JCB 802.7 Plus Mini Excavator Service Repair Workshop Manual

This is the COMPLETE Service and Repair Manual for the JCB 802.7 Plus Mini Excavator Service Repair Workshop Manual. It covers every single detail.

JCB 802.7 Plus Mini Excavator Service Repair Workshop Manual PDF VEHICLE/EQUIPMENT INTRODUCTION: The JCB 802.7 Plus is a compact mini excavator designed by one of Britains largest equipment manufacturers for construction, landscaping and utility work in confined spaces. Weighing approximately 2.7 tonnes, this zero-tail-swing excavator operates efficiently in restricted areas without counterweight overhang, making it ideal for work alongside buildings, in gardens, and within urban construction sites. The 802.7 Plus features a reliable diesel engine, hydraulic pilot controls, and an extendable blade dozer for enhanced digging depth and backfill capabilities. JCBs reputation for durable construction and easy access to service points makes this mini excavator a cost-effective machine that can be maintained by knowledgeable operators and shop technicians alike. SERVICE & REPAIR SCOPE: - Diesel engine major overhaul including cylinder head and block service - Injector testing and fuel pump calibration procedures - Air filtration system maintenance and housing inspection - Hydraulic pump flow testing and valve block service - Cylinder seal kit installation for boom, arm and bucket cylinders - Hydraulic hose inspection, routing and replacement - Hydraulic tank flushing and filter replacement - Dozer blade cylinder service and blade pivot bearing inspection - Swing bearing inspection and swing motor gearbox service - Track tension adjustment and track roller/idler replacement - Travel motor hydraulic service and brake function test - Hydraulic pilot control system adjustment and troubleshooting - Operator station controls inspection and cable adjustment - Electrical system troubleshooting of lights, horn and alarms - Alternator and starter motor testing - Battery maintenance and charging system verification - Complete hydraulic system contamination diagnosis - Cab canopy mounting and ROPS inspection - Attachment quick-hitch mechanism inspection and service - Scheduled maintenance interval procedures and lubrication chart TECHNICAL SPECIFICATIONS: - Operating Weight: approximately 2,750 kg - Engine: Diesel, water-cooled, 4-stroke - Net Power: approximately 16-20 kW - Maximum Digging Depth: approximately 2.5 meters - Maximum Reach: approximately 4.5 meters with blade extended - Swing: 360 degree continuous rotation - Track Width: variable - Travel Speed: Low and High range - Hydraulic System: Load-sensing variable displacement pump - Hydraulic Pressure: approximately 210 bar operating DIAGNOSTIC INFORMATION: - Slow hydraulic operation and loss of digging power causes - Track tension related to track wear and drive performance - Hydraulic cylinder drift diagnosis and packing seal failure - Excessive hydraulic fluid temperature causes - Engine power loss and fuel system restriction identification - Electrical short circuit and blown fuse location guide - Unusual hydraulic system noise and pump cavitation diagnosis - Swing mechanism binding and bearing wear as

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