Need the factory operating procedures for your 1994-2005 JCB Mini Excavator? This 215-page JCB 803 Plus operator manual PDF (OEM #9801/6210) also covers the 802.7 Super, 803 Super, and 804 Super machines. Inside, you get a full breakdown of daily maintenance checks, dashboard indicator charts, and complete service schedules. Open to the safety and operations sections to find exact lifting regulations, safe working loads, and detailed hydraulic schematics for your single and double-acting circuits. Keep your machine alive by confirming the hydraulic system is filled to exactly 80 Litres and swapping out the outer air filter element every 1000 operating hours. Stop ignoring dashboard warnings and guessing at service intervals. Download this bookmarked file right to your phone, search for the spec you need, and get back in the dirt.
What's Inside This JCB 802.7 Super, 803 Plus, 803 Super, 804 Super Operator Manual
| System | Pages | Key Topics |
|---|---|---|
| Introduction - Section a | 3-23 | About This Handbook, Safety - Yours and Other Peoples, General Safety Check List, Operating Safety Check List, Safety Decals, The JCB Mini Excavator, Identifying Your Machine, Tops and Fogs - Optional |
| Engine and Track Controls, Switches and Instruments | 37-50 | Left Track Control Lever, Right Track Control Lever, Hand Throttle Lever, Starter Switch, Working Lights Switch, Windscreen Wiper Switch, Horn Button, Warning Lights |
| Excavator Controls | 51-66 | Slew Lock, Excavator Controllers, Slew/Swing Switch, Boom Swing Stop, Throttle Lever |
| Jump Starting the Engine | 67-80 | Booster Cables, Battery, Engine, Fuel Filler Cap, Radiator, Oil Cooler, Ventilation Grilles, Dozer |
| Working with the Excavator | 81-96 | Bucket, Quickhitch, Bucket Teeth, Boom, Dipper, Lynch Pin, Latch Hook, Tommy Bar |
| Using the Attachments and Site Safety | 97-100 | Attachments, Track Motors, Recoil Units, Track Running Gear, Track Gearbox Sprockets |
| Using the Attachments - Continued | 101-117 | Hydraulic Attachment Circuits, Single Acting Circuit, Double Acting Circuit, Quickhitch Rockbreaker, Hand Held Tools, Disabled Machine, Transporting the Machine, Trailer |
| Maintenance - Section C | 118-173 | Service Contracts, Lubricants - Health and Safety, Maintenance Safety Check List, Bolt and Nut Torque Specifications, Service Schedules |
| Specifications - Section D | 174-215 | Noise and Vibration Data, Static Dimensions, Performance Dimensions |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Air cleaner element replacement interval (in very dusty conditions only) | Every 500 operating hours (or 6 months) | p. 125 |
| Air filter element (outer) replacement interval | Every 1000 operating hours (or yearly) | p. 126 |
| Hydraulic fluid replacement interval | Every 2000 operating hours (or 2 years) | p. 126 |
| Hydraulic System Capacity | 80 Litres (17.60 UK Gal) | p. 170 |
| Hydraulic suction strainer cleaning/replacement interval | Every 2000 operating hours (or 2 years) | p. 126 |
| Idler wheel and track rollers oil and seals service interval | Every 1000 operating hours (or yearly) | p. 126 |
| Track Idler Wheels Oil Capacity | 0.075 Litres (0.02 UK Gal) | p. 170 |
| Fuel Tank Capacity | 43.0 L | p. 169 |
| Engine Oil Capacity | 4.5 L | p. 169 |
| Engine Coolant Capacity (Cab) | 7.0 L | p. 169 |
| Track Gearbox Oil Capacity (each) | 1.5 L | p. 170 |
| Fan Belt Slack | 5 mm | p. 148 |
JCB 802.7 Super, 803 Plus, 803 Super, 804 Super Common Problems This Manual Covers
JCB 802.7 Super and 803 Plus travel performance is poor or rubber tracks feel loose p. 158
Inspect the undercarriage and adjust the grease cylinder to set rubber track tension to 70-90 mm. Check page 158 for the exact measurement procedure. Drain and refill the track gearbox with 1.5 L of oil as shown on page 170 if travel remains sluggish.
Manual Section: Track Tension CheckHydraulic functions are weak, jerky, or stop working completely during normal operation p. 126
Inspect the hydraulic fluid level and top up the 80 L system capacity if low. Drain the system and replace the fluid every 2000 operating hours as specified on page 126. Verify the suction strainer is clean to prevent pump starvation.
Manual Section: Hydraulic Fluid Level Check and AdjustmentEngine runs hot or shows signs of overheating when operating under heavy load p. 148
Check the fan belt slack and adjust the tensioner to achieve exactly 5 mm of deflection as detailed on page 148. Clean all dirt and debris from the radiator cooling fins. Verify the coolant level is full before returning the machine to work.
Manual Section: Fan Belt AdjustmentExcessive black smoke from the exhaust during operation or the engine severely lacks power p. 138
Remove and inspect the air cleaner elements. Replace the outer air filter element every 1000 operating hours as scheduled on page 126. Change the inner element at latest every third time the outer element is changed, following the guidelines on page 138.
Manual Section: Engine Air Filter ReplacementFrequently Asked Questions
What are the replacement specifications for Air cleaner element?
The air cleaner element should be changed every 500 operating hours (or 6 months) if operating in very dusty conditions. The outer air filter element should be changed every 1000 operating hours (or yearly). A new inner element must be fitted at latest every third time the outer element is changed.
What are the replacement specifications for Hydraulic fluid?
The hydraulic fluid and suction strainer should be changed every 2000 operating hours (or 2 years). The hydraulic system has a capacity of 80 litres (17.60 UK Gal) and requires JCB Special Hydraulic Fluid up to 30°C (86°F) or JCB Hydraulic Fluid 46 over 30°C (86°F).
How do you fix JCB 802.7 Super and 803 Plus travel performance is poor or rubber tracks feel loose?
Inspect the undercarriage and adjust the grease cylinder to set rubber track tension to 70-90 mm. Check page 158 for the exact measurement procedure. Drain and refill the track gearbox with 1.5 L of oil as shown on page 170 if travel remains sluggish.
How do you fix hydraulic functions are weak, jerky, or stop working completely during normal operation?
Inspect the hydraulic fluid level and top up the 80 L system capacity if low. Drain the system and replace the fluid every 2000 operating hours as specified on page 126. Verify the suction strainer is clean to prevent pump starvation.
How quickly can I access this JCB 802.7 Super, 803 Plus, 803 Super, 804 Super?
This is a 215-page searchable PDF ready for immediate download. Works on any device, so pull it up on your phone while you're under the hood. No shipping, no waiting.
Am I able to print pages from this JCB 802.7 Super, 803 Plus, 803 Super, 804?
The PDF is DRM-free. Print whatever sections you need to take out to the shop. Standard letter or A4 paper works.
Does this JCB 802.7 Super, 803 Plus, 803 Super, 804 Super manual include?
Yes, this JCB 802.7 Super, 803 Plus, 803 Super, 804 Super Operator Manual includes a hydraulic system diagram.
Document Quality
This is a scanned document with an OCR layer, allowing you to search and copy the full text. The text is crisp and easy to read, and the diagrams and illustrations are clear with readable labels. Pages are clean with no significant scan artifacts or marks, though some intentional blank pages are present as noted in the table of contents.
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