JCB 802.7 Plus, 802.7 Super, 803 Plus, 803 Super, 804 Plus, 804 Super Service Manual (9803/3145-3)

JCB 802.7 Plus, 802.7 Super, 803 Plus, 803 Super, 804 Plus, 804 Super Compact Excavators Service Manual (9803/3145-3)

This factory-authorized Service Manual provides comprehensive technical coverage for the full JCB 802.7, 803, and 804 Plus & Super compact excavator range. It includes detailed servicing procedures, system diagnostics, adjustment specifications, hydraulic and electrical schematics, torque settings, and troubleshooting instructions required for professional maintenance and reliable machine performance.

Model Covers:

JCB 802.7 Plus

JCB 802.7 Super

JCB 803 Plus

JCB 803 Super

JCB 804 Plus

JCB 804 Super

Note: Model specifications and servicing procedures may vary slightly between Plus and Super versions. Always reference the correct serial identification and configuration when performing diagnostic or repair operations.

File Format: PDF

Size: 13.44 MB

No. of pages: 250

Language: English

Delivery Method: Instant Download - Access your manual immediately after purchase.

📑 Included Sections:

Section 1 - General Information

• Machine identification, VIN interpretation, and engine identification numbering
• Machine storage procedures, reactivation steps, and preparation guidelines
• Operational overview and system description

Section 2 - Care and Safety

• Safety precautions for operation and maintenance
• Safe servicing practices and workshop procedures
• Machine stability, load-handling behavior, and safe operating guidelines

Section 3 - Routine Maintenance

• Maintenance schedules and lubrication plans
• Hydraulic, engine, and transmission fluid specifications
• Adjustments, torque settings, and intervals for inspection

Section A - Optional Equipment

• Auxiliary hydraulic circuits and attachment integration
• Quickhitch system components and servicing
• Handheld hydraulic tool connections and flow settings

Section B - Body & Framework

• Cab and canopy frameworks, interior layout, and external structures
• Doors, windows, access panels, and operator environment components
• Seat arrangements and control station configuration

Section C - Electrics

• Electrical circuit schematics and system routing
• Battery and charging circuits with alternator and starter servicing
• Instrument cluster, indicators, switches, and control electronics

Section D - Controls

• Track travel control mechanisms and pedal functions
• Excavator operating controls for boom, dipper, and bucket
• Dozer controls and hydraulic modulation systems

Section E - Hydraulics

• Complete hydraulic system layout and circuit flow description
• Pumps, spool valves, hoses, and pressure regulation components
• Hydraulic fittings, routing clamps, diagnostics, and relief valve settings

Section F - Transmission

• Track motors, drive gear arrangements, and internal servicing
• Final drive assemblies and wear component inspection

Section G - Brakes

• Track braking systems and operational overview
• Parking brake mechanisms and adjustment procedures

Section H - Steering

• Track steering control and directional drive systems

Section J - Engine

• Engine specifications and identification data
• Fuel delivery system, cooling components, and exhaust routing
• Air intake system and servicing intervals

Section K - Electronic Data Systems

• Electronic diagnostic procedures and system access
• Fault codes, operational monitoring, and system verification

Appendices

• Torque settings and tightening tables
• Special service tools and diagnostic adapters
• Conversion tables for units, pressure, and measurement standards

This Service Manual serves as an essential reference for technicians, maintenance engineers, and equipment specialists working on JCB 802.7, 803, and 804 Plus & Super compact excavators, providing complete technical guidance for accurate troubleshooting, servicing, and system-level repair.