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' Perkins General Technical Information Bulletin'



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                                                                                                      CONTENTS
                        TECHNICAL
                        INFORMATION
                         GENERAL T.I. BULLETIN INDEX
                                        Click on bulletin title to view

T.I. 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 Recommendations -
                     Fluoroelastomeric 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 Identification                                                         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 Service/Warranty 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 4.236 & 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 O-rings          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              Gn001
engineer has a sound knowledge of safety procedures and has been trained in the          (JCB Gen 003)
maintenance and repair of ITL equipment. If you are unsure or do not understand
information contained in the Service Bulletins then ask your supervisor for advice.
                                                                                         Issue                 1
Remember SAFETY MUST COME FIRST.                                                         Date         March 1990

SUBJECT:                       Tappet Adjustment                                                            Page 1 of 1

PRODUCTS AFFECTED:             All Perkins 1000 series Engines

TO BE CARRIED OUT:             At Next Service / As Required


SERVICE PROCEDURE:

When tappet adjustment is required, it is important to re-torque the adjusting screw lock nut A. If this is not correctly
actioned the adjusting screw will become loose which could cause damage to the tappet assembly and push rod.

Lock Nut Torque - 20 lbs ft.




  THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES
        NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES

          ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I.T.L., WREXHAM, CLWYD, LL13 9UF, UNITED KINGDOM
                                                                                                         INDEX
                                       TECHNICAL
                                       INFORMATION                                                 General

! SAFETY NOTICE - Instructions in the Service Bulletins assume that the               Number             Gn002
engineer has a sound knowledge of safety procedures and has been trained in the       (JCB Gen 005)
maintenance and repair of ITL equipment. If you are unsure or do not understand
information contained in the Service Bulletins then ask your supervisor for advice.
                                                                                      Issue                  1
Remember SAFETY MUST COME FIRST.                                                      Date           July 1990

SUBJECT:                     Rocker Shaft Security                                                      Page 1 of 1

PRODUCTS AFFECTED:           All Perkins 1000 Series Engines

TO BE CARRIED OUT:           Information Only


SERVICE INFORMATION:

Introduction of new fasteners for the rocker assembly.

SERVICE PROCEDURE:

Flanged nuts A replace the three nuts and washers securing the rocker shaft to the cylinder head. The single bolt and
washer is replaced by a flanged bolt.

If the new fasteners are fitted to earlier engines the washers must be removed.

Torque tighten the new fasteners to 40 Nm (30 lbf ft).

PARTS INFORMATION

Cut-in from engine serial number U544908U.

02/291060      NUT              replaces     1370/0401Z
02/291048      SET SCREW        replaces     02/291125
02/291064      WASHER           -            Not Required




  THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES
        NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES

          ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I.T.L., WREXHAM, CLWYD, LL13 9UF, UNITED KINGDOM
                                                                                                              INDEX
                                        TECHNICAL
                                        INFORMATION                                                     General

! SAFETY NOTICE - Instructions in the Service Bulletins assume that the                   Number              Gn003
engineer has a sound knowledge of safety procedures and has been trained in the           (JCB Gen 010)
maintenance and repair of ITL equipment. If you are unsure or do not understand
information contained in the Service Bulletins then ask your supervisor for advice.
                                                                                          Issue                  1
Remember SAFETY MUST COME FIRST.                                                          Date          March 1991

SUBJECT:                      Crankshaft Rear Main Oil Seal and Housing                                      Page 1 of 3

PRODUCTS AFFECTED:            All Perkins 1000 Series Engines

TO BE CARRIED OUT:            Information Only

A number of reports by Perkins have been received concerning crankshaft rear main oil seal leaks. Little or no detail
is completed in the comments section of the warranty claim form. Information given in the comments section will
enable Perkins to identify the exact fault and take the correct remedial action.

The following instructions will enable you to locate and rectify the exact fault, this fault should then be stated in the
comments section of all warranty claims, failure to do so will invalidate the warranty claim.

REAR OIL SEAL/HOUSING

If oil is leaking past the rear seal, oil will normally be found inside the flywheel housing with some evidence of leakage
from the low inspection plate.

To rectify

1    Remove the transmission.

2    Remove the flywheel using guide studs (remove two
     diametrically opposite bolts and temporarily fit guide
     studs).

3    Remove seal 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 PD.145D (see Perkins Service Manual), this
     will pre-set the seal depth as required.

Note: The service tool will set seal to 4 different depths, on new engines position 1 should be used.

5    Make sure that the two dowels C are fitted in the cylinder block. PUT A NEW JOINT in position on the dowels.

6    Put the seal guide A on the crankshaft flange. Lubricate the crankshaft flange, the seal lip and the seal guide with
     clean engine oil.

7    Put the seal housing B complete with seal on the seal guide A (PD.145D). Carefully push the assembly into
     position on the crankshaft flange and onto the two dowels C. Remove the seal guide, fit and torque the housing
     securing setscrews M8 to 22 Nm (16 lbf ft) and the capscrews M8 to 18 Nm (13 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 I.T.L., WREXHAM, CLWYD, LL13 9UF, UNITED KINGDOM
Page 2 of 3                                                                          Gn003               Issue 1

OIL LEAKAGE FROM REAR OF ENGINE

When investigating oil leakage at the rear of the engine the following areas should be checked and corrected as found
necessary.

1   Main Oil Gallery Plug/Washer

A leak from this area can usually be identified by a trace of oil
along the contact face of block and flywheel housing on the
fuel pump side of the engine.

This can be rectified as follows

    1.1 Remove the transmission.

    1.2 Remove the flywheel using guide studs (remove two
        diametrically opposite bolts and temporarily fit guide

    1.3 Removethe starter motor.

    1.4 Remove the flywheel housing (it may be necessary to
        tap the housing using a soft hammer to disengage
        the housing dowels).

    1.5 Remove the threaded gallery plug D located top left
        of cylinder block using appropriate allen key.

    1.6 Fit a new plug/washer using Loctite 574 Multigasket
        and torque to 85 Nm (62.5 lbf ft).

    1.7 Refit flywheel housing and torque securing screws
        M10 to 44 Nm (33 lbf ft) and M12 to 75 Nm (55 lbf ft).

    1.8 Refit flywheel using guide studs and torque retaining bolts to 105 Nm (77 lbf ft).

2   Camshaft Rear End Plug

Leakage from the cam end plug will normally produce a trace of oil at the contact face between block and flywheel
housing on the manifold side.

To rectify:

    2.1 Remove the transmission.

    2.2 Remove the flywheel using guide studs (remove two diametrically opposite bolts and temporarily fit guide
        studs).

    2.3 Remove the starter motor.

    2.4 Remove the flywheel housing (it may be necessary to tap the housing using a soft hammer to disengage the
        housing dowels).

    2.5 Remove camshaft end plug E located top right of the cylinder block.

    2.6 Fit new plug using Loctite 574 Multigasket.

    2.7 Refit flywheel housing and torque securing screws M10 to 44 Nm (33 lbf ft) and M12 to 75 Nm (55 lbf ft)

    2.8 Refit flywheel using guide studs and torque retaining bolts to 105 Nm (77 lbf ft).
Page 3 of 3                                                                          Gn003              Issue 1

OIL LEAKAGE FROM REAR OF ENGINE (cont'd)

3   Bridge Piece.

Lubrication oil leakage from the bridge piece F can be identified in two ways; oil may be seen around the sump rear
face or oil will be evident inside the flywheel housing. There are two possible causes for leakage from the bridge
piece, misalignment and/or lack of sealant.

To rectify misalignment:

    3.1 Remove the flywheel using guide studs
        (remove two diametrically opposite bolts and
        temporarily fit guide studs).

    3.2 Remove the starter motor.

    3.3 Remove the flywheel housing (it may be
        necessary to tap the housing using a soft
        hammer to disengage the housing dowels).

    3.4 Remove the rear seal housing as described
        in the section titled `REAR OIL SEAL
        HOUSING'.

    3.5 Remove the lubrication oil sump.

    3.6 Release the two securing capscrews G in the bridge piece remove the bridge piece and old sealant trom all
        faces. Loosely refit the bridge piece and align the face of the bridge piece to the rear block face using a
        straight edge as shown. Alignment to be within 0.05 mm (0.002 in). Tighten the securing cap screws to 9 Nm
        (6 lbf ft).

    3.7 Apply Loctite 574 Multigasket to bridge piece end slots H using applicator gun until sealant can be seen
        coming from the chamfered edges of the bridge piece contact face with the cylinder block.

    3.8 Refit flywheel housing and torque securing screws M10 to 44 Nm (33 lbf ft) and M12 to 75 Nm (55 lbf ft).

    3.9 Refit flywheel using guide studs and torque retaining bolts to 105 Nm (77 Ibf ft).

To rectify lack of sealant:

    3.10 Remove lubrication oil sump.

    3.11 Complete sealing process as described in step 3.7 above.

    3.12 Refit lubrication oil sump using a new joint.
                                                                                                                       INDEX
                                           TECHNICAL
                                           INFORMATION                                                          General

! SAFETY NOTICE - Instructions in the Service Bulletins assume that the                          Number                Gn004
engineer has a sound knowledge of safety procedures and has been trained in the                  (JCB Gen 013)
maintenance and repair of ITL equipment. If you are unsure or do not understand
information contained in the Service Bulletins then ask your supervisor for advice.
                                                                                                 Issue                    1
Remember SAFETY MUST COME FIRST.                                                                 Date             Dec. 1991

SUBJECT:                        Turbocharger Fault Diagnosis                                                          Page 1 of 3

PRODUCTS AFFECTED:              All Perkins Turbo Engines (AB and AC Builds)

TO BE CARRIED OUT:              Information Only

A number of turbochargers have been replaced unnecessarily. When inspected by the supplier, no fault has been
found or the fault differs from the failure code and/or description on the claim.

Service Procedure

1    To assist in the correct diagnosis of general faults, please refer to the attached fault finding charts.

2    Fuel Starting Aid (Thermostart)

     A problem has occurred several times where the inside of the induction manifold has been found to be wet and
     the turbocharger has been returned as faulty. After investigation, the turbocharger was found to have no fault.

     If the inside of the induction manifold is wet, check that there is not a fuel leak from the fuelled starting aid (if fitted):

     2.1    How to check the fuelled starting aid

     2.1.1 Disconnect the fuel pipe A and the electrical
           connector B at the starting aid C. Remove the
           starting aid from the manifold and fit a suitable plug
           in the manifold.

     2.1.2 Connect the fuel pipe to the starting aid, but leave
           the union nutconnection loose. Do not fit the
           electrical connection, but ensure that the connector
           is covered with a suitable insulator. Operate the
           lever of the fuel lift pump until fuel free of air -
           comes from the union nut connection.Tighten the
           union nut at the starting aid.

     2.1.3 Start the engine and operate it at low speed. Check
           that there is no fuel leakage from the valve of the
           starting aid.

     2.1.4 If there is no leakage, remove the plug from the
           induction manifold and fit the starting aid. Connect
           the fuel pipe to the starting aid and remove the air
           from the pipe as described above. Connect the
           electrical connector to the starting aid.

     2.1.5 If there is a leak from the valve of the starting aid, fit a new starting aid.

3    Warranty Claim 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 I.T.L., 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 turbochargers. Opposite the faults is a column
titled `Possible Causes Code Numbers'; these code numbers refer to a description of possible cause(s) associated
with the fault. The descriptions for possible causes can be found on page 3.

FAULT                                                    POSSIBLE CAUSES CODE NUMBERS

A. Not enough power                                      1,4,5,6.7,8,9,10,11,18,20,21, 22,25,26,27,28,34,35,36

B. Black smoke                                           1,4,5,6,7,8,9,10,11,18,20,21, 22,25,26,27,28,34,35,36

C. Blue smoke                                            1,2,4,6,8,9,17,19,20,21,22, 30,31,32,34

D. High lubricating oil consumption                      2,8,15,17,19,20,28,29,31,32,34

E. Too much lubricating oil at turbine end               2,7,8,17,19,20,22,28,30,31,32

F. Too much lubricating oil at compressor end            1,2,4,5,6,8,19,20,21,28,31,32

G. Not enough lubrication                                8,12,14,15,16,23,24,29,32,33, 37,38

H. Lubricating oil in the exhaust manifold               2,7,17,18,19,20,22,28,31,32

I. Inside of the induction manifold wet                  1,2,3,4,5,6,8,10,11,17,18,19, 20,21,28,32,34,39,40

J. Damaged compressor impellor                           3,4,6,8,12,15,16,20,21,23,24, 29,32,33,37,38

K. Damaged turbine rotor                                 7,8,12,13,14,15,16,18,20,22, 23,24,25,27,29,32,33,37,38

L. Rotating assembly does not turn freely                3,6,7,8,12,13,14,15,16,18,20, 21,22,23,24,29,32,33,37,38

M. Worn - bearings, bearing bores, journals              6,7,8,12,13,14,15,16,23,24, 29,33,37,38

N. Noise from turbocharger                               1 , 3, 4, 5, 6, 7, 8, 9,10, 1 1 ,12,13,14,15,16,18,
                                                         20,21,22,23,24, 29,32,33,34,37,38

O. Sludge or carbon deposit in bearing housing           2, 1 1, 13, 14, 15, 1 7, 18, 24, 29, 33, 37, 38
Page 3 of 3                                                                             Gn004                   Issue 1

Fault Finding Charts (cont'd)

DESCRIPTION OF POSSIBLE CAUSES/SYMPTOM

1.    Element of the air filter dirty
2.    Restricted crankcase breather
3.    Element of the air filter missing, leaking, or not sealing correctly. Loose connection to turbocharger.
4.    Internal distortion or restriction in pipe from air filter to turbocharger.
5.    Damaged/restricted crossover pipe - turbocharger to induction manifold.
6.    Restriction between air filter and turbocharger.
7.    Restriction in exhaust system.
8.    Turbocharger loose or clamps/setscrews loose.
9.    Induction manifold cracked or loose, flanges distorted.
10.   Exhaust manifold cracked or loose, flanges distorted.
11.   Restricted exhaust system.
12.   Delay of lubricating oil to turbocharger at engine start.
13.   Insufficient lubrication.
14.   Dirty lubricating oil.
15.   Incorrect lubricating oil.
16.   Restricted lubricating oil supply pipe.
17.   Restricted lubricating oil drain pipe.
18.   Turbine housing damaged or restricted.
19.   Leakage from turbocharger seals.
20.   Worn turbocharger bearings.
21.   Excessive dirt in compressor housing.
22.   Excessive carbon behind turbine rotor.
23.   Engine speed raised too rapidly at initial start.
24.   Insufficient engine idle period.
25.   Faulty fuel injection pump.
26.   Worn or damaged atomisers.
27.   Valves burned.
28.   Worn piston rings.
29.   Lubricating oil leakage from supply pipe.
30.   Excessive preservation fluid (on initial engine start).
31.   Excessive engine idle period.
32.   Restriction in turbocharger bearing housing.
33.   Restriction in lubricating oil filter.
34.   Wet type air cleaner: Restricted, dirly element, viscosity of oil too low/high.
35.   Wastegate (if fitted) actuator faulty or damaged.
36.   Wastegate (if fitted) valve not free.
37.   Engine stopped too soon from high load.
38.   Insufficient lubricating oil.
39.   Fuel leakage from fuelled starting aid.
40.   Crack in backplate of compressor.
                                                                                                         INDEX
                                      TECHNICAL
                                      INFORMATION                                                  General

! SAFETY NOTICE - Instructions in the Service Bulletins assume that the                Number            Gn005
engineer has a sound knowledge of safety procedures and has been trained in the        (JCB Gen 002)
maintenance and repair of ITL equipment. If you are unsure or do not understand
information contained in the Service Bulletins then ask your supervisor for advice.
                                                                                       Issue                1
Remember SAFETY MUST COME FIRST.                                                       Date        March 1992

SUBJECT:                     HEALTH & SAFETY RECOMMENDATIONS -                                          Page 1 of 2
                             FLUOROELASTOMERIC MATERIALS

PRODUCTS AFFECTED:           ALL

                                                 ! WARNING
Due to recent publicity regarding the potential hazards associated with the handling of fluoroelastomeric materials
(`Viton', `Fluorel', `Technoflon', etc.), commonly used in the production of oil seals and gaskets for the automotive
industry, the following health and safety statement should be noted.

Note: Examples of the use of these materials on ITL products are the `Viton' crankshaft oil seals on Perkins engines
and `Viton' shaft and brake seals in the axles.

New Components

The normal handling of new cured fluoroelastomeric components at ambient temperature presents no known hazard
and requires no special handling precautions.

Removal of Old Components during Servicing

No special precautions are required when handling old fluoroelastomeric material that has been subjected only to
normal service conditions. However, before removal, a preliminary visual examination should establish whether
normal service temperatures have been exceeded giving rise to thermal degradation. If evidence of decomposition
(charring etc.) is found, the material and surrounding areas should not be touched without observing the precautions
detailed below.

Removal of Old Material Subjected to Abnormally Hiqh Temperatures

At temperatures in excess of 300° C, e.g. engine fires, fluoroelastomeric materials can decompose, producing small
but significant amounts of hydrofluoric acid. This acid is highly corrosive and will cause SEVERE BURNS if in contact
with the skin.

Vehicles or components that have been subjected to abnormally high temperatures should be subjected to the
following decontamination procedure which must be conducted by competent personnel. This will require the use of
appropriate safety equipment (neoprene rubber or heavy duty gloves, plus special safety glasses are essential).

1    Ensure that components have cooled then carefully remove and transfer suspect material to plastic bags.

2    Wash the contaminated area with a 10% calcium hydroxide or other suitable alkali solution, if necessary using
     wire wool to remove residual adherent decomposition products.

3    Thoroughly wash contaminated area with detergent and water.


cont'd


    THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES
          NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES

           ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I.T.L., WREXHAM, CLWYD, LL13 9UF, UNITED KINGDOM
Page 2 of 2                                                                        Gn005                 Issue 1

4   Place all removed material, protective gloves and wire wool used in the operation, in sealed plastic bags prior to
    landfill disposal in accordance with Local Authority Regulations.

5   Fluoroelastomeric materials should NOT be incinerated.

If there is contamination of the skin or eyes, wash the affected area with a continuous supply of clean water or with
calcium hydroxide solution for 15-60 minutes. Obtain immediate medical attention.
                                                                                                            INDEX
                                        TECHNICAL
                                        INFORMATION                                                    General

! SAFETY NOTICE - Instructions in the Service Bulletins assume that the                  Number              Gn006
engineer has a sound knowledge of safety procedures and has been trained in the          (JCB Gen 021)
maintenance and repair of ITL equipment. If you are unsure or do not understand
information contained in the Service Bulletins then ask your supervisor for advice.
                                                                                         Issue                   1
Remember SAFETY MUST COME FIRST.                                                         Date            Feb. 1993

SUBJECT:                      Turbochargers                                                                 Page 1 of 1

PRODUCTS AFFECTED:            Turbocharged Perkins (90 BHP) Engines

TO BE CARRIED OUT:            Information Only



SERVICE INFORMATION:
From engine serial number No. AB50440U610051X (28/1/93), a 'Garret' turbocharger is fitted; this replaces the
'Schwitzer' unit. The Garret turbocharger gives improved service reliability.



SERVICE PROCEDURE:
If for any reason a warranty repair is to be completed on the turbo unit, then a full written report on the repair/fault
must be submitted with the claim or the Perkins Service Information. ITL T.I. Gn004 can be used to aid fault diagnosis
and specifying the fault.

Perkins dealers should carry out this work.

Failure to follow this instruction may result in the claim being rejected.



PARTS INFORMATION
DESCRIPTION      PART NO.                  COMMENTS
'Garret' Unit    02/200460                 was 'Schwitzer' unit - part no. 02/200340 (applicable to 90BHP only)




  THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES
        NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES

           ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I.T.L., WREXHAM, CLWYD, LL13 9UF, UNITED KINGDOM
                                                                                                              INDEX
                                       TECHNICAL
                                       INFORMATION                                                     General

! SAFETY NOTICE - Instructions in the Service Bulletins assume that the                  Number               Gn007
engineer has a sound knowledge of safety procedures and has been trained in the          (JCB 2/085)
maintenance and repair of ITL equipment. If you are unsure or do not understand
information contained in the Service Bulletins then ask your supervisor for advice.
                                                                                         Issue                   1
Remember SAFETY MUST COME FIRST.                                                         Date            Feb. 1993

SUBJECT:                     Piston and Piston Ring Improvements                                            Page 1 of 1

PRODUCTS AFFECTED:           4-Cylinder Turbocharged Engines

TO BE CARRIED OUT:           Information Only


SERVICE INFORMATION:
A new improved oil control piston and ring pack has been fitted to the Perkins 4-cylinder turbocharged engines from
January 1993. Engine cut-in numbers: AB 50424U 608291 W
                                           AB 50440U 608301 W
One of the advantages of the new design is that it reduces oil consumption after the initial 'bedding-in' period. The
average oil to fuel used consumption is reduced from 0.5% to 0.2%. The following information should be covered
during new machine installation:
i    Engine 'running-in' is not a requirement.
ii   Periods of engine idling/tick over should be kept to a minimum to prevent cylinder bore glazing.


SERVICE PROCEDURE:
1    The new piston and ring pack can be used as service replacements - in sets of 4 pistons and ring kits.

2    When fitting the new piston and ring pack in service, there is no need to de-glaze the cylinder bore (glaze
     busting).

3    JCB Technical Information Bulletin 2/004 (issue 2) details the service procedure to be completed if oil
     consumption concerns are raised by the customer before contacting the Perkins Dealer:
     i On engines prior to the new piston and ring pack, normal oil consumption remains at 0.3% to 0.5% of fuel
        used, further investigation may be required if the oil consumption exceeds 0.7%.
     ii On engines fitted with the new piston and ring pack, further investigation may be required if the oil consumption
        exceeds 0.5%.


PARTS INFORMATION
VENDOR PART NO.              BHP         DESCRIPTION
AB50440                      90          Engine
AB50441                      96          Engine
AB50459                      96          Engine

1    Piston Assembly - 02/200860
2    Ring Kit - 02/200859




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           ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I.T.L., WREXHAM, CLWYD, LL13 9UF, UNITED KINGDOM
                                                                                                       INDEX
                                      TECHNICAL
                                      INFORMATION                                                General

! SAFETY NOTICE - Instructions in the Service Bulletins assume that the               Number           Gn008
engineer has a sound knowledge of safety procedures and has been trained in the       (JCB 2/109; C26/N. Am.)
maintenance and repair of ITL equipment. If you are unsure or do not understand
information contained in the Service Bulletins then ask your supervisor for advice.
                                                                                      Issue                1
Remember SAFETY MUST COME FIRST.                                                      Date         Nov. 1993

SUBJECT:                    Alternator Connectors on the Mainframe Harness                            Page 1 of 1

PRODUCTS AFFECTED:          Perkins Engines as applicable

TO BE CARRIED OUT:          Information Only


SERVICE INFORMATION:

Two types of alternator connectors
have been supplied. The alternator
`euro plug' connector (item X - FIG 1)
is no longer supplied. Instead, a ring
terminal and lucar connector (item Y -
FIG 2) are now supplied.

Align the harness connectors and the
corresponding alternator connections
using the wire numbers.

If the harness has a `euro plug'
connector (item X) fitted, install the
harness as shown in FIG 1. If the
harness has a ring terminal and lucar
connector (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 I.T.L., WREXHAM, CLWYD, LL13 9UF, UNITED KINGDOM
                                                                                                               INDEX
                                        TECHNICAL
                                        INFORMATION                                                      General

! SAFETY NOTICE - Instructions in the Service Bulletins assume that the                    Number              Gn009
engineer has a sound knowledge of safety procedures and has been trained in the            (JCB Gen 028; K58/N. Am.)
maintenance and repair of ITL equipment. If you are unsure or do not understand
information contained in the Service Bulletins then ask your supervisor for advice.
                                                                                           Issue                 1
Remember SAFETY MUST COME FIRST.                                                           Date         March 1994

SUBJECT:                         Low Sulphur Fuels                                                            Page 1 of 1

MACHINES AFFECTED:               All Perkins 1000 Series Engines

TO BE CARRIED OUT:               Information Only




SERVICE INFORMATION

Low sulphur fuels are commonly used throughout the world. These fuels contain fewer lubrication additives. The DPA
and DPS fuel pumps currently fitted to the Perkins 1000 Series engine are lubricated by the diesel fuel, therefore using
low sulphur fuels may, in the long term, affect the pump.

If you are using a low sulphur diesel fuel, it is recommended that additional lubrication is added to the diesel.

Customers should contact their local fuel supplier to obtain a locally supplied and recommended additive. There is no
current 'MIL' or 'FORD' standard, so the customer must be guided by the fuel supplier.




  THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES
        NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES

           ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I.T.L., WREXHAM, CLWYD, LL13 9UF, UNITED KINGDOM
                                                                                                               INDEX
                                        TECHNICAL
                                        INFORMATION                                                     General

! SAFETY NOTICE - Instructions in the Service Bulletins assume that the                    Number              Gn010
engineer has a sound knowledge of safety procedures and has been trained in the            (JCB MI428/H,401/E;M97N.Am)
maintenance and repair of ITL equipment. If you are unsure or do not understand
information contained in the Service Bulletins then ask your supervisor for advice.
                                                                                           Issue                   1
Remember SAFETY MUST COME FIRST.                                                           Date            Mar. 1994

SUBJECT:                     Brake Master Cylinder Kits                                                       Page 1 of 1

Master cylinder seal repair kits should no longer be supplied. Any kits in Distributor stocks should be returned to the
OEM. Contact Mr. P. Hassall at JCB Service for return/disposal instructions for JCB supplied seals.

In the near future, master cylinder kits listed below will no longer be available. Only the master cylinder assemblies will
be available for replacement, this is because it is not good practice to re-seal old master cylinders, also seal
replacement by untrained customers is not recommended.

The relevant Service Manual procedures will be updated accordingly.


Master Cylinder Seal Kit Part Numbers.

    15/107001
    15/104700
    15/106600
    15/903803
    15/904102
    15/904301
    15/908201


Note: Master cylinder 15/908200 is no longer available. If a master cylinder is required then part number 15/910800
must be used (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 I.T.L., WREXHAM, CLWYD, LL13 9UF, UNITED KINGDOM
                                                                                                                               INDEX
                                          TECHNICAL
                                          INFORMATION                                                                  General

! SAFETY NOTICE - Instructions in the Service Bulletins assume that the                                Number                  Gn011
engineer has a sound knowledge of safety procedures and has been trained in the                        (JCB MI452/H,423/E;E114N.Am)
maintenance and repair of ITL equipment. If you are unsure or do not understand
information contained in the Service Bulletins then ask your supervisor for advice.
                                                                                                       Issue                    1
Remember SAFETY MUST COME FIRST.                                                                       Date             June 1994

SUBJECT:                       Hydraulic Ram Identification                                                                   Page 1 of 1

Over the last twenty years JCB has made a number of design and manufacturing improvements to hydraulic rams.
Some difficulty is being experienced identifying the various rams for parts ordering purposes. The following
illustrations show some different types of ram fitted to JCB machines. It is important to correctly identify the type of
ram fitted prior to ordering spare parts because in most instances parts will not be interchangeable.



                                                                                                                      IMPERIAL RAM
                                                                                                                           4 in x 2 in.

                                                                                                                         1972 to 1979
                                                                           End Cap
                                                                      Gland Seals (located in Gland Bearing)
                  Split Pin Retention




                                                                                                                     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
                                                                                                                          RAM
                                                                                                                       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
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          ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I.T.L., WREXHAM, CLWYD, LL13 9UF, UNITED KINGDOM
                                                                                                       INDEX
                                        TECHNICAL
                                        INFORMATION                                                  General

! SAFETY NOTICE - Instructions in the Service Bulletins assume that the               Number            Gn012
engineer has a sound knowledge of safety procedures and has been trained in the       (JCB Gen 031; K60/N. Am.)
maintenance and repair of ITL equipment. If you are unsure or do not understand
information contained in the Service Bulletins then ask your supervisor for advice.
                                                                                      Issue                  1
Remember SAFETY MUST COME FIRST.                                                      Date           July 1994

SUBJECT:                         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.
                                                                                            C
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 passes
through the hole in the idler shaft to the bush in the idler gear.

If it is found in service that more lubrication is necessary for the
                                                                        S209440
bush of the idler gear, renew the bush, part # 02/290006. Fit the
new idler shaft part # 02/201131 and the new lubricating oil
pump, part # 02/201050 (four cylinder engines) or 02/201130 (six
cylinder engines).

Fit the lubricating oil pump and the idler shaft in accordance with
the procedure given in operations 19A-06 and 19A-06A
respectively of the workshop manual. In addition to these
instructions ensure that the hole D in the idler shaft is at the
bottom and that the flat E is at the top before the shaft is pressed
into the bearing cap.
                                                                                        E
! 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 # 4101/0651.
                                                                                        D
                                                                           D
                                                                                                            S209450
If the new lubricating oil pump is fitted the end-float for the idler
gear is as follows:
· Four cylinder engines 0.012/0.643 mm (0.0005/0.0253 in)
· Six cylinder engines 0.020/0.650mm (0.0008/0.0256 in)

PARTS INFORMATION
Part No.     Description                                   Part No.      Description
02/290006    Bush                                          02/201050     Pump (4 Cylinder Engines)
02/201131    Shaft                                         02/201130     Pump (6 Cylinder Engines)
4101/0651    Loctite 648 Retainer

Note: The above information can be implemented only when excessive wear is evident.

  THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES
        NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES

           ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I.T.L., WREXHAM, CLWYD, LL13 9UF, UNITED KINGDOM
                                                                                                            INDEX
                                       TECHNICAL
                                       INFORMATION                                                    General

! SAFETY NOTICE - Instructions in the Service Bulletins assume that the                  Number             Gn013
engineer has a sound knowledge of safety procedures and has been trained in the          (JCB Gen 035; F47/N. Am.)
maintenance and repair of ITL equipment. If you are unsure or do not understand
information contained in the Service Bulletins then ask your supervisor for advice.
                                                                                         Issue                  1
Remember SAFETY MUST COME FIRST.                                                         Date           Feb. 1995

SUBJECT:                     Stake Nuts, Input and Output Flanges                                          Page 1 of 1

PRODUCTS AFFECTED:           All ITL Transmissions and Axles

TO BE CARRIED OUT:           Information Only

SERVICE INFORMATION

1    AXLES
     Axle stake nuts A are now a combined nut and washer (instead of the
     separate nut and washer arrangement). If this type of nut is used on an
     earlier type axle or 4WD flange, the old separate washer must be
     discarded.

2    TRANSMISSIONS
     The stake nut for the gearbox rear (2WD) output flange is now
     manufactured from 46 mm hexagonal bar. The existing 13/4 inch
     socket can not be used on the 46 mm nuts. Make sure both types of
     socket are available in the event of site repair.

     Note: The transmission rear (2WD) output flange is still
     retained by the separate nut and washer
     arrangement, the washer should be replaced
     with a new one if damaged or distorted.                                                             S224080


Input & Output Flanges -
The axle flanges and transmission output
flanges are now hardened (at the sealing                                               Note: The illustration shows a
area). The hardened flanges prevent possible                                           typical axle arrangement.
oil leaks and loss of bearing pre-load 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 Manual.

PARTS INFORMATION
Part No.                     Description       Qty    Comments
826/01482                    Combine Stake Nut/Washer A/R    M22
826/01483                    Combine Stake Nut/Washer A/R    M24
826/01551                    Stake Nut A/R     46 mm - Gearbox




    THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES
          NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES

           ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I.T.L., WREXHAM, CLWYD, LL13 9UF, UNITED KINGDOM
                                                                                                          INDEX
                                      TECHNICAL
                                      INFORMATION                                                    General

! SAFETY NOTICE - Instructions in the Service Bulletins assume that the                   Number          Gn014
engineer has a sound knowledge of safety procedures and has been trained in the           (JCB Gen 041; K68/N. Am.)
maintenance and repair of ITL equipment. If you are unsure or do not understand
information contained in the Service Bulletins then ask your supervisor for advice.
                                                                                          Issue              1
Remember SAFETY MUST COME FIRST.                                                          Date     August 1995

SUBJECT:                    Fuel Injection Pump - Seal Failure                                           Page 1 of 2

PRODUCTS AFFECTED:          Perkins 1000 Series Engines

TO BE CARRIED OUT:          By Perkins Dealers


SERVICE INFORMATION:
The possibility exists that the shaft seal of the fuel injection pump has been damaged during the assembly process.
The seal must be replaced with a new one otherwise serious damage to the engine could occur. Replacement of the
seal is a specialised task and must only be done by the C.A.V. engineer; therefore please note the following:

1 The OEM Distributor must contact the local C.A.V. agent and quote reference number D137.

2 The OEM Dealer and the C.A.V. agent then arrange with the machine owner a suitable time to complete the repair
  procedures (repair time 3.0 hours).

3 On arrival at the machine, the OEM engineer will remove the injection pump (see SERVICE PROCEDURES), once
  the pump has been removed it is given to the C.A.V. agent who will then replace the shaft seal.

4 The injection pump (complete with new seal) must then be refitted to the machine by the OEM engineer.


SERVICE PROCEDURES

Fuel Injection Pump Removal

Special Tools Required:     Gear Puller - part number PD155C      Note: Existing workshop special tools - these items
                            Adaptors - part number PD155B/5       are not reclaimable on this FSI
                            Spanner - part number PD199

1 Park the machine on firm level ground, engage the parking brake and set the transmission to neutral.

2 Raise the loader arms or the boom if necessary to access engine and fit safety strut.

3 Switch off the the engine and remove the starter key. Disconnect the battery.


                                                                        ....continued




  THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES
        NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES

          ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I.T.L., WREXHAM, CLWYD, LL13 9UF, UNITED KINGDOM
Page 2 of 2                                                                      Gn014                     Issue 1

SERVICE PROCEDURES (continued)

4 Remove the injection pump:

   4.1   Remove all the pipes, cables and electrical
         connections from the pump.

   4.2   Remove the gear cover from the cover of the timing
         case. Remove the gear nut and spring washer.
                                                                        A
   4.3   Rotate the crankshaft to ensure that the keyway in
         the drive gear of the fuel pump is at or near to the     C
         top.
                                                                    S235040
   4.4   Remove the setscrew and the nut of the support
         bracket below the fuel pump. Release the flange
         nuts A of the fuel pump (see note). If access to the
         flange nuts is restricted, use tool PD199.
                                                                    B
Note: Leave one flange nut loose on the end of the thread,
this will prevent the pump from falling when the gear is
removed (step 4.5).

   4.5   Loosen the drive gear of the fuel injection pump
         with the puller PD155C and adaptors PD155B/5, as
         shown at B (items 1 and 2).

   4.6   Remove the fuel pump; ensure that the key does
         not fall from the drive shaft.
                                                                                                              S235030

Fuel Injection Pump Replacement

1 Rotate the drive shaft of the fuel injection pump to align the key with the keyway in the drive gear. Ensure that the
  key is correctly fitted and fit the fuel pump to the gear.

2 Align the mark on the flange of the fuel pump with the mark on the rear face of the timing case, shown at C. Fit the
  flange nuts A and the setscrew and the nut of the support bracket. Ensure that force is not applied to the fuel pump
  when the support bracket is fitted.

3 Fit the spring washer and the nut to the drive shaft of the fuel pump and tighten the nut to 80 Nm (59 Ibf ft) 8,2 kgf
  m. Fit the gear cover to the cover of the timing case together with a new joint.

4 Fit all the pipes, cables and electrical connections. Reconnect the battery.

5 Eliminate air from the fuel system. Operate the engine and check for leakage. With the engine at the normal
  temperature of operation, check that the idle speed is correct.



SERVICE PARTS:
Part No.  Description           Qty          Comments
02/200976 Gasket                1            Injection Pump to Timing Case
02/200029 Gasket                1            Injection Pump Gear Cover
                                                                                                      INDEX
                                      TECHNICAL
                                      INFORMATION                                                General

! SAFETY NOTICE - Instructions in the Service Bulletins assume that the               Number          Gn015
engineer has a sound knowledge of safety procedures and has been trained in the       (JCB Gen 038; F66/N. Am.)
maintenance and repair of ITL equipment. If you are unsure or do not understand
information contained in the Service Bulletins then ask your supervisor for advice.
                                                                                      Issue                1
Remember SAFETY MUST COME FIRST.                                                      Date         Feb. 1996

SUBJECT:                    Engine Lubrication System - Relief Valve Housing                         Page 1 of 2

PRODUCTS AFFECTED:          All Fitted with Perkins 1000 Series Engines

TO BE CARRIED OUT:          By Perkins Dealers

SERVICE INFORMATION:
The possibility exists that engine relief valve housing A
may fail. The relief valve controls the engine lubricating                            A
system oil pressure, therefore a failure of the housing
could result in the loss of engine oil pressure and cause
subsequent damage to the engine.

Investigation has shown that the relief valve housing has                   D
been machined incorrectly and remedial procedures have
already been implemented to ensure all relief valve                    E
housings are now machined to the correct specification.

Check the relief valve housing as described in SERVICE
PROCEDURES.


SERVICE PROCEDURE:
Note: The following procedures apply to a typical machine,
the method for gaining access to the engine oil relief valve
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 INSTRUCTIONS
Refer to Perkins dealers for warranty information and repairs.


ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I.T.L., WREXHAM, CLWYD, LL13 9UF, UNITED KINGDOM
                                                                                                          ENGLISH
Page 2 of 2                                                                  Gn015                         Issue 1

SERVICE PROCEDURE (continued):
5   Provide a support for the sump and remove the sump retaining bolts. Lower the sump and remove the sealing
    gasket.
6     Inspect the relief valve housing:
      6.1       Look at the side of the relief valve housing A for the manufacturer's number.
      6.2       If the number has a `1' below it as shown at B, then the housing is made to the correct specification,
                move to step 9.
      6.3       If the number has a `2' below it as shown at C, then the housing is made to the wrong specification
                and must be replaced with a new one, move to step 7.

Important note: Relief valves obtained from service parts stock with a number `2' are manufactured to the correct
specification.

7     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.

PARTS REQUIRED
Part No.   Description                       Qty          Comment
02/200102  Relief Valve Assy                 1            Turbo Engine
02/200106  Relief Valve Assy                 1            Naturally Aspirated Engine
02/102069  Engine Sump Gasket                1            Cast Iron Sump
02/200875  Engine Sump Gasket                1            Alloy Sump
02/200198  Drain Plug `O' ring               1            available only in units of 50 - part number 02/200198A
                                                                                                          INDEX
                                      TECHNICAL
                                      INFORMATION                                                   General

! SAFETY NOTICE - Instructions in the Service Bulletins assume that the                Number             Gn016
engineer has a sound knowledge of safety procedures and has been trained in the        (JCB 2/156; D19/N. Am.)
maintenance and repair of ITL equipment. If you are unsure or do not understand
information contained in the Service Bulletins then ask your supervisor for advice.
                                                                                       Issue                  1
Remember SAFETY MUST COME FIRST.                                                       Date           Feb. 1996

SUBJECT:                    Parkbrake Clevis Pin Improvements                                            Page 1 of 2

PRODUCTS AFFECTED:          Transmissions with Clysdale Type Park Brake

TO BE CARRIED OUT:          Information Only


SERVICE INFORMATION

A new method of retaining the parkbrake cable to the lever and the caliper has been introduced. In place of the
existing clevis pin arrangement, new type shouldered bolts (items A and B) are used. The shouldered bolts are
directly interchangeable with the clevis pin arrangement. When required, the shouldered bolts can be fitted as
described in SERVICE PROCEDURES.

SERVICE PROCEDURES

1 Park the machine on firm level ground, engage the parking brake and set the transmission to neutral. Lower the
  equipment to the ground and stop the engine.

2 Remove the parkbrake lever gaiter (item C).

3 Remove the clevis that holds the cable to the lever (item D), and in its place fit a new shouldered bolt (item A),
  washers (items E and F) and retaining nut (item G).

4 Remove the clevis that holds the cable to the caliper (item H), and in its place fit a new shouldered bolt (item B),
  washer (item F) and retaining nut (item G).

5 Check that the parkbrake fully engages (do a parkbrake test - refer to Operator Handbook). If necessary adjust the
  parkbrake as required.

6 Refit the parkbrake lever gaiter.

PARTS INFORMATION

Item No.    Part No.       Description           Qty     Comments
A           826/01596      Shouldered Bolt       1       Parkbrake cable to parkbrake lever
B           826/01597      Shouldered Bolt       1       Parkbrake cable to caliper
E           1420/0007Z     8 mm Flat Washer      2
F           1420/0006Z     6 mm Flat Washer      2
G           1370/0103Z     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 I.T.L., WREXHAM, CLWYD, LL13 9UF, UNITED KINGDOM
Page 2 of 2                               Gn016       Issue 1




                      G


    A                 F
                  E
              E




         C


                          D




                                                  H




                                      F
                              B

                                  G
                                                                                                         INDEX
                                       TECHNICAL
                                       INFORMATION                                                 General

! SAFETY NOTICE - Instructions in the Service Bulletins assume that the               Number             Gn017
engineer has a sound knowledge of safety procedures and has been trained in the       (JCB Gen 045)
maintenance and repair of ITL equipment. If you are unsure or do not understand
information 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 engines

SERVICE INFORMATION

A new specification of starter motor having a larger and stronger inertia clutch has been introduced in two forms for
either left hand or right hand mounting.

The engine serial cut-in numbers are:
Right hand mounting on four cylinder engines:    U 746654 B
Left hand mounting on four cylinder engines:     U 747324 B
Six cylinder engines:                            U 620352 B.

The two new part numbers are fully interchangeable with the earlier starter motors as detailed below. For specific
machine applications, refer to the parts information.

Note that all starter motors failing within the warranty period should be repaired by the nearest Magnetti Marelli
distributor. See T.I. Gn018 for list of Magneti Marelli distributors.

Contact Perkins or Perkins Dealer for further information.

Parts Required

Part No             Description
714/29300           Starter motor, left hand mounting (supersedes 714/09100)
714/29500           Starter motor, right hand mounting (supersedes 714/14300)




  THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES
        NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES

          ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I.T.L., WREXHAM, CLWYD, LL13 9UF, UNITED KINGDOM
                                                                                                                INDEX
                                        TECHNICAL
                                        INFORMATION                                                        General

! SAFETY NOTICE - Instructions in the Service Bulletins assume that the                     Number              Gn018
engineer has a sound knowledge of safety procedures and has been trained in the             (JCB MI 461/H, 431/E)
maintenance and repair of ITL equipment. If you are unsure or do not understand
information contained in the Service Bulletins then ask your supervisor for advice.
                                                                                            Issue                   2
Remember SAFETY MUST COME FIRST.                                                            Date            Feb. 1999

SUBJECT:                     Magneti Marelli Service/Warranty Support                                           Page 1 of 5

PRODUCTS AFFECTED: All Fitted with Magneti Marelli Alternators and/or Starter Motors

From 1st January 1996, Service Warranty Support for Magnetti Marelli electrical equipment fitted on Perkins Engines
will be provided by Magnetti Marelli Distributors.

The addresses of the Magneti Marelli European main headquarters are listed below. The remaining pages identify
distributors in your country, so for instance, the translated JCB French version of this bulletin will only list the French
distributor network, the German the German network, and so on. If there is no local Magneti Marelli agent, the
starter/alternator can either be repaired by a local electrical agent and the repair invoice submitted with a Warranty
claim to a Perkins Dealer, or if required, a new unit can be supplied by a Perkins Dealer.

MAGNETI MARELLI SERVICE HEADQUARTERS

U.K. -          Magneti Marelli Aftermarket                    GERMANY -         Magneti Marelli KV
                Shaftsmoor Lane                                                  Wannenackerstrasse 71
                Hall Green                                                       74078 Heilbronn
                Birmingham                                                       Germany
                B28 8SW
                                                                                 Tel: 00-49-71312910
                Tel: 0121-6258788                                                Fax: 00-49- 7131176928
                Fax: 0121-6258625
                                                               SPAIN -           Magneti Marelli Iberica
ITALY -         Magneti Marelli                                                  Avda de Roma 80-82
                Viale Aldo Borletti 61/63                                        08015 Barcelona
                20011 Corbetta                                                   Spain
                Milano
                Italia                                                           Tel: 00-34-32263176
                                                                                 Fax: 00-34-32262109
                Tel: 00-39-0297200602
                Fax: 00-39-0297200500

FRANCE -        Magneti Marelli France
                19 Rue Lavoisier                                 Note: If difficulty is experienced in finding support or
                92000 Nanterre                                   overseas warranty cover, contact Perkins U.K. on:
                France
                                                                 Tel: (UK 44)(0) 1733 567474
                Tel: 00-33-147297000                             Fax:        (0) 1733 582240
                Fax: 00-33-147297274

Note: For JCB Language versions, only the front page is issue raised. When filing, replace the front sheet only.


  THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES
        NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES

          ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I.T.L., WREXHAM, CLWYD, LL13 9UF, UNITED KINGDOM
NAME                           ADDRESS                                                   TOWN               COUNTY           POST       TELEPHONE
                                                                                                                             CODE       NUMBER
AVON
Bristol Auto Electrical        357 Bath Road                  Brislington                Bristol            Avon             BS4 3EU    0117-971-2242
                                                                                                                                                        Page 2 of 5




Gloucester Automotive          Unit 4 Locksbrook Court        Locksbrook Road            Bath               Avon             BA1 3EN    01225-483882

BEDFORDSHIRE
Electrodiesel Services Ltd     Murdock Road                                              Bedford            Bedfordshire     MK41 7RA   01234-217025
Radial Ltd                     42-44 Hasting Street                                      Luton              Bedfordshire     LU1 5BQ    01582-22431

BERKS
Cafco Automotive Ltd           13 The Paddock                 Hambridge Road             Newbury            Berks            RG14 5TQ   01635-580707
Cafco Automotive Ltd           4 Nimrod Way                   Elgar Road                 Reading            Berks            RG2 0EB    01734-868456
Cafco Automotive Ltd           13 Eastheath Avenue                                       Wokingham          Berks            RG11 2PP   01734-784321
Cafco Automotive Ltd           6 Bracknell Business Centre    Downmill Road              Bracknell          Berks            RG12 1QS   01344-51011

BUCKS
Cafco Automotive Ltd           2 Bridgegate Business Park     Gatehouse Way              Aylesbury          Bucks            HP19 3XN   01296-392955
Cafco Automotive Ltd           9 Wessex Road                                             Bourne End         Bucks            SL8 5DT    01628-525544
Cafco Automotive Ltd           22a Buckingham Avenue                                     Slough             Bucks            SL1 3EA    01753-692030
Cafco Automotive Ltd           2b Alma Road Ind. Estate                                  Chesham            Bucks            HP5 3HB    01494-772635
Hereward Car & Truck

CAMBRIDGESHIRE
Components Ltd                 19 Harvester Way               Fengate                    Peterborough       Cambridgeshire   PE1 5UT    01733-346564

CHESHIRE
Auto Battery Services Ltd      100/102 King Street                                       Dukinfield         Cheshire         SK16 4JZ   0161-330-2236

CLEVELAND
Electrodiesel North East Ltd   Portrack Grange Road                                      Stockton on Tees   Cleveland        TS18 2PH   01642-679741

CORNWALL
Mill Auto Supplies             Head Office                    42 West Hill               St Austell         Cornwall         PL25 5EY   01726-73063
Mill Auto Supplies             Church Works                   Mount Street               Penzance           Cornwall         TR13 2EU   01736-60301
Mill Auto Supplies             49-51 Wendron Street                                      Helston            Cornwall                    01326-561222
Mill Auto Supplies             Penmarrin House                Commercial Road            Penryn             Cornwall                    01326-373343
Mill Auto Supplies             Trevenna House                 Nettles Hill               Redruth            Cornwall         TR15 1AL   01209-218774
Mill Auto Supplies             Units 1 & 2, Old Sation Yard   Berrycombe Road            Bodmin             Cornwall                    01208-78166
Mill Auto Supplies             Eddystone Rd Ind. Estate                                  Wadebridge         Cornwall                    01208-813254
Mill Auto Supplies             1 Miller Bus Park              Station Road               Liskeard           Cornwall         PL14 4DA   01579-346555

DEVON
Autolec Services               Marsh Green Road               Marsh Green Trading Est.   Exeter             Devon                       01392-54931
                                                                                                                                                        Gn018
NAME                              ADDRESS                                              TOWN            COUNTY          POST       TELEPHONE
                                                                                                                       CODE       NUMBER
ESSEX
GP Auto                           119 Victoria Road                                    Romford         Essex           RM1 2LX    01708-722913
                                                                                                                                                     Page 3 of 5




Motex Express Auto Factors        14 Oban Court                Hurricane Way           Wickford        Essex           SS11 8YB   01268-561562

GLOUC ESTER
Central Motor Factors             9-13 High Street                                     Lydney          Gloucester      GL15 4DP   01594-845011
Central Motor Factors             New Road                     Parkend                 Lyndey          Gloucester      GL15 4JA   01594-563499
Gloucester Automotive             53 St. Catherine Street                                              Gloucester      GL1 2BS    01452-302989
Gloucester Automotive             Unit 5 Lower Mill Street                             Cheltenham      Gloucester      GL51 8JN   01242-584494
Gloucester Automotive             Riverside Works                                      Severn Road     Gloucester      GL1 2LE    01452-415555

HAMPSHIRE
A.R.E. Ltd                        Aldershot Truck Spares       16 Connaught Road       Aldershot       Hampshire       GU12 4RN   01252-343228
A.R.E. Ltd                        Eastern Road                                         Aldershot       Hampshire       GU12 4TD   01252-331448
A.R.E. Ltd                        Unit 1 Amey Ind. Est.        Frenchmans Road         Petersfield     Hampshire       GU32 3AN   01730-268431

HERTS
Radial Ltd                        103 Longspring                                       Watford         Herts           WD2 5PO    01923-232311
Radial Ltd                        7 Railway Place                                      Hertford        Herts           SG13 7BS   01992-581493

IRELAND
Edmunds Walker                    JFK Industrial Estate        Naas Road               Dubln 12        Ireland                    00-353-1-4502866
Edmunds Walker                    College Commercial Park      Dennehys Cross          Cork            Ireland                    00-353-21-344688
Edmunds Walker                    23 Nicholas Street                                   Limerick        Ireland                    00-353-61-419200

KENT
Cafco Automotive Ltd              43 Sittingbourne Ind. Park   Crown Quay Lane         Sittingbourne   Kent            ME10 3JG   01795-475321

LANCASHIRE
Auto Battery Services Ltd         School Lane                                          Rochdale        Lancashire      OL16 1QR   01706-522522
Auto Battery Services Ltd         Elliot House               Greenacres Road           Oldham          Lancashire      OL4 1HB    0161-627-5638
PF Jones (Diesel Service) Ltd     Nuttall Street                                       Manchester      Lancashire      M16 9JA    0161-872-4755
Ribblesdale Distribution          Cocker Road, Bamber Bridge Walton Summit Ind Est.    Preston         Lancashire      PR5 8AL    01772-629639
Leyland Auto Elec. & Diesel Ltd   Unit 220, Bamber Bridge    Walton Summit Ind. Est.   Preston         Lancashire      PR5 5AL

LINCS
Hereward Car & Truck              Brownlow Street                                      Stamford        Lincs           PE9 2EL    01780-481234

LONDON
Motor Trade Services              246/250 Cavendish Road                               Balham          London          SW12 0BY   0181-673-5555
Radial Ltd                        Hillway                                              Highgate        London          N6 6QE     0181-341-0553

MID GLAMORGAN
Autoparts South Wales             Ynysangharad Road                                    Pontypridd      Mid Glamorgan   CF37 4DA   01443-405726
                                                                                                                                                     Gn018
NAME                         ADDRESS                                             TOWN                 COUNTY            POST       TELEPHONE
                                                                                                                        CODE       NUMBER
MIDDLESEX
Cafco Automotive Ltd         96 Oxford Road                Denham                Uxbridge             Middlesex         UB8 1LV    01895-256451
                                                                                                                                                   Page 4 of 5




NORFOLK
Panks Auto Electrical        15 Higham Street                                    Norwich              Norfolk           NR2 4TE    01603-629967

NORTH YORKSHIRE
Andrew Page Ltd              Unit 25 Raylor Centre         James Street          York                 North Yorkshire   YO1 3DP    01904-414466
Andrew Page Ltd              Unit 6 Thirsk Ind. Park       York Road             Thirsk               North Yorkshire   YO7 3TA    01845-526688
S.A.S. Ltd                   Unit 17 Provincial Works      The Avenue            Harrogate            North Yorkshire   HG1 4QE    01423-889021
S.A.S. Ltd                   Westgate                                            Otley                North Yorkshire   LS21 3AT   01943-467514

NOTTS
Midland Magneto              Trent Works                   Canel Street          Nottingham           Notts             NG1 7HL    0115-9552233

OXFORDSHIRE
Cafco Automotive Ltd         29b Milton Park                                     Abingdon             Oxon              OX14 4RT   01235-834888
Cafco Automotive Ltd         59 Murdock Road                                     Bicester             Oxon              OX6 7PP    01869-244612

SCOTLAND
D & A Factors Ltd            2 West Hendersons Wynd                              Dundee               Scotland          DD1 5BT    01382-228202
D & A Factors Ltd            42 Canmore Street                                   Forfar               Scotland                     01307-464914
D & A Factors Ltd            13 Baltic Street                                    Montrose             Scotland                     01674-676260
D & A Factors Ltd            Unit 7 whitefriars                                  Perth                Scotland                     01738-636409
European Vehicle Equipment   13 Scotland Street                                  Glasgow              Scotland          G5 9PU     0141-429-2704
Stanley R Harris Ltd         24/40 Seaward Street                                Glasgow              Scotland          G41 1HL    0141-429-3141

SOUTH YORKSHIRE
Andrew Page Ltd              Unit 4 Silver Court           Intercity Way         Bramley              South Yorkshire   L13 4LY    0113-236-2122
Sutton Auto Factors          Newcross Street                                     Sutton in Ashfield   South Yorkshire              01623-441331

STAFFS
Car Bar Components Ltd       Kettlebrook Road                                    Tamworth             Staffs            B77 1AG    01827-60111
Car Bar Components Ltd       1 Horninglow Street                                 Burton-on-Trent      Staffs            DE14 1NG   01283-534066
Midwest Motor Factors        Brownhills Business Park      Linden Road           Brownhills           Staffs            WS8 7BW    01543-375156
Potteries Diesel             Mason Street                  Fenton                Stoke on Trent       Staffs            ST4 3NE    01782-744556

SURREY
A.R.E. Ltd                   285 Worplesdon Road                                 Guildford            Surrey            GU2 6XN    01483-233003
A.R.E. Ltd                   Unit 1 Goldsworth Ind. Est.   Goldworth Road        Woking               Surrey            GU21 1LY   01483-722424
A.R.E. Ltd                   Hare Lane                                           Goldalming           Surrey            GU7 3EG    01483-428585
A.R.E. Ltd                   Unit 1 Weydown Road                                 Halsmere             Surrey            GU27 1DW   01428-654061
A.R.E. Ltd                   1-3 East Street                                     Farnham              Surrey            GU9 7RX    01252-737654
A.R.E. Ltd                   Guildford Truck Spares        139 Worplesdon Road   Guildford            Surrey            GU2 6XA    01483-573311
                                                                                                                                                   Gn018
NAME                              ADDRESS                                                  TOWN                COUNTY           POST       TELEPHONE
                                                                                                                                CODE       NUMBER
SURREY
A.R.E. Ltd                        282 Walton Road                                          East Molesey        Surrey           KT8 0HU    0181-941-7955
                                                                                                                                                           Page 5 of 5




A.R.E. Ltd                        Unit 1 Downside                Guildford Road            Chertsey            Surrey           KT16 9BQ   01932-570820
A.R.E. Ltd                        78 Holmethorpe Avenue          Holmethorpe Ind. Est.     Redhill             Surrey           RH1 2NL    01737-767000
A.R.E. Ltd                        Walton Motor Factors           151-153 Hersham Road      Hersham             Surrey           KT12 5NR   01932-231298

TYNE AND WEAR
Andrew Page Ltd                   Unit 15 Brough Park            Fossway                   Newcastle-upon-Tyne Tyne and Wear    NE6 2YF    0191-224-2345
Tyneside Auto Electrical Ltd      St Lawrence Road                                         Newcastle-upon-Tyne Tyne and Wear    NE6 1AQ    0191-265-4426

WEST MIDLANDS
Midwest Motor Factors             Units 10/11 Eruria Way         Barton Park Ind. Estate   Bilston             West Midlands    WV14 7AH   01902-353515
Midwest Motor Factors             Walsall Road                                             Willenhall          West Midlands    WV13 2ED   01902-633005
Midwest Motor Factors             Units 2, 3 & 6                 Brandon Way Ind. Estate   West Bromwich       West Midlands    B70 9PW    0121-525-4775

WEST YORKSHIRE
Andrew Page Ltd                   Apson House                    53/59 Mabgate             Leeds               West Yorkshire   LS9 7DY    0113-200-1010
Andrew Page Ltd                   Grantley Way                   Stanley Road              Wakefield           West Yorkshire   WF1 4PY    01924-365727
Andrew Page Ltd                   Unit 5                         Hall Lane                 Bradford            West Yorkshire   BD4 7DG    01274-723156
Andrew Page Ltd                   Units 29-30 Beck Road          Ringway Ind. Estate       Huddersfield        West Yorkshire   HD1 5DG    01484-420077
Andrew Page Ltd                   Units 15/17 Ashley Ind. Est.   Elmfield Road             Morley              West Yorkshire   LS27 0EL   0113-252-6600

WILTS
Melksham Motor Spares Ltd         16 Church Street                                         Melksham            Wilts            SN12 6LS   01225-790123

WINCESTER
H.A.E. Ltd                        Wykeham Industrial Estate      Easton Lane               Winnall             Wincester        SO23 7RX   01962-841010

WORCESTER
Mobile Electric (Worcester) Ltd   Gregorys Mill Street                                     Worcester           Worcestershire   WR3 8BS    01905-25284




SCANDINAVIA
Norway - Jahre Motor A/S          Brynsveien 2-4                 0602 Oslo 6
Finland - Atoy OY1                Lauttasaarenti 54              0200 Helenski
Denmark - Dybbroe A/S             Tomsagervey 8-10               08230 Aabyhoj (Aarhus)
                                                                                                                                                           Gn018
                                                                                                             INDEX
                                       TECHNICAL
                                       INFORMATION                                                    General

! SAFETY NOTICE - Instructions in the Service Bulletins assume that the                  Number              Gn019
engineer has a sound knowledge of safety procedures and has been trained in the          (JCB M.I. 525/HA)
maintenance and repair of ITL equipment. If you are unsure or do not understand
information 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 Transmissions.

Service Marketing is becoming increasingly important in generating distributor revenue. Introduction of ECU and EMS
units incorporating Service Indicators represents a major opportunity for distributors to ensure they obtain all routine
service work.

To support transmissions fitted with these systems, Distributor Service Personnel need to have the appropriate
Computer Diagnostic equipment. All new ITL electronic systems will use the PSION Workabout hand held computer
for this purpose.

This bulletin describes the requirements for and technical specification of these computerised diagnostic tools.

1   PSION WORKABOUT

    This low cost, rugged, hand held computer is now the ITL and JCB Group Diagnostic Tool. It is widely used in
    service industries for in-field use.

    All new ITL and JCB products with electronic systems requiring support from Service personnel will use software
    running on the PSION.

    Electronic units requiring the PSION workabout will be as follows:-

    Transmission ECU
         Fitted to:        PS700 four and five speed transmissions

          Function:        Control of powershift gearbox.

          Use of PSION: Fault finding of ECU inputs and outputs.

The technical details of the PSION Workabout are:

    Specification                  PSION Workabout                                PSION Part No.       ITL/JCB part No.
                                   RS 232 and TTL Serial Interfaces               1800 0006-11         892/00924

    Docking Holster                One required per depot for                     1801 0003-01         892/00925
                                   transferring software from PC
                                   to PSION Workabout

    PsiWin Link and Software       To transfer JCB software from                  1601 0039-10         892/00926
                                   PC to PSION Workabout - one per depot

    ITL Software
          This will be provided on the Parts CD ROM and will be transferred from a desktop computer via PsiWin
          software to the PSION Workabout. A Psion disc is also available, JCB part No. 892/00963.

    Cable links to machine
         Connecting cable for connecting the PSION Workabout to any ITL machine is part no. 892/00952, available
         from JCB Service

    A service kit comprising the above items is available, JCB part No. 892/00962
          ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I.T.L., 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) 1713174122.


Technical details of the Notebook PC are:

    Specification:
         Preferably a ruggedised portable computer having:
         Pentium processor
         16 Meg memory or greater.
         1 Gb hard drive or greater.
         Internal CD ROM drive (4 speed or greater)

    Operating System:
         Windows 3.11 or Windows 95

    ITL Software:
          Will be provided on the Parts CD ROM

    Cable links to machine:
         ITL part numbers will be advised in workshop manuals.

    Availability:
          Any reputable computer supplier, JCB Service or ITL direct.


The facts about Workabout

Processor:               16-bit NEC V30H (80C86 compatible), multi-tasking, windowing environment.
                         MS-DOS compatible file formats.

Memory:                  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 Backlight.

Keyboard:                57 key alphanumeric

Power Supply:            2 AA batteries, Rechargeable battery pack
                         (optional) Lithium backup battery
                         External power via mains adaptor
                         or Docking Station.

Integral applications:   OPL language, Database,
                         Spreadsheet and Calculator

Optional interfaces:     Barcode wand and RS-232;
                         TTL and RS-232 (for scanners)

Accessories:             Elasticated strap

Operating Conditions:    -20 to +60 Celsius,
                         Humidity 90% max
                         non-condensing

Drop resistance:         One metre onto concrete

Weatherproofing:         Standard model splashproof,
                         optional on expansion interfaces

Dimensions:              180mm x 90mm x 35mm;
                         325g (including batteries)
PSION DISTRIBUTOR                  Country        Address                                                                        Telephone Number     Fax Number           E-mail
ASK INTERNATIONAL S.A.R.L.         ALGERIA        94 RN 133, 42380 SOUIDANIA, W.TIPASA                                           (213) 2791130        (213) 2791130
                                                                                                                                                                                                              3 of 3


PSIAR                              ARGENTINA      AVENIDA DE MAYO 963, 3RD FLOOR, BUENOS AIRES1084                               (541) 345 2351       (541) 345 3605       psiar@satlink.com
PSITECH PTY                        AUSTRALIA      RMB 3585, VALLEY ROAD, KANGY ANGY, NEW SOUTH WALES 2258                        (61) 4362 2014       (61) 4362 2014
HAYWARD COMPUTER-PERIPHERIE        AUSTRIA        POSTFACH 79, A-5071 WALS 405                                                   (43) 662 8587 0      (43) 662 8587 80     mschinwald@hayward.co.at
COMPUTER WORLD                     BAHRAIN        273 EXHIBITION AVENUE, HOORA PO BOX 26178, MANAMA                              (973) 293 493        (973) 292 253
SHARANEE LTD                       BANGLADESH     B-172 LANE-23, NEW D.O.H.S., DHAKA 1206                                        (880) 2885 219       (880) 2881 470
MICROCONNECTION DISTRIBUTION       BELGIUM        KORTE WINKLESTRAAT 15, B-2000 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       psf@brunet.bn
IMIC                               CAMBODIA       2 BLVD NORODOM, PHNOM PENH, CAMBODIA                                           (855) 23 362 392     (855) 23 721 756     craigm@uni.fi
SYSCAN INTERNATIONAL INC.          CANADA         2775 SHERBROOKE EAST, MONTREAL, QUEBEC, H2K 1B9                                (514) 521 0482       (514) 521 0949
RADIO-HOLLAND CARIBBEAN N.V.       CARIBBEAN      ATHDLLIDGEROAD 106, PO BOX 1102, ST.MAARTENS                                   (599) 525 414        (599) 522 589        merkus@ibm.net
BINARIA SA                         CHILE          COMPANIA 1357, PISO 7, SANTIAGO                                                (562) 696 2133       (562) 696 9368
POINT X S.R.O.                     CZECH REP.     TRUHLARSKA 3, 11000 PRAGUE 1                                                   (42) 2 231 9395      (42) 2 2481 0821     pointx@login.cz
MOBI DATA A/S                      DENMARK        FUGLEBAKKEVEJ 88-90, DK-2000 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 ANGLO-NORDIC AB                 FINLAND        HYTTIMESTARINTIE 3, 02780 ESPOO                                                (358) 9 819211       (358) 9 811338       psion@anglo.fi
PSION FRANCE                       FRANCE         78 RUE CHAMPIONNET, F 75018 PARIS                                              (33) 1 53411 200     (33) 1 53411 201
PSION GMBH                         GERMANY        DAIMLERSTRASSE 16, D-61352 BAD HOMBURG                                         (49) 6172 6630       (49) 6172 663100
INT ELECTRONIC                     GREECE         72 SYNGROU AVENUE, GR - 11742, ATHENS                                          (30) 1 9233013       (30) 1 9234273       int@hol.gr
ONFLO INTERNATIONAL LTD            HONG KONG      SUITE 1818 18/F MIRAMAR TOWER 1 KIMBERLEY RD, TSIMSHATSUI, KOWLOON             (852) 2314 5550      (852) 2377 3261      dominic@onflo.com.hk
PSION MAGYARORSZAG KFT             HUNGARY        SZT. GELLERT TER.3, 1111 BUDAPEST                                              (36) 1209 3804       (36) 1209 3805       100324.102@compuserve.com
PT KOMTELINDO HITEK INTI           INDONESIA      WISMA MULTI BINLANG, JL DR SOEPOMO SH NO 44, JAKATA                            (62) 3 61756248      (62) 3 61756284      komtel@ibm.net
SIS SURVEY                         IRELAND        UNIT 6A, BALLYMOUNT CROSS INDUSTRIAL ES, DUBLIN 12                             (353) 456 8650       (353) 456 8653       hem@cix.compulink
VIDEO COMPUTER                     ITALY          VIA ANTONELLI 36,10093 COLLEGNO                                                (39) 11 403 4828     (39) 11 403 3325
PSION JAPAN                        JAPAN          NISHI SHINJUKU FOREST BLD., LB FLOOR NISHI SHINJUKU 4-32-1SHINJUKU-KU, TOKYO   (81) 3 3378 5933     (81) 3 3378 5943
ANWAR ESSA AL SALEH ESTAB.         KUWAIT         AL-RABIE BLDG,SALMIYA, PO BOX 4704, SAFAT, 13048                               (965) 573 7684       (965) 571 6674       esaleh@kuwait.net
COMPUTEL S.A.R.L.                  LEBANON        JUSTINIAN CENTRE, JUSTINIAN ST, SANAYEH, PO BOX 113 6413, BE                   (961) 1 353 748      (961) 1 602 193      COMP@DM.NET.LB
ALCHEMY 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 4469446
POCKET SOLUTIONS                   NEW ZEALAND    11 RUTHERFORD STREET, PO BOX 44070, LOWER HUT WELLINGTON                       (64) 4566 7808       (64) 4569 6452       psol002@ibm.net
DEBIS                              NIGERIA        110 OBAFEMI AWOLOWO WAY, IKEJA, LAGOS STATE                                    (234) 14970226/7     (234) 14970228/9
UCOM                               NORWAY                                                                                        (47) 32203300        (47) 32203459
OHI ELECTRONICS & TRADING CO LLC   OMAN           PO BOX 889, MUSCAT 113,SULTANATE OF OMAN                                       (968) 959 085        (968) 603 467
CHARLES FREWEN                     PARAGUAY       VALIANA SAL, PAETONALCORONELMONELOS 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      bthimktg@globe.com.ph
CIE CENTRUM INFORMATYKI ENERGETY   POLAND         UL MYSIA 2, SKR- POCZT 143, 00-950 WARSZAWA 1                                  (48) 22 625 3397     (48) 22 693 1357     ciesm@elmo.nask.waw.pl
COMP 3 LDA                         PORTUGAL       RUA AUGUSTO GILL 30 A/B, 1100 LISBON                                           (351) 1 795 1872     (351) 1 795 1928
PSI-RUSSIA                         RUSSIA         INTERNATIONAL UNIVERSITY OF ENG6 LENINSKY PROSPEKT, GSP, MOSCOW 117933         (7) 095 236 6531     (7) 095 236 976      kenmore@roditi.co.uk
NABIL ALI SINDI TRADING ESTABLIS   SAUDI ARABIA   PO BOX 2951, JEDDAH 21461                                                      (966) 2 6829454      (966) 2 6828801
SYSTECH                            SINGAPORE      25 KALLANG AVENUE#02.01/03, KALLANG BASIN INDUSTRIAL ESTAT339416               (65) 299 2933 x236   (65) 299 9688        systech@singnet.com.sg
PSIONET 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 4872516
KINGSLAKE ENG SYSTEMS              SRI LANKA      12 TICKELL ROAD, COLOMBO 8, SRI LANKA                                          (94) 1 695395        (94) 1 695874        dharma@sri.lanka.net
SVENSKA INDUSTRIELEKTRONIC AB      SWEDEN         F O PETERSONS GATA, 421 31 VASTRA FROLUNDA, SWEDEN                             (46) 31 709 1605     (46) 31 47 8520      sten.sohle@industrielektronik.se
EXCOM AG                           SWITZERLAND    MOOSACHER STRASSE 6, CH 8820 WADENSWIL                                         (41) 1 782 2111      (41) 1 781 1361      infos@excom.ch
O.ABOU KHALIL TRADING CO           SYRIA          PO BOX 1054, DAMASCUS                                                          (963) 11 23174 60    (963) 11 4421966
JEBSEN & JESSEN                    THAILAND       1779/1 NEW PETCHBURI RD, BANGKOK 10320, THAILAND                               (66) 2 253 1290      (66) 2 253 1705
INSTITUT MASSMEDIA                 TUNISIA        GALAXIE 2000, RUE D'LAK BLOC A 7 EME ETAGE,1002 TUNIS                          (216) 1 793 939      (216) 1 794 949
ALPHA 55 CO. L.L.C.                UAE            1st Floor BIN KHEDIA CENTER, AL GARHOUD, DUBAI                                 (971) 4 822267       (971) 4 822265       alpha55@emirates.net.ae
PSION UK PLC                       UK             1 RED PLACE, MAYFAIR, LONDON W1Y 3RE                                           0171 317 4100
PSION UK SERVICE CENTRE            UK             6 DERBY ROAD, METROPOLITAN CENTRE, GREENFORD, MIDD'X, 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             Gn020
engineer has a sound knowledge of safety procedures and has been trained in the        (JCB M.I. 612/H, 548/E)
maintenance and repair of ITL equipment. If you are unsure or do not understand
information contained in the Service Bulletins then ask your supervisor for advice.
                                                                                       Issue                  1
Remember SAFETY MUST COME FIRST.                                                       Date          April 1998

ENGINE WORKSHOP MANUALS                                                                                   Page 1 of 1

Perkins New 1000 Series ("Darwin")

With the introduction of the `New 1000' Series range of engines, Perkins produced a new Workshop Manual which is
available under publication number 9806/2140.

Issue 3 of this publication is now available incorporating two additional engine models (AR and AS) which are for
machines sold primarily in North America and Scandinavia. The new issue also incorporates various general
revisions.

Any future orders for 9806/2140 will be supplied as issue 3.

French and German translations of issue 3 should be available by the end of May. Other languages will follow later.

Translated part numbers are:       French:       9806/2141
                                   German:       9806/2142
                                   Spanish:      9806/2143
                                   Italian:      9806/2144

Note: Replacement pages are not supplied for engine service manuals. To obtain the latest issue a new manual must
be ordered.

Engine models now covered by the new manual will be: 4 Cylinder: Models AJ to AS




  THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES
        NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES

          ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I.T.L., WREXHAM, CLWYD, LL13 9UF, UNITED KINGDOM
                                                                                                          INDEX
                                        TECHNICAL
                                        INFORMATION                                                 General

! SAFETY NOTICE - Instructions in the Service Bulletins assume that the                 Number            Gn021
engineer has a sound knowledge of safety procedures and has been trained in the         (JCB 10/107)
maintenance and repair of ITL equipment. If you are unsure or do not understand
information contained in the Service Bulletins then ask your supervisor for advice.
                                                                                        Issue                   1
Remember SAFETY MUST COME FIRST.                                                        Date           April 1998

SUBJECT                       Axle Propshafts                                                             Page 1 of 1

PRODUCTS AFFECTED             All Machine Installations

SERVICE INFORMATION
On installation of any machine it is important to ensure that the following points regarding propshaft lubrication and
protection are highlighted to the operator. Failure to do so may result in premature wear or consequential damage to
transmission components.

1     Lubrication

Propshafts must be greased as follows:

a)    Interval
          -        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     Protection

When working in loose straw or grass it is important that
an undershield is fitted to the machine to prevent material
wrapping around the propshafts.

Failure to protect the propshafts adequately may result in
damage to oil seals, propshafts and other transmission
components.

Parts Information

Part No          Description
4003/2017        JCB HP Grease (400 g cartridge)         Available from JCB Service and Dealers


     THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES
           NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES

            ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I.T.L., WREXHAM, CLWYD, LL13 9UF, UNITED KINGDOM
                                                                                                       INDEX
                                        TECHNICAL
                                        INFORMATION                                                 General

! SAFETY NOTICE - Instructions in the Service Bulletins assume that the               Number            Gn022
engineer has a sound knowledge of safety procedures and has been trained in the       (JCB 2/029)
maintenance and repair of ITL equipment. If you are unsure or do not understand
information contained in the Service Bulletins then ask your supervisor for advice.
                                                                                      Issue                 1
Remember SAFETY MUST COME FIRST.                                                      Date          Nov. 1990

SUBJECT:                      Engine Silencer Improvements                                             Page 1 of 1

PRODUCTS AFFECTED:            Perkins Engines

TO BE CARRIED OUT:            For Information Only


Product Improvement

The quality of ITL Silencers has been improved:

1    Turbo Engine Build Silencers

     a The end plates have been strengthened by
       increasing the section width. A rain cap A must be
       fitted on the new silencers as the water drain hole is
       now deleted.
     b The gauge has been increased from 1.6mm to 2.0mm.

2    Naturally Aspirated Silencers

     a A secondary support bracket B is fitted to silencers
       installed on naturally aspirated engines, this will
       reduce failures caused by vibration. The bracket is
       bolted to the silencer and mounted on the exhaust
       manifold studs.
     b The gauge has been increased from 1.6mm to 2.0mm.

Parts Required

Turbo Engine

Silencer x 1 - 993/66300 replaces 123/01468 and123/01136

Naturally Aspirated Engine

Silencer x 1 - 993/66200 replaces 123/01481 and123/00741
Support x 1 - 123/01482
Bolt x 1 - 1305/0204Z
Washer x 1 - 1411/0003Z



    THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES
          NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES

           ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I.T.L., WREXHAM, CLWYD, LL13 9UF, UNITED KINGDOM
                                                                                                       INDEX
                                       TECHNICAL
                                       INFORMATION                                                General

! SAFETY NOTICE - Instructions in the Service Bulletins assume that the                 Number          Gn023
engineer has a sound knowledge of safety procedures and has been trained in the         (JCB Gen 087, N.Am K91)
maintenance and repair of ITL equipment. If you are unsure or do not understand
information contained in the Service Bulletins then ask your supervisor for advice.
                                                                                        Issue               1
Remember SAFETY MUST COME FIRST.                                                        Date        Oct. 1998

SUBJECT:                     Change of position for the exhaust manifold alignment bushes              Page 1 of 1

PRODUCTS AFFECTED:           New Perkins 1000 Series Engines (Models AJ to AS and YG to YK)

TO BE CARRIED OUT:           For information


SERVICE INFORMATION:

The information published in section 12 of the New Perkins
1000 Series Workshop manual, 9806/2140 has changed. New
alignment bushes must be fitted in accordance with this
Service Bulletin.

Note: Always use the engine identification number to order
new parts, alignment bushes are not fitted to all engines.

The exhaust manifolds fitted to some four and six cylinder
engines have large clearance holes for the setscrews. It is
important that these manifolds are correctly fitted to the                              1
cylinder head.

Caution: Damage to the exhaust manifold can occur if it is not
aligned and tightened correctly.
                                                                                                            2
SERVICE PROCEDURE:
                                                                                        1
If the manifold is renewed, it is important that the two
alignment bushes (1), JCB part number 02/201783 are in
position. New alignment bushes are not necessary when the
original manifold is removed and fitted.

Tighten the exhaust manifold setscrews evenly and gradually
to 44 Nm (33 lbf ft, 4.5 kgf m) in the sequence shown). Use the
same sequence and torque tighten the setscrews again.

The front of the engine is shown by the arrow (2).

Refer to Perkins or a Perkins dealer for Perkins part numbers or further information.



  THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES
        NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES

          ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I.T.L., WREXHAM, CLWYD, LL13 9UF, UNITED KINGDOM
                                                                                                      INDEX
                                        TECHNICAL
                                        INFORMATION                                              General

! SAFETY NOTICE - Instructions in the Service Bulletins assume that the               Number           Gn024
engineer has a sound knowledge of safety procedures and has been trained in the       (JCB Gen 089; K94/N.Am)
maintenance and repair of ITL equipment. If you are unsure or do not understand
information contained in the Service Bulletins then ask your supervisor for advice.
                                                                                      Issue                1
Remember SAFETY MUST COME FIRST.                                                      Date         Jan. 1999

SUBJECT:                      Pin-timed Fuel Injection Pumps                                          Page 1 of 1

PRODUCTS AFFECTED:            All Perkins New 1000 Series Engines (Models AJ to AS & YG to YK)

TO BE CARRIED OUT:            For Information Only


SERVICE INFORMATION:

The latest fuel injection pumps have a hub A which is
mounted permanently onto the drive shaft.

The manufacturer fits the hub to the pump to ensure very
accurate timing. Engines that have this arrangement,
require a pin B (part no. 892/00956) to accurately time the        B
pump in service.

Caution: Do not release the nut C from the fuel injection
pump. Illustration 2 shows the nut C in position when the                  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 engine.

Always refer to the relevant workshop manual
(publication no. 9806/2140) for the correct procedure
before you start to work on the engine.

To remove the fuel injection pump from the engine it is only
necessary to remove the four setscrews D which secure
the fuel pump gear to the hub. It is important to follow the                      C
instructions in the workshop manual to ensure the engine
timing is correct.
                                                                                               D

                                                                  2


  THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES
        NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES

          ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I.T.L., WREXHAM, CLWYD, LL13 9UF, UNITED KINGDOM
                                                                                                         INDEX
                                      TECHNICAL
                                      INFORMATION                                                  General

! SAFETY NOTICE - Instructions in the Service Bulletins assume that the               Number             Gn025
engineer has a sound knowledge of safety procedures and has been trained in the       (JCB Gen 090; K95/N.Am)
maintenance and repair of ITL equipment. If you are unsure or do not understand       Issue                1
information contained in the Service Bulletins then ask your supervisor for advice.
                                                                                      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 engine
Introduction of an improved Oil Cooler with a                to cool down before the oil pipes are released.
Pressed 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 the
YB-------U647452C.                                               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
                                                                                      C
        M


                                                                                D
                     B




                                                                                               E          J
                             A
                                                                                  G
                  H

                                                                                       F

  THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES
        NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES

          ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I.T.L., WREXHAM, CLWYD, LL13 9UF, UNITED KINGDOM
Page 2 of 3                                                                           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 connections.
4   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 fitted.

Note: 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, 2.2 kgf m).
02/201718, 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, 2.2 kgf m).




      K          P
                  L            N
                                                                                          C
         M


                                                                                     D
                       B




                                                                                                    E
                                                                                                                 J
                                A
                                                                                       G
                   H

                                                                                               F
Page 3 of 3                                                                           GN025                  Issue 1

4   Remove and discard the three-piece `O' ring N from          4   Fit the two-piece flanges A onto the studs H.
    the element.                                                    Tighten the nuts to retain the element when the oil
                                                                    cooler assembly is fitted to the engine.
Warning! 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 three-piece `O' ring and
    renew the `O' rings N.

2   Clean the flange face P for the three-piece `O' rings
    on the inside of the cover.

3   Fit the cover of the oil cooler to the element M.




      K          P
                  L            N
                                                                                           C
        M


                                                                                      D
                       B




                                                                                                   E             J
                                A
                                                                                       G
                    H

                                                                                            F
                                                                                                      INDEX
                                        TECHNICAL
                                        INFORMATION                                              General

! SAFETY NOTICE - Instructions in the Service Bulletins assume that the               Number           Gn026
engineer has a sound knowledge of safety procedures and has been trained in the       (JCB Gen 091; K96/N.Am)
maintenance and repair of ITL equipment. If you are unsure or do not understand
information contained in the Service Bulletins then ask your supervisor for advice.
                                                                                      Issue            1
Remember SAFETY MUST COME FIRST.                                                      Date February 1999

Perkins 4.236 or 1000 Series Engines                                                                  Page 1 of 1

Introduction of a Wear Sleeve for the Front Oil Seal

The latest timing case fitted to 4.236 and 1000 Series
engines, does not have a service position for the front
oil seal, as shown in section 15 of the relevant
workshop manual.
                                                                                        A       B

The change improves the efficiency of the oil seal in
service and was introduced from engine number:

L------U786357C for 4.236 engines.
A------U802612C for 4 cylinder 1000 series.
                                                                                            C
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 number
02/202027 is fitted over the spigot.

Full instructions and a special tool to fit the wear sleeve
are in each service kit.

The dimension to press the new oil seal into the timing
case, with or without a wear sleeve fitted, is 9.3 mm
(0.366 in), from the front face of the timing case. The
special tool supplied in the kit can be used to set the
correct depth.

It is not necessary to remove the flange C of the wear
sleeve after it has been fitted.

A new front oil seal must be used when a wear sleeve is
fitted.




  THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES
        NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES

          ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I.T.L., WREXHAM, CLWYD, LL13 9UF, UNITED KINGDOM
                                                                                                      INDEX
                                       TECHNICAL
                                       INFORMATION                                               General

! SAFETY NOTICE - Instructions in the Service Bulletins assume that the               Number           Gn027
engineer has a sound knowledge of safety procedures and has been trained in the       (JCB Gen 092; K97/N.Am)
maintenance and repair of ITL equipment. If you are unsure or do not understand
information contained in the Service Bulletins then ask your supervisor for advice.
                                                                                      Issue            1
Remember SAFETY MUST COME FIRST.                                                      Date February 1999

New Perkins 1000 Series Engines                                                                       Page 1 of 1
(Models AJ to AS & YG TO YK)

Washers for the Fuel Injection Pump Gear

Caution: Ensure that the washers are fitted before the
screws are tightened.

A washer, part number 02/101686, is fitted to each of
the screws A with effect from the following engine serial
numbers:

A----U812611C for 4 cylinder engines
                                                                              A
Y----U660846C for 6 cylinder engines

Engines before the above numbers do not need to have
these washers fitted.




  THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES
        NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES

          ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I.T.L., WREXHAM, CLWYD, LL13 9UF, UNITED KINGDOM
                                                                                                       INDEX
                                        TECHNICAL
                                        INFORMATION                                               General

! SAFETY NOTICE - Instructions in the Service Bulletins assume that the               Number            Gn028
engineer has a sound knowledge of safety procedures and has been trained in the       (JCB Gen 093; K98/N.Am)
maintenance and repair of ITL equipment. If you are unsure or do not understand
information 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 been
introduced. The new guide has a groove B to retain the
valve seal C.

To remove and fit the valve guides, refer to Section 12
of the Workshop Manual.
                                                                                                B
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 fitted.

Parts Information

Item Part Number Description              Supersedes
A    02/202064   Valve guide              02/201511 and
                                          02/201817




    THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES
          NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES

           ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I.T.L., WREXHAM, CLWYD, LL13 9UF, UNITED KINGDOM
                                                                                                                   INDEX
                                         TECHNICAL
                                         INFORMATION                                                       General

! SAFETY NOTICE - Instructions in the Service Bulletins assume that the                      Number                Gn029
engineer has a sound knowledge of safety procedures and has been trained in the              (JCB Gen 096; E194/N. Am)
maintenance and repair of ITL equipment. If you are unsure or do not understand
information contained in the Service Bulletins then ask your supervisor for advice.
                                                                                             Issue                 1
Remember SAFETY MUST COME FIRST.                                                             Date         March 1999

SUBJECT:                      ITL Hydraulic Hose Fittings and O-rings                                           Page 1 of 2

PRODUCTS AFFECTED:            All ITL Products

TO BE CARRIED OUT:            Information Only


SERVICE INFORMATION

ITL products use their own type of special BSP hydraulic hose fitting. This fitting combines the standard BSP type
coned connector with an O-ring seal X fitted in the face of the taper.

The O-ring is bonded to the fitting to ensure its security. However, if for any reason the O-ring becomes damaged or
separated from the fitting, it can be replaced.

It is very important to use the correct O-ring size for the fitting. Any deviation in O-ring size or specification (eg. O-ring
taken from a selection kit that appears to be the correct size and material) will cause joint integrity and leaking
problems.

The correct O-rings X required for the various sizes of hydraulic fitting are shown below:

Hydraulic Fitting                 O-ring                O-ring Inner            O-ring Section          Material
Size                           Part Number             Diameter (mm)            Diameter (mm)            Type

1/4"     BSP fitting            828/00237                6.5 (± 0.15)             1.0 (± 0.08)              A
3/8"     BSP fitting            2301/0006                8.1 (± 0.15)             1.6 (± 0.08)              A
1/2"     BSP fitting            2301/0010                12.1 (± 0.2)             1.6 (± 0.08)              A
5/8"     BSP fitting            2301/0011                13.1 (± 0.2)             1.6 (± 0.08)              A
3/4"     BSP fitting            2301/0015                17.1 (± 0.2)             1.6 (± 0.08)              A
1"       BSP fitting            2301/0018               22.1 (± 0.25)             1.6 (± 0.08)              A
1 1/4"   BSP fitting            2302/0907               29.1 (± 0.25)             1.6 (± 0.08)              B
1 1/2"   BSP fitting            2302/0908                35.1 (± 0.3)             1.6 (± 0.08)              B

Material Type:

A - Nitrile synthetic rubber suitable for use between -40° and +135° Celsius with a hardness value of 80 IRHD.
B - Polyurethane material suitable for use between -40° and +130°Celsius with a Shore hardness value of 93A.

Ensure that only the above O-ring part numbers are used as replacements in ITL hydraulic hose fittings.




  THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES
        NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES

           ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I.T.L., WREXHAM, CLWYD, LL13 9UF, UNITED KINGDOM
Page 2 of 2                                                                          Gn029                  Issue 1




                                                                                  X




WARRANTY INFORMATION

If submitting a warranty claim for rectification of a problem with a hydraulic fitting O-ring (eg. oil leak), ensure the
correct O-ring part number is specified within the claim as the failed part. Incorrect O-ring part number claims will not
be accepted.
                                                                                                           INDEX
                                        TECHNICAL
                                        INFORMATION                                                   General

! SAFETY NOTICE - Instructions in the Service Bulletins assume that the                  Number             Gn030
engineer has a sound knowledge of safety procedures and has been trained in the          (JCB MI642/H)
maintenance and repair of ITL equipment. If you are unsure or do not understand
information 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 IMPROVEMENTS

New Perkins Diesel Engine

·    Improved exhaust emissions
·    Wastegated turbo charger
·    Improved injection pump
·    Increased peak torque
·    Improved cold starting
     performance




    THIS BULLETIN CONTAINS INFORMATION WHICH SHOULD BE COVERED DURING CUSTOMER MACHINE
    INSTALLATION AND SHOULD BE COPIED TO ALL MACHINE INSTALLATION PERSONNEL.

    Please ensure a copy of this bulletin is distributed to field based 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 I.T.L., WREXHAM, CLWYD, LL13 9UF, UNITED KINGDOM
Page 2 of 3                                                                         Gn030                   Issue 1

The Perkins low emission diesel engine has been introduced for all Powertrains with turbo-charged engines sold in
the EEC after 1st January 1999, and for all Powertrains with naturally aspirated engines sold in the EEC after 1st April
1999. These dates apply to the engine build date and not the machine build date.

The engines comply with mandatory emission legislation and incorporate the following changes:

·    Revised cylinder head
·    Four branch inlet and exhaust manifolds
·    Revised piston design with modified combustion chamber
·    Wastegated turbo charger
·    Improved fuel injection pump
·    Increased compression ratio

The previous 75 hp (56 kW) engine is now uprated to 80 hp (59 kW) and develops 290 Nm (214 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 torque.

Torque Comparison

The comparison shows the increased back-up torque at lower engine speed produced by the new low emission
engine. Peak torque is increased up to a possible 411 Nm (lbf ft) from 354 Nm (261 lbf ft) depending on air filter and
exhaust silencer specification.

     420
                 Torque
                  (Nm)



    400




     380




    360




    340

                                                                                           1
                                                                                           1
    320

                                     1    102 hp Perkins new low emission engine:
                                     1    Max. torque 411 Nm (303 lbf ft) @ 1400 rev/min
                                                                                                                  2
    300                              2
                                     2
                                          106 hp engine:                                                          2
                                          Max. torque 354 Nm (261 lbf ft) @ 1800 rev/min


    280
           800        1000    1200        1400        1600       1800        2000        2200        2400        2600

                                                 Engine Speed (rev/min)
Page 3 of 3                                                                         Gn030                    Issue 1

1   Engine Specifications

                                 Nat. Asp. Build                  Turbo Build

Horsepower:                      80hp                             102hp
Injection pump type:             DP203                            DP203
Governing:                       Mechanical                       Mechanical
Pump setting code:               2644G521/YG/1/2350               2644C705/BG/1/2350
Static timing:                   Pre-set                          Pre-set
Idle speed:                      800 rpm                          800 rpm
Max. rated speed:                2200 rpm                         2200 rpm
Max. no-load speed:              2350 rpm                         2350 rpm
Injector codes:                  KW                               KN
Injector setting pressure:       294 atm                          294 atm

Note: Either 65A or 85A alternators may be fitted (refer to ITL Technical Sales).

2   Regulations

The new engines meet EEC Stage 1 emission regulations. Smoke emission is dramatically reduced and now meets
ECE R24.03.

3   Servicing

Routine engine service intervals remain unchanged at initial 100 hour and 500 hour periods. Valve clearance must be
checked every 1000 hours. There is no change to the engine oil or fuel filter part numbers. Only use oil meeting or
exceeding CF4/SG specification for the low emission engine. The fuel injector pump is significantly more sophisticated
and because the emissions are reduced by increasing the accuracy of the timing, alterations to the fuel pump are not
possible. Any alteration to the fuel pump settings will invalidate the emission certification.

4   Starting

Cold start performance has been improved. This is achieved via an additional temperature switch situated in the rear
of the timing case which causes fuel injection timing to advance in cold conditions. In line with these cold start
improvements, the diameter of the battery leads has been increased.

5   Special Tool Requirement

All essential special tool requirements are incorporated into the relevant Perkins engine service manuals.

6   Technical Publications

With the introduction of the new low emission range of engines, a new engine workshop manual is available from teh
organisation using the following publication numbers:

                                         English          French          German          Spanish            Italian
Engine Workshop Manual                   9806/2140        9806/2141       9806/2142       9806/2143          9806/2144

7   Mandatory and Recommended Distributor Parts Lists

Contact Perkins Service for mandatory and recommended parts list requirements.

8   Training

Contact Perkins Service/Dealers.
                                                                                                        INDEX
                                        TECHNICAL
                                        INFORMATION                                               General

! SAFETY NOTICE - Instructions in the Service Bulletins assume that the               Number            Gn031
engineer has a sound knowledge of safety procedures and has been trained in the       (JCB Gen 105; E215/N.Am)
maintenance and repair of ITL equipment. If you are unsure or do not understand
information contained in the Service Bulletins then ask your supervisor for advice.
                                                                                      Issue                 1
Remember SAFETY MUST COME FIRST.                                                      Date          Nov. 1999

SUBJECT:                      Hydraulic Ram Sealing Procedure                                          Page 1 of 3

PRODUCTS AFFECTED:            All Machines with ITL Rams

TO BE CARRIED OUT:            Information Only


SERVICE INFORMATION:

In an effort to reduce the number of hydraulic leaks on ITL rams a revised procedure has been introduced for fitting
seals to the ram end cap and piston head.

The introduction of the new procedure also introduces new tools which are detailed on sheet 3.

Service Manuals will be revised at the next convenient Replacement Page Set.


SERVICE PROCEDURE:

To fit new rod seal:
                                                               B                       A
Use seal fitting tool (892/00334) to fit rod seals, the size
(diameter) and position of pins A is determined by the
diameter and radial width of the rod seal being fitted.

The pins are screwed into threaded holes in the tool
body, the spacing of the holes is designed to suit small
or large diameter rod seals.
                                                                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 I.T.L., WREXHAM, CLWYD, LL13 9UF, UNITED KINGDOM
Page 2 of 3                                                            Gn031   Issue 1

Note: Later ram end caps and piston heads have metric
threads. 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                  A187361
damage when fitting end cap onto the piston rod. There
are various sizes of sleeve, see Parts Information. Make
sure the hexagon on the end cap is towards the eye
end of the rod.

Fit new piston head seals:

6   Use a blunt instrument (892/01027) shown at F,
    lever the inner seal G into the piston head seal           F
    groove, do not let the seal twist. There are
    identification marks on the outer diameter of the
    seal, make sure the marks are visible and the seal
    is free to rotate, if not remove the seal and refit            G
7   Fit outer seal H using the same procedure as step
    6. Check the external grooves are visible.                                     338470




                                                                   H

                                                                                   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 piston/rod assembly into the cylinder.
   Align the rod and head assembly until parallel with
   the cylinder then push the assembly into the
   cylinder.

12 Fit the end cap, refer to the relevant section for
   torque figure and completion of ram assembly.


PARTS INFORMATION




          7mm
                11o

20mm       10mm                                                                                            S338410


                                                               Ram Seal Protection Sleeves
          5mm
                                                      m        892/01016    For 25 mm Rod Diameter
                                                    3m         892/01017    For 30 mm Rod Diameter
                                                R
                                                               892/01018    For 40 mm Rod Diameter
                                                               892/01019    For 50 mm Rod Diameter
                                                               892/01020    For 50 mm Rod Diameter (slew ram)
                 110mm                                         892/01021    For 60 mm Rod Diameter
                                                               892/01022    For 60 mm Rod Diameter (slew ram)
                         175mm                                 892/01023    For 65 mm Rod Diameter
                                                               892/01024    For 70 mm Rod Diameter
                                                          3o   892/01025    For 75 mm Rod Diameter
                                               R               892/01026    For 80 mm Rod Diameter
                                                   1.4
                                                      mm



    892/01027     Piston Seal Assembly Tool
                                                     338500
                                                                                                           INDEX
                                         TECHNICAL
                                         INFORMATION                                                 General

! SAFETY NOTICE - Instructions in the Service Bulletins assume that the                 Number             Gn032
engineer has a sound knowledge of safety procedures and has been trained in the         (JCB Gen 110; K110 N/Am)
maintenance and repair of ITL equipment. If you are unsure or do not understand
information contained in the Service Bulletins then ask your supervisor for advice.
                                                                                        Issue                  1
Remember SAFETY MUST COME FIRST.                                                        Date           Jan. 2001

SUBJECT:                      Oil Control Rings                                                           Page 1 of 1

PRODUCTS AFFECTED:            1000 series engine models AR & AS only

TO BE CARRIED OUT:            For Information Only


SERVICE INFORMATION

A small taper has been added to the face of the oil control ring to reduce oil consumption during the early life of the
engine. The ring is marked `TOP' on the top face and a blue mark has been added to the left of the ring gap.

The oil control ring is a component of a ring kit (see part numbers listed below). The ring kit could be supplied with
either the earlier or the later oil control ring.


SERVICE PROCEDURE

When fitting the oil control ring, check if there is a blue mark at X.

If there is a blue mark at X, the ring must be fitted with the mark to the
left of the ring gap. The word `TOP' will then be towards the top of the
piston.                                                                          X
If there is no blue mark, the ring can be fitted either way up.


Ring Kit Part Numbers

Standard                          02/201804
0.5 mm oversize                   02/201791
1.0 mm oversize                   02/201793




  THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES
        NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES

           ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I.T.L., WREXHAM, CLWYD, LL13 9UF, UNITED KINGDOM
                                                                                                      INDEX
                                         TECHNICAL
                                         INFORMATION                                             General

! SAFETY NOTICE - Instructions in the Service Bulletins assume that the               Number           Gn033
engineer has a sound knowledge of safety procedures and has been trained in the       (JCB Gen 112; K112 N.Am)
maintenance and repair of ITL equipment. If you are unsure or do not understand
information contained in the Service Bulletins then ask your supervisor for advice.
                                                                                      Issue                1
Remember SAFETY MUST COME FIRST.                                                      Date         Jan. 2001

SUBJECT:                    Plastic Thermostat Housings                                               Page 1 of 1

PRODUCTS AFFECTED:          All 1000 series engines

TO BE CARRIED OUT:          For Information Only


SERVICE INFORMATION

Plastic thermostat housings, fitted to some engines, will be damaged if temperature senders or blanking plugs are
overtightened.


SERVICE PROCEDURE

When fitting the items listed, ensure that the following
torque settings are used:

Item                                Nm    kgf m    lbf ft
A - Sender (aluminium)              16     12       12
A - Sender (brass)                  24     2.4      18
B - 1/2 inch Plug (metal or plastic) 4     0.4       3
B - 3/4 inch Plug (metal or plastic) 4     0.4       3

Note: The illustration shows a typical installation which
may differ from some engines.
                                                               B

                                                                                                       A




  THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES
        NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES

          ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I.T.L., WREXHAM, CLWYD, LL13 9UF, UNITED KINGDOM
                                                                                                             INDEX
                                         TECHNICAL
                                         INFORMATION                                                     General

! SAFETY NOTICE - Instructions in the Service Bulletins assume that the
                                                                                             Number          Gn034
engineer has a sound knowledge of safety procedures and has been trained in the
                                                                                             (JCB Gen 114; K109/N. Am)
maintenance and repair of ITL equipment. If you are unsure or do not understand
information contained in the Service Bulletins then ask your supervisor for advice.          Issue                1
Remember SAFETY MUST COME FIRST.                                                             Date         Feb. 2001

SUBJECT:                       Introduction of Improved Fuel Lift Pump                                       Page 1 of 2

PRODUCTS AFFECTED:             All Perkins Four Cylinder 1000 Series Engines

TO BE CARRIED OUT:             Information only


SERVICE INFORMATION:

An improved fuel lift pump has been introduced for use on Perkins four-cylinder 1000 Series diesel engines. The new
pump is a one piece assembly and cannot be dismantled. The new pump is interchangeable with the earlier pump.

The procedure to remove and fit the new pump has not changed. Remove and clean fuel inlet strainer 2 if this
procedure is recommended in the relevant machine handbook or service manual.

Cleaning the Strainer

1    Allow the engine to cool. Remove the fuel filler cap to vent the system and reduce loss of fuel. Disconnect the
     fuel inlet pipe to the lift pump.

2    Unscrew the fuel filter A. Remove strainer 2 and O-ring 3.

3    Clean the strainer in clean diesel fluid and dry with low pressure compressed air. Renew the strainer and O-ring
     if damaged.

4    Fit the strainer into the fuel inlet connection. Fit the fuel filter A and tighten to
     20Nm (15 lbf ft). Fit the fuel inlet pipe carefully to prevent damage to the
     strainer, and tighten the union nut.
                                                                                                         1

     IMPORTANT: The fuel strainer can be damaged and fuel flow can be
     restricted if the fuel pipe is inserted too far into the inlet connection. This
     should be checked if a fuel restriction is suspected.

     Make sure the olive on the fuel inlet pipe is in good condition and forms an
     effective seal. Renew the olive or pipe if necessary to prevent air entering the
     fuel system.

5    Fit the tank cap and prime the fuel system. Start the engine and check for
     fuel leakage.




    THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES
          NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES
            ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I.T.L., WREXHAM, CLWYD, LL13 9UF, UNITED KINGDOM
Page 2 of 2                                                              Gn 034   Issue 1

PARTS INFORMATION

Item   Part No.     Description
1      17/913600    Fuel Lift Pump Kit (complete with Gasket)
2&3    17/913601    Fuel Strainer & O-ring Kit
4      02/201189    Gasket only




                                          A

                                               2
                                     3

                                                 1




                                                                4




                                                                366610
                                                                                                         INDEX
                                        TECHNICAL
                                        INFORMATION                                                  General

! SAFETY NOTICE - Instructions in the Service Bulletins assume that the
                                                                                       Number                Gn035
engineer has a sound knowledge of safety procedures and has been trained in the
                                                                                       (JCB 5/217; K119/N.Am.)
maintenance and repair of ITL equipment. If you are unsure or do not understand
information contained in the Service Bulletins then ask your supervisor for advice.    Issue                  1
Remember SAFETY MUST COME FIRST.                                                       Date          April 2001

SUBJECT:                      Coolant Pressure Cap                                                       Page 1 of 1

PRODUCTS AFFECTED:            All Perkins 1000 Series Engines

TO BE CARRIED OUT:            Information Only


SERVICE INFORMATION:
                                                                          A
Some instances of overheating have been reported which were
caused by the engine coolant filler cap not being correctly fitted.
This results in the coolant system failing to pressurise, so
reducing its efficiency.


SERVICE PROCEDURE:

When fitting the filler cap, ensure that the cap is correctly fitted.
Fit and turn the cap to the first notch, as shown at A, then
PRESS DOWN and continue turning FULLY clockwise, as
shown at B, until the end stop is met. Failure to do this will
result in inefficient cooling and may result in injury when the cap
is removed.



                                                                          B




  THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES
        NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES
            ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I.T.L., WREXHAM, CLWYD, LL13 9UF, UNITED KINGDOM
                                                                                                              INDEX
                                        TECHNICAL
                                        INFORMATION                                                      General

! SAFETY NOTICE - Instructions in the Service Bulletins assume that the
                                                                                           Number              Gn036
engineer has a sound knowledge of safety procedures and has been trained in the
                                                                                           (JCB Gen 120; K120N.Am.)
maintenance and repair of ITL equipment. If you are unsure or do not understand
information contained in the Service Bulletins then ask your supervisor for advice.        Issue                   1
Remember SAFETY MUST COME FIRST.                                                           Date           April 2001

SUBJECT:                     Engine Oil Consumption                                                           Page 1 of 2

PRODUCTS AFFECTED:           Perkins Low Emission Engines (AJ to AS and YG to YK)

TO BE CARRIED OUT:           For Information Only


SERVICE INFORMATION:

Engine oil consumption can only be correctly measured as a percentage against fuel used under controlled
conditions. If, after consideration of the observations below the oil consumption appears to exceed the expected
amount, carry out the Service Procedure as detailed.

     Oil consumption does not normally exceed 4.5 litres (1.0 UK gal., 1.19 US gal) per 100 hours average machine use.

     No test should be carried out on new engines prior to the bedding in period, minimum of 100 hours.

     Engines should not be idled for long periods and should be worked hard from new, (for example, engine speed
     should be above 1500 rev/min.).

     Extended periods of idle and/or high speed roading will dramatically increase the hourly consumption rates.

     Dust ingress via leaks in the air intake 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 handbook.

SERVICE PROCEDURE:

Normal oil consumption after running in should be between 3 and 5 litres of oil per 1000 litres of fuel consumed (0.66
and 1.1 UK gal per 220 UK gal: 0.79 and 1.32 US gal per 264 US gal) OR 0.30 and 0.50% of fuel consumption.

1    Position the machine on level ground. Drain and refill with the correct grade and quantity of oil as specified in
     the owners handbook.

2    Allow time for the oil level to settle and check level on dipstick. If oil level is either above or below existing MAX
     mark, re-mark dipstick at this level.

3    Record the dimensions of any change to the MAX mark. Do not alter the MIN mark on the dipstick.



    THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES
          NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES
            ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I.T.L., WREXHAM, CLWYD, LL13 9UF, UNITED KINGDOM
Page 2 of 2                                                                                 Gn 036                Issue 1

4   Fill fuel tank to the maximum.

5   Record the hour meter reading and date, return the machine to service.

6   Record all amounts of fuel and engine oil added during the test period on the chart below, excluding the initial fill.

Note: Only add oil when the level reaches or is near the MIN mark.

7   On completion of test, 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

 DISTRIBUTOR:

 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              Gn037
engineer has a sound knowledge of safety procedures and has been trained in the
                                                                                         (JCB TSDB 390)
maintenance and repair of ITL equipment. If you are unsure or do not understand
information contained in the Service Bulletins then ask your supervisor for advice.      Issue                  1
Remember SAFETY MUST COME FIRST.                                                         Date            May 2001

SUBJECT:                     Rocker Cover                                                                 Page 1 of 2

PRODUCTS AFFECTED:           Perkins AR, AJ, AK Low Emission 1000 Series 4-Cylinder Engines

TO BE CARRIED OUT:           Only with Authorisation from ITL


SERVICE INFORMATION
Reports have been received of excessive oil loss from the rocker cover breather tube. It should be noted that oil
showing at the breather tube is a normal function caused by vapourised oil in the crank case escaping to
atmosphere. However, for `green' countries where strict limitations on oil emission are enforced, an improved
rocker cover is now available from ITL. The new cover has an integral oil separator which greatly reduces the amount
of oil showing at the breather tube.

SERVICE PROCEDURE (refer to fig on page 2):
1    Park the machine on firm level ground, engage the parking brake and set the transmission to neutral. Lower
     any attachments to the ground and stop the engine.

2      Gain access to the engine compartment, if necessary remove any ancillary equipment such as the exhaust
       stack, pre-cleaner, air filter etc.

3      Remove and discard the breather pipe (item A), remove the rocker cover cap nuts (item B) together with the
       steel washers (item C) and sealing washers (item E).

4      Remove the old rocker cover (item F) together with joint (item H).

IMPORTANT NOTE: When the rocker cover is fitted, the cap nuts are tightened onto the nuts of the rocker brackets.
During removal of the cap nuts, it is possible to loosen the nuts of the rocker brackets. The nuts of the rocker
brackets should be tightened to the correct torque every time the cover is removed.

5       Fit the new rocker cover with its new joint. Torque tighten cap nuts to 20 Nm; 15 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     02/201338          Hose            1
F     02/202220          Rocker Cover    1
J     02/202217          Breather        1
K     2201/0007          Clip            1



    THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES
          NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES
            ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I.T.L., WREXHAM, CLWYD, LL13 9UF, UNITED KINGDOM
Page 2 of 2                                                        Gn 037        Issue 1

WARRANTY INFORMATION
This improvement will not be considered for warranty




                                                               J




                                           B                           S239790


                                                C

                                                 E




                      F
                                                           L

                       H
                                                       K




                                                       A
                                                                                                            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                Gn038
maintenance and repair of ITL equipment. If you are unsure or do not understand       Issue                         1
information contained in the Service Bulletins then ask your supervisor for advice.
Remember SAFETY MUST COME FIRST.                                                      Date            Jan 2002

SUBJECT:                    New ITL NAPSC Network                                                       Page 1 of 2

Introduction of a new service and parts support network for International Transmissions Limited from February 17th
2002. All previous parts ordering through 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 1GO.

Services available to the OEM ­
1) 1 866 734 8562 (1 866 73 ITL NA) toll free number, Fax 519 738 3477, or e-mail seltech@mnsi.net.
2) 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 48231-2547.
4) Help ensuring correct parts needed are identified.
5) 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 electronically onto the local database enabling the UK ITL service
   desk to view the claim simultaneously. Consequently, time to settlement of claims will be speeded up with target
   of 15 to 45 days max.
7) Parts discount level - ITL list less 30%. Emergency parts orders shipped next Business day 5% Surcharge.
   Critical/VD (vehicle down) orders placed before 3.00 p.m. (local NAPSC time), shipped with 7% premium. 40%
   discount on stock orders, minimum value £5,000.00 (excluding shipping costs). Orders limited to 2 stock orders
   per year and terms CIF at the OEM. Lead-time for stock orders despatch 6 weeks. Any type of shipping method
   can be specified and orders can be drop shipped to any address specified in North America.

Also Note the introduction of 3 New ITL Principal Service Centers

ITL PSC ­ California, Texas and Michigan.
Approved for ITL Warranty repair work.
Complete ITL component strip down, repair and test facilities available.
Remanufactured units
Competent to carry out repairs from the end user, subject to OEM approval.

Principal Service Centers
Leaman Equipment Co.
16550 Railroad Ave. (L)
Morgan Hill CA 95037      Tel 408 778 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 I.T.L., WREXHAM, CLWYD, LL13 9UF, UNITED KINGDOM
Page 2 of 2                                                                        Gn 038                Issue 1


Great Lakes Power Products
2006 Tobsal Court
Warren, MI 48091                Tel 810 759 5500        Fax 810 759 0879


ITL Service Centers

Centers throughout USA and Canada. In the event of repair work needed contact ITL Service Department (Keith
Bridges) in UK (Tel 01144 1978 666513).

1) Approved for ITL Warranty work
2) Provide Support for OEM vehicle repairs.
3) Competent to carry out repairs, for the end user, subject to ITL, and OEM approval.


OEM's capable of carrying out repairs through their own dealership, should continue to operate as normal. They
may find the ITL Principal Service Centers particularly useful in those cases where expert internal repairs are
required.

OEM's, with or without their own dealer back up, can take full advantage of the ITL Service Centers. However,
before initially approaching a Service Center, we ask that our Service Department be 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              Gn039
engineer has a sound knowledge of safety procedures and has been trained in the
                                                                                          (JCB Gen 151)
maintenance and repair of ITL equipment. If you are unsure or do not understand
information contained in the Service Bulletins then ask your supervisor for advice.       Issue                  1
Remember SAFETY MUST COME FIRST.                                                          Date            Sep 2002

SUBJECT:                      Safety precautions when an engine is cleaned                                  Page 1 of 1

PRODUCTS AFFECTED:            All Engines

TO BE CARRIED OUT:            Information only


SERVICE INFORMATION:

Care should be taken when an engine is cleaned with the use of a high pressure hose.

Cautions:

·    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 Shut-off Solenoid (ESOS) or any electrical components of the FIP when the engine is
     hot.

If these cautions are ignored, the engine or certain components could be damaged, fail to operate and also make the
manufacturer's warranty invalid.




    THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES
          NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES
            ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I.T.L., WREXHAM, CLWYD, LL13 9UF, UNITED KINGDOM


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Disclaimer:
The information on this web site has not been checked for accuracy. It is for entertainment purposes only and should be independently verified before using for any other reason. There are five sources. 1) Documents and manuals from a variety of sources. These have not been checked for accuracy and in many cases have not even been read by anyone associated with L-36.com. I have no idea of they are useful or accurate, I leave that to the reader. 2) Articles others have written and submitted. If you have questions on these, please contact the author. 3) Articles that represent my personal opinions. These are intended to promote thought and for entertainment. These are not intended to be fact, they are my opinions. 4) Small programs that generate result presented on a web page. Like any computer program, these may and in some cases do have errors. Almost all of these also make simplifying assumptions so they are not totally accurate even if there are no errors. Please verify all results. 5) Weather information is from numerious of sources and is presented automatically. It is not checked for accuracy either by anyone at L-36.com or by the source which is typically the US Government. See the NOAA web site for their disclaimer. Finally, tide and current data on this site is from 2007 and 2008 data bases, which may contain even older data. Changes in harbors due to building or dredging change tides and currents and for that reason many of the locations presented are no longer supported by newer data bases. For example, there is very little tidal current data in newer data bases so current data is likely wrong to some extent. This data is NOT FOR NAVIGATION. See the XTide disclaimer for details. In addition, tide and current are influenced by storms, river flow, and other factors beyond the ability of any predictive program.