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Section 2 - Care and Safety

2 - 1

9803-6530

2 - 1

Safety Check List

Safety Notices

In this publication and on the machine, there are safety
notices. Each notice starts with a signal word. The signal
word meanings are given below.

!M

DANGER

Denotes an extreme hazard exists. If proper
precautions are not taken, it is highly probable that the
operator (or others) could be killed or seriously
injured.

INT-1-2-1

!M

WARNING

Denotes a hazard exists. If proper precautions are not
taken, the operator (or others) could be killed or
seriously injured.

INT-1-2-2

!M

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

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Summary of Contents for JZ140 ZT

Page 1: ...E World Class 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 9803 6530 1 Publication No 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 Tr...

Page 2: ...ued by JCB Technical Publications JCB Service World Parts Centre Beamhurst Uttoxeter Staffordshire ST14 5PA England Tel 44 1889 590312 Fax 44 1889 593377 9803 6530 1 Publication No Section 1 General Information 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 a...

Page 3: ...ce tools 2 Care Safety includes warnings and cautions pertinent to aspects of workshop procedures etc 3 Routine Maintenance includes service schedules and recommended lubricants for all the machine The remaining sections are alphabetically coded and deal with Dismantling Overhaul etc of specific components for example The page numbering in each alphabetically coded section is not continuous This a...

Page 4: ...cation this may be anything between neutral circuit pressure and MRV operating pressure Pink Pressure Pressure that is above neutral circuit pressure but lower than that denoted by Red Orange Servo Oil pressure used in controlling a device servo Blue Neural Neutral circuit pressure Green Exhaust Light Green Cavitation Oil subjected to a partial vacuum due to a drop in pressure cavitation Yellow Lo...

Page 5: ...of the rear frame and the engine number is at C Fig 1 Fig 2 Typical Vehicle Identification Number VIN 1 World Manufacturer Identification SLP JCB 2 Machine Type JZ Tracked 3 Machine Model 14 140 4 Generation 5 Year of Manufacture 1 2001 2 2002 3 2003 4 2004 5 2005 6 2006 6 Manufacturers Location E England 7 Machine Serial Number 1137001 B A 732820 1 2 3 4 5 6 7 SLP JZ 14 C 4 E 1137000 Find manuals...

Page 6: ... number will be wrong Either stamp the new number on the plate or stamp out the old one This will prevent the wrong number being quoted when you order replacement parts Fig 3 a Engine Type AB 4 cylinder turbo b Engine Parts List c Country of Manufacture d Engine Serial Number e Year of Manufacture a b c d e AB 50316 J 000001 2 C Find manuals at http best manuals com search s JCB 9803 6530 1 ...

Page 7: ...olt should not be used in conjunction with a Zinc and Yellow plated nut as this could change the torque characteristics of the torque settings further For the same reason a 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 Note Dacromet bolts due ...

Page 8: ... 19 1 1 8 407 41 5 300 7 8 22 2 1 5 16 650 66 3 480 1 25 4 1 1 2 970 99 0 715 1 1 4 31 7 1 7 8 1940 198 0 1430 1 1 2 38 1 2 1 4 3390 345 0 2500 Bolt size Torque Settings Dia mm Nm kgf m lbf ft M3 3 1 2 0 12 0 9 M4 4 3 0 0 3 2 0 M5 5 6 0 0 6 4 5 M6 6 10 0 1 0 7 5 M8 8 24 0 2 5 18 0 M10 10 48 0 4 9 35 5 M12 12 82 0 8 4 60 5 Bolt size Torque Settings Dia mm Hexagon Nm kgf m lbf ft A F mm M5 5 8 7 0 7...

Page 9: ...ed washers Diameter Torque Settings mm Nm kgf m lbf ft M3 2 0 2 1 5 M4 6 0 6 4 5 M5 11 1 1 8 M6 19 1 9 14 M8 46 4 7 34 M10 91 9 3 67 M12 159 16 2 117 M16 395 40 292 M18 550 56 406 M20 770 79 568 M24 1332 136 983 A343780 BSP Size Nm kgf m lbf ft inches 1 8 14 1 4 10 1 4 24 2 5 18 3 8 33 3 3 24 1 2 44 4 8 35 5 8 58 6 0 43 3 4 84 8 6 62 1 115 11 8 85 1 1 2 244 24 9 180 BSP Size Nm kgf m lbf ft inches...

Page 10: ...205 M20 x 2 5 392 40 289 M24 x 3 675 69 498 M30 x 3 5 1348 138 994 Bolt Size Torque Settings Dia Nm kgf m lbf ft M6 x 1 0 13 5 1 4 10 M8 x 1 25 35 3 6 26 M10 x 1 5 62 5 6 4 46 M12 x 1 75 115 11 7 85 M14 x 2 175 17 9 129 M16 x 2 300 30 6 221 M18 x 2 5 395 40 291 M20 x 2 5 559 57 412 M24 x 3 962 98 710 M30 x 3 5 1920 196 1416 Bolt Size Torque Settings Dia Nm kgf m lbf ft M6 x 1 0 15 1 5 11 M8 x 1 25...

Page 11: ...X 1 10 826 01102 M8 x 21mm Rivet Nut Fig 2 X 1 10 826 01103 M8 x 18mm Rivet Nut Fig 2 X 1 10 826 01104 M10 x 23mm Rivet Nut Fig 2 X 1 10 826 01105 M10 x 26mm Rivet Nut Fig 2 X 1 10 892 00842 Glass Lifter Fig 3 X 1 10 892 00843 Folding Stand for Holding Glass Fig 4 X 1 10 892 00844 Long Knife Fig 5 X 1 11 892 00845 Cartride Gun Fig 6 X 1 11 892 00846 Glass Extractor Handles Fig 7 X 1 11 892 00847 N...

Page 12: ...for the removal of polyurethane adhesives Fig 2 Installation Tool Available from Bollhoff Fastenings Ltd Midacre The Willenhall Estate Rose Hill Willenhall West Midlands WV13 2JW Fig 3 892 00842 Note minimum 2 off essential for glass installation 2 required to handle large panes of glass Ensure suction cups are protected from damage during storage Fig 4 892 00483 Note essential for preparing new g...

Page 13: ...Fig 7 892 00846 Note used with braided cutting wire below to cut out broken glass Fig 8 892 0847 Note general tool used for smoothing sealants also used to re install glass in rubber glazing because metal tools will chip the glass edge Fig 9 892 00848 Note used to access braided cutting wire through original polyurethane seal Fig 10 892 00849 Note approx 25 m length consumable heavy duty cut out w...

Page 14: ...s fitted with a male plug 703 23201 which fits into a female socket 715 04300 Fig 13 Note available with 2 or 6 cartridge capacity 992 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 Fig 14 992 12800 Note used to remove broken glass Fig 15 992 12801 Note unit quantity ...

Page 15: ...able locally from any good tool supplier Part Number Description Tool Detail Reference 892 00283 Tool Kit Case Fig 16 X 1 14 892 00281 AVO Meter Fig 16 X 1 14 892 00286 Surface Temperature Fig 16 X 1 14 892 00284 Microtach Digital Tachometer Fig 16 X 1 14 892 00282 Shunt open type Fig 16 X 1 14 892 00285 Hydraulic Oil Temperature Probe Fig 16 X 1 14 892 00298 Fluke 85 Multimeter Fig 16 X 1 14 718 ...

Page 16: ...00285 Hydraulic Oil Temperature Probe 7 892 00298 Fluke 85 Multimeter Fig 17 718 20237 Interconnecting cable DLA to machine ECU diagnostics socket D F A B C H J E G A408030 Fig 18 892 01033 Data Link Adaptor DLA enables data exchange between the machine ECU Electronic Control Unit and a laptop PC loaded with the applicable diagnostics software 3 Kit carrying case 4 Serial Interconnecting cable DLA...

Page 17: ...le DLA to machine ECU diagnostics socket 3 Kit carrying case 4 USB Interconnecting cable DLA to laptop PC 5 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 6 Serial Interconnecting cable DLA to laptop PC D F A B C H J E G 3 5 6 4 1 2 Find manuals at http best manuals com search s JCB 980...

Page 18: ...B Fig 21 X 1 18 816 55038 Pressure Test T Adapter 3 8 in BSP x 3 8 in F BSP x Test Point Fig 24 X 1 19 816 55040 Pressure Test T Adapter 1 2 in BSP x 1 2 in F BSP x Test Point Fig 24 X 1 19 816 60096 3 4 in BSP A x 3 4 in BSP B Fig 21 X 1 18 892 00055 Female Cone Blanking Plug 1 4 in BSP Fig 25 X 1 19 892 00056 Female Cone Blanking Plug 3 8 in BSP Fig 25 X 1 19 892 00057 Female Cone Blanking Plug ...

Page 19: ...Spanner 60 mm A F Fig 28 X 1 20 993 99514 Spanner 65 mm A F Fig 28 X 1 20 993 99515 Spanner 70 mm A F Fig 28 X 1 20 993 99516 Spanner 75 mm A F Fig 28 X 1 20 993 99517 Spanner 85 mm A F Fig 28 X 1 20 993 99518 Spanner 90 mm A F Fig 28 X 1 20 993 99519 Spanner 100 mm A F Fig 28 X 1 20 993 99520 Spanner 110 mm A F Fig 28 X 1 20 993 99521 Spanner 115 mm A F Fig 28 X 1 20 993 99522 Anchor Side Plate s...

Page 20: ...pplied loose unwelded 993 99523 Anchor Cross Member supplied loose unwelded 993 99524 Ram Eye End Modification Plate Assembly 556 43400 Lift Ram 545 18000 Lynch Pin 811 50232 1 1 4 Pivot Pin Fig 21 T Adapter 816 50005 T adapter 1 2 in BSP A x 1 2 in BSP B 816 60096 T adapter 3 4 in BSP A x 3 4 in BSP B 816 00018 T adapter 1 in BSP A x 1 in BSP B Fig 22 Male Cone Blanking Plug 816 00294 1 4 in BSP ...

Page 21: ...4 3 4 in BSP x 3 4 in F BSP x Test Point 892 00265 1 in M BSP x 1 in F BSP x Test Point 892 00266 1 1 4 in M BSP x 1 1 4 in F BSP x Test Point 892 00267 1 1 2 in M BSP x 1 1 2 in F BSP x Test Point Fig 25 Female Cone Blanking Plug 892 00055 1 4 in BSP 892 00056 3 8 in BSP 892 00057 1 2 in BSP 892 00058 5 8 in BSP 892 00059 3 4 in BSP 892 00060 1 in BSP Fig 26 892 00223 Note Components listed below...

Page 22: ...00347 Connector 4 892 00254 Hose Fig 28 Ram Piston Nut Removal Fitting Spanner 993 99512Spanner 55 mm A F 993 99513Spanner 60 mm A F 993 99514Spanner 65 mm A F 993 99515Spanner 70 mm A F 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 ...

Page 23: ...n Service Tools Tool Detail Reference Section E Hydraulics 1 21 9803 6530 1 21 Fig 29 Socket Box Wrench Note For disassembly and assembly of slew motor gearbox A408900 Find manuals at http best manuals com search s JCB 9803 6530 1 ...

Page 24: ...tion Service Tools Tool Detail Reference Section E Hydraulics 1 22 9803 6530 1 22 Fig 30 Nut Adapter Note For disassembly and assembly of slew motor gearbox A408860 Find manuals at http best manuals com search s JCB 9803 6530 1 ...

Page 25: ...ervice Tools Tool Detail Reference Section E Hydraulics 1 23 9803 6530 1 23 Fig 31 Seal Ring Tool Note For assembly and disassembly of slew motor gearbox seal A408880 C1 Find manuals at http best manuals com search s JCB 9803 6530 1 ...

Page 26: ...al Information Service Tools Tool Detail Reference Section E Hydraulics 1 24 9803 6530 1 24 Fig 32 Stopper Note For assembly of slew motor gearbox A408890 Find manuals at http best manuals com search s JCB 9803 6530 1 ...

Page 27: ...Information Service Tools Tool Detail Reference Section E Hydraulics 1 25 9803 6530 1 25 Fig 33 Bearing Rig Note For removal of slew motor bearing A408870 C1 Find manuals at http best manuals com search s JCB 9803 6530 1 ...

Page 28: ...hydraulics These tools are available from JCB Service Note Tools other than those listed will be required It is expected that such general tools will be available in any well equipped workshop or be available locally from any good tool supplier Part Number Description Tool Detail Reference SST0037 Re sealing Tool Fig 34 X 1 27 Stopper Fig 35 X 1 27 Puller Fig 36 X 1 28 Find manuals at http best ma...

Page 29: ...erence Section F Transmission Note Not all service tools are illustrated Illustrations are shown in tool number order Fig 34 SST0037 Re sealing Tool Note All dimensions are in mm Fig 35 Stopper Note for the assembly of Hydraulic motor on track gearbox A409010 C1 Find manuals at http best manuals com search s JCB 9803 6530 1 ...

Page 30: ... Section F Transmission 1 28 9803 6530 1 28 Fig 36 Puller Note For the removal of Track motor Bushes All dimensions in mm 1 Handle 2 Sliding Hammer 3 Bar 4 Nut M12 5 Washer 13 x 24 6 Bush 7 Bolt M10 x 35 Find manuals at http best manuals com search s JCB 9803 6530 1 ...

Page 31: ...m diameter and for hydraulic fittings up to 25 mm diameter 4101 0550 10 ml 4101 0552 200 ml JCB Threadseal A medium strength thread sealing compound 4102 1951 50 ml JCB Activator A cleaning primer which speeds the curing rate of anaerobic products 4104 0251 200 ml Aerosol 4104 0253 1 ltr Bottle JCB Cleaner Degreaser For degreasing components prior to use of anaerobic adhesives and sealants 4104 15...

Page 32: ...ssued by JCB Technical Publications JCB Service World Parts Centre Beamhurst Uttoxeter Staffordshire ST14 5PA England Tel 44 1889 590312 Fax 44 1889 593377 9803 6530 1 Publication No Section 2 Care and Safety 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...

Page 33: ...ot taken it is highly probable that the operator or others could be killed or seriously injured INT 1 2 1 MWARNING Denotes a hazard exists If proper precautions are not taken the operator or others could be killed or seriously injured INT 1 2 2 MCAUTION Denotes a reminder of safety practices Failure to follow these safety practices could result in injury to the operator or others and possible dama...

Page 34: ... unsure of anything about the machine or the job ask someone who knows Do not assume anything Remember BE CAREFUL BE ALERT BE SAFE GEN 1 6 As well as the warnings in the following pages specific warnings are given throughout the book This section is designed to give a safety code for use of the machine generally and for operation and maintenance practices Note This section includes a certain amoun...

Page 35: ... Drugs It is extremely dangerous to operate machinery when under the influence of alcohol or drugs Do not consume alcoholic drinks or take drugs before or whilst operating the machine or attachments Be aware of medicines which can cause drowsiness INT 1 3 9 MWARNING Clothing You can be injured if you do not wear the proper clothing Loose clothing can get caught in the machinery Wear protective clo...

Page 36: ...MWARNING Controls You or others can be killed or seriously injured if you operate the control levers from outside the cab Operate the control levers only when you are correctly seated inside the cab INT 2 1 3 MWARNING Visibility Accidents can be caused by working in poor visibility Use your lights to improve visibility Keep the road lights windows and mirrors clean Do not operate the machine if yo...

Page 37: ...rds when fitted Please inspect these areas frequently and clean at the beginning of each work shift or more often if required Before opening the engine cover ensure that the top is clear of debris 5 3 1 12_2 MWARNING Electrical Power Cables You could be electrocuted or badly burned if you get the machine or its attachments too close to electrical power cables You are strongly advised to make sure ...

Page 38: ...working on the engine Do not refuel with the engine running There could be a fire and injury if you do not follow these precautions INT 3 2 2 MWARNING Oil Oil is toxic If you swallow any oil do not induce vomiting seek medical advice Used engine oil contains harmful contaminants which can cause skin cancer Do not handle used engine oil more than necessary Always use barrier cream or wear gloves to...

Page 39: ...iency of the rams will be affected if they are not kept free of solidified dirt Clean dirt from around the rams regularly When leaving or parking the machine close all rams if possible to reduce the risk of weather corrosion INT 3 2 10 MCAUTION O rings Seals and Gaskets Badly fitted damaged or rotted O rings seals and gaskets can cause leakages and possible accidents Renew whenever disturbed unles...

Page 40: ...OR SURROUNDING AREA Used fluoroelastomeric components subjected to temperatures greater than 300 C e g engine fire must be treated using the following safety procedure Make sure that heavy duty gloves and special safety glasses are worn 1 Thoroughly wash contaminated area with 10 calcium hydroxide or other suitable alkali solution if necessary use wire wool to remove burnt remains 2 Thoroughly was...

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