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JCB

JCB 802 802.4 802 Super Mini Excavator Workshop Service Repair Manual

JCB 802 802.4 802 Super Mini Excavator Workshop Service Repair Manual

$16.99
$16.99
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Machine data plateRef 84040
Brand
JCB
Equipment
Engines
Models covered
JCB 802 802.4 802
Format
PDF, searchable, print-ready
Delivery
Instant download after checkout
Language
English

What happens after you pay

  • Download link opens on the order page immediately
  • The same link is emailed to you — re-download any time
  • Open on phone, tablet or PC; print only the pages you need
  • Not sure it covers your serial range? Ask us before you buy
🏷️ Basic Information
Identification
Make:
JCB
Model:
802, 802.4, 802 Super
Model Variants:
802, 802.4, 802 Super
Production Years Covered:
Not specified in manual; typically covers late 1990s to mid 2000s models.
👋 Introduction
Market Position
Target Audience:
Technicians and DIY owners maintaining JCB mini excavators.
Market Segment:
Compact construction equipment
Competitive Analysis
Advantage:
Comprehensive factory service information ensures accurate repairs and maintenance, extending machine life.
Key Features
Complete Coverage:
Detailed service and repair procedures for engines, hydraulics, electrical, and more.
Factory Specifications:
Contains torque settings, clearances, and capacities required for proper servicing.
📋 Manual Details
Manual Coverage
Systems Covered:
Engine, Hydraulic, Electrical, Undercarriage, Track, and more.
Procedures Included:
Disassembly, assembly, inspection, and adjustment.
Technical Depth:
Comprehensive factory service manual with step-by-step instructions.
Parts Information:
Includes detailed diagrams and part numbers.
Format
Manual Type:
Service manual (workshop manual)
Language:
English
File Format:
PDF (Portable Document Format)
Delivery Method:
Instant download after purchase
Page Count:
Approximately several hundred pages (exact count not specified).
📖 Manual Coverage
Systems and Procedures
Engine:
Complete service, repair, and overhaul procedures for the diesel engine.
Fuel System:
Injection pump, injectors, and fuel tank service.
Cooling System:
Radiator, water pump, thermostat and cooling fan.
Lubrication System:
Oil pump, filter, and lubrication circuit.
Electrical System:
Wiring diagrams, starter, alternator, and battery.
Hydraulic System:
Pumps, valves, cylinders, and hydraulic lines.
Hydrostatic Transmission:
Troubleshooting and repair of hydrostatic drive components.
Undercarriage and Tracks:
Track tensioning, idlers, rollers, and sprockets.
Swing Mechanism:
Swing motor and reduction gear service.
Final Drives:
Inspection and repair of final drive motors.
Cab and Controls:
Control levers, pedals, and instrumentation.
Buckets and Attachments:
Boom and dipper assembly, bucket linkage adjustments.
Troubleshooting:
Systematic fault diagnosis for engine, hydraulics, and electrical.
Scheduled Maintenance:
Checklist for daily, 10-hour, 250-hour, and longer intervals.
Torque Specifications:
Fastener torque values for critical components.
Capacities:
Fluid capacities for engine oil, hydraulic oil, coolant, etc.
Wiring Schematics:
Detailed electrical circuit diagrams.
Component Pictures:
Clear photos and illustrations to assist in disassembly and assembly.
Special Tools:
List of required service tools with JCB part numbers where applicable.
Standard Service Data:
Key measurements and clearances for component inspection.
Safety Instructions:
Warnings and cautions for servicing heavy machinery.
📊 Manual Specifications
File Format
File Type:
PDF
Compatibility:
Works on PC, Mac, and mobile devices
Requirements:
Adobe Acrobat Reader or other PDF reader
Searchability:
Searchable text
Print
Print Quality:
High resolution - suitable for clear reading and printing
Binding Type:
Digital (no physical binding)
Paper Type:
Not applicable (digital file)
⚙️ Engine Specifications
Primary Engine
Engine Make:
Perkins (diesel engine)
Engine Model:
e.g., Perkins 103-10 (exact model varies by variant)
Power:
Varies by model; approximate 20-25 hp (15-18 kW)
Displacement:
Approximately 1.0–1.1 liters
Fuel System:
Direct injection diesel
Engine Options
Optional Engine:
Not specified in manual; likely no alternate engine option.
🔧 Transmission
Standard Transmission
Type:
Hydrostatic (manual states hydrostatic transmission)
Features
Drive:
Track drive via hydraulic motors
Speed Range:
Not specified in manual.
Optional Transmission:
Not specified - likely not available for this model.
📐 Dimensions
Exterior Dimensions
Wheelbase:
Not applicable (tracked machine)
Length (of tracks on ground):
Varies by model; approx 1.2 m
Overall Length (with blade):
Not specified in manual.
Overall Width:
Varies by model; approx 1.0 m
Weights
Operating Weight:
Varies by model; approx 1.5-2.0 tonnes
Curb Weight:
Same as operating weight typically.
🛡️ Safety Features
Active Safety Features
Stability:
Wide track base for stability
Operator Protection:
Rollover protective structure (ROPS) per manufacturer
Passive Safety Measures
Warning Systems:
Standard instrumentation includes engine and hydraulic warning lights
💡 Technology Features
Infotainment
Audio System:
Not applicable for construction machinery
Operator Aids
Control System:
Standard pilot or servo controls for precise operation
Monitoring:
Basic gauges (coolant temp, hydraulic oil temp, fuel level)
🔧 Maintenance
Service Intervals
Engine Oil:
Every 250 hours (or as specified in manual)
Hydraulic Oil:
Every 1000 hours or annually
Air Filter:
Check every 10 hours, replace as needed
Fluid Specifications
Engine Oil Type:
15W-40 API CH-4 or better
Hydraulic Oil Type:
ISO VG 32 or 46 anti-wear hydraulic oil
Coolant Type:
Ethylene glycol based with anti-corrosion additives
Common Wear Items
Track Components:
Tracks, sprockets, idlers
Pins and Bushes:
Bucket linkage and boom pins
Filters:
Oil, fuel, hydraulic filters
📚 Vehicle History
Brand Heritage
Manufacturer:
JCB (J.C. Bamford Excavators Ltd)
Founded:
1945 in Uttoxeter, Staffordshire, UK
Model Evolution
Series:
JCB 802 series encompasses 802, 802.4, and 802 Super
Notes:
The 802 Super is an enhanced variant with more power and features.
Production Location
Plant:
JCB Compact Construction Products factory in Cheadle, UK or Hameln, Germany
🏆 Awards & Recognition
Model Recognitions
Recognition:
N/A - no specific awards documented for this model.

Delivery & file format

This is a digital PDF download, not a printed book. After payment the download link appears on your order confirmation page and is emailed to the address you entered. Files open in any PDF reader on phone, tablet or computer and can be printed.

Check the serial range before you buy

Manufacturers change procedures and part numbers by serial-number break. If your data plate shows a serial prefix that is not listed above, contact us with the model and serial number and we will confirm coverage before you order.

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