JCB 802.7 803 804 Plus & Super Mini Excavator Service Repair Manual – PDF

Description

JCB 802.7 803 804 Plus & Super Mini Excavator Service Repair Manual

This is the complete service and repair manual for JCB 802.7, 803 and 804 Plus & Super mini excavators. Published by the Technical Publications Department of JCB Compact Products Ltd, this manual (Publication No. 9803/3145, Issue 3) gives service engineers and technicians the specialised information needed to maintain, diagnose and overhaul these compact excavators.

Whether you are servicing a machine in the workshop or carrying out repairs in the field, this JCB mini excavator service manual provides the procedures, torque settings, tolerances, hydraulic circuit descriptions and electrical schematics required to do the job correctly.

File Details

• Manual type: Service / Repair Manual
• Brand: JCB
• Models covered: 802.7, 803, 804 Plus & Super Mini Excavators
• Publication No.: 9803/3145
• Issue: 3
• Publisher: Technical Publications Department, JCB Compact Products Ltd
• Language: English
• File format: PDF

Chapters Covered

The manual is divided into numbered and alphabetically coded sections:

• 1 — General Information: torque settings, service tools, identification, VIN and engine number explanation
• 2 — Care & Safety: warnings and cautions, preparation for storage, operation safety
• 3 — Routine Maintenance: service schedules, fluids and lubricants, capacities and specifications, engine lubrication chart, torque settings, hydraulic fittings, fuel system, coolant mixtures, greasing, hydraulic fluid level, track gearbox
• A — Optional Equipment: cab working lights, double acting auxiliary pipework, 3CX hand controller pattern, hose burst protection valves, radio kit, dipper and dozer options, rubber or steel tracks
• B — Body & Framework: bucket linkage, bucket ram pivot and linkage, dipper, boom, upper structure, kingpost, control mechanism
• C — Electrics: technical data, battery, fan belt, alternator, starter motor, beacon, circuit diagram, wiring harness specifications and diagrams, instrument panel
• D — Controls: servo hand controllers, port identification, switchable ISO/SAE mode, changing excavator control mode, track levers, dozer lever
• E — Hydraulics: technical data, hydraulic circuit schematics, servo circuit, fault diagnosis, hydraulic pump, track motor, slew motor, control valves, main relief valves, servo relief valve, dipper boost dump valve, auxiliary relief valve, rams, rotary coupling, pressure testing, hydraulic oil cooler
• F — Gearboxes: track gearbox operation, oil level, drain and refill, removal and replacement, dismantling and assembly; slew gearbox removal and replacement, slew motor dismantling and assembly
• J — Track & Running Gear: track cleaning and inspection, removal and replacement, changing, track tensioning, converting tracks, track guides, track rollers, idler and recoil unit, driven sprocket, track roller metallic face seals
• L — Engine: technical data, engine oil drain and refill, oil filter, oil cooler, oil pressure relief valve, oil sump, suction pipe and strainer, fuel filter, fuel lift pump, fuel injection pump, fuel injection timing, fuel injectors and fuel pipe assemblies, fuel system bleeding, air filter, engine coolant, water pump and thermostat housing, engine removal and replacement, cylinder head, pistons and connecting rods, timing gear case, idler gear and oil pump assembly, camshaft assembly and tachometer drive, crankshaft

Across these sections the manual provides the full scope of service information for the JCB 802.7, 803 and 804 Plus & Super mini excavators. It opens with identification and general information, then moves through safety and routine maintenance before addressing each major system in detail. The body and framework section covers the front attachment and upper structure. The electrics section includes full wiring harness specifications, circuit diagrams and component testing. The controls section explains the servo hand controllers and the ISO/SAE control pattern changeover. The hydraulics section is extensive, covering circuit schematics, fault diagnosis, pump operation for both the gear pump and variable displacement pump, track and slew motors, control valve sections, relief valves, ram dismantling and assembly, rotary coupling and pressure testing procedures. The gearbox section covers both track and slew gearboxes. The track and running gear section deals with tracks, rollers, idler and recoil unit, and driven sprocket. The engine section covers the complete Perkins 100 Series engine, from routine oil changes through to crankshaft removal and assembly.

Coverage & Serial Numbers

This manual covers the JCB 802.7, 803 and 804 Plus & Super mini excavators. The hydraulic circuit descriptions and technical data reference specific serial number ranges, including 802.7 to M747210 and M747211 on; 803 to M827239 and M827240 on; 804 to M734833 and M734834 on. Earlier machines use the three-section gear pump, while later machines (802.7 Super, 803 Super and 804) use the variable displacement piston pump.

The engine is the Perkins KE 103-15 IDI, a vertical in-line, 3-cylinder, normally aspirated, 4-stroke, water-cooled diesel with a swept volume of 1.493 litres. Power output varies by model and serial number, ranging from 19.2 kW to 21 kW.

Technical Highlights

• Torque settings for metric grade 8.8 bolts and important tightening torques for track motor, slew ring, hydraulic tank, engine mountings and more
• Hydraulic fittings and torque settings including O-ring face seal adaptors and outer sleeve nuts
• Full hydraulic circuit schematics for 802.7/803 and 803 Super/804 machines
• Servo circuit description and pressure testing procedures
• Engine lubrication chart and coolant mixture specifications
• Complete wiring harness specifications with wire ID numbers, colours, plug IDs, terminal sizes and destinations
• Circuit diagram for the 804 machine with main components, lamps and connector references
• Fault diagnosis charts for the hydraulic system
• Pressure testing procedures for main relief valves, auxiliary relief valves, servo relief valves, crossline relief valves and dipper boost dump valve
• Ram dismantling, assembly and inspection with piston rod warp limits, bush clearances and torque values
• Track tensioning specifications for steel and rubber tracks
• Engine technical data including cylinder head, crankshaft, piston and ring tolerances, valve clearances and injection timing

Why This Manual Matters

Correct service information is essential when working on compact excavators. The JCB 802.7, 803 and 804 are precision machines with hydraulic systems operating at pressures up to 190 bar (2750 lbf/in²) and engines with specific torque and clearance requirements. Using the wrong torque setting, the wrong hydraulic fluid or an incorrect relief valve pressure can lead to component failure, poor performance or unsafe machine operation.

This manual gives you the exact specifications and procedures that JCB service engineers use. From routine maintenance schedules and lubricant capacities to complete dismantling and assembly sequences for the engine, hydraulics, gearboxes and running gear, it covers the jobs that keep these machines working reliably.

Who This Manual Is For

This JCB mini excavator service manual is written for JCB distributor service engineers who have received training from the JCB Technical Training Department. It assumes a sound knowledge of workshop practice, safety procedures and general techniques associated with the maintenance and repair of hydraulic earthmoving equipment. It is therefore suited to professional mechanics, technicians and experienced owners who need access to the specialised information concerning particular aspects of the machine or component.

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Instant PDF Delivery

This JCB 802.7 803 804 Plus & Super Mini Excavator Service Repair Manual is delivered as an instant PDF download after payment. There is no shipping and no waiting for a physical book. The PDF can be viewed on any device — computer, tablet or smartphone — and pages can be printed for use in the workshop.

With this manual you can carry out routine servicing, diagnose hydraulic and electrical faults, overhaul the engine, repair the track and running gear, and maintain the machine to the correct specifications. Everything you need is in one document, ready to download now.