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' Perkins General Technical Information Bulletin'




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CONTENTS
TECHNICAL
INFORMATION
GENERAL TI BULLETIN INDEX
Click on bulletin title to view
TI No Issue Subject Products Affected Date
Gn 001 1 Tappet Adjustment Perkins 1000 Series Engines Mar 90
Gn 002 1 Rocker Shaft Security Perkins 1000 Series Engines July 90
Gn 003 1 Crankshaft Rear Main Oil Seal Housing Perkins 1000 Series Engines Mar 91
Gn 004 1 Turbocharger Fault Diagnosis Perkins 1000 Series Engines Dec 91
Gn 005 1 Health Safety
Materials All Mar 92
Gn 006 1 Turbochargers Turbocharged Perkins 90 BHP Feb 93
Gn 007 1 Piston Piston Ring Improvements 4 cyl Turbocharged Engines Feb 93
Gn 008 1 Alternator Connections on Mainframe Harness Perkins Engines as applicable Nov 93
Gn 009 1 Low Sulphur Fuels Perkins 1000 Series Engines Mar 94
Gn 010 1 Brake Master Cylinder Kits As Detailed on Bulletin Mar 94
Gn 011 1 Hydraulic Ram Jun 94
Gn 012 1 Oil Pump Idler Gear Perkins 1000 Series Engines July 94
Gn 013 1 Stake Nuts Input and Output Flanges All ITL Transmissions Axles Feb 95
Gn 014 1 Fuel Injection Pump Seal Failure Perkins 1000 Series Engines Aug 95
Gn 015 1 Engine Lubrication System Relief Valve Housing Perkins 1000 Series Engines Feb 96
Gn 016 1 Parkbrake Clevis Pin Improvements Trans with Clysdale Park Brake Feb 96
Gn 017 1 Starter Motors All Perkins Engines Mar 96
Gn 018 2 Magneti Marelli Support All Perkins Engines Feb 99
Gn 019 2 Service Department Computer Diagnostic Equipment Dec 98
Gn 020 1 Engine Workshop Manuals Perkins New 1000 Series April 98
Gn 021 1 Axle Propshafts All machine installations April 98
Gn 022 1 Engine Silencer Improvements Perkins Engines Nov 90
Gn 023 1 Change of position exhaust manifold bushes New Perkins 1000 Series Oct 98
Gn 024 1 Pin Timed Fuel Injection Pumps All Perkins New 1000 Series Jan 99
Gn 025 1 Improved Oil Cooler with Pressed Steel Cover All Perkins 1000 Series Jan 99
Gn 026 1 Introduction of Wear Sleeve for Front Oil Seal Perkins 4236 1000 Series Feb 99
Gn 027 1 Washers for Fuel Injection Pump Gear New Perkins 1000 Series Feb 99
Gn 028 1 Improved Exhaust Valve Guide New Perkins 1000 Series Feb 99
Gn 029 1 ITL Hydraulic Hose Fittings and Orings All ITL Products Mar 99
Gn 030 1 Perkins Low Emission Diesel Engine New Perkins 1000 Series Apr 99
Gn 031 1 Hydraulic Ram Sealing Procedure All Machines with ITL Rams Nov 99
Gn 032 1 Oil Control Rings 1000 Series models AR AS Jan 01
Gn 033 1 Plastic Thermostat Housings All Perkins 1000 Series Jan 01
Gn 034 1 Introduction of Improved Fuel Lift Pump All Perkins 1000 Series Feb 01
Gn 035 1 Coolant Pressure Cap All Perkins 1000 Series Apr 01
Gn 036 1 Engine Oil Consumption Perkins Low Emission Engines Apr 01
Gn 037 1 Engine Rocker Cover Perkins Low Emission Engines May 01
Gn 038 1 New ITL NAPSC Network New North American Network Jan 02
Gn 039 1 Safety Precautions When an Engine is Cleaned All Engines Sep 02
DATE DEC 02 PAGE 1 OF 1 ISSUE 8
INDEX
TECHNICAL
INFORMATION General
SAFETY NOTICE Instructions in the Service Bulletins assume that the Number has a sound knowledge of safety procedures
and has been trained in the JCB Gen and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask
your supervisor for advice
Issue 1
Remember SAFETY MUST COME FIRST Date March Tappet Adjustment
Page 1 of 1
PRODUCTS AFFECTED All Perkins 1000 series Engines
TO BE CARRIED OUT At Next Service As tappet adjustment is required it is important to retorque the adjusting screw lock nut A If this
is not 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 ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM
INDEX
TECHNICAL
INFORMATION General
SAFETY NOTICE Instructions in the Service Bulletins assume that the Number has a sound knowledge of safety procedures and
has been trained in the JCB Gen and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your
supervisor for advice
Issue 1
Remember SAFETY MUST COME FIRST Date July Rocker Shaft Security
Page 1 of 1
PRODUCTS AFFECTED All Perkins 1000 Series Engines
TO BE CARRIED OUT Information of new fasteners for the rocker 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 tighten the new fasteners to 40 Nm 30 lbf ft
PARTS from engine serial number NUT replaces SET SCREW replaces 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 ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM
INDEX
TECHNICAL
INFORMATION General
SAFETY NOTICE Instructions in the Service Bulletins assume that the Number has a sound knowledge of safety procedures
and has been trained in the JCB Gen and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask
your supervisor for advice
Issue 1
Remember SAFETY MUST COME FIRST Date March 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 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 Remove the flywheel using guide studs remove two
diametrically opposite bolts and temporarily fit guide
studs
3 Remove seal housing 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 PD145D see Perkins Service Manual this
will preset the seal depth as 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 PD145D 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 lbf 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 ITL 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 Main Oil Gallery 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
11 Remove the 12 Remove the flywheel using guide studs remove two
diametrically opposite bolts and temporarily fit guide
13 Removethe starter motor
14 Remove the flywheel housing it may be necessary to
tap the housing using a soft hammer to disengage
the housing dowels
15 Remove the threaded gallery plug D located top left
of cylinder block using appropriate allen key
16 Fit a new plugwasher using Loctite 574 Multigasket
and torque to 85 Nm 625 lbf ft
17 Refit flywheel housing and torque securing screws
M10 to 44 Nm 33 lbf ft and M12 to 75 Nm 55 lbf ft
18 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 on the manifold side
To rectify
21 Remove the 22 Remove the flywheel using guide studs remove two diametrically opposite bolts and temporarily fit guide
studs
23 Remove the starter motor
24 Remove the flywheel housing it may be necessary to tap the housing using a soft hammer to disengage the
housing dowels
25 Remove camshaft end plug E located top right of the cylinder block
26 Fit new plug using Loctite 574 27 Refit flywheel housing and torque securing screws M10 to 44 Nm 33 lbf ft and M12 to 75 Nm 55 lbf ft
28 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 contd
3 Bridge 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 andor lack of sealant
To rectify 31 Remove the flywheel using guide studs
remove two diametrically opposite bolts and
temporarily fit guide studs
32 Remove the starter motor
33 Remove the flywheel housing it may be
necessary to tap the housing using a soft
hammer to disengage the housing dowels
34 Remove the rear seal housing as described
in the section titled REAR OIL SEAL
HOUSING
35 Remove the lubrication oil sump
36 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 005 mm 0002 in Tighten the securing cap screws to 9 Nm
6 lbf ft
37 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
38 Refit flywheel housing and torque securing screws M10 to 44 Nm 33 lbf ft and M12 to 75 Nm 55 lbf ft
39 Refit flywheel using guide studs and torque retaining bolts to 105 Nm 77 Ibf ft
To rectify lack of sealant
310 Remove lubrication oil sump
311 Complete sealing process as described in step 37 above
312 Refit lubrication oil sump using a new joint
INDEX
TECHNICAL
INFORMATION General
SAFETY NOTICE Instructions in the Service Bulletins assume that the Number has a sound knowledge of safety
procedures and has been trained in the JCB Gen and repair of ITL equipment If you are unsure or do not contained in the Service
Bulletins then ask your supervisor for advice
Issue 1
Remember SAFETY MUST COME FIRST Date Dec
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 When inspected by the supplier no fault has been
found or the fault differs from the failure code andor description on the Procedure
1 To assist in the correct diagnosis of general faults please refer to the attached fault finding charts
2 Fuel Starting Aid 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 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
21 How to check the fuelled starting aid
211 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
212 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 the
union nut at the starting aid
213 Start the engine and operate it at low speed Check
that there is no fuel leakage from the valve of the
starting aid
214 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
215 If there is a leak from the valve of the starting aid fit a new starting aid
3 Warranty Claim Procedure
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 ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM
Page 2 of 3 Gn004 Issue 1
Fault Finding Charts
Items A to O below describe possible general faults associated with Opposite the faults is a column
titled Possible Causes Code Numbers these code numbers refer to a description of possible causes the fault The descriptions for possible causes can
be found on page 3
FAULT POSSIBLE CAUSES CODE NUMBERS
A Not enough power Black smoke Blue smoke
High lubricating oil consumption Too much lubricating oil at turbine end Too much lubricating
oil at compressor end Not enough lubrication 3738
H Lubricating oil in the exhaust manifold Inside of the induction manifold wet Damaged compressor impellor
Damaged turbine rotor Rotating assembly does not turn freely Worn bearings
bearing bores journals Noise from turbocharger 1 3 4 5 6 7 8 910 1 1
Sludge or carbon deposit in bearing housing 2 1 1 13 14 15 1 7 18 24 29 33 37 38
Page 3 of 3 Gn004 Issue 1
Fault Finding Charts OF POSSIBLE Element of the air filter dirty
2 Restricted crankcase breather
3 Element of the air filter missing leaking or not sealing correctly Loose connection to Internal distortion or restriction in pipe from air
filter to crossover pipe turbocharger to induction manifold
6 Restriction between air filter and Restriction in exhaust system
8 Turbocharger loose or loose
9 Induction manifold cracked or loose flanges Exhaust manifold cracked or loose flanges Restricted exhaust system
12 Delay of lubricating oil to turbocharger at engine start
13 Insufficient Dirty lubricating oil
15 Incorrect lubricating oil
16 Restricted lubricating oil supply pipe
17 Restricted lubricating oil drain pipe
18 Turbine housing damaged or 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 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 lowhigh
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
INDEX
TECHNICAL
INFORMATION General
SAFETY NOTICE Instructions in the Service Bulletins assume that the Number has a sound knowledge of safety procedures and
has been trained in the JCB Gen and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your
supervisor for advice
Issue 1
Remember SAFETY MUST COME FIRST Date March HEALTH SAFETY
Page 1 of 2
AFFECTED ALL
WARNING
Due to recent publicity regarding the potential hazards associated with the handling of Fluorel Technoflon etc commonly used in the production of
oil seals and gaskets for the 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 normal handling of new cured components at ambient temperature presents no known hazard
and requires no special handling of Old Components during Servicing
No special precautions are required when handling old material that has been subjected only to
normal service conditions However before removal a preliminary visual examination should establish service temperatures have been exceeded giving
rise to thermal degradation If evidence of etc is found the material and surrounding areas should not be touched without observing the of Old
Material Subjected to Abnormally Hiqh temperatures in excess of 300 C eg engine fires 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 or components that have been subjected to abnormally high temperatures should be subjected to the
following procedure which must be conducted by competent personnel This will require the use safety equipment neoprene rubber or heavy duty gloves
plus special safety glasses are 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 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 ITL 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 materials should NOT be 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 1560 minutes Obtain immediate medical attention
INDEX
TECHNICAL
INFORMATION General
SAFETY NOTICE Instructions in the Service Bulletins assume that the Number has a sound knowledge of safety procedures
and has been trained in the JCB Gen and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask
your supervisor for advice
Issue 1
Remember SAFETY MUST COME FIRST Date Feb Turbochargers
Page 1 of 1
PRODUCTS AFFECTED Turbocharged Perkins 90 BHP Engines
TO BE CARRIED OUT Information engine serial number No 28193 a Garret turbocharger is fitted this replaces unit The Garret turbocharger
gives improved service PROCEDURE
If for any reason a warranty repair is to be completed on the turbo unit then a full written report on the be submitted with the claim or the Perkins
Service Information ITL TI Gn004 can be used to aid fault diagnosis
and specifying the dealers should carry out this to follow this instruction may result in the claim being PART NO Unit
02200460 was Schwitzer unit part no 02200340 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 ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM
INDEX
TECHNICAL
INFORMATION General
SAFETY NOTICE Instructions in the Service Bulletins assume that the Number has a sound knowledge of safety procedures
and has been trained in the JCB and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your
supervisor for advice
Issue 1
Remember SAFETY MUST COME FIRST Date Feb Piston and Piston
Ring Improvements Page 1 of 1
PRODUCTS AFFECTED 4Cylinder Turbocharged Engines
TO BE CARRIED OUT Information new improved oil control piston and ring pack has been fitted to the Perkins 4cylinder turbocharged engines
from
January 1993 Engine cutin 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 beddingin period The
average oil to fuel used consumption is reduced from 05 to 02 The following information should be new machine Engine runningin is not a
Periods of engine idlingtick over should be kept to a minimum to prevent cylinder bore 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 deglaze the cylinder bore glaze
busting
3 JCB Technical Information Bulletin 2004 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 03 to 05 of fuel
used further investigation may be required if the oil consumption exceeds 07
ii On engines fitted with the new piston and ring pack further investigation may be required if the oil consumption
exceeds 05
PARTS PART NO BHP 90 96 96 Engine
1 Piston Assembly 02200860
2 Ring Kit 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 ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM
INDEX
TECHNICAL
INFORMATION General
SAFETY NOTICE Instructions in the Service Bulletins assume that the Number has a sound knowledge of safety procedures and
has been trained in the JCB 2109 C26N and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your
supervisor for advice
Issue 1
Remember SAFETY MUST COME FIRST Date Nov Alternator Connectors on the
Mainframe Harness Page 1 of 1
PRODUCTS AFFECTED Perkins Engines as BE CARRIED OUT Information types of alternator been supplied The plug connector item X
FIG 1
is no longer supplied Instead a ring
terminal and lucar connector item Y
FIG 2 are now the harness connectors and alternator the wire numbers
If the harness has a euro item X fitted install the
harness as shown in FIG 1 If the
harness has a ring terminal and item Y fitted install the FIG 1
harness as shown in FIG 2
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 SERVICE DEPARTMENT OF ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM
INDEX
TECHNICAL
INFORMATION General
SAFETY NOTICE Instructions in the Service Bulletins assume that the Number has a sound knowledge of safety
procedures and has been trained in the JCB Gen 028 K58N and repair of ITL equipment If you are unsure or do not contained in the Service
Bulletins then ask your supervisor for advice
Issue 1
Remember SAFETY MUST COME FIRST Date March Low Sulphur
Fuels Page 1 of 1
MACHINES AFFECTED All Perkins 1000 Series Engines
TO BE CARRIED OUT Information sulphur fuels are commonly used throughout the world These fuels contain fewer lubrication additives The
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 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 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 ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM
INDEX
TECHNICAL
INFORMATION General
SAFETY NOTICE Instructions in the Service Bulletins assume that the Number has a sound knowledge of safety
procedures and has been trained in the JCB and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins
then ask your supervisor for advice
Issue 1
Remember SAFETY MUST COME FIRST Date Mar 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 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 reseal old master cylinders also by untrained customers is not relevant
Service Manual procedures will be updated Cylinder Seal Kit Part Numbers
15107001
15104700
15106600
15903803
15904102
15904301
Master cylinder 15908200 is no longer available If a master cylinder is required then part number be used either 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 ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM
INDEX
TECHNICAL
INFORMATION General
SAFETY NOTICE Instructions in the Service Bulletins assume that the Number has a sound knowledge of
safety procedures and has been trained in the JCB and repair of ITL equipment If you are unsure or do not contained in the
Service Bulletins then ask your supervisor for advice
Issue 1
Remember SAFETY MUST COME FIRST Date June
Hydraulic Ram 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 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
IMPERIAL RAM
4 in x 2 in
1972 to 1979
End Cap
Gland Seals located in Gland Bearing
Split Pin UN SERIES RAM
100 mm x 60 mm
Loctite Piston 80 87
Wire Clip Piston 87 90
Dowel Piston 90 92
Gland Nut including Seals
Gland Bearing
Dowelled Piston Head
METRIC
SERIES RAM
100 mm x 60 mm
1992 to 1993
Gland Nut Bearing One Piece
may also be fitted with Glazier Bearing
Dowelled Piston Head
METRIC
FABRICATED
100 mm x 60 mm
Current 1994
Gland Nut Bearing One Piece
Case End Welded to Tube Glazier Bearing except 70 x 40 rams
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 ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM
INDEX
TECHNICAL
INFORMATION General
SAFETY NOTICE Instructions in the Service Bulletins assume that the Number has a sound knowledge of safety procedures and
has been trained in the JCB Gen 031 K60N and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask
your supervisor for advice
Issue 1
Remember SAFETY MUST COME FIRST Date July Oil Pump Idler Gear
Page 1 of 1
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 A
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 B
main bearing passes down the channel in the body of the pump
to the oil hole in the idler shaft The lubricating oil then 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
S209440
bush of the idler gear renew the bush part 02290006 Fit the
new idler shaft part 02201131 and the new lubricating oil
pump part 02201050 four cylinder engines or 02201130 six
cylinder the lubricating oil pump and the idler shaft in accordance with
the procedure given in operations 19A06 and of the workshop manual In addition to 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
Caution The idler shaft for the lubricating oil pump used on E
four cylinder engines is not retained in the bearing cap by a pin
but is retained by Loctite 648 Retainer part 41010651
S209450
If the new lubricating oil pump is fitted the endfloat for the idler
gear is as follows
Four cylinder engines 00120643 mm in
Six cylinder engines 00200650mm in
PARTS No Description Part No Bush 02201050 Pump 4
Cylinder Shaft 02201130 Pump 6 Cylinder Loctite 648 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 ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM
INDEX
TECHNICAL
INFORMATION General
SAFETY NOTICE Instructions in the Service Bulletins assume that the Number has a sound knowledge of safety procedures
and has been trained in the JCB Gen 035 F47N and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins
then ask your supervisor for advice
Issue 1
Remember SAFETY MUST COME FIRST Date Feb Stake Nuts Input and
Output Flanges Page 1 of 1
PRODUCTS AFFECTED All ITL Transmissions and Axles
TO BE CARRIED OUT Information Only
SERVICE 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 The stake nut for the gearbox rear 2WD output flange is now
manufactured from 46 mm hexagonal bar The existing 134 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
with a new one if damaged or distorted Output Flanges
The axle flanges and transmission are now hardened at the sealing Note The illustration shows a
area The hardened flanges prevent possible typical axle leaks and loss of bearing preload by
reducing the risk of fretting and subsequent A
loosening of the flanges
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 No Description Qty Combine Stake NutWasher AR M22
82601483 Combine Stake NutWasher AR M24
82601551 Stake Nut AR 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 ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM
INDEX
TECHNICAL
INFORMATION General
SAFETY NOTICE Instructions in the Service Bulletins assume that the Number has a sound knowledge of safety procedures and
has been trained in the JCB Gen 041 K68N and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then
ask your supervisor for advice
Issue 1
Remember SAFETY MUST COME FIRST Date August Fuel Injection Pump Seal
Failure Page 1 of 2
PRODUCTS AFFECTED Perkins 1000 Series Engines
TO BE CARRIED OUT By Perkins 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 CAV engineer therefore please note the following
1 The OEM Distributor must contact the local CAV agent and quote reference number D137
2 The OEM Dealer and the CAV agent then arrange with the machine owner a suitable time to complete the repair
procedures repair time 30 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 CAV 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 Injection Pump Tools Required Gear Puller part
number PD155C Note Existing workshop special tools these items
Adaptors part number PD155B5 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
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 ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM
Page 2 of 2 Gn014 Issue 1
SERVICE PROCEDURES Remove the injection pump
41 Remove all the pipes cables and electrical
connections from the pump
42 Remove the gear cover from the cover of the timing
case Remove the gear nut and spring washer
43 Rotate the crankshaft to ensure that the keyway in
the drive gear of the fuel pump is at or near to the C
S235040
44 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 45
45 Loosen the drive gear of the fuel injection pump
with the puller PD155C and adaptors PD155B5 as
shown at B items 1 and 2
46 Remove the fuel pump ensure that the key does
not fall from the drive shaft
S235030
Fuel Injection Pump 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 82 kgf
m Fit the gear cover to the cover of the 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 PARTS
Part No Description Qty Gasket 1 Injection Pump to Timing Gasket 1 Injection
Pump Gear Cover
INDEX
TECHNICAL
INFORMATION General
SAFETY NOTICE Instructions in the Service Bulletins assume that the Number has a sound knowledge of safety procedures and has
been trained in the JCB Gen 038 F66N and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your
supervisor for advice
Issue 1
Remember SAFETY MUST COME FIRST Date Feb 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 possibility exists that engine relief valve housing A
may fail The relief valve controls the engine lubricating A
system oil pressure therefore a failure of the housing
could result in the loss of engine oil pressure and damage to the has shown that the relief valve housing has D
been machined incorrectly and remedial procedures have
already been implemented to ensure all relief valve E
housings are now machined to the correct the relief valve housing as described in The following procedures apply to a typical machine
the method for gaining access to the engine oil relief valve
may differ slightly
1 Park the machine on firm level ground engage the
3766K021 3766K021
parking brake and set the transmission to neutral
Lower the attachments to the ground and stop the
2C 1B
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 to Perkins dealers for warranty information and BY THE TECHNICAL SERVICE DEPARTMENT OF ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM
ENGLISH
Page 2 of 2 Gn015 Issue 1
SERVICE PROCEDURE Provide a support for the sump and remove the sump retaining bolts Lower the sump and remove the sealing
gasket
6 Inspect the relief valve housing
61 Look at the side of the relief valve housing A for the number
62 If the number has a 1 below it as shown at B then the housing is made to the correct move to step 9
63 If the number has a 2 below it as shown at C then the housing is made to the wrong 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 Remove the relief valve housing retaining
bolt D and then remove the relief valve housing A
8 Fit a new replacement relief valve housing torque tighten the retaining bolt to 22 Nm 16 lbf 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
9 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 lbf ft Refit the dipstick and
dipstick tube
10 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
Part No Description Qty Relief Valve Assy 1 Turbo Relief Valve Assy 1
Naturally Aspirated Engine Sump Gasket 1 Cast Iron Engine Sump Gasket 1 Alloy
Drain Plug O ring 1 available only in units of 50 part number 02200198A
INDEX
TECHNICAL
INFORMATION General
SAFETY NOTICE Instructions in the Service Bulletins assume that the Number has a sound knowledge of safety procedures and
has been trained in the JCB 2156 D19N and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask
your supervisor for advice
Issue 1
Remember SAFETY MUST COME FIRST Date Feb Parkbrake Clevis Pin
Improvements Page 1 of 2
PRODUCTS AFFECTED Transmissions with Clysdale Type Park Brake
TO BE CARRIED OUT Information 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 with the clevis pin arrangement When required the shouldered bolts can be fitted as
described in 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
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 No Part No Description Qty Comments
A 82601596 Shouldered Bolt 1 Parkbrake cable to parkbrake lever
B 82601597 Shouldered Bolt 1 Parkbrake cable to caliper
E 14200007Z 8 mm Flat Washer 2
F 14200006Z 6 mm Flat Washer 2
G 13700103Z 6 mm Nut 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 ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM
Page 2 of 2 Gn016 Issue 1
A F
INDEX
TECHNICAL
INFORMATION General
SAFETY NOTICE Instructions in the Service Bulletins assume that the Number has a sound knowledge of safety procedures and
has been trained in the JCB Gen and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your
supervisor for advice
Issue 1
Remember SAFETY MUST COME FIRST Date March 1996
SUBJECT Starter Motors Page 1 of 1
PRODUCTS AFFECTED All Perkins 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 engine serial cutin 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 with the earlier starter motors as detailed below For applications refer to the parts that all starter motors
failing within the warranty period should be repaired by the nearest Magnetti See TI Gn018 for list of Magneti Marelli Perkins or Perkins Dealer for
further No Starter motor left hand mounting supersedes Starter motor right hand mounting supersedes 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 ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM
INDEX
TECHNICAL
INFORMATION General
SAFETY NOTICE Instructions in the Service Bulletins assume that the Number has a sound knowledge of safety
procedures and has been trained in the JCB MI 461H and repair of ITL equipment If you are unsure or do not contained in the Service
Bulletins then ask your supervisor for advice
Issue 2
Remember SAFETY MUST COME FIRST Date Feb Magneti Marelli
Support Page 1 of 5
PRODUCTS AFFECTED All Fitted with Magneti Marelli Alternators andor Starter Motors
From 1st January 1996 Service Warranty Support for Magnetti Marelli electrical equipment fitted on Perkins Engines
will be provided by Magnetti Marelli addresses of the Magneti Marelli European main headquarters are listed below The remaining pages in your
country so for instance the translated JCB French version of this bulletin will only list the network the German the German network and so on If
there is no local Magneti Marelli agent can either be repaired by a local electrical agent and the repair invoice submitted with a to a Perkins
Dealer or if required a new unit can be supplied by a Perkins MARELLI SERVICE Magneti Marelli Aftermarket GERMANY
Magneti Marelli KV
Shaftsmoor Lane 71
Hall Green 74078 Heilbronn
Birmingham Germany
B28 8SW
Tel Tel 01216258788 Fax 0049 7131176928
Fax 01216258625
SPAIN Magneti Marelli Iberica
ITALY Magneti Marelli Avda de Roma 8082
Viale Aldo Borletti 6163 08015 Barcelona
20011 Corbetta Spain
Milano
Italia Tel
Fax Tel Fax Magneti Marelli France
19 Rue Lavoisier Note If difficulty is experienced in finding support or
92000 Nanterre overseas warranty cover contact Perkins UK on
France
Tel UK 440 1733 567474
Tel Fax 0 1733 582240
Fax 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 ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM
NAME ADDRESS TOWN COUNTY POST TELEPHONE
CODE Auto Electrical 357 Bath Road Brislington Bristol Avon BS4 3EU
Page 2 of
Automotive Unit 4 Locksbrook Court Locksbrook Road Bath Avon BA1 3EN Services Ltd
Murdock Road Bedford Bedfordshire MK41 7RA Ltd 4244 Hasting Street
Luton Bedfordshire LU1 5BQ Automotive Ltd 13 The Paddock Hambridge
Road Newbury Berks RG14 5TQ Automotive Ltd 4 Nimrod Way Elgar Road
Reading Berks RG2 0EB Automotive Ltd 13 Eastheath Avenue Wokingham
Berks RG11 2PP Automotive Ltd 6 Bracknell Business Centre Downmill Road Bracknell Berks
RG12 1QS Automotive Ltd 2 Bridgegate Business Park Gatehouse Way Aylesbury Bucks HP19 3XN
Automotive Ltd 9 Wessex Road Bourne End Bucks SL8 5DT Automotive Ltd
22a Buckingham Avenue Slough Bucks SL1 3EA Automotive Ltd 2b Alma Road
Ind Estate Chesham Bucks HP5 3HB Car Ltd 19 Harvester Way
Fengate Peterborough PE1 5UT Battery Services Ltd 100102 King Street
Dukinfield Cheshire SK16 4JZ North East Ltd Portrack Grange Road Stockton on Tees
Cleveland TS18 2PH Auto Supplies Head Office 42 West Hill St Austell Cornwall
PL25 5EY Auto Supplies Church Works Mount Street Penzance Cornwall TR13 2EU Auto
Supplies 4951 Wendron Street Helston Cornwall Auto Supplies
Penmarrin House Commercial Road Penryn Cornwall Auto Supplies Trevenna House
Nettles Hill Redruth Cornwall TR15 1AL Auto Supplies Units 1 2 Old Sation Yard
Berrycombe Road Bodmin Cornwall Auto Supplies Eddystone Rd Ind Estate
Wadebridge Cornwall Auto Supplies 1 Miller Bus Park Station Road Liskeard
Cornwall PL14 4DA Services Marsh Green Road Marsh Green Trading Est Exeter Devon
0139254931
Gn018
NAME ADDRESS TOWN COUNTY POST TELEPHONE
CODE Auto 119 Victoria Road Romford Essex RM1 2LX 01708722913
Page 3 of 5
Motex Express Auto Factors 14 Oban Court Hurricane Way Wickford Essex SS11 8YB ESTER
Central Motor Factors 913 High Street Lydney Gloucester GL15 4DP Motor Factors
New Road Parkend Lyndey Gloucester GL15 4JA Automotive 53 St Catherine Street
Gloucester GL1 2BS Automotive Unit 5 Lower Mill Street
Cheltenham Gloucester GL51 8JN Automotive Riverside Works Severn Road Gloucester
GL1 2LE Ltd Aldershot Truck Spares 16 Connaught Road Aldershot Hampshire GU12 4RN Ltd
Eastern Road Aldershot Hampshire GU12 4TD Ltd Unit 1 Amey
Ind Est Frenchmans Road Petersfield Hampshire GU32 3AN Ltd 103 Longspring
Watford Herts WD2 5PO Ltd 7 Railway Place Hertford
Herts SG13 7BS Walker JFK Industrial Estate Naas Road Dubln 12 Ireland
Walker College Commercial Park Dennehys Cross Cork Ireland Walker
23 Nicholas Street Limerick Ireland Automotive Ltd 43 Sittingbourne Ind Park
Crown Quay Lane Sittingbourne Kent ME10 3JG Battery Services Ltd School Lane
Rochdale Lancashire OL16 1QR Battery Services Ltd Elliot House Greenacres Road Oldham
Lancashire OL4 1HB Jones Diesel Service Ltd Nuttall Street Manchester Lancashire M16 9JA
Distribution Cocker Road Bamber Bridge Walton Summit Ind Est Preston Lancashire PR5 8AL Auto Elec Diesel Ltd Unit
220 Bamber Bridge Walton Summit Ind Est Preston Lancashire PR5 Car Truck Brownlow Street
Stamford Lincs PE9 2EL Trade Services 246250 Cavendish Road Balham
London SW12 0BY Ltd Hillway Highgate London N6 6QE
South Wales Ynysangharad Road Pontypridd Mid Glamorgan CF37 4DA 01443405726
Gn018
NAME ADDRESS TOWN COUNTY POST TELEPHONE
CODE Automotive Ltd 96 Oxford Road Denham Uxbridge Middlesex UB8 1LV 01895256451
Page 4 of Auto Electrical 15 Higham Street Norwich Norfolk NR2 4TE Page Ltd
Unit 25 Raylor Centre James Street York North Yorkshire YO1 3DP Page Ltd Unit 6 Thirsk
Ind Park York Road Thirsk North Yorkshire YO7 3TA Ltd Unit 17 Provincial Works The Avenue
Harrogate North Yorkshire HG1 4QE Ltd Westgate Otley
North Yorkshire LS21 3AT Magneto Trent Works Canel Street Nottingham Notts
NG1 7HL Automotive Ltd 29b Milton Park Abingdon Oxon OX14 4RT Automotive
Ltd 59 Murdock Road Bicester Oxon OX6 7PP A Factors Ltd 2 West
Hendersons Wynd Dundee Scotland DD1 5BT A Factors Ltd 42 Canmore Street
Forfar Scotland A Factors Ltd 13 Baltic Street
Montrose Scotland A Factors Ltd Unit 7 whitefriars Perth
Scotland Vehicle Equipment 13 Scotland Street Glasgow Scotland G5 9PU
R Harris Ltd 2440 Seaward Street Glasgow Scotland G41 1HL Page Ltd
Unit 4 Silver Court Intercity Way Bramley South Yorkshire L13 4LY Auto Factors Newcross Street
Sutton in Ashfield South Yorkshire Bar Components Ltd Kettlebrook Road
Tamworth Staffs B77 1AG Bar Components Ltd 1 Horninglow Street Staffs
DE14 1NG Motor Factors Brownhills Business Park Linden Road Brownhills Staffs WS8 7BW Diesel
Mason Street Fenton Stoke on Trent Staffs ST4 3NE Ltd 285 Worplesdon
Road Guildford Surrey GU2 6XN Ltd Unit 1 Goldsworth Ind Est Goldworth
Road Woking Surrey GU21 1LY Ltd Hare Lane Goldalming
Surrey GU7 3EG Ltd Unit 1 Weydown Road Halsmere Surrey
GU27 1DW Ltd 13 East Street Farnham Surrey GU9 7RX Ltd
Guildford Truck Spares 139 Worplesdon Road Guildford Surrey GU2 6XA 01483573311
Gn018
NAME ADDRESS TOWN COUNTY POST TELEPHONE
CODE Ltd 282 Walton Road East Molesey Surrey KT8 0HU

Page 5 of 5
ARE Ltd Unit 1 Downside Guildford Road Chertsey Surrey KT16 9BQ Ltd
78 Holmethorpe Avenue Holmethorpe Ind Est Redhill Surrey RH1 2NL Ltd Walton
Motor Factors 151153 Hersham Road Hersham Surrey KT12 5NR AND WEAR
Andrew Page Ltd Unit 15 Brough Park Fossway Tyne and Wear NE6 2YF Auto Electrical Ltd St
Lawrence Road Tyne and Wear NE6 1AQ Motor Factors Units 1011 Eruria Way Barton
Park Ind Estate Bilston West Midlands WV14 7AH Motor Factors Walsall Road
Willenhall West Midlands WV13 2ED Motor Factors Units 2 3 6 Brandon Way Ind Estate West Bromwich
West Midlands B70 9PW Page Ltd Apson House 5359 Mabgate Leeds West Yorkshire
LS9 7DY Page Ltd Grantley Way Stanley Road Wakefield West Yorkshire WF1 4PY Page
Ltd Unit 5 Hall Lane Bradford West Yorkshire BD4 7DG Page Ltd
Units 2930 Beck Road Ringway Ind Estate Huddersfield West Yorkshire HD1 5DG Page Ltd Units 1517
Ashley Ind Est Elmfield Road Morley West Yorkshire LS27 0EL Motor Spares Ltd 16 Church Street
Melksham Wilts SN12 6LS Ltd Wykeham Industrial Estate Easton Lane
Winnall Wincester SO23 7RX Electric Worcester Ltd Gregorys Mill Street Worcester
WR3 8BS Jahre Motor AS Brynsveien 24 0602 Oslo 6
Finland Atoy OY1 54 0200 Dybbroe AS Tomsagervey 810 08230 Aabyhoj Aarhus
Gn018
INDEX
TECHNICAL
INFORMATION General
SAFETY NOTICE Instructions in the Service Bulletins assume that the Number has a sound knowledge of safety procedures
and has been trained in the JCB MI and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your
supervisor for advice
Issue 2
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 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 work
To support transmissions fitted with these systems Distributor Service Personnel need to have the Diagnostic equipment All new ITL electronic systems
will use the PSION Workabout hand held computer
for 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 infield 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 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 ITLJCB part No
RS 232 and TTL Serial Interfaces 1800 000611 89200924
Docking Holster One required per depot for 1801 000301 89200925
transferring software from PC
to PSION Workabout
PsiWin Link and Software To transfer JCB software from 1601 003910 89200926
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 89200963
Cable links to machine
Connecting cable for connecting the PSION Workabout to any ITL machine is part no 89200952 available
from JCB Service
A service kit comprising the above items is available JCB part No 89200962
ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM
2 of 3 Gn019 Issue 2
Availability
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 details of the Notebook PC are
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 311 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
Any reputable computer supplier JCB Service or ITL direct
The facts about 16bit NEC V30H 80C86 compatible windowing environment
MSDOS compatible file 256k 1 MByte RAM 2 Solid State Disk drives for additional 16Mbytes
LCD Screen 39 characters x 12 lines 240x100 pixels
Black and grey scale 57 key Supply 2 AA batteries Rechargeable battery pack
optional Lithium backup battery
External power via mains adaptor
or Docking applications OPL language Database
Spreadsheet and interfaces Barcode wand and RS232
TTL and RS232 for Elasticated Conditions 20 to 60 Celsius
Humidity 90 max
resistance One metre onto Standard model splashproof
optional on expansion 180mm x 90mm x 35mm
325g including DISTRIBUTOR Country Address Telephone
Number Fax Number Email
ASK INTERNATIONAL SARL ALGERIA 94 RN 133 42380 SOUIDANIA WTIPASA 213 2791130 213
2791130
3 of 3
PSIAR ARGENTINA AVENIDA DE MAYO 963 3RD FLOOR BUENOS AIRES1084 541 345 2351 541
345 3605 PTY AUSTRALIA RMB 3585 VALLEY ROAD KANGY ANGY NEW SOUTH WALES 2258 61 4362 2014
61 4362 2014
HAYWARD AUSTRIA POSTFACH 79 A5071 WALS 405 43 662 8587 0 43 662 8587 80
WORLD BAHRAIN 273 EXHIBITION AVENUE HOORA PO BOX 26178 MANAMA 973 293 493 973 292 253
SHARANEE LTD BANGLADESH B172 LANE23 NEW DOHS DHAKA 1206 880 2885 219 880 2881
DISTRIBUTION BELGIUM KORTE WINKLESTRAAT 15 B2000 ANTWERPEN 32 3232 3468 32 3226 1749
KPF CONSERVE CO BRUNEI DARUSSALANO 117 BANGUNAN KUMBANG PASANG
JALAN GADONG 3180 BANDER SERI BEGAWAN 673 2448101 673 2 220988
CAMBODIA 2 BLVD NORODOM PHNOM PENH CAMBODIA 855 23 362 392 855 23 721 756 INTERNATIONAL INC
CANADA 2775 SHERBROOKE EAST MONTREAL QUEBEC H2K 1B9 514 521 0482 514 521 CARIBBEAN NV
CARIBBEAN 106 PO BOX 1102 STMAARTENS 599 525 414 599 522 589 SA CHILE
COMPANIA 1357 PISO 7 SANTIAGO 562 696 2133 562 696 9368
POINT X SRO CZECH REP TRUHLARSKA 3 11000 PRAGUE 1 42 2 231 9395 42 2
2481 0821 DATA AS DENMARK FUGLEBAKKEVEJ 8890 DK2000 FREDRIKESBURG 45 38 33 55 01
45 38 33 55 85
PROTRADE EGYPT 11 SHEHAB STREET MOHANDESSEEN CAIRO 20 2 35481847 20 2
3607638
OY ANGLONORDIC AB FINLAND 3 02780 ESPOO 358 9 819211 358 9 811338
FRANCE FRANCE 78 RUE CHAMPIONNET F 75018 PARIS 33 1 53411 200 33 1
53411 201
PSION GMBH GERMANY 16 D61352 BAD HOMBURG 49 6172 6630 49 6172 663100
INT ELECTRONIC GREECE 72 SYNGROU AVENUE GR 11742 ATHENS 30 1 9233013 30 1
9234273 INTERNATIONAL LTD HONG KONG SUITE 1818 18F MIRAMAR TOWER 1 KIMBERLEY RD TSIMSHATSUI KOWLOON 852 2314 5550
852 2377 3261 MAGYARORSZAG KFT HUNGARY SZT GELLERT TER3 1111 BUDAPEST 36 1209
3804 36 1209 3805 KOMTELINDO HITEK INTI INDONESIA WISMA MULTI BINLANG JL DR SOEPOMO SH NO 44 JAKATA
62 3 61756248 62 3 61756284 SURVEY IRELAND UNIT 6A BALLYMOUNT CROSS INDUSTRIAL ES DUBLIN 12
353 456 8650 353 456 8653 COMPUTER ITALY VIA ANTONELLI 3610093 COLLEGNO
39 11 403 4828 39 11 403 3325
PSION JAPAN JAPAN NISHI SHINJUKU FOREST BLD LB FLOOR NISHI SHINJUKU TOKYO 81 3 3378 5933 81 3 3378 5943
ANWAR ESSA AL SALEH ESTAB KUWAIT ALRABIE BLDGSALMIYA PO BOX 4704 SAFAT 13048 965 573 7684 965 571
6674 SARL LEBANON JUSTINIAN CENTRE JUSTINIAN ST SANAYEH PO BOX 113 6413 BE 961 1 353 748 961 1
602 193 TECHNOLOGY SDN BHD MALAYSIA MUI PLAZA 3RD FLOOR KUALA LUMPAR 50250 60 3248 3318
60 3245 6318
BDS MALTA CASA LEONE PIAZZA ROBERT SAMUT FLORIANNA VLT 14 356 239200 356
248693
TDT MEXICO PASA FLORENTINO 47 SANTA FE CP 01 260 52 5 397 8290 52 5
361 3755
PSION NEDERLAND BV NETHERLANDS AVIO TRADE PARK ZANDSTEEN 54 2132 MR HOOFDDORP 31 20 4469444 31
20 SOLUTIONS NEW ZEALAND 11 RUTHERFORD STREET PO BOX 44070 LOWER HUT WELLINGTON 64 4566 7808 64 4569
6452 NIGERIA 110 OBAFEMI AWOLOWO WAY IKEJA LAGOS STATE 234 149702267
234 NORWAY 47 32203300 47
32203459
OHI ELECTRONICS TRADING CO LLC OMAN PO BOX 889 MUSCAT 113SULTANATE OF OMAN 968 959 085 968
603 467
CHARLES FREWEN PARAGUAY VALIANA SAL 135 CASI AV SAN BLAS 55 45522 1451 55 45522 1451
BORROMEO PHILLIPPINES G A BLDG 2303 PASONG TAMO BLDG 63 2 893 7722 63 2
816 4107 CENTRUM INFORMATYKI ENERGETY POLAND UL MYSIA 2 SKR POCZT 143 00950 WARSZAWA 1 48 22 625 3397
48 22 693 1357 3 LDA PORTUGAL RUA AUGUSTO GILL 30 AB 1100 LISBON 351
1 795 1872 351 1 795 RUSSIA INTERNATIONAL UNIVERSITY OF ENG6 LENINSKY PROSPEKT GSP MOSCOW 117933 7 095
236 6531 7 095 236 976 ALI SINDI TRADING ESTABLIS SAUDI ARABIA PO BOX 2951 JEDDAH 21461
966 2 6829454 966 2 SINGAPORE 25 KALLANG KALLANG BASIN INDUSTRIAL ESTAT339416 65 299 2933
x236 65 299 9688 DISTRIBUTORS CC SOUTH AFRICA PO BOX 36233 GLOSDERRY CAPE TOWN 7700 27
21 683 1192 27 21 683 1196
PARESA SPAIN RAMLA CATALUNYA 35 PRAL 08007 BARCELONA 34 3 4516505 34 3
ENG SYSTEMS SRI LANKA 12 TICKELL ROAD COLOMBO 8 SRI LANKA 94 1 695395 94 1 695874
AB SWEDEN F O PETERSONS GATA 421 31 VASTRA FROLUNDA SWEDEN 46 31 709 1605 46 31 47 8520 AG
SWITZERLAND MOOSACHER STRASSE 6 CH 8820 WADENSWIL 41 1 782 2111 41 1 781 1361
KHALIL TRADING CO SYRIA PO BOX 1054 DAMASCUS 963 11 23174 60 963
11 JESSEN THAILAND 17791 NEW PETCHBURI RD BANGKOK 10320 THAILAND 66 2 253 1290 66 2 253
1705
INSTITUT MASSMEDIA TUNISIA GALAXIE 2000 RUE DLAK BLOC A 7 EME ETAGE1002 TUNIS 216 1 793 939 216 1
794 949
ALPHA 55 CO LLC UAE 1st Floor BIN KHEDIA CENTER AL GARHOUD DUBAI 971 4 822267 971 4
822265 UK PLC UK 1 RED PLACE MAYFAIR LONDON W1Y 3RE 0171 317 4100
PSION UK SERVICE CENTRE UK 6 DERBY ROAD METROPOLITAN CENTRE GREENFORD MIDDX UB6 8UJ 0181 566 6162 0181
566 6268
PSION INC USA 150 BAKER AVENUE CONCORD MA 01742 001 508 371 0310 001
508 371 9611
AL AHMAR GROUP YEMEN AL SALAM EST YEMEN 967 271506 967
273990
Gn019 Issue 2
INDEX
TECHNICAL
INFORMATION General
SAFETY NOTICE Instructions in the Service Bulletins assume that the Number has a sound knowledge of safety procedures and
has been trained in the JCB MI 612H and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your
supervisor for advice
Issue 1
Remember SAFETY MUST COME FIRST Date April 1998
ENGINE WORKSHOP MANUALS Page 1 of 1
Perkins New 1000 Series the introduction of the New 1000 Series range of engines Perkins produced a new Workshop Manual which is
available under publication number 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 future orders for 98062140 will be supplied as issue
French and German translations of issue 3 should be available by the end of May Other languages will follow part numbers are French
98062141
German 98062142
Spanish 98062143
Italian Replacement pages are not supplied for engine service manuals To obtain the latest issue a new manual must
be models now covered by the new manual will be 4 Cylinder Models AJ to AS
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 ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM
INDEX
TECHNICAL
INFORMATION General
SAFETY NOTICE Instructions in the Service Bulletins assume that the Number has a sound knowledge of safety procedures and
has been trained in the JCB and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your
supervisor for advice
Issue 1
Remember SAFETY MUST COME FIRST Date April 1998
SUBJECT Axle Propshafts Page 1 of 1
PRODUCTS AFFECTED All Machine installation of any machine it is important to ensure that the following points regarding propshaft
lubrication are highlighted to the operator Failure to do so may result in premature wear or consequential damage must be greased as follows
a Interval
Every 50 hours of operation
Daily if working in muddy conditions
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 high pressure water jets at universal joints
3 working in loose straw or grass it is important that
an undershield is fitted to the machine to prevent around the to protect the propshafts adequately may result in
damage to oil seals propshafts and other No 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 ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM
INDEX
TECHNICAL
INFORMATION General
SAFETY NOTICE Instructions in the Service Bulletins assume that the Number has a sound knowledge of safety procedures and
has been trained in the JCB and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your
supervisor for advice
Issue 1
Remember SAFETY MUST COME FIRST Date Nov Engine Silencer
Improvements Page 1 of 1
PRODUCTS AFFECTED Perkins Engines
TO BE CARRIED OUT For Information 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 silencers as the water drain hole is
now deleted
b The gauge has been increased from 16mm to 20mm
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 16mm to 20mm
Parts x 1 99366300 replaces 12301468 Aspirated x 1 99366200 replaces 12301481 x 1 x 1 x 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 ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM
INDEX
TECHNICAL
INFORMATION General
SAFETY NOTICE Instructions in the Service Bulletins assume that the Number has a sound knowledge of safety procedures and
has been trained in the JCB Gen 087 NAm and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask
your supervisor for advice
Issue 1
Remember SAFETY MUST COME FIRST Date Oct 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 published in section 12 of the New Perkins
1000 Series Workshop manual 98062140 has changed New
alignment bushes must be fitted in accordance with this
Service Always use the engine number to order
new parts alignment bushes are not fitted to all engines
The exhaust manifolds fitted to some four and six have large clearance holes for the setscrews It is
important that these manifolds are correctly fitted to the 1
cylinder 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 02201783 are in
position New alignment bushes are not necessary when the
original manifold is removed and the exhaust manifold setscrews evenly and gradually
to 44 Nm 33 lbf ft 45 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 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 ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM
INDEX
TECHNICAL
INFORMATION General
SAFETY NOTICE Instructions in the Service Bulletins assume that the Number has a sound knowledge of safety procedures and
has been trained in the JCB Gen 089 and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your
supervisor for advice
Issue 1
Remember SAFETY MUST COME FIRST Date Jan Pintimed Fuel Injection
Pumps Page 1 of 1
PRODUCTS AFFECTED All Perkins New 1000 Series Engines Models AJ to AS YG to YK
TO BE CARRIED OUT For Information 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 a pin B part no 89200956 to accurately time the B
pump in Do not release the nut C from the fuel Illustration 2 shows the nut C in position when the C
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 A
is in the correct position for timing If the nut is removed 1
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 refer to the relevant workshop no 98062140 for the correct you start to work on the engine
To remove the fuel injection pump from the engine it is to remove the four setscrews D which secure
the fuel pump gear to the hub It is important to follow the 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 ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM
INDEX
TECHNICAL
INFORMATION General
SAFETY NOTICE Instructions in the Service Bulletins assume that the Number has a sound knowledge of safety procedures and
has been trained in the JCB Gen 090 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
Date January 1999
Remember SAFETY MUST COME FIRST
Page 1 of 3
All Perkins 1000 Series Engines Models YA to YK
Warning The engine oil may be hot Allow the of an improved Oil Cooler with a to cool down before the oil pipes are Steel Cover
Caution Do not remove both of the oil pipes together
An improved oil cooler with a pressed steel cover has
been introduced with effect from engine serial number 2 Put a drip tray under the cooler and remove
lubricating oil pipes from the oil cooler Do not
remove both of the oil pipes together Remove one
To Remove of the pipes then fit the flanges A and nuts B onto
1 Drain the cooling system refer to the relevant the studs again before the other pipe is removed
service manual This will ensure that the element is fastened to the
cover when the assembly is removed
K P
L N
E J
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 ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM
Page 2 of 3 Gn025 Issue 1
3 Discard the O rings C 3 Clean the seats for the O rings and renew the O
rings C of the pipe Release the fasteners D from the cover of the oil
cooler and remove the oil cooler assembly E Caution Do not remove the flanges A and nuts B from
the studs H before one of the oil pipes is fitted to the
5 Thoroughly clean the flange face of the cover and cover This will ensure that the element is held in
of the cylinder block position on the cover J while the oil pipes are A liquid joint is used in the factory This
must be 4 Fit the oil pipes to the cooler and tighten the nuts to
removed and a new paper joint F JCB part number 22 Nm 16 lbf ft 22 kgf fitted in its place
5 Fill the cooling system
6 If an overhaul of the oil cooler is necessary see To
Dismantle and To Assemble on pages 2 and 3 of 6 Operate the engine and check for oil or coolant
this bulletin leakage
To Fit To Dismantle
1 If the four studs G have been removed from the 1 Remove the oil cooler from the cylinder block refer
cylinder block flange and are to be fitted again to page 1 of this bulletin
clean the threads in the cylinder block and on the
studs Apply High Strength Retainer before the 2 Put the oil cooler assembly E on a clean work
studs are fitted to the cylinder block to prevent surface Release the four nuts B that retain the
leakage of the coolant flanges for the lubricating oil pipes The pipe
flanges A are in two pieces
2 Put a new paper joint into position on the studs the
joint is fitted dry Fit the oil cooler assembly E to the 3 Remove the cover K from the four studs L of the oil
cylinder block Gradually and evenly tighten the cooler element M
fasteners D to 22 Nm 16 lbf ft 22 kgf m
K P
L N
Page 3 of 3 GN025 Issue 1
4 Remove and discard the threepiece O ring N from 4 Fit the twopiece flanges A onto the studs H
the element Tighten the nuts to retain the element when the oil
cooler assembly is fitted to the Do not allow compressed air to contact your
skin If compressed air enters your skin obtain medical 5 Fit the oil cooler to the cylinder block see page 2 of
help immediately this bulletin
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 threepiece O ring and
renew the O rings N
2 Clean the flange face P for the threepiece O rings
on the inside of the cover
3 Fit the cover of the oil cooler to the element M
K P
L N
E J
INDEX
TECHNICAL
INFORMATION General
SAFETY NOTICE Instructions in the Service Bulletins assume that the Number has a sound knowledge of safety procedures and
has been trained in the JCB Gen 091 and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your
supervisor for advice
Issue 1
Remember SAFETY MUST COME FIRST Date February 1999
Perkins 4236 or 1000 Series Engines Page 1 of of a Wear Sleeve for the Front Oil
Seal
The latest timing case fitted to 4236 and 1000 does not have a service position for the front
oil seal as shown in section 15 of the manual
A B
The change improves the efficiency of the oil seal in
service and was introduced from engine for 4236 for 4 cylinder 1000 series
Caution If the lip of the oil seal has worn a groove in
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 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 93 mm
0366 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 after it has been fitted
A new front oil seal must be used when a wear sleeve 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 ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM
INDEX
TECHNICAL
INFORMATION General
SAFETY NOTICE Instructions in the Service Bulletins assume that the Number has a sound knowledge of safety procedures and
has been trained in the JCB Gen 092 and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your
supervisor for advice
Issue 1
Remember SAFETY MUST COME FIRST Date February 1999
New Perkins 1000 Series Engines Page 1 of 1
Models AJ to AS YG TO YK
Washers for the Fuel Injection Pump Ensure that the washers are fitted before the
screws are tightened
A washer part number 02101686 is fitted to each of
the screws A with effect from the following engine for 4 cylinder engines
for 6 cylinder 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 WARRANTY REPAIRS ON MACHINES
ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM
INDEX
TECHNICAL
INFORMATION General
SAFETY NOTICE Instructions in the Service Bulletins assume that the Number has a sound knowledge of safety procedures and
has been trained in the JCB Gen 093 and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your
supervisor for advice
Issue 1
Remember SAFETY MUST COME FIRST Date February 1999
New Perkins 1000 Series Engines Page 1 of 1
Models AJ to AS YG to YK
Improved Exhaust Valve Guide
An improved exhaust valve guide A has 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
C A
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 to 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 Part Number Description Supersedes
A 02202064 Valve guide 02201511 and
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 ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM
INDEX
TECHNICAL
INFORMATION General
SAFETY NOTICE Instructions in the Service Bulletins assume that the Number has a sound knowledge of safety
procedures and has been trained in the JCB Gen 096 E194N and repair of ITL equipment If you are unsure or do not contained in the
Service Bulletins then ask your supervisor for advice
Issue 1
Remember SAFETY MUST COME FIRST Date March ITL Hydraulic
Hose Fittings and Orings Page 1 of 2
PRODUCTS AFFECTED All ITL Products
TO BE CARRIED OUT Information products use their own type of special BSP hydraulic hose fitting This fitting combines the standard BSP
type
coned connector with an Oring seal X fitted in the face of the taper
The Oring is bonded to the fitting to ensure its security However if for any reason the Oring becomes damaged or
separated from the fitting it can be replaced
It is very important to use the correct Oring size for the fitting Any deviation in Oring size or specification eg Oring
taken from a selection kit that appears to be the correct size and material will cause joint integrity and correct Orings X required for the various
sizes of hydraulic fitting are shown Fitting Oring Oring Inner Oring Section Material
Size Part Number Diameter mm Diameter mm Type
14 BSP fitting 82800237 65 015 10 008 A
38 BSP fitting 23010006 81 015 16 008 A
12 BSP fitting 23010010 121 02 16 008 A
58 BSP fitting 23010011 131 02 16 008 A
34 BSP fitting 23010015 171 02 16 008 A
1 BSP fitting 23010018 221 025 16 008 A
1 14 BSP fitting 23020907 291 025 16 008 B
1 12 BSP fitting 23020908 351 03 16 008 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 130Celsius with a Shore hardness value of 93A
Ensure that only the above Oring part numbers are used as replacements in ITL hydraulic hose 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 ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM
Page 2 of 2 Gn029 Issue 1
submitting a warranty claim for rectification of a problem with a hydraulic fitting Oring eg oil leak ensure the
correct Oring part number is specified within the claim as the failed part Incorrect Oring part number claims will not
be accepted
INDEX
TECHNICAL
INFORMATION General
SAFETY NOTICE Instructions in the Service Bulletins assume that the Number has a sound knowledge of safety procedures
and has been trained in the JCB and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your
supervisor for advice
Issue 1
Remember SAFETY MUST COME FIRST Date April 1999
Page 1 of 3
PERKINS LOW EMISSION DIESEL ENGINE ITL PRODUCT Perkins Diesel Engine
Improved exhaust emissions
Wastegated turbo charger
Improved injection pump
Increased peak torque
Improved cold starting
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 service 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 ITL 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 turbocharged 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 lbf 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 lbf ft peak comparison shows the increased backup torque at lower engine speed produced by the new low Peak torque is increased up to a
possible 411 Nm lbf ft from 354 Nm 261 lbf ft depending on air filter and
exhaust silencer 420
Torque
1 102 hp Perkins new low emission engine
1 Max torque 411 Nm 303 lbf ft 1400 revmin
300 2
106 hp engine 2
Max torque 354 Nm 261 lbf ft 1800 revmin
800 1000 1200 1400 1600 1800 2000 2200 2400 2600
Engine Speed 3 of 3 Gn030 Issue 1
1 Engine Nat Asp Build Turbo 80hp pump type
DP203 Mechanical setting code timing
Preset Preset
Idle speed 800 rpm 800 rpm
Max rated speed 2200 rpm 2200 rpm
Max noload 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 new engines meet EEC Stage 1 emission regulations Smoke emission is dramatically reduced and now meets
ECE R2403
3 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 CF4SG specification for the low emission engine The fuel injector pump is significantly more because the emissions are reduced by
increasing the accuracy of the timing alterations to the fuel pump are not
possible Any alteration to the fuel pump settings will invalidate the emission 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 the diameter of the battery leads has
been increased
5 Special Tool essential special tool requirements are incorporated into the relevant Perkins engine service manuals
6 Technical the introduction of the new low emission range of engines a new engine workshop manual is available from using the following
publication numbers
English French German Spanish Workshop Manual 98062140 98062141 98062142
98062143 98062144
7 Mandatory and Recommended Distributor Parts Perkins Service for mandatory and recommended parts list Perkins
INDEX
TECHNICAL
INFORMATION General
SAFETY NOTICE Instructions in the Service Bulletins assume that the Number has a sound knowledge of safety procedures and
has been trained in the JCB Gen 105 and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your
supervisor for advice
Issue 1
Remember SAFETY MUST COME FIRST Date Nov Hydraulic Ram Sealing
Procedure Page 1 of 3
PRODUCTS AFFECTED All Machines with ITL Rams
TO BE CARRIED OUT Information 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 fit new rod seal
B A
Use seal fitting tool 89200334 to fit rod seals the 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
C D
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 ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM
Page 2 of 3 Gn031 Issue 1
Note Later ram end caps and piston heads have The seals are also different make sure the
correct seals are fitted On metric threaded rams make
sure the seals are fitted the correct way round as
shown at P and Q P
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 Q
4 Locate the seal in the end cap groove shown at D
153212
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 E 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 89201027 shown at F
lever the inner seal G into the piston head seal F
groove do not let the seal twist There are
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 G
7 Fit outer seal H using the same procedure as step
6 Check the external grooves are visible 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 K
section for torque figure and completion of ram J
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 L
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 pistonrod 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 7mm
20mm 10mm S338410
Ram Seal Protection Sleeves
m 89201016 For 25 mm Rod Diameter
3m 89201017 For 30 mm Rod Diameter
89201018 For 40 mm Rod Diameter
89201019 For 50 mm Rod Diameter
89201020 For 50 mm Rod Diameter slew ram
110mm 89201021 For 60 mm Rod Diameter
89201022 For 60 mm Rod Diameter slew ram
175mm 89201023 For 65 mm Rod Diameter
89201024 For 70 mm Rod Diameter
3o 89201025 For 75 mm Rod Diameter
R 89201026 For 80 mm Rod Diameter
89201027 Piston Seal Assembly Tool
338500
INDEX
TECHNICAL
INFORMATION General
SAFETY NOTICE Instructions in the Service Bulletins assume that the Number has a sound knowledge of safety procedures
and has been trained in the JCB Gen 110 K110 and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then
ask your supervisor for advice
Issue 1
Remember SAFETY MUST COME FIRST Date Jan Oil Control Rings
Page 1 of 1
PRODUCTS AFFECTED 1000 series engine models AR AS only
TO BE CARRIED OUT For Information 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 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 X
If there is no blue mark the ring can be fitted either way up
Ring Kit Part 02201804
05 mm oversize 02201791
10 mm oversize 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 ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM
INDEX
TECHNICAL
INFORMATION General
SAFETY NOTICE Instructions in the Service Bulletins assume that the Number has a sound knowledge of safety procedures and
has been trained in the JCB Gen 112 K112 and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask
your supervisor for advice
Issue 1
Remember SAFETY MUST COME FIRST Date Jan Plastic Thermostat Housings
Page 1 of 1
PRODUCTS AFFECTED All 1000 series engines
TO BE CARRIED OUT For Information thermostat housings fitted to some engines will be damaged if temperature senders or blanking plugs
fitting the items listed ensure that the settings are used
Item Nm kgf m lbf ft
A Sender aluminium 16 12 12
A Sender brass 24 24 18
B 12 inch Plug metal or plastic 4 04 3
B 34 inch Plug metal or plastic 4 04 3
Note The illustration shows a typical installation which
may differ from some engines
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 ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM
INDEX
TECHNICAL
INFORMATION General
SAFETY NOTICE Instructions in the Service Bulletins assume that the
Number has a sound knowledge of safety procedures and has been trained in the
JCB Gen 114 K109N and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your supervisor for advice
Issue 1
Remember SAFETY MUST COME FIRST Date Feb Introduction of
Improved Fuel Lift Pump Page 1 of 2
PRODUCTS AFFECTED All Perkins Four Cylinder 1000 Series Engines
TO BE CARRIED OUT Information improved fuel lift pump has been introduced for use on Perkins fourcylinder 1000 Series diesel engines The
pump is a one piece assembly and cannot be dismantled The new pump is with the earlier pump
The procedure to remove and fit the new pump has not changed Remove and clean fuel inlet strainer 2 if is recommended in the relevant machine
handbook or service the Strainer
1 Allow the engine to cool Remove the fuel filler cap to vent the system and reduce loss of fuel Disconnect the
fuel inlet pipe to the lift pump
2 Unscrew the fuel filter A Remove strainer 2 and Oring 3
3 Clean the strainer in clean diesel fluid and dry with low pressure compressed air Renew the strainer and Oring
if damaged
4 Fit the strainer into the fuel inlet connection Fit the fuel filter A and tighten to
20Nm 15 lbf 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 ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM
Page 2 of 2 Gn 034 Issue 1
PARTS Part No Description
1 17913600 Fuel Lift Pump Kit complete with Gasket
23 17913601 Fuel Strainer Oring Kit
4 02201189 Gasket only
366610
INDEX
TECHNICAL
INFORMATION General
SAFETY NOTICE Instructions in the Service Bulletins assume that the
Number has a sound knowledge of safety procedures and has been trained in the
JCB 5217 and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your supervisor for advice Issue
1
Remember SAFETY MUST COME FIRST Date April Coolant Pressure Cap
Page 1 of 1
PRODUCTS AFFECTED All Perkins 1000 Series Engines
TO BE CARRIED OUT Information 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 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 ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM
INDEX
TECHNICAL
INFORMATION General
SAFETY NOTICE Instructions in the Service Bulletins assume that the
Number has a sound knowledge of safety procedures and has been trained in the
JCB Gen 120 and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your supervisor for advice
Issue 1
Remember SAFETY MUST COME FIRST Date April 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 oil consumption can only be correctly measured as a percentage against fuel used under If after
consideration of the observations below the oil consumption appears to exceed the carry out the Service Procedure as detailed
Oil consumption does not normally exceed 45 litres 10 UK gal 119 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 revmin
Extended periods of idle andor high speed roading will dramatically increase the hourly consumption rates
Dust ingress via leaks in the air intake system 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 oil consumption after running in should be between 3 and 5 litres of oil per 1000
litres of fuel consumed 066
and 11 UK gal per 220 UK gal 079 and 132 US gal per 264 US gal OR 030 and 050 of fuel 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 remark 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 ITL 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 replenish 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
OPERATOR
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
INDEX
TECHNICAL
INFORMATION General
SAFETY NOTICE Instructions in the Service Bulletins assume that the
Number has a sound knowledge of safety procedures and has been trained in the
JCB TSDB and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your supervisor for advice Issue
1
Remember SAFETY MUST COME FIRST Date May Rocker Cover
Page 1 of 2
PRODUCTS AFFECTED Perkins AR AJ AK Low Emission 1000 Series 4Cylinder Engines
TO BE CARRIED OUT Only with Authorisation from ITL
SERVICE have been received of excessive oil loss from the rocker cover breather tube It should be noted that oil
showing at the breather tube is a normal function caused by vapourised oil in the crank case escaping However for green countries where strict
limitations on oil emission are enforced an 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 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 precleaner 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 NOTE When the rocker cover is fitted the cap nuts are tightened onto the nuts of
the rocker removal of the cap nuts it is possible to loosen the nuts of the rocker brackets The nuts of the 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 lbf ft
6 Fit new breather pipe item A to the breather assembly item J using new hose clip item K
PARTS REQUIRED
Item Part Number Description Qty
A 02201338 Hose 1
F 02202220 Rocker Cover 1
J 02202217 Breather 1
K 22010007 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 ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM
Page 2 of 2 Gn 037 Issue 1
WARRANTY improvement will not be considered for warranty
B S239790
INDEX
TECHNICAL
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 Number 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 SAFETY MUST COME FIRST
Date Jan New ITL NAPSC Network Page 1 of of a new service and
parts support network for International Transmissions Limited from February 17th
2002 All previous parts ordering through JCB Burlington Canada and JCB 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 available to the OEM
1 1 866 734 8562 1 866 73 ITL NA toll free number Fax 519 738 3477 or email Parts supply availability and pricing information Contact Colin Sellick
ext 226
3 Shipping out of Harrow Ontario or USA address PO Box 312547 Detroit MI Help ensuring correct parts needed are Technical support contact Ron
Peters ext 238
6 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 onto the local database enabling the UK ITL service
desk to view the claim 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
CriticalVD vehicle down orders placed before 300 pm local NAPSC time shipped with 7 premium 40
discount on stock orders minimum value 500000 excluding shipping costs Orders limited to 2 stock orders
per year and terms CIF at the OEM Leadtime 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 Note the introduction of 3 New ITL Principal Service Centers
ITL PSC California Texas and for ITL Warranty repair ITL component strip down repair and test facilities to carry out repairs from the end user
subject to OEM Service Equipment Co
16550 Railroad Ave L
Morgan Hill CA 95037 Tel 408 778 9677 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 ITL 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 throughout USA and Canada In the event of repair work needed contact ITL Service Department 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 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 with or without their own dealer back up
can take full advantage of the ITL Service Centers initially approaching a Service Center we ask that our Service Department be 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
INDEX
TECHNICAL
INFORMATION General
SAFETY NOTICE Instructions in the Service Bulletins assume that the
Number has a sound knowledge of safety procedures and has been trained in the
JCB Gen and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your supervisor for advice Issue
1
Remember SAFETY MUST COME FIRST Date Sep Safety precautions
when an engine is cleaned Page 1 of 1
PRODUCTS AFFECTED All Engines
TO BE CARRIED OUT Information should be taken when an engine is cleaned with the use of a high pressure Do not wash an engine while
it is running or it is hot If cold cleaning fluids are applied to a hot engine certain
components on the engine could be damaged
Leave the engine to cool for at least one hour and disconnect battery connections before cleaning
Do not wash any part of the Fuel Injection Pump
Ensure that the altemator starter motor and any other electrical components are shielded and not directly
cleaned by high pressure hose
Do not wash the Electrical Shutoff 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 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 ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM

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