jcb 3CX, 214, 4CX, 214e, 215 Service Manual

Service Manual

Backhoe Loader

9803/3280 3CX, 4CX 930001 to 960000

214e, 214, 215, 217 903000 Onwards

Publication No.

S2-eng

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,

Issued by JCB Technical Publications, JCB Service, World Parts Centre, Beamhurst, Uttoxeter, Staffordshire, ST14 5PA, England. Tel [phone] Fax [phone]

electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.

World Class

Customer Support

General Information

1

Care & Safety

2

Routine Maintenance

3

Attachments

A

Body & Framework

B

Electrics

C

Controls

D

Hydraulics

E

Transmission

F

Brakes

G

Steering

H

Engine

K

Service

Manual

3CX, 4CX,

214e, 214, 215, 217

& VARIANTS

Backhoe

Loader

From M/c No. 930000 Onwards

From M/c No. 903000 Onwards (USA)

PUBLISHED BY THE

TECHNICAL PUBLICATIONS DEPARTMENT

OF JCB SERVICE; © WORLD PARTS CENTRE,

WATERLOO PARK, UTTOXETER, ST14 5PA

ENGLAND

Tel. ROCESTER [phone]

PRINTED IN ENGLAND

Publication No. 9803/3280 Issue 9

Servo Controls

(Precision Controls)

L

Introduction

This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training
by JCB Technical Training Department.

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 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 & 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:

A = Attachments
B = 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.

All sections are listed on the front cover; tabbed divider cards align directly with individual sections on the front cover for rapid
reference.

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.

With the exception of slewing operations 'Left Hand' and 'Right Hand' are as viewed from the rear of the machine facing
forwards.

Machine Nomenclature

In this Service Manual, reference is made to machine models, e.g. 3CX, 4CX, these are European machine model names.
North American machine models have different names, the table below shows the European and the equivalent North
American nomenclature.

European North American

3CX = 214
4CX = 214S, 215S, 217S

9803/3280 Issue 1

Colour Coding

The following colour coding, used on illustrations to denote various conditions of oil pressure and flow, is standardised
throughout JCB Service publications.

9803/3280 Issue 1

A390940

Red

Pink

Orange

Blue

Green
Light

Green
Yellow

Full Pressure

Pressure generated from operation of a service. Depending on application this may
be anything between neutral circuit pressure and M.R.V. operating pressure.

Pressure

Pressure that is above neutral circuit pressure but lower than that denoted by red.

Servo

Oil pressure used in controlling a device (servo).

Neutral

Neutral circuit pressure.

Exhaust
Cavitation

Oil subjected to a partial vacuum due to a drop in pressure (cavitation).

Lock Up

Oil trapped within a chamber or line, preventing movement of components (lock up).

i

Section 1 General Information

9803/3280

Section 1

i

Issue 2*

Contents Page No.

Machine Identification Plate 1 - 1

Typical Vehicle Identification Number (VIN) 1 - 1

Typical Engine Identification Number 1 - 1

Serial Plates 1 - 2

Torque Settings 2 - 1

Service Tools Numerical List 3 - 1

Service Tools

- Body & Framework 4 - 1

- Electrics 4 - 4

- Hydraulics 4 - 6

- Transmission 4 - 10

- Engine 4 - 19*

Sealing and Retaining Compounds 5 - 1

Machine Identification Plate

Your machine has an identification plate mounted on the
loader tower. The serial numbers of the machine and its
major units are stamped on the plate.

The serial number of each major unit is also stamped on the
unit itself. If a major unit is replaced by a new one, the serial
number on the identification plate will be wrong. Either
stamp the new number of the unit on the identification plate,
or simply stamp out the old number. This will prevent the
wrong unit number being quoted when replacement parts
are ordered.

The machine and engine serial numbers can help identify
exactly the type of equipment you have.

1 - 1

Typical Vehicle
Identification Number (VIN)

SLP 3CX T S V E 930000

AB

CC DD EE FF GG

A

World Manufacturer Identification

B

Machine Model

C

Steer Type (T= 2WS, F=4WS)

D

Build Type (S=Sideshift, C=Centremount, L=Loader)

E

Year of Manufacture:
2 = 2002

3 = 2003
4 = 2004
5 = 2005
6 = 2006
7 = 2007
8 = 2008

F

Manufacturer Location (E = England)

G

Product Identification Number (PIN)

Typical Engine
Identification Number

AB 50262 U 500405 P

ABCDE

A Engine Type

AB = 4 cylinder turbo

B Build Number

C Country of Origin

D Engine Sequence Number

E Year of Manufacture

Section 1 General Information

9803/3280

Section 1

1 - 1

Issue 1

S218131

U.K. and R.O.W.

North America

A246740

1 - 2

Serial Plates

A Front Axle (2WS machine)
B Front Axle (4WS machine)
C Rear Axle (2WS machine)
D Rear Axle (4WS machine)
E Synchro Shuttle Transmission
F Powershift Transmission
G Engine

Section 1 General Information

9803/3280

Section 1

1 - 2

Issue 1

EE

FF

GG

AA

S257580

A401030

S260120

BB

CC

S259100

S156571

S259110

DD

2 - 1

Torque Settings

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.

UNF Grade 'S' Bolts

Bolt Size Hexagon (A/F) Torque Settings
in (mm) in 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 (19.0) 11/8 407 41.5 300
7/8 (22.2) 15/16 650 66.3 480
1 (25.4) 11/2 970 99.0 715
11/4 (31.7) 17/8 1940 198.0 1430
11/2 (38.1) 21/4 3390 345.0 2500

Metric Grade 8.8 Bolts

Bolt Size Hexagon (A/F) Torque Settings

(mm) 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
M20 (20) 30 476 48 352
M24 (24) 36 822 84 607
M30 (30) 46 1633 166 1205
M36 (36) 55 2854 291 2105

Rivet Nut Bolts/Screws

Bolt Size Torque Settings (for steel rivet nuts)

(mm) Nm kgf m lbf ft

M3 (3) 1.2 0.12 0.9
M4 (4) 3.0 0.3 2.0
M5 (5) 6.0 0.6 4.5
M6 (6) 10.0 1.0 7.5
M8 (8) 24.0 2.5 18.0
M10 (10) 48.0 4.9 35.5
M12 (12) 82.0 8.4 60.5

Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification.

Section 1 General Information

9803/3280

Section 1

2 - 1

Issue 1

3 - 1

460/15708 Flow Test Adapter 4 - 13
460/15707 Banjo Bolt 4 - 13
1406/0011 Bonded Washer 4 - 7
1406/0014 Bonded Washer 4 - 7
1406/0018 Bonded Washer 4 - 7, 13
1406/0021 Bonded Washer 4 - 6, 4 - 7
1406/0029 Bonded Washer 4 - 7
1604/0003 Male Adapter 4 - 7
1604/0004 Male Adapter 4 - 7, 13
1604/0006 Male Adapter 4 - 6, 4 - 7
1604/0008 Adapter 4 - 6
1606/0003 Male Adapter 4 - 7
1606/0004 Male Adapter 4 - 7
1606/0007 Male Adapter 4 - 7
1606/0008 Male Adapter 4 - 7
1606/0009 Male Adapter 4 - 7
1606/0012 Male Adapter 4 - 6, 4 - 7
1606/0014 Male Adapter 4 - 7
1606/0015 Male Adapter 4 - 6, 4 - 7
1606/0017 Male Adapter 4 - 7
1612/0006 Adapter 4 - 6
2401/0222 O-ring 4 - 13
2403/0110 O-ring 4 - 13
2403/0108 O-ring 4 - 13
4101/0651 Retainer (High Strength) 5 - 1
4101/0250 Threadlocker and Sealer (10 ml) 5 - 1
4101/0251 Threadlocker and Sealer (50 ml) 5 - 1
4101/0451 Threadlocker 5 - 1
4102/0502 High Strength Gasketing 5 - 1
4102/0551 High Strength Threadlocker 5 - 1
4102/0933 Clear Silicone Sealant 5 - 1
4102/1212 Multi-Gasket 5 - 1
4102/1951 Threadseal 5 - 1
4102/2309 Black Polyurethane Sealant 5 - 1
4103/2109 Ultra Fast Adhesive (310ml) 5 - 1
4104/0251 Activator (Aersol) 5 - 1
4104/0253 Activator (Bottle) 5 - 1
4104/1203 Active Wipe 205 (250g) 5 - 1
4104/1206 Active Wipe 205 (30 ml) 5 - 1
4104/1310 Hand Cleaner 4 - 1
4104/1538 JCB Cleaner & Degreaser 5 - 1
4104/1557 Cleaner/Degreaser (400 ml) 5 - 1
4201/4906 Black Primer 206J (30ml) 5 - 1
721/10885 Interconnecting cable 4 - 18

(G/box ECU to Data Link Adaptor)
816/00017 Adapter 4 - 8
816/00189 Blanking Cap 4 - 8
816/00190 Blanking Cap 4 - 8
816/00193 Blanking Cap 4 - 8
816/00196 Blanking Cap 4 - 8
816/00197 Blanking Cap 4 - 8
816/00294 Blanking Cap 4 - 8
816/00439 Male Adapter 4 - 7
816/00440 Male Adapter 4 - 7
816/15007 Male Adapter 4 - 7
816/15008 Male Adapter 4 - 7
816/15118 Pressure Test Adapter 4 - 6
816/20008 Adapter 4 - 6
816/20013 Adapter 4 - 6
816/50005 Adapter 4 - 8
816/50043 Adapter 4 - 8
816/55038 Pressure Test 'T' Adapter 4 - 6

816/55040 Pressure Test 'T' Adapter 4 - 6
816/60096 Adapter 4 - 8
823/10420 Shim Kit - Powershift gearbox,

layshaft clutch 4 - 17
825/00410 Crowfoot Wrench 4 - 4
825/99833 Adapter for 825/00410 4 - 4
826/01099 Rivet Nut 4 - 1
826/01101 Rivet Nut 4 - 1
826/01102 Rivet Nut 4 - 1
826/01103 Rivet Nut 4 - 1
826/01104 Rivet Nut 4 - 1
826/01105 Rivet Nut 4 - 1
892/00011 Spool Clamp 4 - 8
892/00041 De-glazing Tool 4 - 21
892/00047 Adapter 4 - 8
892/00048 Adapter 4 - 8
892/00049 Adapter 4 - 8
892/00051 Adapter 4 - 8
892/00055 Blanking Plug 4 - 8
892/00056 Blanking Plug 4 - 8
892/00057 Blanking Plug 4 - 8
892/00058 Blanking Plug 4 - 8
892/00059 Blanking Plug 4 - 8
892/00060 Blanking Plug 4 - 8
892/00071 Male Adapter 4 - 7
892/00074 Female Connector 4 - 8
892/00075 Female Connector 4 - 8
892/00076 Female Connector 4 - 8
892/00077 Female Connector 4 - 8
892/00078 Connector 4 - 6
892/01054 Adaptor for Compression Testing 4 - 21
892/00137 Micro-Bore Hose 1/4in. BSP, 3 Metres 4 - 7
892/00167 Ram Seal Protection Sleeve 90 mm 4 - 9
892/00174 Measuring Cup 4 - 11
892/00179 Bearing Press 4 - 10
892/00180 Seal Fitting Tool 4 - 20
892/00181 Replacement Plastic Boss 4 - 20
892/00182 Bearing Pad Driver 4 - 12
892/00223 Hand Pump 4 - 7
892/00224 Impulse Extractor 4 - 11
892/00225 Adapter for Extractor 4 - 11
892/00252 Test Block for Loader Valve A.R.V 4 - 9

(214e Machines Only)
892/00253 Pressure Test Kit 4 - 6
892/00255 Pressure Test Adapter 4 - 6
892/00256 Pressure Test Adapter 4 - 6
892/00257 Pressure Test Adapter 4 - 6
892/00258 Pressure Test Adapter 4 - 6
892/00259 Pressure Test Adapter 4 - 6
892/00260 Pressure Test Adapter 4 - 6
892/00261 Pressure Test Adapter 4 - 6
892/00262 Pressure Test 'T' Adapter 4 - 6, 4 - 7
892/00263 Pressure Test 'T' Adapter 4 - 6
892/00264 Pressure Test 'T' Adapter 4 - 6
892/00265 Pressure Test 'T' Adapter 4 - 6
892/00268 Flow Monitoring Unit 4 - 6
892/00269 Sensor Head 4 - 6
892/00270 Load Valve 4 - 6
892/00271 Adapter 4 - 6
892/00272 Adapter 4 - 6
892/00273 Sensor Head 4 - 6
892/00274 Adapter 4 - 7

Section 1 General Information

9803/3280

Section 1

3 - 1

Issue 4*

Service Tools Numerical List

Page No. Page No.

*

*

3 - 2

892/00275 Adapter 4 - 6
892/00276 Adapter 4 - 6
892/00277 Adapter 4 - 6
892/00278 Gauge 4 - 7
892/00279 Gauge 4 - 7
892/00282 Shunt 4 - 4
892/00283 Tool Kit Case 4 - 4
892/00284 Tachometer 4 - 4
892/00285 Hydraulic Oil Temperature Probe 4 - 4
892/00286 Surface Temperature Probe 4 - 4
892/00293 Connector Pipe 4 - 6
892/00294 Connector Pipe 4 - 6
892/00298 Fluke Meter 4 - 4
892/00301 Flow Test Adapter 4 - 10
892/00302 Flow Test Adapter 4 - 10
892/00309 ARV Test Kit 4 - 7
892/00333 Heavy Duty Socket 4 - 11
892/00334 Ram Seal Fitting Tool 4 - 9
892/00335 ARV Cartridge Removal Tool 4 - 7
892/00347 Connector - Hose to gauge 4 - 6
892/00706 Test Probe 4 - 6, 4 - 7
892/00812 Drive Coupling Spanner 4 - 10
892/00817 Heavy Duty Socket 4 - 11
892/00818 Heavy Duty Socket 4 - 11
892/00819 Heavy Duty Socket 4 - 11
892/00822 Splined Bolt Socket 4 - 11
892/00836 Lifting Wire Assembly 4 - 21
892/00842 Glass Lifter 4 - 2
892/00843 Folding Stand 4 - 1
892/00844 Long Knife 4 - 3
892/00845 Cartridge Gun 4 - 1
892/00846 Glass Extractor (Handles) 4 - 2
892/00847 Nylon Spatula 4 - 3
892/00848 Wire Starter 4 - 2
892/00849 Braided Cutting Wire 4 - 3
892/00881 Spool Seal Fitting Tool 4 - 7
892/00882 Alternator Pulley Socket 4 - 5
892/00891 Wheel Hub Seal - Fitting Tool 4 - 19
892/00918 Setting Tool Kit 4 - 16
892/00920 Flow Test Adapter 4 - 10
892/00948 Charging Kit 4 - 9
892/00949 Pressure Gauge 4 - 9
892/00956 Timing Pin 4 - 21
892/00964 Test Point (1/8BSP) 4 - 12
892/00965 Test Point (3/8BSP) 4 - 12
892/00966 Test Point (1/4BSP 4 - 12
892/01016 Ram Seal Protection Sleeve 25 mm 4 - 9
892/01017 Ram Seal Protection Sleeve 30 mm 4 - 9
892/01018 Ram Seal Protection Sleeve 40 mm 4 - 9
892/01019 Ram Seal Protection Sleeve 50 mm 4 - 9
892/01020 Ram Seal Protection Sleeve 50 mm 4 - 9

(slew ram)
892/01021 Ram Seal Protection Sleeve 60 mm 4 - 9
892/01022 Ram Seal Protection Sleeve 60 mm 4 - 9

(slew ram)
892/01023 Ram Seal Protection Sleeve 65 mm 4 - 9
892/01024 Ram Seal Protection Sleeve 70 mm 4 - 9
892/01025 Ram Seal Protection Sleeve 75 mm 4 - 9
892/01026 Ram Seal Protection Sleeve 80 mm 4 - 9
892/01027 Piston Seal Assembly Tool 4 - 9
892/01033 Electronic Service Tool Kit 4 - 18

892/01079 Ring Socket Spanner

Mainshaft setting ring 4 - 13

892/01080 Ring Socket Spanner

Layshaft setting ring 4 - 13

892/01077 Synchro Shuttle Gearbox Selector

Shaft Lock Screw 4 - 13

892/01078 Synchro Shuttle Gearbox

Mainshaft Adjuster 4 - 13

892/01076 Synchro Shuttle Support Plate

Transfer gear end float setting 4 - 13
892/01082 Powershift - Assembly Cradle 4 - 17
892/01083 Powershift - Assembly tool,

transfer gear 4 - 17
892/01084 Powershift - Transfer gear, bearing

assembly 4 - 17
892/01085 Powershift - Seal fitting tool 4 - 17
892/01092 Wheel Hub Service Kit 4 - 19
892/01096 Speed Sensor Test Harness 4 - 17
892/01110 Torque Converter Alignment Tool 4 - 18
926/15500 Rubber Spacer Blocks 4 - 3
992/04000 Torque Multiplier 4 - 12
992/04800 Flange Spanner 4 - 12
992/07608 Bearing Adapter 4 - 10
992/07609 Bearing Adapter 4 - 10
992/07610 Bearing Adapter 4 - 10
992/07611 Bearing Adapter 4 - 10
992/07612 Bearing Adapter 4 - 10
992/07613 Bearing Adapter 4 - 10
992/09100 Spool Clamp 4 - 8
992/09200 Charging Tool 4 - 1
992/09300 Ram Spanner 4 - 8
992/09400 Ram Spanner 4 - 8
992/09500 Ram Spanner 4 - 8
992/09600 Ram Spanner 4 - 8
992/09700 Ram Spanner 4 - 8
992/09900 Ram Spanner 4 - 8
992/10000 Ram Spanner 4 - 8
992/12300 12V Mobile Oven 4 - 1
992/12400 Static Oven - 2 Cartridge 4 - 2
992/12600 Static Oven - 6 Cartridge 4 - 2
992/12800 Cut-Out Knife 4 - 2
992/12801 "L" Blades 4 - 2
993/55700 Direct Glazing Kit 5 - 1
993/59500 Impulse Extractor Adapter 4 - 11
993/68100 Slide Hammer Kit 4 - 3
993/69800 Seal Kit 4 - 6
993/70111 Breakback Torque Wrench 4 - 15
993/85700 Battery Tester 4 - 4
998/10650 Powershift Torque Converter

- Pressure Test Kit 4 - 12
998/10738 Powershift Clutch - Adapter Spanner 4 - 13
7210/0001 Dummy Plug 4 - 5
7210/0002 Wire Seal (1.4 - 2.2 mm dia.) 4 - 5
7210/0003 Wire Seal (2.2 - 2.9 mm dia.) 4 - 5
7212/0001 2 Way Socket Connector 4 - 5
7212/0002 2 Way Pin Housing 4 - 5
7212/0003 2 Way Socket Retainer 4 - 5
7212/0004 2 Way Pin Retainer 4 - 5
7213/0001 3 Way Socket Connector 4 - 5
7213/0002 3 Way Pin Housing 4 - 5
7213/0003 3 Way Socket Retainer 4 - 5
7213/0004 3 Way Pin Retainer 4 - 5

Section 1 General Information

9803/3280

Section 1

3 - 2

Issue 6*

Service Tools Numerical List

Page No. Page No.

*
*

3 - 3

The following parts are replacement items for kits and would
normally be included in the kit numbers quoted on pages
1/3-1 and 1/3-2.

Service Tools Numerical List Page No.

Replacement item for kit no. 892/00180
892/00181 4 - 9

Replacement items for kit no. 892/00253
892/00201 Replacement Gauge 4 - 6
892/00202 Replacement Gauge 4 - 6
892/00203 Replacement Gauge 4 - 6
892/00254 Replacement Hose 4 - 6

Replacement items for kit no. 892/00309
892/00340 Test Block Body 4 - 7
892/00341 Setting Body 4 - 7
892/00343 Spanner 4 - 7
892/00345 Anti-Cavitation Lock Out Bung 4 - 7
993/68300 Adjusting Pin 4 - 7

Replacement items for kit no. 993/68100
993/68101 Slide Hammer 4 - 3
993/68102 End Stops 4 - 3
993/68103 Adaptor - M20 x 5/8" UNF 4 - 3
993/68104 Adaptor - M20 x 1" UNF 4 - 3
993/68105 Adaptor - M20 x M20 4 - 3
993/68106 Adaptor - M20 x M24 4 - 3
993/68107 Bar - M20 x M20 X 800MM 4 - 3
993/68108 Adaptor - M20 x 7/8" UNF 4 - 3
993/68109 Adaptor - M20 x M12 4 - 3
993/68110 Adaptor - M20 x 5/8" UNF (Shoulder) 4 - 3
993/68111 Adaptor - M20 x 1/2" UNF 4 - 3

Section 1 General Information

9803/3280

Section 1

3 - 3

Issue 5*

Service Tools Numerical List

Page No.

7213/0005 3 Way Socket Connector (DT) 4 - 5
7213/0006 3 Way Pin Housing (DT) 4 - 5
7213/0007 3 Way Socket Retainer (DT) 4 - 5
7213/0008 3 Way Pin Retainer (DT) 4 - 5
7214/0001 4 Way Socket Connector 4 - 5
7214/0002 4 Way Pin Housing 4 - 5
7214/0003 4 Way Socket Retainer 4 - 5
7214/0004 4 Way Pin Retainer 4 - 5
7216/0001 6 Way Socket Connector 4 - 5
7216/0002 6 Way Pin Housing 4 - 5
7216/0003 6 Way Socket Retainer 4 - 5
7216/0004 6 Way Pin Retainer 4 - 5
7218/0001 8 Way Socket Connector 4 - 5
7218/0002 8 Way Pin Housing 4 - 5
7218/0003 8 Way Socket Retainer 4 - 5
7218/0004 8 Way Pin Retainer 4 - 5
7219/0001 10 Way Socket Connector 4 - 5
7219/0002 10 Way Pin Housing 4 - 5
7219/0003 10 Way Socket Retainer 4 - 5
7219/0004 10 Way Pin Retainer 4 - 5
7219/0005 14 Way Socket Connector 4 - 5
7219/0006 14 Way Pin Housing 4 - 5
7219/0007 14 Way Socket Retainer 4 - 5
7219/0008 14 Way Pin Retainer 4 - 5

*
*

Folding Stand for
Holding Glass -

essential for preparing
new glass prior to
installation.

JCB part number ­892/00843

S186280

12V Mobile Oven - 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).

JCB part number - 992/12300

Hand Cleaner - special blend for the removal of
polyurethane adhesives.

JCB part number - 4104/1310
(454g; 1 lb tub)

S186240

826/01099 M6 x 16mm Rivet Nut
826/01101 M6 x 19mm Rivet Nut
826/01103 M8 x 18mm Rivet Nut
826/01102 M8 x 21mm Rivet Nut
826/01104 M10 x 23mm Rivet Nut
826/01105 M10 x 26mm Rivet Nut

Installation Tool Available from:
Bollhoff Fastenings Ltd.
Midacre
The Willenhall Estate
Rose Hill
Willenhall
West Midlands, WV13 2JW

4 - 1

Section 1 General Information

9803/3280

Section 1

4 - 1

Issue 1

Service Tools (cont'd)

Section B - Body & Framework

Cartridge Gun - hand operated - essential for the

application of sealants, polyurethane materials etc.
JCB part number - 892/00845

S186270

S261210

S186250

'L' Blades - 25 mm (1 in) cut - replacement blades for
cut-out knife (above).

JCB part number - 992/12801 (unit quantity = 5 off)

Glass Lifter - minimum 2 off - essential for glass
installation, 2 required to handle large panes of glass.
Ensure suction cups are protected from damage
during storage.

JCB part number - 892/00842

240V Static Oven - available with 2 or 6 cartridge
capacity - required to pre-heat adhesive prior to use.
No plug supplied. Note: 110V models available upon
request - contact JCB Technical Service.

JCB part number:
992/12400 - 2 Cartridge x 240V
992/12600 - 6 Cartridge x 240V

Wire Starter - used to
access braided cutting wire
(below) through original
polyurethane seal.

JCB part number - 892/00848

Service Tools (cont'd)

Section B - Body & Framework

4 - 2

Section 1 General Information

9803/3280

Section 1

4 - 2

Issue 1

S186300

S186260

Cut-Out Knife - used to
remove broken glass.

JCB part number - 992/12800

Glass Extractor (Handles) - used with braided cutting
wire (below) to cut out broken glass.

JCB part number - 892/00846

S186320

S186350

S186310

S186340

Long Knife - used to give extended reach for normally
inaccessible areas.

JCB part number - 892/00844

Braided Cutting Wire - consumable heavy duty cut-out
wire used with the glass extraction tool (above).

JCB part number - 892/00849
(approx 25 m length)

S186330

4 - 3

Section 1 General Information

9803/3280

Section 1

4 - 3

Issue 1

Service Tools (cont'd)

Section B - Body & Framework

S186360

Slide Hammer Kit - 993/68100

1 :993/68101 Slide Hammer 6 :993/68106 Adaptor - M20 x M24
2 :993/68102 End Stops 7 :993/68107 Bar - M20 x M20 X 800MM
3 :993/68103 Adaptor - M20 x 5/8" UNF 8 :993/68108 Adaptor - M20 x 7/8" UNF
4 :993/68104 Adaptor - M20 x 1" UNF 9 :993/68109 Adaptor - M20 x M12
5 :993/68105 Adaptor - M20 x M20 10 :993/68110 Adaptor - M20 x 5/8" UNF (Shoulder)

11 :993/68111 Adaptor - M20 x 1/2" UNF

Nylon Spatula ­general tool used for
smoothing sealants - also
used to re-install glass in
rubber glazing because metal tools
will chip the glass edge.

JCB part number - 892/00847

S186470

Rubber Spacer Blocks - used to provide the correct
set clearance between glass edge
and cab frame.

JCB part number - 926/15500
(unit quantity = 500 off)

S186550

S196910

1

2

2

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825/00410 15 mm Crowfoot Wrench
825/99833 Adapter

S216200

S216770

892/00882 Socket for Alternator Pulley Nut993/85700 Battery Tester

S239510

AVO Test Kit
1 892/00283 Tool Kit Case

2 892/00298 Fluke Meter 85
3 892/00286 Surface Temperature Probe
4 892/00284 Venture Microtach Digital Tachometer
5 892/00282 100 amp Shunt - open type
6 892/00285 Hydraulic Temperature Probe

S188231

4 - 4

Section 1 General Information

9803/3280

Section 1

4 - 4

Issue 1

Service Tools (cont'd)

Section C - Electrics

4 - 5

Section 1 General Information

9803/3280

Section 1

4 - 5

Issue 1

Service Tools (cont'd)

Section C - Electrics

1 Electrical Repair Kit
2A :7212/0002 2 Way Pin Housing
2B :7212/0004 2 Way Pin Retainer
2C :7212/0003 2 Way Socket Retainer
2D :7212/0001 2 Way Socket Connector
3A :7213/0002 3 Way Pin Housing
3B :7213/0004 3 Way Pin Retainer
3C :7213/0003 3 Way Socket Retainer
3D :7213/0001 3 Way Socket Connector
4A :7213/0006 3 Way Pin Housing (DT)
4B :7213/0008 3 Way Pin Retainer (DT)
4C :7213/0007 3 Way Socket Retainer (DT)
4D :7213/0005 3 Way Socket Connector (DT)
5A :7214/0002 4 Way Pin Housing
5B :7214/0004 4 Way Pin Retainer
5C :7214/0003 4 Way Socket Retainer
5D :7214/0001 4 Way Socket Connector

6A :7216/0002 6 Way Pin Housing
6B :7216/0004 6 Way Pin Retainer
6C :7216/0003 6 Way Socket Retainer
6D :7216/0001 6 Way Socket Connector
7A :7218/0002 8 Way Pin Housing
7B :7218/0004 8 Way Pin Retainer
7C :7218/0003 8 Way Socket Retainer
7D :7218/0001 8 Way Socket Connector
8A :7219/0002 10 Way Pin Housing
8B :7219/0004 10 Way Pin Retainer
8C :7219/0003 10 Way Socket Retainer
8D :7219/0001 10 Way Socket Connector
9A :7219/0006 14 Way Pin Housing
9B :7219/0008 14 Way Pin Retainer
9C :7219/0007 14 Way Socket Retainer
9D :7219/0005 14 Way Socket Connector
10 :7210/0001 Dummy Plug
11 :7210/0002 Wire Seal (1.4 - 2.2 mm dia.)
12 :7210/0003 Wire Seal (2.2 - 2.9 mm dia.)

S188380

11