1994-2005 JCB 802.7, 803, 804 Plus & Super Mini Excavator Service Manual
Technical reference spanning 1994-2005 JCB 802.7, 803, 804 Plus & Super models. This manual covers maintenance, repair, and troubleshooting procedures.
Manual Preview
Sample pages from the 1994-2005 JCB 802.7, 803, 804 Plus & Super Mini Excavator Service Manual manual
Purchase & Download
JCB Models Covered & Key Technical Specifications
Models: JCB 802.7, JCB 803, JCB 804
Sub-models / Variants: Plus, Super, Standard, Canopy, Cabin
Build Years: 1994–2005
Serial Numbers: 0802.7, 0803, 0804
Technical Data:
- Engine electrical system: 12V negative earth
- Battery capacity (802.7/803): 75 Ah (wet), 60 Ah (dry)
- Battery capacity (804): 103 Ah (wet), 96 Ah (dry)
- Hydraulic pump type: Triple gear pump or variable displacement pump depending on model
- Main Relief Valve (M.R.V.) pressure: 172 bar (2500 lbf/in²) to 190 bar (2750 lbf/in²)
- Slew motor speed: 9.5 rev/min (802.7/803), 10.3 rev/min (804 Plus)
- Main bypass filtration pressure: 1.5 bar (22 lbf/in²)
JCB Manual Features & Content Preview
JCB 802.7, 803, 804 Service Documentation
- Covers 1994–2005 JCB 802.7, 803, and 804 mini excavators, including Plus and Super variants with standard or canopy configurations
- Official JCB publication 9803/3145, Issue 3, documenting core mechanical and electrical specifications
- Contains 4 detailed hydraulic circuit schematics and 14 electrical harness reference tables for diagnostic analysis
- Laid out for standard letter and A4 printing
- Full-text search finds any part number in seconds
- This 196-page technical manual serves as the primary factory reference for the 802-3-4 series build
Operational Guidance and Electrical Systems
This JCB 802.7, 803, and 804 manual provides structural technical data for the how factory workshop documentation is structured regarding machine operation, electrical circuits, and hydraulic configurations. The content details safe starting procedures, cab controls, heater operation, and maintenance tasks including fan belt replacement and alternator servicing. The electrical section breaks down wiring harness specifications, fuse block ratings, and circuit diagrams for the 802.7, 803, and 804 models. Troubleshooting logic is provided for identifying hydraulic pump issues, relief valve performance, and electrical faults within the instrument cluster.
Hydraulic Data and Specifications
Technical specifications cover pump flow rates, relief valve operating pressures, and cylinder dimensions. The manual documents main relief valve pressures across various model-specific serial numbers. Slew motor performance metrics and hydraulic filtration pressure settings are listed for each variant. Hydraulic system fault diagnosis is supported by component-level identification and pressure testing descriptions for main, auxiliary, and servo relief valves. Note: All service data shown here is for reference only — qualified technicians and the original OEM documentation remain the authoritative source for any hands-on work. This 196-page official JCB service manual documents the 1994–2005 JCB 802.7, 803, and 804 mini excavator series, covering electrical systems, hydraulic circuits, and control pattern configurations for the Plus and Super build generations.
Manual FAQ, Purchase & Download Details
Customer Reviews
Read what our customers say about this JCB Mini Excavator manual and share your own experience.