Home

Perkins General TI Bulletin - Cape Dory Sailboat Owners Association

1. Page 3 of 3 4 Remove and discard the three piece O ring N from the element Warning Do not allow compressed air to contact your skin If compressed air enters your skin obtain medical help immediately 5 Clean the element and check for cracks If a solution is used to clean the outside of the element ensure that this does not enter the element Check that there is nothing to restrict the flow of lubricating oil through the element of the oil cooler If the inside of the element needs to be cleaned use a solvent which is suitable for copper Dry the element with low pressure air and then flush it with clean engine lubricating oil To Assemble 1 Clean the seats of the three piece O ring and renew the O rings N Clean the flange face P for the three piece O rings on the inside of the cover Fit the cover of the oil cooler to the element M GN025 Issue 1 Fit the two piece flanges A onto the studs H Tighten the nuts to retain the element when the oil cooler assembly is fitted to the engine Fit the oil cooler to the cylinder block see page 2 of this bulletin Intemational TECHNICAL i INFORMATION General SAFETY NOTICE instructions in the Service Bulletins assume that the engineer has a sound knowledge of safety procedures and has been trained in the maintenance and repair of
2. SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn008 engineer has a sound knowledge of safety procedures and has been trained in the JCB 2 109 C26 N Am maintenance and repair of ITL equipment If you are unsure or do not understand Issue 1 information contained in the Service Bulletins then ask your supervisor for advice Remember SAFETY MUST COME FIRST Date Nov 1993 SUBJECT Alternator Connectors on the Mainframe Harness Page 1 of 1 PRODUCTS AFFECTED Perkins Engines as applicable TO BE CARRIED OUT Information Only SERVICE INFORMATION Two types of alternator connectors have been supplied The alternator euro plug connector item X FIG 1 is no longer supplied Instead a ring terminal and lucar connector item Y FIG 2 are now supplied Align the harness connectors and the corresponding alternator connections using the wire numbers If the harness has a euro plug connector item X fitted install the harness as shown in FIG 1 If the W Terminal 412 ai harness has a ring terminal and lucar connector item Y fitted install the FIG 1 harness as shown in FIG 2 IND Terminal OSs Cc 412 O W Terminal 412 B Terminal 200A 200 S198850 FIG 2 THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL S
3. T I No Gn 001 Gn 002 Gn 003 Gn 004 Gn 005 PPP PP Gn 006 Gn 007 Gn 008 Gn 009 Gn 010 Gn 011 Gn 012 Gn 013 Gn 014 Gn 015 Gn 016 Gn 017 Gn 018 Gn 019 Gn 020 Gn 021 Gn 022 Gn 023 Gn 024 Gn 025 Gn 026 Gn 027 Gn 028 Gn 029 Gn 030 Gn 031 Gn 032 Gn 033 Gn 034 Gn 035 Gn 036 Gn 037 Gn 038 Gn 039 PP PRP PRP PRP PPP PHP PPP PPP PENNP PPP PPP PPP PY DATE DEC 02 TECHNICAL INFORMATION CONTENTS GENERAL T I BULLETIN INDEX Click on bulletin title to view Issue Subject Tappet Adjustment Rocker Shaft Security Crankshaft Rear Main Oil Seal amp Housing Turbocharger Fault Diagnosis Health amp Safety Recommendations Fluoroelastomeric Materials Turbochargers Piston amp Piston Ring Improvements Alternator Connections on Mainframe Harness Low Sulphur Fuels Brake Master Cylinder Kits Hydraulic Ram Identification Oil Pump Idler Gear Stake Nuts Input and Output Flanges Fuel Injection Pump Seal Failure Engine Lubrication System Relief Valve Housing Parkbrake Clevis Pin Improvements Starter Motors Magneti Marelli Service Warranty Support Products Affected Perkins 1000 Series Engines Perkins 1000 Series Engines Perkins 1000 Series Engines Perkins 1000 Series Engines All Turbocharged Perkins 90 BHP 4 cyl Turbocharged Engines Perkins Engines as applicable Perkins 1000 Series Engines As Detailed on Bulletin Perkins 1000 Series Engines All ITL Transmiss
4. 5 Check that the parkbrake fully engages do a parkbrake test refer to Operator Handbook If necessary adjust the parkbrake as required 6 Refit the parkbrake lever gaiter PARTS INFORMATION Item No Part No Description Q Comments A 826 01596 Shouldered Bolt 1 Parkbrake cable to parkbrake lever B 826 01597 Shouldered Bolt 1 Parkbrake cable to caliper E 1420 0007Z 8 mm Flat Washer 2 F 1420 0006Z 6 mm Flat Washer 2 G 1370 0103Z 6mmNut 2 THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I T L WREXHAM CLWYD LL13 9UF UNITED KINGDOM International TECHNICAL Gano INFORMATION pasha SAFETY NOTICE instructions in the Service Bulletins assume that the Number Gn017 engineer has a sound knowledge of safety procedures and has been trained in the JCB Gen 045 maintenance and repair of ITL equipment If you are unsure or do not understand Issue 1 information contained in the Service Bulletins then ask your supervisor for advice Remember SAFETY MUST COME FIRST Date March 1996 SUBJECT Starter Motors Page 1 of 1 PRODUCTS AFFECTED All Perkins engines SERVICE INFORMATION A new specification of starter motor having a larger and stronger inertia clutch has been introduced in two forms for either left hand or right hand mounting The engine serial cut
5. PARTS INFORMATION Part No Description Qty Comments 826 01482 Combine Stake Nut Washer A R M22 826 01483 Combine Stake Nut Washer A R M24 826 01551 Stake Nut A R 46 mm Gearbox THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I T L WREXHAM CLWYD LL13 9UF UNITED KINGDOM Intemational TECHNICAL in INFORMATION General SAFETY NOTICE instructions in the Service Bulletins assume that the Number Gn014 engineer has a sound knowledge of safety procedures and has been trained in the JCB Gen 041 K68 N Am maintenance and repair of ITL equipment If you are unsure or do not understand information contained in the Service Bulletins then ask your supervisor for advice Remember SAFETY MUST COME FIRST Issue 1 Date August 1995 SUBJECT Fuel Injection Pump Seal Failure Page 1 of 2 PRODUCTS AFFECTED Perkins 1000 Series Engines TO BE CARRIED OUT By Perkins Dealers SERVICE INFORMATION The possibility exists that the shaft seal of the fuel injection pump has been damaged during the assembly process The seal must be replaced with a new one otherwise serious damage to the engine could occur Replacement of the seal is a specialised task and must only be done by the C A V engineer therefore please note the following 1 The OEM Distributor must contact
6. 338500 International TECHNICAL Mz INFORMATION General DAT HIGHWAY DEPAB_ INE SYSTEME SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn032 engineer has a sound knowledge of safety procedures and has been trained in the JCB Gen 110 K110 N Am maintenance and repair of ITL equipment If you are unsure or do not understand Issue 1 information contained in the Service Bulletins then ask your supervisor for advice Remember SAFETY MUST COME FIRST Date Jan 2001 SUBJECT Oil Control Rings Page 1 of 1 PRODUCTS AFFECTED 1000 series engine models AR amp AS only TO BE CARRIED OUT For Information Only SERVICE INFORMATION A small taper has been added to the face of the oil control ring to reduce oil consumption during the early life of the engine The ring is marked TOP on the top face and a blue mark has been added to the left of the ring gap The oil control ring is a component of a ring kit see part numbers listed below The ring kit could be supplied with either the earlier or the later oil control ring SERVICE PROCEDURE When fitting the oil control ring check if there is a blue mark at X If there is a blue mark at X the ring must be fitted with the mark to the left of the ring gap The word TOP will then be towards the top of the piston If there is no blue mark the ring can be fitted either way up Ring Kit Part Numbers Standard 02 201804 0 5
7. 9Sg 8LE9 mare 09 61 209 196 pZ99 es 6 r6S aie 8 GZEE EOY L 68 E998 9Sp EGE eee 9 GO8E 6021 9 Loze Lez zg8 08 p gg oz t gp gg 69 1S s8 29 ELVES L 001899 2219 6 LOZ LLF8S L 8EELLS 6 ies BE9ZL09E Z 0 S8 SS E BE S 1280 Lee 2 Z 8986 969 Z 68S 22S 6 660 IZS v 9S2 122 EZ S 9860ZZ Z 6rt l 9ZZE ZE 0Zt 188z 088 ESZ 262 ae 08 2898 299 Ep vl0z 29 r 19 GO9E SYE LYS 0811648 E12 1J quinN xe4 90S 122 296 OLEO LZE 80S 100 Z919 99S 1840 OOL ZLE LZLO L9ZZZ8 t 126 6 6 62 912 0621 ESZ 09 tZL8Z LL LLLe 282 v S094 602 LE 9 S6 S69 L S0S919Sr v Z6LL 89 IZ Z 9EZX EE6z 662 S pSv6289 Z 99 LEG9 9Ez S60 Z 2281 G6L LS L6EE G29 zz 8 ZeLL 68 Z Lati 22SGp S G80 696 ie oogEeoeze z 2 9 Z0L6 l Wis L 8082 99S r brveorr 02 0628 L6E S Z ooz6ez a 8LEE BrZE 0 Srl EGE 196 p89Z ELS S96 6G BLEE x 8Z8 E0r L 0S98 9S ce 8tZ29SZ 9 Z YOSE 6021 9 0SSS v LEZ ZS ELOEEZG L 0 99 2Z19 6 te 002 LIVES L LLZ6L8 6 e LvBLBPSE Z 0 L0 SS 8E G S6E6 LEZ Z Z EELZ 969 295 vly SZS 6 2800 LZS r Z6E Z9 Ez S LOL8rre2 96 Lv 9p v6 ve 22 S9 6 2 8p 9 gs Ly v9 zS 09 8 6 9 98 8 0g p ge 02 p zp S 9 8 9 66 vk ss EZ Bove ZEZE zg 612 988Z 088
8. SUBJECT Stake Nuts Input and Output Flanges Page 1 of 1 PRODUCTS AFFECTED AIIITL Transmissions and Axles TO BE CARRIED OUT Information Only SERVICE INFORMATION 1 AXLES Axle stake nuts A are now a combined nut and washer instead of the separate nut and washer arrangement If this type of nut is used on an earlier type axle or 4WD flange the old separate washer must be discarded 2 TRANSMISSIONS The stake nut for the gearbox rear 2WD output flange is now manufactured from 46 mm hexagonal bar The existing 13 4 inch socket can not be used on the 46 mm nuts Make sure both types of socket are available in the event of site repair Note The transmission rear 2WD output flange is still retained by the separate nut and washer arrangement the washer should be replaced Re with a new one if damaged or distorted Y Input amp Output Flanges L N The axle flanges and transmission output flanges are now hardened at the sealing area The hardened flanges prevent possible oil leaks and loss of bearing pre load by reducing the risk of fretting and subsequent loosening of the flanges S224080 Note The illustration shows a typical axle arrangement In the event of a flange becoming loose or wearing a new hardened type flange and new seal should be fitted Apply a small bead of Loctite 936 around the shaft spline Full details for removing and replacing output flanges are given in the relevant Workshop Manual
9. g6r 62 a 0 2898 Z99 Ep vlL0z Z9Et 19 LG z Sve LYS O 1 L622 ELZ 1 quinN uoud 1 NAWAA 1S3 WV TVS TV ZYLO WW GHOONOO SNN3AV HAAY 0SH NS 9GN X GGIW GYOANASYD SYLNAO NVLIIOdOYU LAW GvO A9430 9 FYE ALM NOGNOT HIVAAV SOW 1d Gat IVAN GNOHYVD TV H31N30 VIGSHM NIG 10014 3S SINNL Z001 3SV13 AWS V 9078 MV1 d ant 0002 3IXV1vS GNV1IVH1 0ZE0L MOMDNVE CY IHNAHOLId MAN I 6ZZ1 SNOSWNVC 90 XOd Od TIMSNAGVM 0288 HO 9 3SSVH1S YAHOVSOON NAGaMS VONN10U4 VH1SVA LE Lzy V1V SNOSt3l13d O d V3MNV1 IHS 8 OBNO1OO2 GVOt TISMOIL ZL VNOT13Ot gt iV8 20080 IWud Se VANNIVLV9 VINVH 0022 NMOL AdVO Att3GSO 19 8298 XOH Od QL PEEELVLSA TWIHLSNGNI NISV8 ONVT1V 0 L0 z0 3nN3AV SNVTIV3 SZ t97 iz HYadar S62 XO Od 6L1 MOOSOW dS9 LAIdSOYd AASNINII 99N3 dO ALISHSAINN TWNOILVNYALNI NO SI1 OOF a v 0 THD OLSNONY YNY YMYZSYYM 056 00 rl 1ZOOd YAS Z VISAW IN Sq18 ONVL SNOSvVd 0 2 9078 V 9 9 SV18 NYS AY ISY9 SEL SOT3NONT3NOHOOTVNOL3Vd IYS VNVITVA NVWO dO 3LYNYLTINS ELL LYOSNN 688 XO Od 31V1S SODVT YIA AYM OMOTOMY INAYO OFF NOLONITIAM LAH Y3MO7 020rr XO8 Od 133YLS GHOIYSHLNY HH dYOdd400H YN ZEL tS NJJLSANYZ Vd 3AYYL OIAV 092 10 dO 34 YLNYS Zy ONILN3HO1T4 WSVd tL LTA YNNYIHOT4 LOWVS L43904 VZZVId 3NO31 VSVO 0S20S YVdINT YIYNYJ HOOT AYE VZV 1d INN 38 Lt9 L XOG Od HAAVNV
10. s 0N0 9 peoy u gA8S SOM SPISJOAIY SAOWOINY J8 S89N0 5 vy6rrss cryzlO NT8LS1S Jays99no 5 weyuay yo 19 41S IIIN 48M07 S HUN SANOWOINY J8 S8ON0 5 686Z08 ZS 10 sgz 119 1 1s ono JOS uu uleO IS EG eAOWOINY 181s 59no o 667E9S r6S10 Yrr Sro 1 s 0N0 9 pu q pusyJed peoy MeN 10 9e JOJO es UED LLOS78 v6SlL0 daar S19 Ja seono 5 up q 1201S uBiH g L 6 S10 9 84 JOJO IPEllu9O ya1s3 9no15 Z9GLOS 89Zl0 GASILILSS x ssg D4OJN IAA Ae SueounH nop uedo yL s10 oe olnv ss dx4 X JON l6Z7Z 80Z10 XIZ LW x ss3 pioJuuoli peoy HOA 6L L olny d9 xassa tH38INDN 3009 3NOHd3131 1SOd ALNNOO NMOL ssaydav 3INVN Gn018 Page 4 of 5 LLEEZS E8plL0 YX9 zn5 uns piojpiino peoy uops IldioAA 68 L seseds yond puiojpiino O E S A YS9Z Z ZSZLO X82 6N9 Aans weyue JOOS 1sed g L pn FHV L90PG9 SzrlL0 Mad Zend Kung aJaws eH peoy umopfany HUN pn E S A G8S8zr esrl0 Dae ZNO Aans Bulwyepjos aue7 AeH o THY veve2l E8vl0 ATL LEND uns Buryom peoy YWOMpOy 83 pul YYOMSPIOD llu o a y V goosez 8r10 NX9 zn5 uns Puoypyins peoy uops ldio A S8Z o a H V A3duns 9GSrrZ Z8Z10 JNE VLS SHES 1lu 11 uo 40 S uo u 4 19941S UOSEN I8s iq s u llod Q9SISZE E7S10 M Z8SM SIS sliyumog peoy uapu yed ssouisng silluunolg 10 OB 4 JOJOY S MPIN 990rES E87T10 ON vlad SEIS quad L uo uoung 89 1S MO GuUIUOH py sjusuodwog seg 129 LLLOQ Z2Z8L0 Ovi 22g SEIS ypomwe L peoy yoosqa mey pl sjusuodwog seg 129 S43Vl1S LESI YY EZ940 J1ySYIOA YI
11. lt VY AWA QD TILIA Z UN 5 UN SERIES RAM 100 mm x 60 mm lt Z gt LIZLLLLLLLILILL RSS Gland Bearing Dowelled Piston Head Loctite Piston 80 87 Wire Clip Piston 87 90 Dowel Piston 90 92 METRIC CR SERIES RAM 100 mm x 60 mm 1992 to 1993 Gland Nut amp Bearing One Piece may also be fitted with Glazier Bearing Dowelled Piston Head Wig ILL LLLA N A S C C LLL ZZZ7 Case End Welded to Tube Glazier Bearing except 70 x 40 rams METRIC FABRICATED RAM 100 mm x 60 mm Current 1994 Gland Nut amp Bearing One Piece THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I T L WREXHAM CLWYD LL13 9UF UNITED KINGDOM r we ational TECHNICAL INFORMATION DRUTEN HIGHWAY DEPAB INE SYSTEME General SAFETY NOTICE Instructions in the Service Bulletins assume that the engineer has a sound knowledge of safety procedures and has been trained in the maintenance and repair of ITL equipment If you are unsure or do not understand information contained in the Service Bulletins then ask your supervisor for advice Remember SAFETY MUST COME FIRST SUBJECT Oil Pump I
12. 1998 SUBJECT Change of position for the exhaust manifold alignment bushes Page 1 of 1 PRODUCTS AFFECTED New Perkins 1000 Series Engines Models AJ to AS and YG to YK TO BE CARRIED OUT For information SERVICE INFORMATION The information published in section 12 of the New Perkins 1000 Series Workshop manual 9806 2140 has changed New alignment bushes must be fitted in accordance with this Service Bulletin Note Always use the engine identification number to order new parts alignment bushes are not fitted to all engines The exhaust manifolds fitted to some four and six cylinder engines have large clearance holes for the setscrews It is important that these manifolds are correctly fitted to the cylinder head Caution Damage to the exhaust manifold can occur if it is not aligned and tightened correctly SERVICE PROCEDURE If the manifold is renewed it is important that the two alignment bushes 1 JCB part number 02 201783 are in position New alignment bushes are not necessary when the original manifold is removed and fitted Tighten the exhaust manifold setscrews evenly and gradually to 44 Nm 33 Ibf ft 4 5 kgf m in the sequence shown Use the same sequence and torque tighten the setscrews again The front of the engine is shown by the arrow 2 Refer to Perkins or a Perkins dealer for Perkins part numbers or further information THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCU
13. 261 Ibf ft depending on air filter and exhaust silencer specification 420 380 360 340 320 102 hp Perkins new low emission engine Max torque 411 Nm 303 Ibf ft 1400 rev min 300 2 106 hp engine 2 Max torque 354 Nm 261 Ibf ft 1800 rev min 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 Engine Speed rev min Page 3 of 3 Gn030 Issue 1 1 Engine Specifications Nat Asp Build Turbo Build Horsepower 80hp 102hp Injection pump type DP203 DP203 Governing Mechanical Mechanical Pump setting code 2644G521 YG 1 2350 2644C705 BG 1 2350 Static timing Pre set Pre set Idle speed 800 rpm 800 rpm Max rated speed 2200 rpm 2200 rpm Max no load speed 2350 rpm 2350 rpm Injector codes KW KN Injector setting pressure 294 atm 294 atm Note Either 65A or 85A alternators may be fitted refer to ITL Technical Sales 2 Regulations The new engines meet EEC Stage 1 emission regulations Smoke emission is dramatically reduced and now meets ECE R24 03 3 Servicing Routine engine service intervals remain unchanged at initial 100 hour and 500 hour periods Valve clearance must be checked every 1000 hours There is no change to the engine oil or fuel filter part numbers Only use oil meeting or exceeding CF4 SG specification for the low emission engine The fuel injector pump is significantly more sophisticated and because the emissions are reduced by increasing the accuracy of the timing alterations t
14. 94 Jun 94 J uly 94 Feb 95 Aug 95 Feb 96 Feb 96 Mar 96 Feb 99 Dec 98 April 98 April 98 Nov 90 Oct 98 Jan 99 Jan 99 Feb 99 Feb 99 Feb 99 Mar 99 Apr 99 Nov 99 Jan 01 Jan 01 Feb 01 Apr 01 Apr 01 May 01 Jan 02 Sep 02 ISSUE 8 Intemational TECHNICAL in INFORMATION General SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gno01 engineer has a sound knowledge of safety procedures and has been trained in the JCB Gen 003 maintenance and repair of ITL equipment If you are unsure or do not understand Issue 1 information contained in the Service Bulletins then ask your supervisor for advice Remember SAFETY MUST COME FIRST Date March 1990 SUBJECT Tappet Adjustment Page 1 of 1 PRODUCTS AFFECTED All Perkins 1000 series Engines TO BE CARRIED OUT At Next Service As Required SERVICE PROCEDURE When tappet adjustment is required it is important to re torque the adjusting screw lock nut A If this is not correctly actioned the adjusting screw will become loose which could cause damage to the tappet assembly and push rod Lock Nut Torque 20 lbs ft THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I T L WREXHAM CLWYD LL13 9UF UNITED KINGDOM International TECHNICAL anes IN
15. Feb 1999 SUBJECT Magneti Marelli Service Warranty Support Page 1 of 5 PRODUCTS AFFECTED All Fitted with Magneti Marelli Alternators and or Starter Motors From 1st January 1996 Service Warranty Support for Magnetti Marelli electrical equipment fitted on Perkins Engines will be provided by Magnetti Marelli Distributors The addresses of the Magneti Marelli European main headquarters are listed below The remaining pages identify distributors in your country so for instance the translated JCB French version of this bulletin will only list the French distributor network the German the German network and so on If there is no local Magneti Marelli agent the starter alternator can either be repaired by a local electrical agent and the repair invoice submitted with a Warranty claim to a Perkins Dealer or if required a new unit can be supplied by a Perkins Dealer MAGNETI MARELLI SERVICE HEADQUARTERS U K Magneti Marelli Aftermarket GERMANY Magneti Marelli KV Shaftsmoor Lane Wannenackerstrasse 71 Hall Green 74078 Heilbronn Birmingham Germany B28 8SW Tel 00 49 71312910 Tel 0121 6258788 Fax 00 49 7131176928 Fax 0121 6258625 SPAIN Magneti Marelli Iberica ITALY Magneti Marelli Avda de Roma 80 82 Viale Aldo Borletti 61 63 08015 Barcelona 20011 Corbetta Spain Milano Italia Tel 00 34 322631 76 Fax 00 34 32262109 Tel 00 39 0297200602 Fax 00 39 0297200500 FRANCE Magneti Marelli France 19 Rue Lavoisier Note
16. General SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn003 engineer has a sound knowledge of safety procedures and has been trained in the JCB Gen 010 maintenance and repair of ITL equipment If you are unsure or do not understand Issue 1 information contained in the Service Bulletins then ask your supervisor for advice Remember SAFETY MUST COME FIRST Date March 1991 SUBJECT Crankshaft Rear Main Oil Seal and Housing Page 1 of 3 PRODUCTS AFFECTED All Perkins 1000 Series Engines TO BE CARRIED OUT Information Only A number of reports by Perkins have been received concerning crankshaft rear main oil seal leaks Little or no detail is completed in the comments section of the warranty claim form Information given in the comments section will enable Perkins to identify the exact fault and take the correct remedial action The following instructions will enable you to locate and rectify the exact fault this fault should then be stated in the comments section of all warranty claims failure to do so will invalidate the warranty claim REAR OIL SEAL HOUSING If oil is leaking past the rear seal oil will normally be found inside the flywheel housing with some evidence of leakage from the low inspection plate To rectify 1 Remove the transmission 2 Remove the flywheel using guide studs remove two diametrically opposite bolts and temporarily fit guide studs 3 Remove seal housi
17. IaNYS vISsnd WONLYOd aNv10d SANIddITMHd AVNOVEVd NYNO AVMYON Vld3SIN NV 1V3Z MAN SONVTYSHLAN OOIXAWN VLIVW VISAV IVI NONV831 LIVMNY NYdYf ATV1I GNV Tati VISSNOGNI AYVONNH SNO SNOH 303399 ANVWd39S AONVYs QNVINIS 1dA9A MYVWNAG day HO3ZO 31IHO NVv3aggluvo VAVNVO vidoaNvo INNY WNn19138 HS3QVIONVE NIVYHVa VIdLSNV VOVYLsSnv VNILNADYV VIHAD1V Ayyunog dNOYS YYNHY TV ONI NOISd AYLNAO SDIAYSS MN NOISd d AN NOISd O11 09 SS VHdTV VIQ3NSSVI LOLILSNI Nassaf 9 Nasaar O9 ONIGVEL TIVWHY NOPV O OV WOOXa4 gY OINOu 133 TAIN LSNGNI VUSNAAS SWALSAS DNA AMV ISONIA Vsadvd 99 SHOLNEIYLSIG LANOISd HOALSAS SI 18V1S3 ONIGVYLL IGNIS NV TYN vISSNd lSd Yaq dNOO A13943N4 IMALYWHOJNI WNYLNI9 SIO O3NWOduO8 N3Addd S3TdVHO OTI O9 SNIdVu1 9 SOINOYLOATA IHO WOON Sig3aq SNOILN1IOS 13340Od A8 QNV 1d3G3N NOISd 1al sag H NAS ASOTONHO31 AWSHO1W TH V S TALNdNOO aVLSA H3TVS 1Y VSS3 HYMNY NYdYf NOISd YALNdNOO OACIA AAAUNS SIS ILNI MALIH OGNITALWOX Ld 14 SVZSHdOHVASVIN NOISd G11 IWNOILVNYSLNI O 1d4NO OINOYLOATA LNI H8N9 NOISd 3ONVtd NOISd 8V OIGHON OTONV AO 3qvdlOtdd SMW VLVd ION O S X LNIOd VS VIEVNIG NN NV388ldVO9 GNVTIOH OIGVY ONI TWNOILWNYSLNI NVOSAS SII O9 3Ad3SNOO dd NOILNGIYLSIG NOILOANNOOOXOIN a11 SANVYVHS THOM YALNdNOO AIWAHdIdAd YALNdWOO QHVAAAVH Ald HOSLISd HVISd TY V S TWNOILVNYALNI MSV YOLNEIYLSIG NOISd Inte
18. If difficulty is experienced in finding support or 92000 Nanterre overseas warranty cover contact Perkins U K on France Tel UK 44 0 1733 567474 Tel 00 33 147297000 Fax 0 1733 582240 Fax 00 33 147297274 Note For JCB Language versions only the front page is issue raised When filing replace the front sheet only THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I T L WREXHAM CLWYD LL13 9UF UNITED KINGDOM Gn018 Page 2 of 5 LE6BVS C6ELO uoA 1J9 9x3 s4 Bupe L u 9 15 ySIe N PeOY uaa yssen SBDIAIBS 99 0 nV NOA3G GSS9rE 6ZS10 Vdrrlid FEMUOD pueeysi peoy uonels wed Sng N L s ijddns ony IIN FSZ818 80ZL0 emuo abpuqepen ayeysy pul py euojsAppy salddns ony III 99182 80210 IIPWu10O uluipog peoy equoosiueg pied ules PIO Z 8 shun saliddngs ony IIN vLZ812 60Z10 WISIYL EMULOD ylmipey IIH SEMEN SNOH LUUAL s ddns ony IIN r88 S 9c8 0 IIEWUu10O uAiuad peoy ElOJBWWOD snoH UleCWUSd sal ddns olny IIN ZZZL9S 9ZE L0 IIEWU10O Uuo sl H 19811S UOIPU M LS 6r saiddns ony IIN LOE09 9EZ10 NAT ELYL IIEWUu10O Suezu q 1901S JUNON SOM YoINYD saddns ony IIN 90 2 9ZL10 AJS SZld emu100 II 1snv 1S IIH ISOM Zt 89IJJO PL H s lilddnS Ony IIN TIVMNYOO LpZ6Z9 2p9L0 Hd 8ISL pu A9 O S L uo UO0 490 S peoy BueioS yod p11 Ise YON I s lpo15 l3 GNV1
19. If the nut is removed and the hub moves the hub will need to be accurately fitted to the pump by use of specialist equipment before the pump can be fitted to the engine Always refer to the relevant workshop manual publication no 9806 2140 for the correct procedure before you start to work on the engine To remove the fuel injection pump from the engine it is only necessary to remove the four setscrews D which secure the fuel pump gear to the hub It is important to follow the instructions in the workshop manual to ensure the engine timing is correct THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I T L WREXHAM CLWYD LL13 9UF UNITED KINGDOM a E TRANSMI SS10N5 LTO DAT HIGHWAY DEPAB INE SY STEMS International TECHNICAL Ld INFORMATION General SAFETY NOTICE Instructions in the Service Bulletins assume that the engineer has a sound knowledge of safety procedures and has been trained in the maintenance and repair of ITL equipment If you are unsure or do not understand information contained in the Service Bulletins then ask your supervisor for advice Remember SAFETY MUST COME FIRST All Perkins 1000 Series Engines Models YA to YK Introduction of an improved Oil Cooler with a Pressed Steel Cover An improved oil cooler
20. TECHNICAL Po INFORMATION General OMT HINA DEPABL IE S STE Rag A SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn036 engineer has a sound knowledge of safety procedures and has been trained in the J CB Gen 120 K120N Am maintenance and repair of ITL equipment If you are unsure or do not understand information contained in the Service Bulletins then ask your supervisor for advice Issue 1 Remember SAFETY MUST COME FIRST Date April 2001 SUBJECT Engine Oil Consumption Page 1 of 2 PRODUCTS AFFECTED Perkins Low Emission Engines AJ to AS and YG to YK TO BE CARRIED OUT For Information Only SERVICE INFORMATION Engine oil consumption can only be correctly measured as a percentage against fuel used under controlled conditions If after consideration of the observations below the oil consumption appears to exceed the expected amount carry out the Service Procedure as detailed Oil consumption does not normally exceed 4 5 litres 1 0 UK gal 1 19 US gal per 100 hours average machine use No test should be carried out on new engines prior to the bedding in period minimum of 100 hours Engines should not be idled for long periods and should be worked hard from new for example engine speed should be above 1500 rev min Extended periods of idle and or high speed roading will dramatically increase the hourly consumption rates Dust ingress via leaks in the air intake syst
21. THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I T L WREXHAM CLWYD LL13 9UF UNITED KINGDOM International TECHNICAL TRANSMISSIONS LTD i INFORMATION General SAFETY NOTICE instructions in the Service Bulletins assume that the Number Gn034 engineer has a sound knowledge of safety procedures and has been trained in the J CB Gen 114 K109 N Am maintenance and repair of ITL equipment If you are unsure or do not understand i information contained in the Service Bulletins then ask your supervisor for advice Issue 1 Remember SAFETY MUST COME FIRST Date Feb 2001 SUBJECT Introduction of Improved Fuel Lift Pump Page 1 of 2 PRODUCTS AFFECTED All Perkins Four Cylinder 1000 Series Engines TO BE CARRIED OUT Information only SERVICE INFORMATION An improved fuel lift pump has been introduced for use on Perkins four cylinder 1000 Series diesel engines The new pump is a one piece assembly and cannot be dismantled The new pump is interchangeable with the earlier pump The procedure to remove and fit the new pump has not changed Remove and clean fuel inlet strainer 2 if this procedure is recommended in the relevant machine handbook or service manual Cleaning the Strainer 1 Allow the engine to cool Remove the fuel filler cap to vent the system and reduc
22. as shown at C then the housing is made to the wrong specification and must be replaced with a new one move to step 7 Important note Relief valves obtained from service parts stock with a number 2 are manufactured to the correct specification 7 8 10 Remove the relief valve housing retaining bolt D and then remove the relief valve housing A Fit a new replacement relief valve housing torque tighten the retaining bolt to 22 Nm 16 Ibf ft Make sure that the O ring at each end of tube E are in good condition and securely in place before tightening the retaining bolt Refit the engine sump together with a new gasket Tighten the sump retaining bolts to 22 Nm 16 lbf ft Fit the sump drain plug together with a new O ring torque tighten the plug to 34 Nm 25 Ibf ft Refit the dipstick and dipstick tube Using the engine oil drained at step 3 refill the engine sump make sure that the engine oil reaches the MAX mark on the dipstick top up as required PARTS REQUIRED Part No Description 02 200102 Relief Valve Assy 02 200106 Relief Valve Assy 02 102069 Engine Sump Gasket 02 200875 Engine Sump Gasket 02 200198 Drain Plug O ring Comment Turbo Engine Naturally Aspirated Engine Cast lron Sump Alloy Sump available only in units of 50 part number 02 200198A k oo 9 lt Intemational TECHNICAL i INFORMATION General SAFETY NOTICE Instructions in the Service
23. contacted first in order that ITL can give the OEM or your customer an introduction and help ensure that the Service Centers are fully aware of any special instructions or needs you may have In any event of warranty being requested of a Service Center we ask that ITL authorize any work to be carried out TECHNICAL INFORMATION A SAFETY NOTICE Instructions in the Service Bulletins assume that the engineer has a sound knowledge of safety procedures and has been trained in the maintenance and repair of ITL equipment If you are unsure or do not understand information contained in the Service Bulletins then ask your supervisor for advice Remember SAFETY MUST COME FIRST SUBJ ECT Safety precautions when an engine is cleaned PRODUCTS AFFECTED All Engines TO BE CARRIED OUT Information only SERVICE INFORMATION Number Gn039 J CB Gen 151 Issue 1 Date Sep 2002 Page 1of1 Care should be taken when an engine is cleaned with the use of a high pressure hose Cautions components on the engine could be damaged Do not wash any part of the Fuel Injection Pump cleaned by high pressure hose hot Do not wash an engine while it is running or it is hot If cold cleaning fluids are applied to a hot engine certain Leave the engine to cool for at least one hour and disconnect battery connections before cleaning Ensure that the altemator starter motor and any other electrical components ar
24. mm oversize 02 201791 1 0 mm oversize 02 201793 THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I T L WREXHAM CLWYD LL13 9UF UNITED KINGDOM Intemational TECHNICAL i INFORMATION General SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn033 engineer has a sound knowledge of safety procedures and has been trained in the JCB Gen 112 K112 N Am maintenance and repair of ITL equipment If you are unsure or do not understand Issue 1 information contained in the Service Bulletins then ask your supervisor for advice Remember SAFETY MUST COME FIRST Date Jan 2001 SUBJECT Plastic Thermostat Housings Page 1 of 1 PRODUCTS AFFECTED All 1000 series engines TO BE CARRIED OUT For Information Only SERVICE INFORMATION Plastic thermostat housings fitted to some engines will be damaged if temperature senders or blanking plugs are overtightened SERVICE PROCEDURE When fitting the items listed ensure that the following torque settings are used Item Nm kgfm Ibfft A Sender aluminium 16 12 12 A Sender brass 24 2 4 18 1 2 inch Plug metal or plastic 4 0 4 3 3 4 inch Plug metal or plastic 4 0 4 3 Note The illustration shows a typical installation which may differ from some engines
25. showing at the breather tube is a normal function caused by vapourised oil in the crank case escaping to atmosphere However for green countries where strict limitations on oil emission are enforced an improved rocker cover is now available from ITL The new cover has an integral oil separator which greatly reduces the amount of oil showing at the breather tube SERVICE PROCEDURE refer to fig on page 2 1 Park the machine on firm level ground engage the parking brake and set the transmission to neutral Lower any attachments to the ground and stop the engine 2 Gain access to the engine compartment if necessary remove any ancillary equipment such as the exhaust stack pre cleaner air filter etc 3 Remove and discard the breather pipe item A remove the rocker cover cap nuts item B together with the steel washers item C and sealing washers item E 4 Remove the old rocker cover item F together with joint item H IMPORTANT NOTE When the rocker cover is fitted the cap nuts are tightened onto the nuts of the rocker brackets During removal of the cap nuts it is possible to loosen the nuts of the rocker brackets The nuts of the rocker brackets should be tightened to the correct torque every time the cover is removed 5 Fit the new rocker cover with its new joint Torque tighten cap nuts to 20 Nm 15 Ibf ft 6 Fit new breather pipe item A to the breather assembly item J using new hose clip item K PARTS REQUIRED It
26. the local C A V agent and quote reference number D137 2 The OEM Dealer and the C A V agent then arrange with the machine owner a suitable time to complete the repair procedures repair time 3 0 hours 3 On arrival at the machine the OEM engineer will remove the injection pump see SERVICE PROCEDURES once the pump has been removed it is given to the C A V agent who will then replace the shaft seal 4 The injection pump complete with new seal must then be refitted to the machine by the OEM engineer SERVICE PROCEDURES Fuel Injection Pump Removal Special Tools Required Gear Puller part number PD155C Note Existing workshop special tools these items Adaptors part number PD155B 5 F are not reclaimable on this FSI Spanner part number PD199 1 Park the machine on firm level ground engage the parking brake and set the transmission to neutral 2 Raise the loader arms or the boom if necessary to access engine and fit safety strut 3 Switch off the the engine and remove the starter key Disconnect the battery continued THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I T L WREXHAM CLWYD LL13 9UF UNITED KINGDOM Page 2 of 2 Gn014 Issue 1 SERVICE PROCEDURES continued 4 Remove the injection pump 4 1 Remove all the pipes cables and electrical connections f
27. timing case together with a new joint 4 Fit all the pipes cables and electrical connections Reconnect the battery 5 Eliminate air from the fuel system Operate the engine and check for leakage With the engine at the normal temperature of operation check that the idle speed is correct SERVICE PARTS Part No Description Qty Comments 02 200976 Gasket 1 Injection Pump to Timing Case 02 200029 Gasket 1 Injection Pump Gear Cover 7 TECHNICAL SUSE INFORMATION General SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn015 engineer has a sound knowledge of safety procedures and has been trained in the JCB Gen 038 F66 N Am maintenance and repair of ITL equipment If you are unsure or do not understand Issue 1 information contained in the Service Bulletins then ask your supervisor for advice Remember SAFETY MUST COME FIRST Date Feb 1996 SUBJECT Engine Lubrication System Relief Valve Housing Page 1 of 2 PRODUCTS AFFECTED All Fitted with Perkins 1000 Series Engines TO BE CARRIED OUT By Perkins Dealers SERVICE INFORMATION The possibility exists that engine relief valve housing A may fail The relief valve controls the engine lubricating system oil pressure therefore a failure of the housing could result in the loss of engine oil pressure and cause subsequent damage to the engine Investigation has shown that the relief valve housing has been machined incorrectly and r
28. to carry out repairs from the end user subject to OEM approval Principal Service Centers Leaman Equipment Co 16550 Railroad Ave L Morgan Hill CA 95037 Tel 408 7789677 Fax 408 778 9646 CIA Machinery INC 3199 West Danieldale St Lancaster TX 75134 Tel 972 224 5501 or 800 527 6406 Fax 972 224 8204 continued THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I T L WREXHAM CLWYD LL13 9UF UNITED KINGDOM Page 2 of 2 Gn 038 Issue 1 Great Lakes Power Products 2006 Tobsal Court Warren MI 48091 Tel 810 759 5500 Fax 810 759 0879 ITL Service Centers Centers throughout USA and Canada In the event of repair work needed contact ITL Service Department Keith Bridges in UK Tel 01144 1978 666513 1 Approved for ITL Warranty work 2 Provide Support for OEM vehicle repairs 3 Competent to carry out repairs for the end user subject to ITL and OEM approval OEM s capable of carrying out repairs through their own dealership should continue to operate as normal They may find the ITL Principal Service Centers particularly useful in those cases where expert internal repairs are required OEM s with or without their own dealer back up can take full advantage of the ITL Service Centers However before initially approaching a Service Center we ask that our Service Department be
29. u u l uodn llSEeSA N Aemsso wed ynog S PUN pr bed maspuy YV4AM ANY ANAL 86clEc cE610 NS Ll3 uns weysI H peoy WEysSI H EGL LGL S10 0 4 JOJO UOYEM I aH O00Z9Z ZEZLO INZ LHH Aans IIUp q 1s3 pul dioul uiloH nu Av diuoul uloH BZ PY 3 d V OZ80ZS cE610 O69ILM Aans su uo peoy pioljpiino plsuAod PUN PY d3 d V SS6Z Lr6 L81L0 NHO 813 Aans s oNW sey peoy UO eM z8z po aH A3duns ud38g8IWnN 3GO9 3NOHd31T31 1SOd ALNNOS NMOL ssayuqqv SINVN International TECHNICAL Gano INFORMATION pasha SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn019 engineer has a sound knowledge of safety procedures and has been trained in the JCB M I 525 HA maintenance and repair of ITL equipment If you are unsure or do not understand Issue 2 information contained in the Service Bulletins then ask your supervisor for advice Remember SAFETY MUST COME FIRST Date Dec 1998 SERVICE DEPARTMENT COMPUTER DIAGNOSTIC EQUIPMENT Page 1 of 3 Electronic Control Units ECU have been introduced to control the functions of Transmissions Service Marketing is becoming increasingly important in generating distributor revenue Introduction of ECU and EMS units incorporating Service Indicators represents a major opportunity for distributors to ensure they obtain all routine service work To support transmissions fitted with these systems Distributor Service Personnel need to h
30. with a pressed steel cover has been introduced with effect from engine serial number YB U647452C To Remove 1 Drain the cooling system refer to the relevant service manual Number Gn025 JCB Gen 090 K95 N Am Issue 1 Date January 1999 Page 1 of 3 Warning The engine oil may be hot Allow the engine to cool down before the oil pipes are released Caution Do not remove both of the oil pipes together 2 Put a drip tray under the cooler and remove the lubricating oil pipes from the oil cooler Do not remove both of the oil pipes together Remove one of the pipes then fit the flanges A and nuts B onto the studs again before the other pipe is removed This will ensure that the element is fastened to the cover when the assembly is removed THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I T L WREXHAM CLWYD LL13 9UF UNITED KINGDOM Page 2 of 3 3 Discard the O rings C 4 Release the fasteners D from the cover of the oil cooler and remove the oil cooler assembly E 5 Thoroughly clean the flange face of the cover and of the cylinder block Note A liquid joint is used in the factory This must be removed and a new paper joint F JCB part number 02 201718 fitted in its place 6 Ifan overh
31. 3A319 9EZZ OES L9L0 Zr 9LAS ys yo preyuping 1901S Bury ZOL 00L pl saamas M peg olny 3YIHSAHO VOSIPE SEZI0 1NG 3d ays puqweg yBnosoqe ed aye6bue4 Ke NM J8 SOMeH 6L pr slu uoduioo FYIHSSDCINEINVO yond 9 Jed DIEA 19H GE9ZZl v6v10 JHE SdH syong weyseyo le1s3 pul peoy ely qz pl eajowoyny oeg 0 0269 SZ10 Y VIS syong u6nols nu Av weypuyong ezz pl eajowoyny oyeg vySSzS 8z910 1as 81s syong pua eusnog peoy xesseM 6 pl eajowony ooJeo GG6Z6E 96Z10 NXE 6LdH syong Ainqsa Ay Aen asnoyayery Yed ssouisng leDB Dpig z pl Anouuiolnv ooJeo sy ng LLOLS prELO SOLZL9Y syleg jeuyoeg peoy IWUMOG eswu o ss uisng ll uyoeig 9 pl eanowoyny oojJeo LZEv8Z vEZ10 ddz Llu slog weybuyoMm nu Av ule ulsed L pl S Allouuol nv o5jJeo 9St898 Y L10 g3o0z9H slog Bulpesy peoy 12613 AEN POAWIN Y pl eAowo NY Ceo ZOZ08S SE91L0 OLS LOY sy1 g Ainqmen peoy ebpyquey yoopped aul L pl aanowojyny ooyeg syy3g Lerzz zgs10 Ogs NI liuspioJjp q uoln1 189145 Busey rp zr p7 yeipey GZOLL2 vETLO VH LIHAN aulyspsojpag piojp g peoy 390DInIN PI S 9IAJ8S s lpo1o9l3 3sulHsquo3aqagq Z88esr Secl0 Noe ivg UOAY yyeg peoy yooiqsyoo1 YNOD Yoogsyo07 HUN SANOWOINY J8 S89N0 5 Zvec lZ6 ZtL10 naevsa UOAY sug uo 6ul sig peoy uleg ZSE Ie9u o9l3 olnv Iolsug NOAV YSgINNN 3009 J3NOHdJ14L 1SOd ALNNOO NMOL ssayqqv SINVN Gn018 Page 3 of 5 92ZG0r Ervl0 YAY Z 49 ueBiowe 5 PIN ppud juod peoy peieybueshu s je Mm unos syedoiny NVOYONVT9 AIN ESS0 LYE
32. 5 of 5 snuysey foyAqey oez80 4SUS 9H 00ZO 9 OISO Z090 01 8 Aeniabeswo pa ljJugseeseyne7 p z u l Asu ug SMV 01qq q yaewusag LAO Aowy pue ul4 S V 109014 ayer AeMION VIAVNIGNVOS v8cSc S0610 sg8 SHM SIIYSIO SOVOM 18 S S1O A 19941S IIIN SOBI p Uaso NM 9199 3 QON YALSADYOM OLOLVS c9610 XYZ EZOS 1J S SUIAA IIEUUIAA sue uojseg eyelsq emsnpu weyay M PY 3 V H YALSAONIM EcLO6Z Sec10 S19 ZLNS SHIM weysyN 19911S YOINYD 9 pl seueds JoloN uieuSyl N SLIIM 0099 2S2 E1 10 130 22S SIIYSHIOA ISOM Kalo peoy pawg s3 pul Agiysy 44 94 shun pr abe maspuy LLOO V V8r L0 ds LAH SIYSHIOA ISOM Pisysseppny ayeisy pul Aembury peoy 498g 08 67 SHUN pr e6ed maipuy 9SGLECL VLZL0 Sq vag SIYSHIOA ISOM piojpeig ue IPH S HUN pr 9B5eq A 1puy Z S98 VC6L0 Adv HA A SIIYSHIOA ISOM PlsyeyeM peoy Agiueis Kem Aauess pr e6ed maipuy OLOL O02 EL LO AZ 6S1 SIIYSHIOA ISOM sp 7 ae bqenN 6S ES snoH uosdy pr abe mospuy SAYIHSHYOA LSAM GLLv GeS lolO Md6 029 SPURIPI ISOM YSIMWOIG S AA eyelsy pu Aem uopueig 9 9 Z shun 10 9e 4 1JO O S MPIIN GOOEE9 c0610 AAZ ELAM SpueIpIN ISOM IFEYUST IM peoy IIeSIEAA S10 0 4 10 0 IS ADIN GLSEGSE Z0610 HYZ VLAM SpueIpIIN ISOM uo s g 94 Ss4 pul Yed uopeg AeM Bundy LL 0L SHUN S10 0 4 10 0I ISOMPI SGNV1IGIIN LSIM 9Zrr S92 L6L0 OV I 93N Je AA pue u u l uodn llISeSoAW N peoy souaime7 1S p11 jeo1j99 9 olny pis u Sr z2 rtZC L6L0 JAZ 93N Je AA pue
33. 7 Apply Loctite 574 Multigasket to bridge piece end slots H using applicator gun until sealant can be seen coming from the chamfered edges of the bridge piece contact face with the cylinder block 3 8 Refit flywheel housing and torque securing screws M10 to 44 Nm 33 Ibf ft and M12 to 75 Nm 55 Ibf ft 3 9 Refit flywheel using guide studs and torque retaining bolts to 105 Nm 77 Ibf ft To rectify lack of sealant 3 10 Remove lubrication oil sump 3 11 Complete sealing process as described in step 3 7 above 3 12 Refit lubrication oil sump using a new joint 7 TECHNICAL SESE INFORMATION General SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn004 engineer has a sound knowledge of safety procedures and has been trained in the JCB Gen 013 maintenance and repair of ITL equipment If you are unsure or do not understand Issue 1 information contained in the Service Bulletins then ask your supervisor for advice Remember SAFETY MUST COME FIRST Date Dec 1991 SUBJECT Turbocharger Fault Diagnosis Page 1 of 3 PRODUCTS AFFECTED All Perkins Turbo Engines AB and AC Builds TO BE CARRIED OUT Information Only A number of turbochargers have been replaced unnecessarily When inspected by the supplier no fault has been found or the fault differs from the failure code and or description on the claim Service Procedure 1 To assist in the correct diagnosis of general faults please refer to th
34. 87361 338470 338480 Page 3 of 3 Gn031 Issue 1 8 Ensure O ring is fitted into the internal seal groove on the piston head Screw the piston head onto the thread of the piston rod refer to the relevant section for torque figure and completion of ram assembly 9 Fit the piston head retaining dowel see ram dismantling and assembling relevant section 10 Fit wear rings J and K Rotate the wear rings so that the piston retention dowel is covered by the wear ring NOT as shown at L 338490 Fit the piston rod and head assembly into the cylinder 11 Insert the piston rod assembly into the cylinder Align the rod and head assembly until parallel with the cylinder then push the assembly into the cylinder 12 Fit the end cap refer to the relevant section for torque figure and completion of ram assembly PARTS INFORMATION 10mm 338410 Ram Seal Protection Sleeves lt 892 01016 For 25 mm Rod Diameter Q2 892 01017 For 30 mm Rod Diameter 892 01018 For 40 mm Rod Diameter C 892 01019 For 50 mm Rod Diameter I 892 01020 For 50 mm Rod Diameter slew ram 110mm 892 01021 For 60 mm Rod Diameter 892 01022 For60 mm Rod Diameter slew ram 175mm 892 01023 For 65 mm Rod Diameter 892 01024 For 70 mm Rod Diameter 3 892 01025 For 75 mm Rod Diameter Ay 892 01026 For 80 mm Rod Diameter Z gt gt 892 01027 Piston Seal Assembly Tool
35. Bulletins assume that the Number Gn016 engineer has a sound knowledge of safety procedures and has been trained in the JCB 2 156 D19 N Am maintenance and repair of ITL equipment If you are unsure or do not understand Issue 1 information contained in the Service Bulletins then ask your supervisor for advice Remember SAFETY MUST COME FIRST Date Feb 1996 SUBJECT Parkbrake Clevis Pin Improvements Page 1 of 2 PRODUCTS AFFECTED Transmissions with Clysdale Type Park Brake TO BE CARRIED OUT Information Only SERVICE INFORMATION A new method of retaining the parkbrake cable to the lever and the caliper has been introduced In place of the existing clevis pin arrangement new type shouldered bolts items A and B are used The shouldered bolts are directly interchangeable with the clevis pin arrangement When required the shouldered bolts can be fitted as described in SERVICE PROCEDURES SERVICE PROCEDURES 1 Park the machine on firm level ground engage the parking brake and set the transmission to neutral Lower the equipment to the ground and stop the engine 2 Remove the parkbrake lever gaiter item C 3 Remove the clevis that holds the cable to the lever item D and in its place fit a new shouldered bolt item A washers items E and F and retaining nut item G 4 Remove the clevis that holds the cable to the caliper item H and in its place fit a new shouldered bolt item B washer item F and retaining nut item G
36. DAY HIHAAF GRAS iq oY aE A SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn035 engineer has a sound knowledge of safety procedures and has been trained in the J CB 5 217 K119 N Am maintenance and repair of ITL equipment If you are unsure or do not understand N information contained in the Service Bulletins then ask your supervisor for advice Issue 1 Remember SAFETY MUST COME FIRST Date April 2001 SUBJECT Coolant Pressure Cap Page 1 of1 PRODUCTS AFFECTED All Perkins 1000 Series Engines TO BE CARRIED OUT Information Only SERVICE INFORMATION Some instances of overheating have been reported which were caused by the engine coolant filler cap not being correctly fitted This results in the coolant system failing to pressurise so reducing its efficiency SERVICE PROCEDURE When fitting the filler cap ensure that the cap is correctly fitted Fit and turn the cap to the first notch as shown at A then PRESS DOWN and continue turning FULLY clockwise as shown at B until the end stop is met Failure to do this will result in inefficient cooling and may result in injury when the cap is removed THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I T L WREXHAM CLWYD LL13 9UF UNITED KINGDOM Intemational
37. ERVICE DEPARTMENT OF I T L WREXHAM CLWYD LL13 9UF UNITED KINGDOM Intemational TECHNICAL inn INFORMATION General SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn009 engineer has a sound knowledge of safety procedures and has been trained in the JCB Gen 028 K58 N Am maintenance and repair of ITL equipment If you are unsure or do not understand information contained in the Service Bulletins then ask your supervisor for advice Issue 1 Remember SAFETY MUST COME FIRST Date March 1994 SUBJECT Low Sulphur Fuels Page 1 of 1 MACHINES AFFECTED All Perkins 1000 Series Engines TO BE CARRIED OUT Information Only SERVICE INFORMATION Low sulphur fuels are commonly used throughout the world These fuels contain fewer lubrication additives The DPA and DPS fuel pumps currently fitted to the Perkins 1000 Series engine are lubricated by the diesel fuel therefore using low sulphur fuels may in the long term affect the pump If you are using a low sulphur diesel fuel it is recommended that additional lubrication is added to the diesel Customers should contact their local fuel supplier to obtain a locally supplied and recommended additive There is no current MIL or FORD standard so the customer must be guided by the fuel supplier THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACH
38. FORMATION General SAFETY NOTICE instructions in the Service Bulletins assume that the engineer has a sound knowledge of safety procedures and has been trained in the maintenance and repair of ITL equipment If you are unsure or do not understand information contained in the Service Bulletins then ask your supervisor for advice Remember SAFETY MUST COME FIRST SUBJECT Rocker Shaft Security PRODUCTS AFFECTED All Perkins 1000 Series Engines TO BE CARRIED OUT Information Only SERVICE INFORMATION Introduction of new fasteners for the rocker assembly SERVICE PROCEDURE Number Gn002 JCB Gen 005 Issue 1 Date July 1990 Page 1 of 1 Flanged nuts A replace the three nuts and washers securing the rocker shaft to the cylinder head The single bolt and washer is replaced by a flanged bolt If the new fasteners are fitted to earlier engines the washers must be removed Torque tighten the new fasteners to 40 Nm 30 Ibf ft PARTS INFORMATION Cut in from engine serial number U544908U 02 291060 NUT replaces 1370 0401Z 02 291048 SET SCREW replaces 02 291125 02 291064 WASHER Not Required THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I T L WREXHAM CLWYD LL13 9UF UNITED KINGDOM m i Umermational TECHNICAL SA INFORMATION
39. INES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I T L WREXHAM CLWYD LL13 9UF UNITED KINGDOM Intemational TECHNICAL inn INFORMATION General SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn010 engineer has a sound knowledge of safety procedures and has been trained in the JCB MI428 H 401 E M97N Am maintenance and repair of ITL equipment If you are unsure or do not understand Issue 1 information contained in the Service Bulletins then ask your supervisor for advice Remember SAFETY MUST COME FIRST Date Mar 1994 SUBJECT Brake Master Cylinder Kits Page 1 of 1 Master cylinder seal repair kits should no longer be supplied Any kits in Distributor stocks should be returned to the OEM Contact Mr P Hassall at JCB Service for return disposal instructions for JCB supplied seals In the near future master cylinder kits listed below will no longer be available Only the master cylinder assemblies will be available for replacement this is because it is not good practice to re seal old master cylinders also seal replacement by untrained customers is not recommended The relevant Service Manual procedures will be updated accordingly Master Cylinder Seal Kit Part Numbers 15 107001 15 104700 15 106600 15 903803 15 904102 15 904301 15 908201 Note Master cylinder 15 908200 is no longer available If a master cylinder is required then part number 15 910800 must be used eit
40. ITL equipment If you are unsure or do not understand information contained in the Service Bulletins then ask your supervisor for advice Remember SAFETY MUST COME FIRST Perkins 4 236 or 1000 Series Engines Introduction of a Wear Sleeve for the Front Oil Seal Number Gn026 JCB Gen 091 K96 N Am Issue 1 Date February 1999 Page 1 of 1 The latest timing case fitted to 4 236 and 1000 Series engines does not have a service position for the front oil seal as shown in section 15 of the relevant workshop manual The change improves the efficiency of the oil seal in service and was introduced from engine number L U786357C for 4 236 engines A U802612C for 4 cylinder 1000 series Caution If the lip of the oil seal has worn a groove in JU the spigot A of the crankshaft pulley oil will continue to leak after the new oil seal is fitted To renew a worn crankshaft pulley for engines with the latest timing case a wear sleeve B part number 02 202027 is fitted over the spigot Full instructions and a special tool to fit the wear sleeve are in each service kit The dimension to press the new oil seal into the timing case with or without a wear sleeve fitted is 9 3 mm 0 366 in from the front face of the timing case The special tool supplied in the kit can be used to set the correct depth It is not necessary to remove the flange C of the wear sleeve afte
41. L8LO J09 9N uopuo le6uBiH eNIIIH pry yeipey GGGS EZ9 1810 AGOZLMS uopuo weyeg peoy ysipuanep 0Gz 9rz S 9IA19S Spel I0JON NOGNO1 vVETISv 08Z10 732 63d sou pioJuuelsS 1394S MO UMOIg yond 9 189 puemeseH SONIT IWS SHd ayseoue uo s 1id s4 pul lluutunS uolle A ebpug Jequeg ozz lun pllies iq 9 99 3 Ny pue 1 6 96Z9 ZZZ10 1V8 SHd ayseoue uo s 1d 1s3 pul yuung ugem epg Jequieg peoy 194909 uonnqulsiq leps lqqit GGZ Z28 1910 Yre 9LW yseoue 19 s USuelN 189811S IIENNN pr soles s lq seuor 4d 869G 2Z9 1910 GH VIO aulyseoue weypiO peoy seJeusely snop 1olll3 pl seomas M yeg ony Z2S2zS 90Z10 HYOL9LIO aulyseouey ayepyooy gue OOYOS pl seaiies u lleg ony 3HIHSVONV1 LZESZp G6ZL0 T OL3N lu y uinoqBuniis ue1 Aend umoo Med pul uinoqBullliS ep pl eajowoyny ooyeD LNA 0026 1 19 ES 00 pueja yon w 19911S SEJOYIIN EZ Jey2M Spunwpa 8897rE Ld ESE 00 pue sl 4100 SSo1O s u uu q Wed JPlJSWWOD B loo JOyIEM Spunwp4 998Z0Sr l ES 00 pueja ZL ulqnq peoy seen l 1sd yeuisnpu yr Jey eM spunuip3 GNV134uI 6y18S Z6610 SAZELOS SH H pJOpJ H a0e d emey Z pr jeipey LLEZEZ EZ6L0 OdS ZAM SH H PIONEN Burds6u07 04 p7 reipey SLUSH Levg9z 0 ZL0 NYE ZEND sysdweH playsialed peoy suewyouel4 s4 pul Aowy lun pn THY Srrlee zSzl0 qlr znd nysdweH 1Jousi piv peoy wejsey po THV gzzers ZSZ 0O Nur Zino nysdweH 1ousi piv peoy 1lu6neuuo2o 9 sazeds yon Joysuep y o THY 3HIHSdINVH SSGG Lt ZSY L0 gz 119 1
42. LATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I T L WREXHAM CLWYD LL13 9UF UNITED KINGDOM m i Imemational TECHNICAL i N FORMATION General SAFETY NOTICE instructions in the Service Bulletins assume that the Number Gn024 engineer has a sound knowledge of safety procedures and has been trained in the JCB Gen 089 K94 N Am maintenance and repair of ITL equipment If you are unsure or do not understand Issue 1 information contained in the Service Bulletins then ask your supervisor for advice Remember SAFETY MUST COME FIRST Date Jan 1999 SUBJECT Pin timed Fuel Injection Pumps Page 1 of 1 PRODUCTS AFFECTED All Perkins New 1000 Series Engines Models AJ to AS amp YG to YK TO BE CARRIED OUT For Information Only SERVICE INFORMATION The latest fuel injection pumps have a hub A which is mounted permanently onto the drive shaft The manufacturer fits the hub to the pump to ensure very accurate timing Engines that have this arrangement require a pin B part no 892 00956 to accurately time the pump in service Caution Do not release the nut C from the fuel injection pump Illustration 2 shows the nut C in position when the fuel pump is fitted to the engine The fuel pump hub is fitted to the shaft in the factory to ensure that the fuel pump is in the correct position for timing
43. NOS pleyysy ul Uong 198911S SSOIOMON S10 0 4 olnv UOYINS ZZLZ 9 Z 4 LO Alv 811 JUSYIOA YINOS A jwesg Aen Aoa UNOD J AIIS 7 HUN pr e6eq m ipuy 3HIHS3MHOA HLNOS LPL8 6Zr LPLO THI Lv puel lo5S mobse 5 JOOS PIMPS O PZ pr SEH H luels vOL2 62r l 710 Nd6 S9 pue o5S mobse 5 1891 S puello5S lu uudinbd 9 91494 ue doinag 60r989 88 L0 pue 1o5S yu d SJeuJ PyM J HUN pr S10 0 24 V 9 A 092929 7Z910 pue 1o5S sonuolN Jas deg L pT1 Ssiol9ed V 9 q rFL6r9r 0810 puello5S Jey104 19941S BJOWULD Zy pl siopey V q zOe8ee csel0 Lastad pue lo5sS punq pu N Su0osi1 pu8H ISOM Z pr S101024 V 8 q GNV1LO9S ZL9vvZ 69810 dd 9XO uoxO 19489919 peoy 3o9opiniN 6S pl esAowo ny 099 888res SezclO Luv vlXO uoxO uopbulqy Yed UJIN q6Z p Anouuolnv 099 J YIHSAY04XO eszzSS6 S LO HZ F N SHON weybullion 19891S JeueD SYJOM USI ojeubeyy puelply SLLON vIGZ9r Sv6lL0 V IZS USYJOA YHON Kano ayeblsony ps v s LZ0688 E2 ryl0 FOV L9H 1ySYIOA YHON ayeBoueH nu Ay yL SHIOM IEIUIOd Z HUN p11 S Y S 98992S Sr8l0 YLE ZOA 1ySYIOA YHON ysty L peoy 4 0 Wed pul ysy L 9 HUN pr abe mespuy Q9rvlby p0610 dd LOA JIUSMMOA YHON MIO oars sower nu o sojAey SZ HUN pr ebeg meupuy 3HIHSYMHOA HLYON 296629 0910 alt ZYN YIOHON YOIMJON yeas weUBIH S4 Ig91199 3 olnv syued X1O4HON LGp9SGc S68L0 Alt san x s IlpDIN 6puqxn weyueq PeOY p10 xO 96 pr eAowoNY 09eg xasa1aqllNu ti38INDN 3009 3NOHd3131 1SOd ALNNOO NMOL ssaydav SINVN Gn018 Page
44. PSION Workabout to any ITL machine is part no 892 00952 available from JCB Service A service kit comprising the above items is available JCB part No 892 00962 ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF 1 T L WREXHAM CLWYD LL13 9UF UNITED KINGDOM 2of3 Availability Gn019 Issue 2 A list of PSION agents worldwide is attached PSION Support Technical Support for the PSION Workabout can be obtained from Psion Corporate Support telephone 44 1713174122 Technical details of the Notebook PC are Specification Preferably a ruggedised portable computer having Pentium processor 16 Meg memory or greater 1 Gb hard drive or greater Internal CD ROM drive 4 speed or greater Operating System Windows 3 11 or Windows 95 ITL Software Will be provided on the Parts CD ROM Cable links to machine ITL part numbers will be advised in workshop manuals Availability Any reputable computer supplier JCB Service or ITL direct The facts about Workabout Processor Memory LCD Screen Keyboard Power Supply Integral applications Optional interfaces Accessories Operating Conditions Drop resistance Weatherproofing Dimensions 16 bit NEC V30H 80C86 compatible multi tasking windowing environment MS DOS compatible file formats 256k 1 MByte RAM 2 Solid State Disk drives for additional 16Mbytes 39 characters x 12 lines 240x100 pixels Black and grey scale Backligh
45. RANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I T L WREXHAM CLWYD LL13 9UF UNITED KINGDOM Intemational TECHNICAL in NFORMATION General amp SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn028 engineer has a sound knowledge of safety procedures and has been trained in the JCB Gen 093 K98 N Am maintenance and repair of ITL equipment If you are unsure or do not understand Issue 1 information contained in the Service Bulletins then ask your supervisor for advice Remember SAFETY MUST COME FIRST Date February 1999 New Perkins 1000 Series Engines Page 1 of 1 Models AJ to AS amp YG to YK Improved Exhaust Valve Guide An improved exhaust valve guide A has been introduced The new guide has a groove B to retain the valve seal C To remove and fit the valve guides refer to Section 12 of the Workshop Manual Notes 1 Valve guides are supplied partially finished and must be reamed and the valve seats cut in one operation with a special tool The valve seat and the guide are cut in one operation to ensure the concentricity of the valve seat to the valve guide This will ensure a good seal between the valve and its seat A new valve and new valve seat insert must be fitted each time a new valve guide is fitted Refer to the Workshop Manual 2 If all or most of the original valve guides need to be renewed it may be cost effective t
46. S LS NYINILSNF 3H1N3O NYINILSNF 80E L LVAVS VOL XO Od VAINTvS SG18 3lgvt 1V OAMOL NY NMNPNIHS F 2E 7 NMNPNIHS IHSIN 40074 81 019 LS3HO4d NYNPNIHS IHSIN ON937T10OO 686001 98 ITISNOLNV VIA Zi NONG S3 WIHLSNGNI SSOYO LNNOWATIVE V9 LINN Vive vy ON HS ONOd3OS td Th ONVINIE ILINW VWSIM LISAdVGNE IEEE C HAL LYATISD LZS NOOIMO INSLVHSWISL Gd ATHINA HIMOL HVNVHIN 4 8 8181 SLINS SNSHLV Zr LI YD ANNSAV NOWONAS ZZ SungNoH AVE 2SE19 d 91 SASSVHLSYFINIVG SldVd 810SZ 3 LANNOIdWIWHO ant 84 OOdS3 08220 SILNINVLSAWILLAH OUIVO N33SS3dNVHON 133H4LS GVHSHS LL SungsaylHq3atid 0002 Md 06 88 FAASMMVES TONS L ANDVHd 00011 VYSHVIHNYL ODVILNVS Z OSId S L VINVdINOO SN31HVVNW1S ZOLL XO8 Od 901 GVOHSDCITIGHLY 68 XZH O383 O 1V3H1INON 1SV3 3MOOtigtidHS 9227 VIQOSINVO9 HN3d WONHd WOGOHON dA 18 Z NYMY934 I43S HadNV8 081 S9NOGV9 NVTvr SNVSVd ONVENNY NYVNNONVE LL ONVIVSSNYVG NAdYaMLNV 0002 4 St LVVH1S3 MINIMA ILHOM 902 VyVHd S H O d MAN 2 SNV1 2Z1 d VINVNVW 82192 XO8 Od VHOOH INNIAY NOILISIHXS 22 SOv STVM 120S V 64 HOWALSOd 8922 SATVM HLNOS MAN ADNV ADNY CVO A3TIVA S8S IWH v80lSAuIV SONIN 4O07 CHE 96 OAV 30 VdIN3AV VSVdIL M VINVGINOS 088 Cel NY 76 ss ppy NAWSA vsn AN AN avn VISINON L QNVTIVHL VIYAS QNVTYAZLIMS N3qQ3ANS VANYI IHS NIVdS VOlddV HLNOS AYOdVONIS Viqvuv
47. UED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I T L WREXHAM CLWYD LL13 9UF UNITED KINGDOM Intemational TECHNICAL i NFORMATION General SAFETY NOTICE instructions in the Service Bulletins assume that the Number Gn0o21 engineer has a sound knowledge of safety procedures and has been trained in the JCB 10 107 maintenance and repair of ITL equipment If you are unsure or do not understand information contained in the Service Bulletins then ask your supervisor for advice Remember SAFETY MUST COME FIRST Issue 1 Date April 1998 SUBJECT Axle Propshafts Page 1 of 1 PRODUCTS AFFECTED All Machine Installations SERVICE INFORMATION On installation of any machine it is important to ensure that the following points regarding propshaft lubrication and protection are highlighted to the operator Failure to do so may result in premature wear or consequential damage to transmission components 1 Lubrication Propshafts must be greased as follows a Interval s Every 50 hours of operation Daily if working in muddy conditions S K 7 Immediately after washing the machine b Ensure that all bearing caps are purged with grease c Only High Pressure Grease such as Mobil HP222 should be used 2 Washing Do not direct
48. Y OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I T L WREXHAM CLWYD LL13 9UF UNITED KINGDOM Page 2 of 2 Gn029 Issue 1 Y Gf WARRANTY INFORMATION If submitting a warranty claim for rectification of a problem with a hydraulic fitting O ring eg oil leak ensure the correct O ring part number is specified within the claim as the failed part Incorrect O ring part number claims will not be accepted m i Umerational TECHNICAL OE TRANSMISSIONS LTO INFORMATION General DRUTEN HIGHWAY DEPAB_ INE SYSTEME SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn030 engineer has a sound knowledge of safety procedures and has been trained in the JCB MI642 H maintenance and repair of ITL equipment If you are unsure or do not understand Issue 1 information contained in the Service Bulletins then ask your supervisor for advice Remember SAFETY MUST COME FIRST Date April 1999 Page 1 of 3 PERKINS LOW EMISSION DIESEL ENGINE ITL PRODUCT IMPROVEMENTS New Perkins Diesel Engine Improved exhaust emissions Wastegated turbo charger Improved injection pump Increased peak torque Improved cold starting performance THIS BULLETIN CONTAINS INFORMATION WHICH SHOULD BE COVERED DURING CUSTOMER MACHINE INSTALLATION AND SHOULD BE COPIED TO ALL MACHINE INSTALLATION PERSONNEL Please ensure a copy of this bulletin is distributed to field based s
49. are unsure or do not understand Issue 1 information contained in the Service Bulletins then ask your supervisor for advice Remember SAFETY MUST COME FIRST Date March 1992 SUBJECT HEALTH amp SAFETY RECOMMENDATIONS Page 1 of 2 FLUOROELASTOMERIC MATERIALS PRODUCTS AFFECTED ALL A WARNING Due to recent publicity regarding the potential hazards associated with the handling of fluoroelastomeric materials Viton Fluorel Technoflon etc commonly used in the production of oil seals and gaskets for the automotive industry the following health and safety statement should be noted Note Examples of the use of these materials on ITL products are the Viton crankshaft oil seals on Perkins engines and Viton shaft and brake seals in the axles New Components The normal handling of new cured fluoroelastomeric components at ambient temperature presents no known hazard and requires no special handling precautions Removal of Old Components during Servicing No special precautions are required when handling old fluoroelastomeric material that has been subjected only to normal service conditions However before removal a preliminary visual examination should establish whether normal service temperatures have been exceeded giving rise to thermal degradation If evidence of decomposition charring etc is found the material and surrounding areas should not be touched without observing the precautions detaile
50. aul of the oil cooler is necessary see To Dismantle and To Assemble on pages 2 and 3 of this bulletin To Fit 1 If the four studs G have been removed from the cylinder block flange and are to be fitted again clean the threads in the cylinder block and on the studs Apply High Strength Retainer before the studs are fitted to the cylinder block to prevent leakage of the coolant 2 Put anew paper joint into position on the studs the joint is fitted dry Fit the oil cooler assembly E to the cylinder block Gradually and evenly tighten the fasteners D to 22 Nm 16 lbf ft 2 2 kgf m Gn025 Issue 1 3 Clean the seats for the O rings and renew the O rings C of the pipe connections Caution Do not remove the flanges A and nuts B from the studs H before one of the oil pipes is fitted to the cover This will ensure that the element is held in position on the cover J while the oil pipes are fitted 4 Fit the oil pipes to the cooler and tighten the nuts to 22 Nm 16 lbf ft 2 2 kgf m 5 Fill the cooling system 6 Operate the engine and check for oil or coolant leakage To Dismantle 1 Remove the oil cooler from the cylinder block refer to page 1 of this bulletin 2 Put the oil cooler assembly E on a clean work surface Release the four nuts B that retain the flanges for the lubricating oil pipes The pipe flanges A are in two pieces 3 Remove the cover K from the four studs L of the oil cooler element M
51. ave the appropriate Computer Diagnostic equipment All new ITL electronic systems will use the PSION Workabout hand held computer for this purpose This bulletin describes the requirements for and technical specification of these computerised diagnostic tools 1 PSION WORKABOUT This low cost rugged hand held computer is now the ITL and JCB Group Diagnostic Tool It is widely used in service industries for in field use All new ITL and JCB products with electronic systems requiring support from Service personnel will use software running on the PSION Electronic units requiring the PSION workabout will be as follows Transmission ECU Fitted to PS700 four and five speed transmissions Function Control of powershift gearbox Use of PSION Fault finding of ECU inputs and outputs The technical details of the PSION Workabout are Specification PSION Workabout PSION Part No ITL JCB part No RS 232 and TTL Serial Interfaces 1800 0006 11 892 00924 Docking Holster One required per depot for 1801 0003 01 892 00925 transferring software from PC to PSION Workabout PsiWin Link and Software To transfer JCB software from 1601 0039 10 892 00926 PC to PSION Workabout one per depot ITL Software This will be provided on the Parts CD ROM and will be transferred from a desktop computer via PsiWin software to the PSION Workabout A Psion disc is also available JCB part No 892 00963 Cable links to machine Connecting cable for connecting the
52. d below Removal of Old Material Subjected to Abnormally High Temperatures At temperatures in excess of 300 C e g engine fires fluoroelastomeric materials can decompose producing small but significant amounts of hydrofluoric acid This acid is highly corrosive and will cause SEVERE BURNS if in contact with the skin Vehicles or components that have been subjected to abnormally high temperatures should be subjected to the following decontamination procedure which must be conducted by competent personnel This will require the use of appropriate safety equipment neoprene rubber or heavy duty gloves plus special safety glasses are essential 1 Ensure that components have cooled then carefully remove and transfer suspect material to plastic bags 2 Wash the contaminated area with a 10 calcium hydroxide or other suitable alkali solution if necessary using wire wool to remove residual adherent decomposition products 3 Thoroughly wash contaminated area with detergent and water cont d THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I T L WREXHAM CLWYD LL13 9UF UNITED KINGDOM Page 2 of 2 Gn005 Issue 1 4 Place all removed material protective gloves and wire wool used in the operation in sealed plastic bags prior to landfill disposal in accordance with Local Authority Regula
53. dler Gear PRODUCTS AFFECTED All Fitted with a Perkins 1000 Series Engine TO BE CARRIED OUT As Required It has been found in service that excessive wear can occur to the bush for the idler gear of the lubricating oil pump This wear may occur on four and six cylinder engines A new idler shaft A has been introduced which has an oil hole B to provide more lubrication to the bush for the idler gear Also a new lubricating oil pump has been introduced which has a channel C in the body of the pump Lubricating oil from the front main bearing passes down the channel in the body of the pump to the oil hole in the idler shaft The lubricating oil then passes through the hole in the idler shaft to the bush in the idler gear If it is found in service that more lubrication is necessary for the bush of the idler gear renew the bush part 02 290006 Fit the new idler shaft part 02 201131 and the new lubricating oil pump part 02 201050 four cylinder engines or 02 201130 six cylinder engines 209440 Fit the lubricating oil pump and the idler shaft in accordance with the procedure given in operations 19A 06 and 19A 06A respectively of the workshop manual In addition to these instructions ensure that the hole D in the idler shaft is at the bottom and that the flat E is at the top before the shaft is pressed into the bearing cap l l A Caution The idler shaft for the lubricating oil pump used on four cylinder engines is not retain
54. e correct seals are fitted On metric threaded rams make sure the seals are fitted the correct way round as shown at P and Q 2 Close the tool as shown at C The seal must form a reniform kidney shape 3 Before fitting the rod seals check the seal grooves are free of contamination and sharp edges 4 Locate the seal in the end cap groove shown at D when the seal is in position open the tool to release the seal Make sure the seal is correctly installed in its groove and remove the tool 5 Fit rod wiper seal P into seal groove Make sure the seal is correctly installed as shown Note Some rod wipers ie power track rod may use a metal encased seal which is pressed into the housing Care must be taken to ensure the seal is square before it is pressed in Sleeve E must be used to protect the rod seals from damage when fitting end cap onto the piston rod There are various sizes of sleeve see Parts Information Make sure the hexagon on the end cap is towards the eye end of the rod Fit new piston head seals 6 Use a blunt instrument 892 01027 shown at F lever the inner seal G into the piston head seal groove do not let the seal twist There are identification marks on the outer diameter of the seal make sure the marks are visible and the seal is free to rotate if not remove the seal and refit 7 Fit outer seal H using the same procedure as step 6 Check the external grooves are visible Gn031 Issue 1 153212 A1
55. e attached fault finding charts 2 Fuel Starting Aid Thermostart A problem has occurred several times where the inside of the induction manifold has been found to be wet and the turbocharger has been returned as faulty After investigation the turbocharger was found to have no fault If the inside of the induction manifold is wet check that there is not a fuel leak from the fuelled starting aid if fitted 2 1 How to check the fuelled starting aid 2 1 1 Disconnect the fuel pipe A and the electrical connector B at the starting aid C Remove the starting aid from the manifold and fit a suitable plug in the manifold 2 1 2 Connect the fuel pipe to the starting aid but leave the union nutconnection loose Do not fit the electrical connection but ensure that the connector is covered with a suitable insulator Operate the lever of the fuel lift pump until fuel free of air comes from the union nut connection Tighten the union nut at the starting aid 2 1 3 Start the engine and operate it at low speed Check that there is no fuel leakage from the valve of the starting aid 2 1 4 If there is no leakage remove the plug from the induction manifold and fit the starting aid Connect the fuel pipe to the starting aid and remove the air from the pipe as described above Connect the electrical connector to the starting aid 2 1 5 If there is a leak from the valve of the starting aid fit a new starting aid 3 Warranty Claim P
56. e loss of fuel Disconnect the fuel inlet pipe to the lift pump 2 Unscrew the fuel filter A Remove strainer 2 and O ring 3 3 Clean the strainer in clean diesel fluid and dry with low pressure compressed air Renew the strainer and O ring if damaged 4 Fit the strainer into the fuel inlet connection Fit the fuel filter A and tighten to 20Nm 15 Ibf ft Fit the fuel inlet pipe carefully to prevent damage to the strainer and tighten the union nut IMPORTANT The fuel strainer can be damaged and fuel flow can be restricted if the fuel pipe is inserted too far into the inlet connection This should be checked if a fuel restriction is suspected Make sure the olive on the fuel inlet pipe is in good condition and forms an effective seal Renew the olive or pipe if necessary to prevent air entering the fuel system 5 Fit the tank cap and prime the fuel system Start the engine and check for fuel leakage THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I T L WREXHAM CLWYD LL13 9UF UNITED KINGDOM Page 2 of 2 PARTS INFORMATION Item Part No 1 17 913600 2 amp 3 17 913601 4 02 201189 Description Fuel Lift Pump Kit complete with Gasket Fuel Strainer amp O ring Kit Gasket only 366610 Issue 1 International TECHNICAL von Po INFORMATION General
57. e shielded and not directly Do not wash the Electrical Shut off Solenoid ESOS or any electrical components of the FIP when the engine is If these cautions are ignored the engine or certain components could be damaged fail to operate and also make the manufacturer s warranty invalid THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I T L WREXHAM CLWYD LL13 9UF UNITED KINGDOM
58. ecessary 1 Main Oil Gallery Plug Washer A leak from this area can usually be identified by a trace of oil along the contact face of block and flywheel housing on the fuel pump side of the engine This can be rectified as follows 1 1 Remove the transmission 1 2 Remove the flywheel using guide studs remove two diametrically opposite bolts and temporarily fit guide 1 3 Removethe starter motor 1 4 Remove the flywheel housing it may be necessary to tap the housing using a soft hammer to disengage the housing dowels 1 5 Remove the threaded gallery plug D located top left of cylinder block using appropriate allen key 1 6 Fit a new plug washer using Loctite 574 Multigasket and torque to 85 Nm 62 5 Ibf ft 1 7 Refit flywheel housing and torque securing screws M10 to 44 Nm 33 Ibf ft and M12 to 75 Nm 55 Ibf ft 1 8 Refit flywheel using guide studs and torque retaining bolts to 105 Nm 77 lbf ft 2 Camshaft Rear End Plug Leakage from the cam end plug will normally produce a trace of oil at the contact face between block and flywheel housing on the manifold side To rectify 2 1 Remove the transmission 2 2 Remove the flywheel using guide studs remove two diametrically opposite bolts and temporarily fit guide studs 2 3 Remove the starter motor 2 4 Remove the flywheel housing it may be necessary to tap the housing using a soft hammer to disengage the housing dowels 2 5 Remove camshaft end pl
59. ed in the bearing cap by a pin but is retained by Loctite 648 Retainer part 4101 0651 If the new lubricating oil pump is fitted the end float for the idler gear is as follows Four cylinder engines 0 012 0 643 mm 0 0005 0 0253 in e Six cylinder engines 0 020 0 650mm 0 0008 0 0256 in PARTS INFORMATION Part No Description Part No Description 02 290006 Bush 02 201050 02 201131 Shaft 02 201130 4101 0651 Loctite 648 Retainer I l e a Number Gn012 JCB Gen 031 K60 N Am Issue 1 Date July 1994 Page 1 of 1 S209450 Pump 4 Cylinder Engines Pump 6 Cylinder Engines Note The above information can be implemented only when excessive wear is evident THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I T L WREXHAM CLWYD LL13 9UF UNITED KINGDOM International TECHNICAL m N FORMATION General SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn013 engineer has a sound knowledge of safety procedures and has been trained in the JCB Gen 035 F47 N Am maintenance and repair of ITL equipment If you are unsure or do not understand Issue 1 information contained in the Service Bulletins then ask your supervisor for advice Remember SAFETY MUST COME FIRST Date Feb 1995
60. em poor hose hoses clips etc Incorrect servicing of air filters ie elements damaged during cleaning or use of non recommended elements Incorrect grade and quantity of oil not as specified in the owners handbook SERVICE PROCEDURE Normal oil consumption after running in should be between 3 and 5 litres of oil per 1000 litres of fuel consumed 0 66 and 1 1 UK gal per 220 UK gal 0 79 and 1 32 US gal per 264 US gal OR 0 30 and 0 50 of fuel consumption 1 Position the machine on level ground Drain and refill with the correct grade and quantity of oil as specified in the owners handbook 2 Allow time for the oil level to settle and check level on dipstick If oil level is either above or below existing MAX mark re mark dipstick at this level 3 Record the dimensions of any change to the MAX mark Do not alter the MIN mark on the dipstick THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I T L WREXHAM CLWYD LL13 9UF UNITED KINGDOM Page 2 of 2 Gn 036 Issue 1 4 Fill fuel tank to the maximum 5 Record the hour meter reading and date return the machine to service 6 Record all amounts of fuel and engine oil added during the test period on the chart below excluding the initial fill Note Only add oil when the level reaches or is near the MIN mark 7 On completion of test rep
61. em Part Number Description Qty A 02 201338 Hose 1 F 02 202220 RockerCover 1 J 02 202217 Breather 1 K 2201 0007 Clip 1 THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I T L WREXHAM CLWYD LL13 9UF UNITED KINGDOM Page 2 of 2 Gn 037 Issue 1 WARRANTY INFORMATION This improvement will not be considered for warranty I TECHNICAL msmanona INFORMATION General A SAFETY NOTICE Instructions in the Service Bulletins assume that the engineer has a sound knowledge of safety procedures and has been trained in the Number Gn038 maintenance and repair of ITL equipment If you are unsure or do not understand ssue 1 information contained in the Service Bulletins then ask your supervisor for advice Remember SAFETY MUST COME FIRST Date J an 2002 SUBJECT New ITL NAPSC Network Page 1 of 2 Introduction of a new service and parts support network for International Transmissions Limited from February 17th 2002 All previous parts ordering through J CB Burlington Canada and J CB Savannah USA will be discontinued and new accounts for each OEM will be opened with ITL NAPSC ITL North American Product Support Center PO Box 1000 Harrow Ontario NOR 1GO Services available to the OEM 1 866 734 8562 1 866 73 ITL NA toll free number Fax 519 738 3477 or e ma
62. emedial procedures have already been implemented to ensure all relief valve housings are now machined to the correct specification Check the relief valve housing as described in SERVICE PROCEDURES SERVICE PROCEDURE Note The following procedures apply to a typical machine the method for gaining access to the engine oil relief valve 3766K021 3766K021 1 Park the machine on firm level ground engage the parking brake and set the transmission to neutral 20 1 lt Lower the attachments to the ground and stop the engine 2 Place a clean suitable size container underneath the engine oil drain plug located in the sump 3 Remove the sump drain plug and its O ring Drain the engine oil into the container 4 Remove the engine oil dipstick and the dipstick tube S225960 SPECIAL INSTRUCTIONS Refer to Perkins dealers for warranty information and repairs ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I T L WREXHAM CLWYD LL13 9UF UNITED KINGDOM ENGLISH Page 2 of 2 Gn015 Issue 1 SERVICE PROCEDURE continued 5 Provide a support for the sump and remove the sump retaining bolts Lower the sump and remove the sealing gasket Inspect the relief valve housing 6 1 Look at the side of the relief valve housing A for the manufacturer s number 6 2 If the number has a 1 below it as shown at B then the housing is made to the correct specification move to step 9 6 3 If the number has a 2 below it
63. ers as the water drain hole is now deleted b The gauge has been increased from 1 6mm to 2 0mm 2 Naturally Aspirated Silencers a A secondary support bracket B is fitted to silencers installed on naturally aspirated engines this will reduce failures caused by vibration The bracket is bolted to the silencer and mounted on the exhaust manifold studs b The gauge has been increased from 1 6mm to 2 0mm Parts Required Turbo Engine Silencer x 1 993 66300 replaces 123 01468 and123 01136 Naturally Aspirated Engine Silencer x 1 993 66200 replaces 123 01481 and123 00741 Support x 1 123 01482 Bolt x 1 1305 0204Z Washer x 1 1411 0003Z General Number Gn022 JCB 2 029 Issue 1 Date Nov 1990 Page 1 of 1 THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I T L WREXHAM CLWYD LL13 9UF UNITED KINGDOM 7 TECHNICAL iio INFORMATION SAFETY NOTICE instructions in the Service Bulletins assume that the engineer has a sound knowledge of safety procedures and has been trained in the maintenance and repair of ITL equipment If you are unsure or do not understand information contained in the Service Bulletins then ask your supervisor for advice Remember SAFETY MUST COME FIRST General Number Gn023 JCB Gen 087 N Am K91 Issue 1 Date Oct
64. ervice engineers and make sure that a copy is posted on your technical information notice boards THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I T L WREXHAM CLWYD LL13 9UF UNITED KINGDOM Page 2 of 3 Gn030 Issue 1 The Perkins low emission diesel engine has been introduced for all Powertrains with turbo charged engines sold in the EEC after 1st January 1999 and for all Powertrains with naturally aspirated engines sold in the EEC after 1st April 1999 These dates apply to the engine build date and not the machine build date The engines comply with mandatory emission legislation and incorporate the following changes Revised cylinder head Four branch inlet and exhaust manifolds Revised piston design with modified combustion chamber Wastegated turbo charger Improved fuel injection pump Increased compression ratio The previous 75 hp 56 kW engine is now uprated to 80 hp 59 kW and develops 290 Nm 214 Ibf ft peak torque The previous 106 hp 79 kW engine is replaced by a 100 hp 74 kW turbo charged engine which develops 402 Nm 296 Ibf ft peak torque Torque Comparison The comparison shows the increased back up torque at lower engine speed produced by the new low emission engine Peak torque is increased up to a possible 411 Nm lbf ft from 354 Nm
65. ervisor for advice Remember SAFETY MUST COME FIRST Date Nov 1999 SUBJECT Hydraulic Ram Sealing Procedure Page 1 of 3 PRODUCTS AFFECTED All Machines with ITL Rams TO BE CARRIED OUT Information Only SERVICE INFORMATION In an effort to reduce the number of hydraulic leaks on ITL rams a revised procedure has been introduced for fitting seals to the ram end cap and piston head The introduction of the new procedure also introduces new tools which are detailed on sheet 3 Service Manuals will be revised at the next convenient Replacement Page Set SERVICE PROCEDURE To fit new rod seal Use seal fitting tool 892 00334 to fit rod seals the size diameter and position of pins A is determined by the diameter and radial width of the rod seal being fitted The pins are screwed into threaded holes in the tool body the spacing of the holes is designed to suit small or large diameter rod seals 1 Open the tool as shown at B and insert the new rod seal the seal must be fitted behind the two front pins but in front of the rear pin as shown 161750 THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I T L WREXHAM CLWYD LL13 9UF UNITED KINGDOM Page 2 of 3 Note Later ram end caps and piston heads have metric threads The seals are also different make sure th
66. g oil in the exhaust manifold 2 7 17 18 19 20 22 28 31 32 l Inside of the induction manifold wet 1 2 3 4 5 6 8 10 11 17 18 19 20 21 28 32 34 39 40 J Damaged compressor impellor 3 4 6 8 12 15 16 20 21 23 24 29 32 33 37 38 K Damaged turbine rotor 7 8 12 13 14 15 16 18 20 22 23 24 25 27 29 32 33 37 38 L Rotating assembly does not turn freely 3 6 7 8 12 13 14 15 16 18 20 21 22 23 24 29 32 33 37 38 M Worn bearings bearing bores journals 6 7 8 12 13 14 15 16 23 24 29 33 37 38 N Noise from turbocharger 1 3 4 5 6 7 8 9 10 1 1 12 13 14 15 16 18 20 21 22 23 24 29 32 33 34 37 38 O Sludge or carbon deposit in bearing housing 2 11 13 14 15 1 7 18 24 29 33 37 38 Page 3 of 3 Gn004 Issue 1 Fault Finding Charts cont d DESCRIPTION OF POSSIBLE CAUSES SYMPTOM 1 Element of the air filter dirty 2 Restricted crankcase breather Element of the air filter missing leaking or not sealing correctly Loose connection to turbocharger 4 Internal distortion or restriction in pipe from air filter to turbocharger 5 Damaged restricted crossover pipe turbocharger to induction manifold 6 Restriction between air filter and turbocharger rA Restriction in exhaust system 8 Turbocharger loose or clamps setscrews loose 9 Induction manifold cracked or loose flanges distorted 10 Exhaust manifold cracked or loose flanges distorted 11 Restricted exhaust system 12 Delay of lubricating oil to turbocharger at engine s
67. her singly or in pairs THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I T L WREXHAM CLWYD LL13 9UF UNITED KINGDOM Imtemational TECHNICAL a INFORMATION SAFETY NOTICE Instructions in the Service Bulletins assume that the engineer has a sound knowledge of safety procedures and has been trained in the maintenance and repair of ITL equipment If you are unsure or do not understand information contained in the Service Bulletins then ask your supervisor for advice Remember SAFETY MUST COME FIRST SUBJECT Hydraulic Ram Identification General Number Gn011 JCB MI452 H 423 E E114N Am Issue 1 Date June 1994 Page 1 of 1 Over the last twenty years JCB has made a number of design and manufacturing improvements to hydraulic rams Some difficulty is being experienced identifying the various rams for parts ordering purposes The following illustrations show some different types of ram fitted to JCB machines It is important to correctly identify the type of ram fitted prior to ordering spare parts because in most instances parts will not be interchangeable Wy a3 ISE USS a Z IMPERIAL RAM 1 I L_ _ _ a 4 in x 2 in L Z z KZ V 1972 to 1979 en a End Cap Split Pin Retention
68. high pressure water jets at universal joints 3 Protection When working in loose straw or grass it is important that an undershield is fitted to the machine to prevent material wrapping around the propshafts Failure to protect the propshafts adequately may result in damage to oil seals propshafts and other transmission components Parts Information Part No Description 4003 2017 JCB HP Grease 400 g cartridge Available from JCB Service and Dealers THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I T L WREXHAM CLWYD LL13 9UF UNITED KINGDOM Intemational TECHNICAL i INFORMATION SAFETY NOTICE instructions in the Service Bulletins assume that the engineer has a sound knowledge of safety procedures and has been trained in the maintenance and repair of ITL equipment If you are unsure or do not understand information contained in the Service Bulletins then ask your supervisor for advice Remember SAFETY MUST COME FIRST SUBJECT Engine Silencer Improvements PRODUCTS AFFECTED Perkins Engines TO BE CARRIED OUT For Information Only Product Improvement The quality of ITL Silencers has been improved 1 Turbo Engine Build Silencers a The end plates have been strengthened by increasing the section width A rain cap A must be fitted on the new silenc
69. il seltech mnsi net Parts supply availability and pricing information Contact Colin Sellick ext 226 Shipping out of Harrow Ontario or USA address PO Box 312547 Detroit MI 48231 2547 Help ensuring correct parts needed are identified Technical support contact Ron Peters ext 238 All Warranty claims to be submitted on the normal ITL claim form but to be sent to NAPSC address for the attention of Garth Doey Claims will be loaded electronically onto the local database enabling the UK ITL service desk to view the claim simultaneously Consequently time to settlement of claims will be speeded up with target of 15 to 45 days max 7 Parts discount level ITL list less 30 Emergency parts orders shipped next Business day 5 Surcharge Critical VD vehicle down orders placed before 3 00 p m local NAPSC time shipped with 7 premium 40 discount on stock orders minimum value 5 000 00 excluding shipping costs Orders limited to 2 stock orders per year and terms CIF at the OEM Lead time for stock orders despatch 6 weeks Any type of shipping method can be specified and orders can be drop shipped to any address specified in North America AOU J N Also Note the introduction of 3 New ITL Principal Service Centers ITL PSC California Texas and Michigan Approved for ITL Warranty repair work Complete ITL component strip down repair and test facilities available Remanufactured units Competent
70. in numbers are Right hand mounting on four cylinder engines U 746654 B Left hand mounting on four cylinder engines U 747324 B Six cylinder engines U 620352 B The two new part numbers are fully interchangeable with the earlier starter motors as detailed below For specific machine applications refer to the parts information Note that all starter motors failing within the warranty period should be repaired by the nearest Magnetti Marelli distributor See T I Gn018 for list of Magneti Marelli distributors Contact Perkins or Perkins Dealer for further information Parts Required Part No Description 714 29300 Starter motor left hand mounting supersedes 714 09100 714 29500 Starter motor right hand mounting supersedes 714 14300 THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I T L WREXHAM CLWYD LL13 9UF UNITED KINGDOM Intemational TECHNICAL i INFORMATION General SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn018 engineer has a sound knowledge of safety procedures and has been trained in the JCB MI 461 H 431 E maintenance and repair of ITL equipment If you are unsure or do not understand Issue 2 information contained in the Service Bulletins then ask your supervisor for advice Remember SAFETY MUST COME FIRST Date
71. ions amp Axles Perkins 1000 Series Engines Perkins 1000 Series Engines Trans with Clysdale Park Brake All Perkins Engines All Perkins Engines Service Department Computer Diagnostic Equipment Engine Workshop Manuals Axle Propshafts Engine Silencer Improvements Change of position exhaust manifold bushes Pin Timed Fuel Injection Pumps Improved Oil Cooler with Pressed Steel Cover Introduction of Wear Sleeve for Front Oil Seal Washers for Fuel Injection Pump Gear Improved Exhaust Valve Guide ITL Hydraulic Hose Fittings and O rings Perkins Low Emission Diesel Engine Hydraulic Ram Sealing Procedure Oil Control Rings Plastic Thermostat Housings Introduction of Improved Fuel Lift Pump Coolant Pressure Cap Engine Oil Consumption Engine Rocker Cover New ITL NAPSC Network Safety Precautions When an Engine is Cleaned PAGE 1 OF 1 Perkins New 1000 Series All machine installations Perkins Engines New Perkins 1000 Series All Perkins New 1000 Series All Perkins 1000 Series Perkins 4 236 amp 1000 Series New Perkins 1000 Series New Perkins 1000 Series All ITL Products New Perkins 1000 Series All Machines with ITL Rams 1000 Series models AR amp AS All Perkins 1000 Series All Perkins 1000 Series All Perkins 1000 Series Perkins Low Emission Engines Perkins Low Emission Engines New North American Network All Engines Date Mar 90 J uly 90 Mar 91 Dec 91 Mar 92 Feb 93 Feb 93 Nov 93 Mar 94 Mar
72. lenish oil level to the original MAX mark on the dipstick Replenish the fuel tank as required 8 Total all fuel and lubricating oil used during test excluding the initial fill 9 Record machine hour meter reading on completion of test 10 If the oil consumption exceeds the limit specified at beginning of the Service Procedure contact your Regional Service Manager for further advice MACHINE TYPE MACHINE SERIAL No ENGINE SERIAL No TEST COMMENCED Date Hour meter reading DISTRIBUTOR Date Hours Amount of engine oil added Amount of fuel added TOTAL 1000 litres 220 UK gal 264 US gal TEST TERMINATED Date Hour meter reading Signed Intornational TECHNICAL TRANSMISSIONS LTD Po _NFORMATION General A SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn037 engineer has a sound knowledge of safety procedures and has been trained in the J CB TSDB 390 maintenance and repair of ITL equipment If you are unsure or do not understand information contained in the Service Bulletins then ask your supervisor for advice Issue 1 Remember SAFETY MUST COME FIRST Date May 2001 SUBJ ECT Rocker Cover Page 1 of 2 PRODUCTS AFFECTED Perkins AR AJ AK Low Emission 1000 Series 4 C ylinder Engines TO BE CARRIED OUT Only with Authorisation from ITL SERVICE INFORMATION Reports have been received of excessive oil loss from the rocker cover breather tube It should be noted that oil
73. n the claim being rejected PARTS INFORMATION DESCRIPTION PART NO COMMENTS Garret Unit 02 200460 was Schwitzer unit part no 02 200340 applicable to 90BHP only THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I T L WREXHAM CLWYD LL13 9UF UNITED KINGDOM Intemational TECHNICAL i INFORMATION SAFETY NOTICE instructions in the Service Bulletins assume that the engineer has a sound knowledge of safety procedures and has been trained in the maintenance and repair of ITL equipment If you are unsure or do not understand information contained in the Service Bulletins then ask your supervisor for advice Remember SAFETY MUST COME FIRST SUBJECT Piston and Piston Ring Improvements PRODUCTS AFFECTED 4 Cylinder Turbocharged Engines TO BE CARRIED OUT Information Only SERVICE INFORMATION General Number Gn007 JCB 2 085 Issue 1 Date Feb 1993 Page 1 of 1 A new improved oil control piston and ring pack has been fitted to the Perkins 4 cylinder turbocharged engines from January 1993 Engine cut in numbers AB 50424U 608291 W AB 50440U 608301 W One of the advantages of the new design is that it reduces oil consumption after the initial bedding in period The average oil to fuel used consumption is reduced from 0 5 to 0 2 The following i
74. nformation should be covered during new machine installation i Engine running in is not a requirement ii Periods of engine idling tick over should be kept to a minimum to prevent cylinder bore glazing SERVICE PROCEDURE 1 The new piston and ring pack can be used as service replacements in sets of 4 pistons and ring kits 2 When fitting the new piston and ring pack in service there is no need to de glaze the cylinder bore glaze busting 3 JCB Technical Information Bulletin 2 004 issue 2 details the service procedure to be completed if oil consumption concerns are raised by the customer before contacting the Perkins Dealer i On engines prior to the new piston and ring pack normal oil consumption remains at 0 3 to 0 5 of fuel used further investigation may be required if the oil consumption exceeds 0 7 ii On engines fitted with the new piston and ring pack further investigation may be required if the oil consumption exceeds 0 5 PARTS INFORMATION VENDOR PART NO BHP DESCRIPTION AB50440 90 Engine AB50441 96 Engine AB50459 96 Engine 1 Piston Assembly 02 200860 2 Ring Kit 02 200859 THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I T L WREXHAM CLWYD LL13 9UF UNITED KINGDOM J sasam ss ational TECHNICAL i INFORMATION General
75. ng B setscrews Using an appropriate lever gently pry the seal housing away from cylinder block taking care not to damage the housing 4 Press out old seal and fit replacement using tool number PD 145D see Perkins Service Manual this will pre set the seal depth as required Note The service tool will set seal to 4 different depths on new engines position 1 should be used 5 Make sure that the two dowels C are fitted in the cylinder block PUT A NEW JOINT in position on the dowels 6 Put the seal guide A on the crankshaft flange Lubricate the crankshaft flange the seal lip and the seal guide with clean engine oil 7 Put the seal housing B complete with seal on the seal guide A PD 145D Carefully push the assembly into position on the crankshaft flange and onto the two dowels C Remove the seal guide fit and torque the housing securing setscrews M8 to 22 Nm 16 lbf ft and the capscrews M8 to 18 Nm 13 Ibf ft 8 Refit flywheel using guide studs and torque retaining bolts to 105 Nm 77 lbf ft THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I T L WREXHAM CLWYD LL13 9UF UNITED KINGDOM Page 2 of 3 Gn003 Issue 1 OIL LEAKAGE FROM REAR OF ENGINE When investigating oil leakage at the rear of the engine the following areas should be checked and corrected as found n
76. o overhaul or exchange the cylinder head 3 It is important that all the lubricant is removed from the outside diameter of inlet and exhaust valve guides before the valve seal is fitted Parts Information Item PartNumber Description Supersedes A 02 202064 Valve guide 02 201511 and 02 201817 THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I T L WREXHAM CLWYD LL13 9UF UNITED KINGDOM Intemational TECHNICAL i INFORMATION General SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn029 engineer has a sound knowledge of safety procedures and has been trained in the JCB Gen 096 E194 N Am maintenance and repair of ITL equipment If you are unsure or do not understand information contained in the Service Bulletins then ask your supervisor for advice Remember SAFETY MUST COME FIRST Date Issue 1 March 1999 SUBJECT ITL Hydraulic Hose Fittings and O rings Page 1 of 2 PRODUCTS AFFECTED All ITL Products TO BE CARRIED OUT Information Only SERVICE INFORMATION ITL products use their own type of special BSP hydraulic hose fitting This fitting combines the standard BSP type coned connector with an O ring seal X fitted in the face of the taper The O ring is bonded to the fitting to ensure its security However if for an
77. o the fuel pump are not possible Any alteration to the fuel pump settings will invalidate the emission certification 4 Starting Cold start performance has been improved This is achieved via an additional temperature switch situated in the rear of the timing case which causes fuel injection timing to advance in cold conditions In line with these cold start improvements the diameter of the battery leads has been increased 5 Special Tool Requirement All essential special tool requirements are incorporated into the relevant Perkins engine service manuals 6 Technical Publications With the introduction of the new low emission range of engines a new engine workshop manual is available from teh organisation using the following publication numbers English French German Spanish Italian Engine Workshop Manual 9806 2140 9806 2141 9806 2142 9806 2143 9806 2144 7 Mandatory and Recommended Distributor Parts Lists Contact Perkins Service for mandatory and recommended parts list requirements 8 Training Contact Perkins Service Dealers ime rnational TECHNICAL gt SIE INFORMATION General SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn031 engineer has a sound knowledge of safety procedures and has been trained in the JCB Gen 105 E215 N Am maintenance and repair of ITL equipment If you are unsure or do not understand Issue 1 information contained in the Service Bulletins then ask your sup
78. r it has been fitted A new front oil seal must be used when a wear sleeve is fitted THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I T L WREXHAM CLWYD LL13 9UF UNITED KINGDOM International TECHNICAL SEES INFORMATION General SAFETY NOTICE instructions in the Service Bulletins assume that the engineer has a sound knowledge of safety procedures and has been trained in the maintenance and repair of ITL equipment If you are unsure or do not understand information contained in the Service Bulletins then ask your supervisor for advice Remember SAFETY MUST COME FIRST New Perkins 1000 Series Engines Models AJ to AS amp YG TO YK Washers for the Fuel Injection Pump Gear Number Gn027 JCB Gen 092 K97 N Am Issue 1 Date February 1999 Page 1 of 1 Caution Ensure that the washers are fitted before the screws are tightened A washer part number 02 101686 is fitted to each of the screws A with effect from the following engine serial numbers A U812611C for 4 cylinder engines Y U660846C for 6 cylinder engines Engines before the above numbers do not need to have these washers fitted THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WAR
79. rnational TECHNICAL Sn INFORMATION General amp SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn020 engineer has a sound knowledge of safety procedures and has been trained in the JCB M I 612 H 548 E maintenance and repair of ITL equipment If you are unsure or do not understand information contained in the Service Bulletins then ask your supervisor for advice Remember SAFETY MUST COME FIRST Issue 1 Date April 1998 ENGINE WORKSHOP MANUALS Page 1 of 1 Perkins New 1000 Series Darwin With the introduction of the New 1000 Series range of engines Perkins produced a new Workshop Manual which is available under publication number 9806 2140 Issue 3 of this publication is now available incorporating two additional engine models AR and AS which are for machines sold primarily in North America and Scandinavia The new issue also incorporates various general revisions Any future orders for 9806 2140 will be supplied as issue 3 French and German translations of issue 3 should be available by the end of May Other languages will follow later Translated part numbers are French 9806 2141 German 9806 2142 Spanish 9806 2143 Italian 9806 2144 Note Replacement pages are not supplied for engine service manuals To obtain the latest issue a new manual must be ordered Engine models now covered by the new manual will be 4 Cylinder Models AJ to AS THIS BULLETIN IS ISS
80. rocedure All Perkins warranty claims must state clearly the symptom and cause in the comments section of the claim form If there is insufficient space on the claim form then attach a written report Failure to follow this procedure may result in the warranty claim being rejected THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I T L WREXHAM CLWYD LL13 9UF UNITED KINGDOM Page 2 of 3 Fault Finding Charis Gn004 Issue 1 Items A to O below describe possible general faults associated with turbochargers Opposite the faults is a column titled Possible Causes Code Numbers these code numbers refer to a description of possible cause s associated with the fault The descriptions for possible causes can be found on page 3 FAULT POSSIBLE CAUSES CODE NUMBERS A Not enough power 1 4 5 6 7 8 9 10 11 18 20 21 22 25 26 27 28 34 35 36 B Black smoke 1 4 5 6 7 8 9 10 11 18 20 21 22 25 26 27 28 34 35 36 C Blue smoke 1 2 4 6 8 9 17 19 20 21 22 30 31 32 34 D High lubricating oil consumption 2 8 15 17 19 20 28 29 31 32 34 E Too much lubricating oil at turbine end 2 7 8 17 19 20 22 28 30 31 32 F Too much lubricating oil at compressor end 1 2 4 5 6 8 19 20 21 28 31 32 G Not enough lubrication 8 12 14 15 16 23 24 29 32 33 37 38 H Lubricatin
81. rom the pump QZH eo al ji a Cen 4 2 Remove the gear cover from the cover of the timing case Remove the gear nut and spring washer a 4 3 Rotate the crankshaft to ensure that the keyway in the drive gear of the fuel pump is at or near to the top 4 4 Remove the setscrew and the nut of the support bracket below the fuel pump Release the flange nuts A of the fuel pump see note If access to the flange nuts is restricted use tool PD199 Note Leave one flange nut loose on the end of the thread this will prevent the pump from falling when the gear is removed step 4 5 4 5 Loosen the drive gear of the fuel injection pump with the puller PD155C and adaptors PD155B 5 as shown at B items 1 and 2 4 6 Remove the fuel pump ensure that the key does not fall from the drive shaft Fuel Injection Pump Replacement 1 Rotate the drive shaft of the fuel injection pump to align the key with the keyway in the drive gear Ensure that the key is correctly fitted and fit the fuel pump to the gear 2 Align the mark on the flange of the fuel pump with the mark on the rear face of the timing case shown at C Fit the flange nuts A and the setscrew and the nut of the support bracket Ensure that force is not applied to the fuel pump when the support bracket is fitted 3 Fit the spring washer and the nut to the drive shaft of the fuel pump and tighten the nut to 80 Nm 59 Ibf ft 8 2 kgf m Fit the gear cover to the cover of the
82. t 57 key alphanumeric 2 AA batteries Rechargeable battery pack optional Lithium backup battery External power via mains adaptor or Docking Station OPL language Database Spreadsheet and Calculator Barcode wand and RS 232 TTL and RS 232 for scanners Elasticated strap 20 to 60 Celsius Humidity 90 max non condensing One metre onto concrete Standard model splashproof optional on expansion interfaces 180mm x 90mm x 35mm 325g including batteries ae jeu sayesue ggeudye Gn019 Issue 2 YO WODX8 SOjul s yluoly l llsnpui luos u ls Joueyue S ewseyp 6s woo jaubuis yoa sAs yn oo mipo1 Jou u 9y d mewyseu owj gusa yd woo aqob byywiyiq 1 u uuqi zo00losd 81 LAN Wd dNOO 1 u lewny u les yuilnduio5 xi5 u8u 18u uuqI uuoy wov am sndwoo ZO L YZE00L YY WO OJUO olu wop 4A6 ou lu IJ ol6ue uosd zo ui6o xuiod 1 u uuqi snyi u punub uq 1l unuq sd ye00 puemAey pyjemulyosw Uuo9 yullles uJ sd 3of 3 Wew 3 066EZz2 296 L196 LZE 80S 100 8929 99S 1810 S9ZZZ8 t LL 6v6 t6 912 S044 esz z 9 996 LZY LL E96 LIEL 182 L L 0298 ZY Le 9 Y18969 p 9LSZZ8t v 9644 89 IZ Z 8896 66 S L088289 z 996 926 962 S60 2 8261 S6Z 1S8 LGEL 69 Zz 8v ZOLy 918Z 9 Spl 22SSp 99 19v 09 6 12 9 96 v v 6 g 2 9 6SrE0ezE Zr 6 82Z0Z6 pez ZSv9 699r v9 9rr69rr ae GGZE 198 S zS g 698b
83. tart 13 Insufficient lubrication 14 Dirty lubricating oil 15 Incorrect lubricating oil 16 Restricted lubricating oil supply pipe 17 Restricted lubricating oil drain pipe 18 Turbine housing damaged or restricted 19 Leakage from turbocharger seals 20 Worn turbocharger bearings 21 Excessive dirt in compressor housing 22 Excessive carbon behind turbine rotor 23 Engine speed raised too rapidly at initial start 24 Insufficient engine idle period 25 Faulty fuel injection pump 26 Worn or damaged atomisers 27 Valves burned 28 Worn piston rings 29 Lubricating oil leakage from supply pipe 30 Excessive preservation fluid on initial engine start 31 Excessive engine idle period 32 Restriction in turbocharger bearing housing 33 Restriction in lubricating oil filter 34 Wet type air cleaner Restricted dirly element viscosity of oil too low high 35 Wastegate if fitted actuator faulty or damaged 36 Wastegate if fitted valve not free 37 Engine stopped too soon from high load 38 Insufficient lubricating oil 39 Fuel leakage from fuelled starting aid 40 Crack in backplate of compressor Intemational TECHNICAL i NFORMATION General SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn005 engineer has a sound knowledge of safety procedures and has been trained in the JCB Gen 002 maintenance and repair of ITL equipment If you
84. tions 5 Fluoroelastomeric materials should NOT be incinerated If there is contamination of the skin or eyes wash the affected area with a continuous supply of clean water or with calcium hydroxide solution for 15 60 minutes Obtain immediate medical attention International TECHNICAL noe INFORMATION General SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn006 engineer has a sound knowledge of safety procedures and has been trained in the JCB Gen 021 maintenance and repair of ITL equipment If you are unsure or do not understand Issue 1 information contained in the Service Bulletins then ask your supervisor for advice Remember SAFETY MUST COME FIRST Date Feb 1993 SUBJECT Turbochargers Page 1 of 1 PRODUCTS AFFECTED Turbocharged Perkins 90 BHP Engines TO BE CARRIED OUT Information Only SERVICE INFORMATION From engine serial number No AB50440U610051X 28 1 93 a Garret turbocharger is fitted this replaces the Schwitzer unit The Garret turbocharger gives improved service reliability SERVICE PROCEDURE If for any reason a warranty repair is to be completed on the turbo unit then a full written report on the repair fault must be submitted with the claim or the Perkins Service Information ITL T I Gn004 can be used to aid fault diagnosis and specifying the fault Perkins dealers should carry out this work Failure to follow this instruction may result i
85. ug E located top right of the cylinder block 2 6 Fit new plug using Loctite 574 Multigasket 2 7 Refit flywheel housing and torque securing screws M10 to 44 Nm 33 Ibf ft and M12 to 75 Nm 55 Ibf ft 2 8 Refit flywheel using guide studs and torque retaining bolts to 105 Nm 77 lbf ft Page 3 of 3 Gn003 Issue 1 OIL LEAKAGE FROM REAR OF ENGINE cont d 3 Bridge Piece Lubrication oil leakage from the bridge piece F can be identified in two ways oil may be seen around the sump rear face or oil will be evident inside the flywheel housing There are two possible causes for leakage from the bridge piece misalignment and or lack of sealant To rectify misalignment 3 1 Remove the flywheel using guide studs N remove two diametrically opposite bolts and temporarily fit guide studs u e Ss 7 3 2 Remove the starter motor 3 3 Remove the flywheel housing it may be necessary to tap the housing using a soft hammer to disengage the housing dowels 3 4 Remove the rear seal housing as described in the section titled REAR OIL SEAL HOUSING 3 5 Remove the lubrication oil sump 3 6 Release the two securing capscrews G in the bridge piece remove the bridge piece and old sealant trom all faces Loosely refit the bridge piece and align the face of the bridge piece to the rear block face using a straight edge as shown Alignment to be within 0 05 mm 0 002 in Tighten the securing cap screws to 9 Nm 6 Ibf ft 3
86. y reason the O ring becomes damaged or separated from the fitting it can be replaced It is very important to use the correct O ring size for the fitting Any deviation in O ring size or specification eg O ring taken from a selection kit that appears to be the correct size and material will cause joint integrity and leaking problems The correct O rings X required for the various sizes of hydraulic fitting are shown below Hydraulic Fitting O ring O ring Inner O ring Section Material Size Part Number Diameter mm Diameter mm Type 1 4 BSP fitting 828 00237 6 5 0 15 1 0 0 08 A 3 8 BSP fitting 2301 0006 8 1 0 15 1 6 0 08 A 1 2 BSP fitting 2301 0010 12 1 0 2 1 6 0 08 A 5 8 BSP fitting 2301 0011 13 1 40 2 1 6 0 08 A 3 4 BSP fitting 2301 0015 17 1 0 2 1 6 0 08 A 1 BSP fitting 2301 0018 22 1 0 25 1 6 0 08 A 11 4 BSP fitting 2302 0907 29 1 0 25 1 6 0 08 B 11 2 BSP fitting 2302 0908 35 1 0 3 1 6 0 08 B Material Type A Nitrile synthetic rubber suitable for use between 40 and 135 Celsius with a hardness value of 80 IRHD B Polyurethane material suitable for use between 40 and 130 Celsius with a Shore hardness value of 93A Ensure that only the above O ring part numbers are used as replacements in ITL hydraulic hose fittings THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARR

Perkins General TI Bulletin - Cape Dory Sailboat Owners Association

Contents

Download Pdf Manuals

Related Search

Related Contents