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.
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*
, Section 1 General Information Section 1
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
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