JCB ZT20D ZERO TURN MOWER Service Repair Manual Instant Download

1

Service Manual
ZT 20D Section 1 - General Information Section 2
- Care and Safety Section 3 - Routine Maintenance
Section B - Body and Framework Section C -
Electrics Section D - Controls Section E -
Hydraulics Section K - Engine
Publication No. 9803/9430-1
World Class Customer Support
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. Issued by JCB Technical Publications,
JCB Service, World Parts Centre, Beamhurst,
Uttoxeter, Staffordshire, ST14 5PA, England. Tel
44 1889 590312 Fax [phone]
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Section 1 - General Information
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Section 1 - General Information
Contents Page No. Introduction About this
Publication ......................................
........................................ 1 -
1 Machine Identification Identifying Your
Machine ..........................................
............................... 1 - 3 Service
Tools Numerical List .............................
..................................................
........... 1 - 6 Fastener Torque
Chart Numerical List .............................
..................................................
........... 1 - 7 Consumables Sealing and
Retaining Compounds ..............................
........................... 1 - 9
1 - i
4
Section 1 - General Information
Page No.
Contents
1 - ii
5
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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
Worldwide Training.
'Left Hand' and 'Right Hand' are as viewed from
the rear of the machine facing forwards.
This Service Manual covers the following machines
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.
JCB ZT 20D from SN 1225000 to SN 1225999

• 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 also
  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!
• 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 and 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 and Framework...etc.
• Section contents, technical data, circuit
  descriptions, operation descriptions etc. are
  inserted at the beginning of each alphabetically
  coded section.
• All sections are listed on the front cover
  tabbed divider cards align directly with
  individual sections on the front cover for rapid
  reference.

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Section 1 - General Information Introduction About
this Publication
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Section 1 - General Information Machine
Identification Identifying Your Machine
Machine Identification Plate
Typical Product Identification Number (PIN)
Your machine has an identification plate mounted
as shown. K Fig 1. ( 1-3) Information contained
on this plate is the Product Identification
Number, Type, the Weight in kg, Year of
Manufacture, Engine Power in kw and the Engine
RPM.
A typical Product Identification Number is given
below.
JCBZT20D 6 U 1225008
1 2 3 4
1 Machine Model
JCB COMPACT PRODUCTS LIMITED HAREWOOD ESTATE,
LEEK ROAD, CHEADLE STOKE-ON-TRENT, UNITED
KINGDOM, ST102JU
2 Year of Manufacture
Product Identification Number PIN
Type
3 Country of Origin
A WEIGHT (kg) YEAR OF MANUFACTURE ENGINE POWER
kw ENGINE RPM
4 Machine Serial Number
V001950
Fig 1.
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Section 1 - General Information Machine
Identification
Identifying Your Machine Roll Over Protection
Structure (ROPS)
Engine Identification Plate Location
The engine identification plate A is attached to
the right side of the engine block, next to the
electric starter. The information contained on
this plate includes the engine model and serial
numbers. K Fig 2. ( 1-4)
WARNING
Modified and wrongly repaired ROPS, TOPS FOGS
Structures are dangerous. Do not modify the TOPS
Structure. Do not attempt to repair the ROPS,
TOPS FOGS Structure. If the ROPS, TOPS FOGS
Structure has been in an accident, do not use the
machine until the structure has been inspected
and repaired. This must be done by a qualified
person. For assistance, contact your JCB dealer.
Failure to take precautions could result in death
or injury to the operator.
5-3-1-7_2 Your machine is built to the ROPS
standard and has an identification label fitted
on the ROPS bar. A typical identification label
is shown below. K Fig 3. ( 1-4)
Fig 3.
V002060
Component Identification
Fig 2.
Engine Identification The JCB Zero-Turn Mower is
powered by a Yanmar 17 HP 2V750 liquid cooled
V-Twin Engine. The data information is located
on the right side of the Yanmar engine, behind
the RH hydraulic pump, along side the right ROPS
post, K Fig 2. ( 1-4). This data plate decal
contains the engine model, the type, and the
engine serial number. Always refer to this
information when ordering parts, requesting
warranty, etc. Engine information can be
obtained through the Yanmar Europe
web-site. When working on or repairing the
Engine, use genuine engine service parts only.
Engine warranty may be invalidated if after
market parts are used.
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Section 1 - General Information Machine
Identification
Identifying Your Machine Wheel Motor
Identification
Important All matters concerning service and
warranty for the Yanmar engine is handled by
Yanmar. JCB assumes NO service or warranty
responsibility for engine concerns.
Wheel motor identification is found on a round
tag mounted on the end plate of the motor. The
motor type code, model and serial numbers are
engraved into this tag.
Hydraulic Pump Identification Hydraulic pump
identification is located on a bar code decal
fastened to the side of the pump.
Fig 5.
Always refer to this information when ordering
parts, requesting warranty, etc. Hydro-Gear PG
(10cc) Series Hydraulic Pump
Fig 4.
The model number and the date coded serial
numbers are found on this decal. Duplicate pump
decals are also mounted above the serial number
decal on the mainframe. Always refer to this
information when ordering parts, requesting
warranty, etc.
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Section 1 - General Information Service
Tools Numerical List
The tools listed in the table are special tools
required for carrying out the procedures
described in this manual. These tools are
available from JCB Service.
details of all tools, including the content of
kits and sets, see the relevant section in this
manual.
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.
Some tools are available as kits or sets, the
part numbers for parts within such kits or sets
are not listed here. For full
Part Number
Description
Tool Detail Reference - see Section C C C
- -
AVO Test Kit - see tool detail reference for
content Electrical Repair Kit - see tool detail
reference for content Battery Tester
993/85700
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Section 1 - General Information Fastener Torque
Chart Numerical List
All SAE fasteners locally purchased for use on
the JCB Mower must be Grade 5 or equivalent,
unless otherwise specified in the parts manual.
Use the torque chart for all Grade 5 fasteners.
Special fastener torques are shown below the
chart. Important All torque specifications
apply to clean and lightly oiled fasteners,
hoses or fittings. Torque specifications
SHOULD NOT be followed when fastening plastic
parts. Chart - SAE Grade 5 Fasteners
Size Nm Nm lbf ft lbf ft
Lube Dry Lube Dry
1/4-20 9 12 7 9
5/16-18 20 27 15 20
3/8-16 41 47 30 35
7/16-14 61 75 45 55
1/2-13 81 108 60 80
9/16-12 136 163 100 120
5/8-11 176 231 130 170
3/4-10 298 407 220 300
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Section 1 - General Information Fastener Torque
Chart Numerical List
Special Torques
Description Torque
Mowing Blade Bolt - 9/16-12 x 1 3/4 Grade 8 170 Nm (125 lbf ft)
Spindle Pulley Nut - 3/4-16 UNF 109 Nm (80 lbf ft)
Engine Fasteners, M10 39 Nm (29 lbf ft)
Engine Fasteners , M8 20 Nm (15 lbf ft)
ROPS Fasteners - 1/2-13 Bolts Nuts 109 Nm (80 lbf ft)
Spindle Housing Nuts - 7/16-20 UNF 54 Nm (40 lbf ft)
PTO Clutch Bolt - 7/16-20 x 2 1/4 61 Nm (45 lbf ft)
Steering Dampener Nuts - M8-1.25 33 Nm (24 lbf ft)
Fuel Tank Bolts 3/8-16 8.5 Nm (6 lbf ft)
Wheel Motor End Cover Bolts - 3/8-24 Gr. 8 68 Nm (50 lbf ft)
Hydraulic Pump ByPass Valve 12 Nm (9 lbf ft)
Hydraulic Pump End Cap Bolts 22 Nm (16 lbf ft)
Hydraulic Pump Charge Pump Screws 12 Nm (9 lbf ft)
High Pressure Pump/Motor Hoses/Fittings (MUST be lightly oiled) 82 Nm (60 lbf ft)
Important DO NOT use the pulley nut to hold the
spindle while tightening the blade as the pulley
nut could be over torqued. This could cause
spindle spacer and bearing damage.
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Section 1 - General Information Consumables Sealin
g and Retaining Compounds Consumables Sealing and
Retaining Compounds T11-001_3 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)
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. 4104/1203 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. 4103/0956 50 g
Black Polyurethane Sealant To finish exposed edges of laminated glass. 4102/2309 310 ml
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Section 1 - General Information Consumables Sealin
g and Retaining Compounds
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Section 2 - Care and Safety
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Section 2 - Care and Safety
Contents Page No. Safety Notices Introduction
..................................................
............................................ 2 -
1 Safety Checklist ...............................
..................................................
...... 2 - 2 Safety Decals .......................
..................................................
............... 2 - 10
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Section 2 - Care and Safety
Page No.
Contents
2 - ii
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Section 2 - Care and Safety
Safety Notices Introduction T1-006 WARNING Study
the Operator Manual before starting the
machine. You must understand and follow the
instructions in the Operator Manual. You
must observe all relevant laws and regulations.
If you are unsure about anything, ask your JCB
dealer or employer. Do not guess, you or others
could be killed or seriously injured. INT-1-1-1_2
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
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9803/9430-01
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Section 2 - Care and Safety Safety Notices Safety
Checklist Safety Checklist
Safety - Yours and Others
WARNING
INT-1-3-1_3 All machinary can be hazardous. When
a 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.
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
In this manual and on the machine you will find
warning messages. Read and understand them. They
tell you of potential hazards and how to avoid
them. If you do not fully understand the warning
messages, ask your employer or JCB distributor to
explain them.
WARNING
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.
But safety is not just a matter of responding to
the warnings. All the time you are working on or
with the machine you must be thinking what
hazards there might be and how to avoid them.
Do not work with the machine until you are sure
that you can control it.
INT-1-3-6
WARNING
Do not start any job until you are sure that you
and those around you will be safe.
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 while operating the
machine or attachments. Be aware of medicines
which can cause drowsiness.
If you are unsure of anything, about the machine
or the job, ask someone who knows. Do not assume
anything.
Remember
INT-1-3-9_2
BE CAREFUL BE ALERT BE SAFE General Safety
WARNING
Feeling Unwell Do not attempt to operate the
machine if you are feeling unwell. By doing so
you could be a danger to yourself and those you
work with.
T1-007
WARNING
8-1-2-4
Operator Manual You and others can be injured if
you operate or maintain the machine without first
studying the Operator Manual. Read the safety
instructions before operating the machine. If you
do not understand anything, ask your employer or
JCB dealer to explain it. Keep the Operator
Manual clean and in good condition. Do not
operate the machine without an Operator Manual in
the cab, or if there is anything on the machine
you do not understand.
WARNING
Mobile Phones Switch off your mobile phone before
entering an area with a potentially explosive
atmosphere. Sparks in such an area could cause an
explosion or fire resulting in death or serious
injury.
Switch off and do not use your mobile phone when
refuelling the machine.
INT-1-3-2_2
INT-3-3-9
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9803/9430-01
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Section 2 - Care and Safety Safety Notices Safety
Checklist
Operating Safety
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.
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 manual are
completed before using the machine.
INT-1-3-7
INT-2-1-2_2
WARNING
WARNING
Raised Equipment Raised equipment can fall and
injure you. Do not walk or work under raised
equipment unless safely supported.
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.
13-1-1-6
WARNING
INT-2-1-4
Raised Machine NEVER position yourself or any
part of your body under a raised machine which
is not properly supported. If the machine
moves unexpectedly you could become trapped and
suffer serious injury or be killed.
WARNING
Engine/Steering Failure If the engine or steering
fails, stop the machine as quickly as possible.
Do not operate the machine until the fault has
been corrected.
INT-3-3-7_1
INT-2-1-5
DANGER
WARNING
Lightning Lightning can kill you. Do not use the
machine if there is lightning in your area.
The engine has exposed rotating parts. Switch OFF
the engine before working in the engine
compartment. Do not use the machine with the
engine cover open.
5-1-1-2
5-2-6-5
WARNING
WARNING
Machine Modifications This machine is
manufactured in compliance with legislative and
other requirements. It should not be altered in
any way which could affect or invalidate any of
these requirements. For advice consult your JCB
Distributor.
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 and get into fresh air.
INT-1-3-10_2
INT-2-1-10_2
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9803/9430-01
22
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Section 2 - Care and Safety Safety Notices Safety
Checklist
WARNING
WARNING
If the machine is fitted with a Roll Over
Protection Structure (ROPS) and/or a Falling
Objects Protection Structure (FOPS), you could be
killed or seriously injured if you operate the
machine with a damaged or missing ROPS/FOPS. If
the ROPS/FOPS has been in an accident, do not use
the machine until the structure has been renewed.
Modifications and repairs that are not approved
by the manufacturer may be dangerous and will
invalidate the ROPS/FOPS certification.
Ramps and Trailers Water, mud, ice, grease and
oil on ramps or trailers can cause serious
accidents. Make sure ramps and trailers are clean
before driving onto them. Use extreme caution
when driving onto ramps and trailers.
INT-2-2-6
WARNING
Safety Barriers Unguarded machines in public
places can be dangerous. In public places, or
where your visibility is reduced, place barriers
around the work area to keep people away.
INT-2-1-9_5
WARNING
Work Sites Work sites can be hazardous. Inspect
the site before working on it. Look for potholes,
weak ground, hidden rocks etc. Check for
utilities such as electric cables (overhead and
underground), gas and water pipes etc. Mark the
positions of the underground cables and pipes.
Make sure that you have enough clearance beneath
overhead cables and structures.
INT-2-2-8
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-2-2-1
WARNING
INT-2-2-10
Communications Bad communications can cause
accidents. Keep people around you informed of
what you will be doing. If you will be working
with other people, make sure any hand signals
that may be used are understood by everybody.
Work sites can be noisy, do not rely on spoken
commands.
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.
INT-2-2-3
WARNING
INT-2-1-14
Parking An incorrectly parked machine can move
without an operator. Follow the instructions in
the Operator Manual to park the machine correctly.
CAUTION
Regulations Obey all laws, work site and local
regulations which affect you and your machine.
INT-2-2-4_2
INT-1-3-3
WARNING Banks and Trenches Banked material and
trenches can collapse. Do not work or drive too
close to banks and trenches where there is danger
of collapse.
INT-2-2-5
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9803/9430-01
24
Section 2 - Care and Safety Safety Notices Safety
Checklist
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.
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 that the
safety arrangements on site comply with the local
laws and regulations concerning work near
electric power lines.
INT-2-1-1
WARNING
Before you start using the machine, check with
your electricity supplier if there are any buried
power cables on the site.
Reversing Reversing at high speeds can cause
accidents. Do not reverse in a high gear with
full throttle. Always drive at a safe speed to
suit working conditions.
There is a minimum clearance required for working
beneath overhead power cables. You must obtain
details from your local electricity supplier.
INT-2-2-9_1
WARNING
2-2-5-4
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 driveshaft guards (when
fitted). 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.
CAUTION
If you have an attachment which is not covered
in the Operator Manual 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.
5-3-1-12_3
5-5-1-1_2
WARNING
WARNING
Keep the machine controls clean and dry. Your
hands and feet could slide off slippery controls.
If that happens you could lose control of the
machine.
Use only the JCB approved attachments that are
specified for your machine. Operating with non-
specified attachments can overload the machine,
causing possible damage and machine instability
which could result in injury to yourself or
others.
2-2-3-6
WARNING
The use of non-approved attachments could
invalidate your warranty.
Visibility Accidents can be caused by working in
poor visibility. Use your lights to improve
visibility. Keep the road lights, windows and
mirrors clean.
2-4-5-2_1
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.
Do not operate the machine if you cannot see
clearly.
5-1-4-7
INT-2-1-3
2 - 5
9803/9430-01
25
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the link into your browser. The full manual is
available for immediate download. https//www.ebo
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