JCB 802, 802.4 & 802 Super Mini Crawler Excavators Tier 1 Service Manual (9803/3140)

JCB 802, 802.4 & 802 Super Mini Crawler Excavators Tier 1 Service Manual (9803/3140)

This Tier 1 Service Manual provides an extensive technical reference for servicing, repairing, and maintaining the JCB 802, 802.4, and 802 Super Mini Crawler Excavators. The manual includes detailed system diagnostics, operational standards, maintenance procedures, hydraulic and electrical schematics, and essential troubleshooting workflows tailored for early-emission compact excavator models.

Model Covers:

JCB 802 Mini Excavator

JCB 802.4 Mini Excavator

JCB 802 Super Mini Excavator

Applicable to Tier 1 emission range beginning approximately from Serial No. 733847 upward.

Note: Model variations may exist within the Tier 1 range. Always verify component and system specifications against the machine’s serial identification to ensure correct servicing.

File Format: PDF

Size: 9.84 MB

No. of pages: 292

Language: English

Delivery Method: Instant Download - Immediate access after purchase.

📑 Included Sections:

Section 1 - General Information

• Identification plates, VIN coding, and engine-gearbox numbering
• Comprehensive torque settings for structural and mechanical fasteners
• Service tools index, diagnostic tools, and adapter specifications
• Sealing compounds, retaining agents, and application procedures
• Machine storage preparation, reactivation protocols, and corrosion prevention
• Compliance details for ROPS, TOPS, and FOGS structures

Section 2 - Care & Safety

• Operational safety instructions and hazard prevention
• Safe entry and exit procedures for cab and canopy models
• Seat belt usage, visibility requirements, and working environment precautions
• Fire prevention, electrical safety, and emergency protocols

Section 3 - Routine Maintenance

• Daily, weekly, and scheduled maintenance tasks
• Lubrication charts, grease points, and fluid capacity specifications
• Hydraulic oil inspection, filtration checks, and fuel system servicing
• Battery maintenance, testing procedures, and jump-start instructions
• Cold and hot climate operational guidance

Section A - Attachments

• Ditching and general-purpose bucket identification
• Dipper and boom attachment groups
• Quickhitch system components and servicing

Section B - Body & Framework

• Cab and canopy structure layouts
• Main frame, body panels, and access point arrangements
• Kingpost assemblies, boom pivot points, and structural mountings

Section C - Electrics

• Detailed electrical circuits and schematic layouts
• Fuse boxes, relays, and switchgear distribution
• Starter motor, alternator, and battery system servicing
• Instrument panel, control switches, and operational indicators

Section D - Controls

• Excavator and dozer control systems
• ISO / SAE operational pattern selection
• Slew and swing boom functions
• Hydraulic control of boom, dipper, and bucket linkages

Section E - Hydraulics

• Hydraulic flow schematics and circuit architecture
• Main pumps, valve blocks, and actuator testing
• Relief valve calibration and diagnostic procedures
• Hydraulic rams, servo circuits, and pressure testing

Section F - Gearboxes / Travel System

• Track motors and final drive disassembly procedures
• Track frames, rollers, sprockets, and idler configurations
• Track tensioning adjustment instructions

Section J - Engine

• Engine identification and specification overview
• Starting system diagnostics and throttle control mechanisms
• Cooling circuit, air intake, and fuel delivery systems

Section L - Service Tools & Compounds

• Diagnostic tools, testing blocks, and hydraulic adapters
• Threadlockers, sealing compounds, cleaning fluids, and application instructions

This Service Manual is an essential resource for technicians, mechanics, and maintenance personnel working on JCB 802, 802.4, and 802 Super Mini Crawler Excavators, providing the necessary technical detail for expert servicing and reliable machine operation.