JCB JZ140 Tracked Excavator Service Manual – 9803/9910-01

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JCB JZ140 Tracked Excavator Service Manual – 9803/9910-01
(S/N: 1390000 to 1390499)

This service manual PDF download for the JZ140 Tier III 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 III

JCB JZ140 – from S/N: 1390000 to 1390499

TABLE OF CONTENTS :

Section 1 – General Information
Section 2 – Care & Safety
Section 3 – Maintenance
Section B – Body & Framework
Section C – Electrics
Section E – Hydraulics
Section F – Transmission
Section J – Track & Running Gear
Section K – Engine

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Publication No. : 9803/9910-01
Total Pages : 774

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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9803-9910
JZ140

Section 1 – General Information
General Information
Introduction
About this Manual
Machine Model and Serial Number
Using the Service Manual
Section Numbering
Units of Measurement
Cross References
Left Side, Right Side
Schematic Codes
Colour Codes
Identifying your Machine
Identification Your Machine
Machine Identification Plate
Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
Introduction
Bolts and Screws
Hydraulic Connections
‘O’ Ring Face Seal System
‘Torque Stop’ Hose System
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 & Safety
Care & Safety
Safety Notices
Important Information
The Operator Manual
Safety Warnings
Safety Check List
Safety – Yours and Others
General Safety
Operating Safety
Maintenance Safety
Make the Machine Safe
Safety Decals
Safety Decal Recognition
Chart Definitions

Section 3 – Maintenance
Maintenance
Routine Maintenance
Service Requirements
Introduction
Owner/Operator Support
Service/Maintenance Agreements
Obtaining Replacement Parts
Lifting Regulations – Inspections and Tests
Health and Safety
Lubricants
Battery
First Aid – Electrolyte
Service Schedules
Introduction
How to Use the Service Schedules
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
Hydraulic Oil Chart
Cleaning the Machine
Exterior
Interior
Checking for Damage
Checking the FOPS Structure
Torque Setting
Seat Belt
Checking the Seat Belt Condition and Security
Daily Checking
Bolt and Nut Torque Specifications
JZ140 and Variants
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
Fuel
Filling the Tank
Fuel Level
Refuelling Pump
Draining Fuel Tank Impurities
Draining the Primary Filter/Sedimenter
Changing the Primary Filter/Sedimenter Element
Changing the Fuel Feed Pump Filter
Draining the Main Filter/Sedimenter
Changing the Main Filter/Sedimenter Element
Bleeding the 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
Cleaning the Tracks
Checking/Adjusting the Track Tension
Checking Rollers and Idler Wheels for Oil Leaks
Track Plate Inspection
Bucket
Checking/Adjusting for side play
Windshield
Washers
Troubleshooting
Engine and Related Area
Monitor Display – Fault Messages
Operations
Hydraulic pump
Working Attachments
Travel
Slew
Hydraulic ram

Section B – Body & Framework
Body & Framework
Technical Data
Static Dimensions
JZ140 – Monoboom
JZ140 – Triple Articulated Boom
JZ140HD – Monoboom
JZ140HD – Triple Articulated Boom
Dig Depth Chart
JZ140 – Monoboom
JZ140 – Triple Articulated Boom
JZ140HD – 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)
Automatic Temperature Control (ATC) System
Basic Operation
Automatic Temperature Control (ATC) System
Operation
Heater/Air Conditioning Controls (ATC)
Air Conditioning System Operation
Control
Safety Procedures
Fault Finding
Air Conditioning
Preliminary Checks
Error Codes / Error Diagnosis (Automatic Temperature Control (ATC) System)
Service Procedures
HVAC/Air Conditioning Unit
Removal and Replacement
Air Conditioning Compressor
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
Electrics
Technical Data
Fuses
Fuse Identification
Basic System Operation
Controls and Components
Driver Controls and Switches
Right Console
Left Console
Monitor Panel
Fascia Panel
Emergency back-up switch
Cab Interior Lights
Operating Levers/Pedals
Travel Levers
Travel Speed Change Button
Operation Levers
Optional Circuit Pedal (if fitted)
ISO Operating Method
Circuit Symbols
Inputs and Outputs
Component Identification
JZ140
Schematic Diagram
A.M.S (Advanced Management System)
Operation
The AMS System
Circuit Concepts
Inputs
Outputs
Pulse Width Modulation (PWM)
ECU1/EMS/FACIA Power Supply and Network
ECU 1 Supply to Output Drivers
Hardware Sensing
Engine Throttle Control
Operation
Engine Throttle Control for each mode
Auto Boost Pressure
Operation
Engine Oil Level Warning
Engine Pre Heat (Glow plugs)
Operation
Engine Automatic Warm Up
Operation
Engine Automatic Idle
Operation
Engine One Touch Idle
Operation
Engine Auto Idle and One Touch Idle
Engine Start/Stop
Operation
Limp Mode system
Operation
Pump Control for Each Mode
Operation
Pump Torque Vs mA signal
RPM setting Selection
mA Setting Selection
Lever Lock
Operation
Servo Isolator
Operation
Lever Lock and Servo Isolator
Wiper
Operation
Lower Wiper (option)
Operation
Washer
Operation
Horn
Operation
Travel Alarm
Operation
Soft/Hard (Cushion)
Operation
Slew Brake (100%)
Operation
Slew lock (100% Slew Brake)
Operation
Slew Brake Solenoid Valve Failure.
Operation
3-Speed Travel
Operation
“E” Economy, “P” Precision & “A” Auto Modes
Relationship between Travel Modes A / E + P, travel motor swash plate position and Pump “Q max cut output”
“L” Lifting Mode
Work Lamps
Operation
Fuel Level Sensor/Warning
Operation
Engine Temperature Sensor/Warning
Operation
Coolant Level Warning
Operation
Air Filter Blocked Warning
Operation
Warning Indicator Lamps
Hydraulic Temperature Sensor/Warning
Operation
Alternator/ No Charge Warning
Operation
Alternator Charging and Battery Relay
Quick hitch (option)
Operation
Overload Caution (option)
Operation
Beacon
Operation
Hammer Only
Operation
Cab Interior Lamp
Operation
Refuelling Pump
Automatic Mode
Manual Mode
Hydraulic Fan
Operation
Air Conditioning
Heated Seat
24 to 12 Volt Converter, Radio and Cigar Lighter
24 to 12 Volt Converter.
Radio
Cigar lighter
Service Required Warning
Operation
Cancellation of the Service indicator
EMS Set Menu.
EMS Set + Mode Menu
EMS Set+Mode (20 sec) Menu.
Service Off
Solenoid Override
Horse Power Control Data Logging Facility
Throttle Calibration
Fault Finding
JCB Servicemaster
Introduction
Using Servicemaster
Selecting Service Tool Applications
JS Machine Pages
System Menus
Using ECM Setup
HPSetup Overview
DLA Port Configuration
Data Link Adaptor
HPDataLogs
FLASH Programming Application
Introduction to the Diagnostics Tool
Connecting to the Vehicle
Starting Diagnostic Mode
Circuit Diagrams
Indicator Lights (LEDs)
Stopping Diagnostic Mode
Language Setting
Electrical Fault Text Messages Displayed on the EMS.
Fault Finding Without Using the JCB Servicemaster 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 (FSP)
Service Procedure
Using a Multimeter
Measuring DC Voltage
Measuring Resistance
Measuring Continuity
Measuring Frequency
Testing a Diode or a Diode Wire
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 Identification
Fascia Link Harness
Cab Harness (includes ECM)
Connector Identification

Section E – Hydraulics
Hydraulics
Technical Data
General Data
Main Hydraulic Pump
Servo Pump
Proportional Pressure Reducing Valve
Slew Motor
Main Control Valve
Spool Stroke versus Pilot Pressure
Boom Ram
Dipper Ram
Bucket Ram
Ram Torque Settings
Basic System Operation
Hydraulic Component Location
Introduction to Hydraulic Schematic Symbols
General (Basic and Functional Symbols)
Control Valves
Example of Schematic Circuit
Circuit Descriptions
Hydraulic Schematics
JZ140
Servo Line
Components
Servo Pressure and Return Line
Components
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
Hydraulic Pump/Regulator
Hydraulic Pump Operation
Main Pumps (P1 and P2)
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 Dismantling and Assembly
Main Control Valve
Description
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
Installation
Caution During Use
Maintenance, Inspection Points
Removal and Replacement
Typical Bucket Ram
Typical Boom Ram
Typical Dipper Ram
Typical Triple Articulated Boom (TAB) Ram
Dismantling and Assembly
Dozer Rams
Typical Triple Articulated Boom (TAB) Ram
Reconditioning
Procedures for inserting and bedding the seal ring.
Bushing Removal
Bushing Assembly
Wiper Ring Assembly
Cylinder Head Assembly
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
Auxiliary Relief Valves
General
Boom Ram
Slew Motor Pressure Relief
Travel Motor Relief Pressure
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
Transmission
Technical Data
Travel Equipment
JZ140
Fault Finding
Introduction
Fault Finding
Track Motor
Removal and Replacement
Removal
Precautions during Installation
Replacement
Start Up and Running In
Start Up
Running In
Dismantling and Assembly
Dismantling
Inspection
Assembly
Track Gearbox
Dismantling and Assembly
Dismantling
Inspection
Assembly

Section J – Track & Running Gear
Track & Running Gear
Technical Data
Torque Specifications
Idler Wheel and Recoil Unit
Removal
Replacement
Idler Wheel
Dismantling
Assembly
Recoil Unit
Dismantling
Assembly
Drive Sprocket
Removal
Replacement
Top Roller
Removal
Replacement
Dismantling
Assembly
Bottom Roller
Removal
Replacement
Dismantling
Assembly

Section K – Engine
Engine
Technical Data
JZ140
Engine Mounts

 

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JCB JZ140 Tracked Excavator Service Manual – 9803/9910-01.pdf

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