JCB 802 802.4 802 Super Mini Excavator Service Repair Manual

General Information Care & Safety Routine Maintenance Attachments Body & Framework Electrics Controls Hydraulics Gearboxes Track & Running Gear Engine 1 2 3 A B C D E F J L Service 802 802.4 802 Super Super Super Super Super Manual Published by the TECHNICAL PUBLICATIONS DEPARTMENT 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. 1 Issue 9803/3140

General Information Issue 9803/3140 Section 1 Section 1 i i 3* 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

General Information Issue 9803/3140 Section 1 Section 1 1 - 1 1 - 1 Explanation of Engine Identification Number Code A B C D E Example KE 50390 J 000001 y A Engine Type B Engine Parts List C Country of Manufacture D Engine Serial Number E Year of Manufacture 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 Number (VIN) Code A B C D E Example SLP 0802 X E 0732450 A World Manufacturer Identification SLP = JCB B Machine Model 0802 = 802 C Year of Manufacture R = 1994 W = 1998 2 = 2002 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 2* J C BAMFORD EXCAVATORS LTD ROCESTER, STAFFS, ENGLAND CONSTRUCTOR Product Identification Number VIN Vehicle Identification Number ENGINE SERIAL NUMBER SLEW GEARBOX SERIAL NUMBER WEIGHT kg LH TRACK GEARBOX SERI AL NUMBER RH TRACK GEARBOX SERI AL NUMBER ENGINE POWER kW @ RPM FM 14063 OSEN ISO9001 H04343 YEAR OF MANUFACTURE

General Information Issue 9803/3140 Section 1 Section 1 STORAGE Preparation for Storage The operations to place a machine into storage (-15 o C to 44 o C) are given below. 1 Park the machine safely with the bucket and dipper rams retracted and the dig end outstretched. Lower the boom until the bucket rests on the ground. Lower the dozer to the ground. 2 Switch off the engine. Operate controls to release pressure from the rams. 3 Disconnect battery to prevent discharge. 4 Ensure the fuel tank is filled to a maximum, leaving no air space. 5 Ensure hydraulic tank is filled to maximum on the sight gauge. 6 Spray exposed ram rods with Waxoyl. 7 Slacken off rubber tracks until no visible spring tension exists. Preparation after Storage The operations to remove a machine from storage (-15 o C to 44 o C) and prepare it for use are given below. 1 Lower the fuel level to ensure that sufficient air space exists in the tank. 2 Check all oil and water levels, adjust contents to correct levels as necessary. 3 Ensure the battery is fully charged. 4 Reconnect battery. 5 Remove electrical contact from fuel injection pump solenoid. 6 Crank engine for 15 seconds or until oil pressure warning light goes out. 7 Reconnect electrical supply to the fuel injection pump solenoid. 8 Start the engine. If the engine fails to start after several attempts, bleed the fuel system. 9 Adjust track tensions. 10 Grease all lubrication points. 1 - 2 1 - 2 2*

General Information Issue 9803/3140 Section 1 Section 1 ROPS, TOPS AND FOGS WARNING Modified and wrongly repaired ROPS,TOPS & FOPS Structures are dangerous. Do not modify the ROPS,TOPS & FOPS Structure. Do not attempt to repair the ROPS,TOPS & FOPS Structure. If the ROPS,TOPS & FOPS Structure has been in an accident, do not use the machine until the structure has been inspected and repaired. This must be done by a qualified person. For assistance, contact your JCB dealer. Failure to take precautions could result in death or injury to the operator. 5-3-1-7 Machine built to ROPS, TOPS and FOGS standards have an identification label fitted to the cab. WARNING The ROPS,TOPS & FOPS cab is designed to give you protection in an accident. If you do not wear the seat belt you could be thrown about inside the cab, or thrown out of the machine and crushed. You must wear a seat belt when using the machine. Fasten the seat belt before starting the engine. 2-2-1-9 JCB HYDRAPOWER LTD. RIVERSIDE, RUGELEY, STAFFS, ENGLAND JCB MINI EXCAVATOR MODEL 801.4. MAXIMUM WEIGHT 1425 Kg. MEETS ROPS TO ISO 3471 AND FOGS TO ISO/DIS 10262 LEVEL 1 PART No. SERIAL No. 817/04181 H11680 1 - 3 1 - 3 1*

General Information Issue 9803/3140 Section 1 Section 1 Operation 2 - 1 2 - 1 1* INTRODUCTION This chapter is arranged to guide you step-by-step through the task of learning how to use the machine. Read it through from beginning to end. By the end of the chapter you should have a good understanding of the machine and how to operate it. Pay particular attention to all safety messages. They are there to warn you of possible hazards. Do not just read them-think about what they mean. Understand the hazards and how to avoid them. If there is anything you do not understand, ask your JCB dealer, he will be pleased to advise you. When you have learned where the driving controls are and what they do, practise using them. Practise driving the machine in a safe, open space clear of other people. Get to know the "feel" of the machine and its driving controls. Move on to the attachment controls only when you can drive the machine confidently and safely. Take great care when practising with the attachment controls. Practise in an open space, keep people clear. Do not jerk the controls: operate them slowly until you understand the effect they have on the machine. Finally, do not rush the job of learning. Take your time and take it safely. Remember BE CAREFUL BE ALERT SAFE BEFORE ENTERING THE CAB WARNING Walking or working under raised attachments can be hazardous. You could be crushed by the attachments or get caught in the linkages. Lower the attachments to the ground before doing these checks. If you are new to his machine, get an experienced operator to lower them for you. If there is nobody to help you, study this handbook until you have learned how to lower the attachments. Also make sure that the slew lock is fitted before doing these checks. HOP26 The following checks should be made each time you return to the machine after leaving it for any period of time. We advise you also to stop the machine occasionally during long work sessions and do the checks again. All these checks concern the serviceability of the machine. Some concern your safety. Get your service engineer to check and correct any defects. MACHINE WALK ROUND INSPECTION 1 Check for cleanliness: a) Clean the windows and light lenses b) Remove dirt and debris, especially from around the linkages, rams, pivot points and radiator c) Make sure the cab and handrails are clean and dry d) Clean all safety decals. Replace any that are missing or cannot be read. 2 Check for damage: a) Inspect the machine generally for damaged and missing parts. b) Make sure that the bucket teeth are secure and in good condition c) Make sure that all the pivot pins are secured correctly in place d) Inspect the windows for cracks and damage e) Check for oil, fuel and coolant leakages beneath the machine.

General Information Issue 9803/3140 Section 1 Section 1 Operation 2 - 2 2 - 2 1* BEFORE ENTERING THE CAB - continued WARNING You could be killed or injured with damaged tracks. Do not use the machine with damaged or excessively worn tracks. HOP27 3. Check the Tracks (Rubber) Check for cut rubber and penetration by sharp objects. Do not use a machine with damaged tracks. 4. Check the engine cover/panels and fuel filler cap a) Make sure the engine cover / panels are fitted and securely locked. b) Make sure the fuel filler cap is tightly closed (we also recommend that you lock it). ENTERING/EXITING THE CAB WARNING Do not enter or exit the cab unless the arm rest or lever lock is fully engaged. To give sufficient clearance to enter or leave the cab, the left lock must be raised. When the lock is in the raised position the excavator controls cannot be operated. Lowering the lock to the normal position connects the excavator controls and allows the normal operation of the levers. CAUTION On cable operated machines, ensure that the levers are fully locked and the machine controls are disabled before exiting the cab. Note: When entering or leaving a canopy machine, both LH and RH locks must be raised. WARNING Always face the machine when entering or leaving the cab. Use the step(s) and handrails. Make sure the step(s), handrails and your boot soles are clean and dry. Do not jump from the machine. Do not use the machine controls or lever locks as handholds, use the handrails. Failure to follow these instructions could result in unexpected movement of the machine.

General Information Issue 9803/3140 Section 1 Section 1 Operation 2 - 3 2 - 3 1* CAB The cab is bolted on top of the mainframe and is a welded steel construction. The cab has a sliding window on the right side, a hinged door and an up and over windscreen. All windows are of toughened glass. The cab is fitted with a windscreen wiper, heater fan, seat and all operating controls and instruments. CAUTION Do not drive the machine with the door unlatched. It must be correctly closed or secured fully open. HOP29 802 Super machines upto 833847 OPENING AND CLOSING THE DOOR To open a door from the outside, unlock it with the key provided and press the lock barrel to release the catch. To open a door from inside, push lever A downwards. Close the door from the inside by pulling it firmly, it will latch itself. SECURING THE DOOR IN THE OPEN POSITION Swing the door fully open until the spigot E on the side of the cab locates securely in the socket F on the door. To release the door when it is secured fully open, operate the button G on the inside of the door. 802 Super machines from 733848 OPENING AND CLOSING THE DOOR To open a door from the outside, unlock it with the key provided and press the lock barrel B to release the catch. To open a door from the inside, push lever C upwards. Close the door from the inside by pulling it firmly, it will latch itself. SECURING THE DOOR IN THE OPEN POSITION Swing the door fully open until the spigot H on the side of the cab locates securely in the socket J on the door. To release the door when it is secured fully open, operate the button K on the inside of the door. C B A439920 446890 H J

General Information Issue 9803/3140 Section 1 Section 1 Operation 2 - 4 2 - 4 OPENING THE WINDSCREEN To open the up and over window, disengage the latch pins A on both handles and lift the screen to a position parallel with the roof. Secure in place with the latch pins A. Note: Care must be taken when lowering the window not to bump the top edge of the lower front window. H14080 A OPENING THE WINDSCREEN The side windows are held closed by catches A operated from inside the cab. To open the windows, operate catches A and slide the window to the desired position, the window may be secured in position with the use of knob B (if fitted). To close the windows, slide the window fully shut and check that the catch A has located on the frame. H22630 A B 1*

JCB 802 802.4 802 Super Mini Excavator Service Repair Manual

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