JCB JZ140 TIER2 TRACKED EXCAVATOR Service Repair Manual Instant Download

1
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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

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, World Class
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 [phone] Fax [phone]
2
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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 and Running Gear
Section K - Engine
Publication No.
9803/6530-1

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, World Class
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 [phone] Fax [phone]
3
Section 1 - General Information Introduction Abo
ut this Publication
This publication is designed for the benefit of
JCB Distributor Service Engineers who are
receiving, or have received, training by JCB
Technical Training Department.
All sections are listed on the front cover
tabbed divider cards align directly with
individual sections on the front cover for rapid
reference.
These personnel should have a sound knowledge of
workshop practice, safety procedures, and
general techniques associated with the
maintenance and repair of hydraulic earthmoving
equipment.
Where a torque setting is given as a single
figure it may be varied by plus or minus 3.
Torque figures indicated are for dry threads,
hence for lubricated threads may be reduced by
one third.
Renewal of oil seals, gaskets, etc., and any
component showing obvious signs of wear or damage
is expected as a matter of course. It is expected
that components will be cleaned and lubricated
where appropriate, and that any opened hose or
pipe connections will be blanked to prevent
excessive loss of hydraulic fluid and ingress of
dirt. Finally, please remember above all else
SAFETY MUST COME FIRST!
'Left Hand' and 'Right Hand' are as viewed from
the rear of the machine facing forwards.
This Service Manual covers the following
machines JZ140

• The manual is compiled in sections, the first
  three are numbered and contain information as
  follows
• General Information - includes torque settings
  and service tools.
• Care Safety - includes warnings and cautions
  pertinent to aspects of workshop procedures etc.
• 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
• Attachments
• Body Framework...etc.
• The page numbering in each alphabetically coded
  section is not continuous. This allows for the
  insertion of new items in later issues of the
  manual.
• Section contents, technical data, circuit
  descriptions, operation descriptions etc. are
  inserted at the beginning of each alphabetically
  coded section.

1 - 1
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Section 1 - General Information Introduction Schem
atic Codes Schematic Codes Colour Codes 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.
Red
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
Lock Up Oil trapped within a chamber or line,
preventing movement of components (lock up).
6
Section 1 - General Information Identifying
your Machine Identification Plates
Data Plate Your machine has a Data Plate, located
on the outside the cab as shown at A. The machine
serial number is inscribed at B which is the
baseplate of the rear frame and the engine number
is at C.
Typical Vehicle Identification Number (VIN)
1 2 3 4 5 6 7
SLP JZ 14 C 4 E 1137000

1. World Manufacturer Identification (SLP JCB)
2. Machine Type ( JZ Tracked)
3. Machine Model (14 140)

4 Generation
B
A
5 Year of Manufacture (1 2001, 2 2002, 3
2003, 4 2004, 5 2005, 6 2006)

1. Manufacturers Location (E England)
2. Machine Serial Number (1137001)

Fig 1.
732820
Fig 2.
7
Section 1 - General Information Identifying your
Machine Identification Plates Typical Engine
Identification Number If the engine is replaced
by a new one, the data plate serial 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.
C
a b c Fig 3. d e
AB 50316 J 000001 2

1. Engine Type (AB 4 cylinder turbo)
2. Engine Parts List
3. Country of Manufacture
4. Engine Serial Number
5. Year of Manufacture

8
Section 1 - General Information Torque
Settings Introduction - Zinc Plated Fasteners and
Dacromet Fasteners
Some external fasteners on machines are assembled
using an improved type of corrosion resistant
finish. This type of finish is called Dacromet
and replaces the original Zinc and Yellow plating
used on earlier machines.
The two types of fasteners can be readily
identified by colour and part number suffix as
follows
Fastener Type Colour Part Number
Zinc and Yellow Golden finish Z (e.g. 1315/3712Z)
Dacromet Mottled silver finish D (e.g. 1315/3712D)
Note As the Dacromet fasteners have a lower
torque setting than the Zinc and Yellow
fasteners, the torque figures used must be
relevant to the type of fasteners. Note A
Dacromet bolt 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 to
their high corrosion resistance are used areas
where rust could occur. Dacromet bolts are only
used for external applications. They are not used
in application such as gearbox and engine joint
seams or internal applications.
9
Section 1 - General Information Torque
Settings Zinc Plated Fasteners (golden
finish) Zinc Plated Fasteners (golden finish)
Metric Grade 8.8 Bolts
Use only where no torque setting is specified in
the text. Values are for dry threads and may be
within three per cent of the figures stated. For
lubricated threads the values should be REDUCED
by one third.
Bolt size
Torque Settings
Dia. (mm) Hexagon (A/F) mm Nm kgf m lbf ft
M5 (5) 8 7 0.7 5
M6 (6) 10 12 1.2 9
M8 (8) 13 28 3.0 21
M10 (10) 17 56 5.7 42
M12 (12) 19 98 10 72
M16 (16) 24 244 25 180
M18 (18) 27 350 36 258
M20 (20) 30 476 48 352
M24 (24) 36 822 84 607
M30 (30) 46 1633 166 1205
M36 (36) 55 2854 291 2105
UNF Grade S Bolts
Bolt size
Torque Settings
Dia. (mm) Hexagon (A/F) mm Nm kgf m lbf ft
1/4 6.3 7/16 14 1.4 10
5/16 7.9 1/2 28 2.8 20
3/8 9.5 9/16 49 5.0 36
7/16 11.1 5/8 78 8.0 58
1/2 12.7 3/4 117 12.0 87
9/16 14.3 13/16 170 17.3 125
5/8 15.9 15/16 238 24.3 175
3/4 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
Metric Grade 10.9 Bolts
Bolt size (mm) Hexagon
Torque Settings Nm kgf m lbf ft
Dia.
(A/F) mm
M6 (6) 10 16 1.6 12
M8 (8) 13 39 4 29
M10 (10) 17 78 8 57
M12 (12) 19 137 14 101
M16 (16) 24 343 35 253
M20 (20) 30 657 67 485
Rivet Nut Bolts/Screws Bolt size Torque
Settings Dia. (mm) Nm kgf m lbf ft
M3
3
1.2
0.12
0.9
M4 M5 4 5 3.0 6.0 0.3 0.6 2.0 4.5 M24 (24) 36 1157 118 853
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
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Section 1 - General Information Torque Settings
Zinc Plated Fasteners (golden finish) Hydraulic
Hose to Adapter Connections
Metric - All Internal Hexagon Headed Cap Screws
Diameter mm Nm Torque Settings kgf m lbf ft BSP Size (inches) Nm kgf m lbf ft
M3 2 0.2 1.5 1/8 14 1.4 10
M4 6 0.6 4.5 1/4 24 2.5 18
M5 11 1.1 8 3/8 33 3.3 24
M6 19 1.9 14 1/2 44 4.8 35
M8 46 4.7 34 5/8 58 6.0 43
M10 91 9.3 67 3/4 84 8.6 62
M12 159 16.2 117 1 115 11.8 85
M16 395 40 292 1 1/2 244 24.9 180
M18 550 56 406
Hydraulic Adapter into Component Connections with
bonded washers
M20 M24
770 1332
79 136
568 983
Verbs Ripp Bolts
BSP Size (inches) Nm kgf m lbf ft
1/8 20 2.1 15
1/4 34 3.4 25
3/8 75 7.6 55
1/2 102 10.3 75
5/8 122 12.4 90
3/4 183 18.7 135
1 203 20.7 150
1 1/2 305 31 225
A343780
Fig 1. Torque settings for these bolts are
determined by the application. Refer to the
relevant procedure for the required settings.
11
Dacromet Fasteners (mottled silver
finish) Dacromet Fasteners (mottled silver finish)
Metric Grade 12.9 Bolts
Use only where no torque setting is specified in
the text.
plating process do not lubricate. Metric Grade
8.8 Bolts
Bolt Size Dia Nm Torque Settings kgf m lbf ft
M6 x 1.0 15 1.5 11
M8 x 1.25 40 4.1 29
M10 x 1.5 80 8.2 59
M12 x 1.75 133 13.6 98
M14 x 2 225 23 166
M16 x 2 350 35.7 258
M18 x 2.5 463 47 342
M20 x 2.5 654 67 482
M24 x 3 1125 115 830
M30 x 3.5 2247 229 1657
Bolt Size Dia Nm Torque Settings kgf m lbf ft
M6 x 1.0 9 0.9 7
M8 x 1.25 22.5 2.3 17
M10 x 1.5 47.5 4.8 35
M12 x 1.75 80 8.2 59
M14 x 2 133 13.6 98
M16 x 2 200 20.4 148
M18 x 2.5 278 28.4 205
M20 x 2.5 392 40 289
M24 x 3 675 69 498
M30 x 3.5 1348 138 994
Metric Grade 10.9 Bolts
Bolt Size Dia Nm Torque Settings 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
12
Section 1 - General Information Service
Tools Numerical List Section B - Body and
Framework
The tools listed in the table are special tools
required for removal and replacement of Body and
Framework parts. These tools are available from
JCB Service.
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
4104/1310 Hand Cleaner Fig 1. (X 1-10)
826/01099 M6 x 16mm Rivet Nut Fig 2. (X 1-10)
826/01101 M6 x 19mm Rivet Nut Fig 2. (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 Nylon Spatula Fig 8. (X 1-11)
892/00848 Wire Starter Fig 9. (X 1-11)
892/00849 Braided Cutting Wire Fig 10. (X 1-11)
926/15500 Rubber Spacer Blocks Fig 11. (X 1-12)
992/12300 12V Oven Fig 12. (X 1-12)
992/12400 240V Oven 2 Cartridge Fig 13. (X 1-12)
992/12600 240V Oven 6 Cartridge Fig 13. (X 1-12)
992/12800 Cut-Out Knife Fig 14. (X 1-12)
992/12801 L Blades Fig 15. (X 1-12)
1 - 9
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Section 1 - General Information Service
Tools Tool Detail Reference Section B - Body and
Framework Tool Detail Reference Section B - Body
and Framework Note Not all service tools are
illustrated. Illustrations are shown in tool
number order.
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 1. 410/1310
Note Special blend for the removal of
polyurethane adhesives
Fig 4. 892/00483
Fig 2.
Note - essential for preparing new glass prior
to installation..
Installation Tool Available from Bollhoff
Fastenings Ltd. Midacre The Willenhall Estate
Rose Hill Willenhall West Midlands, WV13 2JW
1 - 10
14
Section 1 - General Information Service
Tools Tool Detail Reference Section B - Body and
Framework
Fig 5. 892/00844
Fig 8. 892/0847
Note - used to give extended reach for normally
inaccessible areas.
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 6. 892/00845
Note - hand operated - essential for the
application of sealants, polyurethane materials
etc.
Fig 9. 892/00848
Note - used to access braided cutting wire
through original polyurethane seal.
Fig 10. 892/00849
Fig 7. 892/00846
Note - (approx 25 m length) consumable heavy
duty cut-out wire used with the glass extraction
tool.
Note - used with braided cutting wire (below) to
cut out broken glass.
1 - 11
15
Section 1 - General Information Service
Tools Tool Detail Reference Section B - Body and
Framework
Fig 11. 926/15500
Note - (unit quantity 500 off) used to provide
the correct set clearance between glass edge and
cab frame.
Fig 14. 992/12800
Note - used to remove broken glass.
Fig 12. 992/12300
Fig 15. 992/12801
Note - (unit quantity 5 off) 25 mm (1 in) cut
- replacement blades for cut-out knife (above)..
Note - 1 cartridge capacity - required to
pre-heat adhesive prior to use. It is 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.
1 - 12
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Section 1 - General Information Service
Tools Numerical List Section C -
Electrics Numerical List Section C -
Electrics 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 .
well equipped workshop or be available 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)
718/20237 Interconnecting cable Fig 17. (X 1-14)
892/01033 Electronic Service Tool Kit Fig 18. (X 1-14)
892/01174 Electronic Service Tool Kit Fig 19. (X 1-15)
1 - 13
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Section 1 - General Information Service
Tools Tool Detail Reference Section C -
Electrics Tool Detail Reference Section C -
Electrics Note Not all service tools are
illustrated. Illustrations are shown in tool
number order.
1 2

3
4
5
Fig 18. 892/01033
1 Parallel Interconnecting cable, DLA to laptop PC. Parallel Interconnecting cable, DLA to laptop PC. Parallel Interconnecting cable, DLA to laptop PC.
2 Data Link Adaptor (DLA), enables data exchange between the machine ECU (Electronic Control Unit) and a laptop PC loaded with the applicable diagnostics software. Data Link Adaptor (DLA), enables data exchange between the machine ECU (Electronic Control Unit) and a laptop PC loaded with the applicable diagnostics software. 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. Kit carrying case. Kit carrying case.
4 Serial Interconnecting cable, DLA to laptop PC. Serial Interconnecting cable, DLA to laptop PC. Serial Interconnecting cable, DLA to laptop PC.
5 Interconnecting cable, DLA to machine ECU diagnostics socket. Interconnecting cable, DLA to machine ECU diagnostics socket. Interconnecting cable, DLA to machine ECU diagnostics socket.
Fig 16. Fig 16.
1 892/00283 Tool Kit Case
2 892/00281 AVO Meter
3 892/00286 Surface Temperature
4 892/00284 Microtach Digital Tachometer
5 892/00282 Shunt - open type
6 892/00285 Hydraulic Oil Temperature Probe
7 892/00298 Fluke 85 Multimeter
D
E
B A F
J G
H
A408030
Fig 17. 718/20237
Interconnecting cable, DLA to machine ECU
diagnostics socket.
1 - 14
18
Section 1 - General Information Service
Tools Tool Detail Reference Section C - Electrics
1 2 3 5 4 6 Fig 19. 892/01174 1 2 3 5 4 6 Fig 19. 892/01174
1 Interconnecting cable, DLA to machine ECU diagnostics socket.
2 Interconnecting cable, 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
E
B A F
G
H
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Section 1 - General Information Service
Tools Numerical List Section E-
Hydraulics Numerical List Section E-
Hydraulics The tools listed in the table are
special tools required for 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.
Part Number Description Tool Detail Reference
545/18000 Lynch Pin Fig 20. (X 1-18)
556/43400 Lift Ram Fig 20. (X 1-18)
811/50232 1,1/4 Pivot Pin Fig 20. (X 1-18)
816/00018 1 in BSP (A) x 1 in BSP (B) Fig 21. (X 1-18)
816/00189 Male Cone Blanking Plug 3/8 in BSP Fig 22. (X 1-18)
816/00190 Male Cone Blanking Plug 1/2 in BSP Fig 22. (X 1-18)
816/00193 Male Cone Blanking Plug 1 in BSP Fig 22. (X 1-18)
816/00196 Male Cone Blanking Plug 3/4 in BSP Fig 22. (X 1-18)
816/00197 Male Cone Blanking Plug 5/8 in BSP Fig 22. (X 1-18)
816/00294 Male Cone Blanking Plug 1/4 in BSP Fig 22. (X 1-18)
816/15118 Pressure Test Adapter 3/4 in BSP x Test Point Fig 23. (X 1-19)
816/50005 1/2 in BSP (A) x 1/2 in BSP (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 1/2 in BSP Fig 25. (X 1-19)
892/00058 Female Cone Blanking Plug Female Cone Blanking Plug 5/8 in BSP Fig 25. (X 1-19)
892/00059 Female Cone Blanking Plug 3/4 in BSP Fig 25. (X 1-19)
892/00060 Female Cone Blanking Plug 1 in BSP Fig 25. (X 1-19)
892/00223 Hand Pump Fig 26. (X 1-19)
892/00254 Hose Fig 27. (X 1-20)
892/00255 Pressure Test Adapter 1/4 in BSP x Test Point Fig 23. (X 1-19)
892/00256 Pressure Test Adapter 3/8 in BSP x Test Point Fig 23. (X 1-19)
892/00257 Pressure Test Adapter 1/2 in BSP x Test Point Fig 23. (X 1-19)
892/00258 Pressure Test Adapter 5/8 in BSP x Test Point Fig 23. (X 1-19)
892/00259 Pressure Test Adapter 1 in BSP x Test Point Fig 23. (X 1-19)
892/00260 Pressure Test Adapter 1,1/4 in BSP x Test Point Fig 23. (X 1-19)
892/00261 Pressure Test Adapter 5/8 in UNF x Test Point Fig 23. (X 1-19)
892/00262 Pressure Test T Adapter 1/4 in BSP x 1/4 in F BSP x Test Point Fig 24. (X 1-19)
1 - 16
20
Section 1 - General Information Service
Tools Numerical List Section E- Hydraulics
Part Number Description Tool Detail Reference
892/00263 Pressure Test T Adapter 5/8 in BSP x 5/8 in F BSP x Test Point Fig 24. (X 1-19)
892/00264 Pressure Test T Adapter 3/4 in BSP x 3/4 in F BSP x Test Point Fig 24. (X 1-19)
892/00265 Pressure Test T Adapter 1 in M BSP x 1 in F BSP x Test Point Fig 24. (X 1-19)
892/00266 Pressure Test T Adapters1,1/4 in M BSP x 1,1/4 in F BSP x Test Point Fig 24. (X 1-19)
892/00267 Pressure Test T Adapter 1,1/2 in M BSP x 1,1/2 in F BSP x Test Point Fig 24. (X 1-19)
892/00279 Pressure Gauge 0-400 bar (0-6000 lbf/in2) Fig 27. (X 1-20)
892/00346 Pressure Gauge 0-70 bar (0-1000 lbf/in2) Fig 27. (X 1-20)
892/00347 Connector Fig 27. (X 1-20)
993/99512 Spanner 55 mm A/F Fig 28. (X 1-20)
993/99513 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 (supplied loose unwelded) Fig 20. (X 1-18)
993/99523 Anchor Cross Member (supplied loose unwelded) Fig 20. (X 1-18)
993/99524 Ram Eye End Modification Plate Assembly Fig 20. (X 1-18)
993/99525 Rig Assembly (not including spanners and ram) Fig 20. (X 1-18)
SSP0046 Spanner 80 mm A/F Fig 28. (X 1-20)
SSP0047 Spanner 95 mm A/F Fig 28. (X 1-20)
Socket Box Wrench Fig 29. (X 1-21)
Nut Adapter Fig 30. (X 1-22)
Seal Ring Tool Fig 31. (X 1-23)
Stopper Fig 32. (X 1-24)
Bearing Rig Fig 33. (X 1-25)
1 - 17
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Section 1 - General Information Service
Tools Tool Detail Reference Section E-
Hydraulics Tool Detail Reference Section E-
Hydraulics Note Not all service tools are
illustrated. Illustrations are shown in tool
number order.
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 20. Ram Piston Nut Removal/Fitting Rig
993/99525 Rig Assembly (not including spanners and ram)
993/99522 Anchor Side Plate (supplied 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 22. Male Cone Blanking Plug
816/00294 - 1/4 in BSP
816/00189 - 3/8 in BSP
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
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Section 1 - General Information Service
Tools Tool Detail Reference Section E- Hydraulics
Fig 23. Pressure Test Adapters
892/00255 1/4 in BSP x Test Point
892/00256 3/8 in BSP x Test Point
892/00257 1/2 in BSP x Test Point
892/00258 5/8 in BSP x Test Point
816/15118 3/4 in BSP x Test Point
892/00259 1 in BSP x Test Point
892/00260 1,1/4 in BSP x Test Point
892/00261 5/8 in UNF 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 Fig 26. 892/00223
Note Components listed below also required Note Components listed below also required
Item Description
1 892/00137 Micro-bore Hose 1/4 in BSP x 5 metres
2 892/00274 Adapter 1/4 in M BSP x 3/8 in M BSP Taper
3 892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point
4 892/00706 Test Probe
5 892/00278 Gauge 0 - 40 bar (0 - 600 lb/in2)
6 892/00279 Gauge 0 - 400 bar (0 - 6000 lb/in2)
7 892/00280 Gauge 0 - 600 bar (0 - 8500 lb/in2)
Fig 24. Pressure Test T Adapters
892/00262 1/4 in BSP x 1/4 in F BSP x Test Point
816/55040 1/2 in BSP x 1/2 in F BSP x Test Point
892/00263 5/8 in BSP x 5/8 in F BSP x Test Point
892/00264 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
1 - 19
23
Section 1 - General Information Service
Tools Tool Detail Reference Section E- Hydraulics
Fig 27. Hydraulic Pressure Test Gauges and Connections Fig 27. Hydraulic Pressure Test Gauges and Connections
1 892/00279 Pressure Gauge 0-400 bar (0-6000 lbf/in2)
2 892/00346 Pressure Gauge 0-70 bar (0-1000 lbf/in2)
3 892/00347 Connector
4 892/00254 Hose
JS07050 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/F
1 - 20
24
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
25
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
26
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
27
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
28
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
29
Section 1 - General Information Service
Tools Numerical List Section F -
Transmission Numerical List Section F -
Transmission
The tools listed in the table are special tools
required for testing, removing and replacing
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 SST0037
Description
Tool Detail Reference Fig 34. (X 1-27) Fig 35. (X
1-27) Fig 36. (X 1-28)
Re-sealing Tool Stopper Puller
1 - 26
30
Section 1 - General Information Service
Tools Tool Detail Reference Section F -
Transmission Tool Detail Reference 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.
A409010-C1
Fig 35. Stopper
Note for the assembly of Hydraulic motor on
track gearbox.
1 - 27
31
Section 1 - General Information Service
Tools Tool Detail Reference Section F -
Transmission
Fig 36. Puller Fig 36. Puller
Note For the removal of Track motor Bushes. (All dimensions in mm). 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
1 - 28
32
Section 1 - General Information
Service Consumables Sealing and Retaining
Compounds T11-001_2 Table 1.
Type Description Part No. Quantity
JCB Multi-Gasket A medium strength sealant suitable for all sizes of gasket flanges, and for hydraulic fittings of 25-65 mm diameter. 4102/1212 50 ml
JCB High Strength Threadlocker A high strength locking fluid for use with threaded components. Gasketing for all sizes of flange where the strength of the joint is important. 4102/0551 50 ml
JCB Retainer (High Strength) For all retaining parts which are unlikely to be dismantled. 4101/0651 50 ml
JCB Threadlocker and Sealer A medium strength locking fluid for sealing and retaining nuts, bolts, and screws up to 50 mm diameter, and for hydraulic fittings up to 25 mm diameter. 4101/0250 10 ml
JCB Threadlocker and Sealer A medium strength locking fluid for sealing and retaining nuts, bolts, and screws up to 50 mm diameter, and for hydraulic fittings up to 25 mm diameter. 4101/0251 50 ml
JCB Threadlocker and Sealer (High Strength) A high strength locking fluid for sealing and retaining nuts, bolts, and screws up to 50 mm diameter, and for hydraulic fittings up to 25 mm diameter. 4101/0550 10 ml
JCB Threadlocker and Sealer (High Strength) A high strength locking fluid for sealing and retaining nuts, bolts, and screws up to 50 mm diameter, and for hydraulic fittings up to 25 mm diameter. 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)
JCB Activator A cleaning primer which speeds the curing rate of anaerobic products. 4104/0253 1 ltr (Bottle)
JCB Cleaner/Degreaser For degreasing components prior to use of anaerobic adhesives and sealants. 4104/1557 400 ml (Aerosol)
Anti-Seize Paste A compound used for assembly and prevention of parts seizure. 4003/0211
Direct Glazing Kit For one pane of glass comprises of 1 x Ultra Fast Adhesive (310 ml) 1 x Active Wipe 205 (30 ml) 1 x Black Primer 206J (30 ml) plus applicator nozzle etc. 993/55700
Ultra Fast Adhesive For direct glazing. 4103/2109 310 ml
Active Wipe 205 For direct glazing. 4104/1206 30 ml
Active Wipe 205 For direct glazing. 4104/1203 250 ml
Black Primer 206J For direct glazing. 4201/4906 30 ml
Clear Silicone Sealant To seal butt jointed glass. 4102/0901
Plastic to Metal Bonder To seal plastic to metal joints. 4103/0955
Black Polyurethane Sealant To finish exposed edges of laminated glass. 4102/2309 310 ml
1 - 29
33
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 Running Gear
Section K - Engine
Publication No.
9803/6530-1

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, World Class
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 [phone] Fax [phone]
34
Section 2 - Care and Safety 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. 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 W
ARNING Denotes a hazard exists. If proper
precautions are not taken, the operator (or
others) could be killed or seriously
injured. INT-1-2-2 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
35

• Section 2 - Care and Safety
• Safety Check List
• Safety - Yours and Others
• 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.
• Do not work with the machine until you are sure
  that you can control it.
• Do not start any job until you are sure that you
  and those around you will be safe.
• If you are 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

2 - 2
36
Section 2 - Care and Safety Safety Check
List General Safety General Safety
WARNING
WARNING
Handbook You and others can be injured if you
operate or maintain the machine without first
studying this handbook. Read the safety
instructions before operating the machine. If
you do not understand anything, ask your employer
or JCB dealer to explain it. Keep this handbook
clean and in good condition. Do not operate the
machine without a handbook in the cab, or if
there is anything on the machine you do not
understand.
Clothing You can be injured if you do not wear
the proper clothing. Loose clothing can get
caught in the machinery. Wear protective clothing
to suit the job. Examples of protective clothing
are a hard hat, safety shoes, safety glasses, a
well fitting overall, ear- protectors and
industrial gloves. Keep cuffs fastened. Do not
wear a necktie or scarf. Keep long hair
restrained.
INT-1-3-6
INT-1-3-2
WARNING
WARNING
Lifting Equipment You can be injured if you use
faulty lifting equipment. Make sure that lifting
equipment is in good condition. Make sure that
lifting tackle complies with all local
regulations and is suitable for the job. Make
sure that lifting equipment is strong enough for
the job.
Decals Decals on the machine warn you of
particular hazards. You can be injured if you do
not obey the decal safety instructions.
Each decal is attached close to a part of the
machine where there is a possible hazard.
Make sure replacement parts include warning
decals where necessary.
INT-1-3-7
WARNING
Raised Equipment Raised equipment can fall and
injure you. Do not walk or work under raised
equipment unless safely supported.
Keep all decals clean and readable. Replace lost
or damaged decals. Each decal has a part number
printed on it, use this number to order a new
decal from your JCB distributor.
13-1-1-6
INT-3-3-3_1
DANGER
WARNING
Before removing the boom from the machine, ensure
that the counterweight is adequately supported as
in certain ground conditions the machine could
tip backwards. Never travel or transport the
machine with the boom removed.
Care and Alertness All the time you are working
with or on the machine, take care and stay alert.
Always be careful. Always be alert for hazards.
INT-1-3-5
BF-6-2
WARNING Alcohol and 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
2 - 3
37
Section 2 - Care and Safety Safety Check
List Operating Safety Operating Safety
WARNING
WARNING
Practice You or others can be killed or seriously
injured if you do unfamiliar operations without
first practising them. Practise away from the
work site on a clear area. Keep other people
away. Do not perform new operations until you are
sure you can do them safely.
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 you cannot see
clearly.
INT-2-1-1
5-1-4-7
WARNING
WARNING
Machine Condition A defective machine can injure
you or others. Do not operate a machine which is
defective or has missing parts. Make sure the
maintenance procedures in this handbook are
completed before using the machine
Machine Limits Operating the machine beyond its
design limits can damage the machine, it can also
be dangerous. Do not operate the machine outside
its limits. Do not try to upgrade the machine
performance with unapproved modifications.
INT-2-1-2
INT-2-1-4
CAUTION
WARNING
If you have an attachment which is not covered in
this handbook do not install it, use it or remove
it until you have obtained, read and understood
the pertinent information. Install attachments
only on the machines for which they were designed.
Exhaust Gases Breathing the machine exhaust gases
can harm and possibly kill you. Do not operate
the machine in closed spaces without making sure
there is good ventilation. If possible, fit an
exhaust extension. If you begin to feel drowsy,
stop the machine at once. Get out of the cab into
fresh air.
5-5-1-1
WARNING
INT-2-1-10
Entering/Leaving Entering or leaving the cab or
canopy must only be made where steps and
handrails are provided. Always face the machine
when entering and leaving. Make sure the step(s),
handrails and your boot soles are clean and dry.
Do not jump from the machine. Do not use the
machine controls as handholds, use the handrails.
DANGER
Sparks Explosions and fire can be caused by
sparks from the exhaust or the electrical system.
Do not use the machine in closed areas where
there is flammable material, vapour or dust.
INT-2-1-7_1
INT-2-2-10
WARNING
WARNING
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.
Engine The engine has exposed rotating parts. Do
not open the engine cover while the engine is
running. Do not use the machine with the cover
open.
INT-2-1-6_1
INT-2-1-3
2 - 4
38
Section 2 - Care and Safety Safety Check
List Operating Safety
CAUTION
WARNING
Passengers Passengers in or on the machine can
cause accidents. Do not carry passengers.
Airborne particles of light combustible material
such as straw, grass, wood shavings, etc. must
not be allowed to accumulate within the engine
compartment or in the propshaft guards (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.
INT-2-2-2_1
WARNING
Safe Working Loads Overloading the machine can
damage it and make it unstable. Study the
specifications in this handbook before using the
machine.
5-3-1-12_2
WARNING
7-1-1-8
Electrical Power Cables You could be electrocuted
or badly burned if you get the machine or its
attachments too close to electrical power cables.
WARNING
The Long Reach is larger and higher than a normal
excavating rig. You must take extra care when you
are working in dangerous or restricted height
locations such as under power lines, bridges, etc.
You are strongly advised to make sure that the
safety arrangements on site comply with the local
laws and regulations concerning work near
electric power lines.
8-2-8-10
Before you start using the machine, check with
your electricity supplier if thee are any buried
power cables on the site.
WARNING
When using Quick Hitch Type 2, the attachment can
become unexpectedly disengaged from the Quick
Hitch, when any of the following occurs
There is a minimum clearance required for working
beneath overhead power cables. You must obtain
details from your local electricity supplier.
Power failure to the Electronic Control Unit
(ECU).
2-2-5-4
When the redundancy switch is engaged.
CAUTION
If an electrical component in the Quick Hitch
system should fail.
With certain combinations of bucket or attachment
and boom/dipper configuration, it is possible for
the bucket teeth or attachment extremities to
contact ad cause damage to the structure of the
machine. Check the limit of free movement as the
dipper is brought in towards the machine.
0178
CAUTION
Because of the extra length and height of the
Long Reach boom and dipper, you must be very
careful when slewing. Do not slew quickly and
strike the dipper against obstacles. You may
cause severe damage to the rig structure.
8-2-5-2
WARNING
Hazardous Atmospheres This machine is designed
for use in normal out door atmospheric
conditions. It should not be used in an enclosed
area without adequate ventilation. Do not use
the machine in a potentially explosive
atmosphere, i.e. combustible vapours, gas or
dust, without first consulting your JCB
Distributor.
8-2-8-11
INT-2-1-14
2 - 5
39
Section 2 - Care and Safety Safety Check
List Maintenance Safety Maintenance Safety
WARNING
WARNING
Repairs Do not try to do repairs or any other
type of maintenance work you do not understand.
To avoid injury and/or damage get the work done
by a specialist engineer.
Diesel Fuel Diesel fuel is flammable keep naked
flames away from the machine. Do not smoke while
refuelling the machine or 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.
GEN-1-5
INT-3-2-2
WARNING
WARNING
Metal Splinters You can be injured by flying
metal splinters when driving metal pins in or
out. Use a soft faced hammer or drift to remove
and fit metal pins. Always wear safety glasses.
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 prevent skin contact. Wash skin
contaminated with oil thoroughly in warm soapy
water. Do not use petrol, diesel fuel or paraffin
to clean your skin.
INT-3-1-3
WARNING
Petrol Do not use petrol in this machine. Do not
mix petrol with the diesel fuel in storage tanks
the petrol will rise to the top and form
flammable vapours.
INT-3-2-3
WARNING
INT-3-1-6
Hydraulic Fluid Fine jets of hydraulic fluid at
high pressure can penetrate the skin. Do not use
your fingers to check for hydraulic fluid leaks.
Do not put your face close to suspected leaks.
Hold a piece of cardboard close to suspected
leaks and then inspect the cardboard for signs of
hydraulic fluid. If hydraulic fluid penetrates
your skin, get medical help immediately.
WARNING
Modifications and Welding Non-approved
modifications can cause injury and damage. Parts
of the machine are made from cast iron welds on
cast iron can weaken the structure and break. Do
not weld cast iron. Contact your JCB dealer for
advice before modifying the machine.
INT-3-1-10_1
INT-3-1-2_1
WARNING
WARNING
Fires If your machine is equipped with a fire
extinguisher, make sure it is checked regularly.
Keep it in the operator's cab until you need to
use it.
Electrical Circuits Understand the electrical
circuit before connecting or disconnecting an
electrical component. A wrong connection can
cause injury and/or damage.
Do not use water to put out a machine fire, you
could spread an oil fire or get a shock from an
elecrical fire. Use carbon dioxide, dry
chemical or foam extinguishers. Contact your
nearest fire department as quickly as possible.
Firefighters should use self- contained breathing
apparatus.
INT-3-1-4
INT-3-2-7_1
2 - 6
40
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41
Section 2 - Care and Safety Safety Check
List Maintenance Safety
WARNING
CAUTION
Hydraulic Pressure Hydraulic fluid at system
pressure can injure you. Before disconnecting or
connecting hydraulic hoses, stop the engine and
operate the controls to release pressure trapped
in the hoses. Make sure the engine cannot be
started while the hoses are open.
Rams The efficiency 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-3-1-11_1
INT-3-2-10
WARNING
CAUTION
Hot Coolant The cooling system is pressurised
when the engine is hot. Hot coolant can spray out
when you remove the filler cap. Let the system
cool before removing the filler cap. To remove
the cap turn it to the first notch and let the
system pressure escape, then remove the cap.
'O' rings, Seals and Gaskets Badly fitted,
damaged or rotted 'O' rings, seals and gaskets
can cause leakages and possible accidents. Renew
whenever disturbed unless otherwise
instructed. Do not use Triochloroethane or paint
thinners near 'O' rings and seals.
INT-3-2-12
INT-3-2-9_1
WARNING
CAUTION
If you try to charge a frozen battery, or jump
start and run the engine, the battery could
explode. Do not use a battery if its electrolyte
is frozen. To prevent the battery electrolyte
from freezing, keep the battery at full charge.
Cleaning Cleaning metal parts with incorrect
solvents can cause corrosion. Use only
recommended cleaning agents and solvents.
INT-3-2-11
0125
WARNING
WARNING
Hydraulic Hoses Damaged hoses can cause fatal
accidents. Inspect the hoses regularly for
Battery Gases Batteries give off explosive gases.
Keep flames and sparks away from the battery. Do
not smoke close to the battery. Make sure there
is good ventilation in closed areas where
batteries are being used or charged. Do not check
the battery charge by shorting the terminals with
metal use a hydrometer or voltmeter.

• Damaged hose ends
• Chafed outer covers
• Balloned outer covers
• Kinked or crushed hoses
• Embedded armouring in outer covers
• Displaced end fittings.

INT-3-1-8
WARNING
INT-3-3-2
Battery Terminals The machine is negatively
earthed. Always connect the negative pole of the
battery to earth.
WARNING
Soft Ground A machine can sink into soft ground.
Never work under a machine on soft ground.
When connecting the battery, connect the earth
(-) lead last.
INT-3-2-4
When disconnecting the battery, disconnect the
earth (-) lead first.
INT-3-1-9
2 - 7
2 - 7
9803-6530
42
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