Workshop Manual for Assembling, Disassembling and Repairing Zetor 8011, 8045, 12011, 12045 Tractors 1982

ZETOR 8011-8045 & 12011-12045 Service & Repair Manual - 1982

Maximize uptime and maintain factory-standard performance with this professional-grade technical workshop manual. This documentation is engineered to provide authorized repair shops and owner-operators with the precise data needed for high-precision tractor maintenance and heavy-duty repairs.

Model Coverage & Hardware Details

• Four-Cylinder Series: ZETOR 8011 (2WD) and ZETOR 8045 (4WD) utilizing the Z 8401 Engine.
• Six-Cylinder Series: ZETOR 12011 (2WD) and ZETOR 12045 (4WD) utilizing the Z 8701 Engine.
• Engine Hardware: Naturally aspirated diesel engines featuring a toroid combustion space and a rated speed of 2200 RPM across all models.

Professional Benefits

• Precision Tuning: Achieve factory-spec timing and fuel delivery with exact degree values for advanced fuel injection (24°+2° before T.D.C.).
• Operational Safety: Detailed procedures for safety cab removal, brake system deaeration, and steering clearance adjustments.
• Cost Efficiency: Extend component life by utilizing specific wear limits and service standards for pistons, cylinder liners, and crankshaft bearings.
• Reliable Diagnostics: Identify and resolve systemic issues quickly using specialized trouble-shooting tables for hydraulics, lubrication, and fuel systems.

What’s Included in This Service Manual Set

This digital workshop manual (Edition 1A/1982) serves as a primary technical resource. It encompasses full disassembly and reassembly instructions for major groups including the Engine (Lubricating, Cooling, Fuel Systems), Transmission (Gearbox, Torque Multiplier, Main Housing), and Auxiliary Systems (Hydraulic Power Lift, Pneumatic Brakes, and Electrical Systems).

TECHNICAL DATA & STRUCTURE (Deep Dive)

Technical Identification & Specifications

• Serial Number & ID Locations: Identification for adjustment is located via a checking pin inserted through a hole in the oil vat into specific flywheel holes to determine T.D.C. and injection timing.
• Factory Specifications (Proof of Depth):
  • Main Bearing Bolt Torque: 180–200 Nm (18–20 kpm).
  • Fuel Injection Opening Pressure: 16 ± 0.3 MPa (168 atm).
  • Hydraulic System Working Pressure: 14.7 MPa (150 kp/sq. cm).
  • Valve Clearance (Cold): Suction and Exhaust at 0.3 ± 0.05 mm.
  • Lubrication Pressure (Rated Speed): 350–550 kPa (3.5–5.5 atm).

Visual & Diagnostic Features

• Technical Schematics: Includes detailed cross-sectional views of the In-line Motorpal Injection Pump (Size M), Hydraulic Power Lift system schemes, and Power-Assisted Steering circuits.
• Exploded Views: Comprehensive exploded diagrams for the Gearbox, Torque Multiplier, Centrifugal Oil Cleaner, and Water Pump assemblies.
• Diagnostic Data: Features structured "Trouble Shooting" tables at the end of every major chapter (Engine, Clutch, Gearbox, Brakes, Electrical) to categorize "Cause" and "Remedy" for rapid field diagnostics.

Contents at a Glance

• Engine Group: Cylinder Head, Timing Gears, Crankshaft Mechanism, and Cooling System (including Heat Exchangers for 6-cylinder models).
• Transmission & Drive: Torque Multiplier (Planet Reducer), 4-Speed Gearbox with Reducer, and Front Drive Axle Clutch/Distributor.
• Hydraulics & Chassis: Multi-control Hydraulic Power Lift, Power-Assisted Steering (Worm and Nut with balls), and Pneumatic Braking Systems.
• Maintenance: Specialized sections on Battery Master Switches, Alternator/Regulator relay settings, and a comprehensive List of Assembly Tools.

Professional Value

This manual provides critical wear limits—such as the 0.30 mm maximum permissible cylinder liner wear and specific piston ring side clearances (0.11–0.142 mm for the 1st ring)—to ensure component longevity and prevent catastrophic engine failure during overhauls.