JCB 802.7, 803, 804 Plus/Super Mini Excavator Repair Service Manual

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This service manual PDF download for the 802.7, 803, 804 Plus/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 802.7 plus - From S/N: 747084 to 747210
JCB Excavator 802.7 super - From S/N: 747211 Onwards
JCB Excavator 803 plus - From S/N: 765607 Onwards
JCB Excavator 803 super - From S/N: 765607 Onwards
JCB Excavator 804 plus - From S/N: 734402 to 734629
JCB Excavator 804 super - From S/N: 734630 to 735365
JCB Excavator 804 super - From S/N: 735366 Onwards


TABLE OF CONTENTS :

Section 1: General Information
Section 3: Routine Maintenance
Section A: Optional Equipment
Section B: Body and Framework
Section C: Electrics
Section D: Controls
Section E: Hydraulics
Section F: Gearboxes
Section J: Track and Running Gear
Section L: Engine


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Publication No. : 9803/3145 Issue 3
Total Pages : 250


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 Your Machine
Operation
Introduction
Before Entering the Cab
Entering/Exiting the Cab
Cab
Opening the Windscreen
Opening the Side Window
Heater Controls
Seat
Seat Belt (when fitted)
Engines and Track Controls, Switches and Instruments
Track Controls
Engine Controls
Switches
Instruments
Dozer Controls
Excavator Controls
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 Site/Road Travel
Getting the Machine Moving
Working with the Dozer
Working with the Excavator
Installing a Bucket - non-Quickhitch Models
Replacing Bucket Teeth
Bucket Selection
Removing a Bucket - non-Quickhitch Models
Installing a Bucket on a Quickhitch
Removing a Bucket from a Quickhitch
Working on a Slope
Digging
Moving the Machine While Digging on the Level
Digging Near Walls
Lifting
Safe Work Loads
Using the Attachments and Site Safety
Single/Double Acting Circuits
Removing a Quickhitch Rockbreaker
Using Hand Held Tools
Moving a Disabled Machine
Transporting the Machine
Securing for Transport

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

Section B: Body and Framework
General Description
Bucket Linkage
Removal and Replacement
Bucket Ram Pivot and Linkage
Removal and Replacement
Dipper
Removal and Replacement
Boom
Removal and Replacement
Upper Structure
Dismantling and Assembly
Kingpost
Removal and Replacement

Section C: Electrics
Technical Data
Battery
Fan Belt
Alternator
Starter Motor
Beacon
Circuit Diagram
Wiring Harness (802.7/803)
Wiring Harness (804)
Harness Specifications
Main Harness
Radio Harness
Cab Harness
Instrument Panel Adaptor Harness
Fuel Sender Adaptor Harness
Slew Frame to Cab Adaptor Harness
Slew/Swing Change Over Harness

Section D: Controls
Servo Hand Controllers
Description and Operation
Track Levers
Dozer Levers

Section E: Hydraulics
Technical Data
Hydraulic Circuit (Schematic) 802.7/803
Hydraulic Circuit (Schematic) 803 Super/804
Servo Circuit
Description
Hydraulic System
General Fault Diagnosis
Hydraulic Pump 802.7/803
Operation
Hydraulic Pump 804
Operation
Track Motor
Description and Operation
Slew Motor
Description
Hydraulic Pump
Flow Testing
Hydraulic Pump - 802.7 and 803 Gear Pumps
Removal and Replacement
Hydraulic Pump - 802.7 Super, 803 Super and 804 Variable Displacement Pump
Removal and Replacement
Hydraulic Gear Pump - 802.7 & 803 Machines
Dismantling and Assembly
Hydraulic Pump - 802.7 Super, 803 Super and 804 Variable Displacement Pump
Dismantling and Assembly
Track Motor
Dismantling and Assembly
Control Valves, MRV and Spool Locations
Control Valve
Removal and Replacement
Control Valve Sections
Dismantling and Assembly
Main Relief Valves
Removal and Replacement
Servo Relief Valve
Removal and Replacement
Dipper Boost Dump Valve
Removal and Replacement
Auxiliary Relief Valve
Removal and Replacement
Boom, Dipper and Bucket Rams
Removal and Replacements
Dozer Ram
Removal and Replacement
Swing Ram
Removal and Replacement
Dismantling and Assembly
Inspection
Rotary Coupling
Removal and Replacement
Dismantling and Assembly
Main Relief Valves
Pressure Testing
Description
Procedure
Auxiliary Relief Valves
Pressure Testing
Servo Relief Valves
Pressure Testing
Crossline Relief Valves
Pressure Testing
Dipper Boost Dump Valve
Pressure Testing
Hydraulic Oil Cooler
Removal and Replacement

Section F: Gearboxes
Technical Data
General Description
Track Gearbox
Operation
Check Oil Level
Drain and Refill
Removal and Replacement
Dismantling and Assembly
Slew Gearbox
Removal and Replacement
Slew Motor
Removal and Replacement

Section J: Track and Running Gear
General Description
Tracks
Clean and Inspect
Removal and Replacement
Changing
Track Rollers
Removal and Replacement
Dismantling and Assembly
Track Idler and Recoil Unit
Dismantling and Assembly
Driven Sprocket
Dismantling and Assembly
Track Roller Metallic Face Seals
Removal and Replacement

Section L: Engine
Technical Data
Engine Oil
Draining and Refilling
Oil Filter
Renewing
Oil Cooler
Removing and Refitting
Oil Pressure Relief Valve
Removing and Refitting
Oil Pump, Suction Pipe and Strainer
Removing and Fitting
Fuel Filter
Renewing
Fuel Lift Pump
Removing, Inspecting and Fitting
Dismantling, Inspecting and Assembly
Fuel Injection Pump
Removing and Fitting
Fuel Injection Timing
Checking and Adjusting
Fuel Injectors and Fuel Pipe Assembly
Removing, Dismantling and Inspecting
Fuel System
Bleeding
Air Filter
Renew Outer/inner Element
Engine Coolant
Draining and Filling
Water Pump/Thermostat Housing Assemblies
Removing, Inspecting and Fitting
Cylinder Head
Removing, Inspecting and Fitting
Piston and Connecting Rods
Removing, Inspecting and Fitting
Timing and Gear Case
Removal and Replacement
Idler Gear and Oil Sump Assembly
Removing, Dismantling, Inspecting and Fitting
Camshaft Assembly and Tachometer Drive
Removing, Inspecting and Fitting
Crankshaft
Removing
Dismantling and Inspecting
Assembling

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