 1,0 SA C,D
3 833 1,0 DA4 L 8 600R 2,0 DD2 E,F
4 45 1,0 DA6 L
SA
EARTH SPLICE
WIRE SIZE DEST.
Item Ref. Description 600N 1,0 DA7
600P 1,0 DB2
A Pin Housing, Eight Way
B Pin Retainer, Eight Way 600T 1,0 DE1
C Wire Seal (Blue)
D Pin Terminal, 0.3 - 1.25 mm
E Pin Terminal, 2.0 mm
F Wire Seal (Brown)
G Fastin-Faston Housing, Four Way
H Pos-Lok Terminal, 6.3 mm (0.5 - 1.0 mm)
J Pos-Lok Single Housing
K Ring Terminal, M5
L Fastin-Faston Terminal, 6.3 mm
(0.5 - 1.0 mm)
M Pos-Lok Terminal, 6.3 mm (1.4 - 2.0 mm)
N Heatshrink Sleeving
9803/3145 Issue 1*
10 - 18 10 - 18

Instrument Panel Adaptor Harness
AA
AC
87 65 432 1
7 8 9 10 11 12
1 2 3 4 5 6
65 432 1
AB
H27600
AA PANEL IND. LAMPS A AC NEW PANEL C

1 50 0,6 AC9 F 1 26 0,6 AB1 E
2 - - - - 2 66 0,6 AB6 E
3 49 0,6 AC7 F 3 - - - -
4 - - - - 4 42 0,6 AB2 E
5 47 0,6 AC10 F 5 - - - -
6 9 0,6 AC8 F 6 54 0,6 AB4 E
7 - - - - 7 49 0,6 AA3 E
8 52 0,6 AC11 F 8 9 0,6 AA6 E
9 50 0,6 AA1 E
10 47 0,6 AA5 E
AB PANEL FUEL/HOUR B 11 52 0,6 AA8 E
TERM WIRE SIZE DEST TYPE 12 - - - -
1 26 0,6 AC1 F
2 42 0,6 AC4 F
3 - - - -
4 54 0,6 AC6 F
5 - - - -
6 66 0,6 AC2 F
A Friction Lock Header, Eight Way

B Friction Lock Header, Six Way
C Mini-Fit Receptacle, 12 Way
E Mini-Fit Female Terminal (5556)
F Heatshrink Sleeving, Adhesive Lined
9803/3145 Issue 1*
10 - 19 10 - 19
Fuel Sender Adaptor Harness
AA 2 1 2 1 AB
H27620
AA FUEL SENDER A,B AB MAIN HARNESS E,F

1 408 1,0 AB1 C,D 1 408 1,0 AA1 G
2 600 1,0 AB2 C,D 2 600 1,0 AA2 G
A Econoseal Socket Housing, Two Way

B Econoseal Socket Retainer, Two Way
C Econoseal Socket Terminal,
0.75 - 2.0 mm
D Econoseal Cable Seal
E Junior Timer Pin Housing, Two Way
F Heatshrink Sleeving, Adhesive Lined
G Junior Timer Pin Terminal
9803/3145 Issue 1*
10 - 20 10 - 20
Slew Frame to Cab Adaptor Harness
1 2 3 4 4 3 2 1
NA NB
5 6 7 8 8 7 6 5
H27590
NA PLUG A,B NB SOCKET C,D

1 22U/208 1,0 NB1 J,L 1 22U/208 1,0 NA1 K,L
2 45 1,0 NB6 J,L 2 35RU/832 1,0 NA3 K,L
3 35RU/832 1,0 NB2 J,L 3 124G/217 1,0 NA5 K,L
4 40RN/833 1,0 NB4 J,L 4 40RN/833 1,0 NA4 K,L
5 124G/217 2,0 NB3 J,L 5 39BU/225 2,0 NA6 E,G
6 39BU/225 1,0 NB5 E,F 6 45 1,0 NA2 K,L
7 65B/600N 1,0 NB7 J,L 7 65B/600N 1,0 NA7 K,L
8 70B/600R 2,0 NB8 E,F 8 70B/600R 2,0 NA8 E,G
A Pin Housing, Eight Way

B Pin Retainer, Eight Way
C Socket Housing, Eight Way
D Socket Retainer, Eight Way
E Wire Seal (Brown)
F Pin Terminal, 2.0 mm
G Socket Terminal, 2.0 mm
H Dummy Terminal
J Pin Terminal, 1.0 mm
K Socket Terminal, 1.0 mm
L Wire Seal (Blue)
9803/3145 Issue 1*
10 - 21 10 - 21
Slew/Swing Change Over Harness
Wire identification
There are two types of latching relays fitted to the slew/
swing switch in the left hand console. One has coloured
wires and the other has yellow coded wires. The wires
are arranged in two groups of three. It is important that
the wires are identified and fitted correctly when replacing/
refitting.
Coloured wires Yellow wires (codes)
Black 1-B
Yellow 3-Y
Green/White 4-G/W
Red 8-R
Blue 7-U
Yellow 9-Y
9803/3145 Issue 1*
Section D Controls Section D
i i
Contents Page No.
Servo Hand Controllers
- Description and Operation ............................................... 4 - 1
- Port Identification ............................................................. 4 - 3
- Switchable ISO/SAE Mode .............................................. 4 - 4
- Changing the Excavator Control Mode ............................ 4 - 5
Track Levers ......................................................... See section B 6 - 3
Dozer Lever ........................................................... See section B 6 - 3
9803/3145 Issue 2*
Section D Controls Section D
4-1 4-1
T P
2 3 4
1
12
9
10
11
4 3
T 6
1 2
9803/3145 Issue 1
Section E Hydraulics Section E
i i
Contents Page No.
Technical Data ....................................................................................... 1 - 1
Hydraulic Circuit (Schematic) 802.7 / 803 .............................................. 2 - 2

Hydraulic Circuit (Schematic) 803 Super / 804 ...................................... 2 - 4
Servo Circuit
Description .................................................................................... 2 - 10
Hydraulic System
General Fault Diagnosis ......................................... ...................... 3 - 1
Hydraulic Pump 802.7 / 803

Operation ........................................................................................ 4 - 1
Hydraulic Pump 804
Operation ........................................................................................ 4 - 3
Track Motor
Description and Operation .............................................................. 5 - 2
Slew Motor
Description ...................................................................................... 6 - 1
Hydraulic Pump(s)
Flow Testing .................................................................................... 7 - 2
Removal and Replacement ............................................................. 7 - 4
Hydraulic Pump 804
Removal and Replacement ............................................................. 7 - 6
Dismantling and Assembly .............................................................. 7 - 8
Hydraulic Pump 803 Super / 804
Dismantling and Assembly ............................................................ 7 - 10
Track Motor
Dismantling and Assembly .............................................................. 8 - 1
Control Valves, MRV and Spool Locations .......................................... 12 - 2

Control Valve(s)
Removal and Replacement ........................................................... 12 - 4
Control Valve Sections

Main Relief Valves

Servo Relief Valve

Dipper Boost Dump Valve

Auxiliary Relief Valve

Removal, Dismantling and Assembly, Inspection ......................... 15 - 1
9803/3145 Issue 3*
ii ii
Contents Page No.
Boom, Dipper and Bucket rams

Dozer ram
Swing ram
Inspection .................................................................................... 16 - 16
Rotary Coupling
Main Relief Valves

Pressure Testing Description ........................................................ 18 - 2
Pressure Testing Procedure .......................................................... 19 - 2
Auxiliary Relief Valves

Pressure Testing ........................................................................... 19 - 3
Servo Relief Valves

Cross-line Relief Valves


Pressure Testing` .......................................................................... 19 - 6
Hydraulic Oil Cooler

9803/3145 Issue 3*
1-1 1-1
Technical data
Pump Type 802.7 / 803 Plus

Hydraulic triple gear type, driven directly from the engine crankshaft.
Pump Flow Rates 802.7

Rated at 2350 rev/min. and at M.R.V. pressure:-
Section P1 at 172bar (2500 lbf/in2). New 12.3 litres/min (2.7 UK gal/min. 3.25 US gal/min.)
Service Limit 11.5 litres/min (2.5 UK gal/min. 3.0 US gal/min.)
Section P2 & P3 at 190 bar (2750 lbf/in2). New 19.2 litres/min. (4.2 UK gal/min.5.0 US gal/min.)
Service Limit 18.0 litres/min (4.0 UK gal/min.4.8 US gal/min.)
Pump Flow Rates 803 Plus

Rated at 2200 rev/min. and at M.R.V. pressure:-
Section P1 at 172 bar (2500lbf/in2). New 17.3 litres/min (3.8 UK gal/min. 4.6 US gal/min.)
Section P2 & P3 at 190 bar (2750 lbf/in2). New 26 litres/min. (5.7 UK gal/min. 6.9 US gal/min.)
Pump Type 804 Plus and Super

Single variable displacement piston type with two equal outlet flows in tandem with single gear type, driven directly from the
engine crankshaft.
Pump Flow Rates 804 Plus and Super

Rated at 2110 rev/min. and at neutral circuit pressure:-
Pump P1 22 litres/min. (4.8 UK gal/min., 5.8 US gal/min.).
Pumps P2 and P3 35 litres/min., 9.6 US gal/min.).
Relief Valve Operating Pressures
Machines to Serial No. xxxxxx

802.7 Plus 803 Plus 804 Plus *804 Super
bar lbf/in2 bar lbf/in2 bar lbf/in2 bar lbf/in2

Main Relief Valves (M.R.V.)
*Swing/Slew/Dozer/Dipper Boost 172 2500 172 2500 172 2500 172 2500
Tracks/Dipper/Boom/Bucket/Auxiliary 190 2750 185 2670 190 2750 190 2750
802.7 Super 803 Plus 803 Super 804 Super

M747211 on M827240 on M827240 on M734834 on
Main Relief Valves (M.R.V.)
*Swing/Slew/Dozer/Dipper Boost 172 2500 172 2500 172 2500 172 2500
Tracks/Dipper/Boom/Bucket/Auxiliary 185 2700 185 2700 207 3042 185 2700
802.7 Plus 803 Plus 804 Plus *804 Super

Servo Pressure
Maintenance Valve 25 360 25 360 25 360 25 360
Auxiliary Relief Valves (A.R.V.)

Boom rod and head side 248 3600 248 3600 248 3600 248 3600
Dipper rod and head side 248 3600 248 3600 248 3600 248 3600
*Dozer head side 200 2900 200 2900 200 2900 200 2900
*Swing rod side Anti cavitation valve (all machines)
Slew Crossline Relief Valves 165 2400 165 2400 165 2400 165 2400
to M734508
Dipper Boost Dump Valve 110 1600 110 1600 160 2320 110 1600
M734509 on
110 1600
9803/3145 Issue 3*
1-2 1-2
Rams 802.7 / 803 Plus/Super* 804 Plus*
Bore Rod Dia Stroke Bore Rod Dia Stroke

mm in mm in mm in mm in mm in mm in
-Boom 80 3.15 40 1.57 465 18.31 90 3.54 45 1.77 475 18.7

-Dipper 70 2.76 40 1.57 570 22.44 75 2.95 45 1.77 645 25.39
-Bucket 75 2.95 50 1.97 374 14.72 80 3.15 50 1.97 374 14.72
-Swing 80 3.15 40 1.57 520 20.47 80 3.15 40 1.57 520 20.47
-Dozer 90 3.54 45 1.77 165 6.50 90 3.54 45 1.77 165 6.50
804 Super*
Bore Rod Dia Stroke
mm in mm in mm in
-Boom 90 3.54 45 1.77 475 18.7

-Dipper 75 2.95 45 1.77 646 25.43
-Bucket 80 3.15 50 1.97 377 14.84
-Swing 80 3.15 40 1.57 520 20.47
-Dozer 90 3.54 45 1.77 165 6.50
Motors 802.7 Plus/Super* 803 Plus/Super* 804 Plus*

Track
-Maximum tractive effort 2300 kgf (5071 lbf) 2560 kgf (5645 lbf) 2489 kgf (5487 lbf)
-Motor displacement 30.6/16.6cc per rev 30.6/16.6cc per rev 30.6/16.6cc per rev
-Final displacement 1019/553cc/rev 1019/553cc/rev 1242/674cc/rev
-Weight (w/out g/box) 32 kg (70 lb) 47 kg (104 lb) 47 kg (104 lb)
-Ratio 19.3 : 1 33 : 1 40.6 : 1
Slew Piston Piston Piston

Slew Speed 9.5 rev/min. 9.5 rev/min. 10.3 rev/min.
804 Super*
Track
-Maximum tractive effort 2450 kgf (5401 lbf)

-Motor displacement 30.6/16.6cc per rev
-Final displacement 1242/674 cc/rev
-Weight 47 kg (104 lb)
-Ratio 40.6 : 1
Slew Piston
Slew Speed 9.5 rev/min.
Filtration all machines
-Main Bypass pressure 1.5 bar (22 lbf/in2)
9803/3145 Issue 3*
2-1 2-1
15 16
15B 16B 11
9 10
15A 16A
11A
14
13
11B
13A
18 17 6
12 18A 6A 6B
2B a
2A b
c
1C 1C 1C 1C 1 d
2A g h
3B 3A 1G
1H 1F 1E 1B 22
f a d
7A 7
1D 1D 1D 1D
7B
1D 1A
1D 1D j k
3H 3G 3E
e 3F b c 3D 3C e
1J 1C
f
3
8
g
h
j
k
4B
4F
4
4A
19
4E
4F
P 5
E 4C 4D
P3 P2 P1
20
T 21 H17700
9803/3145 Issue 2*
2-2 2-2
Hydraulic Circuit Schematic - 802.7 / 803 Machines *Hydraulic Circuit Schematic - 802.7 / 803
Component Key *Note: Circuit and description are for ISO machines. The service lines to the dozer ram, the track motors
and the pilot line from the high speed selector to the
P1 Pump Section 1 14 Rotary Coupling The mini-excavator hydraulic circuit is fed from a track motors are routed through a rotary coupling 14.
P2 Pump Section 2 15 L.H. Track Motor hydraulic oil tank T, located to the right of the operator’s This device allows the machine upper structure to turn
P3 Pump Section 3 15A Counterbalance Valve cab. without damaging hoses connected to services mounted
T Tank 15B L.H. Two Speed Tracking on the undercarriage.
E Engine 16 R.H. Track Motor The system is powered by a three section gear pump P,
1 Five Spool Valve Block 16A Counterbalance Valve connected directly to the engine crankshaft. The remaining service lines connect directly to their
1A Main Relief Valve 16B R.H. Two Speed Tracking relevant devices. Return fluid from services or from the
1B Dozer Spool 17 Boom Ram When the engine is running, the pump draws fluid from neutral pressure circuit is routed back to tank through
1C Auxiliary Relief Valves 18 Bucket Ram the tank and routes it through the two main control valve an exhaust line and return filter 20.
1D Load Hold Check Valves 18A Restrictor blocks 1 and 3.
1E Swing Spool 19 Oil Cooler
1F Slew Spool 20 Return Filter with By-pass Valve Pump section P1 supplies the control valve sections Neutral Pressure Circuit
1G Dipper Boost Spool 21 Suction Strainer for:
With the engine running, but no service selected, the
1H Auxiliary Spool 22 Check Valve - Dozer ram, 1B
pump flows are routed from pump sections P1, P2 and
1J Anti-cavitation valves - Swing ram, 1E
P3 to respective valves.
2 High Pressure Carry-over Tube - Slew motor, 1F
2A Non-Return Valve - Dipper Boost, 1G
The valve spools are spring loaded to the neutral
2B Quick Release Couplings - Auxiliary, 1H
position, allowing fluid to pass through the valve’s neutral
3 Six Spool Valve Block
circuit and returned to tank through the return line.
3A Bucket/Boom/RH Track - MRV Pump section P2 supplies the control valve sections
3B L.H. Track/Dipper/Boom Boost - MRV for:
Excess pressure in the selected circuit opens the M.R.V.
3C R.H. Track Spool - Right hand track motor, 16
associated with the valve section supplied and vents
3D Boom Spool - Boom ram, 17
excess pressure back to tank T.
3E Bucket Spool - Bucket ram, 18
3F L.H. Track Spool
3G Dipper Spool Pump section P3 supplies the control valve sections
Dipper Boost
3H Boom Boost Spool for: Dipper speed is increased by an automatic dipper boost
4 Pressure Maintenance Valve - Left hand track motor, 3F system. Dipper boost is achived by adding a fifith spool
4A Pressure Reducing Valve - Dipper ram, 3G 1G between the slew and auxiliary spools in the rear
4B Shuttle Valves - Boom boost, 3H valve block 1, the spool is arranged in series to the slew
4C Servo Isolation Solenoid spool to maintain ‘preferred’ slew operation. The boost
4D Two Speed Tracking Solenoid Supply from all three pumps is also directed to the supply from pump P1 via this fifth spool is piped through
4E Accumulator Non-Return Valve Pressure Maintenance Valve 4, fitted with a single a line mounted relief valve 13 and joins the main dipper
4F Pressure Test Point adjustable pressure reducing valve 4A, Servo Isolation spool 3G flow to the ram L.
5 Accumulator Solenoid Valve 4C and Two Speed Tracking Solenoid Relief valve 13 limits the boost pressure to 110 bar (1600
6 R.H. Joystick Controller 4D. Supply from the pumps is via a servo signal hose lbf/in2) and is pilot operated from pressure developing
6A Boom Control directed into shuttle valves 4B. in the main dipper feed pump P3. This dump valve
6B Bucket Control ensures that when dipper tearout is utilised the boost
7 L.H. Joystick Controller Main relief valves (M.R.V.) 1A, 3A and 3B are fitted in supply is off-loaded back to tank by relief valve 13A
7A Dipper Control the main control valve blocks to vent hydraulic pressure, enabling full system pressure to be generated at the
7B Swing / Slew Control venting excess flow to tank T. main excavator pumps P2 and P3 without overloading
8 Slew / Swing Change-over the engine.
9 Dozer Ram Auxiliary relief valves (A.R.V.) 1C are fitted to protect
10 Swing Ram the dipper, boom and the head side only on the dozer Main Relief Valves
11 Slew Motor ram from damage that might be generated through over- The main relief valves 1A, 3A and 3B are incorporated
11A Cross-line Relief Valves pressure conditions during operation. into the respective control valve blocks
11B Slew anti-cavitation Valves When the A.R.V.’s are open, over pressure fluid is routed
12 Dipper Ram to the control valve exhaust chamber and back to tank
13 Dipper Boost Dump Valve T.
13A Relief Valve
9803/3145 Issue 2*
2-3 2-3
16 17
11
16B 17B
10
17A
16A
9
11A
15
13 11B
19 18 6
12 19A 6A 6B
14A 14 a
6C b
2A 2
c
1C 1C 1C 1
d
1G 1F g 1E h 1B
3B 3A 1H
f a d 7
7A
1D 23
7B
j k 1A
1D 1D
3H 3G 3F 3E 3D 3C
e b c e
1J 1C f
3
8
g
h
j
k
4
4B
4F
4A 4E
P 20
P3 4F
E 4D 5
P2 P1
21 4C
T 22 H17710
9803/3145 Issue 2*
2-4 2-4
*Hydraulic Circuit Schematic - 802.7 Super / 803 Super / 804Plus & Super *Hydraulic Circuit - 802.7 Super / 803 Super / 804Plus & Super
Component Key Note: Circuit and description are for ISO machines. The service lines to the dozer ram, the track motors
and the pilot line from the high speed selector to the
P Pump 14 Auxiliary Couplings (Double Acting) The mini-excavator hydraulic circuit is fed from a track motors are routed through a rotary coupling 15.
P1 Pump Section 1 (variable displacement) 14A Auxiliary Coupling (Single Acting) hydraulic oil tank T, located to the right of the operator’s This device allows the machine upper structure to turn
P2 Pump Section 2 (variable displacement) 15 Rotary Coupling cab. without damaging hoses connected to services mounted
P3 Pump Section 3 (fixed displacement) 16 L.H. Track Motor on the undercarriage.
T Tank 16A Counterbalance Valve The system is powered by a three section pump P,
E Engine 16B Two Speed Tracking Valve connected directly to the engine crankshaft. The remaining service lines connect directly to their
1 Five Spool Valve Block 17 R.H. Track Motor Sections P1 and P2 are constant horsepower variable relevant devices. Return fluid from services or from the
1A Main Relief Valve 17A Counterbalance Valve displacement pumps, section P3 is a fixed displacement neutral pressure circuit is routed back to tank through
1B Dozer Spool 17B Two Speed Tracking Valve gear pump an exhaust line and return filter 21.
1C Auxiliary Relief Valves 18 Boom Ram When the engine is running, the pump draws fluid from
1D Load Hold Check Valves 19 Bucket Ram the tank and routes it through the two main control valve Neutral Pressure Circuit
1E Swing Spool 19A Restrictor blocks 1 and 2.
With the engine running, but no service selected, the
1F Slew Spool 20 Oil Cooler
pump flows are routed from pump sections P1, P2 and
1G Dipper Boost Spool 21 Return Filter with By-pass Valve Pump section P1 supplies the control valve sections
P3 to respective valves.
1H Auxiliary Spool 22 Suction strainer for:
1J Anti-cavitation valve 23 Check Valve - Dozer ram, 1B
The valve spools are spring loaded to the neutral
2 High Pressure Carry-over Tube - Swing ram, 1E
position, allowing fluid to pass through the valve’s neutral
2A Non-Return Valve - Slew motor, 1F
circuit and returned to tank through the return line.
3 Six Spool Valve Block - Dipper Boost, 1G
3A Bucket/Boom/RH Track - MRV - Auxiliary, 1H
Excess pressure in the selected circuit opens the M.R.V.
3B L.H. Track/Dipper/Boom Boost - MRV
associated with the valve section suppied and vents
3C R.H. Track Spool Pump section P2 supplies the control valve sections
excess pressure back to tank T.
3D Boom Spool for:
3E Bucket Spool - Right hand track motor, 17
3F L.H. Track Spool - Boom ram, 18
Dipper Boost
3G Dipper Spool - Bucket ram, 19 Dipper speed is increased by an automatic dipper boost
3H Boom Boost system. Dipper boost is achived by adding a fifth spool
4 Pressure Maintenance Valve Pump section P3 supplies the control valve sections 1G between the slew and auxiliary spools in the rear
4A Pressure Reducing Valve for: valve block 1, the spool is arranged in series to the slew
4B Shuttle Valves - Left hand track motor, 3F spool to maintain ‘preferred’ slew operation. The boost
4C Servo Isolation Solenoid - Dipper ram, 3G supply from pump P1 via this fifth spool is piped through
4D Two Speed Tracking Solenoid - Boom boost, 3H a line mounted relief valve 13 and joins the main dipper
4E Non-return Valve spool 3G flow to the ram L.
4F Pressure Test Points Supply from all three pumps is also directed to the Relief valve 13 limits the boost pressure to 160 bar (2320
5 Accumulator Pressure Maintenance Valve 4, fitted with a single lbf/in2) and is pilot operated from pressure developing
6 R.H. Joystick Controller adjustable pressure reducing valve 4A, Servo Isolation in the main dipper feed pump P3. This dump valve
6A Boom Control Solenoid Valve 4C and Two Speed Tracking Solenoid ensures that when dipper tearout is utilised the boost
6B Bucket Control 4D. Supply from the pumps is via a servo signal hose supply is off-loaded back to tank by relief valve 13A
7 L.H. Joystick Controller directed into shuttle valves 4B. enabling full system pressure to be generated at the
7A Swing / Slew Control main excavator pumps P2 and P3 without overloading
7B Dipper Control Main relief valves (M.R.V.) 1A, 3A and 3B are fitted in the engine.
8 Dual Solenoid Valve the main control valve blocks to vent hydraulic pressure,
9 Dozer Ram venting excess flow to tank T. Main Relief Valves
10 Swing Ram The main relief valves 1A, 3A and 3B are incorporated
11 Slew Motor Auxiliary relief valves (A.R.V.) 1C are fitted to protect into the respective control valve blocks
11A Cross-line Relief Valves the dipper, boom and the head side only on the dozer
11B Slew anti-cavatation Valves ram from damage that might be generated through over-
12 Dipper Ram pressure conditions during operation.
13 Dipper Boost Dump Valve When the A.R.V.’s are open, over pressure fluid is routed
to the control valve exhaust chamber and back to tank
T.
9803/3145 Issue 3*
2-9 2-9
6A
4B
4G
4A
P3 P2 4F
P1
4C
H18410
9803/3145 Issue 1*
2 - 10 2 - 10
Servo circuit
Description
The Servo Pressure Maintenance Valve 4 is fitted with a
single adjustable pressure reducing valve 4A and sole-
noid valves for servo isolation 4C and two speed tracking
selection 4D. The system is supplied from all three pumps
P1, P2 and P3 via a servo signal hose from each of the
pump pressure pipes, into a shuttle valve system 4B.
With the isolator solenoid energised, neutral circuit pres-

sure from the pumps connects to the hand controllers 6
and 7. As the hand controllers are operated, the neutral
circuit pressure is directed to and begins to select the
desired excavator spool, which in turn pressurises the
supplying pump flow. This increase in pressure is avail-
able in the servo system via. shuttle valves 4B to enable
full excavator operation, but is limited and maintained to
correct servo levels by the relief valve cartridge 4A.
Servo pressure can be measured at pressure point 4F

which is located in the forward position on the top face of
the valve.
Because the signal lines from all three pump flows are
capable of being pressurised to full system pressure, a
single pressure test tapping 4G (rear test point on top face
of valve) is fitted which can be used to monitor all main
hydraulic pump pressures.
Boom selection restrictors 6A fitted in servo hose termi-

nations on the boom boost spool are optional on 802.7 /
803, they cushion selection and deselection of the boom
to smooth operation. However when the hydraulic system
is cold an operating delay may occur.
9803/3145 Issue 1
3-1 3-1
Hydraulic System - General Fault Diagnosis
Before carrying out the following checks, ensure that where applicable :-
1 The correct hydraulic fluid is used and the system filled to the correct level.
2 The hydraulic fluid, filter and suction strainer are clean.
3 There are no visible leaks in the system.
4 Engine maximum speed and condition is as specification
5 Hydraulic pressures for each service are correct to specification
If possible the machine should be operated to identify the fault and to bring the systems to their normal working
temperature.
After completing these initial checks, proceed as follows :-
A If all the hydraulic services are at fault start at check 1.

B If servo controllers only are at fault start at check 13.
C If tracking services only are at fault start at check 16.
D If slew service only is at fault start at check 21.
Check Action
1 Is the fault in all services or one only? ALL : Check 2

ONE : Check 6
2 Are the hydraulics inoperative or lacking in power? INOPERATIVE : Check 4

POOR PERFORMANCE :Check 3
3 Is the servo pressure to specification? YES : Check 4.

NO : Adjust
4 Is the pump operating correctly? YES : Check M.R.V's.

NO : Check 5.
5 Is the pump noisy in operation? (803 Super & 804 Super YES : Purge air from pump casing.
only). NO : Check 6
6 Is the pump drive broken? YES : Renew

NO : Check 7.
7 Is one service only down on pressure? YES : Check 8.

NO : Check 9.
8 Is the cable adjustment correct? (Dozer control only) YES : Check 9.

NO : Adjust cable see Section D.
9 Is the control valve spool sticking? YES : Overhaul valve block section
NO : Check 10.
10 Is the service A.R.V. operating correctly? YES : Check 11.

NO : Reset or renew
11 Is the valve block section cracked? YES : Renew section and check
valve block mounting
12 Are the rams faulty? YES : Overhaul or renew
9803/3145 Issue 1*
3-2 3-2
Hydraulic System - General fault diagnosis - cont.
Check Action
13 Is the fault in all servo operated services or only ALL : Check servo isolator microswitch, check servo
one? solenoid valve, check 14.
ONE : Check 15.
14 Is the servo system operating correctly? YES : Check 15

NO : Check servo pressure maintenance valve
15 Is the hand controller plunger leaking/sticking? YES : Service hand controller, see Section D.
16 Is the tracking fault in both tracks and in one or both ONE : Check control linkage, check 17.
directions? BOTH : Check 4.
17 Is the tracking fault in one track in one or both ONE : Swap hoses between pumps P2 & P3, If the fault
directions? changes to other track, service pump. If fault
stays check 18. Check for sticking motor coun-
terbalance spool.
BOTH : Check 18.
18 Is the fault in one track only and in both directions? YES : With track stalled measure lubrication return to
tank flow (1) at top of rotary joint and (2) out of
track motor.
If (1) high and (2) normal service rotary joint. If
(1) high and (2) high check track motor.
19 Is high speed engaging? YES : Check 20.

NO : Check operation of high speed solenoid valve,
rotary joint seals or motor high speed selector
spool.
20 Is the track motor high speed selector servo hose YES : Correct connections
crossed with motor lubrication drain hose?
21 Is the slew motor performance/braking poor? YES : Check for correct pressure settings of cross line
relief valves. Check slew motor anti-cavitation
check valves are closing.
22 Does the slew motor performance improve if bucket YES : Check servo pressure maintenance valve non
service stalled? return valves are closing.
9803/3145 Issue 1*
4-1 4-1
Hydraulic pump - operation

802.7 and 803 Machines
802.7 machines and 803 machines are fitted with a three In each pump section the drive shaft carries a gear wheel,
section gear pump. which meshes with a second gear, carried below the drive
shaft on an independent idler shaft.
Drive is transmitted through the sections of the pump via.
a drive shaft, linked by splined bushes between each The pump is gravity fed from the hydraulic tank which is
pump section P1, P2, P3. mounted higher on the machine than the pump.
Fluid is carried by the rotating gears to the outlet side of

the pump. As the gear teeth 'remesh' on the outlet side,
pressure increases and fluid flows from the pump into the
machine neutral circuit and servo circuit.
9803/3145 Issue 1
4-2 4-2
9803/3145 Issue 1
4-3 4-3
Hydraulic Pump
804 Variable Displacement
Operation
The hydraulic pump is a small lightweight compact unit The constant horsepower control, or summator, is a
containing single piston pump A components, which is simple design incorporating a trunnion mounted 'swash
able to supply two equal flows to the hydraulic system. plate' F which governs the stroke of the pistons in the
Mounted on the back of the pump body is a gear pump B pump barrel. This swash plate is spring loaded to an angle
supplying oil to the dozer, slew and swing circuits. matching the maximum piston stroke hence maximum
flow position. As the pistons G and barrel D rotate, driven
by the engine, the swash plate draws the pistons out of
P1 the barrel, filling the vacated space on top of the piston
S P2 with oil, once past top dead centre the swash plate pushes
the pistons back into the barrel displacing the oil out into
the hydraulic circuits of the machine.
When the machine starts to dig the pressures in the

circuits begin to rise, this is sensed back to the pump
and registers against the crown of the pistons G as the
C barrel rotates. The force of the pressure felt on the piston
crowns is transmitted onto the swash plate and once the
spring force of the summator is exceeded, the swash
The piston pump rotating group of components seal plate angle progressively decreases. This in turn
against a fixed valve plate C in the pump casing. The decreases the piston stroke reducing the volume of oil
valve plate has a single groove S machined for suction, pumped into the hydraulic circuits.
but two concentric pressure grooves P1 & P2 both
bridging the piston bores in the rotating barrel D, the outer The gear pump is a fixed displacement pump, and should
groove supplies one hydraulic circuit whilst the inner this come under pressure whilst the machine is digging,
groove supplies the second, both circuits receive equal the horsepower demands on the engine will increase.
flows. However, there is a pilot gallery H sensing gear pump
pressure, running through the main pump housing to a
The piston pump has a constant horsepower control E plunger J behind the swash plate. This increases the load
which responds to hydraulic system pressure demands, against the summator springs E decreasing the angle of
as pressure in the circuits rise so the volume of oil being swash plate further and so reducing the piston pump flows
pumped into the circuits decreases, maintaining the thus maintaining a constant horsepower demand on the
horsepower demands within the power output of the engine.
engine and preventing an engine stall situation.
9803/3145 Issue 1
5-1 5-1
9803/3145 Issue 1
5-2 5-2
Track Motor
Description Operation
The track motor consists of a fixed section, made up of a When the track is driving forwards, pressure is fed from
hydraulic motor and valve unit, and a rotary section which the main pump via the control valve to port C on the
is a simple double-step planetary speed reduction. motor, this causes a spool to move downwards and the
check valve to open. Flow is then allowed to enter the
When both tracks are selected to operate, the pump motor, oil is returned through P1 back to the tank
section P2 feeds the valve block section for the RH travel
motor, P3 feeds the valve block section for the LH travel Counterbalance Operation
motor. Track feeds from the selected spools flow through When the machine is on an incline ft will tend to travel
the rotary coupling to the respective track motors. under gravity. Under such conditions the motor
overspeeds, acting as a pump, increasing outlet pressure
The motor valve plate A has two sets of ports B and C and and lowering inlet pressure.
is in contact with the swash plate D.
Differential pressure causes the counterbalance plunger
B and C are connected to the motor inlet and outlet lines K to shift and restrict flow from the counterbalance valve.
via the counterbalance valve. When pressurised fluid is Restricted flow from counterbalance valve to motor
introduced through A, pistons E, on the B side are forced causes motor inlet pressure to rise and balance outlet
against the swash plate D. pressure compensating for gravitational action.
Reaction force from the swash plate generates radial Braking

force causing rotation of the cylinder block F. Torque
When control valve is reset to neutral circuit P1 and P2
generated at the cylinder block is transmitted to the
are connected to return line and the motor counterbalance
output shaft G, through splines on the cylinder block.
valve re-centres and integral check valves close P1 and
P2. The low travel inertia of the machine and the notched
The end of the output shaft G has a spline connected gear
shape of the valve spool gradually limit the flow of return
which drives two sets of planetary gears H. These reduce
fluid and the machine motion is stopped smoothly.
output speed in two steps and transmit rotation to the
rotary section of the motor via an integral ring gear J.
Working fluid is discharged from C . When the control

valve, on the main valve block, is selected to opposite
position, C becomes inlet port, B becomes outlet and
rotation is reversed.
For low speed operation, the 2-speed control valve

supplies fluid to all ports on the port B side (or port C side),
producing maximum torque.
*When high speed operation is selected, the 2-speed

control valve spool AA is moved across by servo pressure
against its spring. This masks off gallery BB consequently
supplies pressurised fluid to only one port on side B (or C).
The same volume of oil from the pump is now acting on
two motor pistons instead of 5 increasing the speed of the
motor/gearbox but reducing it's torque. The other port on
side C (or B) are open to drain returning oil to tank via the
selected track motor spool in the valve block.
B
C
BB
AA
9803/3145 Issue 2*
5-3 5-3
H50220
9803/3145 Issue 1*
5-4 5-4
Track Motor - cont.
Motor Low Speed, High Traction Selected

With the high speed button deselected on the dozer
lever, the return spring A above two speed selector spool
B returns the spool to the low speed position.
Service ports C and D are connected via the rotary

coupling to the track spool in the valve block. Depending
on whether track forward or track reverse is selected
either port C or D may be pressurised, the other port then
returns exhaust oil back to tank via the rotary coupling
and the track spool.
The illustration shows the upper service port A

pressurised. Because the two speed tracking selector is
not selected, the return spring A holds the selector spool
B down allowing this pressurised oil to cross the spring
cavity and on to two inlet ports in the valve plate E as well
as across the top waisted section of the spool into the
centre port of the valve plate. This means that at least
four of the motor pistons receive high pressure oil,
driving the motor at maximum torque (tractive effort)
although at the lower speed.
The opposite four pistons of the track motor are connected

to tank via the lower waisted section of the two speed
selector spool.
9803/3145 Issue 1*
5-5 5-5
h50230
9803/3145 Issue 1*
5-6 5-6
Track Motor - cont.
Motor High Speed, Low Traction Selected

With the high speed button selected on the dozer lever,
servo pressure from the servo pressure maintenance
valve via the rotary coupling fills the cavity under the two
speed selector spool B and lifts it against the return
spring A.
Service ports C and D are connected via the rotary

coupling to the track spool in the valve block. Depending
on whether track forward or track reverse is selected
either port C or D may be pressurised, the other port then
returns exhaust oil back to tank via the rotary coupling
and the track spool.
The illustration shows the upper service port A

pressurised. Because servo pressure has lifted spool B,
pressurised oil crosses the top waisted section only of the
spool into the centre port of the valve plate E, supplying
a maximum of two of the motor pistons, driving the motor
at maximum speed (minimum torque/tractive effort).
The opposite two pistons of the track motor displace the

oil to tank via the lower waisted section of the two speed
selector spool.
9803/3145 Issue 1*
6-1 6-1
Slew Motor
Description
The slew motor consists of a reduction gearbox A, The motor located by dowels D to the mainframe and
hydraulic motor B and hydraulic cross-line relief valve secured by setscrews E which may be used as jacking
assembly C. screws when removing the motor from the mainframe.
The hydraulic motor is an axial piston type and converts

hydraulic energy supplied from the hydraulic pump into a
rotary motion.
The hydraulic valve consists of cross-line relief valves,

which in conjunction with a D/A spool fitted to the valve
block ensures that the inertia produced when stopping
the machine is absorbed through the cross-line relief
valves producing a smooth machine stop also preventing
the hydraulic motor becoming overloaded.
The gearbox is a single step planetary type, the gearing

converts high speed rotary motion from the hydraulic
motor into low-speed high torque transmitted to the pinion
shaft.
C
9803/3145 Issue 1
7-1 7-1
9803/3145 Issue 1
7-2 7-2
Hydraulic Pump
Pump Flow Testing 804 Variable Displacement Pumps

To achieve accurate flow figures it is recommended that Before the following flow testing is attempted all hydraulic
the following procedure is adopted. pressures should be checked for accuracy. It may be an
incorrectly set relief valve causing engine over load or
When gear pump testing (802.7 & 803 machines), the poor machine performance.
two main pumps P2 & P3 are equal capacity, it may
therefore only be necessary to compare the flows one to If during normal excavating duties the engine excessively
another. lugs down and black smokes or the hydraulic system
appears to be slow, it may be due to incorrect calibration
When variable displacement pump flow testing (804 of the variable displacement pump. To prove this, the
machines) the results are critical to assessing the pumps pump must be accurately flow tested as follows.
performance and therefore the flow meter must be
checked for accuracy. With the hydraulic system at the correct working
temperature, park the machine with the excavator end
resting on the ground. Stop the engine, leave the isolator
WARNING lever in the 'down' position and ignition switch 'on',
Accurate pump performance can only be measured operate all excavator services to vent residual pressure.
with the hydraulic system at normal operating
temperature. Consequently various hose connections Remove ignition key for safety, open the engine cover
may be required with HOT hoses, pipes and fittings. and disconnect pumps P1 and P2 pressure hoses from
Care must be taken to avoid touching metallic fittings the pressure testing steel pipes. Connect suitable lengths
with bare hands and prevent hot oil dripping onto the of hose to both steel pipes and join together with a Tee
skin. piece A. Run another 1 metre (36 in) length of hose B (to
prevent oil turbulence interfering with the flow meter).
802.7 and 803 Gear Pumps Connect a suitably accurate reading flow meter C ideally
With the hydraulic system at the correct working with an inbuilt pressure gauge and manual pressure
temperature, park the machine with the excavator end loading restrictor valve. Run a length of hose from the
resting on the ground. Stop the engine, leave the isolator meter to a second Tee D piece then divide the flows along
lever in the 'down' position and ignition switch 'on', the correct neutral circuit paths E & F of pumps P1 and
operate all excavator services to vent residual pressure. P2.
Remove ignition key for safety, open the engine cover Ensure load valve on the flow meter is released so that no
and disconnect pump P1 pressure hose from the pressure hydraulic pressure is imposed on engine start. Start the
testing steel pipe. Insert flow meter (See Service Tools engine and set the throttle to rated speed as detailed in
Catalogue) into pump P1 pressure line ensuring there is Technical Data, slowly and progressively screw load
a least 1 metre (36 in) of straight hose with straight fittings valve in until 190 bar (2750 lbf/in2) is recorded on the
from pump to flow meter, this will prevent oil turbulence pressure gauge, check engine speed and reset if
interfering with the recorded flow on the flow meter. necessary. Note recorded flow figure on meter.
Start the engine and run at rated speed as detailed in With 190 bar (2750 lbf/in2) still loaded on system, raise
Technical Data. Operate the dozer service to maximum and stall dozer service, again record flow meter reading.
M.R.V. pressure and check engine speed, readjust if Release dozer service and reduce system pressure
necessary. Note maximum flow recorded on meter. imposed by the load valve to 170 bar (2465 lbf/in2), reset
Refer to Technical Data for correct flow limit, if pump engine speed, and record flow. Stall dozer service and
output falls below service limit, renew pump. record flow.
Move flow meter to pumps P2 and P3 in turn, to measure Continue these flow checks through 150 bar (2175 lbf/in2)
pump P2 the bucket service should be operated to and 100 bar (1450 lbf/in2) pressure settings always re-
maximum ram travel and held at maximum M.R.V. checking engine speed and adjusting.
pressure. Similarly, to measure pump P3 output the
dipper service should be operated and stalled to M.R.V. Contact Service department of JCB Compact Products
pressure, ensuring engine speed is readjusted. Ltd for calibration instructions.
9803/3145 Issue 1
7-3 7-3
G
F
1
5
H15780
9803/3145 Issue 1
7-4 7-4
Hydraulic Pump
802.7 and 803 Gear Pumps
WARNING
Fine jets of hydraulic oil at high pressure can pen-
etrate the skin. Do not use your fingers to check for
hydraulic oil leaks. Do not put your face close to
suspected leak and then inspect the cardboard for
signs of hydraulic oil. If hydraulic oil penetrates your
skin, get medical help immediately.
HYD-001
Removal Replacement
Gain access to the engine compartment. Replacement is the reverse of the removal procedure.
Select the starter switch to the ON position. Renew filtered adaptor B fitted to pump P1.
Relieve pressure from the hydraulic system. Refill the hydraulic tank to the correct level.
Select the starter switch to the OFF position and Before connecting the pipework, fill each pump section
remove the key. Disconnect the battery. with JCB Hydraulic Fluid.
Drain the hydraulic tank into a clean container of suitable Running-in (All machines)
capacity, for reuse. A new pump is correctly bedded in by the manufacturer
and will require no further running in after fitting.
Disconnect hydraulic hoses and pipes 1, 2, 3 and 4 from
the pump, cap open ports to prevent dirt ingress.
Remove the screws and washers 5 securing the pump

to the engine flywheel housing.
Withdraw the pump including drive coupling gear and

remove to a clean working area.
Note: Crankshaft drive gear F is Loctited to flywheel plate

G and will be difficult to dismantle. If the gear requires
renewal, the gear and plate are supplied under one part
number.
Remove the pump drive gear A retaining nut from the

pump shaft, use a suitable puller if necessary to remove
drive gear.
9803/3145 Issue 1
7-5 7-5
9803/3145 Issue 3*
7-6 7-6
Hydraulic Pump
802.7 Super, 803 Super & 804
Variable Displacement Pump
WARNING
Fine jets of hydraulic oil at high pressure can penetrate
the skin. Do not use your fingers to check for hydraulic
oil leaks. Do not put your face close to suspected
leaks. Hold a piece of cardboard close to suspected
leak and then inspect the cardboard for signs of
hydraulic oil. If hydraulic oil penetrates your skin, get
medical help immediately.
HYD-001
Removal Replacement
Gain access to the engine compartment. When refitting drive gear D to pump shaft dimension X
measured from rear face of gear pinch bolt boss to front
Select the starter switch to the ON position. face of pump body as illustrated, must be maintained at
6.5 mm (0.25 in.). Pinch bolt E should then be torque set
Relieve pressure from the hydraulic system. to 49 Nm (36 lb ft).
Select the starter switch to the OFF position and Renew filtered adaptor B fitted to gear pump.
remove the key. Disconnect the battery.
Fill pump body with clean hydraulic fluid through suction
Drain the hydraulic tank into a clean container of suitable port adaptor A. Cap adaptor to prevent oil draining whilst
capacity, for reuse. pump is refitted to flywheel housing.
Disconnect hydraulic hoses and pipes 1, 2, 3 and 4 from Enter the pump drive gear through adaptor plate C
the pump, cap open ports to prevent dirt ingress. ensuring correct meshing of gear teeth with spline of
coupling K. Torque set bolts 5 (see Technical Data).
Remove the screws and washers 5 securing the pump
to the engine flywheel housing. Replace pump connections 1, 2, 3 and 4.
Pump flywheel housing adaptor plate C must NOT be Refit suction hose 1 to adaptor A as quickly as possible
removed. The adaptor plate C is jig mounted to the to prevent oil loss, tighten worm drive clips.
flywheel housing during machine manufacture, any
misalignment of plate will result in premature failure of Refill Hydraulic tank with oil to the correct level.
pump drive coupling K.
Ensure maximum no load engine speed does not exceed
Pump Drive Renewal the figure specified in Engine Technical Data.
If the pump drive has failed prematurely due to pump
misalignment. A new flywheel housing will be necessary Running-in (All machines)
complete with jig aligned adaptor plate. A new pump is correctly bedded in by the manufacturer
and will require no further running in after fitting.
Note: Crankshaft drive gear F is Loctited to flywheel plate
G and will be difficult to dismantle. If the gear requires
renewal, the gear and plate are supplied under one part
number.
*Note: 804 Super has circlip H and two capscrews fitted

from Machine number M734471 on.
9803/3145 Issue 3*
7-7 7-7
C
D
9803/3145 Issue 1
7-8 7-8
Hydraulic Gear Pump

802.7 & 803 Machines
When Dismantling
Note: It is not possible to renew individual components
of the pump. External leaks can be repaired as can, in
some circumstances, the pump's performance be im-
proved by the renewal of seals. Before starting, mark the
pump sections, flange and end cover to ensure correct
alignment on reassembly.
1 Unscrew and remove the tie bolts B, bolts C and

washers D.
2 Using a soft-faced hammer, separate the pump

sections. Do not use levers of any kind to separate
pump components.
3 Remove bushes, gears and seals, keeping

components together in their relative positions.
Inspection
It is normal for the gears to have cut a slight track in the
body bore on the inlet side. The gear track cannot be
measured accurately but will be related to bearing wear.
Examine the bores of the bearing blocks E which are
coated during manufacture with PTFE. If the grey PTFE
is worn through so that large areas of the bronze base are
visible, the complete pump must be renewed.
Renew pump if faces of bearing blocks E are scored or if

side faces of gears F are chipped or damaged. DO NOT
use any abrasive on the bearing blocks or gears as this
would destroy critical manufacturing dimensions.
When Assembling
Note: New seals, tie bolts and nuts are to be fitted on
assembly. Apply Loctite to the threads before assembly.
1 Assemble in reverse order of stripping, maintaining

parts in their relative positions.
2 Tighten the tie bolts B, bolts C and drive coupling

nut A to torque settings specified (see torque setting
table).
9803/3145 Issue 1
7-9 7-9
9803/3145 Issue 1
7 - 10 7 - 10
Hydraulic Pump
802.7 Super, 803 Super & 804
Variable Displacement Pump
When Dismantling
Remove screws 1 retaining gear pump to piston pump
body
Remove locknut 2 and count the number of turns to

remove pump calibration screw 3 from the pump body to
ensure it can be accurately repositioned on assembly.
Follow numerical sequence to continue pump dismantling.
Do not use levers of any kind to separate pump

components. Use a soft-faced hammer to separate pump
sections.
Rotating components 13 should be renewed as a complete

assembly.
Gear pump components 42 to 49 should be renewed as

a complete assembly.
Inspection
Check pump barrel A and pistons B for wear or damage.
Also inspect bearing faces of valve plate 13 renew if there
is any sign of erosion or damage caused by debris.
When Assembling
Note: New seals 'O' rings and gaskets are to be fitted on
assembly. Apply Loctite to the threads before assembly.
Assemble in reverse order of dismantling, maintaining

parts in their relative positions.
9803/3145 Issue 2*
8-1 8-1
Track Motor - (Nachi)
Dismantling Assembling
Note: Cover all open orifices to prevent dirt entering the Renew the O-rings 3, 4, 6, 22, and 26. O-rings 11 and 18
hydraulic system. need only be renewed if the valve plugs 10 and 17 are
disturbed.
Brake Valve Assembly
The numerical sequence shown on the illustration is Torque Settings
intended as a guide to dismantling. Item Nm kgf m lbf ft
1 26-29 2.6-3.0 18-21
For assembly the sequence should be reversed. 5, 10, 12 & 17 167-196 17-20 123-145
21 & 25 49-68 5-7 36-50
When removing the valve spools, note their orientation;
they must be refitted correctly or the valve will not operate
properly.
9803/3145 Issue 1
8-2 8-2
Track Motor

The numerical sequence shown on the illustration is
intended as a guide to dismantling.
For assembly the sequence should be reversed.
When Assembling
Renew the O-ring 3, spring pin 5 and oil seal 22.
Before fitting the oil seal 22, fill the inside of the lip with
grease.
Install the oil seal 22 and the bearing 20 with a compression

force of approximately 500 kgf (1 1 00 lbf).
Before fitting the body 2 to body 23 , pour hydraulic fiuid

into body 23.
Torque Settings
Item Nm kgf m lbf ft
1 51-64 5.2-6.6 38-47
9803/3145 Issue 1
12 - 2 12 - 2
Control Valves, MRV & Spool Locations
23 3 1
16
4 22
15
19 14
21 18
4A 13
24 12
4B 2 10
9 11
8
7 20
6
17
1 Six Spool Valve Block

2 Five Spool Valve Block
3 Dipper Boost Dump Valve
4 Servo Pressure Maintenance Valve
4A Two Speed Tracking Solenoid (Lower)
4B Servo Isolation Solenoid (Upper)
Valve Block Spool Locations Relief Valves
Five Spool 17 M.R.V. Five Spool Valve Block

6 Dozer Spool 18 M.R.V. Six Spool Valve Block
7 Swing Spool R.H. Track
8 Slew Spool Boom
9 Dipper Boost Spool Bucket
10 Auxiliary Spool 19 M.R.V. Six Spool Valve Block
L.H.Track
Six Spool Dipper
11 R.H. Track Spool Boom Boost
12 Boom Spool 20 A.R.V. Five Spool Valve Block
13 Bucket Spool Dozer (head side only)
14 L.H. Track Spool 21 A.R.V. Six Spool Valve Block
15 Dipper Spool Boom (rod and head sides)
16 Boom Boost 22 A.R.V. Six Spool Valve Block
Dipper (rod and head sides)
23 Servo Pressure Maintenance Relief Valve

24 Dipper Boost Relief Valve
9803/3145 Issue 1
12 - 3 12 - 3
G
F
E
H D
E
D
C
A
M
N
K
L J P
10 mm M
9803/3145 Issue 1
12 - 4 12 - 4
Control Valve

The sequences illustrated are typical and refer to all
valve blocks.
WARNING Inspection
Fine jets of hydraulic oil at high pressure can penetrate 1 Check the mating faces of the valve sections for
the skin. Do not use your fingers to check for hydraulic scratching, pitting, burrs and/or corrosion. Renew
oil leaks. Do not put your face close to suspected valve sections as necessary.
leaks and then inspect the cardboard for signs of 2 Check the O-ring seatings, check valve locations
hydraulic oil. If hydraulic oil penetrates your skin, get and check valves for scratching, pitting, burrs and/
medical help immediately. or corrosion. Renew control valve sections or check
HYD-001
valves as necessary.
1 Remove the floor plate.
When Assembling
Note: If the five spool valve block requires removal, the Note: Smear all O-rings with hydraulic fluid on assembly.
engine sump guard should be removed to give access to
the valve block rear fittings. 1 Slide the valve sections onto the tie rods E in the
correct order and orientation, fitting new O -rings H,
2 In order to avoid draining the complete hydraulic new springs F and check valves G as necessary.
system, remove and blank the three feed hoses from
the main pump and release the hydraulic filter cover 2 Fit the nuts D to the tie rods E. Torque tighten.
to avoid syphoning.
3 Fit the valve to the machine.
3 Disconnect and blank the hydraulic pipes and hoses
from the appropriate valve. Cable Fitting Adjustment
4 Screw threaded inner end of new cable J 10mm
4 Remove old control cables and discard, retain fixing into spool end K and tighten locknut L against spool.
screws A.
5 Slide cast sleeve M into position, ensure seal retainer
4 Remove bolts B and C securing the control valve to N and circular nut P locate correctly.
the frame. Remove the valve(s) from the machine Using retaining screws A, secure sleeve to valve
to a clean working area. block
Dismantling and Assembly 6 Set cable position appropriate for the spool.
Check all cable cables operate freely and without
When Dismantling binding.
Caution: Absolute cleanliness is essential when stripping
and assembling hydraulic components. 7 Assemble removed components in reverse order of
Removal section.
Note: It is not necessary to separate valve sections to
remove valve spools, connections, relief valves etc. from 8 Set up the hydraulic circuit.
the valve block.
1 Remove nuts D from tie rods E and remove the end

cover from the valve.
2 Withdraw the valve sections from the tie rods E.

Collect the springs F and check valves G.
Note: Ensure check valves are replaced into sections

from which they were removed.
3 Remove and discard O-rings H
9803/3145 Issue 1
13 - 1 13 - 1
Control Valve Sections
Dismantling Assembly
1 Remove the control valve. 1 Lubricate new O-rings and seals with hydraulic fluid
before assembly.
2 Remove spools one at a time, label the spools and
mark the relevant sections to ensure assembly to
the correct location
Inspection
1 Examin the spool for signs of distortion, cracking
and/or corrosion.
2 Replace the spring if necessary.
3 Discard used O-rings.
DOZER
9803/3145 Issue 1
13 - 2 13 - 2
BOOM BOOST
and
DIPPER BOOST
DIPPER
and
BOOM
TRACK
9803/3145 Issue 1
13 - 3 13 - 3
BUCKET
and
SLEW
AUXILIARY
SWING
9803/3145 Issue 1
14 - 2 14 - 2
Main Relief Valves Removal
WARNING
leaks and then inspect the cardboard for signs of
HYD001
1 Slew machine across tracks to gain access to the

appropriate valve.
2 Relieve hydraulic pressure, if necessary disconnect

and blank hydraulic hoses from the valve
A block.
3 Unscrew the M.R.V.(s) from the valve block, covering

the port(s) to prevent the ingress of dirt.
Remove to a clean working area.
Replacing
B Note: Seals are made from special material, ensure
C
correct replacements are used.
1 Screw the M.R.V. into the appropriate valve

block.
D
2 Reconnect hydraulics and set the valve.
3 Refit the components removed to gain access to

E the valve(s).
M.R.V. Location and Identification
Six section valve block

P3 P2 P1 A Bucket, Boom and R.H. Track (P2)
B Boom Boost, Dipper and L.H. Track (P3)
Five section valve block (All machines)

C Aux., Dipper Boost, Slew, Swing and Dozer
(P1)
Dipper boost dump valve block

D Dipper Boost Relief Valve
Servo pressure maintenance valve

E Servo Relief (P1)
9803/3145 Issue 1
14 - 3 14 - 3
Servo Pressure Relief Valve
Removal
WARNING
Fine jets of hydraulic oil at high pressure can Note: It is possible to remove the relief valve cartridge
penetrate the skin. Do not use your fingers to check for cleaning or resealing without removing the complete
for hydraulic oil leaks. Do not put your face close to valve from the machine.
suspected leaks and then inspect the cardboard for 3 To remove the valve, mark hoses for correct
signs of hydraulic oil. If hydraulic oil penetrates your replacement and remove. plug hoses to prevent the
skin, get medical help immediately. ingress of dirt.
HYD001
4 Remove bolts holding the valve to the slew frame.
1 Stop the machine on level ground with the bucket
resting on the ground. Stop the engine and vent If there is evidence of damage to the valve or its seat
residual pressure from the servo accumulator by caused by debris then the cartridges will require renewing.
turning the ignition on and lowering the L.H. arm If a cartridge or valve complete is renewed it is
rest to the excavator operate position. Operate both recommended that the filtered adapters in the feed ports
excavator control levers in all directions until stored of the valve are also renewed.
servo pressure in the accumulator has been
exhausted. PT - MRV Test Point
PV - Servo Test Point
2 Remove the key. Open the engine canopy to gain
access to the pressure maintenance valve. PT
PV
P2 P1
P3
PT
ACC
T PV
PR BV
Note:- Filter adaptors P1, P2 and P3 should be checked

and cleaned or replaced every 1000 hours, or if the H18250
hydraulic system has been contaminated.
9803/3145 Issue 1
14 - 4 14 - 4
Removal
WARNING
penetrate the skin. Do not use your fingers to check
for hydraulic oil leaks. Do not put your face close to
suspected leaks and then inspect the cardboard for
signs of hydraulic oil. If hydraulic oil penetrates your
skin, get medical help immediately.
HYD001
1 Stop the machine on level ground with the bucket

resting on the ground. Stop the engine and vent
residual pressure from the servo accumulator by
turning the ignition on and lowering the L.H. arm
rest to the excavator operate position. Operate both
control levers in all directions until stored servo
pressure in the accumulator has been exhausted.
2 Remove floor plates as required to gain access to

the valve. Remove and blank hoses connected to
the valve. P4
P1 T
3 Undo securing bolts and remove valve to a clean P3
area.
P2
PT
P3 P2
PT Pressure test point

P1 Dipper boost supply from spool
T
P4 Dipper boost supply from spool
P3 Dipper boost valve to main dipper spool
P2 Dipper boost valve to main dipper spool
PT
P1 P4
9803/3145 Issue 1
15 - 1 15 - 1
Auxiliary Relief Valve
Removal
WARNING
leaks and then inspect the cardboard for signs of
HYD001
Inspection
1 Obtain access to the control valve. 1 Check valve components for scratching, pitting,
distortion and/or corrosion.
2 Relieve hydraulic pressure, disconnect and blank
any hoses or pipes which may interfere with the Note: If any part other than O-rings C and washer D are
removal of the relief valve(s). damaged the entire valve must be renewed.
3 Unscrew the auxiliary relief valve(s) from the control When Assembling
valve and remove to a clean working area. 1 Clean the valve body and components in an
appropriate solvent.
Dismantling and assembly
2 Assemble in the reverse order of dismantling.
When Dismantling
1 Remove acorn nut A, locknut B and O-rings C. 3 Pressure test the valve.
Discard O-rings.
2 Remove washer D.
3 Remove pressure setting plug E.
4 Tip the valve and remove:

- Thrust washers G
- Spring F
- Poppet H
9803/3145 Issue 1
16 - 1 16 - 1
Rams - Boom, Dipper and Bucket
802.7 and 803 Machines with:

Boom Ram Part No.: 903/16600
Dipper Ram Part No.: 903/16500
Bucket Ram Part No.: 903/16400
Removal & Replacement
WARNING
Fine jets of hydraulic oil at high pressure can penetrate When Removing
the skin. Do not use your fingers to check for hydraulic 1 With the engine idling, set the machine with the
oil leaks. Do not put your face close to suspected bucket on the ground.
leak and then inspect the cardboard for signs of 2 Support the excavator under the angle between the
hydraulic oil. If hydraulic oil penetrates your skin, get dipper and boom to ensure it will not move when the
medical help immediately. ram is removed.
HYD001
3 On boom and bucket rams, remove the protection

WARNING
plate. Support the ram under the gland bearing and
A raised and badly supported machine can fall on remove locknut A and bolt B from the pivot at the
you. Position the machine on a firm, level surface eye end of the ram. Drive out the pivot pin C.
before raising one end. Ensure the other end is
securely chocked. Do not rely solely on the machine 4 With the engine idling, gently retract the ram rod
hydraulics or jacks to support the machine when into the cylinder by operating the relevant service.
working under it.
Disconnect the battery, to prevent the engine being 5 On manual control machines, stop the engine.
started while you are beneath the machine. Operate the lever controlling the ram to be removed,
GEN001
in both directions to vent any trapped pressure.
Remove the hoses, plug and cap any open
WARNING hydraulic ports to prevent ingress of dirt.
If air or hydraulic pressure is used to force out the On servo machines, run the engine at idle and with
piston assembly, ensure that the end cap is securely the servo isolator lock in the operate position move
fitted. Severe injury can be caused by a suddenly the control lever rapidly in both directions to vent
released piston rod. any trapped pressure. Stop the engine.
HYD002
CAUTION
This operation may not fully release all the trapped
pressure. Consequently, when removing the hoses,
progressively slacken the fittings to vent any residual
pressure to atmosphere.
6 Support the ram and remove the locknut D and the

bolt E from the pivot at the base of the piston.
Drive out the pivot pin F. Remove the ram from the
machine.
9803/3145 Issue 2*
16 - 2 16 - 2
Rams - Boom, Dipper and Bucket (cont'd)
802.7 and 803 Machines with:

Boom Ram Part No.: 903/16600
Dipper Ram Part No.: 903/16500
Bucket Ram Part No.: 903/16400
Removal & Replacement (cont'd)
When Replacing
1 Locate the pivot point on the ram into the location
on the machine structure. Fit the pivot pin F and
secure using the bolt E and new locknut D.
2 Support the ram under the gland end of the cylinder,

reconnect the hoses. With the engine idling, slowly
extend the ram until the eye end locates correctly in
the machine structure. Fit pin C. Secure using the
bolt B and new locknut A.
3 Apply grease to the pivot points through the grease

nipples G. For grease specification see Lubricants
and Capacities.
4 Connect the hoses to the cylinder, see Hydraulic

Fittings and Torque Settings.
5 On the bucket and boom rams, fit the protection plate

and secure using the bolts.
G C
E
F
G
H18790
9803/3145 Issue 2*
16 - 3 16 - 3
Rams - Boom, Dipper and Bucket - cont.
WARNING When Replacing

Fine jets of hydraulic oil at high pressure can penetrate 1 Locate the pivot point on the ram into the location
the skin. Do not use your fingers to check for on the machine structure. Fit the pivot pin C and
hydraulic oil leaks. Do not put your face close to secure using the bolt B and new locknut A.
suspected leaks and then inspect the cardboard for 2 Fit the pivot point on the ram into its location on the
signs of hydraulic oil. If hydraulic oil penetrates your machine structure. Fit pin F. Secure using the bolt
skin, get medical help immediately. HYD001 E and new locknut D.

WARNING
nipples G. For grease specification and quantities
A raised and badly supported machine can fall on
see page 3 /1 -1.
you. position the machine on a firm, level surface
4 Connect the hoses to !he cylinder, see page 3/1-5
securely chocked. Do not rely solely on the machine
for sealant and torque information.
hydraulics or jacks to support the machine when
working under it. Disconnect the battery, to prevent
5 On the bucket and boom rams, fit the protection plate
the engine being started while you are beneath the
and secure using the bolts.
machine. GEN-001
WARNING
If air or hydraulic pressure is used to force out the
piston assembly, ensure that the end cap is securely
fitted. Severe injury can be caused by a suddenly
released piston rod. HYD002
When Removing
1 Set the machine with the bucket grounded.
2 Locate supporting structure under the boom/dipper

pivot.
3 With the starter switch ON, shut down the hydraulic

circuit and relieve residual pressure by operating the
servo controls.
4 On the boom and bucket rams, remove the

protection plate
5 Disconnect the hydraulic hoses from the pivot end

of the ram to be removed. Blank off the hoses and
the open ports of the ram.
6 Remove the locknut A and the bolt B from the pivot

at the rod end of the piston. Drive out the pivot pin
C.
7 Lower the rod end of the ram onto a suitable support.
8 Remove the locknut D and the bolt E from the pivot

at the base of the piston. Drive out the pivot pin F.
Remove the ram from the machine.
Note: For ram dismantling see pages E/16-4 to E/16-7.
9803/3145 Issue 2*
16 - 4 16 - 4
Rams (cont'd) - Dozer

802.7 / 803 and 804 Machines with:
Ram Part No.: 557/60024

1 Set the machine in the posture shown with the dozer 1 Locate the pivot point on the base of the ram into
grounded onto suitable supports. the dozer frame.
2 With the starter switch turned OFF, relieve residual 2 Fit the pivot pin H and secure using the locking plate
hydraulic pressure by operating the hydraulic controls. G and new screws and spring washers F.
3 Remove the bolts A and take off the protection plate 3 Fit the pivot point at the rod end of the ram to the
B. machine.
4 Disconnect the hydraulic hoses from the pivot end 4 Fit the pivot pin E and secure using the bolt D and
of the ram. Blank off the hoses and the open ports new locknut C
of the ram.
5 Remove the locknut C and the bolt D from the pivot at nipples J. For grease specification see Lubricants
the rod end of the ram. Support the ram and drive out and Capacities.
the pin E. Lower the ram end onto a suitable support.
6 Connect the hoses to the cylinder, see Hydraulic
6 Remove the screws and spring washers F and Fittings and Torque Settings.
locking plate G from the pivot at the dozer end of
the ram. Support the ram and drive out the pivot pin 7 Fit the protection plate B and secure using the bolts
H. Remove the ram from the machine. A.
9803/3145 Issue 2*
16 - 5 16 - 5
Rams (cont'd) - Dozer

1 Set the machine in the posture shown with the dozer 1 Locate the pivot point on the base of the ram into
grounded on suitable supports. the dozer frame.
2 With the starter switch turned OFF, relieve residual 2 Fit the pivot pin H and secure the bolt G and new
hydraulic pressure by operating the control levers. locknut F.
3 Remove the bolts A and take off the protection plate 3 Fit the pivot point at the rod end of the ram into the
B. machine.
4 Disconnect the hydraulic hoses from the pivot end 4 Fit the pivot pin E and secure using the bolt D and
of the ram. Blank off the hoses and the open ports new locknut C.
of the ram.
5 Remove the self-locking nut C and the bolt D from nipples J.
the pivot at the rod end of the ram. Support the ram
and drive out the pivot pin E. Lower the ram end 6 Connect the hoses to the cylinder.
onto a suitable support.
7 Fit the protection plate B and secure using the bolts
6 Remove the locknut F and bolt G from the pivot at A.
the dozer end of the ram. Support the ram and drive
out the pivot pin H. Remove the ram from the
machine.
9803/3145 Issue 3*
16 - 6 16 - 6
Rams (cont'd) - Swing

Ram Part No.: 576/60038
When Removing
1 Position the machine with upper structure slewed at 8 Remove the pivot pin G.
900 right to the tracks.
9 Withdraw ram with hoses attached.
2 Swing the machine dig end through 450 to the left
and lower the excavator to the ground. When Replacing
1 Connect hoses to new/serviced ram. Locate the ram
3 Remove the bolts B and spring washers C securing into the machine upper structure and align the base
the pivot keep plate D at the rod end of the cylinder. pivot point with the mating location in the machine
frame.
4 Support the cylinder A and drive out the pivot pin E.
With the engine idling, slowly retract the ram until 2 Fit the pivot pin G. Refit and secure with bolts, spring
the eye end clears the king post H. Stop the engine. washers F and keep plate.
5 Operate the swing pedal in both directions to vent 3 Reconnect the hoses.
any residual pressure.
4 With the engine idling, slowly extend the ram until
6 Remove floor mat and floorplates. Disconnect the the eye end locates into the kingpost H, stop the
ram feed hoses at the valve block, Plug the hoses engine
and cap the open ports of the valve.
5 Fit the pivot pin E. Refit and secure keep plate D
7 Locate the ram from underneath the upper structure. with bolts B and spring washers C.
Remove the bolts and the spring washers F securing
the keep plate at the base end of the cylinder. Note: See section 1 for torque tightening and sealant
information.
E
H
C A
D
9803/3145 Issue 3*
16- 7 16 - 7
Rams (cont'd)

1 Position the machine with upper structure turned at 1 Locate the ram into the machine lower structure and
90° right to the track. align the eye end pivot point with the mating location
in the machine frame.
2 Swing the machine dig end through 90°.
2 Fit the pivot pin G. Refit and secure with bolts, spring
3 Locate the ram from underneath the upper structure. washers F and keep plate.
4 Disconnect the hoses from the ram. Blank off the 3 Fit the rod end of the ram into the location in the
hoses and the ram. kingpost H.
5 Remove the bolts B and spring washers C securing 4 Fit the pivot pin E. Refit and secure keep plate D
the pivot keep plate D at the rod end of the ram. with bolts B and spring washers C.
6 Support the cylinder A and drive out the pivot pin E. 5 Connect the hoses to the ram.
7 Remove the bolts and the spring washers F securing Note: See section 3 for torque tightening and sealant
the keep plate at the eye end of the ram, located information.
underneath the slew frame.
8 Remove the pivot pin G.
9 Free the rod end of the ram from the kingpost H and
remove the ram from the front of the machine.
9803/3145 Issue 2*
16 - 8 16 - 8
Rams (cont'd)
804 Machines with:
Ram Part No.: 576/60038
Typical - Dismantling and Assembly
9803/3145 Issue 2*
16 - 9 16 - 9
Rams (cont'd)
Ram Part No.: 576/60038
WARNING Pivot Pin Bush Clearances

If air or hydraulic pressure is used to force out the 1 Using an internal micrometer measure the internal
piston assembly, ensure that the end cap is diameter (I.D.) of the pivot pin bushes S in the piston
securely fitted. Severe injury can be caused by a rod and cylinder ends.
suddenly released piston rod. HYD002
2 Compare the readings with the permitted tolerances
The numerical sequence shown in the figures are shown. Remove and replace pin bushes as
intended as a guide to dismantling. necessary.
Note: The only renewable parts for these rams are the
pivot bearings 12 and 14, piston rod 2, ram cylinder and
seals. If any of the other internal components of the ram
are damaged, then the complete ram assembly must be
renewed.
When Dismantling
1 Support the ram as shown.
2 Slacken the end cap 1 using C-spanner part no. 892/

00296 (68/75 mm) or 892/00297 (80/90 mm) for dozer.
3 Pull out the end cap and piston rod assembly.
4 Remove the piston head nut 4.
5 Remove the piston head 3 and collar 7 from the

piston rod 2.
6 Remove piston head seals 3 and discard, remove

also 'O' ring 6 from piston rod and discard.
7 Remove the end cap 1 from the piston rod.
8 Remove and discard all seals, back-up rings and 'O'

rings from the end cap.
Inspection
Piston Rod Warp

1 Support the bear piston rod on a pair of 'V' blocks.
2 Set a dial test indicator (D.T.I.) at the approximate

centre of the rod. Set the D.T.I. to zero.
3 Rotate the piston rod in its blocks, noting any

variation in D.T.I. reading.
4 If warp (half the difference between maximum and

minimum readings) exceeds 0.5 mm (0.02 in) the
piston rod must be replaced.
9803/3145 Issue 2*
16 - 10 16 - 10
Rams (cont'd)
Ram Part No.: 576/60038
When Assembling
1 Thoroughly remove all oil, grease, dirt and hardened
locking compound frm the threads of the piston head
nut C, piston rod B, end cap A and cylinder. Remove
all traces of rust using a wire brush.
2 Lubricate the new seals with clean hydraulic fluid.

Fit rod seal L, back up ring M, dust seal K, 'O' rings
H and J to the end cap A.
3 Fit the end cap to the piston rod. Take care not to
damage the end cap seals when passing the end
cap over the threads and shoulder of the rod.
4 Fit collar E to the piston rod.
5 Fit new hydraulic fluid lubricated 'O' ring G to the

piston rod and seals F to the piston head D.
6 Fit the piston head D to the piston rod B with the

chamfered end outermost.
7 Fit the piston head nut C to the piston rod B and

torque tighten nut to 314 Nm (232 lbf/ft) for all
excavator rams and 345 Nm (255 lbf/ft) dozer ram.
8 Load the piston rod assembly, piston end first, into

the cylinder.
9 Screw the end cap A into the cylinder and torque

tighten to 610 Nm (450 lbf/ft) all excavator rams
and 400 Nm (195 lbf/ft) for the dozer ram.
10 Fit the ram to the machine.
9803/3145 Issue 1*
16 - 11 16 - 11
Rams (cont'd)
WARNING
If air or hydraulic pressure is used to force out of the
fitted. Severe injury can be caused by a suddenly
released piston rod.
HYD002
Illustrations for the Dismantling and Assembly sequences

are of typical rams, slight variations may occur in parts
used.
The numerical sequence shown in the figures are intended

as a guide to dismantling.
For assembly the sequence should be reversed.
Try to lay out the parts in the correct sequence for

assembly.
Support the ram as shown.

Discard all seals and O-rings.
See inspection page E/16-8
Fit new O-rings and seals on assembly. Make sure that

the wiper A and gland B seals are fitted the correct way
around as shown.
Torque tighten the end cap and piston nut, see page 3/1-
3
9803/3145 Issue 1*
16 - 12 16 - 12
Rams (con't) *Ram Machine End cap Piston Head

Nm lbf ft kgf m Nm lbf ft kgf m
Swing 802.7/803 300 221 31 400 295 41
WARNING 804 300 221 31 400 295 41
If air or hydraulic pressure is used to force out the 804 Super 678 499 70 450 331 46
fitted. Severe injury can be caused by a suddenly Dipper 802.7/803 300 221 31 400 295 41
released piston rod. HYD002 804 325 240 33 400 295 41
804 Super 678 499 70 450 331 46
The numerical sequence shown is intended as a guide to
dismantling. Boom 802.7/803 300 221 31 400 295 41
804 325 240 33 400 295 41
When Dismantling 804 Super 678 499 70 450 331 46
Use a 4.75 mm (0.187 in) drill to remove hollow alu-
Dozer 802.7/803 325 240 33 400 295 41
minium dowel (where fitted) from the gland end cap
804 325 240 33 400 295 41
before the end cap can be unscrewed.
804 Super 678 499 70 450 331 46
*Note: Drill depth must not exceed 10 mm (0.39 in). Use
Bucket 802.7/803 350 258 36 400 295 41
a 'C' spanner located in the end cap slots to remove end
804 350 258 36 400 295 41
cap, except for 804 Super; these use ordinary A/F
804 Super 678 499 70 450 331 46
Spanner.
*Piston Head Dowel
The piston head is locked to the rod with a hardened steel
dowel, this dowel is located under the wear ring and must
Ram Machine Drill Dia Dowel hole depth
be removed before the piston nut can be unscrewed. The
dowel is drilled and tapped M3 X 0.5 for ease of removal,
Swing 802.7/804 5.95 mm 26.0 mm
retain the dowel and reuse on assembly.
(0.234 in) (1.02 in)
803 6.0 mm 31.0 mm
Discard all seals and 'O' rings.
(0.236 in) (1.22 in)
Try to lay out the parts in the correct order for assembly.
Dipper 802.7/803 5.95 mm 21.0 mm
(0.234 in) (0.82 in)
When Assembling
804 6.0 mm 26.0 mm
For assembly the sequence should be reversed. (0.236 in) (1.02 in)
Torque set the piston head until the dowel hole aligns with Boom 802.7 5.95 mm 26.0 mm
the hole in the rod. Replace the dowel but do not attempt (0.234 in) (1.02 in)
to peen it in place, the dowel will be held in position by the 803 6.0 mm 31.0 mm
wear ring. If a new piston rod is fitted the dowel hole drill (0.236 in) (1.22 in)
size and depth is as tabulated opposite. 804 6.0 mm 31.0 mm
(0.236 in) (1.22 in)
Fit new 'O' rings and seals on assembly lubricated with 804 Super 8.0mm
hydraulic fluid. (0.315in) N/A
Refit piston rod assembly to the cylinder, fully tighten end Dozer 802.7/803 5.95 mm 26.0 mm
cap. Drill through the same hole in the cylinder using a & 804 (0.234 in) (1.02 in)
4.75 mm (0.187 in) dia drill to a maximum depth of 10 mm 804 Super 8.0mm
(0.39 in). Insert new dowel and peen in position to retain. (0.315) N/A
*804 Super - End Cap A/F Sizes Bucket 802.7/803 5.95 mm 26.0 mm
Swing - 70mm (2 3/4 in) 804 6.0 mm 26.0 mm
Dipper - 70mm (2 3/4 in) (0.236 in) (1.02 in)
Boom - 70mm (2 3/4 in)
Dozer - 75mm (2 15/16 in)
Bucket - 75mm (2 15/16 in)
9803/3145 Issue 1*
16 - 13 16 - 13
Rams (con't)
Boom
10
4
5
6
1 7
2 H24990
10
9803/3145 Issue 1*
16 - 14 16 - 14
Rams (cont'd)
Swing
Bucket
3
4
5
6
1
7
9803/3145 Issue 1*
16 - 15 16 - 15
Rams (cont'd) 8
Dipper 9
3
4
6
5
1
7
8 2
DOZER
8
10 1
7
6
3
4
9
10
2 H19620
9803/3145 Issue 1*
16 - 16 16 - 16
Rams (cont'd)
Ram Part No.: 576/60038
Typical - Inspection
Piston rod warp Piston/Cylinder clearances

1 Support the piston rod on a pair of 'V' blocks. 1 Using internal and external micrometers measure
the piston O.D. and the cylinder I.D.
2 Set a dial test indicator (D.T.I.) at the approximate
centre of the rod at top dead centre. 2 Compare the readings taken with the permitted
tolerances. If necessary replace the piston and/or
3 Rotate the piston rod and read off any variation on the cylinder with new.
the D.T.I.
Pin bush clearances
4 If warp (half the difference between the minimum 1 Using internal micrometers measure the I.D. of the
and maximum readings) exceeds 0.5 mm (0.02 in.) pin bushes in the piston rod and cylinder ends.
the piston rod must be replaced.
2 Compare the readings with the permitted tolerances
Piston rod / Rod bush clearance shown.
1 Using internal and external micrometers measure
the piston rod outside diameter (O.D.) and the rod
bush inside diameter (I.D.).
2 Compare the readings taken with the permitted

clearances. If necessary replace the piston rod and
or remove the rod bush and replace with new.
9803/3145 Issue 1*
16 - 17 16 - 17
Rams (cont'd)
Inspection
Piston rod warp Piston/Cylinder clearances

1 Support the piston rod A on a pair of ‘V’ blocks. 1 Using internal and external micrometers measure
the piston outside diameter (O.D.) and the cylinder
2 Set a dial test indicator (D.T.I.) at the approximate inside diameter (I.D.)
centre of the rod at top dead centre.
3 Rotate the piston rod and read off any variation on tolerances. If necessary replace the piston and/or
the D. T. I. the cylinder with new.
4 If warp (half the difference between the minimum Pin Bush Clearances
and maximum readings) exceeds 0.5 mm ( 0.02 in) 1 Using internal micrometers measure the inside
the piston rod must be replaced. diameter (I.D.) of the pin bushes C in the piston rod
and cylinder ends.
Piston rod / Rod bush clearance
1 Using internal and external micrometers measure 2 Compare the readings with the permitted tolerances
the piston rod outside diameter (O.D.) and the rod shown. Remove and replace pin bushes as
bush B inside diameter (I.D.) necessary.

clearances. If necessary replace the piston rod and/
or remove the rod bush B and replace with new.
9803/3145 Issue 1*
17 - 3 17 - 3
A
A
E
A
A
H
K
B
L
B
B
H18920
9803/3145 Issue 2*
17 - 4 17 - 4
Rotary Coupling
Removal & Replacement Dismantling & Assembly
Removal Dismantling
Note: Before removing a suspected leaking coupling, 1 Note the positions and remove the adaptors A and
ensure that the leak is from the coupling core and not a B from the coupling. Discard the O-rings.
hose adaptor. Ensure all adaptors are tight.
2 Remove the four capscrews retaining cover plate F.
WARNING
3 Remove the external circlip and spacer ring G from
Fine jets of hydraulic oil at high pressure can the base of the coupling.
penetrate the skin. Do not use your fingers to
check for hydraulic oil leaks. Do not put your face 4 From the top of the coupling carefully withdraw the
close to suspected leaks. Hold a piece of cardboard coupling core H from the shell J.
close to suspected leaks and then inspect the
cardboard for signs of hydraulic oil. If hydraulic 5 Remove and discard back-up rings and O-rings K
oil penetrates your skin, get medical help from the core.
immediately.
HYD001
Inspection
WARNING 1 All rotary coupling core O-rings and back-up rings K
A raised and badly supported machine can fall on must be replaced with new and are only available
you. Position the machine on a firm level surface as a set.
securely chocked. Do not rely solely on the machine 2 If the core H or shell J show signs of wear replace
hydraulics or jacks to support the machine when the complete rotary coupling.
working under it.
Disconnect the battery, to prevent the engine being Assembly
started while you are beneath the machine. 1 Assemble in reverse order of dismantling, fitting new
GEN001
O-rings and back-up rings, lightly lubricate with
hydraulic fluid.
1 Remove the floor plate
2 Fit lip seals L in the positions and attitudes shown.
2 Disconnect the hydraulic hoses from the rotary
coupling adaptors A, blank off the hoses and
Replacement
adaptors.
1 Replace in reverse order of removal.
3 From under the machine, remove the rotary coupling
cover plate. 2 Reconnect hydraulic hoses using new lightly
lubricated O-rings.
4 Disconnect the remaining hydraulic hose from the
rotary coupling adaptors B, Blank off the hoses and
adaptors.
5 Remove the bolts, washers and nuts C securing the

coupling flange to undercarriage.
6 Lift the coupling, allowing the reaction peg D to clear

the reaction bracket E on the mainframe floor, turn
the coupling 90 deg. and lower clear of the machine
to a clean working surface.
9803/3145 Issue 2*
18 - 1 18 - 1
802.7 / 803 machines

MRV Pressure Variation Against Oil Temperature
245 (3600)
235 (3400)
220 (3200)
MRV Pressure bar (lbf in2)
207 (3000)
195 (2800)
Excavator MRV
180 (2600)
Dozer MRV
165 (2400)
Slew MRV
152 (2200)
138 (2000)
125 (1800)
110 (1600)
15 20 25 30 35 40 45 50 55 60 65 70 75 80
804 machines
245 (3600)
235 (3400)
220 (3200)
MRV Pressure bar (lbf in2)
Excavator MRV
207 (3000)
195 (2800)
180 (2600)
Dozer MRV
165 (2400)
152 (2200)
138 (2000)
125 (1800)
Slew MRV
110 (1600)
15 20 25 30 35 40 45 50 55 60 65 70 75 80
Hydraulic Oil Temperature (°C)

H15750
9803/3145 Issue 1
18 - 2 18 - 2
Pressure testing - Main Relief Valves
Description
The correct digging performance of these machines can
only be achieved with the Main Relief Valves (M.R.V.'s)
accurately set.
On production they are carefully set with the hydraulic
oil temperature at the correct operating level.
If the pressure setting is attempted with 'cold' hydraulic

oil the pressure drops away as the hydraulic oil warms
up with the machine operating and the power of the ex-
cavator is significantly reduced.
The graphs show the pressure to which the machine

should be set depending on oil temperature.
Select the graph to suit the M.R.V. to be tested and meas-

ure the hydraulic oil temperature. Read off the correct
pressure relating to the recorded oil temperature and set
the relief valves accordingly.
Always test the main relief valves in the following

sequence:-
A Servo Pressure Maintenance

B Slew - Swing - Dozer (P1) D
C L.H. Track, Dipper
D R.H.Track, Boom, Bucket
E Dipper Boost Dump Valve
C
B
9803/3145 Issue 1
19 - 2 19 - 2
Pressure testing - Main Relief Valves

D
1 Remove blanking cap and connect a 0 - 400 bar (0
- 6000 lbf/in2) pressure gauge to port PT on the
pressure maintenance valve, for the circuit to be
tested.
2 With the engine running at maximum speed, and

hydraulic fluid at normal working temperature,
operate the circuit served by the valve under test.
3 Check the gauge reading is as detailed in Technical C

Data. If incorrect, remove cap nut. With the ram
B
held at full travel, undo locknut F, use an allen key
to adjust the M.R.V. by means of the screw E until
the gauge reads the correct pressure.
4 Tighten locknut F. Check gauge reading is correct.

Repeat procedure as necessary.
A
5 Switch off engine. Remove pressure gauge and refit
blanking cap.
A Servo - Pressure maintenance valve

B Slew - Swing - Dozer
C L.H. Track, Dipper
D R.H.Track, Boom, Bucket
PT
F
E
9803/3145 Issue 1
19 - 3 19 - 3
Pressure testing -
Auxiliary Relief Valve(s)
1 Remove the auxiliary relief valve from the control C2 B1

valve and plug the valve port.
2 Install the auxiliary relief valve to test block number

892/00252.
3 Connect a 0 - 400 bar (0 - 6000lbf/in2) pressure gauge

A1
and hand pump, number 892/00223, to test block.
4 Operate pump and adjust pressure setting plug C

until valve opens at correct pressure, refer to C1 B2
Technical Data.
5 Lock the pressure setting plug with the locknut D

and re-test. Remove auxiliary relief valve from
test block and refit to control valve.
A1 Dozer (Head side)
B1 Boom (Rod side)

B2 Boom (Head side)
C1 Dipper (Rod side)

C2 Dipper (Head side)
9803/3145 Issue 1
19 - 4 19 - 4
Pressure testing
Servo Pressure Maintenance Valve
All pressure testing must be carried out with the

machine hydraulic system within the range 30 - 40oC.
Servo Pressure Relief Valve

1 Connect a 0 - 400 bar (0 - 6000 lbf/in2) pressure
gauge to test point PV on the servo pressure
maintaining valve block.
2 With the engine running at maximum speed, fully

select dipper in and hold whilst checking gauge
reading, if pressure is incorrect, remove cap from
relief valve A, slacken locknut and slowly adjust
valve until gauge reading is correct. Tighten locknut
and replace cap, recheck the pressure.
Note: If the relief pressure cannot be achieved then

engine should be shut down and all stored servo
pressure vented from the accumulator.
The relief cartridge removed and inspected for failed
seals or other damage. Prior to installing a repaired or
new relief cartridge remove and discard the three
filtered adaptors in the maintenance valve and replace
with new.
PV
9803/3145 Issue 1
19 - 5 19 - 5
Pressure testing - Crossline Relief Valves
There is a single relief valve A and B for each direction

of slew. These valves are located in the head of the slew B
motor. The pressures should be checked to the values
quoted (refer to Technical Data) using the method
described below.
Ensure the hydraulic system is at correct operating A

temperature.
Crossline Relief Valves A and B

1 Remove floor mat and necessary floor plates to gain
access to the slew motor.
2 Connect a 0 - 400bar (0 - 6000lbf/in2) pressure gauge

at test point PT on the pressure maintenance valve.
3 Engage slew lock. With the engine running at

maximum speed and the hydraulic fluid at working
temperature (refer to Technical Data), fully select
slew left and hold whilst checking the pressure gauge
reading.
4 Check that the pressure gauge reading equals the

crossline relief setting (refer to Technical Data). The
relief valve cartridges are not pressure adjustable,
if the recorded pressure is low, remove the valve
from the motor and check for debris or failed seals.
Clean valve components and renew seals if
necessary, refit to motor and retest. if the correct
pressure is still not obtainable the relief valve should
be changed for a new one.
5 Repeat the test fully selecting slew right.
6 Stop the engine, remove the pressure gauge and fit

blanking cap.
PT
9803/3145 Issue 1
19 - 6 19 - 6
Pressure testing - A
1 Remove blanking cap and connect a 0 - 400 bar (0

- 6000 lbf/in2) pressure gauge A to test point PT on
the pressure maintenance valve B, connect a second
0 - 400 bar (0 - 6000 lbf/in2) gauge C to test point PT
on the dipper boost dump valve D.
2 Run the engine at maximum speed, slowly and

progressively operate dipper IN. The pressure
recorded on gauge C connected to the dipper boost
valve D will suddenly fall back to zero, at this point
the pressure recorded on the gauge A connected to
the pressure maintenance valve B will be the setting PT
of the dipper boost dump valve.
Note:- The pressure on the pressure maintenance valve B

gauge A will continue to rise, for accurate valve setting
the reading MUST be taken at the exact point the pressure
in the dump valve begins to fall to zero.
PT
9803/3145 Issue 1
21 - 1 21 - 1
G
C
G
B
B
F
9803/3145 Issue 2*
21 - 2 21 - 2
Hydraulic Oil Cooler
Removal and Replacement Replacement

Note: The hydraulic oil cooler is mounted directly in front 1 If installing a new cooler, fit top C and bottom D lugs
of the radiator, and under normal circumstances should removed from the old cooler using screws, washers
require no attention. However, periodically debris collected and nuts G.
between the radiator and cooler should be removed. In
this event the cooler can be dismounted and carefully 2 Secure the cooler to the radiator using bolts and
moved clear of the radiator without disconnecting the washers B.
hydraulic pipework. Whilst dismounted, the cooler should
be inspected for damage and leaks. 3 Connect the top and bottom hoses A to the cooler.
4 Fill the hydraulic tank. Run the engine and check

WARNING
for leaks.
penetrate the skin. Do not use your fingers to check Note: Take care to ensure that the breather hose from
for hydraulic oil leaks. Do not put your face close to the hydraulic tank is routed clear of the radiator, and vents
suspected leaks. Hold a piece of cardboard close to into the slew frame on the engine side. If incorrectly
suspected leaks and then inspect the cardboard for positioned, oil mist venting from the hose is drawn through
signs of hydraulic oil. If hydraulic oil penetrates your the radiator matrix coating it with oil. As a consequence,
skin, get medical help immediately. dust picked up by the cooling air passing through the
HYD001
radiator and sticking to the oil may cause the engine to
overheat.
Removal
1 Position the machine on firm level ground with the
bucket resting on the ground. Stop the engine and
vent residual pressure from the system by fully
operating all control levers.
2 Remove the hydraulic oil filler cap and drain the

hydraulic tank.
3 Disconnect the top and bottom hoses A from the

cooler.
4 Remove bolts and washers B securing the upper C

and lower D oil cooler mounting lugs to the top
radiator bracket E and lower mount F.
5 If a new cooler is to be fitted, remove screws,

washers and nuts G to release the upper C and lower
D oil cooler brackets from the old cooler.
Note: Ensure the space between the radiator and oil

cooler is clean and free from debris.
9803/3145 Issue 1
Section F Gearboxes Section F
i i
Contents Page No.
Technical Data........................................................... 1 - 1
General Description ................................................... 1 - 1
Track Gearbox
- Operation ........................................................... 2 - 1
- Check Oil Level .................................................. 2 - 2
- Drain and Refill .................................................. 2 - 2
- Removal and Replacement ................................ 2 - 3
- Dismantling and Assembly ................................. 2 - 5
Slew Gearbox
- Removal and Replacement ................................ 3 - 3
Slew Motor
- Dismantling and Assembly ................................. 3 - 4
9803/3145 Issue 2*
Section J Track & Running Gear Section J
i i
Contents Page
General Description ..................................................................... 1 - 1
Tracks
Clean and Inspection ......................................................... 2 - 1
Removal and Replacement................................................ 2 - 2
Changing ............................................................................ 2 - 4
Track Rollers
Dismantling and Assembly ................................................. 3 - 2
Track Idler and Recoil Unit

Driven Sprocket
Track Roller Metallic Face Seals

9803/3145 Issue 1
1-1 1-1
General Description
The Mini-Excavator track and running gear comprises the tracks fitted to the machine, these may be either of steel
or rubber construction depending on the option selected, the associated sprockets that transmit drive from the
track gearboxes to the tracks and the equipment that provides and maintains the tension of the tracks.
The track and running gear is located on and within the machine undercarriage track boxes.
9803/3145 Issue 1
2-1 2-1
Tracks
Clean
WARNING
If two people are doing this job make sure that the
person operating the controls is a competent
operator. If the wrong control lever is moved, or if
the controls are moved violently, the other person
could be killed or injured.
If you will be working with another person, make
sure that you both understand what is to be done.
Learn and use the recognised signalling procedures.
Do not rely on shouting - he will not hear you.
To clean the tracks you must turn them. When the

tracks are turning, keep clear of rotating parts.
Before starting this job, make sure you have no
loose clothing (cuffs, ties etc.) which could get
caught in moving parts. Keep people not involved
with this job well away!.
MD3-3-2
1 Park the machine on firm level ground. Operate

the controls to slew the cab around as shown, lower
the bucket to the ground.
2 Raise the track to be cleaned clear of the ground

by operating the dipper controls with the bucket
grounded.
WARNING
Rotating the tracks off the ground may cause stones
and other debris to be thrown with considerable
force. If you are on the outside, keep well clear. Keep
other people well clear.
8-3-3-2
3 Rotate the raised track in both directions until all

mud is shaken off. If necessary hose down the track
during rotation to aid cleaning.
Inspect
1 Track rollers, Track wheel sprockets and Idler
wheels for damage or oil leaks. Repair parts as
required.
2 Tracks for damage or wear. Replace tracks as

required.
3 On machines fitted with rubber track option, visually

inspect the track and replace if:
- one or more metal cores are missing.
- steel cord is exposed.
- more than half the track is missing.
- the track comes off although fully tensioned.
9803/3145 Issue 1
2-2 2-2
Tracks (cont'd)
Steel Track
1 Position the machine so that the master pin B is at
the front of the track, as shown.
2 Remove the fastener A and drive out the master

pin B.
WARNING
Ensure that all persons are clear of the track and
especially of the driven sprocket during the following
operations.
TRACK 1-6
3 Slowly reverse the machine until the track is laid

on the ground.
WARNING
The following operations must only be undertaken
by persons familiar with track changing operations
and who are qualified to perform the operations. All
persons must keep clear of the driven sprocket.
TRACK 1-7
4 Lay out the replacement track C, behind the

machine. Drive the machine onto the new track,
guiding the track over the idler wheel D and roller
E, until the ends can be joined.
5 Fit the master pin B and lock using a new fastener

A.
6 Refer to 'Track Tensioning'.
9803/3145 Issue 1
2-3 2-3
Tracks (cont'd) 6 Fit replacement track to the machine. If marked

the 'M' should be in the position indicated. Replace
the grease adaptor C.
7 Tension the track, see 'Track Tensioning'.
Rubber Track
8 Replace the access plate B and secure using the
WARNING bolts A.
you. Position the machine on a firm level surface 9 Remove the machine supports and lower the track
before raising one end. Ensure the other end is to the ground.
hydraulics or jacks to support the machine when Track Tensioning (Steel and Rubber)
working under it. 1 Set the machine in the posture shown, with the track
Disconnect the battery, to prevent the engine being to be tensioned raised from the ground and the
started while you are beneath the machine. undercarriage supported.
GEN-001
2 Remove the bolts A and the access plate B.
1 Position the machine in the posture shown. Fit
suitable supports under the machine lower structure. 3 Check the tension clearance D. The tension
clearance should be between 15mm and 20mm for
2 Remove bolts A and take off access plate B. a rubber track or 40mm and 45mm if a steel track
is fitted.
3 Using a 28mm socket, unscrew and remove the
grease adaptor C. 4 Apply grease (See Lubricants and Capacities) to
the grease adaptor C, to achive the correct tension.
4 Fully release the track tension by pushing the track
idler inwards. 5 Replace and secure the access plate. Remove the
machine supports and lower the machine to the
5 Pull the track clear of the machine. ground.
9803/3145 Issue 1
2-4 2-4
Tracks (cont'd) Track Guides
Converting Tracks Removal and Replacement
CAUTION Track guides are fitted to both sides of each track at the
When converting a machine from steel tracks to idler wheel position. At the drive hub position they are
rubber tracks, the track guides must be removed. fitted to the outer side of the track.
When converting from rubber tracks to steel tracks
the track guides must be fitted. 1 Remove the bolts A securing the guide brackets B to
the subframe, remove the bracket from the subframe.
Damage to the tracks may result if this is not carried
out.
TRACK 1-8
Track change Guides
Steel to rubber OFF

Rubber to steel ON
9803/3145 Issue 1
3-1 3-1
Track Rollers
When Removing
WARNING
you. Position the machine on a firm, level surface
hydraulics or jacks to support the machine when
working under it.
Disconnect the battery, to prevent the engine being

started while you are beneath the machine.
GEN-001
B
1 Set the machine in the posture shown. Fit suitable
supports under the machine lower structure. If
necessary adjust the track tension to allow the track
to become clear of the rollers.
A
Upper Roller
2 Gain access to the roller by removing or splitting
the track.
3 Undo the nut A securing the roller B to its mounting

bracket.
Lower Roller
4 Remove the bolts C, D and washers E. Lower the
roller assembly F from the machine.
When Fitting
1 Fit the rollers in the reverse sequence to removal.
Torque tighten the fittings.
2 Refit and tension the track.
3 Remove the supports and lower the tracks to

theground.
Torque Settings
A 160 16.3 118
C 244 25.0 180
D 244 25.0 180
C
E
F
E
D
9803/3145 Issue 1
3-2 3-2
Track Rollers (cont’d)
Upper Rollers
When Dismantling When Assembling

1 Remove the bolt C and washer D. 1 Press the bearing R into the roller E and fit the
circlip Q.
2 Remove the circlip F, O-ring G and plate H.
2 Install the plate N and seal P on the pin K.
3 Remove the circiip J and partly withdraw the pin K
assembly. 3 Install the pin K assembly through the bearing R.
4 Remove the bearing L. 4 Install the circlip M on the pin K.
5 Remove the circlip M and withdraw the pin K 5 Press the bearing L onto the roller E.
assembly fully.
6 Fit the circlip J to the pin K.
6 Remove the plate N and seal P from the pin K,
7 Turn the assembly so that the opening is uppermost
7 Remove the circlip Q and then the bearing R. and fill the assembly with 27cc of JCB Gear Oil
HD90.
Inspection
1 Check that the roller diameter at the outer edge and 8 Install the O-ring G on the plate H and install the
dimension ‘X’ are within permitted limits, see page assembly in the roller E.
7/1 -1 Renew as necessary.
9 Secure the plate H with the circlip F.
2 Check that the roller bearings run freely and smoothly
and there is no discoloration, scratching, pitting or 10 Fit the washer D and bolt C.
corrosion. Renew as necessary.
9803/3145 Issue 1
3-4 3-4
Track Rollers (Cont'd.)
Lower Rollers
When Dismantling Inspection

1 Remove semi circular clips 1 from grooves in end 1 Check that the roller diameter at the outer edge
of shaft. are within permitted limits, see page 7/1-1. Re-new
as necessary.
2 Remove 'O rings 2 from roller shaft 3 and remove
shaft. 2 Check that the roller bearing bushes 6 are not
marked or worn oval. Renew as necessary.
3 Pry off end caps 4 and drain roller of oil.
3 Check contact area of metallic face seals 5, refer
4 Maintain metallic face seals 5 in original pairs. to page J/6-1.
5 If necessary remove bearing bushes 6. When Assembling

1 Install bearing bushes 6 into roller shell.
2 Fit one pair of metallic face seals 5 to end cap and

roller shell.
3 Replace roller shaft 3 through roller end cap. Renew

'O' rings 2 on roller shaft.
4 Replace semi circular clip 1 in roller shaft groove.
5 Remove filler plug 7 in end cap, fill roller casing

with 75cc of JCB Special Gear Oil.
1
4
5
2
3
2
6
5
4 H13180
1
9803/3145 Issue 1
4-1 4-1
9803/3145 Issue 1
4-2 4-2
Idler and Recoil Unit
When Dismantling
WARNING
The recoil unit spring can cause serious injury if
suddenly released. Take care when removing and
replacing the spring retaining nut.
Scrap recoil units must be dismantled before transfer
from the workshop.
Do not use flame cutting equipment unless
precautions are taken to release the spring pressure
slowly.
Note: If smooth faced idlers are to be rebuilt it is

recommended that they are changed in pairs for the later
sprocket type.
1 Set the machine to remove the track. 9 Withdraw the idler shaft J from the idler K.
2 Undo the recoil adjusting valve nut A to relieve the 10 Withdraw the piston rod N from the tensioner P.
grease pressure. Remove and discard the wiper seal Q and seal R.
3 Carefully raise and support the dozer clear of the 11 Ensure all old grease is removed from the tensioner
track to give sufficient clearance for the removal of P. Remove the cotter pin S from the nut T.
the idler wheel.
13 Using a 2.5 to 3.0 tonne press, compress the spring
4 Support the dozer ram and disconnect the dozer U and remove the nut T.
from the ram.
14 Carefully release the pressure on the unit.
5 Lift the idler and recoil assembly clear of the Remove the cap V and the spring U from the spring
machine undercarriage. support W.
6 Remove bolts B and spring washers C, separate Inspection

the idler wheel assembly from the tensioner 1 Examine the spring U for cracks and distortion.
assembly. Renew if necessary.
7 Drive out the tension pins D and remove the idler 2 Examine the spring support W for wear or damage.
supports E. Renew if required.
8 Remove the lip seals F circlips G and the bearings 3 Examine the cap V for wear or damage. Renew if
H. necessary.
9803/3145 Issue 1
4-3 4-3
9803/3145 Issue 1
4-4 4-4
Idler and Recoil Unit (cont'd)
When Assembling
1 Install the idler shaft J into the idler K. 13 Remove the grease nipple from the valve nut A
and fit valve nut A into the tensioner P. Ensure that
2 Fit new bearings H in the idler K over the idler shaft grease flows from the tensioner P then fit the grease
J. nipple to valve nut A.
3 Secure the bearings H with the circlips G. 14 Attach the idler assembly to the tensioner assembly
with the spring washers C and bolts B.
4 Fit new lip seals F to the idler K over the idler shaft
J. 15 Slide the spring U and cap V over the spring support
W.
5 Fill the idler assembly with 72ml of JCB gear oil
HD90 through the capscrew L hole. 16 Use the 2.5 to 3.0 tonne press to compress the
spring to a length of 213mm at X. Check
6 Fit a new bonded washer M and the capscrew L compression load equals 2216Kgf.
into the idler K.
17 Install the nut T and secure with a new cotter pin S.
7 Position the idler supports E over the idler shaft J
with the tension pin D holes aligned. 18 Release the spring assembly from the press
8 Drive in the tension pins D to secure the idler 19 Install the idler and recoil assembly into the machine
supports to the idler shaft J. undercarriage.
9 Lubricate the new seal R and new wiper seal Q 20 Reconnect the dozer to the dozer ram.
with MPL grease and install them in the tensioner
P. 21 Fit the track to the machine.
10 Fully pack the tensioner P with JCB MPL grease. 22 Set the track tension.
11 Remove the valve nut A.
12 Prime the piston N with JCB MPL grease to ensure

that there are no trapped air pockets.
Carefully install in the tensioner P until grease is
emitted continuously from the valve nut orifice.
9803/3145 Issue 1
5-1 5-1
Driven Sprocket
When Dismantling When Assembling

1 Set up the rnachine and remove the track, see page 1 Install the driven sprocket C onto the track gearbox
J/2-2, J/2-3. Clean off all dirt and accumulated D.
debris.
2 Fit bolts A.
2 Remove the bolts A.
3 Torque tighten the bolts, see page 3 / 1 - 3
3 Remove driven sprocket C from the track gearbox
D. 4 Fit the track, see page J/2-2, J/2-3.
Inspection
1 Check that the driven sprocket conforms to
permitted tolerances.
9803/3145 Issue 1
6-1 6-1
Track Roller metallic face seals
When Removing
CAUTION
Avoid skin contact with surface 'A' as corrosion may
be caused.
Retain face seals in pairs when they are removed. Fit

as matched pairs if suitable for further use.
Inspection
If contact area A is undamaged, estimate remaining life
wear as follows:
New seals Contact area is a narrow band at

outer edge.
Partly worn seals Contact area is wider but does not

extend full width.
Scrap seals Contact area is worn to full width.
Renew pair of seals if contact surface is scratched,

pitted or corroded.
Examine outer edges B, housing ramp C and lip D.

Carefully polish away light damage or corrosion.
When Replacing
Thoroughly clean and dry seals, 'O' rings and housings
before fitting seals as follows:
Note: Do not allow oil to come into contact with the 'O'
rings or housings until the assembly is complete.
Fit 'O' rings onto the seals, check that they seat evenly
and are not twisted.
Press 'O' ring past lip D. Check that dimension is

constant around the circumference of seal.
Immediately before final assembly, clean dust etc. from

surface A and lightly coat with clean oil of the appropriate
grade.
9803/3145 Issue 1
Section L Engine Section L
Contents ...................................................................................... Page
Technical Data .............................................................................. 1 - 1
Engine Oil
Drain and Refilling .................................................................. 2 - 1
Oil Filter
Renewing ................................................................................ 2 - 2
Oil Cooler
Removing and Fitting ............................................................. 2 - 3
Oil Pressure Relief Valve
Oil Sump, Suction Pipe and Strainer
Fuel Filter
Renewing ................................................................................ 5 - 1
Fuel Lift Pump
Removing, Inspecting and Fitting ........................................... 5 - 2
Dismantling, Inspecting and Assembly ................................... 5 - 3
Fuel Injection Pump
Fuel Injection Timing
Checking and Adjusting .......................................................... 5 - 5
Fuel Injectors and Fuel Pipe Assemblies
Removing, Dismantling and Inspecting .................................. 5 - 6
Fuel System
Bleeding .................................................................................. 5 - 8
Air Filter
Renew Outer / Inner Element ................................................. 6 - 1
Engine Coolant
Draining and Filling ................................................................. 7 - 1
Water Pump, Thermostat Housing Assemblies
Removing, Inspecting and Fitting ........................................... 7 - 2
Engine
Removing and Replacing ....................................................... 9 - 2
Cylinder Head
Removing, Inspecting and Fitting ......................................... 10 - 1
Piston and Connecting Rods
Timing Gear Case
Removal and Replacement .................................................. 12 - 1
Idler Gear and Oil Pump Assembly
Removing, Dismantling, Inpecting and Fitting ...................... 13 - 1
Camshaft Assembly and Tachometer Drive
Crankshaft
Removing ............................................................................. 15 - 1
Dismantling and Inspecting .................................................. 15 - 2
Assembling ........................................................................... 15 - 4
9803/3145 Issue 1
1-1 1-1
Technical Data
General
Model
KE 103-15 IDI
Type Vertical in-line, 3 cylinder, normally aspirated, 4 stroke,
water cooled diesel.
Swept Volume 1.493 litre (91.29 in3)
Power Output 802.7 - to M747210 - 20.9 kW (27 hp) @ 2345 rev/min.

803 - to M827239 - 20.1 kW (26.8 hp) @ 2200 rev/min.
804 - to M734833 - 19.2 kW (25.6 hp) @ 2110 rev/min.
802.7 - M747211on - 21 kW (28 hp) @ 2200 rev/min.
803 - M827240 on - 21 kW (28 hp) @ 2200 rev/min.
804 - M734833 on - 21 kW (28 hp) @ 2200 rev/min.
Bore 84 mm (3.31 in.)

Stroke 90mm (3.54in.)
Firing Order 1-2-3
Valve Clearance (cold) 0.2 mm (0.008 in.)
Compression Ratio 22.5:1
Compression Pressure 29.4 bar (30 kgf/cm2, 427 lbf/in.2)
Injection Timing / Injection Pump 220 - 230 B.T.D.C.
Injector Setting 152 - 161.7 bar (155 - 165 kgf/cm2, 2204 - 2346 lbf/in2)
Oil Capacity (min - max) 4.5 - 5.7 litres (1.0 - 1.3 U.K. gallons 1.2 - 1.56 US Gal)
Oil Pressure 1.7 - 4.1 bar (1.8 - 4.2 kgf/cm2, 25 - 60 lbf/in.2)
Weight (dry) 135 kg (297 lb)
Idling Speed 1050 rev/min.
Maximum No load Speed 802.7 Plus - 2580 rev/min

802.7 Super - 2420 rev/min*
803 Plus - 2420 rev/min

803 Super - 2420 rev/min*
804 Plus - 2320 rev/min

804 Super - 2420 rev/min*
Note: All American machines have JCB low emission (EPA) diesel engines fitted. European machines are being
progressively fitted with the EPA engines. On the EPA engines, it is not possible to adjust the engine idle speed, other
than throttle cable adjustment.
Note: * indicates that the engine fitted to these machines is a sealed unit. Do not attempt to adjust the engine idle
speed. You must seek the advice of a registered JCB distributor to rectify this type of problem.
For complete engine servicing refer to Perkins 100 Series Service Manual.
Coolant Capacity 2.65 litres (0.6 U.K. gallons 0.72 US Gals)
9803/3145 Issue 2*
1-2 1-2
Technical Data (cont’d)
Torque Settings Nm kgf m lbf ft

Cylinder Head Bolts 88 to 93.5 9.0 to 9.5 65 to 69 oiled
Connecting Rod Nuts 49 to 54 5.0 to 5.5 36 to 40
Flywheel Bolts 58.3 to 69 6.0 to 7.0 43 to 51
Injector Nozzle 58.3 to 69 6.0 to 7.0 43 to 51
Main Bearing Bolts 24.5 to 29.4 2.5 to 3.0 18 to 22
Big-end Bearing Bolts 49 to 54 5.0 to 5.5 36 to 40
Cooling Fan Bolts 9.5 to 12.2 0.9 to 1.3 7 to 9
Camshaft and Timing Gears
Cam Height (inlet and exhaust) (new) 34.065 to 34.12 mm (1.341 to 1.343in.)
(service limit) 33.7 mm (1.327in.)
Cam Height (injection pump) (new) 41.94 to 42.06mm (1.6512 to 1.6559in.)
(service limit) 41.8mm (1.6457in.)
Cam Height (fuel feed pump) (new) 31.9 to 32.0mm (1.2559 to 1.2598in.)
Timing Gear Backlash (new) 0.08mm (0.003in.)
Connecting Rod
Gudgeon Pin O.D. (new) 27.996 to 28mm (1.1022 to 1.1024in.)
Gudgeon Pin Small End Bush

Clearance (new) 0.01 to 0.025mm (0.0004 to 0.001in.)
(service limit) 0.08mmm (0.003in.)
Crankshaft
End-float (new) 0.10 to 0.40mm (0.004 to 0.016in.)
9803/3145 Issue 2*
1-3 1-3
Crankshaft Alignment (new) 0.03 mm (0.0012 in) or less

(service limit) 0.06 mm (0.0024 in)
Main Journal Diameter (new) 67.957 to 67.970mm (2.6755 to 2.6760 in)

(service limit) 67.9 mm (2. 673 in)
lst Re-grind Diameter (nominal 0.25 mm u/s) 67.707 to 67.72 mm (2.6656 to 2.6661 in)
2nd Re-grind Diameter (nominal 0.5 mm u/s) 67.457 to 67.470 mm (2.6557 to 2.6563 in)
Big-end Journal Diameter (new) 51.964 to 51.975 mm (2.0458 to 2.0463 in)

1st Re-grind Diameter (nominal 0.25 mm u/s) 51.714 to 51.725 mm (2.0360 to 2.0364 in)
(service limit) 51.65 mm (2.0335in)
Crankshaft Bearing (bush)
Diameter (new) 67.957 to 67.97 mm (2.6755 to 2.6760 in)
1 st Re-grind Diameter (nominal 0.25 mm u/s) 67.707 to 67.720 mm (2.6656 to 2.6661 in)
Main Bearing Oil Clearance (new) 0.044 to 0.102 mm (0.0017 to 0.004 in)
Big-end Bearing Oil Clearance (new) 0.035 to 0.083 mm (0.0010 to 0.0030 in)
Crankshaft Bearing (bush)
Oil Clearance (new) 0.044 to 0.116 mm (0.0017 to 0.0046 in)
Fillet Radius (mains) 2.8 to 3.2 mm (0.11 to 0.126 in)

Fillet Radius (big-ends) 2.8 to 3.2 mm (0.11 to 0.126 in)
Surface Finish of Journals and
Thrust Faces 1.6 Z (0.064 in)
Oil Hole Radius 2 to 5 mm (0.0787 to 0. 1960 in)
Cylinder Head
Distortion of Head Surface (max) 0.12 mm (0.005 in)
Piston Protrusion above cylinder block 0.5 to

0.8 mm (0.020 to 0.031 in)
Gasket Thickness (tightened) 1.4 mm (0.055 in)
Gasket No. 111147001
Valve Seal Angle 45°
Valve Seat Width (intake) (new) 1.66 to 1.87 mm (0.065 to 0.074 in)
Valve Seat Width (exhaust) (new) 1.66 to 1.73 mm (0.065 to 0.068 in)
Valve to Valve Guide Clearance
- intake (new) 0.03 to 0.06 mm (0.0012 to 0.0024 in)
-exhaust (new) 0.050 to 0.075 mm (0.002 to 0.003 in)
9803/3145 Issue 2*
1-4 1-4
Cylinder Block
Distortion of Block Surface (new) 0.05 mm (0.002 in)
Cylinder
Bore Diameter (new) 84.000 to 84.019 mm (3.307 to 3.308 in)
Ist Re-bore Diameter (nominal 0.5 mm o/s) 84.500 to 84.51 9 mm (3.327 to 3.328 in)
2nd Re-bore Diameter (nominal 1.0 mm o/s) 85.00 to 85.019 mm (3.347 to 3.348 in)
Fuel Injectors
Nozzle Opening Pressure 152 - 162 bar (155 - 165kg/cm2, 2204 - 2346 lbf/in2)
Dry Nozzle at
Valve Seat Pressure Tightness 98.07 bar (100 kg/cm2, 1422.4 lbf/in2)
Oil Pump
Rotor Lobe Clearances (new) 0.01 to 0.15 mm (0.0004 to 0.006 in)
Rotor-to-Cover Clearance (new) 0.1 to 0.15 mm (0.004 to 0.006 in)
Pistons and Rings

Gudgeon Pin Boss I.D. (new) 27.999 to 28.003 mm (1.1023 to 1.1025 in)
Gudgeon Pin Boss I.D. to
Pin Clearance (new) - 0.001 to + 0.007 mm (- 0.00004 to + 0.0003 in)
Ring Gap
- No. 1 ring (new) 0.20 to 0.35 mm (0.008 to 0.014 in)
- No. 2 ring (now) 0.20 to 0.40 mm (0.008 to 0.016 in)
- Oil ring (now) 0.20 to 0.40 mm (0.008 to 0.016 in)
Ring to Groove Side
Clearance

- Oil ring (new) 0.02 to 0.06 mm (0.0008 to 0.0023 in)
Radiator
Cap Opening Pressure 0.73-0.93 bar (0.75 -0.95 kg/cm2, 6.5-10.8 lbf/in2)
Thermostat
Opening Temperature
- Starts to open 69 to 73°C (156-163°F)
- Fully open 82°C (180°F)
Lift 8.0 mm (0.315 in)
9803/3145 Issue 2*
1-5 1-5
Valves and Springs

Valve Stem Diameter (inlet) 6.955 to 6.97 mm (0.2738 to 0.2744 in)
(exhaust) 6.94 to 6.95 mm (0.273 to 0.274 in)
Valve Stem to Guide Clearance

-inlet (new) 0.03 to 0.06 mm (0.001 to 0.002 in)
-exhaust (new) 0.05 to 0.075 mm (0.002 to 0.003 in)

Valve Head Thickness (new) 0.925 to 1.075 mm (0.0364 to 0.0423 in)

Valve Face Angle 45°

Valve Recessing (new) 0.85 to 1.15 mm (0.034 to 0.045 in)
Spring Free Length (new) 35 mm (1.4 in)

Spring Fitted Length 30.4 mm (1.197 in)
Load to Compress to
Fitted Length (new) 79.43 N (8.1 kgf, 17.9 lbf)
(service limit) 68.65 N (7.0 kgf, 15.4 lbf)
Spring Squareness (new) 3.4%

(service limit) 6.0%
Rocker Shaft Diameter (new) 11.65 to 11.67 mm (0.4587 to 0.4594 in)

Rocker Arm Running Clearance (new) 0.032 to 0.068 mm (0.0013 to 0.0027 in)
9803/3145 Issue 1*
2-1 2-1
Engine Oil
Note: The illustration shown below is for an 803 machine,

however, the procedure for the remaining machines is
similar
Draining and Filling for interval see Service Schedule
WARNING
Used engine oil contains carbon deposits and is
hazardous to health, do not allow excessive contact
with the skin. Thoroughly wash hands with a good
quality cleanser after this operation.
CAUTION
The engine and its oil will be hot and may burn, take
necessary precautions.
Deposit old oil in the correct manner in accordance

with the local authority.
Draining
1 Run the engine to thoroughly warm the lubricating
oil
2 Park the machine on firm level ground. Lower the

excavator to the ground.
4 Open the engine cover.
5 Place a suitable container beneath the engine oil

drain plug to catch the oil, (see page 3 / 1 - 1 for
capacity).
6 Remove the drain plug A and let the oil drain out.
Filling
1 Clean the drain plug A and refit it. Make sure it is
tight.
2 Fill the engine slowly with new oil through the filler
cap B (see page 3/1 - 1 for capacity). Do not pour
the oil in too quickly as it may blow back and flow
over theengine.
3 Disconnect the electrical lead from the fuel solenoid

and crank the engine until the oil pressure warning
light goes out.
4 Check for leaks and top up if necessary with new

oil.
(See page 3/1 - 1 for capacity.)
5 Reconnect the electrical lead to the fuel solenoid.
9803/3145 Issue 1
2-2 2-2
Engine Oil Filter

however, the procedure for the remaining machines is
similar.
Renewing for interval see Service Schedule
1 Drain the engine oil, see page L/2-1.
2 Unscrew the filter canister A. If necessary use a

chain or strap wrench.
3 Clean the filter mounting head B.
4 Smear the new seal C with oil.
5 Screw in the new filter canister - hand tight and

then one quarter turn.
6 Fill the engine with new oil. (See page3/1-1 for

capacity).
7 Motor the engine until the oil pressure warning light

goes out.
8 Check for leaks and top-up the engine with oil.
9803/3145 Issue 1
2-3 2-3
Engine Oil Cooler (If fitted)
Removing
1 Drain the engine oil, see page L/2-1.
2 Drain the engine coolant, see page L/7-1.
3 Disconnect and plug hoses A and B from the engine

oil cooler C. Make a note of the connections to H
ensure correct refitting.
E F D
4 Disconnect engine coolant hoses D, remove
retaining bolt E and remove the engine oil cooler. D
5 Remove engine oil filter H.
6 Remove oil supply hoses from cooler sandwich

block F and associated adapters.
G
7 Unscrew sandwich block F from engine cylinder
block. Remove seals G and discard C
Fitting A B
1 Renew seals G between engine cylinder block and
oil cooler sandwich block F, replace sandwich block
ensuring correct phasing of oil cooler oil supply hose
ports. Replace hose adaptors and hoses.
2 Renew/replace filter H.
3 Connect engine coolant hoses D to the engine oil

cooler C.
4 Connect engine oil hoses A and B to the engine oil

cooler as noted during removal.
5 Refill the engine cooling system, see page L/7-2.
6 Refill the engine with oil, see page L/2-1.
9803/3145 Issue 1
3-1 3-1
Oil Pressure Relief Valve

however, the procedure for remaining machines is similar
Removing
1 Loosen and remove the relief valve A.
Fitting
1 Fit a new 0-ring to the relief valve A.
2 Insert the valve in the cylinder block and tighten.
Torque Settings
A 59-69 6.0-7.0 44-51
9803/3145 Issue 1
4-1 4-1
Oil Sump, Suction Pipe and Strainer

Fitting
Removing
1 Fit a new O-ring D to the pipe C and insert the pipe
1 Drain the engine oil, see page L/2 - 1.
into the cylinder block.
2 Remove all the sump bolts and remove the sump
2 Fft the strainer B to the pipe C.
and gasket.
3 Fit the bolts A and tighten.
3 Loosen and remove the bolts A and remove the
strainer B.
4 Fit the sump with a new gasket. Tighten the bolts
diagonally and evenly.
4 Rotate the pipe C and remove the pipe from the
cylinder block.
Torque Settings
5 Remove and discard the 0-ring D from the pipe C. Item Nm kgf m lbf ft
A 9-13 0.9-1.3 6.5-10
Note: Engine is shown inverted.
9803/3145 Issue 1
5-1 5-1
Fuel Filter
Renewing for interval see Service Schedule
1 Disconnect the battery.
2 Support the bowl A.
3 Unscrew bolt B.
4 Remove the bowl and element C.
5 Wash the bowl in clean fuel.
6 Install the element C with new seals D. Make sure

they seat correctly.
7 Tighten bolt B.
8 Check for leaks.
9 Bleed the fuel system, (see page L/5 - 8).
10 Reconnect the battery.
9803/3145 Issue 1
5-2 5-2
Fuel Lift Pump
Removing, Inspecting and Fitting
Removing
1 Loosen the clamp A and remove the fuel lines.
2 Remove the two securing bolts B complete with

washers.
3 Remove the fuel lift pump C.
4 Remove the gasket D.
5 Drain any fuel from the lift pump.
Inspecting
1 Examine for damage, cracks etc.
2 Make sure that the bottom body E and the piston F

are not seized.
3 Check the top body G as follows:

- draw air from the IN side using a vacuum and
blow air into the OUT side
- if the air stops in both cases, the body is normal.
Fitting
1 Install a new gasket D on the fuel lift pump.
2 Insert the fuel lift pump C in its bore.
3 Fit the two securing bolts B and washers and tighten

them.
4 Fit the fuel lines and tighten the clamps A.
9803/3145 Issue 1
5-3 5-3
Fuel Lift Pump (cont'd)
Dismantling, Inspecting and Assembly
Dismantling
Note: Before dismantling the fuel pump make sure that
the bottom body E and piston F are not seized.
1 Make a note of the reference marks on the cap G,

top body H and bottom body E.
2 Remove the bolts J and separate the top body H

and cap G from the bottom body E. Discard the
gasket K.
3 Remove the swivel couplings L and M from the

cap G.
4 Turn the piston F until the pin N aligns with the

groove in the bottom body E.
5 Hold the diaphragm P and piston F in position

against the spring pressure and remove the pin N.
6 Take care with the springs Q and R, remove

diaphragm P, piston F and springs Q and R.
Inspecting
Note: If the lift pump is found to be unserviceable, a new
lift pump will have to be fitted. The new lift pump will not
have a lift pump lever. Therefore, a priming bulb will also
have to be installed to the fuel system to permit fuel
system priming.
1 Examine the fuel pump components for damage

or wear. Check that the diaphragm P is not cracked
or damaged.
2 Inspect the check valves located in body H and

clean as required.
Assembly
1 Assemble the fuel pump in the reverse order of
dismantling.
2 Make sure that the reference marks align and fit a

new gasket K.
9803/3145 Issue 2*
5-4 5-4
Fuel Injection Pump Assembly
Removing
1 Remove fuel pipe assembly from injectors and fuel

pump, see page L/5 - 6.
2 Remove the two mounting bolts A and nuts B.
3 Carefully lift the fuel injection pump until access to

the link snap pin C is gained.
4 Disconnect the link D and remove the fuel injection

pump.
5 Remove the shim(s) E. Record the number and

thickness of the shim(s) for re-assembly.
Fitting
1 Put the shim(s) E in position.
2 Position the fuel pump and connect the link D. Fit

the snap pin C.
3 Install the fuel pump and fit the mounting bolts A

and nuts B.
4 Tighten the mounting nuts and bolts.
5 Adjust the fuel injection timing, see page L/5 - 5.
6 Fit the fuel pipe assembly, see page L/5 - 6.
9803/3145 Issue 1
5-5 5-5
Fuel Injection Timing

Piston Position and Crankshaft Angle (BTDC)
Checking and Adjusting
- for interval see Service Schedule
Crankshaft Angle Piston Position
(°BTDC) mm (in)
This procedure provides the correct injection timing. If 21 3.895 (0.1533)
the fuel injection pump, the camshaft assembly, or the 22 4.267 (0.168)
cylinder block have been renewed carry out this check. 23 4.655 (0.1833)
When renewing the fuel injection pump start with a shim 24 5.058 (0.1991)
of 0.5 mm (0.0197 in) thickness. 25 5.477 (0.2156)
26 5.912 (0.2328)
1 Remove the fuel pipe assembly. See page L/5 - 6. 27 6.361 (0.2504)
28 6.826 (0.2687)
2 Remove the delivery valve holder A at the front 29 7.304 (0.2876)
(radiator side) of the fuel injection pump B.
5 Move the governor control lever to maximum fuel
3 Remove the delivery valve (IN) C. position. Slowly turn the crankshaft clockwise until
No. 1 piston is a little before ‘X’ degrees BTDC on
4 Refit the spring D and the delivery valve holder A its compression stroke and continue turning until
in the injection pump B. fuel starts to flow from the delivery holder.
Note: When re-assembling the delivery valve holder A, 6 Then slowly turn the crankshaft clockwise until fuel
use a length of wire to align delivery valve E. flowing from delivery holder is stopped. Check the
piston position at this point. If the position is later
than ‘Y’ BTDC, use a thinner shim. If the position
exceeds ‘Z’ BTDC, use a thicker shim.
Note: Changing the shim thickness by 0.1 mm (0.004 in)

will change the timing by approximately one degree.
Increasing the shim thickness makes the timing later (i.e.
decreases the angle) while decreasing the shim thickness
makes the timing earlier (i.e. increases the angle). When
no shims are needed, assemble with coating of liquid
sealant.
Shims are available in the following thicknesses (for part

numbers see parts microfiche): 0.2mm, 0.3mm, 0.4mm,
0.5mm.
Injection Timing and Crankshaft Positions
Engine Model No Degrees Crank BTDC
X Y Z Injection Timing
KE 103-151DI 25 22 23 22-23
7 Remove the delivery valve holder A and fit the

delivery valve (IN) C.
Piston Position and Crankshaft Angle (BTDC)
8 Refit the delivery valve holder A and torque tighten.
Crankshaft Angle Piston Position
(°BTDC) mm (in)
9 Refit the fuel pipe assembly, see page L/5-6.
16 2.278 (0.0897)
17 2.569 (0.1011)
Torque Settings
18 2.875 (0.1132)
19 3.199 (0.1259) Item Nm kgf m lbf ft
20 3.539 (0.1393) A 39-45 4-4.5 29-33
9803/3145 Issue 1
5-6 5-6
Fuel Injectors and Fuel Pipe Assembly
Removing, Dismantling/Inspecting
Removing Dismantling/Inspecting
1 Loosen the fuel pipe nuts H from the injectors and 1 Carefully place the nozzle holder (body) A in a vice
the fuel injector pump. and turn the nozzle nut B to disassemble.
2 Remove the fuel pipes as an assembly. Note: Care should be taken the needle valve does not
fall when the nozzle C is removed.
3 Remove the spring clamp J and the fuel return hose
K. 2 Wash the nozzle body and needle valve and inspect
the nozzle for seizure, sticking and fuel leakage on
4 Loosen and remove the Banjo bolt and three the seat surface. If fuel leakage is detected, replace
securing nuts L. Remove the leak-off rail M. the nozzle.
Remove and discard the three aluminium washers
N. 3 Inspect the upper and lower contact surfaces of the
distance piece D and correct so that positive contact
5 Remove the injectors and discard the cap P and can be obtained.
gaskets Q.
4 Check the nozzle needle valve-contact surface on
the push rod E for wear, and spring seat for cracks.
9803/3145 Issue 1
5-7 5-7
Fuel Injectors and Fuel Pipe Assembly

(cont’d)
Reassembling/Adjusting and Fitting

Fitting
Reassembling/Adjusting
1 Before fitting a new nozzle assembly, soak it in 1 Fit new cap P and gaskets Q on injector body.
heated light oil (50° - 60°C, 122° - 140°F) to remove
anti-corrosive agent from the nozzle. Then slide 2 Fit the injector and torque the body to 59 - 69Nm (6
the body on the needle valve so that they slide - 7 kgf m, 44 - 51 lbf ft).
smoothly.
3 Fit the leak off rail M with new washers N and
2 Turn the nozzle body upside down, fit the shims F, securing nuts L.
spring G, rod E, spacer D and nozzle C, in this
order, and torque tighten to 78 - 98Nm (8 - 10kgf 4 Fit the spring clamp J and the return hose K.
m, 58 -72lbf/ft). using nozzle nut B.
5 Fit the fuel pipe assembly and tighten the nuts H.
3 After reassembly, check the injection pressure of
the nozzle, adjust as required.
Torque Settings
WARNING Item Nm kgf m lbf ft
Avoid contact with the fuel spray and do not inhale B 59-69 6-7 44-51
the fumes. Keep naked flames away and do not H 15-25 1.5-2.5 11-18
smoke while working on the injector. There could
be a fire and injury if you do not follow these
precautions.
8-3-4-8
4 Adjust the pressure with adjusting shims using a

nozzle tester so that the injection starts at 152 bar
(155 - 165 kg/cm2, 2204 - 2346lbf/in2). Note that
the pressure increases or decreases about 10 bar
(10 kg/cm2, 142 lbf/in2) with a shim of 0.1 mm (0.004
in) thick.
Spray condition:
a Fuel drops should not be mixed in the spray
pattern.
b Fuel should be sprayed in conical shape with

respect to the nozzle axis.
c Check that the fuel is sprayed in a circular shape

when tested.
d Hold the pressure at 132 bar (134kg/cm2, 1914

lbf/in2) - i.e. lower by 20 bar (20 kg/cm2, 284.5
lbf/in2) than specified and check that no test oil
drops from the nozzle tip.
5 When the adjustment is correct torque tighten the

nozzle nut B on the body A.
9803/3145 Issue 1
5-8 5-8
Fuel System
Bleeding
WARNING
To bleed the injectors you must turn the engine.
When the engine is turning, there are parts rotating
In the engine compartment.
Before starting this job, make sure that you have no

loose clothing (cuffs, ties etc) which could get
caught In rotating parts.
When the engine Is turning, keep clear of rotating

parts.
2-3-3-8
Should the engine fail to start, misfire, or if any part of the

system has been disconnected or become empty, bleed
the system as follows:-
Note: The fuel injection pump is self-bleeding when the

engine is cranked.
1 Loosen vent screw A on top of the fuel filter.
2 Operate the fuel lift pump priming lever X until air-

free fuel flows from the filter vent point. Tighten
the vent screw A.
Note: If the lift pump priming lever does not operate, turn
the crankshaft one revolution to place the follower on the
back of the cam.
3 Loosen connecting union nuts B, C and D at the

injectors.
4 Open the throttle a little, use the starter key to turn

the engine until air-free fuel flows from the
connections.
5 Tighten the union nuts.
9803/3145 Issue 1
6-1 6-1
Air Filter
Renew Outer Element - for interval see Service Schedule Renew Inner Element - for interval see Service Schedule
1 Unscrew the wingnut H. Pull out the element G. 1 To prevent dust getting into the engine, remove the
Take care not to tap or knock the element as you induction hose A. Cover the hose to prevent rain
remove it. and dirt getting into the engine.
2 Clean the inside of the canister C and dust valve 2 Unscrew wingnut H. Pull out the outer element G.
D.
3 Unscrew nut F. Pull out the inner element E.
3 Insert the new element into the canister. Make sure
it seats correctly, by smearing the seal J with grease 4 Clean the inside of the canister C and dust valve
and checking for a witness mark on the canister D.
base. Fit and tighten the wingnut H. Check all hoses
for condition and tightness. 5 Carefully insert the new inner element into the
canister. Make sure it seats correctly, by
smearing the seal B with grease and checking for
a witness mark on the canister base. Fit and tighten
nut F.
66 Carefully insert the new outer element. Make sure

it seats correctly, by smearing the seal J with grease
and checking for a witness mark on the canister
base. Fit and tighten nut H.
7 Connect the induction hose. Check all hoses for

condition and tightness.
Note: In a dusty working environment, the outer element

may have to be changed more frequently than the
service schedule recommendation. A new inner element
must be fitted at latest, every third time the outer element
is changed. As a reminder, mark the inner element with
a felt tip pen each time you change only the outer
element.
9803/3145 Issue 1
7-1 7-1
Engine Coolant
WARNING Filling
The cooling system is pressurised when the coolant 1 Check the radiator, hoses and clips for security and
is hot. Hot coolant will burn you. Make sure that the damage. Renew if necessary.
engine is cool before checking the coolant level or
draining the system. 2 Clean the radiator drain plug C and refit it. Make
2-3-3-3
sure it is tight.
Draining and Filling - for interval see Service Schedule 3 Close the engine block drain tap B.
Draining 4 Fill the radiator with the correct coolant mixture.
1 Park the machine on level ground. Remove the (See page 3 /1 - 1 for capacity.) Do not fill faster
starter key. than 10 litres/min (2 UK Gal/min 2.4 US Gal/min)
as this may induce an air lock under the thermostat.
2 Open the engine cover.
5 Do not fit radiator cap at this stage. Run engine at
3 Make sure that the radiator is cool and remove the fast idle for five minutes or until all trapped air is
filler cap A. expelled. Top up radiator with coolant to 20 mm (3/
4 in) below neck. Ensure there is at 50 mm (2 in) of
4 Undo the tap B on the engine block. coolant in expansion bottle D.
WARNING 6 Refit the radiator filler cap A and make sure it is

tight.
Keep your face away from the drain hole when
removing the drain plug. 7 Start the engine and run it until engine working
2-3-3-4
temperature is reached.
5 Remove the radiator drain plug C. 8 Stop the engine and check for leaks.
6 Allow the coolant to drain.
7 If necessary flush the system with clean water.
B
A
C D
9803/3145 Issue 1
7-2 7-2
Water Pump/Thermostat Housing Assemblies
Water Pump Inspecting

1 Drain the coolant. 1 Place the thermostat into water. Raise the water
temperature gradually and make sure that the valve
2 Remove the radiator shroud. Slacken the fan belt opening temperature and the valve lift are correct
at the alternator. (see Technical Data). it not, replace the thermostat.
3 Remove the cooling fan mounting bolts A and Note: 3 to 5 minutes will be required before the valve
remove the fan and pulley. starts to open.
4 Remove the fan belt. 2 Examine the water pump for wear, leaks and
damage. Check the bearing for roughness. If
5 Loosen hose clamps B and remove them with hoses defective, replace the assembly.
C.
6 Loosen the securing bolts D and remove the water

pump assembly E, set plate F and gaskets G.
Thermostat Housing
1 Loosen hose clamps B and remove them with hoses
C.
2 Disconnect wiring from the temperature sender unit.
3 Loosen the securing bolts H and remove the

thermostat upper housing J and gasket K.
4 Remove the thermostat L from the lower thermostat

housing M.
5 Loosen bolts N and nut P and remove the lower

thermostat housing and gasket Q.
9803/3145 Issue 1
7-3 7-3
Water Pump/Thermostat Housing Assemblies (cont'd)
Removing, Inspection and fitting
Fitting
Thermostat Housing Water Pump

1 Fit a new gasket Q to the cylinder head using a 1 Fit new gaskets G and set plate F using a Silicon
Silicon RTV type liquid packing. RTV type liquid packing.
2 Secure the lower thermostat housing to the cylinder 2 Place the water pump assembly E in position using
head with attaching parts N and P. a Silicon RTV type liquid packing. Rotate the fan
holder to ensure it is not fouling. Secure evenly
3 Fit the thermostat L in the lower thermostat housing with bolts D.
M.
3 Replace hoses C and secure with clamps B.
4 Fit the gaskets K to the lower thermostat housing
using a Silicon RTV type liquid packing. 4 Fit the cooling fan and pulley to the water pump
assembly. Torque tighten bolts A to 9 - 13 Nm (0.9
5 Place the upper thermostat housing J in position - 1.3 kgf m, 6.5 - 9.5 lbf ft).
and secure evenly with bolts H.
5 Fit the fan belt and adjust.
6 Replace hoses C and secure with clamps B.
6 Fit the radiator shroud.
7 Refill with coolant (see page 3/1-1 for capacity).
8 Run and test.
9803/3145 Issue 1
10 - 1 10 - 1
Cylinder Head
Removing
Note: For clarity, the illustrations show the engine

removed from the machine. If the cylinder head is
removed with the engine in situ, first carry out the
following operations:
- Drain the cooling system, remove the radiator

and heater hoses.
- Disconnect the air cleaner and exhaust silencer

from manifolds.
- Disconnect the water and oil sender units.
The following procedure applies if the engine is either in

situ or has been removed:-
1 Loosen the fuel pipe nuts from the fuel injection

pump and the injectors. Remove the pipes as an
assembly.
2 Remove the injectors, K required, by removing the

three securing nuts. Remove the three aluminium
washers and discard them.
3 Remove the cooling fan and pulley.
4 Remove the water pump assembly and set plate,

see page L/7 - 2.
5 Remove the breather hose B. Loosen and remove

three cap nuts C with washers D. Lift the rocker
cover assembly E.
6 Remove the oil-ring gasket F.
7 Loosen and remove three nuts G, lock washers H

and flat washers J from the rocker pillar studs. Lift
the rocker assembly K.
8 Remove the push rods L and the valve stem caps.
9 Loosen and remove the two banjo bolts N at the

cylinder block main oil gallery and cylinder head
assembly. Remove the oil pipe P.
10 Remove the clamp Q from the fuel injection pump.
11 Loosen the cylinder head bolts starting from the

centre, in a circular pattern, using several steps of
equal torque. Remove the head.
9803/3145 Issue 1
10 - 2 10 - 2
Cylinder Head (cont’d)
Inspecting
1 Using a valve spring compressor, compress the
valve spring A and remove the valve collets B,
retainer C, spring A and valve D.
2 Clean off all the carbon from the cylinder head face,
valves and parts.
3 With a straight edge and a thickness gauge, check

for warping of the cylinder head lower face.
4 Check six positions, as shown at X, for distortion. If

the distortion is excessive (see Technical Data), this
must be corrected using a surface grinder.
5 Check the valve stem for excessive wear or

damage. If it is found to be excessive, renew
the valve.
6 Check the valve stem diameters at positions I, II

and Ill with a micrometer. If the diameter is less
than the permitted value (see Technical Data),
renew the valve.
7 Check the thickness of the valve head Y. If it is

less than the permitted value, renew the valve.
8 Insert the valves into the valve guides and check

the clearance between the valve stem and the valve
guide. If the clearance is excessive (see Technical
Data), renew the guide, recut the valve seat and
renew the valve.
9803/3145 Issue 1
10 - 3 10 - 3
Inspecting
9 Check the condition and width of the valve seats. If
the width Z is more than specified in Technical Data
or if the seat is excessively pitted, recut the seat as
shown.
10 Check the recess dimension of the valves Z1. If

the recess exceeds the limit specified in Technical
Data, renew the valve seat insert (if fitted).
11 Renewal of valve seat insert (where fitted):
- Either 1 . Using a gas burner (700-800°C,1292-

1443°F) heat diagonally across the valve seat
insert. Leave in air for 3 to 5 minutes and remove
the valve seat insert by light tapping (ensuring
head is not damaged).
- Or 2. Machine the insert out taking care not to

damage the head.
- Clean up the insert bore and fit a new insert using

a press (9800-14710N, 1000-1500 kgf, 2204-
3306 lbf) and a suitably smooth surface tool. To
assist the process, chill the valve seat insert with
liquid nitrogen etc. or heat the head to between
60-100°C (140-212°F).
12 Correct the valve seat contact using a valve lapper

and lapping compound. When using a new cylinder
head, obtain correct seat contact width and seat
recess using the seat cutter. Then carry out lapping.
13 Check the valve springs as follows and renew if

outside the limits specified in Technical Data:
- measure the free length.
- Check the squareness by placing the spring

against a set square positioned on a surface
plate and rotating to obtain maximum dimension
E. Measure dimension E and express as a
percentage of free length F.
i.e. squareness E x 100%.

F
- check the spring tension by measuring the load

required to compress the spring to its fitted
length.
9803/3145 Issue 1
10 - 4 10 - 4
Fitting
1 Insert the valves D in the cylinder head and fit the 10 Fit the caps on the valve stems.
spring A (using a spring compressor), the cotter B
and the retainer C. Take care not to damage the 11 Install the push rods L.
valve guide seat.
12 Fit the rocker arm assembly on the rocker pillar
2 Set each piston to T.D.C. and measure the amount studs. Fit the flat washers J, new lock washers H
of protrusion above the cylinder block with a depth and the nuts G on the rocker pillar studs.
gauge or dial gauge. Take the measurement by
pressing the piston lightly. Use the highest reading 13 Tighten the nuts G and torque to 20-24 Nm (2.0-
as the reference. 2.5 kgf m, 14.5-18.1 lbf ft).
3 Check that the cylinder head gasket meets the

tolerance levels (see Technical Data). The last four
digits of the code number are stamped on the head
gasket.
4 Install the head gasket with the code numbers at

the top.
5 Install the cylinder head.
6 Lubricate the cylinder head bolts with a

molybdenum disulphide based grease and install
them.
7 Tighten the cylinder head bolts in a three step

procedure in the order shown.
8 Torque the cylinder head bolts to 88-93 Nm (9.0-

9.5 kgf m, 65-69 lbf ft).
9 Put the oil pipe P in position and fit the banjo bolts
N at the cylinder block main gallery and cylinder
head assembly (see page L/10-1). Torque the banjo
bolts to 10-13 Nm (1.0-1.3 kgf m, 7.2-9.4 lbf ft).
9803/3145 Issue 1
10 - 5 10 - 5
Fitting
14 Adjust the valve clearances (cold) of the inlet and
exhaust valves to 0.2 mm (0.0078 in) as follows:
- loosen nut Z and adjust the screw X on each

tappet. When the clearance is correct, tighten
the nut Z.
15 Adjust the valves in this sequence:
- Set the No.1 piston to T.D.C. (compression

stroke) and adjust both No.1 cylinder valves,
No.2 cylinder inlet valve and No. 3 exhaust
valve.
- Turn the crankshaft counter-clockwise through

360° (viewed from the front).
- Adjust the No.2 cylinder exhaust valve and No.3

cylinder inlet valve.
16 Put the rocker cover oil-ring gasket F in position.
17 Carefully put the rocker cover E in position. Make

sure the oil-ring gasket F stays in position.
18 Fit the washers D and the cap nuts C on the rocker

pillar studs and tighten them evenly. Torque to 8-
12 Nm (0.8-1.2 kgf m, 6-9 lbf ft).
19 Fit the breather hose B.
20 Fit the water pump assembly, radiator and heater

hoses.
21 If necessary, fit the injectors with new aluminium

washers. Torque the injectors to 59-69Nm (6-7 kgf
m, 44-51 lbf ft). Fit the return pipe and the injection
pipes. Torque the injection pipe unions to 15-25Nm
(1.5-2.5 kgf m, 11 -18 lbf ft).
22 Fit the cooling fan pulley and fan to the water pump
assembly. Torque the bolts to 9-13 Nm (0.9-1.3
kgf m, 6.5-9.5 lbf ft).
23 Fit the fan belt and adjust to the correct tension,

see page C/3 - 1
9803/3145 Issue 1
11 - 1 11 - 1
Piston and Connecting Rods
Removing
1 Drain the coolant, see page L/7 - 1.
2 Drain the engine oil, see page L/2 - 1.
3 Remove the cylinder head assembly, see page L/

10 - 1.
4 Remove the oil sump, suction pipe and strainer,

see page L/4 - 1.
5 Remove the big-end nuts F and bolts G and remove

the big-end cap H.
6 Remove any carbon from the cylinder bore. Push

the piston and connecting rod through the cylinder
block.
7 Refit the big-end cap on the removed piston and

connecting rod. Attach a label to each of these
assemblies to ensure replacement in the original
bore.
8 Remove the piston rings A.
9 Remove the circlips B and drive out the gudgeon

pin C.
10 Repeat for each cylinder.
9803/3145 Issue 1
11 - 2 11 - 2
Piston and Connecting Rods (cont’d)
Inspecting
1 Examine the outer surface of the piston D for cracks, 12 Check the oil clearance, using plastigauge, as
scores and burns. If excessive, renew the piston. follows:
· Check the larger diameter of the piston skirt (1 0 - Remove oil or foreign matter from the bearing
mm (0.4 in) from the bottom) and check the inside and crankshaft F.
diameter (thrust direction) of the cylinder bore.
Calculate the clearance between the cylinder and - Cut the plastigauge to the same width as the
the piston. If this clearance is more than the bearing. Place it on the crankshaft. Avoid the oil
permitted value, or the piston diameter is less than hole G.
the permitted value (see Technical Data) renew the
piston.
Note: If the cylinder bore is oversized, make sure that

an oversized piston is used.
3 Measure the inside diameter of the gudgeon pin

hole and the outside diameter of the gudgeon pin.
Calculate the difference. If the clearance is
excessive (see Technical Data), renew as
necessary.
4 Measure the outside diameter of the gudgeon pin.

If less than permitted value (see Technical Data)
renew it.
- Assemble the connecting rod and connecting
5 Clean out the carbon from the piston ring grooves. rod cap and torque tighten to 49-54Nm (5.0-5.5
kgf m, 36-40 lbf ft).
6 Examine the piston rings and renew as necessary.
Note: Never rotate the connecting rod.
7 Insert the rings into the cylinder bore at right angles
to the bore and measure the clearance. If the - Remove the connecting rod cap. Measure the
clearance is excessive (see Technical Data), renew oil clearance with the scale printed on the gauge
as necessary. bag.
8 Measure the clearance between the piston ring Note: Measure the widest area.
groove and the ring. If the clearance is excessive
(see Technical Data), renew the ring. If oil clearance exceeds the permitted value (see
Technical Data), renew the bearing. Or, grind the
9 Check the connecting rod E for distortion between crankshaft and use underside bearings as follows
the large and small ends. If the distortion is (see Microfiche for part numbers):
excessive (see Technical Data), renew the
connecting rod. Bearing Size Crankshaft Pin O.D.
10 Measure the inside diameter of the connecting rod Standard 51.964 - 51.975 mm
small-end bush and calculate the clearance (2.0458 - 2.0463 in)
between the small-end bush and the gudgeon pin.
If the clearance is excessive (see Technical Data), 0.25 mm 51.714 - 51.725 mm
renew as necessary. (0.0098 in) (2.0360 - 2.0364 in)
11 Assemble the connecting rod to the crankshaft and 0.50 mm 51.464 - 51.475 mm
measure the play in the shaft direction. If the play (0.0196 in) (2.0261- 2.0266 in)
is excessive (see Technical Data), renew the
connecting rod. Note: When grinding the outside diameter of the
crankshaft, make sure that the oil clearance is correct
before reassembly.
9803/3145 Issue 1
11 - 3 11 - 3
Piston and Connecting Rods (cont’d)
Cylinder Block, Inspecting Fitting

1 Inspect the cylinder block top face for cracks, 1 Heat the piston to approximately 100°C (212°F).
damage and warping in the same way as for the
cylinder head. If outside limit, replace cylinder block. 2 Align the set marks X and the marks Y on the piston,
as shown.
2 Visually inspect cylinder bore. There should be no
scoring, rust or corrosion. 3 Insert the gudgeon pin C and fit the circlips B.
3 Using a cylinder gauge, measure the cylinder bore 4 Fit the piston rings on the piston with the scribe
at the upper, middle and lower areas (piston ring mark towards the piston crown. Make sure that the
contact area) in the direction of the crankshaft and rings are in the correct position as shown.
at right angle to the crankshaft.
5 When the connecting rod, piston or gudgeon pin
Note : The upper area described in 3 corresponds to the has been renewed, the difference in weight of the
top ring when the piston is at the T.D.C., (about 10mm complete assemblies should not exceed 10 grams
below the cylinder block top surface). The lower area between cylinders.
corresponds to the piston oil ring when the piston is at the
B.D.C. (about l00mm from top face). 6 Refit the oil suction pipe and strainer and the sump,
see page L/4 - 1.
Cylinder Bore Sizes
7 Refit the cylinder head assembly, see page L/10 -
Size Inside Diameter Allowable 1.
Limit
8 Fill the engine with oil, see page L/2 - 1.
Standard 84.00 - 84.019 mm 84.2 mm
(3.307 - 3.308 in) (3.315 in) 9 Fill the cooling system with coolant, see page L/7 -
1.
1st Re-bore 84.50 - 84.519 mm 84.7 mm
0.5 mm (0.02 in) (3.327 - 3.328 in) (3.335 in)
2nd Re-bore 85.00 - 85.019 mm 85.2 mm

0.5 mm (0.02 in) (3.346 - 3.347 in) (3.354 in)
After the second re-bore, replace the cylinder block.
9803/3145 Issue 1
12 - 1 12 - 1
Timing Gear Case
Removal Fitting
1 Remove nut A and washer B. 1 Install the start spring J.
2 Pull the crankshaft pulley C from the crankshaft D. 2 Insert the link through the hole in the cylinder block.
3 Remove the securing bolts E and lift the case off 3 Rotate oil pump cover F to position spring pin hole
the locating dowels to the centre position.
Note: Ensure the engine is not rotated. 4 Install the cover locating pin G in the oil pump cover
plate.
Note: Take care not to damage the oil seal.
6 Turn the mechanical stop lever H clockwise to assist

assembly.
7 Fit the securing bolts E and tighten them evenly.
8 Align the key way and key on the crankshaft pulley

C and the crankshaft D.
9 Fit the washer B and nut A. Torque to 275 - 334

Nm (28 - 34 kgf m, 203 - 246 lbf ft).
9803/3145 Issue 1
13 - 1 13 - 1
Idler Gear and Oil Sump Assembly Inspecting

1 Check all the components for damage and wear
Removing, Dismantling, Inspecting and Fitting and replace as necessary.
Removing 2 Measure the clearance between the rotor L and the

vane G. If the clearance is excessive (allowable
1 Remove the Timing Gear Case, see Page L/12 - 1. limit 0.25mm (0.01 in) replace the vane and rotor.
2 Remove the circlip A. 3 If the idler gear needs replacing contact Perkins
service department.
3 Remove the idler gear and oil pump assembly B
complete.
Fitting
Note: Coat both faces of the rotor and vane with grease
for assembly. DO NOT TURN the crankshaft with the
timing gear case removed.
1 Insert the rotor L in the idler gear M. Fit the pin N

and the spring J.
Dismantling 2 Insert the thrust washer K.
1 Remove the snap ring C.
3 Align the set marks on the idler gear M, crankshaft
2 Remove the collar D, the spring E and the shim F. gear P and camshaft gear Q and fit on to the idler
gear shaft R.
3 Remove the idler gear vane G and the oil pump
cover H together. 4 Install the vane G, the cover H, the shim F, the
spring E, the collar D and the snap ring C.
4 Remove the spring J and the pin N.
5 Adjust with shim 0.10, 0.15, 0.20, 0.50 mm (0.004,
5 Remove the rotor L from the idler gear M. 0.006, 0.008, 0.02 in) so that side clearance of the
oil pump, rotor and vane is between 0.1 - 0.15 mm
Note: When the idler gear assembly is removed. DO (0.0004 - 0.006 in).
NOT TURN the camshaft and crankshaft gears.
6 Fit the timing gear case, see page L/12 - 1.
9803/3145 Issue 1
14 - 1 14 - 1
Camshaft Assembly and Techometer Drive
Removing
1 Remove the timing gear case, see page L/12 - 1.
2 Remove bolt A and then remove keeper plate B.
3 Slide the camshaft assembly C together with the

flyweight retainer out of the camshaft bore.
4 Pull the tachometer drive shaft D from its bore.
Inspecting
1 Check the journals and cams for wear and damage.
Correct uneven wear and small scratches on the
cam surface with an oil stone.
2 Measure the height of the inlet and exhaust cams

at position E.
3 Measure the height of the injection pump cams at

position F.
4 Measure the height of the fuel feed pump cam at

position H.
5 If any of these cam heights is less than the specified

value (see Technical Data), replace the camshaft.
6 Examine the tachometer drive shaft gear,

crankshaft gears J, camshaft gear K and idler gear
L for damage and wear on the contact area.
Replace as necessary.
7 Measure the backlash of the gears. If the backlash

is excessive (see Technical Data) replace ALL
timing gears.
Fitting
1 Install the tachometer shaft.
2 Make sure that the set marks on the crankshaft gear

J and the idler gear L are aligned as at position M.
3 Make sure that the set marks on the idler gear L

and the camshaft gear K are aligned as at position
N and install the camshaft assembly in its bore.
4 Fit the keeper plate B with the bolt A. Torque the

bolt A to 9-14 Nm (0.9-1.3 kgf m, 6.5-10 lbf ft).
5 Fit the timing gear case, see page L/12 - 1.
9803/3145 Issue 1
15 - 1 15 - 1
Crankshaft
Removing
1 Remove the engine, see page L/9 - 2.
2 Remove the starter, see page C/4 - 1
3 Remove the engine oil sump, suction pipe and

strainer, see page L/4 - 1.
4 Remove the oil pump assembly, see page L/13 - 1.
5 Remove the cylinder head, see page L/10 - 1.
6 Remove the push rods and followers.
7 Remove the fuel lift pump, see page L/5 - 2.
8 Remove the fuel injection pump assembly, see page

L/5 - 4.
9 Remove the timing gear case, see page L/12 - 1.
10 Remove the camshaft assembly see page L/14 - 1.
11 Remove the bolts A and lift the front plate B off the
locating dowels C. Remove the gasket D and
discard,
12 Remove the bolts E and extract the flywheel F.
13 Remove the bolts and remove the backplate.
14 Remove the oil seal G.
15 Remove the pistons and connecting rods, refer to

page L/11 - 1.
16 Remove the bolts H fitted through the crankcase

cross members and the two recessed bolts at the
flywheel end.
17 Slide the crankshaft and main bearing assemblies

out of the cylinder block.
9803/3145 Issue 1
15 - 2 15 - 2
Crankshaft (cont'd)
Dismantling and Inspecting
1 Main bearings, No.l, No.2 and No.3. 3 Crankshaft Bush
a Remove the bearing holder and check it for a Check the bearing (bush) for peeling, melting,
peeling, melting, stepped wear and other seizure or poor contact. If found to be defective,
damage. If it is excessively damaged, renew it. renew.
b Using the plastigauge, measure the oil clearance b Using cylinder gauge and micrometer, measure
between the crankshaft journal and the bearing. the oil clearance between the bearing (bush) and
If the oil clearance is more than the allowable the crankshaft journal.
limit, renew the bearing. Or, grind the crankshaft
journal and use undersize bearing (see Microfiche c Measure the inside diameters at positions 1 and
for part numbers). 2. At each position, measure in both directions A
and B as shown. The oil clearance can be
obtained by subtracting the maximum crankshaft
journal diameter from this value.
Crankshaft journal/bush clearance
Standard oil clearance Allowable limit

0.044 - 0.116 mm 0.2 mm
(0.0017 -0.0046 in) (0.0078 in)
Standard oil clearance Allowable limit

0.035 - 0.085 mm 0.200 mm
(0.001 - 0.003 in) (0.0078 in)
Bearing size Crankshaft journal

diameter
Standard 67.957 - 67.970 mm
(2.6755 - 2.6760 in)
0.25 mm u/size 67.707 - 67.720mm

(0.0098 in) (2.6656 - 2.6661 in)
d If the oil clearance exceeds the allowable limit,
0.50 mm u/size 67.457 - 67.470 mm renew the bearing (bush). Or, grind the crankshaft
(0.0196 in) (2.6558 - 2.6563 in) journal. In this case, use undersize bearing
(bush).
2 Thrust washers
· After grinding the crankshaft journal, check the
a Check the thrust washers for wear, poor contact, oil clearance.
burning or other defects. Defective washers
must be renewed. Crankshaft Journal Sizes
Size Outside diameter
Standard Thickness Allowable limit Standard 67.957 - 67.970mm
2.95 - 3.0mm 2.8 mm (2.6755 - 2.6760 in)
(0. 116 - 0.118in) (0.11 in)
0.25 mm u/size 67.707 - 67.720mm
(0.0098 in) (2.6656 - 2.6661 in)
0.50 mm u/size 67.457 - 67.470 mm

(0.0196 in) (2.6558 - 2.6563 in)
9803/3145 Issue 1
15 - 3 15 - 3
Crankshaft (cont'd)
Dismantling and Inspecting When the measured diameter is less than the allowable
limit, correct by grinding and use undersize bearings
4 Crankshaft deflection and bush.
a Support the crankshaft with V-blocks. Position
a dial gauge on the crankshaft journal and turn Shaft diameter of crankshaft journal
the crankshaft gradually by one full turn. If the
gauge reading is more than allowable limit, Standard Allowable
correction or replacement of the crankshaft is diameter limit
needed. Standard 67.957 - 67.970 mm 67.90 mm
(2.6755 - 2.6760 in) (2.6732in)
Standard deflection Allowable limit 0.25 mm 67.707 - 67.720 mm 67.65 mm
0.030 mm or less 0.060 mm u/size (2.6656 - 2.6661 in) (2.6634 in)
(0.001 1 in) (0.0023 in) 0.50 mm 67.457 - 67.470 mm 67.4 mm†
u/size (2.6558 - 2.6563 in†) (2.6535 in†)
Shaft diameter of crankshaft pin
Standard Allowable
diameter limit
Standard 51.964 - 51.975 mm 51.90 mm
(2.0458 - 2.0463 in) (2.0433 in)
0.25 mm 51.714 - 51.725 mm 51.65 mm
u/size (2.0360 - 2.0364 in) (2.0335 in)
0.50 mm 51.464 - 51.475 mm 51.40 mm†
u/size (2.0261 - 2.0266 in) (2.0236 in†)
† If the diameter is less than this value, the crankshaft

b Oil seal contact face and oiI hole. Check the oil must be replaced
seal contact face for damage or wear. Check oil
holes for clogging. Note: When grinding the crankshaft, work with the
following specifications:
c Crankshaft journal and pin for stepped wear.
Take four measurements (AA and BB diameters A Radius at pin/journal 3mm ± 0.2 mm
at positions 1 and 2). If the maximum difference (0.12 ± 0.008 in)
between the measurements is more than B Finish precision 1.6Z (VVV)
allowable limit, correction is required. C Radius around oil hole: 2 mm (0.08 in) max
5 mm (0.20 in) min
Allowable difference (stepped wear)
0.05 mm (0.0019 in) Use No. 400 emery cloth for final polishing.
9803/3145 Issue 1
15 - 4 15 - 4
Crankshaft (cont'd)
Assembling
1 Replace the crankshaft bush if the crankshaft 2 Precautions Before Assembling
journal has been ground underside, see page L/15- a Wash parts before assembling. (Especially, oil
3. gallery, bearings, pistons and cylinder bores
should be washed thoroughly.)
a Removal of bush
b Apply new oil to sliding and rotating surfaces of
1 Remove the bush from the cylinder block using cylinder bores, pistons and bearings, etc.
Bush Driving Tool to prevent damage.
c Replace gasket, packing etc. Use liquid gasket
2 Press fitting the bush to prevent oil leakage where necessary.
Note: Prior to installing the bush inspect the bush d Never over tighten bolts and nuts used on
housing for marks, scratches etc. The bush should be aluminium alloy: tighten to specified tightening
smoothly pressed in to correct depth by using Bush torques.
Driving Tool, adjusting the oil hole and direction of bush
as shown and following sequence. 3 Assemble the bearing holders, main bearings and
thrust washer.
a Face the chamfered part of the bearing holder

toward front. Install the bearing holder which
has reference bit at the centre. Then install the
bearing holder on which the thrust washer is to
be mounted at the flywheel side.
- Press the bush into the cylinder block from the

engine front side.
Note: Do not press the bush into the cylinder block from
the opposite side. The correct pressing side is chamfered
etc. to allow smooth operation.
b Install the thrust washer. Face its oil groove
- Align oil hole of the block and bush. toward thrust face of the crankshaft.
- Lubricate the outer surface of the bush. c Torque the bearing holder bolts to 49-54 Nm
(5.0-5.5 kgf m, 36-40 lbf ft).
- Press in the bushing to the block, until correct
depth, by using Bush Driving Tool. d Set the bearing with oil groove to upper part,
while setting the bearing without the groove to
- Confirm the alignment of oil hole of the block and lower part.
the bushing, also check inner diameter is within
tolerance.
9803/3145 Issue 1
15 - 5 15 - 5
Crankshaft (cont'd)
Assembling
4 With the bearing holders and thrust washers 19 Install the oil pump, see page L/13 - 1.
assembled, insert the crankshaft in the bush at the
front end of the cylinder block. 20 Install the suction pipe and strainer and the oil sump,
see page L/4 - 1.
5 Align the bolt holes in the cylinder block with the
bearing holders on the crankshaft. 21 Install the starter and then install the engine.
6 Install the bolts H, including the two recessed bolts

at the flywheel end.
7 Torque the bolts H to 49-54 Nm (5.0-5.5 kgf m, 36-

40 lbf ft), torque the two recessed bolts to 25-30
Nm (2.5-3.0 kgf m, 18-22 lbf ft).
8 Measure the crankshaft end float.

Standard play Allowable limit
0.1 - 0.4mm 0.5 mm
(0.004 - 0.016in) (0.02 in)
9 Install the press-fit rear oil seal G in the rear of the

cylinder block.
10 Install the back plate on the rear of the cylinder

block.
a Coat the area around the M8 threaded holes with
liquid packing (solvent based sealant) and fix
the back plate with bolts.
b Torque the bolts to 14-17 Nm (1.3-1.7 kgf m, 10
-13 lbf ft).
11 Install the flywheel F noting the location of the

locating spring pin and retain with the bolts E. Torque
the bolts to 58-68 Nm (6.0-7.0 kgf m, 43-50 lbf ft).
12 Install the flywheel housing on the backplate with

the bolts. Torque the bolts to 24-28 Nm (2.4-2.9
kgf m, 18-21 lbf ft)
13 Locate the front plate B with gasket D on the dowels

C and install the bolts A. Torque the bolts to 9-14
Nm (0.9-1.3 kgf m, 6.5-10 lbf ft).
14 Install the camshaft assembly and tachometer

assembly, see page L/14 - 1.
15 Install the timing gear case, see page L/12 - 1.
16 Install the fuel injection pump, see page L/5 - 4.
17 Install the fuel lift pump, see page L/5 - 3.
18 Install the pushrods with followers and the cylinder

head, see page L/10 - 4.
9803/3145 Issue 1

Service Manual: Super Plus

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Service Manual: Super Plus

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General Information 1

Care & Safety 2

Manual Body & Framework B

1 = General Information - includes torque settings and service tools

Contents Page No.

Identifting Your Machine

Explanation of Vehicle Identification Explanation of Engine Identification

Code SLP 0803 T E 0765607 Code A B C D E

A World Manufacturer Identification SLP = JCB A Engine Type

D Manufacturers Location E = England

ENGINE SERIAL NUMBER LH TRACK GEARBOX SERIAL NUMBER

SLEW GEARBOX SERIAL NUMBER RH TRACK GEARBOX SERIAL NUMBER

WEIGHT kg ENGINE POWER kW @ RPM

Preparation for Storage Preparation after Storage

3 Disconnect battery to prevent discharge. 4 Reconnect battery.

9 Adjust track tensions.

10 Grease all lubrication points.

If there is anything you do not understand, ask your

Get to know the "feel" of the machine and its driving

B2 BEFORE ENTERING THE CAB B2

All these checks concern the serviceability of the

Lower the attachments to the ground before doing

If there is nobody to help you, study this handbook

b Remove dirt and debris, especially from WARNING

B5 ENTERING/EXITING THE CAB B5

Note: When entering or leaving a canopy machine,

To release the door when it is secured fully open,

To open the up and over window, disengage the latch

Note: Care must be taken when lowering the window

B9 OPENING THE SIDE WINDOW B9

The side window is held closed by catch A operated

To open the window, operate the catch A and slide

To close the window, slide the window fully shut and

B11 HEATER CONTROLS B11

Hot air can be directed to the cab floor by closing /

For the summer use, the heater element can be

WARNING Suspension seat - when fitted

B13 SEAT BELT - when fitted B13

Fasten the seat belt

Release the seat belt

B15 ENGINE AND TRACK CONTROLS, SWITCHES AND INSTRUMENTS B15

1 Left Track Control Lever

Track controls Forward

Move the lever to increase or decrease the engine

Engine start / stop

O Off/Stop Engine II Heat Position

Note: Do not operate the starter for more than 20

Working Light Switch B Horn Button D

Hourmeter (A) Glow Plug (E)

B27 DOZER CONTROLS B27

The dozer is operated by a single control lever on Raise dozer 'A'

CAUTION Dozer float position 'C'

B29 EXCAVATOR CONTROLS B29

Slew cab right A

B31 EXCAVATORS CONTROLS - continued B31

Select Swing on the Slew/Swing switch A on the left CAUTION

Swing boom right

B33 EXCAVATOR CONTROLS - continued B33

90º Operation (for specific jobs only)

B35 EXCAVATOR CONTROLS - continued B35

WARNING Raise boom

B37 EXCAVATOR CONTROLS - continued B37

Do not use fuel to clean the machine.