jcb 8040ZTS, 8045ZTS, 8050RTS, 8050ZTS Service Manual

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.

World Class

Customer Support

9803/9360-4

Publication No.

Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel [phone] Fax [phone]

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 C - Electrics

Section D - Controls
Section E - Hydraulics
Section F - Gearboxes

Section J - Track and Running Gear

Section K - Engine

4

Section 1 - General Information

1-0 1-0

9803/9360-4

Notes:

Section 1 - General Information

Contents

1-i 1-i

Page No.Contents

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 ............................................................. ... ................... 1-3

Machine Identification Plate ..................................................................1-3

Typical Vehicle Identification Number (VIN) ..........................................1-3

Typical Product Identification 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

Hydraulic Connections .................................. .... ... ... ................................. 1-11

'O' Ring Face Seal System ..................................................................1-11

'Torque Stop' Hose System ..... ... .... ... ... ... .... ... ... ... .... ... ... ... ... .... ... ... ... ..1-14

Service Tools

Numerical List .......................................................................................... 1-15

Tool Detail Reference .......... ............................................. ... ... ... .... ... ... ... . 1-18

Section B - Frame and Bodywork ........................................................1-18

Section C - Electrics .......................................................................... ..1-22

Section E - Hydraulics .........................................................................1-23

Section K - Engine ...............................................................................1-28

Service Consumables

Sealing and Retaining Compounds ......................................................... 1-29

Terms and Definitions

Colour Coding .......................................................................................... 1-31

Hydraulic Schematic Colour Codes .......................... ... ... ... ... .... ... ... ... ..1-31

Section 1 - General Information

Contents

1-ii 1-ii

Page No.Contents

Section 1 - General Information

Introduction

About this Manual

1-1 1-1

9803/9360-4

Introduction

About this Manual

Machine Model and Serial Number

This manual provides information for the following
model(s) in the JCB machine range:

Using the Service Manual

T11-004

This publication is designed for the benefit of JCB
Distributor Service Engineers who are receiving, or have
received, training by JCB Technical Training Department.

These personnel should have a sound knowledge of
workshop practice, safety procedures, and general
techniques associated with the maintenance and repair of
hydraulic earthmoving equipment.

The illustrations in this publication are for guidance only.
Where the machines differ, the text and/or the illustration
will specify.

General warnings in Section 2 are repeated throughout the
manual, as well as specific warnings. Read all safety
statements regularly, so you do not forget them.

Renewal of oil seals, gaskets, etc., and any component
showing obvious signs of wear or damage is expected as
a matter of course. It is expected that components will be
cleaned and lubricated where appropriate, and that any
opened hose or pipe connections will be blanked to
prevent excessive loss of hydraulic fluid and ingress of dirt.

Where a torque setting is given as a sing le 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 one third.

The manufacturer's policy is one of continuous
improvement. The right to change the specification of the
machine without notice is reserved. No responsibility will

be accepted for discrepancies which may occur between
specifications of the machine and the descriptions
contained in this publication.

Finally, please remember above all else safety must come
first!

Section Numbering

T11-005

The manual is compiled in sections, the first three are
numbered and contain information as follows:

The remaining sections are alphabetically coded and deal
with Dismantling, Overhaul etc. of specific components, for
example:

Section contents, technical data, circuit descriptions,
operation descriptions etc. are inserted at the beginning of
each alphabetically coded section.

JCB 8040ZTS from serial number 1056000.
JCB 8045ZTS from serial number 1057000.
JCB 8050ZTS from serial number 1741500.
JCB 8050CTS from serial number 1741500.

1 General Information - includes torque settings and

service tools.

2 Care and Safety - includes warnings and cautions

pertinent to aspects of workshop procedures etc.

3 Maintenance - includes service schedules and

recommended lubricants for all the machine.

A Attachments
B Body and Framework, etc.

Section 1 - General Information

Introduction

About this Manual

1-2 1-2

9803/9360-4

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. It is preceeded by the 'go to' symbol. The
number of the page upon which the subject begins, is
indicated within the brackets. For example: K

Cross

References ( T 1-2).

A

B

Section 1 - General Information

Identifying Your Machine

Identification Plates

1-3 1-3

9803/9360-4

Identifying Your Machine

Identification Plates

Machine Identification Plate

Your machine has an identification plate mounted as
shown. The Product Identification Number (PIN), weight,
engine power, year of manufacture and serial number of
the machine are shown on the plate.

Note: The machine model and build specification is
indicated by the PIN. Refer to Typical Product
Identification Number (PIN).

If the engine is replaced by a new one, the serial number
on the identification plate will be wrong. Either get a
replacement identification plate from your JCB Dealer or
simply remove the old number. This will prevent the wrong
unit number being quoted when replacement 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 Identificati o n (JCB)
2 Machine Type and Model (08045 = 8045)
3 Random Check Letter
4 Year of Manufacture ( 6 = 2006, 7 = 2007, 8 = 2008,

9 = 2009)

5 Product Identification Number (1226501)

Typical Product Identification Number
(PIN)

1 World Manufacturer Identification (3 Digits).

JCB = UK Build.

2 Machine Type and Model (5 Digits).

08040 = 8040.

3 Random Check Letter (1 Digit).

The Check Letter is used to verify the authenticity of
a machine’s PIN.

4 Machine Serial Number (8 Digits).

Each machine has a unique serial number.

S

YEAR OF MANUF.

T

PIN Prod.Ident. No.

ENGINE POWER kW @ RPM

E

I

F

VIN Vehicle Ident. No.

E

R

I

R

M

R

WEIGHT Kg

G

E

D

JCB COMPACT PRODUCTS LIMITED
HAREWOOD ESTATE, LEEK ROAD,
CHEADLE, STOKE ON TRENT,
UNITED KINGDOM, ST10 2JU.

1234 5

JCB 08045 L 7 1226501

123 4

JCB 08040 L 01056000

Section 1 - General Information

Identifying Your Machine

Identification Plates

1-4 1-4

9803/9360-4

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:

1 Engine Type (2 Digits)

2 Country of Manufacture (1 Digit)

U = United Kingdom

3 Build Number (5 Digits)
4 Engine Serial Number (6 Digits)
5 Year of Manufacture (1 Digit)

T017650-2

Fig 2.

GJ U 65692 500405 P

12 3 4 5

GJ = Naturally aspirated, 13.8kW (18.5Hp)

Section 1 - General Information

Identifying Your Machine

Identification Plates

1-5 1-5

9803/9360-4

ROPS, TOPS and FOGS

!MWARNING

Modified and wrongly repaired ROPS, TOPS & FOGS
Structures are dangerous. Do not modify the TOPS
Structure. Do not attempt to repair the ROPS, TOPS &
FOGS Structure. If the ROPS, TOPS & FOGS 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 as sistance,
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
identification label fitted to the cab. K Fig 3. ( T 1-5).

A bolt on falling object guard is available which also carries
a certified label. This label certifies the cab to FOGS
standard. K

Fig 4. ( T 1-5)

When a machine is used in an application with the risk of
falling objects, the machine must be equipped with the
optional FOGS guard. This guard is compliant to
ISO10262 level 1 and is intended for protection from small
objects, e.g. small rocks, small debris and other small
objects encountered in operations such as highway
maintenance, landscaping and other construction site
services.

332/L7066

Fig 3.

Fig 4.

Section 1 - General Information

Identifying Your Machine

Identification Plates

1-6 1-6

9803/9360-4

Page left intentionally blank

Section 1 - General Information

Standard Torque Settings

Zinc Plated Fasteners and Dacromet Fasteners

1-7 1-7

9803/9360-3

Standard Torque Settings

Zinc Plated Fasteners and Dacromet Fasteners

T11-002

Introduction

Some external fasteners on JCB machines are
manufactured using an improved type of corrosion
resistant finish. This type of finish is called Dacromet and
replaces the original Zinc and Yellow Plating used on
earlier machines.

The two types of fasteners can be readily identified by
colour and part number suffix. K

Table 1. Fastener Types

( T 1-7).

T ab le1. Fastener Types

Note: As the Dacromet fasteners have a lower torque
setting than the Zinc and Yellow fasteners, the torque
figures used must be relevant to the type of fastener.

Note: A Dacromet bolt should not be used in conjunction
with a Zinc or Yellow plated nut, as this could change the
torque characteristics of the torque setting further. 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.

Note: Dacromet bolts, due to their high corrosion
resistance are used in areas where rust could occur.
Dacromet bolts are only used for external applications.
They are not used in applications such as gearbox or
engine joint seams or internal applications.

Bolts and Screws

Use the following torque setting tables only where no
torque setting is specified in the text.

Note: Dacromet fasteners are lubricated as part of the
plating process, do not lubricate.

Torque settings are given for the following conditions:

Condition 1

– Un-lubricated fasteners
– Zinc fasteners
– Yellow plated fasteners

Condition 2

– Zinc flake (Dacromet) fasteners
– Lubricated zinc and yellow plated fasteners
– Where there is a natural lubrication. For example,

cast iron components

Verbus Ripp Bolts

Fig 1.

Torque settings for these bolts are determined by the
application. Refer to the relevant procedure for the
required settings.

Fastener
Type

Colour Part No. Suffix

Zinc and
Yellow

Golden finish 'Z' (e.g. 1315/3712Z)

Dacromet Mottled silver finish 'D' (e.g. 1315/3712D)

Section 1 - General Information

Standard Torque Settings

Zinc Plated Fasteners and Dacromet Fasteners

1-8 1-8

9803/9360-3

Table 2. Torque Settings - UNF Grade 'S' Fasteners

Table 3. Torque Settings - Metric Grade 8.8 Fasteners

Bolt Size Hexagon (A/F) Condition 1 Condition 2

in. mm in. Nm kgf m lbf ft Nm kgf m lbf ft

1/4 6.3 7/16 11.2 1.1 8.3 10.0 1.0 7.4

5/16 7.9 1/2 22.3 2.3 16.4 20.0 2.0 14.7

3/8 9.5 9/16 40.0 4.1 29.5 36.0 3.7 26.5

7/16 11.1 5/8 64.0 6.5 47.2 57.0 5.8 42.0

1/2 12.7 3/4 98.00 10.0 72.3 88.0 9.0 64.9

9/16 14.3 13/16 140.0 14.3 103.2 126.0 12.8 92.9

5/8 15.9 15/16 196.0 20.0 144.6 177.0 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 1181.0 120.4 871.1 1063.0 108.4 784.0
1 1/4 38.1 2 1/4 1646.0 167.8 1214.0 1481.0 151.0 1092.3

Bolt Size Hexagon (A/F) Condition 1 Condition 2

ISO Metric

Thread mm mm Nm kgf m lbf ft Nm kgf m lbf ft

M5 5 8 5.8 0.6 4.3 5.2 0.5 3.8
M6 6 10 9.9 1.0 7.3 9.0 0.9 6.6

M8 8 13 24.0 2.4 17.7 22.0 2.2 16.2
M10 10 17 47.0 4.8 34.7 43.0 4.4 31.7
M12 12 19 83.0 8.5 61.2 74.0 7.5 54.6
M16 16 24 205.0 20.9 151.2 184.0 18.8 135.7
M20 20 30 400.0 40.8 295.0 360.0 36.7 265.5
M24 24 36 690.0 70.4 508.9 621.0 63.3 458.0
M30 30 46 1372.0 139.9 1011.9 1235.0 125.9 910.9
M36 36 55 2399.0 244.6 1769.4 2159.0 220.0 1592.4

Section 1 - General Information

Standard Torque Settings

Zinc Plated Fasteners and Dacromet Fasteners

1-9 1-9

9803/9360-3

Table 4. Metric Grade 10.9 Fasteners

Table 5. Metric Grade 12.9 Fasteners

Bolt Size Hexagon (A/F) Condition 1 Condition 2

ISO Metric

Thread mm mm Nm kgf m lbf ft Nm kgf m lbf ft

M5 5 8 8.1 0.8 6.0 7.3 0.7 5.4

M6 6 10 13.9 1.4 10.2 12.5 1.3 9.2

M8 8 13 34.0 3.5 25.0 30.0 3.0 22.1
M10 10 17 67.0 6.8 49.4 60.0 6.1 44.2
M12 12 19 116.0 11.8 85.5 104.0 10.6 76.7
M16 16 24 288.0 29.4 212.4 259.0 26.4 191.0
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 Size Hexagon (A/F) Condition 1 Condition 2

ISO Metric

Thread mm mm Nm kgf m lbf ft Nm kgf m lbf ft

M5 5 8 9.8 1.0 7.2 8.8 0.9 6.5

M6 6 10 16.6 1.7 12.2 15.0 1.5 11.1

M8 8 13 40.0 4.1 29.5 36.0 3.7 26.5
M10 10 17 80.0 8.1 59.0 72.0 7.3 53.1
M12 12 19 139.0 14.2 102.5 125.0 12.7 92.2
M16 16 24 345.0 35.2 254.4 311.0 31.7 229.4
M20 20 30 674.0 68.7 497.1 607.0 61.9 447.7
M24 24 36 1165.0 118.8 859.2 1048.0 106.9 773.0
M30 30 46 2316.0 236.2 1708.2 2084.0 212.5 1537.1
M36 36 55 4049.0 412.9 2986.4 3644.0 371.6 2687.7

Section 1 - General Information

Standard Torque Settings

Zinc Plated Fasteners and Dacromet Fasteners

1-10 1-10

9803/9360-3

Table 6. Torque Settings - Rivet Nut Bolts/Screws

Table 7. Torque Settings - Internal Hexagon Headed Cap Screws (Zinc)

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 lbf ft

ISO Metric

Thread

M3 2.0 0.2 1.5
M4 6.0 0.6 4.5
M5 11.0 1.1 8.0
M6 19.0 1.9 14.0

M8 46.0 4.7 34.0
M10 91.0 9.3 67.0
M12 159.0 16.2 117.0
M16 395.0 40.0 292.0
M18 550.0 56.0 406.0
M20 770.0 79.0 568.0
M24 1332.0 136.0 983.0

Section 1 - General Information

Standard Torque Settings

Hydraulic Connections

1-11 1-11

9803/9360-3

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.

Table 8. Torque Settings - BSP Adaptors

Table 9. Torque Settings - SAE Connections

BSP Adaptor

Size

Hexagon (A/F)

Nm kgf m lbf ftin. 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 21.0 152.0

SAE Tube

Size

SAE Port

Thread Size

Hexagon (A/F)

Nm kgf m lbf ftmm

4 7/16 - 20 15.9 20.0 - 28.0 2.0 - 2.8 16.5 - 18.5
6 9/16 - 18 19.1 46.0 - 54.0 4.7 - 5.5 34.0 - 40.0

8 3/4 - 16 22.2 95.0 - 105.0 9.7 - 10.7 69.0 - 77.0
10 7/8 - 14 27.0 130.0 - 140.0 13.2 - 14.3 96.0 - 104.0
12 1 1/16 - 12 31.8 190.0 - 210.0 19.4 - 21.4 141.0 - 155.0
16 1 5/16 - 12 38.1 290.0 - 310.0 29.6 - 31.6 216.0 - 230.0
20 1 5/8 47.6 280.0 - 380.0 28.5 - 38.7 210.0 - 280.0

Section 1 - General Information

Standard Torque Settings

Hydraulic Connections

1-12 1-12

9803/9360-3

Hoses Screwed into Adaptors

Fig 2.

Hoses 2-B screwed into adaptors 2-A seal onto an `O' ring
2-C which is compressed into a 45° seat machined into the

face of the adaptor port.

Note: Dimension 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 ftin. 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 17.7 - 19.9
3/8 22.0 33.0 - 40.0 3.4 - 4.1 24.3 - 29.5
1/2 27.0 44.0 - 50.0 4.5 - 5.1 32.4 - 36.9
5/8 30.0 58.0 - 65.0 5.9 - 6.6 42.8 - 47.9
3/4 32.0 84.0 - 92.0 8.6 - 9.4 61.9 - 67.8

1 38.0 115.0 - 126.0 11.7 - 12.8 84.8 - 92.9
1 1/4 50.0 189.0 - 200.0 19.3 - 20.4 139.4 - 147.5
1 1/2 55.0 244.0 - 260.0 24.9 - 26.5 180.0 - 191.8

Section 1 - General Information

Standard Torque Settings

Hydraulic Connections

1-13 1-13

9803/9360-3

Adaptors into Component Connections with Bonded W ashers

Table 11. BSP Adaptors with Bonded Washers - Torque Settings

BSP Size

Nm kgf m lbf ftin.

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 75.0
5/8 122.0 12.4 90.0
3/4 183.0 18.7 135.0

1 203.0 20.7 150.0
1 1/4 305.0 31.0 225.0
1 1/2 305.0 31.0 225.0

Section 1 - General Information

Standard Torque Settings

Hydraulic Connections

1-14 1-14

9803/9360-3

'Torque Stop' Hose System

Fig 3.

`Tor que Stop' Hoses 3-B screwed into adaptors 3-A seal
onto an 'O' ring 3-C which is compressed into a 45° seat
machined in the face of the adaptor port. To prevent the '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: Mini mum dimension 3-E fixed by shoulder 3-D.

T able 12. BSP `Torque Stop' Hose - Torque Settings

BSP Hose Size Hexagon (A/F)

Nm kgf m lbf ftin. mm

1/8 14.0 14.0 1.4 10.0
1/4 19.0 27.0 2.7 20.0
3/8 22.0 40.0 4.1 30.0
1/2 27.0 55.0 5.6 40.0
5/8 30.0 65.0 6.6 48.0
3/4 32.0 95.0 9.7 70.0

1 38.0 120.0 12.2 89.0
1 1/4 50.0 189.0 19.3 140.0
1 1/2 55.0 244.0 24.9 180.0