JCB TRANSMISSION Service Repair Manual Instant Download

1
Service Manual
Transmissions Section 1 - General Information Section 2 - Care and Safety Section A - Axle Hubs Section B - Axle Hubs Swivels and Driveshafts Section C - Axle Integral Brakes Section D - Axle Drive Heads Section E - Manual Gearboxes Section F - Powershift Gearboxes Section G - Transfer Gearboxes Publication No. 9803/8610-14 World Class Customer Support
Copyright 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE. World Class Customer Support
Issued by JCB Technical Publications, JCB
Aftermarket Training, Woodseat, Rocester,
Staffordshire, ST14 5BW, England. Tel 44 1889
591300 Fax [phone]
2
Section i - Front Cover
Notes
i-0
i-0
9803/8610-14
3
Section 1
General Information Service Manual - Transmissions Section 1 - General Information Section 2 - Care and Safety Section A - Axle Hubs Section B - Axle Hubs Swivels and Driveshafts Section C - Axle Integral Brakes Section D - Axle Drive Heads Section E - Manual Gearboxes Section F - Powershift Gearboxes Section G - Transfer Gearboxes Publication No. 9803/8610-14 World Class Customer Support
Copyright 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE. World Class Customer Support
Issued by JCB Technical Publications, JCB
Aftermarket Training, Woodseat, Rocester,
Staffordshire, ST14 5BW, England. Tel 44 1889
591300 Fax [phone]
4
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Section 1 - General Information
Notes
1-0
1-0
9803/8610-14
6
Section 1 - General Information
Contents Page No. About This Manual Scope
..................................................
..................................................
.. 1 - 1 Axles ...................................
..................................................
................... 1 - 2 Axle Sub-assembly
Identification ...................................
.................... 1 - 2 Applicable Machines
..................................................
.............................. 1 - 3 Working
Practice .........................................
.......................................... 1 -
10 Torque Settings Zinc Plated Fasteners and
Dacromet Fasteners ...............................
.... 1 - 11 Introduction ........................
..................................................
............. 1 - 11 Bolts and Screws
..................................................
............................ 1 - 11 Hydraulic
Connections ......................................
..................................... 1 - 15 'O'
Ring Face Seal System ............................
................................... 1 -
15 'Torque Stop' Hose System .....................
......................................... 1 -
18 Service Tools Numerical List
..................................................
...................................... 1 -
19 Tool Detail Reference .........................
..................................................
. 1 - 21 Service Aids Sealing and Retaining
Compounds ........................................
............... 1 - 38
1 - i
1 - i
7
Section 1 - General Information
Page No.
Contents
1 - i
1 - ii
8
Section 1 - General Information About This
Manual Scope
The publication is built up in a modular way to
include procedures for dismantling, inspection
and assembly of JCB axles and gearboxes. It
should be noted that procedures given in this
manual are for transmission assemblies only.
Service procedures specific to machine
transmission installations are given in the
relevant machine service manual. When
applicable, procedures in this manual are
referred to in the JCB machine service manual.
To check the cross reference see the
transmission Technical Data pages in the machine
service manual. There are many transmission
variants, ensure that you are referencing the
correct procedures for the applicable
transmission assembly.
9
Section 1 - General Information About This
Manual Axles Axles
Because axles are modular many axle sizes and
types are manufactured using a small number of
sub-assemblies.
For this reason the procedures in this manual are
for axle sub-assemblies not complete axle
assemblies. This means that procedures appear
only once.
Axle Sub-assembly Identification
Sub-assembly Section Typical Axle Assemblies
Axle Hubs (Includes hubs with integral brakes) A
Axle Hub Swivels and Driveshafts B
Axle Integral Brakes C
Axle Drive Heads (Includes drive heads for 1 piece axles (A) and 3 piece axles (B)) D A B
10
Section 1 - General Information About This
Manual Applicable Machines Applicable Machines
The tables show which transmission dismantle and
assembly procedure is applicable to which
machine. Use the cross references to the
procedures in this manual.
K Gearbox Procedures ( 1-3) K Front Axle
Procedures ( 1-4) K Rear Axle Procedures
( 1-6) K Brakes Procedures ( 1-8) K Transfer
Gearbox Procedures ( 1-9)
Important One machine model can have more than
one transmission option. Always cross check the
Transmission Techinical Data in the applicable
Machine Service Manual for the correct
transmission component information.
Table 1. Gearbox Procedures
Machines Service Manual Procedures Procedures
Machines Service Manual Manual Gearboxes(1) Powershift Gearboxes(1)
Backhoe Loaders Section E Section F
2CX, 212 - 930000 on 9803/7130 SS500 Synchro Shuttle -
3CX - 960001 on 9803/3290 SS700 Synchro Shuttle -
3CX - 960001 on 9803/3290 SS700 Type 2 Synchro Shuttle -
3CX, 4CX 960001 on 9803/3290 - PS766 and PS764 - 2004 model Powershift
Loadalls
Side Engined 768740 to 1185999 9803/3630 - PS700 Powershift
Side Engined 768740 to 1185999 9803/3630 - PS750 Powershift(2)
Side Engined up to 10.5m lift height - 1186000 to 1507999 9803/3730 - PS750 Powershift, PS750 Powershift MkIII, PS766 and PS764 - 2004 model Powershift
Side Engined over 10.5m lift height - 1186000 to 1507999 9803/3730 - PS750 Powershift , PS750 Powershift MkIII
Side Engined - 506-36, 507-42, 509-42, 510-55 - 1402000 on 9803/3740 - PS750 Powershift MkIII, PS750 Powershift MKIV
Side Engined Construction Machines 1508000 on 9803/3750 PS750 Powershift MkIII, PS750 Powershift MKIV, PS766 and PS764 - 2004 model Powershift
Side Engined Agricultural Machines 1508000 on 9803/3760 SS700 Type 2 Synchro Shuttle PS750 Powershift MkIII, PS750 Powershift MKIV, PS766 and PS764 - 2004 model Powershift
Rear Engined 1182000 on 9803/3710 SS600 Synchro Shuttle PS750 Powershift, PS750 Powershift MkIII
Rough Terrain Fork Lifts
921, 926, 930, 940 - 600001 on 9803/5100 SS600 Synchro Shuttle -

1. Includes procedures for 2WD and 4WD gearboxes if
   applicable
2. Includes the 5 speed variant

11
Section 1 - General Information About This
Manual Applicable Machines Table 2. Front Axle
Procedures
Machines Service Manual Procedures Procedures Procedures
Machines Service Manual Drive Head Hub Swivel and Driveshaft Hub
Machines Service Manual Section D Section B Section A
Backhoe Loaders
Midi 9803/9400 40 Series Drive Head (3 Piece Axles) - 40 Series Hub
2CX, 212 - 930000 on 9803/7130 55 and 80 Series Drive Head (1 Piece Axles) - 55 and 70 Series Hub
3CX (2WS, 2WD) - 960001 on 9803/3290 - Refer to Hub Dead Steer Hub
3CX, 4CX (2WS, 4WD) - 960001 on 9803/3290 55 and 80 Series Drive Head (1 Piece Axles) 55 Series Hub Swivel and Diveshaft 55 and 70 Series Hub
3CX, 4CX (4WS, 4WD) - 960001 on 9803/3290 55 and 80 Series Drive Head (1 Piece Axles) 55 Series Hub Swivel and Diveshaft 80 Series Hub
Loadalls
Side Engined - 768740 to 1185999 9803/3630 80 Series Drive Head (3 Piece Axles) 55 Series Hub Swivel and Diveshaft 80 Series Hub
Side Engined - 1186000 to 1507999 9803/3730 80 Series Drive Head (3 Piece Axles) 55 Series Hub Swivel and Diveshaft 80 Series Hub
Side Engined - 506-36 - 1402000 on 9803/3740 80 Series Drive Head (3 Piece Axles) 55 Series Hub Swivel and Diveshaft 55 Series Hub
Side Engined - 507-42, 509-42, 510-55 - 1402000 on 9803/3740 80 Series Drive Head (3 Piece Axles) 55 Series Hub Swivel and Diveshaft 80 Series Hub
Side Engined low boom'- 1186000 to 1507999 9803/3730 80 Series Drive Head (3 Piece Axles) 55 Series Hub Swivel and Diveshaft 80 Series Hub
Side Engined Construction Machines - 1508000 on 9803/3750 80 Series Drive Head (3 Piece Axles) 55 Series Hub Swivel and Diveshaft 80 Series Hub
Side Engined Agricultural Machines - 1508000 on 9803/3760 80 Series Drive Head (3 Piece Axles) 55 Series Hub Swivel and Diveshaft 55 and 70 Series Hub, 80 Series Hub
Side Engined Hydrostatic Machines - 527-58 - 1473000 on 9813/0200 55 Series Drive Head (3 Piece Axles) 55 Series Hub Swivel and Diveshaft 55 and 70 Series Hub
12
Section 1 - General Information About This
Manual Applicable Machines
Machines Service Manual Procedures Procedures Procedures
Machines Service Manual Drive Head Hub Swivel and Driveshaft Hub
Machines Service Manual Section D Section B Section A
Rear Engined 1182000 on 9803/3710 80 Series Drive Head (3 Piece Axles) 55 Series Hub Swivel and Diveshaft 80 Series Hub
Compact - 515-40,520-40 from 1012000 9803/3690 40 Series Drive Head (1 Piece Axles) 40 Series Hub Swivel and Driveshaft 40 Series Hub
Compact 524-50,527-55 from 1068000 9803/3690 55 and 80 Series Drive Head (1 Piece Axles) 55 Series Hub Swivel and Diveshaft 40 Series Hub
Rough Terrain Fork Lifts
921, 926, 930, 940 - 600001 on 9803/5100 80 Series Drive Head (3 Piece Axles) 70 Series Driveshaft 55 and 70 Series Hub
13
Section 1 - General Information About This
Manual Applicable Machines Table 3. Rear Axle
Procedures
Machines Service Manual Procedures Procedures Procedures
Machines Service Manual Drive Head Hub Swivel and Driveshaft Hub
Machines Service Manual Section D Section B Section A
Backhoe Loaders
Midi 9803/9400 40 Series Drive Head and Drop Box (3 Piece Axles) 70 Series Driveshaft 40 Series Hub
2CX, 212 - 930000 on 9803/7130 80 Series Drive Head (3 Piece Axles) 70 Series Driveshaft 55 and 70 Series Hub
3CX (2WS, 2WD) - 960001 on 9803/3290 80 Series Drive Head (3 Piece Axles) 70 Series Driveshaft 55 and 70 Series Hub
3CX, 4CX (2WS, 4WD) - 960001 on 9803/3290 80 Series Drive Head (3 Piece Axles) 70 Series Driveshaft 55 and 70 Series Hub
3CX, 4CX (4WS, 4WD) - 960001 on 9803/3290 80 Series Drive Head (3 Piece Axles) 55 Series Hub Swivel and Driveshaft 80 Series Hub
Loadalls
Side Engined up to 10.5 metre lift height - 768740 to 1185999 9803/3630 55 and 80 Series Drive Head (1 Piece Axles) 55 Series Hub Swivel and Driveshaft 55 and 70 Series Hub
Side Engined over 10.5 metre lift height - 768740 to 1185999 9803/3630 55 and 80 Series Drive Head (1 Piece Axles) 55 Series Hub Swivel and Driveshaft 80 Series Hub with Integral Brake
Side Engined up to 10.5 metre lift height - 1186000 to 1507999 9803/3730 55 and 80 Series Drive Head (1 Piece Axles) 55 Series Hub Swivel and Driveshaft 55 and 70 Series Hub
Side Engined low boom'- 1186000 to 1507999 9803/3730 80 Series Drive Head (3 Piece Axles) 55 Series Hub Swivel and Driveshaft 80 Series Hub
Side Engined - 506-36 - 1402000 on 9803/3740 55 Series Drive Head (1 Piece Axles) 55 Series Hub Swivel and Driveshaft 55 Series Hub
Side Engined - 507-42, 509-42, 510-55 - 1402000 on 9803/3740 80 Series Drive Head (3 Piece Axles) 55 Series Hub Swivel and Driveshaft 55 Series Hub
Side Engined over 10.5 metre lift height - 1186000 to 1507999 9803/3730 55 and 80 Series Drive Head (1 Piece Axles) 55 Series Hub Swivel and Driveshaft 80 Series Hub with Integral Brake
14
Section 1 - General Information About This
Manual Applicable Machines
Machines Service Manual Procedures Procedures Procedures
Machines Service Manual Drive Head Hub Swivel and Driveshaft Hub
Machines Service Manual Section D Section B Section A
Side Engined Construction Machines - 1508000 on 9803/3750 55 and 80 Series Drive Head (1 Piece Axles), 80 Series Drive Head (3 Piece Axles) 55 Series Hub Swivel and Driveshaft 80 Series Hub, 80 Series Hub with Integral Brake
Side Engined Agricultural Machines - 1508000 on 9803/3760 55 and 80 Series Drive Head (1 Piece Axles) 55 Series Hub Swivel and Driveshaft 55 and 70 Series Hubs
Side Engined Hydrostatic Machines - 527-58 - 1473000 on 9813/0200 55 and 80 Series Drive Head (1 Piece Axles) 55 Series Hub Swivel and Diveshaft 55 and 70 Series Hub
Rear Engined 1182000 on 9803/3710 80 Series Drive Head (3 Piece Axles) 55 Series Hub Swivel and Driveshaft 80 Series Hub
Compact 515-40,520-40 from 1012000 9803/3690 40 Series Drive Head (1 Piece Axles) 40 Series Hub Swivel and Driveshaft 40 Series Hub
Compact 524-50,527-55 from 1068000 9803/3690 55 and 80 Series Drive Head (1 Piece Axles) 55 Series Hub Swivel and Diveshaft 40 Series Hub
Rough Terrain Fork Lifts
921, 926, 930, 940 2WD - 600001 on 9803/5100 - - Dead Steer Hub
921, 926, 930, 940 4WD - 600001 on 9803/5100 55 and 80 Series Drive Head (1 Piece Axles) 55 Series Hub Swivel and Diveshaft 55 and 70 Series Hub
15
Section 1 - General Information About This
Manual Applicable Machines Table 4. Brakes
Procedures
Machines Service Manual Procedures Procedures
Machines Service Manual Axle Integral Brakes Hub Brakes
Machines Service Manual Section C Section A
Backhoe Loaders
Midi 9803/9400 40 Series Integral Brakes (3 Piece Axles) -
2CX, 212 - 930000 on 9803/7130 70 Series Integral Brakes (3 Piece Axles) -
3CX ,4CX - 960001 on 9803/3290 70 Series Integral Brakes (3 Piece Axles) -
Loadalls
Side Engined up to 10.5 metre lift height - 768740 to 1185999 9803/3630 70 Series Integral Brakes (3 Piece Axles) -
Side Engined over 10.5 metre lift height - 768740 to 1185999 9803/3630 70 Series Integral Brakes (3 Piece Axles) 80 Series Hub with Integral Brake
Side Engined up to 10.5 metre lift height - 1186000 to 1507999 9803/3730 70 Series Integral Brakes (3 Piece Axles) -
Side Engined low boom'- 1186000 to 1507999 9803/3730 70 Series Integral Brakes (3 Piece Axles) 70 Series Integral Brakes (3 Piece Axles)
Side Engined - 506-36 - 1402000 on 9803/3740 70 Series Integral Brakes (3 Piece Axles)
Side Engined - 507-42, 509-42, 510-55 - 1402000 on 9803/3740 70 Series Integral Brakes (3 Piece Axles)
Side Engined over 10.5 metre lift height - 1186000 to 1507999 9803/3730 70 Series Integral Brakes (3 Piece Axles) 80 Series Hub with Integral Brake
Side Engined Construction Machines - 1508000 on 9803/3750 70 Series Integral Brakes (3 Piece Axles) 80 Series Hub with Integral Brake
Side Engined Agricultural Machines -1508000 on 9803/3760 70 Series Integral Brakes (3 Piece Axles) -
Side Engined Hydrostatic Machines - 527-58 - 1473000 on 9813/0200 70 Series Integral Brakes (3 Piece Axles) -
Rear Engined 1182000 on 9803/3710 70 Series Integral Brakes (3 Piece Axles) -
Rough Terrain Fork Lifts
921, 926, 930, 940 - 600001 on 9803/5100 70 Series Integral Brakes (3 Piece Axles) -
16
Section 1 - General Information About This
Manual Applicable Machines Table 5. Transfer
Gearbox Procedures
Machines Service Manual Procedures
Machines Service Manual Section G
Backhoe Loaders
Midi 9803/9400 The drop box is part of the rear axle drive head. K Rear Axle Procedures ( 1-6)
Loadalls
Side Engined - 768740 to 1185999 9803/3630 Bevel Gearbox
Side Engined - 1186000 to 1507999 9803/3730 Bevel Gearbox
Side Engined - 506-36, 507-42, 509-42, 510-55 - 1402000 on 9803/3740 Bevel Gearbox
Side Engined Construction Machines - 1508000 on 9803/3750 Bevel Gearbox
Side Engined Agricultural Machines - 1508000 on 9803/3760 Bevel Gearbox
Rear Engined 1182000 on 9803/3710 70 Series Drop Box
Compact 515-40,520-40 from 1012000 9803/3690 HG 310
Compact 524-50,527-55 from 1068000 to 1069457 9803/3690 HG 700
17
Section 1 - General Information About This
Manual Working Practice Working Practice This
publication is designed for the benefit of JCB
Distributor Service Engineers who are receiving,
or have received, training by JCB Technical
Training Department. These personnel should have
a sound knowledge of workshop practice, safety
procedures, and general techniques associated
with the maintenance and repair of earthmoving
transmissions. Renewal of oil seals, gaskets,
etc., and any component showing obvious signs of
wear or damage is expected as a matter of
course. Cleanliness is of the utmost importance
when servicing transmission assemblies, be sure
to take every precaution to prevent the ingress
of dirt and debris. Finally, please remember
above all else SAFETY MUST COME FIRST!
18
Section 1 - General Information Torque
Settings Zinc Plated Fasteners and Dacromet
Fasteners Torque Settings Zinc Plated Fasteners
and Dacromet Fasteners T11-002
Introduction
Bolts and Screws
Some external fasteners on JCB machines are
manufactured using an improved type of corrosion
resistant finish. This type of finish is called
Dacromet and replaces the original Zinc and
Yellow Plating used on earlier machines.
Use the following torque setting tables only
where no torque setting is specified in the text.
Note Dacromet fasteners are lubricated as part
of the plating process, do not lubricate.
The two types of fasteners can be readily
identified by colour and part number suffix. K
Table 6. Fastener Types ( 1-11).
Torque settings are given for the following
conditions
Condition 1

• Un-lubricated fasteners
• Zinc fasteners
• Yellow plated fasteners

Table 6. Fastener Types
Fastener Type Colour Part No. Suffix
Zinc and Yellow Golden finish 'Z' (e.g. 1315/3712Z)
Dacromet Mottled silver finish 'D' (e.g. 1315/3712D)
Condition 2

• Zinc flake (Dacromet) fasteners
• Lubricated zinc and yellow plated fasteners
• Where there is a natural lubrication. For
  example, cast iron components

Note As the Dacromet fasteners have a lower
torque setting than the Zinc and Yellow
fasteners, the torque figures used must be
relevant to the type of fastener.
Note A Dacromet bolt should not be used in
conjunction with a Zinc or Yellow plated nut, as
this could change the torque characteristics of
the torque setting further. For the same reason,
a Dacromet nut should not be used with a Zinc or
Yellow plated bolt.
Verbus Ripp Bolts
Note All bolts used on JCB machines are high
tensile and must not be replaced by bolts of a
lesser tensile specification.
Fig 1.
Note Dacromet bolts, due to their high corrosion
resistance are used in areas where rust could
occur. Dacromet bolts are only used for external
applications. They are not used in applications
such as gearbox or engine joint seams or
internal applications.
Torque settings for these bolts are determined by
the application. Refer to the relevant procedure
for the required settings.
19
Section 1 - General Information Torque
Settings Zinc Plated Fasteners and Dacromet
Fasteners Table 7. Torque Settings - UNF Grade
'S' Fasteners
Bolt Size Bolt Size Hexagon (A/F) Condition 1 Condition 1 Condition 1 Condition 2 Condition 2 Condition 2
in. mm in. Nm kgf m lbf ft Nm kgf m lbf ft
1/4 6.3 7/16 11.2 1.1 8.3 10.0 1.0 7.4
5/16 7.9 1/2 22.3 2.3 16.4 20.0 2.0 14.7
3/8 9.5 9/16 40.0 4.1 29.5 36.0 3.7 26.5
7/16 11.1 5/8 64.0 6.5 47.2 57.0 5.8 42.0
1/2 12.7 3/4 98.00 10.0 72.3 88.0 9.0 64.9
9/16 14.3 13/16 140.0 14.3 103.2 126.0 12.8 92.9
5/8 15.9 15/16 196.0 20.0 144.6 177.0 18.0 130.5
3/4 19.0 1 1/8 343.0 35.0 253.0 309.0 31.5 227.9
7/8 22.2 1 15/16 547.0 55.8 403.4 492.0 50.2 362.9
1 25.4 1 1/2 814.0 83.0 600.4 732.0 74.6 539.9
1 1/8 31.7 1 7/8 1181.0 120.4 871.1 1063.0 108.4 784.0
1 1/4 38.1 2 1/4 1646.0 167.8 1214.0 1481.0 151.0 1092.3
Table 8. Torque Settings - Metric Grade 8.8
Fasteners
Bolt Size Bolt Size Hexagon (A/F) Condition 1 Condition 1 Condition 1 Condition 2 Condition 2 Condition 2
ISO Metric Thread mm mm Nm kgf m lbf ft Nm kgf m lbf ft
M5 5 8 5.8 0.6 4.3 5.2 0.5 3.8
M6 6 10 9.9 1.0 7.3 9.0 0.9 6.6
M8 8 13 24.0 2.4 17.7 22.0 2.2 16.2
M10 10 17 47.0 4.8 34.7 43.0 4.4 31.7
M12 12 19 83.0 8.5 61.2 74.0 7.5 54.6
M16 16 24 205.0 20.9 151.2 184.0 18.8 135.7
M20 20 30 400.0 40.8 295.0 360.0 36.7 265.5
M24 24 36 690.0 70.4 508.9 621.0 63.3 458.0
M30 30 46 1372.0 139.9 1011.9 1235.0 125.9 910.9
M36 36 55 2399.0 244.6 1769.4 2159.0 220.0 1592.4
20
Section 1 - General Information Torque
Settings Zinc Plated Fasteners and Dacromet
Fasteners Table 9. Metric Grade 10.9 Fasteners
Bolt Size Bolt Size Hexagon (A/F) Condition 1 Condition 1 Condition 1 Condition 2 Condition 2 Condition 2
ISO Metric Thread mm mm Nm kgf m lbf ft Nm kgf m lbf ft
M5 5 8 8.1 0.8 6.0 7.3 0.7 5.4
M6 6 10 13.9 1.4 10.2 12.5 1.3 9.2
M8 8 13 34.0 3.5 25.0 30.0 3.0 22.1
M10 10 17 67.0 6.8 49.4 60.0 6.1 44.2
M12 12 19 116.0 11.8 85.5 104.0 10.6 76.7
M16 16 24 288.0 29.4 212.4 259.0 26.4 191.0
M20 20 30 562.0 57.3 414.5 506.0 51.6 373.2
M24 24 36 971.0 99.0 716.9 874.0 89.1 644.6
M30 30 46 1930.0 196.8 1423.5 1737.0 177.1 1281.1
M36 36 55 3374.0 344.0 2488.5 3036.0 309.6 2239.2
Table 10. Metric Grade 12.9 Fasteners
Bolt Size Bolt Size Hexagon (A/F) Condition 1 Condition 1 Condition 1 Condition 2 Condition 2 Condition 2
ISO Metric Thread mm mm Nm kgf m lbf ft Nm kgf m lbf ft
M5 5 8 9.8 1.0 7.2 8.8 0.9 6.5
M6 6 10 16.6 1.7 12.2 15.0 1.5 11.1
M8 8 13 40.0 4.1 29.5 36.0 3.7 26.5
M10 10 17 80.0 8.1 59.0 72.0 7.3 53.1
M12 12 19 139.0 14.2 102.5 125.0 12.7 92.2
M16 16 24 345.0 35.2 254.4 311.0 31.7 229.4
M20 20 30 674.0 68.7 497.1 607.0 61.9 447.7
M24 24 36 1165.0 118.8 859.2 1048.0 106.9 773.0
M30 30 46 2316.0 236.2 1708.2 2084.0 212.5 1537.1
M36 36 55 4049.0 412.9 2986.4 3644.0 371.6 2687.7
21
Section 1 - General Information Torque
Settings Zinc Plated Fasteners and Dacromet
Fasteners Table 11. Torque Settings - Rivet Nut
Bolts/Screws
Bolt Size Bolt Size Nm kgf m lbf ft
ISO Metric Thread mm Nm kgf m lbf ft
M3 3 1.2 0.1 0.9
M4 4 3.0 0.3 2.0
M5 5 6.0 0.6 4.5
M6 6 10.0 1.0 7.5
M8 8 24.0 2.5 18.0
M10 10 48.0 4.9 35.5
M12 12 82.0 8.4 60.5
Table 12. Torque Settings - Internal Hexagon
Headed Cap Screws (Zinc)
Bolt Size Nm kgf m lbf ft
ISO Metric Thread Nm kgf m lbf ft
M3 2.0 0.2 1.5
M4 6.0 0.6 4.5
M5 11.0 1.1 8.0
M6 19.0 1.9 14.0
M8 46.0 4.7 34.0
M10 91.0 9.3 67.0
M12 159.0 16.2 117.0
M16 395.0 40.0 292.0
M18 550.0 56.0 406.0
M20 770.0 79.0 568.0
M24 1332.0 136.0 983.0
22
Section 1 - General Information Torque
Settings Hydraulic Connections Hydraulic
Connections T11-003 'O' Ring Face Seal
System Adaptors Screwed into Valve
Blocks Adaptor screwed into valve blocks, seal
onto an 'O' ring which is compressed into a 45
seat machined into the face of the tapped
port. Table 13. Torque Settings - BSP Adaptors
BSP Adaptor Size Hexagon (A/F) Nm kgf m lbf ft
in. mm Nm kgf m lbf ft
1/4 19.0 18.0 1.8 13.0
3/8 22.0 31.0 3.2 23.0
1/2 27.0 49.0 5.0 36.0
5/8 30.0 60.0 6.1 44.0
3/4 32.0 81.0 8.2 60.0
1 38.0 129.0 13.1 95.0
1 1/4 50.0 206.0 21.0 152.0
Table 14. Torque Settings - SAE Connections
SAE Tube Size SAE Port Thread Size Hexagon (A/F) Nm kgf m lbf ft
SAE Tube Size SAE Port Thread Size mm Nm kgf m lbf ft
4 7/16 - 20 15.9 20.0 - 28.0 2.0 - 2.8 16.5 - 18.5
6 9/16 - 18 19.1 46.0 - 54.0 4.7 - 5.5 34.0 - 40.0
8 3/4 - 16 22.2 95.0 - 105.0 9.7 - 10.7 69.0 - 77.0
10 7/8 - 14 27.0 130.0 - 140.0 13.2 - 14.3 96.0 - 104.0
12 1 1/16 - 12 31.8 190.0 - 210.0 19.4 - 21.4 141.0 - 155.0
16 1 5/16 - 12 38.1 290.0 - 310.0 29.6 - 31.6 216.0 - 230.0
20 1 5/8 47.6 280.0 - 380.0 28.5 - 38.7 210.0 - 280.0
23
Section 1 - General Information Torque
Settings Hydraulic Connections
Hoses Screwed into Adaptors
Fig 2.
Hoses 2-B screwed into adaptors 2-A seal onto an
O' ring 2-C which is compressed into a 45 seat
machined into the face of the adaptor port.
Note Dimension 2-D will vary depending upon the
torque applied.
Table 15. BSP Hose - Torque Settings
BSP Hose Size Hexagon (A/F) Nm kgf m lbf ft
in. mm Nm kgf m lbf ft
1/8 14.0 14.0 - 16.00 1.4 - 1.6 10.3 - 11.8
1/4 19.0 24.0 - 27.0 2.4 - 2.7 17.7 - 19.9
3/8 22.0 33.0 - 40.0 3.4 - 4.1 24.3 - 29.5
1/2 27.0 44.0 - 50.0 4.5 - 5.1 32.4 - 36.9
5/8 30.0 58.0 - 65.0 5.9 - 6.6 42.8 - 47.9
3/4 32.0 84.0 - 92.0 8.6 - 9.4 61.9 - 67.8
1 38.0 115.0 - 126.0 11.7 - 12.8 84.8 - 92.9
1 1/4 50.0 189.0 - 200.0 19.3 - 20.4 139.4 - 147.5
1 1/2 55.0 244.0 - 260.0 24.9 - 26.5 180.0 - 191.8
24
Section 1 - General Information Torque
Settings Hydraulic Connections Adaptors into
Component Connections with Bonded Washers Table
16. BSP Adaptors with Bonded Washers - Torque
Settings
BSP Size Nm kgf m lbf ft
in. Nm kgf m lbf ft
1/8 20.0 2.1 15.0
1/4 34.0 3.4 25.0
3/8 75.0 7.6 55.0
1/2 102.0 10.3 75.0
5/8 122.0 12.4 90.0
3/4 183.0 18.7 135.0
1 203.0 20.7 150.0
1 1/4 305.0 31.0 225.0
1 1/2 305.0 31.0 225.0
25
Section 1 - General Information Torque
Settings Hydraulic Connections
'Torque Stop' Hose System
Fig 3.
Torque Stop' Hoses 3-B screwed into adaptors 3-A
seal onto an 'O' ring 3-C which is compressed
into a 45 seat machined in the face of the
adaptor port. To prevent the 'O' ring being
damages as a result of over tightening, 'Torque
Stop' Hoses have an additional shoulder 3-D,
which acts as a physical stop.
Note Minimum dimension 3-E fixed by shoulder 3-D.
Table 17. BSP Torque Stop' Hose - Torque Settings
BSP Hose Size Hexagon (A/F) Nm kgf m lbf ft
in. mm Nm kgf m lbf ft
1/8 14.0 14.0 1.4 10.0
1/4 19.0 27.0 2.7 20.0
3/8 22.0 40.0 4.1 30.0
1/2 27.0 55.0 5.6 40.0
5/8 30.0 65.0 6.6 48.0
3/4 32.0 95.0 9.7 70.0
1 38.0 120.0 12.2 89.0
1 1/4 50.0 189.0 19.3 140.0
1 1/2 55.0 244.0 24.9 180.0
26
Section 1 - General Information Service
Tools Numerical List Service Tools Numerical List
The tools listed in the table are special tools
required for dismantling and assembly of the JCB
transmissions covered in this publication. These
tools are available from JCB Service or, in some
instances, can be manufactured locally from
specifications given in this section.
Some tools are supplied as kits. Cross references
are given to tables showing kit contents.
Note Tools other than those listed will be
required. It is expected that such general tools
will be available in any well equipped workshop
or be available locally from any good tool
supplier.
For lists of tools required for a given axle or
gearbox see the relevant transmission section.
Part Description Used In Tool Detail Reference
Number Section
- Torque measuring tool - Wheel hub seals A K Fig 4. ( 1-21)
445/04700 Shim Kit E K Fig 5. ( 1-21)
459/70378 Spacer Kit E K Fig 6. ( 1-22)
459/70379 Spacer Kit E K Fig 7. ( 1-22)
823/10420 Thrust washer kit F K Fig 8. ( 1-23)
823/10547 Spacer Kit F K Fig 9. ( 1-23)
921/M0229 Shim Kit D K Fig 10. ( 1-23)
921/M0103 Spacer Kit D K Fig 11. ( 1-24)
921/52100 Spacer Kit D K Fig 12. ( 1-24)
892/00174 Measuring cup D K Fig 13. ( 1-24)
892/00179 Bearing press A, E K Fig 14. ( 1-25)
892/00182 Bearing pad driver -
892/00224 Impulse extractor B K Fig 16. ( 1-25)
892/00225 Adaptor for extractor -
892/00295 End float setting tool F K Fig 17. ( 1-25)
892/00333 Heavy duty socket - 19mm A K Fig 18. ( 1-25)
892/00812 Drive coupling spanner D, E, F K Fig 19. ( 1-25)
892/00819 Heavy duty socket - 15mm D -
892/00891 Wheel hub seal dolly A K Fig 32. ( 1-29)
892/00912 Heavy duty socket - 46mm G -
892/00914 Heavy duty socket - 55mm G -
892/00915 Reaction block fixture G K Fig 20. ( 1-26)
892/00918 Setting tool kit D, E, F K Fig 21. ( 1-26)
892/01064 Adaptor spanner E K Fig 22. ( 1-26)
892/01065 Holding fixture E K Fig 23. ( 1-26)
27
Section 1 - General Information Service
Tools Numerical List
Part Number Description Used In Section Tool Detail Reference
892/01075 Support bracket D K Fig 24. ( 1-26)
892/01076 Support bracket E K Fig 25. ( 1-27)
892/01077 Selector shaft lock screw E K Fig 26. ( 1-27)
892/01078 Mainshaft adjuster E K Fig 27. ( 1-27)
892/01079 Ring socket spanner - mainshaft setting ring E K Fig 28. ( 1-27)
892/01080 Ring socket spanner - layshaft setting ring E K Fig 29. ( 1-27)
892/01082 Assembly cradle F K Fig 31. ( 1-28)
892/01083 Assembly tool, transfer gear F -
892/01084 Bearing assembly tool F -
892/01085 Seal fitting tool F -
892/01092 Wheel hub service kit A K Fig 32. ( 1-29)
892/01237 Park brake lock-up tool D K Fig 30. ( 1-27)
921/01900 Shim Kit D K Fig 34. ( 1-31)
921/02200 Shim Kit E K Fig 35. ( 1-31)
921/51700 Shim Kit E K Fig 36. ( 1-31)
921/52100 Shim Kit D K Fig 37. ( 1-32)
921/52600 Spacer Kit E, F K Fig 38. ( 1-32)
921/52620 Spacer (13.70mm service use) E, F K Fig 39. ( 1-32)
921/52627 Spacer (14.20 mm service use) D K Fig 40. ( 1-32)
921/53300 Spacer Kit D K Fig 41. ( 1-33)
921/53400 Spacer Kit D, E K Fig 42. ( 1-33)
921/53700 Shim Kit F K Fig 43. ( 1-34)
992/04800 Flange spanner E, F K Fig 44. ( 1-34)
993/59300 Pressure test adaptor and clamp F K Fig 45. ( 1-34)
993/59400 End float setting tool E K Fig 46. ( 1-35)
993/59500 Impulse extractor adapter B K Fig 16. ( 1-25)
993/70100 End float setting tool kit F K Fig 47. ( 1-36)
993/70111 Breakback torque wrench D, E, F K Fig 48. ( 1-37)
997/11000 Support bracket D K Fig 49. ( 1-37)
998/10738 Adaptor spanner F K Fig 50. ( 1-37)
998/M1374 M14 Stud (use with 998/M1375) 4 off required A K Fig 51. ( 1-37)
998/M1375 Reaction plate A K Fig 51. ( 1-37)
990/00083 End float setting tool E K Fig 33. ( 1-31)
28
Section 1 - General Information Service
Tools Tool Detail Reference Tool Detail
Reference Note Not all service tools are
illustrated. Illustrations are shown in tool
number order.
Fig 4. Torque Measuring Tool -
Wheel Hub Seals
Manufacture locally. The procedures in this
manual show checking the wheel hub seal drag
using a rolling force. However, the torque can
be measured using the above locally manufactured
tool.
747030-C1 Fig 5. 445/04700 Shim Kit 747030-C1 Fig 5. 445/04700 Shim Kit
Item Description
1 445/04701 Shim - 0.05mm thick
2 445/04702 Shim - 0.1mm thick
3 445/04703 Shim - 0.2mm thick
4 445/04704 Shim - 0.5mm thick
5 445/04705 Shim - 1.0mm thick
Note After using a shim, obtain a replacement to keep the set complete. Note After using a shim, obtain a replacement to keep the set complete.
29
Section 1 - General Information Service
Tools Tool Detail Reference
747030-C1 Fig 6. 459/70378 Spacer Kit 747030-C1 Fig 6. 459/70378 Spacer Kit
Item Description
1 823/10647 Spacer - 17.80mm thick
2 823/10648 Spacer - 17.85mm thick
3 823/10649 Spacer - 17.90mm thick
4 823/10650 Spacer - 17.95mm thick
5 823/10651 Spacer - 18.00mm thick
6 823/10652 Spacer - 18.05mm thick
7 823/10653 Spacer - 18.10mm thick
8 823/10654 Spacer - 18.15mm thick
9 823/10655 Spacer - 18.20mm thick
10 823/10656 Spacer - 18.25mm thick
11 823/10657 Spacer - 18.30mm thick
12 823/10658 Spacer - 18.35mm thick
13 823/10659 Spacer - 18.40mm thick
14 823/10660 Spacer - 18.45mm thick
15 823/10661 Spacer - 18.50mm thick
16 823/10662 Spacer - 18.55mm thick
17 823/10663 Spacer - 18.60mm thick
18 823/10665 Spacer - 18.65mm thick
19 823/10666 Spacer - 18.70mm thick
20 823/10667 Spacer - 18.75mm thick
21 823/10668 Spacer - 18.80mm thick
22 823/10669 Spacer - 18.85mm thick
23 823/10670 Spacer - 18.90mm thick
24 823/10671 Spacer - 18.95mm thick
25 823/10672 Spacer - 19.00mm thick
26 823/10673 Spacer - 19.05mm thick
27 823/10674 Spacer - 19.10mm thick
28 823/10675 Spacer - 19.15mm thick
29 823/10676 Spacer - 19.20mm thick
Note After using a spacer, obtain a replacement to keep the set complete. Note After using a spacer, obtain a replacement to keep the set complete.
747030-C1 Fig 7. 459/70379 Spacer Kit 747030-C1 Fig 7. 459/70379 Spacer Kit
Item Description
1 823/10679 Spacer - 2.20mm thick
2 823/10680 Spacer - 2.25mm thick
3 823/10681 Spacer - 2.30mm thick
4 823/10682 Spacer - 2.35mm thick
5 823/10683 Spacer - 2.40mm thick
823/10684 Spacer - 2.45mm thick
823/10685 Spacer - 2.50mm thick
823/10686 Spacer - 2.55mm thick
823/10687 Spacer - 2.60mm thick
823/10688 Spacer - 2.65mm thick
823/10689 Spacer - 2.70mm thick
823/10690 Spacer - 2.75mm thick
823/10691 Spacer - 2.80mm thick
823/10692 Spacer - 2.85mm thick
823/10693 Spacer - 2.90mm thick
823/10694 Spacer - 2.95mm thick
823/10695 Spacer - 3.00mm thick
823/10696 Spacer - 3.05mm thick
823/10697 Spacer - 3.10mm thick
823/10698 Spacer - 3.15mm thick
823/10699 Spacer - 3.20mm thick
Note After using a spacer, obtain a replacement to keep the set complete. Note After using a spacer, obtain a replacement to keep the set complete.
30
Section 1 - General Information Service
Tools Tool Detail Reference
Note After using a spacer, obtain a replacement
to keep the set complete.
747030-C1 Fig 8. 823/10420 Thrust Washer Kit 747030-C1 Fig 8. 823/10420 Thrust Washer Kit
Item Description
1 823/10421 Shim - 4.3mm thick
2 823/10422 Shim - 4.4mm thick
3 823/10423 Shim - 4.5mm thick
4 823/10424 Shim - 4.6mm thick
5 823/10425 Shim - 4.7mm thick
6 823/10426 Shim - 4.8mm thick
Note After using a spacer, obtain a replacement to keep the set complete. Note After using a spacer, obtain a replacement to keep the set complete.
747030-C1 Fig 10. 921/M0229 Shim Kit 747030-C1 Fig 10. 921/M0229 Shim Kit
Item Description
1 921/M0230 Shim - 0.15mm thick
2 921/M0231 Shim - 0.2mm thick
3 921/M0232 Shim - 0.25mm thick
4 921/M0233 Shim - 0.5mm thick
5 921/M0234 Shim - 1.0mm thick
Note After using a shim, obtain a replacement to keep the set complete. Note After using a shim, obtain a replacement to keep the set complete.
747030-C1 Fig 9. 823/10547 Spacer Kit 747030-C1 Fig 9. 823/10547 Spacer Kit
Item Description
1 829/30946 Spacer - 13.850mm thick
2 829/30947 Spacer - 13.825mm thick
3 829/30948 Spacer - 13.800mm thick
4 829/30949 Spacer - 13.775mm thick
5 829/30950 Spacer - 13.750mm thick
6 829/30951 Spacer - 13.725mm thick
7 829/30952 Spacer - 13.700mm thick
8 829/30953 Spacer - 13.675mm thick
9 829/30954 Spacer - 13.650mm thick
10 829/30955 Spacer - 13.625mm thick
11 829/30956 Spacer - 13.600mm thick
12 829/30957 Spacer - 13.575mm thick
13 829/30958 Spacer - 13.550mm thick
31
Section 1 - General Information Service
Tools Tool Detail Reference
31 823/M0225 Spacer - 44.915mm thick
Note After using a spacer, obtain a replacement to keep the set complete. Note After using a spacer, obtain a replacement to keep the set complete.
747030-C1 Fig 11. 921/M0103 Spacer Kit 747030-C1 Fig 11. 921/M0103 Spacer Kit
Item Description
1 823/M1095 Spacer - 44.165mm thick
2 823/M0196 Spacer - 44.190mm thick
3 823/M0197 Spacer - 44.215mm thick
4 823/M0198 Spacer - 44.240mm thick
5 823/M0199 Spacer - 44.265mm thick
6 823/M0200 Spacer - 44.290mm thick
7 823/M0201 Spacer - 44.315mm thick
8 823/M0202 Spacer - 44.340mm thick
9 823/M0203 Spacer - 44.365mm thick
10 823/M0204 Spacer - 44.390mm thick
11 823/M0205 Spacer - 44.415mm thick
12 823/M0206 Spacer - 44.440mm thick
13 823/M0207 Spacer - 44.465mm thick
14 823/M0208 Spacer - 44.490mm thick
15 823/M0209 Spacer - 44.515mm thick
16 823/M0210 Spacer - 44.540mm thick
17 823/M0211 Spacer - 44.565mm thick
18 823/M0212 Spacer - 44.590mm thick
19 823/M0213 Spacer - 44.615mm thick
20 823/M0214 Spacer - 44.640mm thick
21 823/M0215 Spacer - 44.665mm thick
22 823/M0216 Spacer - 44.690mm thick
23 823/M0217 Spacer - 44.715mm thick
24 823/M0218 Spacer - 44.740mm thick
25 823/M0219 Spacer - 44.765mm thick
26 823/M0220 Spacer - 44.790mm thick
27 823/M0221 Spacer - 44.815mm thick
28 823/M0222 Spacer - 44.840mm thick
29 823/M0223 Spacer - 44.865mm thick
30 823/M0224 Spacer - 44.890mm thick
747030-C1 Fig 12. 921/52100 Shim Kit 747030-C1 Fig 12. 921/52100 Shim Kit
Item Description
1 921/52108 Shim - 0.2mm thick
2 921/52106 Shim - 0.25mm thick
3 921/52107 Shim - 0.3mm thick
4 921/52104 Shim - 0.5mm thick
5 921/52105 Shim - 1.0mm thick
Note After using a shim, obtain a replacement to keep the set complete. Note After using a shim, obtain a replacement to keep the set complete.
C002510 Fig 13. 892/00174
Measuring Cup
32
Section 1 - General Information Service
Tools Tool Detail Reference
892/00225 Adaptor
993/59500 Adaptor




Fig 14. 892/00179 Bearing Press Fig 14. 892/00179 Bearing Press Fig 14. 892/00179 Bearing Press
992/06300 Bearing Adaptor
992/07609 Bearing Adaptor
992/07610 Bearing Adaptor
992/07611 Bearing Adaptor
992/07612 Bearing Adaptor
992/07613 Bearing Adaptor
992/07613 Bearing Adaptor
Fig 17. 892/00295 End Float Setting Tool
Fig 18. 892/00333 Heavy Duty Socket
Fig 15. 892/00182 Bearing Pad Driver
Fig 19. 892/00812 Drive Coupling
Spanner
Fig 16. 892/00224 Impulse Extractor
33
Section 1 - General Information Service
Tools Tool Detail Reference
Fig 20. 892/00915 Reaction Block
Fixture
Fig 22. 892/01064 Adaptor Spanner
Fig 23. 892/01065 Holding Fixture
1 1a 1b 1c 1d 1e Fig 21. 892/00918 Setting Tool Kit 1 1a 1b 1c 1d 1e Fig 21. 892/00918 Setting Tool Kit
Item Description
1 892/00918 Setting Tool Kit
Additional parts for PS760 series gearboxes only Additional parts for PS760 series gearboxes only
1a 892/01164 Adaptor (PS760 - 2004)
1b 892/01165 Sleeve (PS760 - 2004)
1c 892/01163 Support Bracket (PS760 - 2004)
Additional parts for 40 series drive heads only Additional parts for 40 series drive heads only
1d 998/11350 Adaptor
1e 998/11351 Sleeve (front axles)
998/11352 Sleeve (rear axles)
A396960-C1 Fig 24. 892/01075 Support
Bracket
34
Section 1 - General Information Service
Tools Tool Detail Reference
A396580-C1 Fig 25. 892/01076
Support Bracket
A396590 Fig 28. 892/01079 Ring
Socket Spanner
A396600 Fig 29. 892/01080 Ring
Socket Spanner
A395350 Fig 26. 892/01077 Selector
Shaft Lock Screw
A396510 Fig 27. 892/01078
Mainshaft Adjuster
Fig 30. 892/01237 Park Brake
Lock-Up Tool
35
Section 1 - General Information Service
Tools Tool Detail Reference
620.0
325.0
171.6
103.4
151.9 111.6
20.0
R 5.0 TYP

10.0
168.0 107.3 73.2 REF
160.0
49
R121.0
2
48
51.8
R125.0
600.0
140.1
9
60.7
216.6
263.6
325.6 REF
153.2
R137.0
9
20.0 TYP 9 PLACES
R109.0
R62.0
25.0

2.9
30
53.2
TYP 9 PLACES
95.0
118.7
142.3
746110-C1
A Fig 31. 892/01082 Assembly Cradle
Note Support legs will also be required. These
must be locally manufactured so that the gearbox
can be supported as shown at A.
36
Section 1 - General Information Service
Tools Tool Detail Reference
A 5
1 6 8, 9
7

2 10
3
4
B 15
19,20
13
14
C 16
18
17 8
21
Fig 32. 892/01092 Wheel Hub Service Kit
A Bearing Puller Bearing Puller Bearing Puller Bearing Puller Bearing Puller Bearing Puller
B Bearing Press Bearing Press Bearing Press Bearing Press Bearing Press Bearing Press
C Seal Dolly Seal Dolly Seal Dolly Seal Dolly Seal Dolly Seal Dolly
Comprises of Comprises of Comprises of Comprises of Comprises of Comprises of
1 998/10623 Puller beam - 1off Puller beam - 1off Puller beam - 1off Puller beam - 1off Puller beam - 1off
2 998/1067 Clamp plates - 1off Clamp plates - 1off Clamp plates - 1off Clamp plates - 1off Clamp plates - 1off
3 1315/3731Z Bolt M16 x 220 - 2off Bolt M16 x 220 - 2off Bolt M16 x 220 - 2off Bolt M16 x 220 - 2off Bolt M16 x 220 - 2off
4 1370/0601Z Nut M16 - 2off Nut M16 - 2off Nut M16 - 2off Nut M16 - 2off Nut M16 - 2off
5 998/10614 Reaction tube - 1off Reaction tube - 1off Reaction tube - 1off Reaction tube - 1off Reaction tube - 1off
6 998/10624 Modified wheel stud - 2off Modified wheel stud - 2off Modified wheel stud - 2off Modified wheel stud - 2off Modified wheel stud - 2off
37
Suggest If the above button click is invalid.
Please download this document first, and then
click the above link to download the complete
manual. Thank you so much for reading
38
Section 1 - General Information Service
Tools Tool Detail Reference
7 998/10615 Puller leg - 2off
8 1370/10701Z Nut M20 - 4off
9 1420/0012Z Washer M20
10 998/10610 Rod - 2off
11 1370/0401Z Nut M12 - 2off
12 1420/0009Z Washer M12 - 2off
13 998/10608(1) Bearing centre puller- 1off
14 1315/3414Z Bolt M10 x 60 - 1off
15 1370/0301Z Nut M10 - 1off
16 998/10606 Reaction tube - 1off
17 998/10616 Handle nut - 1off
18 1315/3835Z Bolt M20 x 300 - 2off
19 445/12303 Washer - 2off
20 917/02800 Bearing - 1off
21 892/00891 Seal dolly - 1off
(1) November 2007. Part modified so that it is
compatible with JCB HMEE machines. Make sure you
have the correct part. If necessary get a new
one.
1-30
39
Section 1 - General Information Service
Tools Tool Detail Reference
747030-C1 Fig 36. 921/51700 Shim Kit 747030-C1 Fig 36. 921/51700 Shim Kit
Item Description
1 921/51701 Shim - 0.05mm thick
2 921/51702 Shim - 0.1mm thick
3 921/51703 Shim - 0.2mm thick
4 921/51704 Shim - 0.5mm thick
5 921/51705 Shim - 1.0mm thick
Note After using a shim, obtain a replacement to keep the set complete Note After using a shim, obtain a replacement to keep the set complete
Fig 33. 990/00083 End Float Setting Tool
747030-C1 Fig 34. 921/01900 Shim Kit 747030-C1 Fig 34. 921/01900 Shim Kit
Item Description
1 921/01901 Shim - 0.15mm thick
2 921/01902 Shim - 0.20mm thick
3 921/01903 Shim - 0.25mm thick
4 921/01904 Shim - 0.50mm thick
5 921/01905 Shim - 1.00mm thick
Note After using a shim, obtain a replacement to keep the set complete. Note After using a shim, obtain a replacement to keep the set complete.
747030-C1 Fig 35. 921/02200 Shim Kit 747030-C1 Fig 35. 921/02200 Shim Kit
Item Description
1 921/02201 Shim - 0.05mm thick
2 921/02202 Shim - 0.1mm thick
3 921/02203 Shim - 0.2mm thick
4 921/02204 Shim - 0.5mm thick
5 921/02205 Shim - 1.0mm thick
Note After using a shim, obtain a replacement to keep the set complete. Note After using a shim, obtain a replacement to keep the set complete.
1-30
40
Section 1 - General Information Service
Tools Tool Detail Reference
16 921/52613 Spacer - 13.35mm thick
17 921/52614 Spacer - 13.40mm thick
18 921/52615 Spacer - 13.45mm thick
19 921/52616 Spacer - 13.50mm thick
20 921/52617 Spacer - 13.55mm thick
21 921/52618 Spacer - 13.60mm thick
22 921/52619 Spacer - 13.65mm thick
23 921/52620 Spacer - 13.70mm thick
24 921/52621 Spacer - 13.75mm thick
25 921/52622 Spacer - 13.80mm thick
26 921/52623 Spacer - 13.85mm thick
27 921/52624 Spacer - 13.90mm thick
28 921/52625 Spacer - 13.95mm thick
29 921/52626 Spacer - 14.00mm thick
30 921/52627 Spacer - 14.20mm thick
Note After using a spacer, obtain a replacement to keep the set complete. Note After using a spacer, obtain a replacement to keep the set complete.
747030-C1 Fig 37. 921/52100 Shim Kit 747030-C1 Fig 37. 921/52100 Shim Kit
Item Description
1 921/52108 Shim - 0.2mm thick
2 921/52106 Shim - 0.25mm thick
3 921/52107 Shim - 0.3mm thick
4 921/52104 Shim - 0.5mm thick
5 921/52105 Shim - 1.0mm thick
Note After using a shim, obtain a replacement to keep the set complete Note After using a shim, obtain a replacement to keep the set complete
747030-C1 Fig 38. 921/52600 Spacer Kit 747030-C1 Fig 38. 921/52600 Spacer Kit
Item Description
1 921/52628 Spacer - 12.60mm thick
2 921/52629 Spacer - 12.65mm thick
3 921/52630 Spacer - 12.70mm thick
4 921/52601 Spacer - 12.75mm thick
5 921/52602 Spacer - 12.80mm thick
6 921/52603 Spacer - 12.85mm thick
7 921/52604 Spacer - 12.90mm thick
8 921/52605 Spacer - 12.95mm thick
9 921/52606 Spacer - 13.00mm thick
10 921/52607 Spacer - 13.05mm thick
11 921/52608 Spacer - 13.10mm thick
12 921/52609 Spacer - 13.15mm thick
13 921/52610 Spacer - 13.20mm thick
14 921/52611 Spacer - 13.25mm thick
15 921/52612 Spacer - 13.30mm thick
C002510 Fig 39. 921/52620 Spacer
(service use)
C002510 Fig 40. 921/52627 Spacer
(service use)
1-30
41
Section 1 - General Information Service
Tools Tool Detail Reference
747030-C1 Fig 41. 921/53300 Spacer Kit 747030-C1 Fig 41. 921/53300 Spacer Kit
Item Description
1 921/53322 Spacer - 13.550mm thick
2 921/53323 Spacer - 13.575mm thick
3 921/53324 Spacer - 13.600mm thick
4 921/53325 Spacer - 13.625mm thick
5 921/53301 Spacer - 13.650mm thick
6 921/53302 Spacer - 13.675mm thick
7 921/53303 Spacer - 13.700mm thick
8 921/53304 Spacer - 13.725mm thick
9 921/53305 Spacer - 13.750mm thick
10 921/53306 Spacer - 13.775mm thick
11 921/53307 Spacer - 13.800mm thick
12 921/53308 Spacer - 13.825mm thick
13 921/53309 Spacer - 13.850mm thick
14 921/53310 Spacer - 13.875mm thick
15 921/53311 Spacer - 13.900mm thick
16 921/53312 Spacer - 13.925mm thick
17 921/53313 Spacer - 13.950mm thick
18 921/53314 Spacer - 13.975mm thick
19 921/53315 Spacer - 14.000mm thick
20 921/53316 Spacer - 14.025mm thick
21 921/53317 Spacer - 14.050mm thick
22 921/53318 Spacer - 14.075mm thick
23 921/53319 Spacer - 14.100mm thick
24 921/53320 Spacer - 14.125mm thick
25 921/53321 Spacer - 14.150mm thick
Note After using a spacer, obtain a replacement to keep the set complete. Note After using a spacer, obtain a replacement to keep the set complete.
747030-C1 Fig 42. 921/53400 Spacer Kit 747030-C1 Fig 42. 921/53400 Spacer Kit
Item Description
1 921/52628 Spacer - 12.600 mm thick
2 829/30405 Spacer - 12.625 mm thick
3 921/52629 Spacer - 12.650 mm thick
4 829/30406 Spacer - 12.675 mm thick
5 921/52630 Spacer - 12.700 mm thick
6 829/30407 Spacer - 12.725 mm thick
7 921/52601 Spacer - 12.750 mm thick
8 829/30408 Spacer - 12.775 mm thick
9 921/52602 Spacer - 12.800 mm thick
10 829/30409 Spacer - 12.825 mm thick
11 921/52603 Spacer - 12.850 mm thick
12 829/30410 Spacer - 12.875 mm thick
13 921/52604 Spacer - 12.900 mm thick
14 829/30411 Spacer - 12.925 mm thick
15 921/52605 Spacer - 12.950 mm thick
16 829/30412 Spacer - 12.975 mm thick
17 921/52606 Spacer - 13.000 mm thick
18 829/30413 Spacer - 13.025 mm thick
19 921/52607 Spacer - 13.050 mm thick
20 829/30414 Spacer - 13.075 mm thick
21 921/52608 Spacer - 13.100 mm thick
22 829/30415Spacer - 13.125 mm thick
23 921/52609 Spacer - 13.150 mm thick
24 829/30416 Spacer - 13.175 mm thick
25 921/52610 Spacer - 13.200 mm thick
26 829/30417 Spacer - 13.225 mm thick
27 921/52611 Spacer - 13.250 mm thick
28 921/53424 Spacer - 13.275 mm thick
29 921/53425 Spacer - 13.300 mm thick
30 921/53426 Spacer - 13.325 mm thick
1-30
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