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' Perkins General Technical Information Bulletin'



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CONTENTS TECHNICAL INFORMATION GENERAL TI BULLETIN INDEX Click on bulletin title to viewTI No Issue Subject Products Affected DateGn 001 1 Tappet Adjustment Perkins 1000 Series Engines Mar 90Gn 002 1 Rocker Shaft Security Perkins 1000 Series Engines July 90Gn 003 1 Crankshaft Rear Main Oil Seal Housing Perkins 1000 Series Engines Mar 91Gn 004 1 Turbocharger Fault Diagnosis Perkins 1000 Series Engines Dec 91Gn 005 1 Health Safety Materials All Mar 92Gn 006 1 Turbochargers Turbocharged Perkins 90 BHP Feb 93Gn 007 1 Piston Piston Ring Improvements 4 cyl Turbocharged Engines Feb 93Gn 008 1 Alternator Connections on Mainframe Harness Perkins Engines as applicable Nov 93Gn 009 1 Low Sulphur Fuels Perkins 1000 Series Engines Mar 94Gn 010 1 Brake Master Cylinder Kits As Detailed on Bulletin Mar 94Gn 011 1 Hydraulic Ram Identification Jun 94Gn 012 1 Oil Pump Idler Gear Perkins 1000 Series Engines July 94Gn 013 1 Stake Nuts Input and Output Flanges All ITL Transmissions Axles Feb 95Gn 014 1 Fuel Injection Pump Seal Failure Perkins 1000 Series Engines Aug 95Gn 015 1 Engine Lubrication System Relief Valve Housing Perkins 1000 Series Engines Feb 96Gn 016 1 Parkbrake Clevis Pin Improvements Trans with Clysdale Park Brake Feb 96Gn 017 1 Starter Motors All Perkins Engines Mar 96Gn 018 2 Magneti Marelli Support All Perkins Engines Feb 99Gn 019 2 Service Department Computer Diagnostic Equipment Dec 98Gn 020 1 Engine Workshop Manuals Perkins New 1000 Series April 98Gn 021 1 Axle Propshafts All machine installations April 98Gn 022 1 Engine Silencer Improvements Perkins Engines Nov 90Gn 023 1 Change of position exhaust manifold bushes New Perkins 1000 Series Oct 98Gn 024 1 Pin Timed Fuel Injection Pumps All Perkins New 1000 Series Jan 99Gn 025 1 Improved Oil Cooler with Pressed Steel Cover All Perkins 1000 Series Jan 99Gn 026 1 Introduction of Wear Sleeve for Front Oil Seal Perkins 4236 1000 Series Feb 99Gn 027 1 Washers for Fuel Injection Pump Gear New Perkins 1000 Series Feb 99Gn 028 1 Improved Exhaust Valve Guide New Perkins 1000 Series Feb 99Gn 029 1 ITL Hydraulic Hose Fittings and Orings All ITL Products Mar 99Gn 030 1 Perkins Low Emission Diesel Engine New Perkins 1000 Series Apr 99Gn 031 1 Hydraulic Ram Sealing Procedure All Machines with ITL Rams Nov 99Gn 032 1 Oil Control Rings 1000 Series models AR AS Jan 01Gn 033 1 Plastic Thermostat Housings All Perkins 1000 Series Jan 01Gn 034 1 Introduction of Improved Fuel Lift Pump All Perkins 1000 Series Feb 01Gn 035 1 Coolant Pressure Cap All Perkins 1000 Series Apr 01Gn 036 1 Engine Oil Consumption Perkins Low Emission Engines Apr 01Gn 037 1 Engine Rocker Cover Perkins Low Emission Engines May 01Gn 038 1 New ITL NAPSC Network New North American Network Jan 02Gn 039 1 Safety Precautions When an Engine is Cleaned All Engines Sep 02DATE DEC 02 PAGE 1 OF 1 ISSUE 8 INDEX TECHNICAL INFORMATION General SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn001engineer has a sound knowledge of safety procedures and has been trained in the JCB Gen 003maintenance and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your supervisor for advice Issue 1Remember SAFETY MUST COME FIRST Date March 1990SUBJECT Tappet Adjustment Page 1 of 1PRODUCTS AFFECTED All Perkins 1000 series EnginesTO BE CARRIED OUT At Next Service As PROCEDUREWhen tappet adjustment is required it is important to retorque the adjusting screw lock nut A If this is not the adjusting screw will become loose which could cause damage to the tappet assembly and push rodLock Nut Torque 20 lbs ft THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM INDEX TECHNICAL INFORMATION General SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn002engineer has a sound knowledge of safety procedures and has been trained in the JCB Gen 005maintenance and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your supervisor for advice Issue 1Remember SAFETY MUST COME FIRST Date July 1990SUBJECT Rocker Shaft Security Page 1 of 1PRODUCTS AFFECTED All Perkins 1000 Series EnginesTO BE CARRIED OUT Information OnlySERVICE of new fasteners for the rocker nuts A replace the three nuts and washers securing the rocker shaft to the cylinder head The single bolt andwasher is replaced by a flanged boltIf the new fasteners are fitted to earlier engines the washers must be removedTorque tighten the new fasteners to 40 Nm 30 lbf ftPARTS from engine serial number NUT replaces SET SCREW replaces WASHER Not Required THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM INDEX TECHNICAL INFORMATION General SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn003engineer has a sound knowledge of safety procedures and has been trained in the JCB Gen 010maintenance and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your supervisor for advice Issue 1Remember SAFETY MUST COME FIRST Date March 1991SUBJECT Crankshaft Rear Main Oil Seal and Housing Page 1 of 3PRODUCTS AFFECTED All Perkins 1000 Series EnginesTO BE CARRIED OUT Information OnlyA number of reports by Perkins have been received concerning crankshaft rear main oil seal leaks Little or no detailis completed in the comments section of the warranty claim form Information given in the comments section willenable Perkins to identify the exact fault and take the correct remedial actionThe following instructions will enable you to locate and rectify the exact fault this fault should then be stated in thecomments section of all warranty claims failure to do so will invalidate the warranty claimREAR OIL SEALHOUSINGIf oil is leaking past the rear seal oil will normally be found inside the flywheel housing with some evidence of leakagefrom the low inspection plateTo rectify1 Remove the transmission2 Remove the flywheel using guide studs remove two diametrically opposite bolts and temporarily fit guide studs3 Remove seal housing B setscrews Using an appropriate lever gently pry the seal housing away from cylinder block taking care not to damage the housing4 Press out old seal and fit replacement using tool number PD145D see Perkins Service Manual this will preset the seal depth as requiredNote The service tool will set seal to 4 different depths on new engines position 1 should be used5 Make sure that the two dowels C are fitted in the cylinder block PUT A NEW JOINT in position on the dowels6 Put the seal guide A on the crankshaft flange Lubricate the crankshaft flange the seal lip and the seal guide with clean engine oil7 Put the seal housing B complete with seal on the seal guide A PD145D Carefully push the assembly into position on the crankshaft flange and onto the two dowels C Remove the seal guide fit and torque the housing securing setscrews M8 to 22 Nm 16 lbf ft and the capscrews M8 to 18 Nm 13 lbf ft8 Refit flywheel using guide studs and torque retaining bolts to 105 Nm 77 lbf ft THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOMPage 2 of 3 Gn003 Issue 1OIL LEAKAGE FROM REAR OF ENGINEWhen investigating oil leakage at the rear of the engine the following areas should be checked and corrected as Main Oil Gallery PlugWasherA leak from this area can usually be identified by a trace of oilalong the contact face of block and flywheel housing on thefuel pump side of the engineThis can be rectified as follows 11 Remove the transmission 12 Remove the flywheel using guide studs remove two diametrically opposite bolts and temporarily fit guide 13 Removethe starter motor 14 Remove the flywheel housing it may be necessary to tap the housing using a soft hammer to disengage the housing dowels 15 Remove the threaded gallery plug D located top left of cylinder block using appropriate allen key 16 Fit a new plugwasher using Loctite 574 Multigasket and torque to 85 Nm 625 lbf ft 17 Refit flywheel housing and torque securing screws M10 to 44 Nm 33 lbf ft and M12 to 75 Nm 55 lbf ft 18 Refit flywheel using guide studs and torque retaining bolts to 105 Nm 77 lbf ft2 Camshaft Rear End PlugLeakage from the cam end plug will normally produce a trace of oil at the contact face between block and on the manifold sideTo rectify 21 Remove the transmission 22 Remove the flywheel using guide studs remove two diametrically opposite bolts and temporarily fit guide studs 23 Remove the starter motor 24 Remove the flywheel housing it may be necessary to tap the housing using a soft hammer to disengage the housing dowels 25 Remove camshaft end plug E located top right of the cylinder block 26 Fit new plug using Loctite 574 Multigasket 27 Refit flywheel housing and torque securing screws M10 to 44 Nm 33 lbf ft and M12 to 75 Nm 55 lbf ft 28 Refit flywheel using guide studs and torque retaining bolts to 105 Nm 77 lbf ftPage 3 of 3 Gn003 Issue 1OIL LEAKAGE FROM REAR OF ENGINE contd3 Bridge oil leakage from the bridge piece F can be identified in two ways oil may be seen around the sump rearface or oil will be evident inside the flywheel housing There are two possible causes for leakage from the bridgepiece misalignment andor lack of sealantTo rectify misalignment 31 Remove the flywheel using guide studs remove two diametrically opposite bolts and temporarily fit guide studs 32 Remove the starter motor 33 Remove the flywheel housing it may be necessary to tap the housing using a soft hammer to disengage the housing dowels 34 Remove the rear seal housing as described in the section titled REAR OIL SEAL HOUSING 35 Remove the lubrication oil sump 36 Release the two securing capscrews G in the bridge piece remove the bridge piece and old sealant trom all faces Loosely refit the bridge piece and align the face of the bridge piece to the rear block face using a straight edge as shown Alignment to be within 005 mm 0002 in Tighten the securing cap screws to 9 Nm 6 lbf ft 37 Apply Loctite 574 Multigasket to bridge piece end slots H using applicator gun until sealant can be seen coming from the chamfered edges of the bridge piece contact face with the cylinder block 38 Refit flywheel housing and torque securing screws M10 to 44 Nm 33 lbf ft and M12 to 75 Nm 55 lbf ft 39 Refit flywheel using guide studs and torque retaining bolts to 105 Nm 77 Ibf ftTo rectify lack of sealant 310 Remove lubrication oil sump 311 Complete sealing process as described in step 37 above 312 Refit lubrication oil sump using a new joint INDEX TECHNICAL INFORMATION General SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn004engineer has a sound knowledge of safety procedures and has been trained in the JCB Gen 013maintenance and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your supervisor for advice Issue 1Remember SAFETY MUST COME FIRST Date Dec 1991SUBJECT Turbocharger Fault Diagnosis Page 1 of 3PRODUCTS AFFECTED All Perkins Turbo Engines AB and AC BuildsTO BE CARRIED OUT Information OnlyA number of turbochargers have been replaced unnecessarily When inspected by the supplier no fault has beenfound or the fault differs from the failure code andor description on the claimService Procedure1 To assist in the correct diagnosis of general faults please refer to the attached fault finding charts2 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 21 How to check the fuelled starting aid 211 Disconnect the fuel pipe A and the electrical connector B at the starting aid C Remove the starting aid from the manifold and fit a suitable plug in the manifold 212 Connect the fuel pipe to the starting aid but leave the union nutconnection loose Do not fit the electrical connection but ensure that the connector is covered with a suitable insulator Operate the lever of the fuel lift pump until fuel free of air comes from the union nut the union nut at the starting aid 213 Start the engine and operate it at low speed Check that there is no fuel leakage from the valve of the starting aid 214 If there is no leakage remove the plug from the induction manifold and fit the starting aid Connect the fuel pipe to the starting aid and remove the air from the pipe as described above Connect the electrical connector to the starting aid 215 If there is a leak from the valve of the starting aid fit a new starting aid3 Warranty Claim Procedure All Perkins warranty claims must state clearly the symptom and cause in the comments section of the claim form If there is insufficient space on the claim form then attach a written report Failure to follow this procedure may result in the warranty claim being rejected THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOMPage 2 of 3 Gn004 Issue 1Fault Finding ChartsItems A to O below describe possible general faults associated with turbochargers Opposite the faults is a columntitled Possible Causes Code Numbers these code numbers refer to a description of possible causes associatedwith the fault The descriptions for possible causes can be found on page 3FAULT POSSIBLE CAUSES CODE NUMBERSA Not enough power Black smoke Blue smoke 30313234D High lubricating oil consumption Too much lubricating oil at turbine end Too much lubricating oil at compressor end Not enough lubrication 3738H Lubricating oil in the exhaust manifold Inside of the induction manifold wet Damaged compressor impellor 2932333738K Damaged turbine rotor Rotating assembly does not turn freely Worn bearings bearing bores journals 29333738N Noise from turbocharger 1 3 4 5 6 7 8 910 1 1 121314151618 2021222324 293233343738O Sludge or carbon deposit in bearing housing 2 1 1 13 14 15 1 7 18 24 29 33 37 38Page 3 of 3 Gn004 Issue 1Fault Finding Charts OF POSSIBLE CAUSESSYMPTOM1 Element of the air filter dirty2 Restricted crankcase breather3 Element of the air filter missing leaking or not sealing correctly Loose connection to turbocharger4 Internal distortion or restriction in pipe from air filter to turbocharger5 crossover pipe turbocharger to induction manifold6 Restriction between air filter and turbocharger7 Restriction in exhaust system8 Turbocharger loose or loose9 Induction manifold cracked or loose flanges distorted10 Exhaust manifold cracked or loose flanges distorted11 Restricted exhaust system12 Delay of lubricating oil to turbocharger at engine start13 Insufficient lubrication14 Dirty lubricating oil15 Incorrect lubricating oil16 Restricted lubricating oil supply pipe17 Restricted lubricating oil drain pipe18 Turbine housing damaged or restricted19 Leakage from turbocharger seals20 Worn turbocharger bearings21 Excessive dirt in compressor housing22 Excessive carbon behind turbine rotor23 Engine speed raised too rapidly at initial start24 Insufficient engine idle period25 Faulty fuel injection pump26 Worn or damaged atomisers27 Valves burned28 Worn piston rings29 Lubricating oil leakage from supply pipe30 Excessive preservation fluid on initial engine start31 Excessive engine idle period32 Restriction in turbocharger bearing housing33 Restriction in lubricating oil filter34 Wet type air cleaner Restricted dirly element viscosity of oil too lowhigh35 Wastegate if fitted actuator faulty or damaged36 Wastegate if fitted valve not free37 Engine stopped too soon from high load38 Insufficient lubricating oil39 Fuel leakage from fuelled starting aid40 Crack in backplate of compressor INDEX TECHNICAL INFORMATION General SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn005engineer has a sound knowledge of safety procedures and has been trained in the JCB Gen 002maintenance and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your supervisor for advice Issue 1Remember SAFETY MUST COME FIRST Date March 1992SUBJECT HEALTH SAFETY Page 1 of 2 AFFECTED ALL WARNINGDue to recent publicity regarding the potential hazards associated with the handling of materialsViton Fluorel Technoflon etc commonly used in the production of oil seals and gaskets for the the following health and safety statement should be notedNote Examples of the use of these materials on ITL products are the Viton crankshaft oil seals on Perkins enginesand Viton shaft and brake seals in the axlesNew ComponentsThe normal handling of new cured components at ambient temperature presents no known hazardand requires no special handling of Old Components during ServicingNo special precautions are required when handling old material that has been subjected only tonormal service conditions However before removal a preliminary visual examination should establish whethernormal service temperatures have been exceeded giving rise to thermal degradation If evidence of etc is found the material and surrounding areas should not be touched without observing the belowRemoval of Old Material Subjected to Abnormally Hiqh TemperaturesAt temperatures in excess of 300 C eg engine fires materials can decompose producing smallbut significant amounts of hydrofluoric acid This acid is highly corrosive and will cause SEVERE BURNS if in contactwith the skinVehicles or components that have been subjected to abnormally high temperatures should be subjected to thefollowing procedure which must be conducted by competent personnel This will require the use ofappropriate safety equipment neoprene rubber or heavy duty gloves plus special safety glasses are essential1 Ensure that components have cooled then carefully remove and transfer suspect material to plastic bags2 Wash the contaminated area with a 10 calcium hydroxide or other suitable alkali solution if necessary using wire wool to remove residual adherent decomposition products3 Thoroughly wash contaminated area with detergent and watercontd THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOMPage 2 of 2 Gn005 Issue 14 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 Regulations5 materials should NOT be incineratedIf there is contamination of the skin or eyes wash the affected area with a continuous supply of clean water or withcalcium hydroxide solution for 1560 minutes Obtain immediate medical attention INDEX TECHNICAL INFORMATION General SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn006engineer has a sound knowledge of safety procedures and has been trained in the JCB Gen 021maintenance and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your supervisor for advice Issue 1Remember SAFETY MUST COME FIRST Date Feb 1993SUBJECT Turbochargers Page 1 of 1PRODUCTS AFFECTED Turbocharged Perkins 90 BHP EnginesTO BE CARRIED OUT Information OnlySERVICE engine serial number No 28193 a Garret turbocharger is fitted this replaces theSchwitzer unit The Garret turbocharger gives improved service PROCEDUREIf for any reason a warranty repair is to be completed on the turbo unit then a full written report on the be submitted with the claim or the Perkins Service Information ITL TI Gn004 can be used to aid fault diagnosisand specifying the faultPerkins dealers should carry out this workFailure to follow this instruction may result in the claim being rejectedPARTS PART NO COMMENTSGarret Unit 02200460 was Schwitzer unit part no 02200340 applicable to 90BHP only THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM INDEX TECHNICAL INFORMATION General SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn007engineer has a sound knowledge of safety procedures and has been trained in the JCB and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your supervisor for advice Issue 1Remember SAFETY MUST COME FIRST Date Feb 1993SUBJECT Piston and Piston Ring Improvements Page 1 of 1PRODUCTS AFFECTED 4Cylinder Turbocharged EnginesTO BE CARRIED OUT Information OnlySERVICE INFORMATIONA new improved oil control piston and ring pack has been fitted to the Perkins 4cylinder turbocharged engines fromJanuary 1993 Engine cutin numbers AB 50424U 608291 W AB 50440U 608301 WOne of the advantages of the new design is that it reduces oil consumption after the initial beddingin period Theaverage oil to fuel used consumption is reduced from 05 to 02 The following information should be coveredduring new machine installationi Engine runningin is not a requirementii Periods of engine idlingtick over should be kept to a minimum to prevent cylinder bore glazingSERVICE PROCEDURE1 The new piston and ring pack can be used as service replacements in sets of 4 pistons and ring kits2 When fitting the new piston and ring pack in service there is no need to deglaze the cylinder bore glaze busting3 JCB Technical Information Bulletin 2004 issue 2 details the service procedure to be completed if oil consumption concerns are raised by the customer before contacting the Perkins Dealer i On engines prior to the new piston and ring pack normal oil consumption remains at 03 to 05 of fuel used further investigation may be required if the oil consumption exceeds 07 ii On engines fitted with the new piston and ring pack further investigation may be required if the oil consumption exceeds 05PARTS PART NO BHP 90 EngineAB50441 96 EngineAB50459 96 Engine1 Piston Assembly 022008602 Ring Kit 02200859 THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM INDEX TECHNICAL INFORMATION General SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn008engineer has a sound knowledge of safety procedures and has been trained in the JCB 2109 C26N Ammaintenance and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your supervisor for advice Issue 1Remember SAFETY MUST COME FIRST Date Nov 1993SUBJECT Alternator Connectors on the Mainframe Harness Page 1 of 1PRODUCTS AFFECTED Perkins Engines as applicableTO BE CARRIED OUT Information OnlySERVICE INFORMATIONTwo types of alternator connectorshave been supplied The alternatoreuro plug connector item X FIG 1is no longer supplied Instead a ringterminal and lucar connector item Y FIG 2 are now suppliedAlign the harness connectors and alternator the wire numbersIf the harness has a euro plugconnector item X fitted install theharness as shown in FIG 1 If theharness has a ring terminal and lucarconnector item Y fitted install the FIG 1harness as shown in FIG 2 FIG 2 THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM INDEX TECHNICAL INFORMATION General SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn009engineer has a sound knowledge of safety procedures and has been trained in the JCB Gen 028 K58N Ammaintenance and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your supervisor for advice Issue 1Remember SAFETY MUST COME FIRST Date March 1994SUBJECT Low Sulphur Fuels Page 1 of 1MACHINES AFFECTED All Perkins 1000 Series EnginesTO BE CARRIED OUT Information OnlySERVICE INFORMATIONLow sulphur fuels are commonly used throughout the world These fuels contain fewer lubrication additives The DPAand DPS fuel pumps currently fitted to the Perkins 1000 Series engine are lubricated by the diesel fuel therefore usinglow sulphur fuels may in the long term affect the pumpIf you are using a low sulphur diesel fuel it is recommended that additional lubrication is added to the should contact their local fuel supplier to obtain a locally supplied and recommended additive There is nocurrent 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 ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM INDEX TECHNICAL INFORMATION General SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn010engineer has a sound knowledge of safety procedures and has been trained in the JCB and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your supervisor for advice Issue 1Remember SAFETY MUST COME FIRST Date Mar 1994SUBJECT Brake Master Cylinder Kits Page 1 of 1Master cylinder seal repair kits should no longer be supplied Any kits in Distributor stocks should be returned to theOEM Contact Mr P Hassall at JCB Service for returndisposal instructions for JCB supplied sealsIn the near future master cylinder kits listed below will no longer be available Only the master cylinder assemblies willbe available for replacement this is because it is not good practice to reseal old master cylinders also by untrained customers is not recommendedThe relevant Service Manual procedures will be updated Cylinder Seal Kit Part Numbers 15107001 15104700 15106600 15903803 15904102 15904301 15908201Note Master cylinder 15908200 is no longer available If a master cylinder is required then part number 15910800must be used either singly or in pairs THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM INDEX TECHNICAL INFORMATION General SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn011engineer has a sound knowledge of safety procedures and has been trained in the JCB and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your supervisor for advice Issue 1Remember SAFETY MUST COME FIRST Date June 1994SUBJECT Hydraulic Ram Identification Page 1 of 1Over the last twenty years JCB has made a number of design and manufacturing improvements to hydraulic ramsSome difficulty is being experienced identifying the various rams for parts ordering purposes The show some different types of ram fitted to JCB machines It is important to correctly identify the type ofram fitted prior to ordering spare parts because in most instances parts will not be IMPERIAL RAM 4 in x 2 in 1972 to 1979 End Cap Gland Seals located in Gland Bearing Split Pin 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 NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM INDEX TECHNICAL INFORMATION General SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn012engineer has a sound knowledge of safety procedures and has been trained in the JCB Gen 031 K60N Ammaintenance and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your supervisor for advice Issue 1Remember SAFETY MUST COME FIRST Date July 1994SUBJECT Oil Pump Idler Gear Page 1 of 1PRODUCTS AFFECTED All Fitted with a Perkins 1000 Series EngineTO BE CARRIED OUT As RequiredIt has been found in service that excessive wear can occur to thebush for the idler gear of the lubricating oil pump This wear mayoccur on four and six cylinder engines CA new idler shaft A has been introduced which has an oil hole B Ato provide more lubrication to the bush for the idler gear Also anew lubricating oil pump has been introduced which has achannel C in the body of the pump Lubricating oil from the front Bmain bearing passes down the channel in the body of the pumpto the oil hole in the idler shaft The lubricating oil then passesthrough the hole in the idler shaft to the bush in the idler gearIf it is found in service that more lubrication is necessary for the S209440bush of the idler gear renew the bush part 02290006 Fit thenew idler shaft part 02201131 and the new lubricating oilpump part 02201050 four cylinder engines or 02201130 sixcylinder enginesFit the lubricating oil pump and the idler shaft in accordance withthe procedure given in operations 19A06 and of the workshop manual In addition to ensure that the hole D in the idler shaft is at thebottom and that the flat E is at the top before the shaft is pressedinto the bearing cap E Caution The idler shaft for the lubricating oil pump used on Efour cylinder engines is not retained in the bearing cap by a pinbut is retained by Loctite 648 Retainer part 41010651 D D S209450If the new lubricating oil pump is fitted the endfloat for the idlergear is as follows Four cylinder engines 00120643 mm 0000500253 in Six cylinder engines 00200650mm 0000800256 inPARTS No Description Part No Bush 02201050 Pump 4 Cylinder Shaft 02201130 Pump 6 Cylinder Loctite 648 RetainerNote The above information can be implemented only when excessive wear is evident THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM INDEX TECHNICAL INFORMATION General SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn013engineer has a sound knowledge of safety procedures and has been trained in the JCB Gen 035 F47N Ammaintenance and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your supervisor for advice Issue 1Remember SAFETY MUST COME FIRST Date Feb 1995SUBJECT Stake Nuts Input and Output Flanges Page 1 of 1PRODUCTS AFFECTED All ITL Transmissions and AxlesTO BE CARRIED OUT Information OnlySERVICE INFORMATION1 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 discarded2 TRANSMISSIONS The stake nut for the gearbox rear 2WD output flange is now manufactured from 46 mm hexagonal bar The existing 134 inch socket can not be used on the 46 mm nuts Make sure both types of socket are available in the event of site repair Note The transmission rear 2WD output flange is still retained by the separate nut and washer arrangement the washer should be replaced with a new one if damaged or distorted S224080Input Output Flanges The axle flanges and transmission outputflanges are now hardened at the sealing Note The illustration shows aarea The hardened flanges prevent possible typical axle arrangementoil leaks and loss of bearing preload byreducing the risk of fretting and subsequent Aloosening of the flangesIn the event of a flange becoming loose or wearing a new hardened type flange and new seal should be fitted Applya small bead of Loctite 936 around the shaft spline Full details for removing and replacing output flanges are given inthe relevant Workshop ManualPARTS No Description Qty Combine Stake NutWasher AR M2282601483 Combine Stake NutWasher AR M2482601551 Stake Nut AR 46 mm Gearbox THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM INDEX TECHNICAL INFORMATION General SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn014engineer has a sound knowledge of safety procedures and has been trained in the JCB Gen 041 K68N Ammaintenance and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your supervisor for advice Issue 1Remember SAFETY MUST COME FIRST Date August 1995SUBJECT Fuel Injection Pump Seal Failure Page 1 of 2PRODUCTS AFFECTED Perkins 1000 Series EnginesTO BE CARRIED OUT By Perkins DealersSERVICE INFORMATIONThe possibility exists that the shaft seal of the fuel injection pump has been damaged during the assembly processThe seal must be replaced with a new one otherwise serious damage to the engine could occur Replacement of theseal is a specialised task and must only be done by the CAV engineer therefore please note the following1 The OEM Distributor must contact the local CAV agent and quote reference number D1372 The OEM Dealer and the CAV agent then arrange with the machine owner a suitable time to complete the repair procedures repair time 30 hours3 On arrival at the machine the OEM engineer will remove the injection pump see SERVICE PROCEDURES once the pump has been removed it is given to the CAV agent who will then replace the shaft seal4 The injection pump complete with new seal must then be refitted to the machine by the OEM PROCEDURESFuel Injection Pump RemovalSpecial Tools Required Gear Puller part number PD155C Note Existing workshop special tools these items Adaptors part number PD155B5 are not reclaimable on this FSI Spanner part number PD1991 Park the machine on firm level ground engage the parking brake and set the transmission to neutral2 Raise the loader arms or the boom if necessary to access engine and fit safety strut3 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 ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOMPage 2 of 2 Gn014 Issue 1SERVICE PROCEDURES continued4 Remove the injection pump 41 Remove all the pipes cables and electrical connections from the pump 42 Remove the gear cover from the cover of the timing case Remove the gear nut and spring washer A 43 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 44 Remove the setscrew and the nut of the support bracket below the fuel pump Release the flange nuts A of the fuel pump see note If access to the flange nuts is restricted use tool PD199 BNote Leave one flange nut loose on the end of the threadthis will prevent the pump from falling when the gear isremoved step 45 45 Loosen the drive gear of the fuel injection pump with the puller PD155C and adaptors PD155B5 as shown at B items 1 and 2 46 Remove the fuel pump ensure that the key does not fall from the drive shaft S235030Fuel Injection Pump Replacement1 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 gear2 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 fitted3 Fit the spring washer and the nut to the drive shaft of the fuel pump and tighten the nut to 80 Nm 59 Ibf ft 82 kgf m Fit the gear cover to the cover of the timing case together with a new joint4 Fit all the pipes cables and electrical connections Reconnect the battery5 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 correctSERVICE PARTSPart No Description Qty Gasket 1 Injection Pump to Timing Case02200029 Gasket 1 Injection Pump Gear Cover INDEX TECHNICAL INFORMATION General SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn015engineer has a sound knowledge of safety procedures and has been trained in the JCB Gen 038 F66N Ammaintenance and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your supervisor for advice Issue 1Remember SAFETY MUST COME FIRST Date Feb 1996SUBJECT Engine Lubrication System Relief Valve Housing Page 1 of 2PRODUCTS AFFECTED All Fitted with Perkins 1000 Series EnginesTO BE CARRIED OUT By Perkins DealersSERVICE INFORMATIONThe possibility exists that engine relief valve housing Amay fail The relief valve controls the engine lubricating Asystem oil pressure therefore a failure of the housingcould result in the loss of engine oil pressure and damage to the has shown that the relief valve housing has Dbeen machined incorrectly and remedial procedures havealready been implemented to ensure all relief valve Ehousings are now machined to the correct the relief valve housing as described in PROCEDURENote The following procedures apply to a typical machinethe method for gaining access to the engine oil relief valvemay differ slightly1 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 engine2 Place a clean suitable size container underneath the engine oil drain plug located in the sump3 Remove the sump drain plug and its O ring Drain the engine oil into the container4 Remove the engine oil dipstick and the dipstick tube S225960 SPECIAL to Perkins dealers for warranty information and repairsISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM ENGLISHPage 2 of 2 Gn015 Issue 1SERVICE PROCEDURE continued5 Provide a support for the sump and remove the sump retaining bolts Lower the sump and remove the sealing gasket6 Inspect the relief valve housing 61 Look at the side of the relief valve housing A for the manufacturers number 62 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 63 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 7Important note Relief valves obtained from service parts stock with a number 2 are manufactured to the Remove the relief valve housing retaining bolt D and then remove the relief valve housing A8 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 bolt9 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 tube10 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 requiredPARTS REQUIREDPart No Description Qty Relief Valve Assy 1 Turbo Engine02200106 Relief Valve Assy 1 Naturally Aspirated Engine02102069 Engine Sump Gasket 1 Cast Iron Sump02200875 Engine Sump Gasket 1 Alloy Sump02200198 Drain Plug O ring 1 available only in units of 50 part number 02200198A INDEX TECHNICAL INFORMATION General SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn016engineer has a sound knowledge of safety procedures and has been trained in the JCB 2156 D19N Ammaintenance and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your supervisor for advice Issue 1Remember SAFETY MUST COME FIRST Date Feb 1996SUBJECT Parkbrake Clevis Pin Improvements Page 1 of 2PRODUCTS AFFECTED Transmissions with Clysdale Type Park BrakeTO BE CARRIED OUT Information OnlySERVICE INFORMATIONA new method of retaining the parkbrake cable to the lever and the caliper has been introduced In place of theexisting clevis pin arrangement new type shouldered bolts items A and B are used The shouldered bolts aredirectly with the clevis pin arrangement When required the shouldered bolts can be fitted asdescribed in SERVICE PROCEDURES1 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 engine2 Remove the parkbrake lever gaiter item C3 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 G4 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 G5 Check that the parkbrake fully engages do a parkbrake test refer to Operator Handbook If necessary adjust the parkbrake as required6 Refit the parkbrake lever gaiterPARTS No Part No Description Qty CommentsA 82601596 Shouldered Bolt 1 Parkbrake cable to parkbrake leverB 82601597 Shouldered Bolt 1 Parkbrake cable to caliperE 14200007Z 8 mm Flat Washer 2F 14200006Z 6 mm Flat Washer 2G 13700103Z 6 mm Nut 2 THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOMPage 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 Gn017engineer has a sound knowledge of safety procedures and has been trained in the JCB Gen 045maintenance and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your supervisor for advice Issue 1Remember SAFETY MUST COME FIRST Date March 1996SUBJECT Starter Motors Page 1 of 1PRODUCTS AFFECTED All Perkins enginesSERVICE INFORMATIONA new specification of starter motor having a larger and stronger inertia clutch has been introduced in two forms foreither left hand or right hand mountingThe engine serial cutin numbers areRight hand mounting on four cylinder engines U 746654 BLeft hand mounting on four cylinder engines U 747324 BSix cylinder engines U 620352 BThe two new part numbers are fully with the earlier starter motors as detailed below For applications refer to the parts that all starter motors failing within the warranty period should be repaired by the nearest Magnetti See TI Gn018 for list of Magneti Marelli Perkins or Perkins Dealer for further RequiredPart No Starter motor left hand mounting supersedes Starter motor right hand mounting supersedes 71414300 THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM INDEX TECHNICAL INFORMATION General SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn018engineer has a sound knowledge of safety procedures and has been trained in the JCB MI 461H and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your supervisor for advice Issue 2Remember SAFETY MUST COME FIRST Date Feb 1999SUBJECT Magneti Marelli Support Page 1 of 5PRODUCTS AFFECTED All Fitted with Magneti Marelli Alternators andor Starter MotorsFrom 1st January 1996 Service Warranty Support for Magnetti Marelli electrical equipment fitted on Perkins Engineswill be provided by Magnetti Marelli addresses of the Magneti Marelli European main headquarters are listed below The remaining pages in your country so for instance the translated JCB French version of this bulletin will only list the network the German the German network and so on If there is no local Magneti Marelli agent can either be repaired by a local electrical agent and the repair invoice submitted with a Warrantyclaim to a Perkins Dealer or if required a new unit can be supplied by a Perkins DealerMAGNETI MARELLI SERVICE HEADQUARTERSUK Magneti Marelli Aftermarket GERMANY Magneti Marelli KV Shaftsmoor Lane 71 Hall Green 74078 Heilbronn Birmingham Germany B28 8SW Tel 004971312910 Tel 01216258788 Fax 0049 7131176928 Fax 01216258625 SPAIN Magneti Marelli IbericaITALY Magneti Marelli Avda de Roma 8082 Viale Aldo Borletti 6163 08015 Barcelona 20011 Corbetta Spain Milano Italia Tel 003432263176 Fax 003432262109 Tel 00390297200602 Fax Magneti Marelli France 19 Rue Lavoisier Note If difficulty is experienced in finding support or 92000 Nanterre overseas warranty cover contact Perkins UK on France Tel UK 440 1733 567474 Tel 0033147297000 Fax 0 1733 582240 Fax For JCB Language versions only the front page is issue raised When filing replace the front sheet only THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOMNAME ADDRESS TOWN COUNTY POST TELEPHONE CODE Auto Electrical 357 Bath Road Brislington Bristol Avon BS4 3EU 01179712242 Page 2 of 5Gloucester Automotive Unit 4 Locksbrook Court Locksbrook Road Bath Avon BA1 3EN Services Ltd Murdock Road Bedford Bedfordshire MK41 7RA Ltd 4244 Hasting Street Luton Bedfordshire LU1 5BQ Automotive Ltd 13 The Paddock Hambridge Road Newbury Berks RG14 5TQ Automotive Ltd 4 Nimrod Way Elgar Road Reading Berks RG2 0EB Automotive Ltd 13 Eastheath Avenue Wokingham Berks RG11 2PP Automotive Ltd 6 Bracknell Business Centre Downmill Road Bracknell Berks RG12 1QS Automotive Ltd 2 Bridgegate Business Park Gatehouse Way Aylesbury Bucks HP19 3XN Automotive Ltd 9 Wessex Road Bourne End Bucks SL8 5DT Automotive Ltd 22a Buckingham Avenue Slough Bucks SL1 3EA Automotive Ltd 2b Alma Road Ind Estate Chesham Bucks HP5 3HB Car Ltd 19 Harvester Way Fengate Peterborough Cambridgeshire PE1 5UT Battery Services Ltd 100102 King Street Dukinfield Cheshire SK16 4JZ North East Ltd Portrack Grange Road Stockton on Tees Cleveland TS18 2PH Auto Supplies Head Office 42 West Hill St Austell Cornwall PL25 5EY 0172673063Mill Auto Supplies Church Works Mount Street Penzance Cornwall TR13 2EU 0173660301Mill Auto Supplies 4951 Wendron Street Helston Cornwall Auto Supplies Penmarrin House Commercial Road Penryn Cornwall Auto Supplies Trevenna House Nettles Hill Redruth Cornwall TR15 1AL Auto Supplies Units 1 2 Old Sation Yard Berrycombe Road Bodmin Cornwall 0120878166Mill Auto Supplies Eddystone Rd Ind Estate Wadebridge Cornwall Auto Supplies 1 Miller Bus Park Station Road Liskeard Cornwall PL14 4DA Services Marsh Green Road Marsh Green Trading Est Exeter Devon 0139254931 Gn018NAME ADDRESS TOWN COUNTY POST TELEPHONE CODE NUMBERESSEXGP Auto 119 Victoria Road Romford Essex RM1 2LX 01708722913 Page 3 of 5Motex Express Auto Factors 14 Oban Court Hurricane Way Wickford Essex SS11 8YB ESTERCentral Motor Factors 913 High Street Lydney Gloucester GL15 4DP Motor Factors New Road Parkend Lyndey Gloucester GL15 4JA Automotive 53 St Catherine Street Gloucester GL1 2BS Automotive Unit 5 Lower Mill Street Cheltenham Gloucester GL51 8JN Automotive Riverside Works Severn Road Gloucester GL1 2LE Ltd Aldershot Truck Spares 16 Connaught Road Aldershot Hampshire GU12 4RN 01252343228ARE Ltd Eastern Road Aldershot Hampshire GU12 4TD 01252331448ARE Ltd Unit 1 Amey Ind Est Frenchmans Road Petersfield Hampshire GU32 3AN Ltd 103 Longspring Watford Herts WD2 5PO Ltd 7 Railway Place Hertford Herts SG13 7BS Walker JFK Industrial Estate Naas Road Dubln 12 Ireland Walker College Commercial Park Dennehys Cross Cork Ireland Walker 23 Nicholas Street Limerick Ireland Automotive Ltd 43 Sittingbourne Ind Park Crown Quay Lane Sittingbourne Kent ME10 3JG Battery Services Ltd School Lane Rochdale Lancashire OL16 1QR Battery Services Ltd Elliot House Greenacres Road Oldham Lancashire OL4 1HB 01616275638PF Jones Diesel Service Ltd Nuttall Street Manchester Lancashire M16 9JA Distribution Cocker Road Bamber Bridge Walton Summit Ind Est Preston Lancashire PR5 8AL Auto Elec Diesel Ltd Unit 220 Bamber Bridge Walton Summit Ind Est Preston Lancashire PR5 Car Truck Brownlow Street Stamford Lincs PE9 2EL Trade Services 246250 Cavendish Road Balham London SW12 0BY Ltd Hillway Highgate London N6 6QE 01813410553MID South Wales Ynysangharad Road Pontypridd Mid Glamorgan CF37 4DA 01443405726 Gn018NAME ADDRESS TOWN COUNTY POST TELEPHONE CODE Automotive Ltd 96 Oxford Road Denham Uxbridge Middlesex UB8 1LV 01895256451 Page 4 of 5NORFOLKPanks Auto Electrical 15 Higham Street Norwich Norfolk NR2 4TE Page Ltd Unit 25 Raylor Centre James Street York North Yorkshire YO1 3DP Page Ltd Unit 6 Thirsk Ind Park York Road Thirsk North Yorkshire YO7 3TA 01845526688SAS Ltd Unit 17 Provincial Works The Avenue Harrogate North Yorkshire HG1 4QE 01423889021SAS Ltd Westgate Otley North Yorkshire LS21 3AT Magneto Trent Works Canel Street Nottingham Notts NG1 7HL Automotive Ltd 29b Milton Park Abingdon Oxon OX14 4RT Automotive Ltd 59 Murdock Road Bicester Oxon OX6 7PP A Factors Ltd 2 West Hendersons Wynd Dundee Scotland DD1 5BT 01382228202D A Factors Ltd 42 Canmore Street Forfar Scotland 01307464914D A Factors Ltd 13 Baltic Street Montrose Scotland 01674676260D A Factors Ltd Unit 7 whitefriars Perth Scotland Vehicle Equipment 13 Scotland Street Glasgow Scotland G5 9PU R Harris Ltd 2440 Seaward Street Glasgow Scotland G41 1HL Page Ltd Unit 4 Silver Court Intercity Way Bramley South Yorkshire L13 4LY Auto Factors Newcross Street Sutton in Ashfield South Yorkshire Bar Components Ltd Kettlebrook Road Tamworth Staffs B77 1AG 0182760111Car Bar Components Ltd 1 Horninglow Street BurtononTrent Staffs DE14 1NG Motor Factors Brownhills Business Park Linden Road Brownhills Staffs WS8 7BW Diesel Mason Street Fenton Stoke on Trent Staffs ST4 3NE Ltd 285 Worplesdon Road Guildford Surrey GU2 6XN 01483233003ARE Ltd Unit 1 Goldsworth Ind Est Goldworth Road Woking Surrey GU21 1LY 01483722424ARE Ltd Hare Lane Goldalming Surrey GU7 3EG 01483428585ARE Ltd Unit 1 Weydown Road Halsmere Surrey GU27 1DW 01428654061ARE Ltd 13 East Street Farnham Surrey GU9 7RX 01252737654ARE Ltd Guildford Truck Spares 139 Worplesdon Road Guildford Surrey GU2 6XA 01483573311 Gn018NAME ADDRESS TOWN COUNTY POST TELEPHONE CODE Ltd 282 Walton Road East Molesey Surrey KT8 0HU 01819417955 Page 5 of 5ARE Ltd Unit 1 Downside Guildford Road Chertsey Surrey KT16 9BQ 01932570820ARE Ltd 78 Holmethorpe Avenue Holmethorpe Ind Est Redhill Surrey RH1 2NL 01737767000ARE Ltd Walton Motor Factors 151153 Hersham Road Hersham Surrey KT12 5NR AND WEARAndrew Page Ltd Unit 15 Brough Park Fossway Tyne and Wear NE6 2YF Auto Electrical Ltd St Lawrence Road Tyne and Wear NE6 1AQ Motor Factors Units 1011 Eruria Way Barton Park Ind Estate Bilston West Midlands WV14 7AH Motor Factors Walsall Road Willenhall West Midlands WV13 2ED Motor Factors Units 2 3 6 Brandon Way Ind Estate West Bromwich West Midlands B70 9PW Page Ltd Apson House 5359 Mabgate Leeds West Yorkshire LS9 7DY Page Ltd Grantley Way Stanley Road Wakefield West Yorkshire WF1 4PY Page Ltd Unit 5 Hall Lane Bradford West Yorkshire BD4 7DG Page Ltd Units 2930 Beck Road Ringway Ind Estate Huddersfield West Yorkshire HD1 5DG Page Ltd Units 1517 Ashley Ind Est Elmfield Road Morley West Yorkshire LS27 0EL Motor Spares Ltd 16 Church Street Melksham Wilts SN12 6LS Ltd Wykeham Industrial Estate Easton Lane Winnall Wincester SO23 7RX Electric Worcester Ltd Gregorys Mill Street Worcester Worcestershire WR3 8BS Jahre Motor AS Brynsveien 24 0602 Oslo 6Finland Atoy OY1 Lauttasaarenti 54 0200 Dybbroe AS Tomsagervey 810 08230 Aabyhoj Aarhus Gn018 INDEX TECHNICAL INFORMATION General SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn019engineer has a sound knowledge of safety procedures and has been trained in the JCB MI and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your supervisor for advice Issue 2Remember SAFETY MUST COME FIRST Date Dec 1998 SERVICE DEPARTMENT COMPUTER DIAGNOSTIC EQUIPMENT Page 1 of 3Electronic Control Units ECU have been introduced to control the functions of Marketing is becoming increasingly important in generating distributor revenue Introduction of ECU and EMSunits incorporating Service Indicators represents a major opportunity for distributors to ensure they obtain all routineservice workTo support transmissions fitted with these systems Distributor Service Personnel need to have the Diagnostic equipment All new ITL electronic systems will use the PSION Workabout hand held computerfor this purposeThis bulletin describes the requirements for and technical specification of these computerised diagnostic tools1 PSION WORKABOUT This low cost rugged hand held computer is now the ITL and JCB Group Diagnostic Tool It is widely used in service industries for infield use All new ITL and JCB products with electronic systems requiring support from Service personnel will use software running on the PSION Electronic units requiring the PSION workabout will be as follows Transmission ECU Fitted to PS700 four and five speed transmissions Function Control of powershift gearbox Use of PSION Fault finding of ECU inputs and outputsThe technical details of the PSION Workabout are Specification PSION Workabout PSION Part No ITLJCB part No RS 232 and TTL Serial Interfaces 1800 000611 89200924 Docking Holster One required per depot for 1801 000301 89200925 transferring software from PC to PSION Workabout PsiWin Link and Software To transfer JCB software from 1601 003910 89200926 PC to PSION Workabout one per depot ITL Software This will be provided on the Parts CD ROM and will be transferred from a desktop computer via PsiWin software to the PSION Workabout A Psion disc is also available JCB part No 89200963 Cable links to machine Connecting cable for connecting the PSION Workabout to any ITL machine is part no 89200952 available from JCB Service A service kit comprising the above items is available JCB part No 89200962 ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM2 of 3 Gn019 Issue 2 Availability A list of PSION agents worldwide is attached PSION Support Technical Support for the PSION Workabout can be obtained from Psion Corporate Support telephone 44 details of the Notebook PC are 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 311 or Windows 95 ITL Software Will be provided on the Parts CD ROM Cable links to machine ITL part numbers will be advised in workshop manuals Availability Any reputable computer supplier JCB Service or ITL directThe facts about 16bit NEC V30H 80C86 compatible multitasking windowing environment MSDOS compatible file formatsMemory 256k 1 MByte RAM 2 Solid State Disk drives for additional 16MbytesLCD Screen 39 characters x 12 lines 240x100 pixels Black and grey scale 57 key Supply 2 AA batteries Rechargeable battery pack optional Lithium backup battery External power via mains adaptor or Docking applications OPL language Database Spreadsheet and interfaces Barcode wand and RS232 TTL and RS232 for Elasticated strapOperating Conditions 20 to 60 Celsius Humidity 90 max resistance One metre onto Standard model splashproof optional on expansion 180mm x 90mm x 35mm 325g including batteriesPSION DISTRIBUTOR Country Address Telephone Number Fax Number EmailASK INTERNATIONAL SARL ALGERIA 94 RN 133 42380 SOUIDANIA WTIPASA 213 2791130 213 2791130 3 of 3PSIAR ARGENTINA AVENIDA DE MAYO 963 3RD FLOOR BUENOS AIRES1084 541 345 2351 541 345 3605 PTY AUSTRALIA RMB 3585 VALLEY ROAD KANGY ANGY NEW SOUTH WALES 2258 61 4362 2014 61 4362 2014HAYWARD AUSTRIA POSTFACH 79 A5071 WALS 405 43 662 8587 0 43 662 8587 80 WORLD BAHRAIN 273 EXHIBITION AVENUE HOORA PO BOX 26178 MANAMA 973 293 493 973 292 253SHARANEE LTD BANGLADESH B172 LANE23 NEW DOHS DHAKA 1206 880 2885 219 880 2881 DISTRIBUTION BELGIUM KORTE WINKLESTRAAT 15 B2000 ANTWERPEN 32 3232 3468 32 3226 1749KPF CONSERVE CO BRUNEI DARUSSALANO 117 BANGUNAN KUMBANG PASANG JALAN GADONG 3180 BANDER SERI BEGAWAN 673 2448101 673 2 220988 CAMBODIA 2 BLVD NORODOM PHNOM PENH CAMBODIA 855 23 362 392 855 23 721 756 INTERNATIONAL INC CANADA 2775 SHERBROOKE EAST MONTREAL QUEBEC H2K 1B9 514 521 0482 514 521 CARIBBEAN NV CARIBBEAN ATHDLLIDGEROAD 106 PO BOX 1102 STMAARTENS 599 525 414 599 522 589 SA CHILE COMPANIA 1357 PISO 7 SANTIAGO 562 696 2133 562 696 9368POINT X SRO CZECH REP TRUHLARSKA 3 11000 PRAGUE 1 42 2 231 9395 42 2 2481 0821 DATA AS DENMARK FUGLEBAKKEVEJ 8890 DK2000 FREDRIKESBURG 45 38 33 55 01 45 38 33 55 85PROTRADE EGYPT 11 SHEHAB STREET MOHANDESSEEN CAIRO 20 2 35481847 20 2 3607638OY ANGLONORDIC AB FINLAND 3 02780 ESPOO 358 9 819211 358 9 811338 FRANCE FRANCE 78 RUE CHAMPIONNET F 75018 PARIS 33 1 53411 200 33 1 53411 201PSION GMBH GERMANY DAIMLERSTRASSE 16 D61352 BAD HOMBURG 49 6172 6630 49 6172 663100INT ELECTRONIC GREECE 72 SYNGROU AVENUE GR 11742 ATHENS 30 1 9233013 30 1 9234273 intholgrONFLO INTERNATIONAL LTD HONG KONG SUITE 1818 18F MIRAMAR TOWER 1 KIMBERLEY RD TSIMSHATSUI KOWLOON 852 2314 5550 852 2377 3261 MAGYARORSZAG KFT HUNGARY SZT GELLERT TER3 1111 BUDAPEST 36 1209 3804 36 1209 3805 KOMTELINDO HITEK INTI INDONESIA WISMA MULTI BINLANG JL DR SOEPOMO SH NO 44 JAKATA 62 3 61756248 62 3 61756284 SURVEY IRELAND UNIT 6A BALLYMOUNT CROSS INDUSTRIAL ES DUBLIN 12 353 456 8650 353 456 8653 COMPUTER ITALY VIA ANTONELLI 3610093 COLLEGNO 39 11 403 4828 39 11 403 3325PSION JAPAN JAPAN NISHI SHINJUKU FOREST BLD LB FLOOR NISHI SHINJUKU 4321SHINJUKUKU TOKYO 81 3 3378 5933 81 3 3378 5943ANWAR ESSA AL SALEH ESTAB KUWAIT ALRABIE BLDGSALMIYA PO BOX 4704 SAFAT 13048 965 573 7684 965 571 6674 SARL LEBANON JUSTINIAN CENTRE JUSTINIAN ST SANAYEH PO BOX 113 6413 BE 961 1 353 748 961 1 602 193 TECHNOLOGY SDN BHD MALAYSIA MUI PLAZA 3RD FLOOR KUALA LUMPAR 50250 60 3248 3318 60 3245 6318BDS MALTA CASA LEONE PIAZZA ROBERT SAMUT FLORIANNA VLT 14 356 239200 356 248693TDT MEXICO PASA FLORENTINO 47 SANTA FE CP 01 260 52 5 397 8290 52 5 361 3755PSION NEDERLAND BV NETHERLANDS AVIO TRADE PARK ZANDSTEEN 54 2132 MR HOOFDDORP 31 20 4469444 31 20 4469446POCKET SOLUTIONS NEW ZEALAND 11 RUTHERFORD STREET PO BOX 44070 LOWER HUT WELLINGTON 64 4566 7808 64 4569 6452 NIGERIA 110 OBAFEMI AWOLOWO WAY IKEJA LAGOS STATE 234 149702267 234 149702289UCOM NORWAY 47 32203300 47 32203459OHI ELECTRONICS TRADING CO LLC OMAN PO BOX 889 MUSCAT 113SULTANATE OF OMAN 968 959 085 968 603 467CHARLES FREWEN PARAGUAY VALIANA SAL 135 CASI AV SAN BLAS 55 45522 1451 55 45522 1451BORROMEO PHILLIPPINES G A BLDG 2303 PASONG TAMO BLDG 63 2 893 7722 63 2 816 4107 CENTRUM INFORMATYKI ENERGETY POLAND UL MYSIA 2 SKR POCZT 143 00950 WARSZAWA 1 48 22 625 3397 48 22 693 1357 3 LDA PORTUGAL RUA AUGUSTO GILL 30 AB 1100 LISBON 351 1 795 1872 351 1 795 1928PSIRUSSIA RUSSIA INTERNATIONAL UNIVERSITY OF ENG6 LENINSKY PROSPEKT GSP MOSCOW 117933 7 095 236 6531 7 095 236 976 ALI SINDI TRADING ESTABLIS SAUDI ARABIA PO BOX 2951 JEDDAH 21461 966 2 6829454 966 2 6828801SYSTECH SINGAPORE 25 KALLANG AVENUE020103 KALLANG BASIN INDUSTRIAL ESTAT339416 65 299 2933 x236 65 299 9688 DISTRIBUTORS CC SOUTH AFRICA PO BOX 36233 GLOSDERRY CAPE TOWN 7700 27 21 683 1192 27 21 683 1196PARESA SPAIN RAMLA CATALUNYA 35 PRAL 08007 BARCELONA 34 3 4516505 34 3 ENG SYSTEMS SRI LANKA 12 TICKELL ROAD COLOMBO 8 SRI LANKA 94 1 695395 94 1 695874 AB SWEDEN F O PETERSONS GATA 421 31 VASTRA FROLUNDA SWEDEN 46 31 709 1605 46 31 47 8520 AG SWITZERLAND MOOSACHER STRASSE 6 CH 8820 WADENSWIL 41 1 782 2111 41 1 781 1361 KHALIL TRADING CO SYRIA PO BOX 1054 DAMASCUS 963 11 23174 60 963 11 4421966JEBSEN JESSEN THAILAND 17791 NEW PETCHBURI RD BANGKOK 10320 THAILAND 66 2 253 1290 66 2 253 1705INSTITUT MASSMEDIA TUNISIA GALAXIE 2000 RUE DLAK BLOC A 7 EME ETAGE1002 TUNIS 216 1 793 939 216 1 794 949ALPHA 55 CO LLC UAE 1st Floor BIN KHEDIA CENTER AL GARHOUD DUBAI 971 4 822267 971 4 822265 UK PLC UK 1 RED PLACE MAYFAIR LONDON W1Y 3RE 0171 317 4100PSION UK SERVICE CENTRE UK 6 DERBY ROAD METROPOLITAN CENTRE GREENFORD MIDDX UB6 8UJ 0181 566 6162 0181 566 6268PSION INC USA 150 BAKER AVENUE CONCORD MA 01742 001 508 371 0310 001 508 371 9611AL 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 Gn020engineer has a sound knowledge of safety procedures and has been trained in the JCB MI 612H and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your supervisor for advice Issue 1Remember SAFETY MUST COME FIRST Date April 1998ENGINE WORKSHOP MANUALS Page 1 of 1Perkins New 1000 Series DarwinWith the introduction of the New 1000 Series range of engines Perkins produced a new Workshop Manual which isavailable under publication number 98062140Issue 3 of this publication is now available incorporating two additional engine models AR and AS which are formachines sold primarily in North America and Scandinavia The new issue also incorporates various future orders for 98062140 will be supplied as issue 3French and German translations of issue 3 should be available by the end of May Other languages will follow part numbers are French 98062141 German 98062142 Spanish 98062143 Italian 98062144Note Replacement pages are not supplied for engine service manuals To obtain the latest issue a new manual mustbe orderedEngine models now covered by the new manual will be 4 Cylinder Models AJ to AS THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM INDEX TECHNICAL INFORMATION General SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn021engineer has a sound knowledge of safety procedures and has been trained in the JCB and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your supervisor for advice Issue 1Remember SAFETY MUST COME FIRST Date April 1998SUBJECT Axle Propshafts Page 1 of 1PRODUCTS AFFECTED All Machine INFORMATIONOn installation of any machine it is important to ensure that the following points regarding propshaft lubrication andprotection are highlighted to the operator Failure to do so may result in premature wear or consequential damage totransmission components1 must be greased as followsa Interval Every 50 hours of operation Daily if working in muddy conditions Immediately after washing the machineb Ensure that all bearing caps are purged with greasec Only High Pressure Grease such as Mobil HP222 should be used2 WashingDo not direct high pressure water jets at universal joints3 ProtectionWhen working in loose straw or grass it is important thatan undershield is fitted to the machine to prevent around the to protect the propshafts adequately may result indamage to oil seals propshafts and other No JCB HP Grease 400 g cartridge Available from JCB Service and Dealers THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM INDEX TECHNICAL INFORMATION General SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn022engineer has a sound knowledge of safety procedures and has been trained in the JCB and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your supervisor for advice Issue 1Remember SAFETY MUST COME FIRST Date Nov 1990SUBJECT Engine Silencer Improvements Page 1 of 1PRODUCTS AFFECTED Perkins EnginesTO BE CARRIED OUT For Information OnlyProduct ImprovementThe quality of ITL Silencers has been improved1 Turbo Engine Build Silencers a The end plates have been strengthened by increasing the section width A rain cap A must be fitted on the new silencers as the water drain hole is now deleted b The gauge has been increased from 16mm to 20mm2 Naturally Aspirated Silencers a A secondary support bracket B is fitted to silencers installed on naturally aspirated engines this will reduce failures caused by vibration The bracket is bolted to the silencer and mounted on the exhaust manifold studs b The gauge has been increased from 16mm to 20mmParts RequiredTurbo EngineSilencer x 1 99366300 replaces 12301468 Aspirated EngineSilencer x 1 99366200 replaces 12301481 x 1 12301482Bolt x 1 x 1 14110003Z THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM INDEX TECHNICAL INFORMATION General SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn023engineer has a sound knowledge of safety procedures and has been trained in the JCB Gen 087 NAm K91maintenance and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your supervisor for advice Issue 1Remember SAFETY MUST COME FIRST Date Oct 1998SUBJECT Change of position for the exhaust manifold alignment bushes Page 1 of 1PRODUCTS AFFECTED New Perkins 1000 Series Engines Models AJ to AS and YG to YKTO BE CARRIED OUT For INFORMATIONThe information published in section 12 of the New Perkins1000 Series Workshop manual 98062140 has changed Newalignment bushes must be fitted in accordance with thisService BulletinNote Always use the engine identification number to ordernew parts alignment bushes are not fitted to all enginesThe exhaust manifolds fitted to some four and six have large clearance holes for the setscrews It isimportant that these manifolds are correctly fitted to the 1cylinder headCaution Damage to the exhaust manifold can occur if it is notaligned and tightened correctly 2SERVICE PROCEDURE 1If the manifold is renewed it is important that the twoalignment bushes 1 JCB part number 02201783 are inposition New alignment bushes are not necessary when theoriginal manifold is removed and fittedTighten the exhaust manifold setscrews evenly and graduallyto 44 Nm 33 lbf ft 45 kgf m in the sequence shown Use thesame sequence and torque tighten the setscrews againThe front of the engine is shown by the arrow 2Refer 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 ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM INDEX TECHNICAL INFORMATION General SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn024engineer has a sound knowledge of safety procedures and has been trained in the JCB Gen 089 and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your supervisor for advice Issue 1Remember SAFETY MUST COME FIRST Date Jan 1999SUBJECT Pintimed Fuel Injection Pumps Page 1 of 1PRODUCTS AFFECTED All Perkins New 1000 Series Engines Models AJ to AS YG to YKTO BE CARRIED OUT For Information OnlySERVICE INFORMATIONThe latest fuel injection pumps have a hub A which ismounted permanently onto the drive shaftThe manufacturer fits the hub to the pump to ensure veryaccurate timing Engines that have this a pin B part no 89200956 to accurately time the Bpump in serviceCaution Do not release the nut C from the fuel injectionpump Illustration 2 shows the nut C in position when the Cfuel pump is fitted to the engine The fuel pump hub isfitted to the shaft in the factory to ensure that the fuel pump Ais in the correct position for timing If the nut is removed 1and the hub moves the hub will need to be accurately fittedto the pump by use of specialist equipment before thepump can be fitted to the engineAlways refer to the relevant workshop no 98062140 for the correct you start to work on the engineTo remove the fuel injection pump from the engine it is onlynecessary to remove the four setscrews D which securethe fuel pump gear to the hub It is important to follow the Cinstructions in the workshop manual to ensure the enginetiming 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 ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM INDEX TECHNICAL INFORMATION General SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn025engineer has a sound knowledge of safety procedures and has been trained in the JCB Gen 090 and repair of ITL equipment If you are unsure or do not understand Issue 1information contained in the Service Bulletins then ask your supervisor for advice Date January 1999Remember SAFETY MUST COME FIRST Page 1 of 3All Perkins 1000 Series Engines Models YA to YK Warning The engine oil may be hot Allow the of an improved Oil Cooler with a to cool down before the oil pipes are Steel Cover Caution Do not remove both of the oil pipes togetherAn improved oil cooler with a pressed steel cover hasbeen introduced with effect from engine serial number 2 Put a drip tray under the cooler and remove theYBU647452C lubricating oil pipes from the oil cooler Do not remove both of the oil pipes together Remove oneTo Remove of the pipes then fit the flanges A and nuts B onto1 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 ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOMPage 2 of 3 Gn025 Issue 13 Discard the O rings C 3 Clean the seats for the O rings and renew the O rings C of the pipe connections4 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 the5 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 fittedNote A liquid joint is used in the factory This must be 4 Fit the oil pipes to the cooler and tighten the nuts toremoved and a new paper joint F JCB part number 22 Nm 16 lbf ft 22 kgf m02201718 fitted in its place 5 Fill the cooling system6 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 leakageTo Fit To Dismantle1 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 pieces2 Put a new paper joint into position on the studs the joint is fitted dry Fit the oil cooler assembly E to the 3 Remove the cover K from the four studs L of the oil cylinder block Gradually and evenly tighten the cooler element M fasteners D to 22 Nm 16 lbf ft 22 kgf m K P L N C M D B E J A G H FPage 3 of 3 GN025 Issue 14 Remove and discard the threepiece O ring N from 4 Fit the twopiece flanges A onto the studs H the element Tighten the nuts to retain the element when the oil cooler assembly is fitted to the engineWarning Do not allow compressed air to contact yourskin If compressed air enters your skin obtain medical 5 Fit the oil cooler to the cylinder block see page 2 ofhelp immediately this bulletin5 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 oilTo Assemble1 Clean the seats of the threepiece O ring and renew the O rings N2 Clean the flange face P for the threepiece O rings on the inside of the cover3 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 Gn026engineer has a sound knowledge of safety procedures and has been trained in the JCB Gen 091 and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your supervisor for advice Issue 1Remember SAFETY MUST COME FIRST Date February 1999Perkins 4236 or 1000 Series Engines Page 1 of 1Introduction of a Wear Sleeve for the Front Oil SealThe latest timing case fitted to 4236 and 1000 Seriesengines does not have a service position for the frontoil seal as shown in section 15 of the manual A BThe change improves the efficiency of the oil seal inservice and was introduced from engine for 4236 for 4 cylinder 1000 series CCaution If the lip of the oil seal has worn a groove inthe spigot A of the crankshaft pulley oil will continue toleak after the new oil seal is fittedTo renew a worn crankshaft pulley for engines with thelatest timing case a wear sleeve B part number02202027 is fitted over the spigotFull instructions and a special tool to fit the wear sleeveare in each service kitThe dimension to press the new oil seal into the timingcase with or without a wear sleeve fitted is 93 mm0366 in from the front face of the timing case Thespecial tool supplied in the kit can be used to set thecorrect depthIt is not necessary to remove the flange C of the wearsleeve after it has been fittedA new front oil seal must be used when a wear sleeve isfitted THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM INDEX TECHNICAL INFORMATION General SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn027engineer has a sound knowledge of safety procedures and has been trained in the JCB Gen 092 and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your supervisor for advice Issue 1Remember SAFETY MUST COME FIRST Date February 1999New Perkins 1000 Series Engines Page 1 of 1Models AJ to AS YG TO YKWashers for the Fuel Injection Pump GearCaution Ensure that the washers are fitted before thescrews are tightenedA washer part number 02101686 is fitted to each ofthe screws A with effect from the following engine for 4 cylinder engines AYU660846C for 6 cylinder enginesEngines before the above numbers do not need to havethese washers fitted THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM INDEX TECHNICAL INFORMATION General SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn028engineer has a sound knowledge of safety procedures and has been trained in the JCB Gen 093 and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your supervisor for advice Issue 1Remember SAFETY MUST COME FIRST Date February 1999New Perkins 1000 Series Engines Page 1 of 1Models AJ to AS YG to YKImproved Exhaust Valve GuideAn improved exhaust valve guide A has beenintroduced The new guide has a groove B to retain thevalve seal CTo remove and fit the valve guides refer to Section 12of the Workshop Manual BNotes C A1 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 Manual2 If all or most of the original valve guides need to be renewed it may be cost effective to overhaul or exchange the cylinder head3 It is important that all the lubricant is removed from the outside diameter of inlet and exhaust valve guides before the valve seal is fittedParts Part Number Description SupersedesA 02202064 Valve guide 02201511 and 02201817 THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM INDEX TECHNICAL INFORMATION General SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn029engineer has a sound knowledge of safety procedures and has been trained in the JCB Gen 096 E194N Ammaintenance and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your supervisor for advice Issue 1Remember SAFETY MUST COME FIRST Date March 1999SUBJECT ITL Hydraulic Hose Fittings and Orings Page 1 of 2PRODUCTS AFFECTED All ITL ProductsTO BE CARRIED OUT Information OnlySERVICE INFORMATIONITL products use their own type of special BSP hydraulic hose fitting This fitting combines the standard BSP typeconed connector with an Oring seal X fitted in the face of the taperThe Oring is bonded to the fitting to ensure its security However if for any reason the Oring becomes damaged orseparated from the fitting it can be replacedIt is very important to use the correct Oring size for the fitting Any deviation in Oring size or specification eg Oringtaken from a selection kit that appears to be the correct size and material will cause joint integrity and correct Orings X required for the various sizes of hydraulic fitting are shown belowHydraulic Fitting Oring Oring Inner Oring Section MaterialSize Part Number Diameter mm Diameter mm Type14 BSP fitting 82800237 65 015 10 008 A38 BSP fitting 23010006 81 015 16 008 A12 BSP fitting 23010010 121 02 16 008 A58 BSP fitting 23010011 131 02 16 008 A34 BSP fitting 23010015 171 02 16 008 A1 BSP fitting 23010018 221 025 16 008 A1 14 BSP fitting 23020907 291 025 16 008 B1 12 BSP fitting 23020908 351 03 16 008 BMaterial TypeA Nitrile synthetic rubber suitable for use between 40 and 135 Celsius with a hardness value of 80 IRHDB Polyurethane material suitable for use between 40 and 130Celsius with a Shore hardness value of 93AEnsure that only the above Oring 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 ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOMPage 2 of 2 Gn029 Issue 1 XWARRANTY INFORMATIONIf submitting a warranty claim for rectification of a problem with a hydraulic fitting Oring eg oil leak ensure thecorrect Oring part number is specified within the claim as the failed part Incorrect Oring part number claims will notbe accepted INDEX TECHNICAL INFORMATION General SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn030engineer has a sound knowledge of safety procedures and has been trained in the JCB and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your supervisor for advice Issue 1Remember SAFETY MUST COME FIRST Date April 1999 Page 1 of 3 PERKINS LOW EMISSION DIESEL ENGINE ITL PRODUCT Perkins Diesel Engine Improved exhaust emissions Wastegated turbo charger Improved injection pump Increased peak torque Improved cold starting 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 ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOMPage 2 of 3 Gn030 Issue 1The Perkins low emission diesel engine has been introduced for all Powertrains with turbocharged engines sold inthe EEC after 1st January 1999 and for all Powertrains with naturally aspirated engines sold in the EEC after 1st April1999 These dates apply to the engine build date and not the machine build dateThe 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 ratioThe previous 75 hp 56 kW engine is now uprated to 80 hp 59 kW and develops 290 Nm 214 lbf ft peak torqueThe previous 106 hp 79 kW engine is replaced by a 100 hp 74 kW turbo charged engine which develops 402 Nm296 lbf ft peak torqueTorque ComparisonThe comparison shows the increased backup torque at lower engine speed produced by the new low emissionengine Peak torque is increased up to a possible 411 Nm lbf ft from 354 Nm 261 lbf ft depending on air filter andexhaust 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 revmin 2 300 2 2 106 hp engine 2 Max torque 354 Nm 261 lbf ft 1800 revmin 280 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 Engine Speed revminPage 3 of 3 Gn030 Issue 11 Engine Specifications Nat Asp Build Turbo 80hp 102hpInjection pump type DP203 DP203Governing Mechanical MechanicalPump setting code timing Preset PresetIdle speed 800 rpm 800 rpmMax rated speed 2200 rpm 2200 rpmMax noload speed 2350 rpm 2350 rpmInjector codes KW KNInjector setting pressure 294 atm 294 atmNote Either 65A or 85A alternators may be fitted refer to ITL Technical Sales2 RegulationsThe new engines meet EEC Stage 1 emission regulations Smoke emission is dramatically reduced and now meetsECE R24033 engine service intervals remain unchanged at initial 100 hour and 500 hour periods Valve clearance must bechecked every 1000 hours There is no change to the engine oil or fuel filter part numbers Only use oil meeting orexceeding CF4SG specification for the low emission engine The fuel injector pump is significantly more because the emissions are reduced by increasing the accuracy of the timing alterations to the fuel pump are notpossible Any alteration to the fuel pump settings will invalidate the emission certification4 StartingCold start performance has been improved This is achieved via an additional temperature switch situated in the rearof the timing case which causes fuel injection timing to advance in cold conditions In line with these cold the diameter of the battery leads has been increased5 Special Tool RequirementAll essential special tool requirements are incorporated into the relevant Perkins engine service manuals6 Technical the introduction of the new low emission range of engines a new engine workshop manual is available from using the following publication numbers English French German Spanish ItalianEngine Workshop Manual 98062140 98062141 98062142 98062143 980621447 Mandatory and Recommended Distributor Parts ListsContact Perkins Service for mandatory and recommended parts list requirements8 Perkins ServiceDealers INDEX TECHNICAL INFORMATION General SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn031engineer has a sound knowledge of safety procedures and has been trained in the JCB Gen 105 and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your supervisor for advice Issue 1Remember SAFETY MUST COME FIRST Date Nov 1999SUBJECT Hydraulic Ram Sealing Procedure Page 1 of 3PRODUCTS AFFECTED All Machines with ITL RamsTO BE CARRIED OUT Information OnlySERVICE INFORMATIONIn an effort to reduce the number of hydraulic leaks on ITL rams a revised procedure has been introduced for fittingseals to the ram end cap and piston headThe introduction of the new procedure also introduces new tools which are detailed on sheet 3Service Manuals will be revised at the next convenient Replacement Page SetSERVICE PROCEDURETo fit new rod seal B AUse seal fitting tool 89200334 to fit rod seals the sizediameter and position of pins A is determined by thediameter and radial width of the rod seal being fittedThe pins are screwed into threaded holes in the toolbody the spacing of the holes is designed to suit smallor large diameter rod seals C D1 Open the tool as shown at B and insert the new rod seal the seal must be fitted behind the two front pins but in front of the rear pin as shown 161750 THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOMPage 2 of 3 Gn031 Issue 1Note Later ram end caps and piston heads have metricthreads The seals are also different make sure thecorrect seals are fitted On metric threaded rams makesure the seals are fitted the correct way round asshown at P and Q P2 Close the tool as shown at C The seal must form a reniform kidney shape3 Before fitting the rod seals check the seal grooves are free of contamination and sharp edges Q4 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 tool5 Fit rod wiper seal P into seal groove Make sure the seal is correctly installed as shownNote Some rod wipers ie power track rod may use ametal encased seal which is pressed into the housingCare must be taken to ensure the seal is square beforeit is pressed inSleeve E must be used to protect the rod seals from E A187361damage when fitting end cap onto the piston rod Thereare various sizes of sleeve see Parts Information Makesure the hexagon on the end cap is towards the eyeend of the rodFit new piston head seals6 Use a blunt instrument 89201027 shown at F lever the inner seal G into the piston head seal F groove do not let the seal twist There are 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 G7 Fit outer seal H using the same procedure as step 6 Check the external grooves are visible 338470 H 338480Page 3 of 3 Gn031 Issue 18 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 assembly9 Fit the piston head retaining dowel see ram dismantling and assembling relevant section10 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 338490Fit the piston rod and head assembly into the cylinder11 Insert the pistonrod assembly into the cylinder Align the rod and head assembly until parallel with the cylinder then push the assembly into the cylinder12 Fit the end cap refer to the relevant section for torque figure and completion of ram assemblyPARTS INFORMATION 7mm 11o20mm 10mm S338410 Ram Seal Protection Sleeves 5mm m 89201016 For 25 mm Rod Diameter 3m 89201017 For 30 mm Rod Diameter R 89201018 For 40 mm Rod Diameter 89201019 For 50 mm Rod Diameter 89201020 For 50 mm Rod Diameter slew ram 110mm 89201021 For 60 mm Rod Diameter 89201022 For 60 mm Rod Diameter slew ram 175mm 89201023 For 65 mm Rod Diameter 89201024 For 70 mm Rod Diameter 3o 89201025 For 75 mm Rod Diameter R 89201026 For 80 mm Rod Diameter 14 mm 89201027 Piston Seal Assembly Tool 338500 INDEX TECHNICAL INFORMATION General SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn032engineer has a sound knowledge of safety procedures and has been trained in the JCB Gen 110 K110 NAmmaintenance and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your supervisor for advice Issue 1Remember SAFETY MUST COME FIRST Date Jan 2001SUBJECT Oil Control Rings Page 1 of 1PRODUCTS AFFECTED 1000 series engine models AR AS onlyTO BE CARRIED OUT For Information OnlySERVICE INFORMATIONA small taper has been added to the face of the oil control ring to reduce oil consumption during the early life of theengine The ring is marked TOP on the top face and a blue mark has been added to the left of the ring gapThe oil control ring is a component of a ring kit see part numbers listed below The ring kit could be supplied witheither the earlier or the later oil control ringSERVICE PROCEDUREWhen fitting the oil control ring check if there is a blue mark at XIf there is a blue mark at X the ring must be fitted with the mark to theleft of the ring gap The word TOP will then be towards the top of thepiston XIf there is no blue mark the ring can be fitted either way upRing Kit Part 0220180405 mm oversize 0220179110 mm oversize 02201793 THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM INDEX TECHNICAL INFORMATION General SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn033engineer has a sound knowledge of safety procedures and has been trained in the JCB Gen 112 K112 NAmmaintenance and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your supervisor for advice Issue 1Remember SAFETY MUST COME FIRST Date Jan 2001SUBJECT Plastic Thermostat Housings Page 1 of 1PRODUCTS AFFECTED All 1000 series enginesTO BE CARRIED OUT For Information OnlySERVICE thermostat housings fitted to some engines will be damaged if temperature senders or blanking plugs PROCEDUREWhen fitting the items listed ensure that the settings are usedItem Nm kgf m lbf ftA Sender aluminium 16 12 12A Sender brass 24 24 18B 12 inch Plug metal or plastic 4 04 3B 34 inch Plug metal or plastic 4 04 3Note The illustration shows a typical installation whichmay 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 ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM INDEX TECHNICAL INFORMATION General SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn034engineer has a sound knowledge of safety procedures and has been trained in the JCB Gen 114 K109N Ammaintenance and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your supervisor for advice Issue 1Remember SAFETY MUST COME FIRST Date Feb 2001SUBJECT Introduction of Improved Fuel Lift Pump Page 1 of 2PRODUCTS AFFECTED All Perkins Four Cylinder 1000 Series EnginesTO BE CARRIED OUT Information onlySERVICE INFORMATIONAn improved fuel lift pump has been introduced for use on Perkins fourcylinder 1000 Series diesel engines The newpump is a one piece assembly and cannot be dismantled The new pump is with the earlier pumpThe procedure to remove and fit the new pump has not changed Remove and clean fuel inlet strainer 2 if thisprocedure is recommended in the relevant machine handbook or service manualCleaning the Strainer1 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 pump2 Unscrew the fuel filter A Remove strainer 2 and Oring 33 Clean the strainer in clean diesel fluid and dry with low pressure compressed air Renew the strainer and Oring if damaged4 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 system5 Fit the tank cap and prime the fuel system Start the engine and check for fuel leakage THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOMPage 2 of 2 Gn 034 Issue 1PARTS Part No Description1 17913600 Fuel Lift Pump Kit complete with Gasket23 17913601 Fuel Strainer Oring Kit4 02201189 Gasket only A 2 3 1 4 366610 INDEX TECHNICAL INFORMATION General SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn035engineer has a sound knowledge of safety procedures and has been trained in the JCB 5217 and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your supervisor for advice Issue 1Remember SAFETY MUST COME FIRST Date April 2001SUBJECT Coolant Pressure Cap Page 1 of 1PRODUCTS AFFECTED All Perkins 1000 Series EnginesTO BE CARRIED OUT Information OnlySERVICE INFORMATION ASome instances of overheating have been reported which werecaused by the engine coolant filler cap not being correctly fittedThis results in the coolant system failing to pressurise soreducing its PROCEDUREWhen fitting the filler cap ensure that the cap is correctly fittedFit and turn the cap to the first notch as shown at A thenPRESS DOWN and continue turning FULLY clockwise asshown at B until the end stop is met Failure to do this willresult in inefficient cooling and may result in injury when the capis 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 ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM INDEX TECHNICAL INFORMATION General SAFETY NOTICE Instructions in the Service Bulletins assume that the Number Gn036engineer has a sound knowledge of safety procedures and has been trained in the JCB Gen 120 and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your supervisor for advice Issue 1Remember SAFETY MUST COME FIRST Date April 2001SUBJECT Engine Oil Consumption Page 1 of 2PRODUCTS AFFECTED Perkins Low Emission Engines AJ to AS and YG to YKTO BE CARRIED OUT For Information OnlySERVICE oil consumption can only be correctly measured as a percentage against fuel used under If after consideration of the observations below the oil consumption appears to exceed the expectedamount carry out the Service Procedure as detailed Oil consumption does not normally exceed 45 litres 10 UK gal 119 US gal per 100 hours average machine use No test should be carried out on new engines prior to the bedding in period minimum of 100 hours Engines should not be idled for long periods and should be worked hard from new for example engine speed should be above 1500 revmin Extended periods of idle andor high speed roading will dramatically increase the hourly consumption rates Dust ingress via leaks in the air intake system poor hose hoses clips etc Incorrect servicing of air filters ie elements damaged during cleaning or use of non recommended elements Incorrect grade and quantity of oil not as specified in the owners oil consumption after running in should be between 3 and 5 litres of oil per 1000 litres of fuel consumed 066and 11 UK gal per 220 UK gal 079 and 132 US gal per 264 US gal OR 030 and 050 of fuel consumption1 Position the machine on level ground Drain and refill with the correct grade and quantity of oil as specified in the owners handbook2 Allow time for the oil level to settle and check level on dipstick If oil level is either above or below existing MAX mark remark dipstick at this level3 Record the dimensions of any change to the MAX mark Do not alter the MIN mark on the dipstick THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOMPage 2 of 2 Gn 036 Issue 14 Fill fuel tank to the maximum5 Record the hour meter reading and date return the machine to service6 Record all amounts of fuel and engine oil added during the test period on the chart below excluding the initial fillNote Only add oil when the level reaches or is near the MIN mark7 On completion of test replenish oil level to the original MAX mark on the dipstick Replenish the fuel tank as required8 Total all fuel and lubricating oil used during test excluding the initial fill9 Record machine hour meter reading on completion of test10 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 Gn037engineer has a sound knowledge of safety procedures and has been trained in the JCB TSDB 390maintenance and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your supervisor for advice Issue 1Remember SAFETY MUST COME FIRST Date May 2001SUBJECT Rocker Cover Page 1 of 2PRODUCTS AFFECTED Perkins AR AJ AK Low Emission 1000 Series 4Cylinder EnginesTO BE CARRIED OUT Only with Authorisation from ITLSERVICE have been received of excessive oil loss from the rocker cover breather tube It should be noted that oilshowing at the breather tube is a normal function caused by vapourised oil in the crank case escaping toatmosphere However for green countries where strict limitations on oil emission are enforced an improvedrocker cover is now available from ITL The new cover has an integral oil separator which greatly reduces the amountof oil showing at the breather tubeSERVICE PROCEDURE refer to fig on page 21 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 engine2 Gain access to the engine compartment if necessary remove any ancillary equipment such as the exhaust stack precleaner air filter etc3 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 E4 Remove the old rocker cover item F together with joint item HIMPORTANT NOTE When the rocker cover is fitted the cap nuts are tightened onto the nuts of the rocker bracketsDuring removal of the cap nuts it is possible to loosen the nuts of the rocker brackets The nuts of the rockerbrackets should be tightened to the correct torque every time the cover is removed5 Fit the new rocker cover with its new joint Torque tighten cap nuts to 20 Nm 15 lbf ft6 Fit new breather pipe item A to the breather assembly item J using new hose clip item KPARTS REQUIREDItem Part Number Description QtyA 02201338 Hose 1F 02202220 Rocker Cover 1J 02202217 Breather 1K 22010007 Clip 1 THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOMPage 2 of 2 Gn 037 Issue 1WARRANTY 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 theengineer has a sound knowledge of safety procedures and has been trained in the Number and repair of ITL equipment If you are unsure or do not understand Issue 1information contained in the Service Bulletins then ask your supervisor for adviceRemember SAFETY MUST COME FIRST Date Jan 2002SUBJECT New ITL NAPSC Network Page 1 of 2Introduction of a new service and parts support network for International Transmissions Limited from February 17th2002 All previous parts ordering through JCB Burlington Canada and JCB Savannah USA will be discontinued andnew accounts for each OEM will be opened with ITL NAPSCITL North American Product Support Center PO Box 1000 Harrow Ontario NOR 1GOServices available to the OEM 1 1 866 734 8562 1 866 73 ITL NA toll free number Fax 519 738 3477 or email Parts supply availability and pricing information Contact Colin Sellick ext 2263 Shipping out of Harrow Ontario or USA address PO Box 312547 Detroit MI 4823125474 Help ensuring correct parts needed are identified5 Technical support contact Ron Peters ext 2386 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 max7 Parts discount level ITL list less 30 Emergency parts orders shipped next Business day 5 Surcharge CriticalVD vehicle down orders placed before 300 pm local NAPSC time shipped with 7 premium 40 discount on stock orders minimum value 500000 excluding shipping costs Orders limited to 2 stock orders per year and terms CIF at the OEM Leadtime for stock orders despatch 6 weeks Any type of shipping method can be specified and orders can be drop shipped to any address specified in North AmericaAlso Note the introduction of 3 New ITL Principal Service CentersITL PSC California Texas and for ITL Warranty repair workComplete ITL component strip down repair and test facilities unitsCompetent to carry out repairs from the end user subject to OEM Service CentersLeaman Equipment Co16550 Railroad Ave LMorgan Hill CA 95037 Tel 408 778 9677 Fax 408 778 9646CIA Machinery INC3199 West Danieldale StLancaster TX 75134 Tel 972 224 5501 or 800 527 6406 Fax 972 224 8204 continued THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOMPage 2 of 2 Gn 038 Issue 1Great Lakes Power Products2006 Tobsal CourtWarren MI 48091 Tel 810 759 5500 Fax 810 759 0879ITL Service CentersCenters throughout USA and Canada In the event of repair work needed contact ITL Service Department KeithBridges in UK Tel 01144 1978 6665131 Approved for ITL Warranty work2 Provide Support for OEM vehicle repairs3 Competent to carry out repairs for the end user subject to ITL and OEM approvalOEMs capable of carrying out repairs through their own dealership should continue to operate as normal Theymay find the ITL Principal Service Centers particularly useful in those cases where expert internal repairs with or without their own dealer back up can take full advantage of the ITL Service Centers Howeverbefore initially approaching a Service Center we ask that our Service Department be contacted first in orderthat ITL can give the OEM or your customer an introduction and help ensure that the Service Centers are fully awareof any special instructions or needs you may haveIn 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 Gn039engineer has a sound knowledge of safety procedures and has been trained in the JCB Gen 151maintenance and repair of ITL equipment If you are unsure or do not contained in the Service Bulletins then ask your supervisor for advice Issue 1Remember SAFETY MUST COME FIRST Date Sep 2002SUBJECT Safety precautions when an engine is cleaned Page 1 of 1PRODUCTS AFFECTED All EnginesTO BE CARRIED OUT Information onlySERVICE should be taken when an engine is cleaned with the use of a high pressure hoseCautions Do not wash an engine while it is running or it is hot If cold cleaning fluids are applied to a hot engine certain components on the engine could be damaged Leave the engine to cool for at least one hour and disconnect battery connections before cleaning Do not wash any part of the Fuel Injection Pump Ensure that the altemator starter motor and any other electrical components are shielded and not directly cleaned by high pressure hose Do not wash the Electrical Shutoff Solenoid ESOS or any electrical components of the FIP when the engine is hotIf these cautions are ignored the engine or certain components could be damaged fail to operate and also make warranty invalid THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF ITL WREXHAM CLWYD LL13 9UF UNITED KINGDOM

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