2004–2007 JCB 8013, 8015, 8017, 8018 & 801 Gravemaster Mini Excavator Service Manual (P/N 9803/3105)

This JCB factory service manual (P/N 9803/3105, Issue 3) covers the 2004–2007 JCB 8013, 8015, 8017, and 8018 mini excavators, alongside the 801 Gravemaster variant. It combines routine maintenance information with component inspection, diagnosis, and repair procedures.

PDF Search, Bookmarks and Wiring Detail

Finding pages and reading diagrams: Ordinary word searches are unreliable because of the file’s character encoding. The 16 numbered bookmarks jump in 20-page blocks rather than follow workshop sections; one opens a blank page. Small wiring labels are legible when enlarged, and some diagram pages require rotation.

The download contains one printable, 305-page PDF, including the cover, introduction, and 18 blank pages. The text is in English, with French section headings on two hydraulic schematic sheets.

Hydraulic Fault Finding, Drive Repairs and Engine Overhaul

The following selected workshop topics show the manual’s repair coverage. Other sections include preparation for storage and machine transport.

• Hydraulic diagnosis: Fault-finding charts, gear-pump inspection, control-valve service, and pressure testing for main, auxiliary, servo, and slew crossline relief valves.

• Track and slew drives: Single- and two-speed track-motor dismantling and assembly, planetary gearbox repair, slew-motor service, and configuration-specific rotary couplings.

• Engine repair: Engine removal, cylinder-head inspection, piston and connecting-rod work, crankshaft bearing checks, and timing-gear service.

• Electrical service: Alternator and starter-motor inspection, charging-system tests, electrical schematics, harness drawings, wire identification, and sealed wiring repairs.

• Front attachment and cab: Bucket linkage inspection, dipper, boom and kingpost removal, plus step-by-step instructions for replacing directly bonded cab glass.

• Track and running gear: Steel and rubber track replacement, track tensioning, roller service, metallic face-seal inspection, and idler/recoil-unit dismantling and assembly.

Written for JCB distributor service engineers receiving or having completed JCB technical training, this manual assumes sound workshop knowledge and experience maintaining hydraulic earthmoving equipment.

Hydraulic Circuits and Drive Components

Separate circuit descriptions distinguish cable-operated controls, servo controls, and the extending-undercarriage/two-speed configuration. The related schematics and component keys let technicians trace pump supplies and control functions before selecting pressure tests or dismantling components.

The motor fault-finding charts connect symptoms such as failure to rotate, uneven speed, and leakage with probable causes and inspection actions. Exploded assemblies and track-motor section views support bench work on the associated components.

Rotary-coupling procedures distinguish single-speed machines from the two-speed, extending-undercarriage arrangement used on the 8017/8018. Single- and double-acting attachment-circuit installation drawings are representative; the instructions supplied with each attachment kit remain necessary for its installation.

Engine, Fuel Injection and Cooling

Section L covers the KD 103-10 I.D.I. engine. Match the engine identification before using its overhaul data: the engine output table identifies 8014 and 8015/8016 applications.

Step-by-step procedures cover fuel-injection-pump removal and timing adjustment, injector dismantling and testing, water-pump replacement, and thermostat inspection. Internal engine work includes valve-seat assessment, piston-ring inspection, crankshaft measurement, and bearing-clearance checks.

The fuel-injection timing section includes a piston-position/crankshaft-angle table. Engine lubrication charts, wear limits, and component torque settings provide references for inspection and reassembly.

Charging Tests and Harness Identification

The electrical section includes earlier and later machine schematics, alternator-regulator circuit diagrams, and production harness drawings with connector destinations. Voltage-output, current-output, field-output, and continuity tests help distinguish alternator, regulator, and wiring faults.

Starter-motor coverage extends to armature, field-coil, brush, and solenoid inspection. Harness repair instructions describe crimped, sealed splices.

Framework, Maintenance and Repair Cautions

Direct-glazing procedures cover braided cutting wire, frame preparation, adhesive application, and curing requirements. Framework sections also address the upper structure, dozer blade, and 8017/8018 blade extensions.

Maintenance coverage includes fuel-system bleeding, hydraulic fluid checks, cold-climate warm-up, and service schedules. Torque tables distinguish zinc-plated and Dacromet fasteners, alongside component settings for the slew ring, track rollers, idlers, and engine. TOPS and FOGS precautions address damaged or modified protective structures.

The manual warns that overgreasing the slew ring can displace its grease seal, and towing a disabled machine can permanently damage the track motors.

Fine jets of high-pressure hydraulic fluid can penetrate the skin, so you must carefully vent the system and properly support the chassis before opening lines.

A Preview of Engine Clearances and Hydraulic Pressure Data

For the KD 103-10 I.D.I., the engine section specifies cold valve clearance of 0.2 mm. Timing-gear backlash is listed as 0.08 mm when new, with a 0.33 mm service limit.

The hydraulic data distinguish the track/dipper/boom/bucket main relief pressure: 230 bar for the 8017 and 220 bar for the 8018. The pressure-testing procedures specify hydraulic fluid at working temperature and maximum engine speed for these checks.