jcb 8040ZTS Service Manual
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jcb 8040ZTS Service Manual

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Service Manual
8040ZTS, 8045ZTS, 8050RTS, 8050ZTS
Service Manual - 8040ZTS, 8045ZTS, 8050RTS, 8050ZTS
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Maintenance
Section A - Attachments
Section B - Body and Framework
Section D - Controls
Section F - Gearboxes
Section J - Track and Running Gear
Publication No.
9803/9360-4
World Class
Customer Support
Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400

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  • Page 1 Customer Support Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
  • Page 2 Section 1 - General Information Notes: 9803/9360-4...

  • Page 3: Table Of Contents

    Section 1 - General Information Contents Contents Page No. Introduction About this Manual ..................1-1 Machine Model and Serial Number ............1-1 Using the Service Manual ..............1-1 Section Numbering ................1-1 Left Side, Right Side ................1-2 Cross References ..................1-2 Identifying Your Machine Identification Plates ...................
  • Page 4 Section 1 - General Information Contents Contents Page No. 1-ii 1-ii...

  • Page 5: About This Manual

    General Information - includes torque settings and T11-004 service tools. This publication is designed for the benefit of JCB Care and Safety - includes warnings and cautions Distributor Service Engineers who are receiving, or have pertinent to aspects of workshop procedures etc.

  • Page 6: Left Side, Right Side

    Section 1 - General Information Introduction About this Manual Left Side, Right Side In this manual, 'left' A and 'right' B mean your left and right when you are seated correctly in the machine. Fig 1. Cross References T1-004_2 In this publication, page cross references are made by presenting the subject title printed in bold, italic and underlined.

  • Page 7: Identifying Your Machine Identification Plates

    Random Check Letter on the identification plate will be wrong. Either get a replacement identification plate from your JCB Dealer or Year of Manufacture ( 6 = 2006, 7 = 2007, 8 = 2008, simply remove the old number. This will prevent the wrong...

  • Page 8: Typical Engine Identification Number

    Section 1 - General Information Identifying Your Machine Identification Plates Typical Engine Identification Number The engine data label is located on the cylinder block as shown. The data label includes the engine identification number. A typical engine identification number is: 65692 500405 Engine Type (2 Digits)

  • Page 9: Rops, Tops And Fogs

    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_2 Machines built to ROPS and TOPS standards have an K Fig 3.
  • Page 10 Section 1 - General Information Identifying Your Machine Identification Plates Page left intentionally blank 9803/9360-4...

  • Page 11: Introduction

    For the same reason, a Dacromet nut should not be used with a Zinc or Yellow plated bolt. Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification.
  • Page 12 Section 1 - General Information Standard Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 2. Torque Settings - UNF Grade 'S' Fasteners Bolt Size Hexagon (A/F) Condition 1 Condition 2 kgf m lbf ft kgf m lbf ft 7/16 11.2 10.0 5/16...
  • Page 13 Section 1 - General Information Standard Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 4. Metric Grade 10.9 Fasteners Bolt Size Hexagon (A/F) Condition 1 Condition 2 ISO Metric Thread kgf m lbf ft kgf m lbf ft 13.9 10.2 12.5 34.0...
  • Page 14 Section 1 - General Information Standard Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 6. Torque Settings - Rivet Nut Bolts/Screws Bolt Size ISO Metric Thread kgf m lbf ft 10.0 24.0 18.0 48.0 35.5 82.0 60.5 Table 7. Torque Settings - Internal Hexagon Headed Cap Screws (Zinc) Bolt Size ISO Metric Thread...

  • Page 15: Hydraulic Connections

    Section 1 - General Information Standard Torque Settings Hydraulic Connections Hydraulic Connections T11-003 'O' Ring Face Seal System Adaptors Screwed into Valve Blocks Adaptor screwed into valve blocks, seal onto an 'O' ring which is compressed into a 45° seat machined into the face of the tapped port.
  • Page 16 Section 1 - General Information Standard Torque Settings Hydraulic Connections Hoses Screwed into Adaptors Fig 2. Hoses 2-B screwed into adaptors 2-A seal onto an `O' ring Note: Dimension 2-D will vary depending upon the torque 2-C which is compressed into a 45° seat machined into the applied.
  • Page 17 Section 1 - General Information Standard Torque Settings Hydraulic Connections Adaptors into Component Connections with Bonded Washers Table 11. BSP Adaptors with Bonded Washers - Torque Settings BSP Size kgf m lbf ft 20.0 15.0 34.0 25.0 75.0 55.0 102.0 10.3 75.0 122.0...

  • Page 18: Torque Stop' Hose System

    Section 1 - General Information Standard Torque Settings Hydraulic Connections 'Torque Stop' Hose System Fig 3. `Torque Stop' Hoses 3-B screwed into adaptors 3-A seal Stop' Hoses have an additional shoulder 3-D, which acts onto an 'O' ring 3-C which is compressed into a 45° seat as a physical stop.

  • Page 19: Service Tools Numerical List

    Note: Tools other than those listed will be required. It is carrying out the procedures described in this manual. expected that such general tools will be available in any These tools are available from JCB Service. well equipped workshop or be available locally from any good tool supplier.
  • Page 20 Section 1 - General Information Service Tools Numerical List Part Description See Section Number 892/00277 Adapter 892/00279 Gauge 892/00280 Gauge 892/00281 AVO Meter 892/00284 Digital Tachometer 892/00285 Hyd. Oil Temperature Probe 892/00298 Fluke Meter 892/00334 Ram Seal Fitting Tool 892/00346 Gauge 892/00347 Connector...
  • Page 21 Section 1 - General Information Service Tools Numerical List Part Description See Section Number 992/09700 Hexagon Spanner 95mm A/F 992/09900 Hexagon Spanner 115mm A/F 992/10000 Hexagon Spanner 125mm A/F 992/10100 Spool Clamp 992/12300 12V Mobile Oven 992/12400 24V Static Oven (2 Cartridge) 992/12800 Cut-Out Knife 992/12801...

  • Page 22: Tool Detail Reference

    Section 1 - General Information Service Tools Tool Detail Reference Tool Detail Reference Section B - Frame and Bodywork Fig 1. 993/68100 Slide Hammer Kit 993/68101 Slide Hammer 993/68107 Bar - M20 x M20 X 800 mm 993/68102 End Stops 993/68108 Adaptor - M20 x 7/8"...
  • Page 23 Section 1 - General Information Service Tools Tool Detail Reference Fig 3. 892/00842 Glass Lifter Minimum 2 off - Essential for glass installation, 2 required to handle large panes of glass. Ensure suction cups are protected from damage during storage. Fig 6.
  • Page 24 K Fig 6. ( T supplied. extraction tool. 1-19). Approx 25 m length. Note: 110V models available upon request - contact JCB Technical Service. Fig 10. 926/15500 Rubber Spacer Blocks Used to provide the correct set clearance between glass edge and cab frame. Unit quantity = 500 off.
  • Page 25 Section 1 - General Information Service Tools Tool Detail Reference Fig 15. 4104/1310 Hand Cleaner Special blend for the removal of polyurethane adhesives (454g; 1 lb tub). 1-21 9803/9360-3 1-21...

  • Page 26: Section C - Electrics

    Section 1 - General Information Service Tools Tool Detail Reference Section C - Electrics Fig 16. 892/00298 Fluke Meter Fig 17. 892/00285 Hydraulic Temperature Probe Fig 18. 892/00284 Venture Microtach Digital Tachometer 1-22 9803/9360-3 1-22...

  • Page 27: Section E - Hydraulics

    Section 1 - General Information Service Tools Tool Detail Reference Section E - Hydraulics Male Adapters - BSP x BSP 1606/2052 3/8 in. x 1/4 in. 1604/0003A 3/8 in. x 3/8 in. 892/00071 3/8 in. x 3/8 in. taper 1606/0004 1/2 in.
  • Page 28 Section 1 - General Information Service Tools Tool Detail Reference 892/00047 3/8 in. BSP (A) x 1/4 in. BSP (B) 892/00048 1/2 in. BSP (A) x 1/4 in. BSP (B) 892/00049 5/8 in. BSP (A) x 1/4 in. BSP (B) 816/50043 3/4 in.
  • Page 29 Section 1 - General Information Service Tools Tool Detail Reference 892/01016 For 25 mm Rod Diameter 892/01017 For 30 mm Rod Diameter 892/01018 For 40 mm Rod Diameter 892/01019 For 50 mm Rod Diameter 892/01020 For 50 mm Rod Diameter (slew ram) 892/01021 For 60 mm Rod Diameter 892/01022...
  • Page 30 Section 1 - General Information Service Tools Tool Detail Reference 892/00268 Flow Monitoring Unit 892/00269 Sensor Head 0 - 100 l/min (0 - 22 UK gal/min) 892/00273 Sensor Head 0 - 380 l/min (0 - 85.5 UK gal/min) 892/00293 Connector Pipe 892/00270 Load Valve 1406/0021...
  • Page 31 Section 1 - General Information Service Tools Tool Detail Reference 892/00279 Pressure Gauge 0-400 bar (0-6000 lbf/in 892/00346 Pressure Gauge 0-70 bar (0-1000 lbf/in 892/00347 Connector 892/00254 Hose 892/00280 Pressure Gauge 0-600 bar (0-9000 lbf/in Fig 33. Hydraulic Circuit Test Gauges and Connections 892/00223 Hand Pump...

  • Page 32: Section K - Engine

    Section 1 - General Information Service Tools Tool Detail Reference Section K - Engine Fig 38. 892/00041 - De-glazing Tool for Cylinder Bores To assist bedding-in of new piston rings. For details of other engine service tools refer to: – Publication No. 9806/2100 English –...

  • Page 33: Service Consumables Sealing And Retaining Compounds

    A medium strength sealant suitable for all sizes of 4102/1212 50 ml gasket flanges, and for hydraulic fittings of 25-65 mm diameter. JCB High Strength Threadlocker A high strength locking fluid for use with threaded 4102/0551 50 ml components. Gasketing for all sizes of flange where the strength of the joint is important.
  • Page 34 Section 1 - General Information Service Consumables Sealing and Retaining Compounds Page left intentionally blank 1-30 9803/9360-3 1-30...

  • Page 35: Terms And Definitions Colour Coding

    The following colour coding, used on illustrations to denote various conditions of oil pressure and flow, is standardised throughout JCB Service Publications. Full Pressure: Pressure generated from operation of a service. Depending on application this may be anything between neutral circuit pressure and MRV operating pressure.
  • Page 36 Section 1 - General Information Terms and Definitions Colour Coding Page left intentionally blank 1-32 9803/9360-3 1-32...
  • Page 37 Section 2 - Care and Safety Notes: 9803/9360-4...
  • Page 38 Section 2 - Care and Safety Contents Page No. Safety Notices Important Information ................2-1 The Operator Manual ................2-1 Safety Warnings ..................2-1 Safety Check List ..................2-2 Safety - Yours and Others ..............2-2 General Safety ..................2-2 Operating Safety ...................2-4 Maintenance Safety ................2-8 Safety Labels ...................
  • Page 39 Section 2 - Care and Safety Contents Page No. 2-ii 2-ii...
  • Page 40 Operator Manual. If you do not other operators. understand anything, ask your employer or JCB dealer to explain it. In this publication and on the machine, there are safety INT-1-4-2 notices.
  • Page 41 JCB distributor to explain them. with it. If you don't, you will not do your job well, and you will be a danger to yourself and others.
  • Page 42 Sparks in altered in any way which could affect or invalidate any such an area could cause an explosion or fire of these requirements. For advice consult your JCB resulting in death or serious injury. Distributor.
  • Page 43 Section 2 - Care and Safety Safety Notices Safety Check List Operating Safety WARNING Work Sites WARNING Work sites can be hazardous. Inspect the site before working on it. You could be killed or injured if the Machine Condition ground gives way under your machine or if piled A defective machine can injure you or others.
  • Page 44 5-5-1-1_2 INT-2-1-1 WARNING WARNING Use only the JCB approved attachments that are specified for your machine. Operating with non- Airborne particles of light combustible material such specified attachments can overload the machine, as straw, grass, wood shavings, etc. must not be...
  • Page 45 Section 2 - Care and Safety Safety Notices Safety Check List DANGER WARNING Working Platform Machines with a TOPS structure are equipped with a Using the machine as a working platform is seat belt. The TOPS structure is designed to give you hazardous;...
  • Page 46 Section 2 - Care and Safety Safety Notices Safety Check List CAUTION WARNING Passengers Machine Safety Passengers in or on the machine can cause accidents. Stop work at once if a fault develops. Abnormal Do not carry passengers. sounds and smells can be signs of trouble. Inspect and repair before resuming work.
  • Page 47 Section 2 - Care and Safety Safety Notices Safety Check List Maintenance Safety WARNING Fluid Under Pressure WARNING Fine jets of fluid at high pressure can penetrate the skin. Keep face and hands well clear of fluid under Communications pressure and wear protective glasses and gloves. Bad communications can cause accidents.
  • Page 48 Section 2 - Care and Safety Safety Notices Safety Check List CAUTION CAUTION It is illegal to pollute drains, sewers or the ground. 'O' rings, Seals and Gaskets Clean up all spilt fluids and/or lubricants. Badly fitted, damaged or rotted 'O' rings, seals and gaskets can cause leakages and possible accidents.
  • Page 49 WARNING WARNING Certain seals and gaskets (e.g. crankshaft oil seal) on To avoid burning, wear protective gloves when JCB machines contain fluoroelastomeric materials handling hot components. To protect your eyes, wear ® ® goggles when using a brush to clean components.
  • Page 50 Keep the systems incorporating accumulators, the system electrolyte away from your clothes, skin, mouth and pressure must be exhausted by a JCB distributor, as eyes. Wear safety glasses. the sudden release of the hydraulic fluid or gas may INT-3-2-1_3 cause injury.
  • Page 51 Keep all safety labels clean and readable. Replace lost or damaged safety labels. Make sure replacement parts include safety labels where necessary. Each safety label has a part number printed on it, use this number to order a new safety label from your JCB distributor. 2-12 9803/9360-4 2-12...
  • Page 52 Section 2 - Care and Safety Safety Notices Safety Labels ISO-07B ISO-010A Part Number: 817/70018 Part Number: 817/70029 Description: Crush hazard. Do not Description: Crush hazard. Wear the operate the controls from outside of seatbelt when operate the machine. machine. 817-70018-2 817-70029-3 ISO-07D...
  • Page 53 Section 2 - Care and Safety Safety Notices Safety Labels ISO-15E Part Number: 332/V3761 Description: Flying debris warning. Refer to Optional Attachments. 332-V3761-1 ISO-09A Part Number: 332/P4581 Description: Severing of hands or fingers. Keep clear of/do not reach into the moving parts. Stop the engine and remove the starter key before you start maintenance work.
  • Page 54 Section 2 - Care and Safety Safety Notices Safety Labels Page left intentionally blank 2-16 9803/9360-4 2-16...
  • Page 55 Section 3 - Maintenance Notes: 9803/9360-4...
  • Page 56 Section 3 - Maintenance Contents Page No. Routine Maintenance Service Requirements ................3-1 Introduction ....................3-1 Owner/Operator Support ...............3-1 Service/Maintenance Agreements ............3-1 Fit for Purpose Tests for Lifting Equipment ..........3-1 Obtaining Replacement Parts ..............3-2 Health and Safety ..................3-3 Lubricants ....................3-3 Battery ....................3-5 Service Schedules ..................
  • Page 57 Section 3 - Maintenance Contents Contents Page No. Fuel System ..................... 3-43 Introduction ..................3-43 Water Separator and Engine Fuel Filter ..........3-44 Bleeding the System ................3-47 Hydraulic System ..................3-48 Introduction ..................3-48 Releasing the Hydraulic Pressure ............3-49 Oil and Filter ..................3-50 Tracks and Running Gear ...............
  • Page 58 JCB together with your Distributor wants you to be maximum performance, economy and ease of use under a completely satisfied with your new JCB machine. If you do wide variety of operating conditions. Prior to delivery, your encounter a problem however, you should contact your...
  • Page 59 Thank you very much for your reading. Please Click Here Then More Information.

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