JCB 8040Z, 8045Z Mini Excavator Service Manual – 9803/9360-3

This workshop repair service manual PDF download for the 8040Z, 8045Z JCB Mini Excavator has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

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

– JCB Excavator 8040Z from S/N: 1056000
– JCB Excavator 8045Z from S/N: 1057000

TABLE OF CONTENTS :

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

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9803/9360-3
Total Pages : 414

This JCB Mini Excavator service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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9803-9360

Section 1 – General Information
Introduction
About this Manual
Machine Model and Serial Number
Using the Service Manual
Section Numbering
Units of Measurement
Left Side, Right Side
Cross References
Identifying Your Machine
Identification Plates
Data Plate
Typical Vehicle Identification Number (VIN)
Typical Engine Identification Number
ROPS, TOPS and FOGS
Standard Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
Introduction
Bolts and Screws
Hydraulic Connections
‘O’ Ring Face Seal System
‘Torque Stop’ Hose System
Service Tools
Numerical List
Tool Detail Reference
Section B – Frame and Bodywork
Section C – Electrics
Section E – Hydraulics
Section K – Engine
Service Consumables
Sealing and Retaining Compounds
Terms and Definitions
Colour Coding
Hydraulic Schematic Colour Codes

Section 2 – Care and Safety
Safety Notices
Important Information
The Operator Manual
Safety Warnings
Safety Check List
Safety – Yours and Others
General Safety
Operating Safety
Maintenance Safety
Safety Decals
Safety Decal Recognition

Section 3 – Maintenance
Routine Maintenance
Service Requirements
Introduction
Owner/Operator Support
Service/Maintenance Agreements
Obtaining Replacement Parts
Health and Safety
Lubricants
Battery
First Aid – Electrolyte
Service Schedules
Introduction
How to Use the Service Schedules
Pre Start Cold Checks, Service Points and Fluid Levels
Functional Test and Final Inspection
Fluids, Lubricants and Capacities
Coolant Mixtures
Fuels
Cleaning the Machine
Introduction
Cleaning the Tracks
Checking for Damage
Seat Belt
Checking the Seat Belt Condition and Security
Checking the Cab/Canopy Frame
Greasing
Introduction
Pivot Pins
Every 50 Hours
Every 1000 Hours
Electrical System
Battery
Fuses
Bulbs
Engine and Hydraulic Bay Covers
Opening the Engine Cover
Closing the Engine Cover
Opening the Hydraulic Bay Cover
Closing the Hydraulic Bay Cover
Engine
Checking the Oil Level
Changing the Oil and Filter
Air Filter
Checking the Coolant Level
Changing the Coolant
Adjusting the Fan Belt
Fuel System
Filling the Tank
Draining the Fuel Filter/Sedimenter (Tier 2 Machines)
Replacing the Fuel Filter Element (Tier 2 Machines)
Replacing the Fuel In-line Pre Filter (Tier 2 Machines)
Bleeding the System (Tier 2 Machines)
Draining the Fuel Filter/Sedimenter (Tier 3 Machines)
Replacing the Fuel Filter Element (Tier 3 Machines)
Replacing the Fuel Pre Filter Element (Tier 3 Machines)
Bleeding the System (Tier 3 Machines)
Hydraulic System
Checking and Adjusting the Fluid Level
Replacing the Hydraulic Filter
Checking the Ram Piston Rods
Tracks and Running Gear
Checking the Track Gearbox Oil Level
Changing the Track Gearbox Oil
Checking the Track Tension

Section A – Attachments
Attachments
Attachments for your Machine
Introduction
Installing the Quickhitch
Removing the Quickhitch
Maintenance
Installing Excavator Quickhitch Attachments
Removing Excavator Quickhitch Attachments
Quick Release Couplings
Connecting and Disconnecting
Buckets
Bucket Selection
Removing a Bucket – Non Quickhitch Models
Installing a Bucket – Non Quickhitch Models
Removing a Bucket from a Quickhitch
Installing a Bucket on a Quickhitch
Replacing Bucket Teeth
Quickhitch Rockbreaker
Removing a Quickhitch Rockbreaker
Installing a Quickhitch Rockbreaker
Operation

Section B – Body and Framework
Service Procedures
Rivet Nuts
Fitting Procedure
Glazing
Direct Glazing
Kingpost
Removal and Replacement
Removal
Replacement
Dipper
Removal and Replacement
Removal
Inspection
Replacement
Bucket Ram Pivot and Linkage
Removal and Replacement
Removal
Inspection
Replacement
Boom
Removal and Replacement
Removal
Inspection
Replacement
Slew Ring
Removal and Replacement
Removal
Checking Slew Bearing Backlash
Checking Slew Bearing Vertical Lift

Section C – Electrics
Technical Data
General Electrical Data
Service Procedures
Using a Multimeter
Measuring DC Voltage
Measuring Resistance
Measuring Continuity
Measuring Frequency
Testing a Diode or a Diode Wire
Alternator
General Description
Service Precautions
Charging Circuit Test
Alternator Charging Test
Starter Motor
Starting Circuit Test
Battery
Maintenance
First Aid – Electrolyte
Testing
Specific Gravity Testing
Wiring Harness Repair
Introduction
Repair Procedure
Alternator
Removal and Replacement
Removal
Replacement
Starter Motor
Removal and Replacement
Removal
Replacement
Schematic Circuits
Machines Built Up to September 2006
Component Key
Component Key
Tier 2 Machines Built September 2006 to January 2008
Component Key
Component Key
Tier 3 Machines Built after January 2008
Component Key
Harness Data
Wire and Harness Number Identification
Introduction
Wire Numbers and Functions
Mainframe Harness – Machines Built up to September 2006
Drawings
Mainframe Harness – Machines Built September 2006 to January 2008
Drawings
Mainframe Harness – Tier 3 Machines Built January 2008 Onwards
Drawings

Section D – Controls
Controls
Controls Identification
Fault Finding
Servo Hand Controllers
Servo Hand Controllers
Introduction
Operation
Inspection
Leakage Amount
Spool
Plunger
Loose Movement in the Operating Controls
Actuation Stability
Dismantling and Assembly
Dismantling
Assembly
Fault Finding
Track Levers
Operation
Track Controls
Dozer Lever
Operation
Dozer Controls
Engine Throttle
Cable Adjustment and Calibration
Cable Adjustment
System Calibration

Section E – Hydraulics
Technical Data
All Machines
Basic System Operation
Introduction to Hydraulic Schematic Symbols
General (Basic and Functional Symbols)
Control Valves
Example of Schematic Circuit
Service Procedures
Hydraulic Contamination
Hydraulic Fluid Quality
Effects of Contamination
Cleaning Operation
Contaminant Standards
Filters
Schematic Circuits
All Machines
Component Key
Hose Colour Data
Neutral Circuit
Main Services Circuit
Traction Circuit
Slew Circuit
Fault Finding
Hydraulic System
General Fault Diagnosis
Slew Motor and Gearbox
Main Relief Valve
Removal and Replacement
Removal
Replacement
Testing and Setting
Auxiliary Relief Valves
Removal and Inspection
Removal
Inspection
Testing and Setting
Pressure Maintenance Valve
Description
Removal and Replacement
Removal
Replacement
Testing and Setting
Setting Servo Pressure
Testing the P.M.V.
Hydraulic Pump
Description
Testing and Setting
Setting the Pressure Control Valve
Setting the Flow Control Valve
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
External Components
Internal Components
Track Motor
Description
Component Key
Hydraulic Motor Section
Two Speed Motor Operation
Hydraulic Valve Section
Parking Brake Section
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Track Motor
Track Gearbox
Brake Valve
Slew Motor/Gearbox
Description
Component Key
Component Key
Hydraulic Motor Section
Parking Brake Section
Shockless Relief Valve Section
Check Valve Section
Parking Brake Timer Valve Section
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Slew Motor
Slew Gearbox
Parking Brake Timer Valve
Cross Line Relief Valve
Control Valve
Description
Component Locations
Schematics
Regeneration
Removal and Replacement
Removal
Replacement
Dismantling, Inspection and Assembly
Dismantling
Inspection
Assembly
Control Valve Sections
Inlet/Outlet
Slew
Boom
Auxiliary
Bucket
Dipper
Dozer
Swing
Track Right
Track Left
Rotary Coupling
Removal and Replacement
Removal
Replacement
Dismantling, Inspection and Assembly
Dismantling
Inspection
Assembly
Hydraulic Rams
Precautions During Use
Installation
Caution During Use
Maintenance, Inspection Points
Removal and Replacement
Boom, Dipper and Bucket Rams
Dozer Ram
Swing Ram
Dismantling and Assembly
All Rams

Section F – Gearboxes
Technical Data
General Description

Section J – Track and Running Gear
Tracks and Running Gear
General Description
Technical Data
Major Component Torque Settings
Steel Track
Removal and Replacement
Rubber Track
Removal and Replacement
Track Guides
Introduction
Removal and Replacement
Removal
Replacement
Track Rollers
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Lower Rollers
Upper Rollers
Idler and Recoil Unit
Removal and Replacement
Removal
Replacement
Dismantling, Inspection and Assembly
Dismantling
Inspection
Assembly
Track Rollers
Track Roller Metallic Face Seals
When Removing
Inspection
When Replacing
Driven Sprocket
Removal and Replacement
Removal
Inspection
Replacement

Section K – Engine
General
Technical Data

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