jcb 2CX User 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
S2-eng
Publication No.
Issued by JCB Technical Publications, JCB Service, World Parts Centre, Beamhurst, Uttoxeter, Staffordshire, ST14 5PA, England. Tel [phone] Fax [phone]
Service Manual
Backhoe Loader
Part Number Machine Model Serial Numbers
9803/7110 2CX, 2DX 657001 to 763230
210, 212 481196 Onwards

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
2CX, 2DX, 210, 212
& VARIANTS
Backhoe
Loader
From M/c No. 657001 TO
763230
&
481196 Onwards
PUBLISHED BY THE
TECHNICAL PUBLICATIONS DEPARTMENT
OF JCB SERVICE; © WORLD PARTS CENTRE,
CHEADLE ROAD, UTTOXETER, ST14 7BS
ENGLAND
Tel. ROCESTER [phone]
PRINTED IN ENGLAND
Publication No. 9803/7110
R
Find manuals at http://best-manuals.com/search?&s=JCB-9803-7110

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. 2CX, 2DX, 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
2CX = 210S
2DX = 213S
9803/7110 Issue 2*
*
Find manuals at http://best-manuals.com/search?&s=JCB-9803-7110

i
Section 1 General Information
9803/7110
Section 1
i
Issue 1
Contents Page No.
Machine Identification Plate 1 - 1
Typical Machine Identification Number 1 - 1
Typical Engine Identification Number 1 - 1
Unit Identification 1 - 2
Torque Settings 2 - 1
Service Tools Numerical List 3 - 1
Service Tools
Electrics 4 - 1
Hydraulics 4 - 2
Transmission 4 - 5
Engine 4 - 7
Sealing and Retaining Compounds 5 - 1
Find manuals at http://best-manuals.com/search?&s=JCB-9803-7110

1 - 1
Machine Identification Plate
Your machine has an identification plate mounted on the
right hand side of the machine just below the driver's cab
door. 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.
Typical Machine
Identification Number
SLP 2DX T S R E 123456
AB
CCDDEEFFGG
AWorld Manufacturer Identification
BMachine Model
CSteer Type (T= 2WS, F=4WS)
DBuild Type (S=Sideshift, C=Centremount, L=Loader)
EYear of Manufacture:
R = 1994 1 = 2001
S = 1995 2 = 2002
T = 1996 3 = 2003
V = 1997 4 = 2004
W = 1998 5 = 2005
X = 1999 6 = 2006
Y = 2000 7 = 2007
FManufacturer Location (E = England)
GMachine Serial Number:
Typical Engine
Identification Number
AB 50262 U 500405 P
ABCDE
AEngine Type
AB = 4 cylinder turbo
BBuild Number
CCountry of Origin
DEngine Sequence Number
EYear of Manufacture
Section 1 General Information
9803/7110
Section 1
1 - 1
Issue 3*
S227230
*
*
Find manuals at http://best-manuals.com/search?&s=JCB-9803-7110

1 - 2
Unit Identification
The engine serial number is stamped on a plate mounted on
the left hand side of the cylinder block (looking towards the
front of the machine).
The rear axle serial number is stamped on a plate mounted
to the front face of the axle, as shown below.
The front axle serial number is stamped on a plate mounted
to the rear face of the axle, as shown below.
Section 1 General Information
9803/7110
Section 1
1 - 2
Issue 1
175510
175520
The Syncro Shuttle serial number is stamped on a label
which is mounted to the rear face of the unit.
Find manuals at http://best-manuals.com/search?&s=JCB-9803-7110

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
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
9803/7110
Section 1
2 - 1
Issue 1
Find manuals at http://best-manuals.com/search?&s=JCB-9803-7110

3 - 1
Page No.
816/00189 Blanking Cap 4 - 6
816/00190 Blanking Ca 4 - 6
816/00193 Blanking Cap 4 - 6
816/00196 Blanking Cap 4 - 6
816/00197 Blanking Cap 4 - 6
816/00294 Blanking Cap 4 - 6
816/15118 Pressure Test Adapter 4 - 4
816/20008 Adapter 4 - 4
816/50043 'T' Adapter 4 - 6
816/55038 Pressure Test 'T' Adapter 4 - 4
816/55040 Pressure Test 'T' Adapter 4 - 4
816/60096 'T' Adapter 4 - 6
892/00041 De-glazing Tool 4 - 9
892/00047 'T' Adapter 4 - 6
892/00048 'T' Adapter 4 - 6
892/00055 Blanking Plug 4 - 6
892/00056 Blanking Plug 4 - 6
892/00057 Blanking Plug 4 - 6
892/00059 Blanking Plug 4 - 6
892/00060 Blanking Plug 4 - 6
892/00074 Female Connector 4 - 6
892/00075 Female Connector 4 - 6
892/00077 Female Connector 4 - 6
892/00137 Hose 4 - 5
892/00153 Test Block for Excavator A.R.V. 4 - 5
892/00167 Ram Seal Protection Sleeve 90mm 4 - 6A
892/00174 Measuring Cup 4 - 8
892/00179 Bearing Press 4 - 7
892/00180 Seal Fitting Tool 4 - 6
892/00223 Hand Pump 4 - 5
892/00224 Extractor 4 - 8
892/00225 Adapter - Impulse Extractor 4 - 7
892/00252 Test Block 4 - 5
892/00253 Pressure Test Kit 4 - 4
892/00255 Pressure Test Adapter 4 - 4
892/00256 Pressure Test Adapter 4 - 4
892/00257 Pressure Test Adapter 4 - 4
892/00258 Pressure Test Adapter 4 - 4
892/00259 Pressure Test Adapter 4 - 4
892/00260 Pressure Test Adapter 4 - 4
892/00261 Pressure Test Adapter 4 - 4
892/00262 Pressure Test 'T' Adapter 4 - 4/4 - 5
892/00263 Pressure Test 'T' Adapter 4 - 4
892/00264 Pressure Test 'T' Adapter 4 - 4
892/00265 Pressure Test 'T' Adapter 4 - 4
892/00268 Flow Monitoring Unit 4 - 4
892/00269 Sensor Head 4 - 4
892/00270 Load Valve 4 - 4
892/00271 Adapter 4 - 4
892/00272 Adapter 4 - 4
892/00274 Adapter 4 - 5
892/00275 Adapter 4 - 4
892/00276 Adapter 4 - 4
892/00277 Adapter 4 - 4
892/00278 Gauge 4 - 5
892/00279 Gauge 4 - 5
892/00282 Shunt 4 - 3
892/00283 Tool Kit Case 4 - 3
892/00284 Tachometer 4 - 3
892/00285 Hydraulic Oil Temperature Probe 4 - 3
892/00286 Surface Temperature Probe 4 - 3
892/00298 Fluke Meter 85 4 - 3
Page No.
892/00301 Flow Test Adapter 4 - 7
892/00302 Flow Test Adapter 4 - 7
892/00304 Flow Test Adapter 4 - 7
892/00334 Ram Seal Fitting Tool 4 - 6
892/00347 Gauge Connector 4 - 4
892/00706 Test Probe 4 - 5
892/00812 Drive Coupling Spanner 4 - 7
892/00822 Splined Bolt Socket 4 - 8
892/00833 Annulus Removal Tool 4 - 8
892/00843 Folding Stand 4 - 1
892/00844 Long Knife 4 - 2
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 - 2
892/00956 Timing Pin 4 - 9
892/01016 Ram Seal Protection Sleeve 25 mm 4 - 6A
892/01017 Ram Seal Protection Sleeve 30 mm 4 - 6A
892/01018 Ram Seal Protection Sleeve 40 mm 4 - 6A
892/01019 Ram Seal Protection Sleeve 50 mm 4 - 6A
892/01020 Ram Seal Protection Sleeve 50 mm 4 - 6A
892/01021 Ram Seal Protection Sleeve 60 mm 4 - 6A
892/01022 Ram Seal Protection Sleeve 60 mm 4 - 6A
892/01023 Ram Seal Protection Sleeve 65 mm 4 - 6A
892/01024 Ram Seal Protection Sleeve 70 mm 4 - 6A
892/01025 Ram Seal Protection Sleeve 75 mm 4 - 6A
892/01026 Ram Seal Protection Sleeve 80 mm 4 - 6A
892/01027 Piston Seal Assembly Tool 4 - 6A
926/15500 Rubber Spacer Blocks 4 - 3
992/00800 Extractor 4 - 8
992/01003 Plug 4 - 5
992/10200 Body for Hamworthy A.R.V. 4 - 5
992/02400 Tee-piece 4 - 5
992/04000 Torque Multiplier 4 - 8
992/07609 Bearing Adapter 4 - 8
992/09300 Spanner 4 - 5
992/09400 Spanner 4 - 5
992/10800 Spanner 4 - 5
992/12300 12v Mobile Oven 4 - 1
992/12400 Static Oven - 2 Cartridge 4 - 1
992/12600 Static Oven - 6 Cartridge 4 - 1
992/12800 Cut-out Knife 4 - 2
992/12801 'L' Blades 4 - 2
993/59400 End Float Setting Tool 4 - 8
993/59500 Bearing Extractor 4 - 7
993/68100 Slide Hammer Kit 4 - 2A
993/85700 Battery Tester 4 - 3
1406/0011 Bonded Washer 4 - 5
1406/0018 Bonded Washer 4 - 5
1406/0021 Bonded Washer 4 - 5
1406/0029 Bonded Washer 4 - 5
1604/0003 Adapter 4 - 5
1604/0004 Adapter 4 - 5
1604/0006 Adapter 4 - 5
1606/0003 Adapter 4 - 5
1606/0004 Adapter 4 - 5
1606/0007 Adapter 4 - 5
1606/0008 Adapter 4 - 5
1606/0009 Adapter 4 - 5
1612/0006 Adapter 4 - 4
2401/0103 ‘O’ Ring 4 - 5
Section 1 General Information
9803/7110
Section 1
3 - 1
Issue 7*
Service Tools Numerical List
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
Find manuals at http://best-manuals.com/search?&s=JCB-9803-7110

3 - 2
4104/1310 Hand Cleaner 4 - 1
The following parts are replacement items for kits and would
normally be included in the kit numbers quoted on page 1/3-
1.
Replacement item for kit no. 892/00180
892/00181 Replacement Plastic Boss 4 - 6
Replacement items for kit no. 892/00253
892/00201 Replacement Gauge 4 - 4
892/00202 Replacement Gauge 4 - 4
892/00203 Replacement Gauge 4 - 4
892/00254 Replacement Hose 4 - 4
Replacement items for kit no. 993/59400
993/59401 Base Plate 4 - 8
993/59402 Setting Yoke 4 - 8
993/59403 Mainshaft Adapter (long) 4 - 8
993/59404 Mainshaft Adapter (short) 4 - 8
993/59405 Ouput Yoke Adapter Plate 4 - 8
993/59406 Setting Yoke Support Pillars 4 - 8
Replacement items for kit no. 993/68100
993/68101 Slide Hammer 4 - 2A
993/68102 End Stops 4 - 2A
993/68103 Adaptor - M20 x 5/8" UNF 4 - 2A
993/68104 Adaptor - M20 x 1" UNF 4 - 2A
993/68105 Adaptor - M20 x M20 4 - 2A
993/68106 Adaptor - M20 x M24 4 - 2A
993/68107 Bar - M20 x M20 X 800MM 4 - 2A
993/68108 Adaptor - M20 x 7/8" UNF 4 - 2A
993/68109 Adaptor - M20 x M12 4 - 2A
993/68110 Adaptor - M20 x 5/8" UNF (Shoulder) 4 - 2A
993/68111 Adaptor - M20 x 1/2" UNF 4 - 2A
Section 1 General Information
9803/7110
Section 1
3 - 2
Issue 2*
Service Tools Numerical List (cont'd)Page No.
*
Find manuals at http://best-manuals.com/search?&s=JCB-9803-7110

Cartridge Gun - hand operated - essential for the
application of sealants, polyurethane materials etc.
JCB part number -
892/00845
Service Tools
Section B - Body & Framework
4 - 1
Section 1 General Information
9803/7110
Section 1
4 - 1
Issue 2
S186250
S186240
S186300
Hand Cleaner - special blend for the removal of
polyurethane adhesives.
JCB part number - 4104/1310
(454g; 1 lb tub)
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
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
Folding Stand for
Holding Glass -
essential for preparing
new glass prior to
installation.
JCB part number -
892/00843
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
S186260
S186280
S186270
Find manuals at http://best-manuals.com/search?&s=JCB-9803-7110

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)
Glass Extractor (Handles) - used with braided cutting
wire (below) to cut out broken glass.
JCB part number - 892/00846
Cut-Out Knife - used to remove
broken glass.
JCB part number - 992/12800
Wire Starter - used to access
braided cutting wire (below)
through original polyurethane
seal.
JCB part number - 892/00848
'L' Blades - 25 mm (1 in) cut - replacement blades for
cut-out knife (above).
JCB part number - 992/12801 (unit quantity = 5 off)
Long Knife - used to give extended reach for normally
inaccessible areas.
JCB part number - 892/00844
4 - 2
Section 1 General Information
9803/7110
Section 1
4 - 2
Issue 2
Service Tools (cont'd)
Section B - Body & Framework
S186320
S186310
S186360
S186330
S186350
S186340

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
S188230
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
Service Tools (cont'd)
Section B - Body & Framework
4 - 3
Section 1 General Information
9803/7110
Section 1
4 - 3
Issue 3*
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
Section C - Electrics
*993/85700 Battery Tester
S188230

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
Pressure Test 'T' Adapters
892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point
816/55038 3/8 in M BSP x 3/8 in F BSP x Test Point
816/55040 1/2 in M BSP x 1/2 in F BSP x Test Point
892/00263 5/8 in M BSP x 5/8 in F BSP x Test Point
892/00264 3/4 in M BSP x 3/4 in F BSP x Test Point
892/00265 1 in M BSP x 1 in F BSP x Test Point
Hydraulic Circuit Pressure Test Kit
892/00253 Pressure Test Kit
892/00201 Replacement Gauge 0-20 bar (0-300 lbf/in2)
892/00202 Replacement Gauge 0-40 bar (0-600 lbf/in2)
892/00203 Replacement Gauge 0-400 bar (0-6000 lbf/in2)
892/00254 Replacement Hose
892/00347 Gauge Connector
4 - 4
Section 1 General Information
9803/7110
Section 1
4 - 4
Issue 2
S188130
S188120
S200140
Service Tools (cont'd)
Section E - Hydraulics
Flow Test Equipment
892/00268 Flow Monitoring Unit
892/00269 Sensor Head 0 - 100 l/min (0 - 22 UK gal/min)
892/00270 Load Valve
1406/0021 Bonded Washer
1604/0006 Adapter 3/4 in M x 3/4 in M BSP
1612/0006 Adapter 3/4 in F x 3/4 in M BSP
892/00271 Adapter 3/4 in F x 5/8 in M BSP
892/00272 Adapter 5/8 in F x 3/4 in M BSP
816/20008 Adapter 3/4 in F x 1/2 in M BSP
892/00275 Adapter 1/2 in F x 3/4 in M BSP
892/00276 Adapter 3/4 in F x 3/8 in M BSP
892/00277 Adapter 3/8 in F x 3/4 in M BSP S188150

Hand Pump Equipment
892/00223 Hand Pump
892/00137 Micro-bore Hose 1/4 in BSP x 5 metres
892/00274 Adapter 1/4 in M BSP x 3/8 in M BSP
Taper
892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point
892/00706 Test Probe
892/00278 Gauge 0 - 40 bar (0 -
600 lbf/in2)892/00279
Gauge 0 - 400 bar (0 -
6000 lbf/in2)
892/00252 Test Block for A.R.V. Tool Components for Hamworthy A.R.V. testing
1992/02400 Tee-piece
21606/0003 Adapter 3/8 in. x 1/4 in. BSP
31406/0011 Bonded Washer
42401/0103 ‘O’ Ring
51406/0018 Bonded Washer
6992/01003 Plug
7992/10200 Body for Hamworthy A.R.V.
8892/00153 Test Block Excavator A.R.V.
4 - 5
Section 1 General Information
9803/7110
Section 1
4 - 5
Issue 4*
S193850
S220840 S230730
S188140
Service Tools (cont'd)
Section E - Hydraulics
Hexagon Spanners for Ram Pistons and End Caps
992/10800 50 mm A/F
992/09300 55 mm A/F
992/09400 65 mm A/F
Male Adapters - BSP x BSP
1606/0003 3/8 in x 1/4 in
1604/0003 3/8 in x 3/8 in
1606/0004 1/2 in x 1/4 in
1606/0007 1/2 in x 3/8 in
1604/0004 1/2 in x 1/2 in
1606/0008 3/4 in x 3/8 in
1606/0009 3/4 in x 1/2 in
1604/0006 3/4 in x 3/4 in
Bonded Washers
1406/0011 1/4 in BSP
1406/0018 1/2 in BSP
1406/0021 3/4 in BSP
1406/0029 1.1/4 in BSP
S193860
S193930
*

'T' Adapters
892/00047 3/8 in BSP (A) x 1/4 in BSP (B)
892/00048 1/2 in BSP (A) x 1/4 in BSP (B)
816/50043 3/4 in BSP (A) x 1/4 in BSP (B)
816/60096 3/4 in BSP (A) x 3/4 in BSP (B)
Male Cone Blanking Cap
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
Female Cone Blanking Plug
892/00055 1/4 in BSP
892/00056 3/8 in BSP
892/00057 1/2 in BSP
892/00059 3/4 in BSP
892/00060 1 in BSP
4 - 6
Section 1 General Information
9803/7110
Section 1
4 - 6
Issue 4*
Service Tools (cont'd)
Section E - Hydraulics
S193870
S191750
S193880
Female Connectors
892/00074 3/8 in BSP x 3/8 in BSP
892/00075 1/2 in BSP x 1/2 in BSP
892/00077 3/4 in BSP x 3/4 in BSP
S193890
S193900
892/00180 Seal Fitting Tool for fitting 'O' ring and kin
ring to Danfoss Orbitrol Unit
892/00181 Replacement Plastic Boss * 892/003334 Ram Seal Fitting Tool
S216250

4 - 6A
Section 1 General Information
9803/7110
Section 1
4 - 6A
Issue 1
Service Tools (cont'd)
Section E - Hydraulics
Ram Seal Protection Sleeves
892/01016 For 25 mm Rod Diameter
892/01017 For 30 mm Rod Diameter
892/01018 For 40 mm Rod Diameter
892/01019 For 50 mm Rod Diameter
892/01020 For 50 mm Rod Diameter (slew ram)
892/01021 For 60 mm Rod Diameter
892/01022 For 60 mm Rod Diameter (slew ram)
892/01023 For 65 mm Rod Diameter
892/01024 For 70 mm Rod Diameter
892/01025 For 75 mm Rod Diameter
892/01026 For 80 mm Rod Diameter
892/00167 For 90 mm Rod Diameter
S338410
892/01027 Piston Seal Assembly Tool
110mm 175mm
R 1.4mm
3o
R3mm
7mm
11o
10mm
20mm
5mm
338500

A 892/00304 Flow Test Adapter
B 892/00301 Flow Test Adapter
C 892/00302 Flow Test Adapter
892/00812 Drive Coupling Spanner for front and rear
axle yoke couplings and for 4WD output
coupling on Syncro Shuttle
4 - 7
Section 1 General Information
9803/7110
Section 1
4 - 7
Issue 2
Service Tools (cont'd)
Section F - Transmission
892/00179 Bearing Press
(use with appropriate adapters)
S188200
S107750
892/00225 Adapter - Impulse Extractor
Small 17mm to 25mm
Medium 25mm to 45mm
Large 45mm to 80mm
993/59500 Adapter - Impulse Extractor
S188210
S197080

4 - 8
Section 1 General Information
9803/7110
Section 1
4 - 8
Issue 1
S204180
S200170
Service Tools (cont'd)
Section F - Transmission
992/04000 Torque Multiplier (use in conjunction with a
torque wrench to give a 5:1 multiplication
when tightening pinion nuts)
993/59400 End Float Setting Tool for gearbox:
:993/59401 Base Plate
:993/59402 Setting Yoke
:993/59403 Mainshaft Adapter (long)
:993/59404 Mainshaft Adapter (short)
:993/59405 Ouput Yoke Adapter Plate
:993/59406 Setting Yoke Support Pillars
992/07609 Adapter - Steer/Drive Axle Pinion Bearing
Cone
892/00833 Annulus Removal Tool
892/00822 Splined Bolt Socket for driveshafts
892/00224 Impulse Extractor Set for Hub Bearing
Seals
992/00800 Extractor for removing front axle pivot pin 892/00174 Measuring Cup - Pinion Head Bearing
S197070
S188160
S197060
S197050
S190770
S197030

4 - 9
Section 1 General Information
9803/7110
Section 1
4 - 9
Issue 2*
Service Tools (cont'd)
Section K - Engine
892/00041 De-glazing Tool for Cylinder Bores (to assist
bedding-in of new piston rings)
Note: For other engine tools refer to the Engine Service
Manual.
S192390
* 892/00956 Timing pin for fuel injection pump
(AK, AM, AR)
A314530
S216250

5 - 1
Sealing and Retaining Compounds
JCB Multi-Gasket A medium strength sealant suitable for all
sizes of gasket flanges, and for hydraulic fittings
of 25-65mm diameter. 4102/1212
JCB High Strength Threadlocker A high strength locking fluid for use with threaded
components. 4102/0551
JCB Retainer (High Strength) For all retaining parts which are unlikely to be
dismantled. 4101/0651
JCB Threadlocker and Sealer A high strength locking fluid for sealing
and retaining nuts, bolts, and screws up to
50mm diameter, and for hydraulic fittings up
to 25mm diameter. 4101/0252
Threadseal A medium strength thread sealing compound. 4102/1951
Threadlocker A locking fluid for use on threads larger than
50mm dia. 4101/0451
Activator A cleaning primer which speeds the curing rate 4104/0251 150ml
of anaerobic products. 4104/0253 1 litre
Cleaner / Degreaser For degreasing components prior to use of
anaerobic adhesives and sealants. 4104/1557 400ml
Direct Glazing Kit For one pane of glass, comprises items
marked † below 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
4104/1203 250 g
† Black Primer 206J For direct glazing 4201/4906 30 ml
Clear Silicone Sealant To seal butt jointed glass 4102/0933
Black Polyurethane Sealant To finish exposed edges of laminated glass 4102/2309 310 ml
JCB Cleaner & Degreaser For degreasing components prior to use of anaerobic
adhesives and sealants. 4104/1538 Aerosol
Section 1 General Information
9803/7110
Section 1
5 - 1
Issue 3*
*
*
*
*
*
*
*