JCB 802, 802.4, 802 Super Mini Excavator Repair Service Manual

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This service manual PDF download for the 802, 802.4, 802 Super JCB Mini Excavator has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.


APPLICABLE MODELS :

JCB Mini Excavator

JCB Excavator 802 - From S/N: 732001 to 732449
JCB Excavator 802.4 - From S/N: 732450 to 732999
JCB Excavator 802 super - From S/N: 733001 to 733847
JCB Excavator 802 super - From S/N: 733848 Onwards


TABLE OF CONTENTS :

General Information
Care & Safety
Routine Maintenance
Attachments
Body & Framework
Electrics
Controls
Hydraulics
Gearboxes
Track & Running Gear
Engine


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Publication No. : 9803/3140 Issue 4
Total Pages : 293


This JCB Mini Excavator service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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Cover
Contents
Introduction

Section 1: General Information
Identification
Storing the Machine
ROPS, TOPS and FOGS
Introduction
Before Entering the Cab
Entering/Exiting the Cab
Cab
Opening the Windscreen
Opening the Sidescreen
Heater Controls
Seat
Seat Belt (when fitted)
Engine and Track Controls, Switches and Instruments
Track Controls
Engine Controls
Switches
Instruments
Dozer Controls
Excavator Controls
Changing the Excavator Control Pattern
Slew Cab
Swing Boom
Boom Swing Stop
Raise/Lower Boom
Dipper
Bucket
Refuelling the Machine
Before Starting the Engine
Starting the Engine
Jump Starting the Engine
Cold Climate Warm Up
Operating in High/Low Temperatures
Stopping and Parking the Machine
Preparing for road/site travel
Getting the Machine Moving
Working with the Dozer
Working the Excavator
Digging
Moving the Machine While Digging on the Level
Digging Near Walls
Lifting Regulations and Safe Working Loads
Using the Attachments and Site Safety
Moving a Disabled Machine
Transporting the Machine
Securing for Transport
Service Tools
Numerical List
Section B - Body and Framework
Section C - Electrics
Section E - Hydraulics
Section K - Engine
Sealing and Retaining Compounds

Section 2: Care and Safety
Safety Notices
General Safety
Operating Safety
Maintenance Safety

Section 3: Routine Maintenance
Lubricants and Capacities
Engine Lubrication Chart
Lubricants - Health and Safety
Torque Settings
Hydraulic Fittings and Torque Settings
Service Schedule
Every 10 Operating Hours (Or Daily)
Every 50 Operating Hours (Or Weekly)
First 100 Hours Only
Every 100 Operating Hours (Or 2 Weeks)
First 250 Operating Hours Only
Every 250 Operating Hours (Or Monthly)
Every 500 Operating Hours (Or 6 Months)
Every 1000 Operating Hours (Or Yearly)
Every 2000 Operating Hours (Or 2 Years)
Greasing
Daily
Every 250 Hours
Every 1000 Hours
Fuel System
Types of Fuel
Fuel Standards
Filling the Tank
Draining the Fuel Filter
Renewing the Fuel Filter
Draining the Sedimenter Bowl
Cooling System
Coolant Mixtures
Fan Belt Adjustment
Fan Belt - Removal and Replacement
Engine Oil
Checking the oil level
Oil Filter
Air Filter
Hydraulics
Checking the Hydraulic Fluid Level
Changing the Hydraulic Filter
Tracks and Running Gear
Track Gearbox
Tensioning the Tracks
Battery
Warning Symbols
First Aid - Electrolyte
Checking the Electrolyte Level

Section A: Attachments
Available Attachments
Buckets
Bucket Selection
Removing a Bucket - non Quickhitch models
Installing a Bucket - non Quickhitch models
Replacing Bucket Teeth
Quickhitch
Installing the Quickhitch
Removing the Quickhitch
Maintenance
Installing a Bucket on a Quickhitch
Removing a Bucket From a Quickhitch
Hydraulic Attachment Circuits
Attachments
Single Acting Hydraulic Circuit
Making the Machine Ready
Installing the Boom and Dipper Pipes and Hoses
Installing the Boom to Mainframe Hoses
Fitting the Auxiliary Pedal and Cable
Installing the Mainframe Pipes and Hoses
Double Acting Hydraulic Circuit
Making the Machine Ready
Installing the Boom and Dipper Pipes and Hoses
Installing the Boom to Mainframe Hoses
Fitting the Auxiliary Pedal and Cable
Installing the Mainframe Pipes and Hoses
Hydraulic Breakers
Removing a Quickhitch Rockbreaker
Installing a Quickhitch Rockbreaker
Hydraulic Tool Kit
Fitting Instructions
Making the Machine Ready
Assembly/Installation
Using Hand Held Tools

Section B: Body and Framework
General Description
Bucket Ram Pivot and Linkage
Removal and Replacement
Dipper
Removal and Replacement
Boom
Removal and Replacement
King Post
Removal and Replacement
Slew Ring
Removal and Replacement
Cab Floorplates
Removal and Replacement
Seat and Control Pods
Removal and Replacement
Cab
Removal and Replacement
Engine Cover
Removal and Replacement

Section C: Electrics
Technical Data
Electrical System – General Fault Diagnosis
Battery
Negative Earth Electrical System
Inspection
Testing the Specific Gravity
High Rate Discharge Test
Alternator
Removal and Replacement
Service Precautions
Charging Test
Starter Motor
Removal and Refitting
Beacon
Mounting
Bulb Change
Schematic Diagrams
802 machines upto M732449
802.4 machines upto M732999
802 Super machines upto M733847
802 Super machines from M733848
Harness Data
Wiring Harness Repair
Wire Identification
Harness Drawings
Mainframe Harness
802.4 machines from 732558 upto 732999
802 Super machines from 733001 upto 733847
802 Super machines from 733848
Cab Harness
802 / 802.4 machines
802 Super machines from 733001 upto 733847
802 Super machines from 733848

Section D: Controls
Track and Dozer Levers
Removal and Replacement
Servo Hand Controllers - 802
Removal and Replacement
Servo Hand Controllers - 802.4
Description and Operation
Port Identification
Removal and Replacement
Auxiliary Pedal and Control Cable
Removal and Replacement

Section E: Hydraulics
Technical Data
Hydraulic Circuit
Circuit Description
Servo Circuit
Circuit Description
Hydraulic Pump
Operation
Removal and Replacement
Dismantling and Assembly
Flow Testing
Track Motor
Operation
Dismantling and Assembly
Slew Motor
Operation
Removal and Replacement
Dismantling and Assembly
Fault Finding
Control Valve
Location
Removal and Replacement
Dismantling and Assembly
Auxiliary Relief Valve
Removal
Dismantling and Assembly
Rams
Boom, Dipper and Bucket - Removal and Replacement
Dozer - Removal and Replacement
Swing - Removal and Replacement
Typical Dismantling and Assembly
Typical Inspection
Rotary Coupling
Removal and Replacement
Dismantling and Assembly
Pressure Testing
Main Relief Valves
Auxiliary Relief Valves
Servo Relief Valves
Crossline Relief Valves and Slew Start-up Pressure Control Valves

Section F: Gearboxes
Technical Data
General Description
Track Gearbox
Operation
Removal and Replacement
Dismantling and Assembly
Slew Motor/Gearbox - 802 to M732356, 802.4 to M732449
Removal and Replacement
Dismantling and Assembly
Check Oil Level
Drain and Refill
Slew Motor/Gearbox - 802 M732357 to M732449, 802.4 M732450 on
Removal and Replacement
Dismantling and Assembly

Section J: Track and Running Gear
General Description
Tracks
Clean
Removal and Replacement - Steel Track
Removal and Replacement - Rubber track
Track Rollers
Removal and Replacement
Dismantling and Assembly
Metallic Face Seals
Idler and Recoil Unit
Dismantling and Assembly
Track Gearbox Sprocket
Removal and Replacement

Section L: Engine
Technical Data
Oil Pressure Relief Valve
Removal and Replacement
Oil Sump, Suction Pipe and Strainer
Removal and Replacement
Fuel Lift Pump
Removal, Inspection and Replacement
Dismantling, Inspection and Reassembly
Fuel Injection Pump Assembly
Removal and Replacement
Fuel Injection Timing
Checking and Adjusting
Fuel Injectors and Fuel Pipe Assembly
Removing, Dismantling/Inspecting
Reassembly/Adjusting and Replacement
Fuel System
Bleeding
Water Pump/Thermostat Housing Assemblies
Removal, Inspection and Replacement
Alternator
Removal and Replacement
Starter Motor
Removal and Replacement
Engine
Removal and Replacement
Cylinder Head
Removal, Inspection and Replacement
Piston and Connecting Rods
Removal, Inspection and Replacement
Timing Gear Case
Removal and Replacment
Idler Gear and Oil Pump Assembly
Removal, Dismantling, Inspection and Replacement
Crankshaft Assembly and Tachometer Drive
Removal, Inspection and Replacement
Crankshaft
Removal
Dismantling and Inspection
Reassembling and Replacing

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