JCB 8035 Bucket Ram Repair and Reseal

[MikePhua]

The JCB 8035 is a popular mini excavator, commonly used in various construction and landscaping projects due to its compact size and versatile performance. One of its key components is the bucket hydraulic ram, which is responsible for controlling the movement of the bucket. Like any hydraulic component, over time, the bucket ram can experience wear and tear, leading to leaks or loss of function. Repairing and resealing the bucket ram can significantly extend the life of the machine and ensure it continues to perform optimally. This article will guide you through the process of repairing and resealing the bucket ram on a JCB 8035, including tips, considerations, and best practices.
Understanding the Bucket Ram and Its Function
The bucket ram, or hydraulic cylinder, is a critical part of the excavator's arm assembly. It uses hydraulic pressure to push or pull the bucket, allowing the operator to dig, lift, and move material. Over time, the seals in the bucket ram can wear out, causing hydraulic fluid to leak. A leaking hydraulic cylinder can result in reduced performance, loss of hydraulic pressure, and potentially even damage to the hydraulic pump or other components.
The JCB 8035 features a compact design, making it easier to maneuver in tight spaces. However, due to its size and frequent use in demanding environments, its hydraulic systems are prone to wear. Proper maintenance, including regular checks on the bucket ram and resealing, is crucial to prevent costly repairs and downtime.
Signs of a Failing Bucket Ram
Before diving into the repair process, it’s important to recognize the signs of a failing bucket ram. The most common issues include:

1. Hydraulic Fluid Leaks: If you notice hydraulic fluid leaking around the cylinder or seals, it’s a clear indication that the seals have worn out and need replacement.
   
2. Reduced Bucket Performance: If the bucket is moving slowly or not as smoothly as usual, it could be a sign of insufficient hydraulic pressure due to seal failure.
   
3. Inconsistent or Jerky Movements: If the bucket is jerking or moving erratically, it could indicate internal damage to the ram or a problem with the hydraulic fluid flow.
   

Tools and Materials Needed for the Repair
To repair and reseal the bucket ram on a JCB 8035, you will need a variety of tools and materials. These include:

• Wrenches and Socket Set: For removing bolts and fittings.
  
• Hydraulic Cylinder Seal Kit: Make sure to use a high-quality seal kit designed for the JCB 8035. The kit should include all necessary seals, o-rings, and backup rings.
  
• Seal Puller or Pliers: Used to remove old seals without damaging the cylinder.
  
• Hydraulic Oil: For refilling after the repair is complete.
  
• Clean Rags and Degreaser: To clean the parts before reassembly.
  
• Torque Wrench: To ensure that bolts are tightened to the correct specifications.
  
• Hydraulic Jack: To safely lift the excavator and support the arm assembly during the repair.
  

Step-by-Step Guide to Repairing and Resealing the Bucket Ram
1. Preparation and Safety
Before beginning any repair work, ensure that the excavator is safely parked on a flat surface and that the hydraulic system is depressurized. Always wear the appropriate safety gear, including gloves and safety glasses, to protect yourself from potential hazards such as high-pressure hydraulic fluid or sharp edges.
2. Remove the Bucket and Ram
To access the bucket ram, you will need to remove the bucket from the excavator’s arm assembly. This process typically involves:

• Detaching the bucket by removing the pin that connects it to the arm.
  
• Using a hydraulic jack or lifting equipment to raise the arm slightly, which will relieve pressure on the ram.
  
• Unscrewing any bolts or fasteners securing the ram in place, and carefully removing it from the arm.
  

Take note of how the ram is installed and the orientation of any parts as they are removed. This will make reassembly easier.
3. Disassemble the Bucket Ram
Once the ram is removed, you can begin disassembling it. Start by carefully removing any retaining rings, bolts, or fasteners that hold the ram together. Use a seal puller or pliers to remove the old seals from the piston, rod, and cylinder. Be sure to note the position and orientation of the seals so you can correctly install the new ones.
It is essential to clean all components thoroughly before proceeding with the resealing. Use a degreaser to remove any dirt, debris, and old hydraulic oil, and dry the parts with clean rags.
4. Install New Seals
Next, install the new seals from the seal kit. Start by applying a thin layer of hydraulic oil to the seals to make the installation process smoother and prevent any damage. Carefully install the new seals onto the piston, rod, and cylinder, ensuring they are seated correctly. Pay close attention to the orientation and positioning of the seals.
It’s important to use the right type of seals for the specific model of the JCB 8035. Using incorrect seals can lead to leaks or damage to the hydraulic system.
5. Reassemble the Bucket Ram
Once the new seals are in place, carefully reassemble the bucket ram, making sure all components are aligned properly. Tighten all bolts and fasteners to the manufacturer’s recommended torque specifications using a torque wrench.
6. Reinstall the Bucket Ram
With the ram reassembled, you can now reinstall it onto the arm assembly. Position the ram carefully and align the pin holes. Reattach the bucket and any fasteners, making sure everything is secure. Double-check the hydraulic connections to ensure there are no leaks.
7. Refill Hydraulic Fluid and Test
After reassembling the bucket ram and reinstalling it on the excavator, refill the hydraulic system with the appropriate hydraulic fluid. Start the engine and operate the bucket to check for smooth movement and ensure there are no leaks. Test the bucket’s range of motion and make sure it responds correctly.
8. Final Inspection
Perform a final inspection to ensure everything is properly sealed and that the hydraulic system is functioning as expected. Look for any signs of leaks, unusual noises, or erratic movements. If everything is working smoothly, the repair is complete.
Common Issues and Troubleshooting
Despite careful repair work, issues may still arise. Some common problems include:

• Leaks at the Seals: If you notice continued leaks after resealing, check for proper installation of the seals and ensure they are the correct size and type. Additionally, inspect the cylinder for any damage that could compromise the seal integrity.
  
• Slow or Jerky Movement: If the bucket is still moving slowly or erratically, the issue may lie with the hydraulic pump or the fluid. Check the pump pressure and fluid levels to ensure everything is functioning properly.
  
• Damaged Piston or Cylinder: If the piston or cylinder is damaged during the repair, it may require replacement. This can happen if the seals were improperly installed or if the cylinder was scored.
  

Conclusion
Repairing and resealing the bucket ram on the JCB 8035 is a straightforward task that can significantly extend the life of the excavator and improve its performance. By following the proper steps, using high-quality seals, and ensuring correct reassembly, operators can avoid costly downtime and maintain the machine’s productivity. Regular maintenance and prompt attention to issues like hydraulic leaks can keep the JCB 8035 running smoothly for years, making it a valuable asset on any job site.