JCB Mini Excavators 802.7, 803, 804 Plus & Super Series Service Manual PDF

This service manual contains detailed descriptions and instructions for use, technical data, operation and routine maintenance instructions, and safety measures for maintenance of the JCB Mini Excavators 802.7 Plus, 802.7 Super, 803 Plus, 803 Super, 804 Plus, 804 Super.

This manual also contains a lot of illustrations, pictures hydraulic diagrams and electrical circuits. Individual drawings may vary slightly from a specific product due to technical improvements constantly being made to the design of the excavator.

This chapter is arranged to guide you step-by-step through the task of learning how to use the machine.

The service manual comes in PDF format, that's why you can save and print this repair manual with the help of an application that reads PDF files. This workshop manual doesn't require any installation (INSTANT DOWNLOAD). 

This service manual is intended for service personnel working and engaged in the operation and maintenance of excavators of this type and this brand.

Publication No. 9803/3145 Issue 3

Models covered:
802.7 Plus,
802.7 Super,
803 Plus,
803 Super,
804 Plus,
804 Super.

Contents:

• Section 1 - General Information
  • Identification
  • Storing your machine 
  • Operation
• Section 3 - Routine Maintenance
  • Fluids, Lubricants, Capacities, and Specifications 
  • Engine Lubrication Chart
  • Torque Settings
  • Hydraulic Fittings 
  • Fuel Systems
  • Coolant Mixtures
  • Service Schedules
  • Greasing
  • Hydraulic Fluid Level
  • Track Gearbox
• Section A - Optional Equipment
  • General Description
• Section B - Body & Framework
  • General Description
  • Bucket Linkage
  • Bucket Ram Pivot and Linkage
  • Dipper
  • Boom
  • Upper Structure
  • Kingpost
• Section C - Electrics
  • Technical Data
  • Battery
  • Fan Belt 
  • Alternator
  • Starter Motor
  • Beacon
  • Circuit Diagram
  • Wiring Harness (802.7 / 803)
  • Wiring Harness (804) 
  • Harness Specifications
• Section D - Controls
  • Servo Hand Controllers
  • Track Levers (See section B)
  • Dozer Lever
• Section E - Hydraulics
  • Technical Data
  • Servo Circuit
  • Hydraulic System
  • Hydraulic Pump 802.7 / 803
  • Hydraulic Pump 804
  • Track Motor
  • Slew Motor
  • Hydraulic Pump(s)
  • Hydraulic Pump 802.7 / 803
  • Hydraulic Pump 804
  • Hydraulic Pump 802.7 / 803
  • Hydraulic Pump 803 Super / 804
  • Track Motor
  • Control Valve Sections
  • Main Relief Valves
  • Servo Relief Valve
  • Dipper Boost Dump Valve
  • Auxiliary Relief Valve
  • Boom, Dipper and Bucket rams
  • Dozer ram
  • Swing ram
  • Rotary Coupling
  • Main Relief Valves
  • Auxiliary Relief Valves
  • Servo Relief Valves
  • Cross-line Relief Valves
  • Dipper Boost Dump Valve
  • Hydraulic Oil Cooler
• Section F - Gearboxes
  • Technical Data
  • General Description
  • Track Gearbox
  • Slew Gearbox
  • Slew Motor
• Section J - Track & Running Gear
  • General Description
  • Tracks
  • Track Rollers
  • Track Idler and Recoil Unit
  • Driven Sprocket
  • Track Roller Metallic Face Seals
• Section L - Engine
  • Technical Data 
  • Engine Oil
  • 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
  • Air Filter
  • Engine Coolant
  • Water Pump, Thermostat Housing Assemblies
  • Engine
  • Cylinder Head
  • Piston and Connecting Rods
  • Timing Gear Case
  • Idler Gear and Oil Pump Assembly
  • Camshaft Assembly and Tachometer Drive
  • Crankshaft