JCB ZT20D ZERO TURN MOWER Service Repair Manual

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. World Class Customer Support 9803/9430-1 Publication No. Issued by JCB Technical Publications, JCB Service, World Parts Centre, Beamhurst, Uttoxeter, Staffordshire, ST14 5PA, England. Tel +44 1889 590312 Fax +44 1889 593377 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

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Page No. Contents Section 1 - General Information 1 - i 1 - i 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

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Section 1 - General Information 1 - 1 1 - 1 9803/9430-01 Introduction About 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. 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. 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: 1 General Information - includes torque settings and service tools. 2 Care and 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: 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. 'Left Hand' and 'Right Hand' are as viewed from the rear of the machine facing forwards. This Service Manual covers the following machines: JCB ZT 20D from SN 1225000 to SN 1225999 A Attachments B Body and Framework...etc.

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Section 1 - General Information 1 - 3 1 - 3 9803/9430-01 Machine Identification Identifying Your Machine Machine Identification Plate Your machine has an identification plate mounted as shown. K Fig 1. ( T 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. Fig 1. Typical Product Identification Number (PIN) A typical Product Identification Number is given below. 1 Machine Model 2 Year of Manufacture 3 Country of Origin 4 Machine Serial Number V001950 JCB COMPACT PRODUCTS LIMITED HAREWOOD ESTATE, LEEK ROAD, CHEADLE STOKE-ON-TRENT, UNITED KINGDOM, ST102JU Product Identification Number PIN Type A WEIGHT (kg) YEAR OF MANUFACTURE ENGINE POWER kw ENGINE RPM JCBZT20D 6 U 1225008 1 2 3 4

Section 1 - General Information Machine Identification Identifying Your Machine 1 - 4 1 - 4 9803/9430-01 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. ( T 1-4) Fig 2. Roll Over Protection Structure (ROPS) ! 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. ( T 1-4) Fig 3. Component Identification 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. ( T 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. V002060

Section 1 - General Information Machine Identification Identifying Your Machine 1 - 5 1 - 5 9803/9430-01 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. Hydraulic Pump Identification Hydraulic pump identification is located on a bar code decal fastened to the side of the 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. Wheel Motor Identification 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. Fig 5. Always refer to this information when ordering parts, requesting warranty, etc. Hydro-Gear PG (10cc) Series Hydraulic Pump

Section 1 - General Information 1 - 6 1 - 6 9803/9430-01 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. Some tools are available as kits or sets, the part numbers for parts within such kits or sets are not listed here. For full 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. Part Number Description Tool Detail Reference - see Section: - AVO Test Kit - see tool detail reference for content C - Electrical Repair Kit - see tool detail reference for content C 993/85700 Battery Tester C

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JCB ZT20D ZERO TURN MOWER Service Repair Manual

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