JCB JZ140 ZTS Tracked Excavator Service Manual – 9803/6530-1

(S/N: 1137000 Onwards)
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This workshop repair service manual PDF download for the JZ140 ZTS JCB Tracked 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 :

JCB Tracked Excavator JZ140 Tier II – from S/N: 1137000 Onwards

TABLE OF CONTENTS :

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

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9803/6530-1
Total Pages : 677

This JCB Hydraulic 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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9803-6530-1

Section 1 General Information
Introduction
Schematic Codes
Identifying your Machine
Identification Plates
Data Plate
Typical Vehicle Identification Number (VIN)
Typical Engine Identification Number
Torque Settings
Zinc Plated Fasteners (golden finish)
Dacromet Fasteners (mottled silver finish)
Service Tools
Numerical List Section B – Body and Framework
Tool Detail Reference Section B – Body and Framework
Numerical List Section C – Electrics
Tool Detail Reference Section C – Electrics
Numerical List Section E- Hydraulics
Tool Detail Reference Section E- Hydraulics
Numerical List Section F – Transmission
Tool Detail Reference Section F – Transmission
Service Consumables
Sealing and Retaining Compounds

Section 2 Care and Safety
Safety Check List
Safety Notices
Safety – Yours and Others
General Safety
Operating Safety
Maintenance Safety
Safety Decals
Safety Decal Recognition
Chart Definitions

Section 3 Maintenance
Routine Maintenance
Health and Safety
Lubricants
Battery
First Aid – Electrolyte
Service Schedules
Introduction
Pre Start Cold Checks, Service Points and Fluid Levels
Functional Test and Final Inspection
Service Intervals for Attachments
Periodic Replacement of Safety Related Components
Lubricants and Capacities
JZ140 and Variants
Engine Lubrication Chart
Cleaning the Machine
Exterior
Interior
Checking for Damage
Daily Checking
Bolt and Nut Torque Specifications
JZ140 and Variants
Checking the FOPS Structure
Torque Setting
Seat Belt
Checking the Seat Belt Condition and Security
Greasing
General Notes
Slew Ring Bearing
Slew Ring Teeth and Slew Pinion
Greasing Points
Electrical System
Battery
Jump-Starting the Engine
Fuses
Engine
Checking the Oil Level
Changing the Oil and Filter
Changing the Outer Air Filter Element
Changing the Inner Air Filter Element
Checking the Fan Belt Tension
Fitting a New Fan Belt
Checking the Coolant Level
Cleaning the Radiator and Oil Cooler
Changing The Coolant
Coolant Mixtures
Fuel System
Types of Fuel
Filling the Tank and Fuel Level Checking
Petrol
Changing the Fuel Filter Element
Cleaning the Lift Pump Strainer
Draining Fuel Tank Impurities
Draining the Water Separator
Cleaning the Water Separator
Bleeding the Fuel System
Hydraulic System
Checking the Fluid Level
Releasing Tank Pressure
Topping-up Fluid Level
Changing the Fluid
Draining Water and Sediment from the Hydraulic Tank
Cleaning/Changing the Suction Strainer
Changing the Return Filter
Changing the Plexus Filter
Changing the Air Breather Element
Changing the Pilot Oil Filter
Changing the Breaker In-line Filter
Changing the Drain Line Filter
Checking the Slew Gearbox Oil Level
Changing the Slew Gearbox Oil Level
Air Bleeding Procedures
Travel Gearbox
Checking the Track Gearbox Oil Level
Changing the Track Gearbox Oil
Tracks and Running Gear
Checking/Adjusting the Track Tension
Checking Rollers and Idler Wheels for Oil Leaks
Track Plate Inspection
Cleaning the Tracks
Bucket
Checking/Adjusting for side play
Windscreen
Washers
Troubleshooting
Engine and Related Area
Monitor Display – Fault Messages
Operations
Hydraulic pump
Working Attachments
Travel
Slew
Hydraulic ram

Section B Body and framework
Technical Data
Static Dimensions
Monoboom
Triple Articulated Boom
Dig Depth Chart
Monoboom
Shipping Weight
Attachments
Location
Boom and Slew Frame Installation
Boom Ram and Slew Frame Installation
Boom Ram Installation
Dipper Ram Installation
Dipper Pivot Installation
Dipper and Dipper Ram Installation
Bucket Ram Installation
Dipper and Dipper Link Installation
Bucket and Bucket Link Installation
Bucket Link and Bucket Ram Installation
Bucket and Dipper Installation
Air Conditioning (option)
Basic Operation
Air Conditioning
Operation
Heater/Air Conditioning Controls
Air Conditioning System Operation
Control
Pressures Switch Settings
Safety Procedures
Fault Finding
Air Conditioning
Preliminary Checks
Electrical Component Location
Electrical Fault Finding
Service Procedures
HVAC/Air Conditioning Unit
Removal and Repacement
Air Conditioning Compressor
Removal and Repacement
Condenser Assembly
Removal and Replacement
Cab Structure
Direct Glazing
Checks
Checking the FOPS Structure
Cab Panels
Cab Panel Removal
Right Hand Cab Panels
Left hand Cab Panels

Section C Electrics
Technical data
Fuses
Basic System Operation
Controls and Components
Driver Controls and Switches
Right Console
Left Console
Monitor Panel
Fascia Panel
Emergency back-up switch
Heater/Air Conditioning Controls
Cab Interior Lights
Radio
Operating Levers/Pedals
Travel Levers
Travel Speed Change Button
Operation Levers
Optional Circuit Pedal (if fitted)
ISO Operating Method
Circuit Symbols
Component Identification
Schematic Diagram
A.M.S (Advanced Management System)
Operation
The AMS System
Circuit Concepts
Pulse Width Modulation (PWM)
ECU1/EMS/FACIA Power Supply and Network
ECU 1 Supply to Output Drivers
Engine Throttle Control
Throttle control system
Throttle control circuit
Engine Throttle Control for each mode
Auto Boost Pressure
Engine Reverse Rotation Prevention
Engine Pre Heat (Glow plugs)
Engine Automatic Warm Up
Engine Automatic Idle
Engine One Touch Idle
Engine Auto Idle and One Touch Idle
Engine Start/Stop
Limp Mode system
Pump Control for Each Mode
“A” Auto Mode
“E” Economy mode
“L” Lifting mode & “P” Precision mode
Lever Lock
Servo Isolator
Lever Lock and Servo Isolator
Wiper
Lower Wiper (option)
Washer
Horn
Travel Alarm
Soft/Hard (Cushion)
Slew Brake (100%)
Slew lock (100% Slew Brake)
Slew Brake Solenoid Valve Failure.
3-Speed Travel
Operation
“E” Economy, “P” Precision & “A” Auto Modes
“L” Lifting Mode
Work Lamps
Fuel Level Sensor/Warning
Engine Temperature Sensor/Warning
Coolant Level Warning
Air Filter Blocked Warning
Warning Indicator Lamps
Hydraulic Temperature Sensor/Warning
Alternator/ No Charge Warning
Operation
Alternator Charging and Battery Relay
Quick hitch (option)
Overload Caution (option)
Beacon
Grab/rotate
Hammer
Scrap Magnet Option
Cab interior light
Refuelling Pump
Hydraulic Fan
Air Conditioning
Heated Seat
24 to 12 Volt Converter, Radio and Cigar Lighter
24 to 12 Volt Converter.
Radio
Cigar lighter
Service Required Warning
Cancellation of the Service indicator
EMS Set Menu.
EMS Set + Mode (5 Sec) Menu
EMS Set+Mode (20 sec) Menu.
Fault Finding
JCB Service Master
Using Service Master
Selecting Service Tool Applications
System Menus
HPSetup Overview
Using HPSetup
1 Connecting the Data Link Adaptor (DLA)
2 Starting HPSetup
3 Setting Up A Vehicle Profile
4 Writing Vehicle Profile <F12>
5 Reading Vehicle Profile <F11>
6 Closing HPSetup
7 Options – Multi Language Support
Guidelines for setting up a vehicle using the set up tool
Alternative Language Cross Reference
Data Link Adaptor
DLA Trouble Shooting
HPDataLogs
FLASH Programming Application
“FLASHECU” Training Guide
Using FLASHECU
Introduction to the Diagnostics Tool
Connecting to the vehicle
Starting Diagnostic Mode
Circuit Diagrams
Indicator Lights (LEDs)
Stopping Diagnostic Mode
Language Setting
List of text messages displayed on the EMS.
Table 1: Error messages
Table 2: Status messages
Table 3: AMS System fault error code
Throttle Errors
Fault Finding Without using the JCB Service Master Diagnostic Tool
Introduction
Changing Machine Components
Fault Diagnosis (General)
Permanent Battery Supply. ( Ignition Off )
Ignition On
Ground Tests.
Can – Bus Network Tests.
Harness Tests.
Unit Tests.
Fault Diagnosis ECU-1
EMS Failure.
Fault Diagnosis – Facia Switch panel (F S P)
Service Procedure
Testing of ECU Inputs + Outputs
Testing low side input
Testing High side input
Testing low side output
Testing high side output
Wiring Harness Repair
Introduction
Repair Procedure
Battery
Maintenance
First Aid – Electrolyte
Testing
Specific Gravity Testing
Harness Data
Main Harness Connector Location
Key to Connectors
Key To Wire Colours
Main Harness A
Main Harness B
Main Harmess C
Main Harness D
Facia Link Harness Connector Location
Facia Link Harness A
Facia Link Harness B
Cab Harness Connector Location
Cab Harness A
Cab Harness B
Cab Harness C
Cab Harness D
Cab Harness E
Cab Harness F

Section E Hydraulics
Technical Data
General Data
Main Hydraulic Pump
Servo Pump
Proportional Pressure Reducing Valve
Slew Motor
Main Contol Valve
Spool Stroke versus Pilot Pressure
Boom Ram
Dipper Ram
Bucket Ram
Ram Torque Settings
Travel Equipment
Hydraulic Cooling Fan Motor
Basic System Operation
Hydraulic Component Location
Introduction to Hydraulic Schematic Symbols
General (Basic & Functional Symbols)
Control Valves
Example of Schematic Circuit
Circuit Descriptions
Component Identification
Main Hydraulic Schematic
Servo Line
Components
Servo Pressure and Return Line
Components
Main Control Valve
Hydraulic Pump Operation
Main Pumps (P1 and P2)
Hydraulic Pump Regulation
Neutral Circuit
Straight Line Travel
Travel – Middle Speed
Travel motor operation (Middle speed)
Slow speed travel (Creep)
Travel motor operation (High speed)
Boom Up
Boom Down
Dipper Out
Dipper In
Bucket Opening
Bucket Close
Slew Circuit
Slew over Dipper Priority (A)
100% Slew Lock
Auxiliary Flow
Hammer
ISO/SAE Controls
Service Procedure
Pressure Testing – General
Confirmation of the Oil Temperature
Warming-up Procedure
Pressure Testing Points
Pressure Relief Valve Location
Main Relief Valve (MRV) Pressure
Servo Relief Pressure
Slew Motor Pressure Relief
Auxiliary Relief Valves
General
Boom Ram
Travel Motor Relief Pressure
Hydraulic Pump/Regulator
Hydraulic Pump Removal and Replacement
Removal
Replacement
Pump Hydraulic Circuit Diagram
Hydraulic Pump/Regulator
Hydraulic Pump
Hydraulic Pump Dismantling and Assembly
Dismantling
Assembly
Regulator
Regulator Dismantiling and Assembly
Remote Control Valve (Hand Control)
Operation
Function
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Dismantling
Inspection
Assembly
Travel Pedal Valve
Dismantling and Assembly
Dismantling
Inspection
Assembly
Solenoid Valve (8 Spool)
Operation
Slew Brake. (CT1)
Isolator. (CT2)
Slew Lock. (CT3)
Maximum flow cut. (CT4)
2 Stage travel. (CT5).
Slew shut off (CT6)
2 Stage relief. (CT7)
Cushion control. (CT8)
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Dismantling
Inspection
Assembly
Shuttle Valve
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Dismantling
Inspection
Assembly
Cushion Valve
Operation
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Dismantling
Inspection
Assembly
Slew Motor
Removal and Replacement
Removal
Replacement
Torque Settings
Slew Motor Configuration
Slew Motor Reduction Gear
Reduction Gear Structure and Working Principles
Dismantling and Assembly
Dismantling
Inspection
Assembly
Slew Motor Reduction Gear Assembly
Dismantling and Assembly
Dismantling
Inspection
Assembly
Rotary Coupling
Operation
Removal and Replacement
Removal
Replacement
Dismantling
Assembly
Hydraulic Rams
Precautions During Use
Bucket Ram
Removal
Replacement
Dipper Ram
Removal
Replacement
Boom Ram
Removal
Replacement
Triple articulated Boom (TAB) Ram
General
Removal
Replacement
Dismantling and Assembly
Dozer Rams
Dismantling and Assembly
Ram Piston Head Nut
Removal and Fitting
Reconditioning
Procedures for inserting and bedding the seal ring.
Bushing Removal
Bushing Assembly
Wiper Ring Assembly
Cylinder Head Assembly
Fault Finding
Hydraulic Contamination
Hydraulic Fluid Quality
Effects of Contamination
Cleaning Operation
Contaminant Standards
Filters
Main Control Valve
Relief Valve
Hydraulic System
Slew Motor
Hydraulic Pump
Hydraulic Rams
Fault Finding Tests
Slow or Underpowered:
Harsh Operation When Selecting:
Tracking Off Line
Poor Tractive Effort
Loss of Creep Speed
Loss of High Speed
Machine Selects High Speed Travel
Slew Bearing Faults
Test 001: Testing Negative Control Signal
Test 002: Test Max Flow Signal
Test 003: Testing Main Pump Pressure
Test 004: Testing Horsepower Control
Test 005: Checking the Operation of the Main Hydraulic Spool
Test 006: Testing Pressure Switches
Symptoms of Pressure Switch Failures
Test 007: Testing Engine Speed Settings
Test 008: Testing Machine Cycle Times
a Bucket Ram speed.
b Dipper Ram speed
c Boom Ram speed
d Slew Speed
e Travel Speed
f Travel Linearity.
Test 010: Testing Hose Burst Check Valve – Dipper Ram
Test 011: Testing Swing brake pressure
Test 012: Testing Track Motor Relief Valve Settings
Testing Track Motor ARV Settings
Test 013: Testing Track Motor Drain Line Flow Rate
Test 014: Loss of High Speed Tracking
Additional information
Test 015: High Gear Selection, Monitor Displays Another Travel Gear
Test 016: Flow testing Hydraulic Pumps
To Confirm Minimum Flow Setting
To Confirm Maximum Flow Setting
To Confirm Horse Power Control
Test 016 – Flow Testing Hydraulic Pumps – Record Sheet
Test 017: Testing Slew Bearing
Checking Slew Bearing Backlash
Checking Slew Bearing Vertical Lift
Ram Creep Tests – All Services
Test for Ram Creep

Section F Transmission
Technical Data
Travel Equipment
Fault Finding
Introduction
Fault Finding
Track Motor
Removal and Replacement
Removal
Precautions during Installation
Replacement
Start Up and Running In
Track Gearbox
Dismantling and Assembly
Dismantling
Inspection
Assembly
Track Motor
Dismantling and Assembly
Dismantling
Inspection
Assembly
Torque Setting

Section J Track and Running Gear
Technical Data
Torque Specifications
Idler Wheel and Recoil Unit
Removal
Replacement
Idler Wheel
Dismantling
Assembly
Wear Limits
Recoil Unit
Dismantling
Assembly
Grease Cylinder
Dismantling
Assembly
Drive Sprocket
Removal
Replacement
Wear Limits
Top Roller
Removal
Replacement
Dismantling
Assembly
Bottom Roller
Removal
Replacement
Dismantling
Assembly
Wear Limits

Section K Engine
Technical Data
JZ140

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