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Section 1 - General Information

Identifying Your Machine

Identification Plates

1-6

1-6

9803/9360-4

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Summary of Contents for 8040ZTS

Page 1: ...ion No Issued by JCB Technical Publications JCB Aftermarket Training Woodseat Rocester Staffordshire ST14 5BW England Tel 44 1889 591300 Fax 44 1889 591400 Service Manual 8040ZTS 8045ZTS 8050RTS 8050Z...

Page 2: ...Section 1 General Information 1 0 1 0 9803 9360 4 Notes...

Page 3: ...cation Number PIN 1 3 Typical Engine Identification Number 1 4 ROPS TOPS and FOGS 1 5 Standard Torque Settings Zinc Plated Fasteners and Dacromet Fasteners 1 7 Introduction 1 7 Bolts and Screws 1 7 Hy...

Page 4: ...Section 1 General Information Contents 1 ii 1 ii Page No Contents...

Page 5: ...d and ingress of dirt Where a torque setting is given as a single figure it may be varied by plus or minus 3 Torque figures indicated are for dry threads hence for lubricated threads may be reduced by...

Page 6: ...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 It...

Page 7: ...cement parts are ordered The machine and engine serial numbers can help identify exactly the type of equipment you have Fig 1 Typical Vehicle Identification Number VIN 1 World Manufacturer Identificat...

Page 8: ...the cylinder block as shown The data label includes the engine identification number A typical engine identification number is 1 Engine Type 2 Digits 2 Country of Manufacture 1 Digit U United Kingdom...

Page 9: ...utions could result in death or injury to the operator 5 3 1 7_2 Machines built to ROPS and TOPS standards have an identification label fitted to the cab K Fig 3 T 1 5 A bolt on falling object guard i...

Page 10: ...Section 1 General Information Identifying Your Machine Identification Plates 1 6 1 6 9803 9360 4 Page left intentionally blank...

Page 11: ...inc 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 Note Dacromet bolts due to their high corrosion resis...

Page 12: ...4 6 177 0 18 0 130 5 3 4 19 0 1 1 8 343 0 35 0 253 0 309 0 31 5 227 9 7 8 22 2 1 15 16 547 0 55 8 403 4 492 0 50 2 362 9 1 25 4 1 1 2 814 0 83 0 600 4 732 0 74 6 539 9 1 1 8 31 7 1 7 8 1181 0 120 4 87...

Page 13: ...91 0 M20 20 30 562 0 57 3 414 5 506 0 51 6 373 2 M24 24 36 971 0 99 0 716 9 874 0 89 1 644 6 M30 30 46 1930 0 196 8 1423 5 1737 0 177 1 1281 1 M36 36 55 3374 0 344 0 2488 5 3036 0 309 6 2239 2 Bolt Si...

Page 14: ...inc Bolt Size Nm kgf m lbf ft ISO Metric Thread mm M3 3 1 2 0 1 0 9 M4 4 3 0 0 3 2 0 M5 5 6 0 0 6 4 5 M6 6 10 0 1 0 7 5 M8 8 24 0 2 5 18 0 M10 10 48 0 4 9 35 5 M12 12 82 0 8 4 60 5 Bolt Size Nm kgf m...

Page 15: ...tor Size Hexagon A F Nm kgf m lbf ft in mm 1 4 19 0 18 0 1 8 13 0 3 8 22 0 31 0 3 2 23 0 1 2 27 0 49 0 5 0 36 0 5 8 30 0 60 0 6 1 44 0 3 4 32 0 81 0 8 2 60 0 1 38 0 129 0 13 1 95 0 1 1 4 50 0 206 0 21...

Page 16: ...n 2 D will vary depending upon the torque applied Table 10 BSP Hose Torque Settings BSP Hose Size Hexagon A F Nm kgf m lbf ft in mm 1 8 14 0 14 0 16 00 1 4 1 6 10 3 11 8 1 4 19 0 24 0 27 0 2 4 2 7 17...

Page 17: ...to Component Connections with Bonded Washers Table 11 BSP Adaptors with Bonded Washers Torque Settings BSP Size Nm kgf m lbf ft in 1 8 20 0 2 1 15 0 1 4 34 0 3 4 25 0 3 8 75 0 7 6 55 0 1 2 102 0 10 3...

Page 18: ...O ring being damages as a result of over tightening Torque Stop Hoses have an additional shoulder 3 D which acts as a physical stop Note Minimum dimension 3 E fixed by shoulder 3 D Table 12 BSP Torque...

Page 19: ...tail Reference Section 1 for content E Hydraulic Flow Test Equipment see Tool Detail Reference Section 1 for content E Hydraulic Hand Pump Equipment see Tool Detail Reference Section 1 for content E M...

Page 20: ...mm Rod Diameter E 892 01018 Ram Protection Sleeve for 40 mm Rod Diameter E 892 01019 Ram Protection Sleeve for 50 mm Rod Diameter E 892 01020 Ram Protection Sleeve for 50 mm Rod Diameter slew ram E 89...

Page 21: ...9900 Hexagon Spanner 115mm A F E 992 10000 Hexagon Spanner 125mm A F E 992 10100 Spool Clamp E 992 12300 12V Mobile Oven B 992 12400 24V Static Oven 2 Cartridge B 992 12800 Cut Out Knife B 992 12801 L...

Page 22: ...or M20 x 5 8 UNF 9 993 68109 Adaptor M20 x M12 4 993 68104 Adaptor M20 x 1 UNF 10 993 68110 Adaptor M20 x 5 8 UNF Shoulder 5 993 68105 Adaptor M20 x M20 11 993 68111 Adaptor M20 x 1 2 UNF 6 993 68106...

Page 23: ...ass prior to installation Fig 5 892 00845 Cartridge Gun Hand operated Essential for the application of sealants polyurethane materials etc Fig 6 892 00846 Glass Extractor Handles Used with braided cut...

Page 24: ...me Unit quantity 500 off Fig 11 992 12300 Mobile Oven 12V 1 cartridge capacity Required to pre heat adhesive prior to use It is fitted with a male plug 703 23201 which fits into a female socket 715 04...

Page 25: ...Section 1 General Information Service Tools Tool Detail Reference 1 21 1 21 9803 9360 3 Fig 15 4104 1310 Hand Cleaner Special blend for the removal of polyurethane adhesives 454g 1 lb tub...

Page 26: ...Information Service Tools Tool Detail Reference 1 22 1 22 9803 9360 3 Section C Electrics Fig 16 892 00298 Fluke Meter Fig 17 892 00285 Hydraulic Temperature Probe Fig 18 892 00284 Venture Microtach D...

Page 27: ...5008 1 2 in x 3 8 in 1606 0015 1 in x 1 1 4 in Fig 20 Pressure Test Adapters 892 00255 1 4 in BSP x Test Point 892 00256 3 8 in BSP x Test Point 892 00257 1 2 in BSP x Test Point 892 00258 5 8 in BSP...

Page 28: ...Fig 23 Female Blanking Caps 892 00055A 1 4 in BSP 892 00056A 3 8 in BSP 892 00057 1 2 in BSP 892 00058A 5 8 in BSP 892 00059A 3 4 in BSP 892 00060 1 in BSP Fig 24 Male Cone Blanking Caps 816 90045 1...

Page 29: ...92 01022 For 60 mm Rod Diameter slew ram 892 01023 For 65 mm Rod Diameter 892 01024 For 70 mm Rod Diameter 892 01025 For 75 mm Rod Diameter 892 01026 For 80 mm Rod Diameter 892 00167 For 90 mm Rod Dia...

Page 30: ...x 1 2 in M BSP 892 00275 Adapter 1 2 in F x 3 4 in M BSP 892 00276 Adapter 3 4 in F x 3 8 in M BSP 892 00277 Adapter 3 8 in F x 3 4 in M BSP 1606 0015 Adapter 1 1 4 in M BSP x 1 in M BSP 892 00078 Co...

Page 31: ...ar 0 9000 lbf in2 Fig 34 Hand Pump Equipment 892 00223 Hand Pump 892 00137 Micro bore Hose 1 4 in BSP x 3 metres 892 00274 Adapter 1 4 in M BSP x 3 8 in M BSP Taper 892 00262 1 4 in M BSP x 1 4 in F B...

Page 32: ...or details of other engine service tools refer to Publication No 9806 2100 English Publication No 9806 2101 French Publication No 9806 2102 German Publication No 9806 2103 Spanish Publication No 9806...

Page 33: ...r and Sealer High Strength A high strength locking fluid for sealing and retaining nuts bolts and screws up to 50 mm diameter and for hydraulic fittings up to 25 mm diameter 4101 0550 10 ml 4101 0552...

Page 34: ...Section 1 General Information Service Consumables Sealing and Retaining Compounds 1 30 1 30 9803 9360 3 Page left intentionally blank...

Page 35: ...ure generated from operation of a service Depending on application this may be anything between neutral circuit pressure and MRV operating pressure Pink Pressure Pressure that is above neutral circuit...

Page 36: ...Section 1 General Information Terms and Definitions Colour Coding 1 32 1 32 9803 9360 3 Page left intentionally blank...

Page 37: ...Section 2 Care and Safety 2 0 2 0 9803 9360 4 Notes...

Page 38: ...otices 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 Lab...

Page 39: ...Page No Contents Section 2 Care and Safety 2 ii 2 ii...

Page 40: ...becomes unreadable Safety Warnings In this publication and on the machine there are safety notices Each notice starts with a signal word The signal word meanings are given below MDANGER Denotes an ex...

Page 41: ...fely you must know the machine and have the skill to use it You must abide by all relevant laws health and safety regulations that apply to the country you are operating in The Operator Manual instruc...

Page 42: ...th all local regulations INT 1 3 7_2 MWARNING Raised Equipment Never walk or work under raised equipment unless it is supported by a mechanical device Equipment which is supported only by a hydraulic...

Page 43: ...the site before working on it You could be killed or injured if the ground gives way under your machine or if piled material collapses onto it Check for potholes and hidden debris logs ironwork etc An...

Page 44: ...each work shift or more often if required Before opening the engine cover ensure that the top is clear of debris 5 3 1 12_3 MWARNING Keep the machine controls clean and dry Your hands and feet could s...

Page 45: ...e the machine until the structure has been renewed Modifications and repairs that are not approved by the manufacturer may be dangerous and will invalidate the ROPS FOPS certification INT 2 1 9_6 MWAR...

Page 46: ...and jump from the cab Stay in the cab with your seat belt fastened INT 2 1 12 MWARNING Seat Belt Operating the machine without a seat belt can be dangerous Before starting the engine make sure your se...

Page 47: ...ARNING Fluid Under Pressure Fine jets of fluid at high pressure can penetrate the skin Keep face and hands well clear of fluid under pressure and wear protective glasses and gloves Hold a piece of car...

Page 48: ...nded cleaning agents and solvents INT 3 2 11 MWARNING When using cleaning agents solvents or other chemicals you must adhere to the manufacturer s instructions and safety precautions GEN 1 9 MCAUTION...

Page 49: ...3 5_4 MWARNING Protect your eyes when grinding metal Wear safety glasses or goggles Remove or protect any combustible materials from the area which could be ignited by sparks GEN 1 12 MWARNING To avo...

Page 50: ...on in closed areas where batteries are being used or charged Do not check the battery charge by shorting the terminals with metal use an approved battery tester INT 3 1 8_2 MDANGER Electrolyte Battery...

Page 51: ...re you wear them when reading the safety labels Do not over stretch or place yourself in dangerous positions to read the safety labels If you do not understand the hazard shown on the safety label the...

Page 52: ...aintenance Section ISO 09C 817 70102 3 Part Number 817 70102 Description Crushing of fingers or hands Remove the starter key and refer to the Service Manual before you start maintenance work ISO 010A...

Page 53: ...Attachments ISO 09A 332 P4581 1 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 st...

Page 54: ...Section 2 Care and Safety Safety Notices Safety Labels 2 16 2 16 9803 9360 4 Page left intentionally blank...

Page 55: ...Section 3 Maintenance 3 0 3 0 9803 9360 4 Notes...

Page 56: ...o the Machine 3 17 Prepare the Machine for Maintenance 3 18 Introduction 3 18 How to Make the Machine Safe Excavator Lowered 3 18 Cleaning the Machine 3 19 Introduction 3 19 Preparing the Machine for...

Page 57: ...3 47 Hydraulic System 3 48 Introduction 3 48 Releasing the Hydraulic Pressure 3 49 Oil and Filter 3 50 Tracks and Running Gear 3 51 Checking the Track Gearbox Oil Level 3 51 Changing the Track Gearbox...

Page 58: ...ed which will enable you to plan your service requirements and keep a service history record It should be dated signed and stamped by your Distributor each time your machine is serviced Remember if yo...

Page 59: ...Thank you very much for your reading Please Click Here Then Get More Information...

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