Need to fix the JCB 802, 802.4, Super, or 801.4 mini excavator sitting in your bay? All 293 pages of this JCB 802 service manual PDF (OEM #9803/3140 Issue 4) focus on getting your 1994-2005 machine back to factory condition. You get complete hydraulic circuit schematics, detailed wiring diagrams, and a full section of step-by-step pump teardown procedures. Open the file to find exact flow testing methods, track gearbox dismantling instructions, and fault-finding charts to track down stubborn leaks. Lock down the cylinder head bolts to exactly 88-93 Nm, and tighten the track motor valve bolts to 51-64 Nm before testing the system. Don't risk a costly comeback by guessing on pressures. Download the bookmarked file, pull it up on your shop tablet, and get to work.
What's Inside This JCB 802, 802.4, 802 Super, 801.4 Manual
| System | Pages | Key Topics |
|---|---|---|
| General Information | 1-48 | Contents, Identifying Your Machine, Storage, ROPS, Tops and Fogs, Introduction, Entering/Exiting the Cab, Cab, Opening the Windscreen |
| Care & Safety | 49-54 | Contents, Safety Notices, General Safety, Operating Safety, Maintenance Safety |
| Routine Maintenance | 55-83 | Lubricants and Capacities, Engine Lubrication Chart, Lubricants - Health and Safety, Torque Settings, Hydraulic Fittings and Torque Settings, Service Schedule, Greasing |
| Attachments | 84-105 | Available Attachments, Buckets (Selection, Removal, Installing a Bucket, Replacing Bucket Teeth), Quickhitch, Hydraulic Attachment Circuits |
| Body & Framework | 106-119 | Bucket Ram Pivot and Linkage (Removal, Inspection and Replacement), Dipper (Removal and Replacement), Boom (Removal, Kingpost (Removal and Replacement) |
| Electrics | 120-150 | Technical Data, Battery, Alternator (Removal & Replacement), Starter Motor (Removal & Replacement), Beacon (Mounting, Bulb Change), Schematic Diagrams |
| Controls | 151-159 | Excavator and Dozer Levers (Removal & Replacement), Servo Hand Controllers - 802 (Removal & Replacement) |
| Hydraulics | 160-227 | Technical Data, Hydraulic Circuit (Circuit Description), Servo Circuit (Circuit Description), Hydraulic Pump (Operation, Removal, Dismantling & Assembly, Flow Testing) |
| Gearboxes | 228-240 | Technical Data, Track Gearbox (Operation, Removal and Replacement, Dismantling & Assembly) |
| Track & Running Gear | 241-252 | Tracks (Clean, Inspect, Removal & Replacement, Steel Track, Rubber Track), Track Rollers (Removal & Replacement, Dismantling & Assembly, Metallic Face Seals) |
| Engine | 253-293 | Technical Data, Oil Pressure Relief Valve (Removal & Replacement), Oil Sump, Suction Pipe & Strainer (Removal & Replacement) |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Cylinder Head Bolts (oiled) | 88-93 Nm (9.0-9.5 kgf m, 65-69 lbf ft) | p. 60 |
| Track Motor Valve Bolts (Item 1) | 51-64 Nm (5.2-6.6 kgf m, 38-47 lbf ft) | p. 186 |
| Hydraulic System Pressure Release (venting) | Operate the controls several times to release any trapped hydraulic pressure. Slowly release the hydraulic tank filler cap. | p. 91 |
| General Hydraulic Leak Check | Check for visible leaks in the system. If hydraulic fluid penetrates skin, get medical help immediately. | p. 163 |
| Track Motor Oil Leakage (between valve and motor) | Tighten bolts, or replace O-rings and gasket. | p. 192 |
| Engine Oil Filter Replacement Interval | First 100 Hours Only, then Every 250 Operating Hours (Or Monthly) | p. 63 |
| Engine Oil Filter Tightening | hand tight and then one quarter turn | p. 76 |
| Fuel Filter Element Replacement Interval | Every 500 Operating Hours (Or 6 Months) | p. 63 |
| Fuel Sediment Bowl Drain Interval | Every 50 Operating Hours (Or Weekly) | p. 63 |
| Fan Belt Adjustment Interval | Every 50 Operating Hours (Or Weekly) | p. 63 |
| Fan Belt Tension (slack) | 5 mm (0.2 in.) | p. 72 |
| Track Gearbox Oil Capacity (each) | 1.2 litres (0.26 UK gal) | p. 56 |
JCB 802, 802.4, 802 Super, 801.4 Common Problems This Manual Covers
JCB 802 engine cranks but will not start after winter storage or fuel filter replacement p. 267
Bleed the fuel system to remove trapped air. Loosen the injector lines and crank until clear fuel flows, as detailed on page 267. Replace the fuel filter element every 500 operating hours (page 63). Ensure the battery is fully charged.
Manual Section: Fuel System - BleedingEngine overheating and reduced cooling performance with loose or squealing drive belts p. 72
Check the fan belt adjustment and tension. Apply 5 kgf (10 lbf) of force to the belt and verify the slack measures exactly 5 mm (0.2 in.). Refer to page 72 for tensioning instructions. Clean the radiator matrix thoroughly to remove dirt and debris buildup.
Manual Section: Routine MaintenanceTravel drive performance feels abnormal with excessive track looseness or poor tension p. 81
Inspect the running gear and measure rubber track tension. Adjust the grease cylinder until track sag measures 70mm to 90mm at the bottom center roller, as detailed on page 81. Drain and refill the track gearbox with 1.2 litres of oil if drive remains sluggish.
Manual Section: Track & Running GearExcavator services inoperative or slow with weak hydraulic functions and erratic response p. 161
Test the main relief valve pressure. Connect a gauge and verify the tracks, dipper, boom, and bucket circuits reach exactly 200 bar. Check page 161 for pressure specifications. Inspect all lines for visible leaks and replace the hydraulic fluid return filter element.
Manual Section: Hydraulic Pressure TestingFrequently Asked Questions
How do I reset error codes on a JCB 802 mini excavator?
For machines from serial number 733848, if a fault is ignored, the buzzer will sound continuously for 180 seconds, then intermittently. To reset all operations, switch the ignition off. This procedure also applies to fuel sender circuit faults.
What are the torque specs for JCB 802 track motor bolts?
For track motor valve bolts (Item 1), the torque specification is 51-64 Nm (5.2-6.6 kgf m, 38-47 lbf ft). For sprocket mounting bolts, torque to 113 Nm (83.3 lbf ft).
What are the torque specs for JCB 802 hydraulic fittings?
For 'O' Ring Face Seal System adaptors, torque ranges from 14 Nm (10 lbf ft) for 1/8"-BSP to 206 Nm (152 lbf ft) for 1 1/4"-BSP. For SAE Tube Size fittings, torque ranges from 20-28 Nm (16.5-18.5 lbf ft) for size 4 to 280-380 Nm (210-280 lbf ft) for size 20. 'Torque Stop' Hose System fittings have specific torque values, for example, 14 Nm (10 lbf ft) for 1/8" BSP.
How to reset JCB 802 fault code
For machines from serial number 733848, if a fault is ignored, the buzzer will sound continuously for 180 seconds, then intermittently. To reset all operations, switch the ignition off. This procedure also applies to fuel sender circuit faults.
How will I receive this JCB 802, 802.4, 802 Super, 801.4 Service Manual?
You get a 293-page searchable PDF that downloads instantly after checkout. Open it on your laptop, tablet, or phone, and bring it right to the shop floor.
Are there any print restrictions on this JCB 802, 802.4, 802 Super, 801.4?
Yes, print as many copies as you want, and there are no restrictions. Many mechanics print the section they need and bring it to the shop floor.
Does this JCB 802, 802.4, 802 Super, 801.4 manual include wiring diagrams?
Complete wiring diagrams are included, covering all electrical circuits, harness routing, and connector pinouts for the JCB 802, 802.4, 802 Super, 801.4.
Document Quality
This document is a scanned PDF with an OCR text layer, allowing you to search and copy text throughout the manual. The text quality is consistently crisp and easy to read on all pages. Diagrams and illustrations are raster images, but they are clear, and all labels are readable. The pages are clean with no noticeable scan artifacts, stains, marks, or skewing.
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