Wheeled Loading Shovel - 412S, 414S, 416S
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Routine Maintenance
Section B - Body and Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section H - Hydraulic Steering
Section K - Engine
9803/4170-14
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
Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400 Service Manual
Publication No.
Section 1 - General Information 1 - 0 1 - 0 9803/4170-10
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Page No. Contents
1 - i 1 - i Introduction About this Publication .............................................................................. 1 - 1 Identifying your Machine Identification Plates ................................................................................. 1 - 2 Torque Settings Zinc Plated Fasteners (golden finish) ...................................................... 1 - 5 JCB Standard Torque Settings B.S.P. Port Connection (Colour Coded) 1 - 6 JCB Standard Torque Settings for Hose Ends and Flanged Fittings (Colour Coded) ............................................................. 1 - 7 Service Tools Numerical List Section B - Body and Framework .................................... 1 - 8 Tool Detail Reference Section B - Body and Framework ........................ 1 - 9 Numerical List Section C - Electrics ...................................................... 1 - 13 Tool Detail Reference Section C - Electrics ........................................... 1 - 14 Numerical List Section E - Hydraulics ................................................... 1 - 15 Tool Detail Reference Section E- Hydraulics ......................................... 1 - 18 Numerical List Section F - Transmission ............................................... 1 - 22 Tool Detail Reference Section F - Transmission .................................... 1 - 23 Numerical List Section K - Engine ......................................................... 1 - 26 Tool Detail Reference Section K - Engine ............................................. 1 - 27 Service Consumables Sealing and Retaining Compounds ....................................................... 1 - 28
Section 1 - General Information
Page No. Contents Section 1 - General Information 1 - ii 1 - ii
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 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:
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.
'Left Hand' and 'Right Hand' are as viewed from the rear of the machine facing forwards.
This Service Manual covers the following machines:
412S Wheeled Loading Shovel from machine serial number 535000
414S Wheeled Loading Shovel from machine serial number 537000
416S Wheeled Loading Shovel from machine serial number 543000
The information provided in this manual for the 414S machine also applies to the 416S machine except where speciified.
Smoothshift Transmission introduced from the following serial numbers:
412S Wheeled Loading Shovel from machine serial number 535500
414S Wheeled Loading Shovel from machine serial number 537300
416S Wheeled Loading Shovel from machine serial number 543100
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.
JCB 444 Series engine added to 412S Wheeled Loading Shovel from machine serial number 1242000.
Section 1 - General Information 1 - 1 1 - 1 9803/4170-10
Attachments B Body & Framework...etc.
A
Identifying your Machine
Identification Plates
Identification Plate
Your machine has an identification plate 1X mounted on the left hand side of the machine on the loader arm pillar. The serial numbers of the machine and its major units are stamped on the plate.
Explanation of Vehicle Identification Number (VIN)
12345
SLP412S0SE0527001
1 World Manufacturer Identification, SLP = JCB
2 Machine Model, 412S0 = 412S
3 Year of Manufacture S, (P = 1993, R = 1994, S = 1995, T = 1996, V = 1997, W = 1998, X = 1999, Y = 2000, 1 = 2001, 2 = 2002, 3 = 2003, 4 = 2004)
4 Manufacturing Location (E = England)
5 Machine Serial Number (0527001)
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.
Unit Identification
The engine serial number is stamped on a plate 2Y or 3Y which is fastened to the right side of the cylinder block, near the fuel filter.
Note: For machines with the JCB 444 Series engine, see Section K, Technical Data.
Section 1 - General Information 1 - 2 1 - 2
9803/4170-10
Fig 1.
Fig 2. 412S Machines
Typical Engine Identification Number
12345
AA50261U500405P
1 Engine Type,
a AA = 4 cylinder naturally aspirated
b AB = 4 cylinder turbo
2 Build Number
3 Country of Origin
4 Engine Sequence Number
5 Year of Manufacture
Section 1 - General Information
Identifying your Machine Identification Plates
Transmission Identification
The Transmission serial number is stamped on plate 4Z or 5Z as shown.
9803/4170-10
1 - 3 1 - 3
Fig 3. 414S Machines
Fig 4. 412S Machines
Identifying your Machine Identification Plates
1 - General Information
Section
1 - 4 1 - 4 9803/4170-10
Fig 5. 414S Machines
Torque Settings
Zinc Plated Fasteners (golden finish)
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
Metric Grade 8.8 Bolts
Bolt
Rivet Nut Bolts/Screws
Section 1 - General Information 1 - 5 1 - 5
9803/4170-10
sizeTorque Settings Dia.(mm)Hexagon Nmkgf mlbf ft (A/F) mm 1/46.37/16141.410 5/167.91/2282.820 3/89.59/16495.036 7/1611.15/8788.058 1/212.73/411712.087 9/1614.313/1617017.3125 5/815.915/1623824.3175 3/4191 1/840741.5300 7/822.21 5/1665066.3480 125.41 1/297099.0715 1 1/431.71 7/81940198.01430 1 1/238.12 1/43390345.02500
Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification. sizeTorque Settings Dia.(mm)Hexagon Nmkgf mlbf ft (A/F) mm M5(5)870.75 M6(6)10121.29 M8(8)13283.021 M10(10)17565.742 M12(12)19981072 M16(16)2424425180 M18(18)2735036258 M20(20)3047648352 M24(24)3682284607 M30(30)4616331661205 M36(36)5528542912105 Bolt sizeTorque Settings (for steel rivet nuts) Dia.(mm)Nmkgf mlbf ft M3(3)1.20.120.9 M4(4)3.00.32.0 M5(5)6.00.64.5 M6(6)10.01.07.5 M8(8)24.02.518.0 M10(10)48.04.935.5 M12(12)82.08.460.5
Section 1 - General Information
Torque Settings
JCB Standard Torque Settings B.S.P. Port Connection (Colour Coded)
JCB Standard Torque Settings B.S.P. Port Connection (Colour Coded)
Note: All adapters, elbows and hoses should be tightened to JCB standard torque settings unless stated otherwise.
9803/4170-10
1 - 6 1 - 6
Fig 1.
Section 1 - General Information
Torque Settings
JCB Standard Torque Settings for Hose Ends and Flanged Fittings (Colour Coded)
JCB Standard Torque Settings for Hose Ends and Flanged Fittings
(Colour Coded)
Note: All adapters, elbows and hoses should be tightened to JCB standard torque settings unless stated otherwise.
9803/4170-10
1 - 7 1 - 7
Fig 2.
Service Tools
Numerical List Section B - Body and Framework
The tools listed in the table are special tools required for removal and replacement of Body and Framework parts. These tools are available from JCB Service.
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.
Section 1 - General Information 1 - 8 1 - 8
9803/4170-10
Part Number DescriptionTool Detail Reference 825/99849Dummy Boss K Fig 12. ( T 1-11) 825/99850Bearing Locator K Fig 12. ( T 1-11) 826/01179M6 x 16mm Rivet Nut K Fig 1. ( T 1-9) 826/01106M6 x 19mm Rivet Nut K Fig 1. ( T 1-9) 826/01177M8 x 18mm Rivet Nut K Fig 1. ( T 1-9) 826/01176M10 x 23mm Rivet Nut K Fig 1. ( T 1-9) 826/01333M10 x 26mm Rivet Nut K Fig 1. ( T 1-9) 892/00842Glass Lifter K Fig 3. ( T 1-9) 892/00843Glass Stand K Fig 2. ( T 1-9) 892/00844Long Knife K Fig 11. ( T 1-11) 892/00846Glass Extractor (Handles) K Fig 8. ( T 1-10) 892/00847Nylon Spatula K Fig 4. ( T 1-9) 892/00848Wire Starter K Fig 6. ( T 1-10) 892/00849Braided Cutting Wire K Fig 10. ( T 1-11) 926/15500Rubber Spacer Blocks K Fig 5. ( T 1-10) 992/12800Cut-Out Knife K Fig 7. ( T 1-10) 992/12801'L' Blades K Fig 9. ( T 1-11)
Tool Detail Reference Section B - Body and Framework
Tool Detail Reference Section B - Body and Framework
Note: essential for preparing new glass prior to installation.
Note: 826/01179 M6 x 16mm Rivet Nut, 826/01106 M6 x 19mm Rivet Nut, 826/01177 M8 x 18mm Rivet Nut, 826/01176 M10 x 23mm Rivet Nut, 826/01333 M10 x 26mm Rivet Nut
Installation Tool Available from:
Bollhoff Fastenings Ltd.
Midacre
The Willenhall Estate
Rose Hill
Willenhall
West Midlands, WV13 2JW
Note: - minimum 2 off - essential for glass installation, 2 required to handle large panes of glass. Ensure suction cups are protected from damage during storage.
Note: - general tool used for smoothing sealants - also used to re-install glass in rubber glazing because metal tools will chip the glass edge.
Section 1 - General Information Service Tools
1 - 9 1 - 9 9803/4170-10
Fig 1.
Fig 2. 892/00843
Fig 3. 892/00842
Fig 4. 892/00847
Note: - used to provide the correct set clearance between glass edge and cab frame. (unit quantity = 500 off)
Note: - used to remove broken glass.
Note: - used to access braided cutting wire (below) through original polyurethane seal.
Note: - used with braided cutting wire (below) to cut out broken glass.
1 - General Information Service Tools
Section B - Body and
1 - 10 1 - 10 9803/4170-10
Section
Tool Detail Reference
Framework
Fig 5. 926/15500
Fig 6. 892/00848
Fig 7. 992/12800
Fig 8. 892/00846
Note: - 25 mm (1 in) cut - replacement blades for cut-out knife (above), (unit quantity = 5 off)
Tool Detail Reference Section B - Body and Framework
Note: - consumable heavy duty cut-out wire used with the glass extraction tool (above), (approx 25 m length)
Note: - used with bearing locator to set up Upper Centre Pivot.
Note: - used to give extended reach for normally inaccessible areas.
Note: - used with dummy bush to set up Upper Centre Pivot.
Section 1 - General Information Service Tools
1 - 11 1 - 11 9803/4170-10
Fig 9. 992/12801
Fig 10. 892/00849
Fig 11. 892/00844
Fig 12. 825/99849
Fig 13. 825/99850
Note: - used to support cab in the raised position. A minimum of 2 are required to support the side where work is being carried out. It is recommended that 4 are used to support the cab level.
Manufacture from mild steel.
Tube wall and plate minimum thickness must be 3 mm.
1 - General Information Service Tools Tool Detail Reference Section B - Body and Framework 1 - 12 1 - 12 9803/4170-10
Section
Fig 14. Cab Prop
Numerical List Section C - Electrics
The tools listed in the table are special tools required for testing electrics. These tools are available from JCB Service .
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.
Numerical List Section C - Electrics 1 - 13 1 - 13 9803/4170-10
Section 1 - General Information Service Tools
Part Number Description Tool Detail Reference 892/00282Shunt K Fig 15. ( T 1-14) 892/00283Tool Kit Case K Fig 15. ( T 1-14) 892/00284Digital Tachometer K Fig 15. ( T 1-14) 892/00285Hyd. Oil Temperature Probe K Fig 15. ( T 1-14) 892/00286Surface Temperature Probe K Fig 15. ( T 1-14) 892/00298Fluke Meter K Fig 15. ( T 1-14) 993/85700Battery Tester K Fig 16. ( T 1-14)
Section 1 - General Information Service Tools
Tool Detail Reference Section C - Electrics
Tool Detail Reference Section C - Electrics
1892/00283 Tool Kit Case
2892/00298 Fluke Meter
3892/00286 Surface Temperature Probe
4892/00284 Venture Microtach Digital Tachometer
5892/00282 100 amp Shunt - open type
6892/00285 Hydraulic Temperature Probe
9803/4170-10
1 - 14 1 - 14
Fig 15.
Fig 16. 993/85700
Numerical List Section E - Hydraulics
Numerical List Section E - Hydraulics
The tools listed in the table are special tools required for testing, removing and replacing hydraulics. These tools are available from JCB Service .
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.
Section 1 - General Information Service Tools
1 - 15 1 - 15 9803/4170-10
Part Number Description Tool Detail Reference 1406/0011Bonded Washer K Fig 19. ( T 1-18) 1406/0014Bonded Washer K Fig 19. ( T 1-18) 1406/0018Bonded Washer K Fig 19. ( T 1-18) 1406/0021Bonded Washer K Fig 19. ( T 1-18) 1406/0029Bonded Washer K Fig 19. ( T 1-18) 1604/0006Adapter K Fig 20. ( T 1-18) 1612/0006Adapter K Fig 20. ( T 1-18) 816/00189Blanking Cap K Fig 22. ( T 1-19) 816/00190Blanking Cap K Fig 22. ( T 1-19) 816/00193Blanking Cap K Fig 22. ( T 1-19) 816/00196Blanking Cap K Fig 22. ( T 1-19) 816/00197Blanking Cap K Fig 22. ( T 1-19) 816/00294Blanking Cap K Fig 22. ( T 1-19) 816/15118Pressure Test Adapter K Fig 23. ( T 1-19) 816/20008Adapter K Fig 20. ( T 1-18) 816/55038Pressure Test Adapter K Fig 18. ( T 1-18) 816/55040Pressure Test Adapter K Fig 18. ( T 1-18) 892/00039Spool Clamp K Fig 26. ( T 1-20) 892/00055Blanking Plug K Fig 21. ( T 1-19) 892/00056Blanking Plug K Fig 21. ( T 1-19) 892/00057Blanking Plug K Fig 21. ( T 1-19) 892/00058Blanking Plug K Fig 21. ( T 1-19) 892/00059Blanking Plug K Fig 21. ( T 1-19) 892/00060Blanking Plug K Fig 21. ( T 1-19) 892/00074Female Connector K Fig 24. ( T 1-19) 892/00075Female Connector K Fig 24. ( T 1-19) 892/00076Female Connector K Fig 24. ( T 1-19) 892/00077Female Connector K Fig 24. ( T 1-19) 892/00137Micro-Bore Hose K Fig 27. ( T 1-20) 892/00223Hand Pump K Fig 27. ( T 1-20) 892/00239Charging Tool K Fig 28. ( T 1-20)
Section 1 - General Information Service Tools
Numerical List Section E - Hydraulics
1 - 16 1 - 16 9803/4170-10 892/00253Pressure Test Kit K Fig 17. ( T 1-18) 892/00255Pressure Test Adaptor K Fig 23. ( T 1-19) 892/00256Pressure Test Adaptor K Fig 23. ( T 1-19) 892/00257Pressure Test Adaptor K Fig 23. ( T 1-19) 892/00258Pressure Test Adaptor K Fig 23. ( T 1-19) 892/00259Pressure Test Adaptor K Fig 23. ( T 1-19) 892/00260Pressure Test Adaptor K Fig 23. ( T 1-19) 892/00261Pressure Test Adaptor K Fig 23. ( T 1-19) 892/00262Pressure Test Adaptor K Fig 27. ( T 1-20) 892/00263Pressure Test Adaptor K Fig 18. ( T 1-18) 892/00264Pressure Test Adaptor K Fig 18. ( T 1-18) 892/00265Pressure Test Adaptor K Fig 18. ( T 1-18) 892/00268Flow Monitoring Unit K Fig 20. ( T 1-18) 892/00269Sensor Head K Fig 20. ( T 1-18) 892/00270 Load Valve K Fig 20. ( T 1-18) 892/00274Adapter K Fig 27. ( T 1-20) 892/00275Adapter K Fig 20. ( T 1-18) 892/00279Gauge K Fig 27. ( T 1-20) 892/00309 A.R.V. Pressure Test Kit K Fig 29. ( T 1-21) 892/00335 A.R.V. Cartridge Removal Tool K Fig 29. ( T 1-21) 892/00340Test Block Body K Fig 29. ( T 1-21) 892/00341Setting Body K Fig 29. ( T 1-21) 892/00343Spanner K Fig 29. ( T 1-21) 892/00345Anti-cavitation Lock Out Bung K Fig 29. ( T 1-21) 892/00706Test Probe K Fig 27. ( T 1-20) 892/00948Charging Tool K Fig 28. ( T 1-20) 892/01042 Charging Tool K Fig 28. ( T 1-20) 892/01043 Adapter K Fig 28. ( T 1-20) 992/09300Spanner K Fig 25. ( T 1-20) 992/09400Spanner K Fig 25. ( T 1-20) 992/09500Spanner K Fig 25. ( T 1-20) 992/09600Spanner K Fig 25. ( T 1-20) 992/09700Spanner K Fig 25. ( T 1-20) 992/10000Spanner K Fig 25. ( T 1-20) 992/10100Spool Clamp K Fig 26. ( T 1-20) 993/68300Adjusting Pin K Fig 29. ( T 1-21) Part Number Description Tool Detail Reference
The following parts are replacement items for kits and would normally be included in the kit numbers above.
Numerical List Section E - Hydraulics
Replacement items for kit no. 892/00253
Section 1 - General Information Service Tools
1 - 17 1 - 17
9803/4170-10
Part Number Description Tool Detail Reference 892/00201Replacement Gauge K Fig 17. ( T 1-18) 892/00202Replacement Gauge K Fig 17. ( T 1-18) 892/00203Replacement Gauge K Fig 17. ( T 1-18) 892/00254Replacement Hose K Fig 17. ( T 1-18)
Tool Detail Reference Section E- Hydraulics
892/00253 Pressure Test Kit
1406/0011 1/4 in BSP
1406/0018 1/2 in BSP
1406/0014 5/8 in BSP
gauge 0-20 bar (0-300 lbf/in2) 892/00202
892/00201
gauge 0-40 bar (0-600 lbf/in2) 892/00203
gauge 0-400 bar (0-6000 lbf/ in2) 892/00254
1406/0021 3/4 in BSP
1406/0029 1.1/4 in BSP
892/00268 Flow Monitoring Unit
892/00269 Sensor Head 0 to 100 l/min (0 to 22 UK gal/min)
892/00270 Load Valve
1406/0021Bonded Washer
Tool Detail Reference Section E- Hydraulics 1 - 18 1 - 18 9803/4170-10
Section 1 - General Information Service Tools
Fig 17. Hydraulic Circuit Pressure test Kit
Replacement
Replacement
Replacement
Replacement
Hose
BSP
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 BSP x 5/8 in F BSP x Test Point 892/00264 3/4 in BSP x 3/4 in F BSP x Test Point 892/00265 1 in M BSP x 1 in F BSP x Test Point
Fig 18. Pressure Test `T' Adapters
892/00262 1/4 in
x 1/4 in F BSP x
Fig 19. Bonded Washers
Fig 20. Flow Test Equipment
Section 1 - General Information Service Tools
1604/0006 Adapter 3/4 in M x 3/4 M BSP
1612/0006 Adapter 3/4 in F x 3/4 M BSP
816/20008 Adapter 3/4 in F x 1/2 M BSP
892/00275 Adapter 1/2 in F x 3/4 M BSP
Pressure
892/00255 1/4 in BSP x Test Point
3/8 in BSP x Test Point
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
1/4 in BSP
892/00260 1.1/4 in BSP x Test Point 892/00261 5/8 in UNF x Test Point
816/00294 1/4 in BSP
816/00189 3/8 in BSP 816/00190 1/2 in BSP 816/00197 5/8 in BSP
892/00074 3/8 in BSP x 3/8 in BSP 892/00075 1/2 in BSP x 1/2 in BSP 892/00076 5/8 in BSP x 5/8 in BSP 892/00077 3/4 in BSP x 3/4 in BSP
Detail Reference Section E- Hydraulics 1 - 19 1 - 19 9803/4170-10
Tool
892/00056
892/00057
892/00058
892/00059
892/00060
Fig 21. Female Cone Blanking Cap
892/00055
3/8 in BSP
1/2 in BSP
5/8 in BSP
3/4 in BSP
1 in BSP
Fig 22. Male Cone Blanking Cap
816/00193
816/00196 3/4 in BSP
1 in BSP
Fig 23.
Test Adapters
892/00256
892/00257 1/2
Fig 24. Female Connectors
992/09300 55 mm
992/09400 65 mm
992/09500 75 mm
992/09600 85 mm 992/09700 95 mm 992/10000 125 mm
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
892/00279 Gauge 0 - 400 bar (0 - 6000 lbf/in2)
892/00039 Spool Clamp
992/10100 Spool Clamp
892/00239 Charging Tool (Diaphragm Accumulators)
892/01042 Charging Tool (Diaphragm Accumulators)
892/01043 Adatper (use with 892/01042)
892/00948 Charging Tool (Piston Accumulators)
1 - 20 1 - 20 9803/4170-10
Section 1 - General Information Service Tools Tool Detail Reference Section E- Hydraulics
Fig 25. Hexagon Spanners for Ram Pistons and End Caps
Fig 26. Spool Clamps
Fig 27. Hand Pump Equipment
Fig 28. Accumulator Charge Equipment
892/00309 A.R.V. Pressure Test Kit
1 892/00340 Test Block Body
2 892/00341 Setting Body
3 993/68300 Adjusting Pin
4 892/00343 Spanner
5 892/00345 Anti-cavitation Lock Out Bung
6 892/00335 A.R.V. Cartridge Removal Tool
Tool Detail Reference Section E- Hydraulics 1 - 21 1 - 21 9803/4170-10
Section 1 - General Information Service Tools
Fig 29. Components for Valve Block A.R.V. Testing
Numerical List Section F - Transmission
The tools listed in the table are special tools required for removal and replacement of Body and Framework parts. These tools are available from JCB Service.
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.
Numerical List Section F - Transmission 1 - 22 1 - 22 9803/4170-10
Section 1 - General Information Service Tools
Part Number Description Tool Detail Reference 892/00817Heavy Duty Socket K Fig 31. ( T 1-23) 892/00818Heavy Duty Socket K Fig 31. ( T 1-23) 892/00819Heavy Duty Socket K Fig 31. ( T 1-23) 892/00859Spanner Stake Nut K Fig 34. ( T 1-24) 892/00860Bearing Shim Remover K Fig 37. ( T 1-24) 892/00861Bearing Remover Base Tool K Fig 37. ( T 1-24) 892/00862Tab Washer Fitting Tool K Fig 34. ( T 1-24) 892/00863Blanking Plate Fitting Tool K Fig 38. ( T 1-24) 892/00864PD90 Locknut Spanner K Fig 36. ( T 1-24) 892/00865Computer Test Harness K Fig 33. ( T 1-23) 892/00866Computer Test Indicator Box K Fig 33. ( T 1-23) 892/00867Computer Test Interrogator Box K Fig 33. ( T 1-23) 892/00891Fitting Tool Assembly K Fig 39. ( T 1-24) 892/00909Hub Puller K Fig 36. ( T 1-24) 892/01066 Interrogation lead K Fig 40. ( T 1-25) 992/04000Torque Multiplier K Fig 32. ( T 1-23) 992/07603Replacer - Bearing Cup K Fig 30. ( T 1-23)
892/00817 17 mm A/F x 3/4 in. Square Drive
892/00818 22 mm A/F x 3/4 in. Square Drive
892/00819 15 mm A/F x 1/2 in. Square Drive
Note: Use in conjunction with a torque wrench to give a 5:1 multiplication when tightening pinion nuts etc.
892/00865 Computer test harness
892/00866 Computer test indicator box
892/00867 Computer test interrogator box
Section 1 - General Information Service Tools Tool Detail Reference Section F - Transmission 1 - 23 1 - 23 9803/4170-10
Tool Detail Reference Section F - Transmission
Fig 30. 992/07603
Fig 31. Heavy Duty Socket for Durlock Bolts
Fig 32. 992/04000
Fig 33.
General Information Service Tools Tool Detail Reference Section F - Transmission 1 - 24 1 - 24 9803/4170-10
Section 1 -
Fig 34. 892/00859
Fig 35. 892/00862
Fig 36. 892/00864
Fig 37.
1 892/00860 Bearing Remover Shim
2 892/00861 Bearing Remover Base Tool
Fig 38. 892/00863
Fig 39. 892/00891
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Section 1 - General Information Service Tools Tool Detail Reference Section F - Transmission 1 - 25 1 - 25 9803/4170-10
Fig 40. 892/01066
Fig 41. 892/01066
