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jcb JZ140 ZT Service Manual
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jcb JZ140 ZT Service Manual

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Service Manual
JZ140 ZTS
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Maintenance
Section B - Body and Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmissions
Section J - Track and Running Gear
Section K - Engine
Publication No.
9803/6530-1
World Class
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.
Customer Support
Issued by JCB Technical Publications, JCB Service, World Parts Centre, Beamhurst, Uttoxeter, Staffordshire, ST14 5PA, England.
Tel +44 1889 590312 Fax +44 1889 593377

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Summary of Contents for jcb JZ140 ZT

  • Page 1 World Class 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.

  • Page 2: General Information

    World Class 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.

  • Page 3: About This Publication

    Section 1 - General Information Introduction About this Publication This publication is designed for the benefit of JCB All sections are listed on the front cover; tabbed divider Distributor Service Engineers who are receiving, or have cards align directly with individual sections on the front received, training by JCB Technical Training Department.
  • Page 4 The following colour coding, used on illustrations to denote various conditions of oil pressure and flow, is standardised throughout JCB Service Publications. Full Pressure: Pressure generated from operation of a service. Depending on application this may be anything between neutral circuit pressure and MRV operating pressure.

  • Page 5: Identifying Your Machine

    A. The machine serial number is inscribed at B which is the baseplate of the rear frame and the engine number is at C. 1137000 World Manufacturer Identification (SLP = JCB) Machine Type ( JZ = Tracked) Machine Model (14 = 140) Generation...
  • Page 6 Fig 3. 50316 000001 a Engine Type (AB= 4 cylinder turbo) b Engine Parts List c Country of Manufacture d Engine Serial Number e Year of Manufacture 1 - 4 1 - 4 9803-6530 Find manuals at http://best-manuals.com/search?&s=JCB-9803-6530-1...

  • Page 7: Torque Settings

    Dacromet nut should not be used in conjunction with a Zinc and 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.
  • Page 8 (A/F) mm Rivet Nut Bolts/Screws Bolt size Torque Settings (10) Dia. (mm) kgf m lbf ft (12) (16) 0.12 (20) (24) 1157 10.0 24.0 18.0 48.0 35.5 82.0 60.5 1 - 6 1 - 6 9803-6530 Find manuals at http://best-manuals.com/search?&s=JCB-9803-6530-1...
  • Page 9 (inches) 10.3 A343780 12.4 Fig 1. 18.7 20.7 Torque settings for these bolts are determined by the application. Refer to the relevant procedure for the 1 1/2 required settings. 1 - 7 1 - 7 9803-6530 Find manuals at http://best-manuals.com/search?&s=JCB-9803-6530-1...
  • Page 10 M6 x 1.0 13.5 M8 x 1.25 M10 x 1.5 62.5 M12 x 1.75 11.7 M14 x 2 17.9 M16 x 2 30.6 M18 x 2.5 M20 x 2.5 M24 x 3 M30 x 3.5 1920 1416 9803-6530 Find manuals at http://best-manuals.com/search?&s=JCB-9803-6530-1...

  • Page 11: Service Tools

    Tools other than those listed will be required. It is removal and replacement of Body and Framework parts. expected that such general tools will be available in any These tools are available from JCB Service. well equipped workshop or be available locally from any good tool supplier.
  • Page 12 Fig 2. Note: - essential for preparing new glass prior to Installation Tool Available from: installation.. Bollhoff Fastenings Ltd. Midacre The Willenhall Estate Rose Hill Willenhall West Midlands, WV13 2JW 1 - 10 1 - 10 9803-6530 Find manuals at http://best-manuals.com/search?&s=JCB-9803-6530-1...
  • Page 13 Note: - (approx 25 m length) consumable heavy duty Note: - used with braided cutting wire (below) to cut cut-out wire used with the glass extraction tool. out broken glass. 1 - 11 1 - 11 9803-6530 Find manuals at http://best-manuals.com/search?&s=JCB-9803-6530-1...
  • Page 14 12400 - 2 Cartridge x 240V, 992/12600 - 6 Cartridge x 240V) - required to pre-heat adhesive prior to use. No plug supplied. 110V models available upon request - contact JCB Technical Service. 1 - 12 1 - 12 9803-6530...
  • Page 15 The tools listed in the table are special tools required for Note: Tools other than those listed will be required. It is testing electrics. These tools are available from JCB expected that such general tools will be available in any Service .
  • Page 16 892/00298 Fluke 85 Multimeter Serial Interconnecting cable, DLA to laptop PC. Interconnecting cable, DLA to machine ECU diagnostics socket. A408030 Fig 17. 718/20237 Interconnecting cable, DLA to machine ECU diagnostics socket. 1 - 14 1 - 14 9803-6530 Find manuals at http://best-manuals.com/search?&s=JCB-9803-6530-1...
  • Page 17 USB Data Link Adaptor (DLA), enables data exchange between the machine ECU (Electronic Control Unit) and a laptop PC loaded with the applicable diagnostics software. Serial Interconnecting cable, DLA to laptop PC. 1 - 15 1 - 15 9803-6530 Find manuals at http://best-manuals.com/search?&s=JCB-9803-6530-1...
  • Page 18 Note: Tools other than those listed will be required. It is testing, removing and replacing hydraulics. These tools expected that such general tools will be available in any are available from JCB Service . well equipped workshop or be available locally from any good tool supplier.
  • Page 19 Fig 29. (X 1-21) Socket Box Wrench Nut Adapter Fig 30. (X 1-22) Fig 31. (X 1-23) Seal Ring Tool Stopper Fig 32. (X 1-24) Bearing Rig Fig 33. (X 1-25) 1 - 17 1 - 17 9803-6530 Find manuals at http://best-manuals.com/search?&s=JCB-9803-6530-1...
  • Page 20 816/00189 - 3/8 in BSP 811/50232 1,1/4” Pivot Pin 816/00190 - 1/2 in BSP 816/00197 - 5/8 in BSP 816/00196 - 3/4 in BSP 816/00193 - 1 in BSP 1 - 18 1 - 18 9803-6530 Find manuals at http://best-manuals.com/search?&s=JCB-9803-6530-1...
  • Page 21 892/00267 1,1/2 in M BSP x 1,1/2 in F BSP x Test Point 892/00279 Gauge 0 - 400 bar (0 - 6000 lb/in2) 892/00280 Gauge 0 - 600 bar (0 - 8500 lb/in2) 1 - 19 1 - 19 9803-6530 Find manuals at http://best-manuals.com/search?&s=JCB-9803-6530-1...
  • Page 22 993/99516Spanner 75 mm A/F 993/99517Spanner 85 mm A/F 993/99518Spanner 90 mm A/F 993/99519Spanner 100 mm A/F 993/99520Spanner 110 mm A/F 993/99521Spanner 115 mm A/F SSP0046Spanner 80 mm A/F SSP0047Spanner 95 mm A/F 1 - 20 1 - 20 9803-6530 Find manuals at http://best-manuals.com/search?&s=JCB-9803-6530-1...
  • Page 23 Section 1 - General Information Service Tools Tool Detail Reference Section E- Hydraulics A408900 Fig 29. Socket Box Wrench Note: For disassembly and assembly of slew motor gearbox. 1 - 21 1 - 21 9803-6530 Find manuals at http://best-manuals.com/search?&s=JCB-9803-6530-1...
  • Page 24 Section 1 - General Information Service Tools Tool Detail Reference Section E- Hydraulics A408860 Fig 30. Nut Adapter Note: For disassembly and assembly of slew motor gearbox. 1 - 22 1 - 22 9803-6530 Find manuals at http://best-manuals.com/search?&s=JCB-9803-6530-1...
  • Page 25 Section 1 - General Information Service Tools Tool Detail Reference Section E- Hydraulics A408880-C1 Fig 31. Seal Ring Tool Note: For assembly and disassembly of slew motor gearbox seal. 1 - 23 1 - 23 9803-6530 Find manuals at http://best-manuals.com/search?&s=JCB-9803-6530-1...
  • Page 26 Section 1 - General Information Service Tools Tool Detail Reference Section E- Hydraulics A408890 Fig 32. Stopper Note: For assembly of slew motor gearbox. 1 - 24 1 - 24 9803-6530 Find manuals at http://best-manuals.com/search?&s=JCB-9803-6530-1...
  • Page 27 Section 1 - General Information Service Tools Tool Detail Reference Section E- Hydraulics A408870-C1 Fig 33. Bearing Rig Note: For removal of slew motor bearing. 1 - 25 1 - 25 9803-6530 Find manuals at http://best-manuals.com/search?&s=JCB-9803-6530-1...
  • Page 28 Note: Tools other than those listed will be required. It is testing, removing and replacing hydraulics. These tools expected that such general tools will be available in any are available from JCB Service . well equipped workshop or be available locally from any good tool supplier.
  • Page 29 Fig 34. SST0037 Re-sealing Tool Note: All dimensions are in mm. A409010-C1 Fig 35. Stopper Note: for the assembly of Hydraulic motor on track gearbox. 1 - 27 1 - 27 9803-6530 Find manuals at http://best-manuals.com/search?&s=JCB-9803-6530-1...
  • Page 30 Fig 36. Puller Note: For the removal of Track motor Bushes. (All dimensions in mm). Handle Sliding Hammer Nut M12 Washer 13 x 24 Bush Bolt M10 x 35 1 - 28 1 - 28 9803-6530 Find manuals at http://best-manuals.com/search?&s=JCB-9803-6530-1...

  • Page 31: Service Consumables

    A medium strength sealant suitable for all sizes of 4102/1212 50 ml gasket flanges, and for hydraulic fittings of 25-65 mm diameter. JCB High Strength Threadlocker A high strength locking fluid for use with threaded 4102/0551 50 ml components. Gasketing for all sizes of flange where the strength of the joint is important.
  • Page 32 World Class 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.

  • Page 33: Safety Checklist

    CAUTION Denotes a reminder of safety practices. Failure to follow these safety practices could result in injury to the operator (or others) and possible damage to the machine. INT-1-2-3 2 - 1 2 - 1 9803-6530 Find manuals at http://best-manuals.com/search?&s=JCB-9803-6530-1...
  • Page 34 Safety - Yours and Others All construction and agricultural equipment can be hazardous. When a JCB machine is correctly operated and properly maintained, it is a safe machine to work with. But when it is carelessly operated or poorly maintained it can become a danger to you (the operator) and others.
  • Page 35 If you do not understand Examples of protective clothing are: a hard hat, safety anything, ask your employer or JCB dealer to explain shoes, safety glasses, a well fitting overall, ear- it. Keep this handbook clean and in good condition. Do protectors and industrial gloves.
  • Page 36 Do not Operate the control levers only when you are correctly use the machine with the cover open. seated inside the cab. INT-2-1-6_1 INT-2-1-3 2 - 4 2 - 4 9803-6530 Find manuals at http://best-manuals.com/search?&s=JCB-9803-6530-1...
  • Page 37 It should not be used in an enclosed area without adequate ventilation. Do not machine potentially explosive atmosphere, i.e. combustible vapours, gas or dust, without first consulting your JCB Distributor. INT-2-1-14 2 - 5 2 - 5 9803-6530 Find manuals at http://best-manuals.com/search?&s=JCB-9803-6530-1...
  • Page 38 If hydraulic fluid penetrates iron; welds on cast iron can weaken the structure and your skin, get medical help immediately. break. Do not weld cast iron. Contact your JCB dealer for advice before modifying the machine. INT-3-1-10_1...
  • Page 39 A machine can sink into soft ground. Never work lead last. under a machine on soft ground. INT-3-2-4 When disconnecting the battery, disconnect the earth (-) lead first. INT-3-1-9 2 - 7 2 - 7 9803-6530 Find manuals at http://best-manuals.com/search?&s=JCB-9803-6530-1...
  • Page 40 Section 2 - Care and Safety Safety Check List Maintenance Safety WARNING Certain seals and gaskets (e.g. crankshaft oil seal) on JCB machines contain fluoroelastomeric materials such Viton, Fluorel Technoflon. Fluoroelastomeric materials subjected high temperatures produce highly corrosive hydrofluoric acid. THIS ACID CAN SEVERELY BURN.
  • Page 41 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...