General Information
1
Care & Safety 2
Routine Maintenance 3
Attachments A
Body & Framework B
Electrics C
Service
Manual Controls D
Hydraulics E
802 Gearboxes F
802.4
Track & Running Gear J
802 Super
Published by the
TECHNICAL PUBLICATIONS DEPARTMENT
Engine L
of
JCB COMPACT PRODUCTS LTD;
Harewood Estate
Leek Road, Cheadle
Stoke-on Trent
Staffordshire, England
ST10 2JU
Tel: 01538 757500, Fax: 01538 757590
Publication No. 9803/3140 Issue 4
,Introduction
This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received,
training by JCB Technical Training Department.
It is assumed that these personnel have a sound knowledge of workshop practice, safety procedures and general
techniques associated with the maintenance and repair of hydraulic earthmoving equipment. Therefore, these basic
subjects generally are omitted from this manual, the intention being to convey only more specialised information
concerning particular aspects of a machine or component.
For example, renewal of oil seals, gaskets etc., and any component showing obvious signs of wear or damage is
expected as a matter of course and, therefore, information of this nature is included only in the context of specialised
procedures or where a range of wear tolerances is required. Similarly, it is expected that components will be cleaned
and lubricated where appropriate, also that any opened hose or pipe connections will be blanked to prevent excessive
loss of hydraulic fluid and ingress of dirt. Finally, please remember above all SAFETY MUST COME FIRST!
The manual is compiled in sections, the first three are numbered and contain information as follows:
1 = General Information - includes torque settings and service tools
2 = Care & Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc.
3 = Routine Maintenance - includes service schedules and recommended lubricants for the machine.
The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for
example:
A = Attachments
B = Body & Framework ... etc.
The page numbering in each alphabetically coded section may not be continuous. This allows for the insertion of new
items in later issues of the manual.
Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of each
alphabetically coded section.
All sections are listed on the front cover; tabbed divider cards align directly with individual sections on the front cover for
rapid reference.
Illustrations which show a dismantled component are numbered as a guide to the dismantling sequence, which generally
can be reversed for assembly.
Torque settings are given as a 'mean' figure which may be varied by plus or minus 3%. Torque figures indicated are for
dry threads, hence for lubricated threads may be reduced by one third.
'Left Hand' and 'Right Hand' are as viewed from the rear of the machine.
References to alternative servicing intervals are to be treated on a 'whichever occurs first' basis.
9803/3140 Issue 1
,Section 1 General Information Section 1
i i
Contents Page No.
Identification 1-1
Storing the machine 1-2
ROPS, TOPS and FOGS 1-3
Introduction 2-1
Before entering the cab 2-1
Entering/exiting the cab 2-2
Cab 2-3
Opening the windscreen 2-4
Opening the sidescreen 2-4
Heater controls 2-5
Seat 2-6
Seat belt (when fitted) 2-6
Engine and track controls,
Switches and instruments 3-1
Track controls 3-2
Engine controls 3-3
Switches 3-4
Instruments 3-6
Dozer controls 4-1
Excavator controls 4-2
Changing the Excavator Control Pattern 4-3
Slew cab 4-4
Swing boom 4-5
Boom swing stop 4-6
Raise / Lower boom 4-7
Dipper 4-8
Bucket 4-8
Refuelling the machine 4-8
Before starting the engine 5-1
Starting the engine 5-1
Jump starting the engine 5-2
Cold climate warm up 5-3
Operating in high / low temperatures 5-3
Stopping and parking the machine 6-1
Preparing for road / site travel 6-2
Getting the machine moving 6-3
Working with the dozer 7-1
Working with the excavator
Working on a slope 7-1
Digging 7-2
Moving the Machine While
Digging on the Level 7-3
Digging near walls 7-3
Lifting Regulations and Safe Working Loads 7-4
Using the attachments and site safety 7-5
Moving a disabled machine 10 - 1
Transporting the machine 10 - 2
Securing for Transport 10 - 2
Service Tools 11 - 1
Sealing and Retaining Compounds 13 - 1
9803/3140 Issue 3*
, Section 1 General Information Section 1
1-1 1-1
IDENTIFYING YOUR MACHINE
The machine has a Data Plate attached to the left hand
front face of the machine.
The serial numbers of the machine, engine and gearboxes
are stamped on this plate.
If the engine is replaced, stamp the new serial number in
place of the old one.
Explanation of Vehicle Identification Explanation of Engine Identification
Number (VIN) Number
Code A B C D E Code A B C D E
Example SLP 0802 X E 0732450 Example KE 50390 J 000001 y
A World Manufacturer Identification SLP = JCB A Engine Type
B Machine Model 0802 = 802 B Engine Parts List
C Country of Manufacture
C Year of Manufacture D Engine Serial Number
R = 1994 W = 1998 2 = 2002 E Year of Manufacture
S = 1995 X = 1999 3 = 2003
T = 1996 Y = 2000 4 = 2004
V = 1997 1 = 2001 5 = 2005
D Manufacturers Location E = England
E Machine Serial Number 0732450
OSEN ISO9001
J C BAMFORD EXCAVATORS LTD
ROCESTER, STAFFS, ENGLAND
CONSTRUCTOR
FM 14063
Product
Identification
VIN Vehicle Identification Number Number
ENGINE SERIAL NUMBER LH TRACK GEARBOX SERIAL NUMBER
SLEW GEARBOX SERIAL NUMBER RH TRACK GEARBOX SERIAL NUMBER
WEIGHT kg ENGINE POWER kW @ RPM
YEAR OF MANUFACTURE
H04343
9803/3140 Issue 2*
1
Care & Safety 2
Routine Maintenance 3
Attachments A
Body & Framework B
Electrics C
Service
Manual Controls D
Hydraulics E
802 Gearboxes F
802.4
Track & Running Gear J
802 Super
Published by the
TECHNICAL PUBLICATIONS DEPARTMENT
Engine L
of
JCB COMPACT PRODUCTS LTD;
Harewood Estate
Leek Road, Cheadle
Stoke-on Trent
Staffordshire, England
ST10 2JU
Tel: 01538 757500, Fax: 01538 757590
Publication No. 9803/3140 Issue 4
,Introduction
This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received,
training by JCB Technical Training Department.
It is assumed that these personnel have a sound knowledge of workshop practice, safety procedures and general
techniques associated with the maintenance and repair of hydraulic earthmoving equipment. Therefore, these basic
subjects generally are omitted from this manual, the intention being to convey only more specialised information
concerning particular aspects of a machine or component.
For example, renewal of oil seals, gaskets etc., and any component showing obvious signs of wear or damage is
expected as a matter of course and, therefore, information of this nature is included only in the context of specialised
procedures or where a range of wear tolerances is required. Similarly, it is expected that components will be cleaned
and lubricated where appropriate, also that any opened hose or pipe connections will be blanked to prevent excessive
loss of hydraulic fluid and ingress of dirt. Finally, please remember above all SAFETY MUST COME FIRST!
The manual is compiled in sections, the first three are numbered and contain information as follows:
1 = General Information - includes torque settings and service tools
2 = Care & Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc.
3 = Routine Maintenance - includes service schedules and recommended lubricants for the machine.
The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for
example:
A = Attachments
B = Body & Framework ... etc.
The page numbering in each alphabetically coded section may not be continuous. This allows for the insertion of new
items in later issues of the manual.
Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of each
alphabetically coded section.
All sections are listed on the front cover; tabbed divider cards align directly with individual sections on the front cover for
rapid reference.
Illustrations which show a dismantled component are numbered as a guide to the dismantling sequence, which generally
can be reversed for assembly.
Torque settings are given as a 'mean' figure which may be varied by plus or minus 3%. Torque figures indicated are for
dry threads, hence for lubricated threads may be reduced by one third.
'Left Hand' and 'Right Hand' are as viewed from the rear of the machine.
References to alternative servicing intervals are to be treated on a 'whichever occurs first' basis.
9803/3140 Issue 1
,Section 1 General Information Section 1
i i
Contents Page No.
Identification 1-1
Storing the machine 1-2
ROPS, TOPS and FOGS 1-3
Introduction 2-1
Before entering the cab 2-1
Entering/exiting the cab 2-2
Cab 2-3
Opening the windscreen 2-4
Opening the sidescreen 2-4
Heater controls 2-5
Seat 2-6
Seat belt (when fitted) 2-6
Engine and track controls,
Switches and instruments 3-1
Track controls 3-2
Engine controls 3-3
Switches 3-4
Instruments 3-6
Dozer controls 4-1
Excavator controls 4-2
Changing the Excavator Control Pattern 4-3
Slew cab 4-4
Swing boom 4-5
Boom swing stop 4-6
Raise / Lower boom 4-7
Dipper 4-8
Bucket 4-8
Refuelling the machine 4-8
Before starting the engine 5-1
Starting the engine 5-1
Jump starting the engine 5-2
Cold climate warm up 5-3
Operating in high / low temperatures 5-3
Stopping and parking the machine 6-1
Preparing for road / site travel 6-2
Getting the machine moving 6-3
Working with the dozer 7-1
Working with the excavator
Working on a slope 7-1
Digging 7-2
Moving the Machine While
Digging on the Level 7-3
Digging near walls 7-3
Lifting Regulations and Safe Working Loads 7-4
Using the attachments and site safety 7-5
Moving a disabled machine 10 - 1
Transporting the machine 10 - 2
Securing for Transport 10 - 2
Service Tools 11 - 1
Sealing and Retaining Compounds 13 - 1
9803/3140 Issue 3*
, Section 1 General Information Section 1
1-1 1-1
IDENTIFYING YOUR MACHINE
The machine has a Data Plate attached to the left hand
front face of the machine.
The serial numbers of the machine, engine and gearboxes
are stamped on this plate.
If the engine is replaced, stamp the new serial number in
place of the old one.
Explanation of Vehicle Identification Explanation of Engine Identification
Number (VIN) Number
Code A B C D E Code A B C D E
Example SLP 0802 X E 0732450 Example KE 50390 J 000001 y
A World Manufacturer Identification SLP = JCB A Engine Type
B Machine Model 0802 = 802 B Engine Parts List
C Country of Manufacture
C Year of Manufacture D Engine Serial Number
R = 1994 W = 1998 2 = 2002 E Year of Manufacture
S = 1995 X = 1999 3 = 2003
T = 1996 Y = 2000 4 = 2004
V = 1997 1 = 2001 5 = 2005
D Manufacturers Location E = England
E Machine Serial Number 0732450
OSEN ISO9001
J C BAMFORD EXCAVATORS LTD
ROCESTER, STAFFS, ENGLAND
CONSTRUCTOR
FM 14063
Product
Identification
VIN Vehicle Identification Number Number
ENGINE SERIAL NUMBER LH TRACK GEARBOX SERIAL NUMBER
SLEW GEARBOX SERIAL NUMBER RH TRACK GEARBOX SERIAL NUMBER
WEIGHT kg ENGINE POWER kW @ RPM
YEAR OF MANUFACTURE
H04343
9803/3140 Issue 2*
