Page 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. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400


Section i - Front Cover

Notes:

i-0

9803/8610-14

i-0


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. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400


Section 1 - General Information

Notes:

1-0

9803/8610-14

1-0


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 ................................... Introduction ....................................................................................... Bolts and Screws .............................................................................. Hydraulic Connections ........................................................................... 'O' Ring Face Seal System ............................................................... 'Torque Stop' Hose System ..............................................................

1 - 11 1 - 11 1 - 11 1 - 15 1 - 15 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


Section 1 - General Information Contents

1 - ii

Page No.

1 - ii


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.

1-1

9803/8610-14

1-1


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

1-2

9803/8610-14

1-2


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 ( T 1-3) K Front Axle Procedures ( T 1-4) K Rear Axle Procedures ( T 1-6)

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.

Machines

K Brakes Procedures ( T 1-8) K Transfer Gearbox Procedures ( T 1-9)

Table 1. Gearbox Procedures Service Procedures Manual Manual Gearboxes(1)

Backhoe Loaders

Powershift Gearboxes(1)

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

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, 9803/3740 510-55 - 1402000 on

-

PS750 Powershift MkIII, PS750 Powershift MKIV

Loadalls

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

9803/5100

SS600 Synchro Shuttle

-

Rough Terrain Fork Lifts 921, 926, 930, 940 - 600001 on

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

1-3

9803/8610-14

1-3


Section 1 - General Information About This Manual Applicable Machines Machines

Table 2. Front Axle Procedures Service Procedures Manual Drive Head Hub Swivel and Driveshaft

Hub

Section D

Section B

Section A

-

40 Series Hub

Backhoe Loaders Midi

9803/9400

40 Series Drive Head (3 Piece Axles)

2CX, 212 - 930000 on

9803/7130

55 and 80 Series Drive Head (1 Piece Axles)

3CX (2WS, 2WD) - 960001 on

9803/3290

-

3CX, 4CX (2WS, 4WD) - 960001 on

9803/3290

55 Series Hub 55 and 80 Series Drive Head (1 Piece Swivel and Diveshaft Axles)

55 and 70 Series Hub

3CX, 4CX (4WS, 4WD) - 960001 on

9803/3290

55 and 80 Series 55 Series Hub Drive Head (1 Piece Swivel and Axles) Diveshaft

80 Series Hub

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 - 9803/3740 1402000 on

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

Refer to Hub

55 and 70 Series Hub Dead Steer Hub

Loadalls

1-4

9803/8610-14

1-4


Section 1 - General Information About This Manual Applicable Machines Machines

Service Manual

Procedures Drive Head

Hub Swivel and Driveshaft

Hub

Section D

Section B

Section A

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 55 Series Hub Drive Head (1 Piece Swivel and Axles) Diveshaft

40 Series Hub

9803/5100

80 Series Drive Head (3 Piece Axles)

55 and 70 Series Hub

Rear Engined 1182000 on

Rough Terrain Fork Lifts 921, 926, 930, 940 - 600001 on

1-5

9803/8610-14

70 Series Driveshaft

1-5


Section 1 - General Information About This Manual Applicable Machines Machines

Table 3. Rear Axle Procedures Service Procedures Manual Drive Head Hub Swivel and Driveshaft Section D

Section B

Hub Section A

Backhoe Loaders Midi

9803/9400

40 Series Drive 70 Series Head and Drop Box Driveshaft (3 Piece Axles)

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 9803/3630 - 768740 to 1185999

55 Series Hub 55 and 80 Series Drive Head (1 Piece Swivel and Axles) Driveshaft

55 and 70 Series Hub

Side Engined over 10.5 metre lift height 9803/3630 - 768740 to 1185999

55 and 80 Series 55 Series Hub Drive Head (1 Piece Swivel and Axles) Driveshaft

80 Series Hub with Integral Brake

Side Engined up to 10.5 metre lift height 9803/3730 - 1186000 to 1507999

55 and 80 Series 55 Series Hub Drive Head (1 Piece Swivel and Axles) 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 - 9803/3740 1402000 on

80 Series Drive Head (3 Piece Axles)

55 Series Hub Swivel and Driveshaft

55 Series Hub

Side Engined over 10.5 metre lift height 9803/3730 - 1186000 to 1507999

55 and 80 Series 55 Series Hub Drive Head (1 Piece Swivel and Axles) Driveshaft

80 Series Hub with Integral Brake

1-6

9803/8610-14

1-6


Section 1 - General Information About This Manual Applicable Machines Machines

Service Manual

Procedures Drive Head

Hub Swivel and Driveshaft

Hub

Section D

Section B

Section A

Side Engined Construction Machines 1508000 on

9803/3750

55 and 80 Series 55 Series Hub Drive Head (1 Piece Swivel and Axles), 80 Series Driveshaft Drive Head (3 Piece Axles)

80 Series Hub, 80 Series Hub with Integral Brake

Side Engined Agricultural Machines 1508000 on

9803/3760

55 and 80 Series 55 Series Hub Drive Head (1 Piece Swivel and Axles) Driveshaft

55 and 70 Series Hubs

Side Engined Hydrostatic Machines 527-58 - 1473000 on

9813/0200

55 and 80 Series 55 Series Hub Drive Head (1 Piece Swivel and Axles) 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 55 Series Hub Drive Head (1 Piece Swivel and Axles) Diveshaft

40 Series Hub

921, 926, 930, 940 2WD - 600001 on

9803/5100

-

Dead Steer Hub

921, 926, 930, 940 4WD - 600001 on

9803/5100

55 Series Hub 55 and 80 Series Drive Head (1 Piece Swivel and Axles) Diveshaft

Rough Terrain Fork Lifts

1-7

9803/8610-14

-

55 and 70 Series Hub

1-7


Section 1 - General Information About This Manual Applicable Machines Machines

Table 4. Brakes Procedures Service Procedures Manual Axle Integral Brakes

Hub Brakes

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)

-

Side Engined up to 10.5 metre lift height - 768740 9803/3630 to 1185999

70 Series Integral Brakes (3 Piece Axles)

-

Side Engined over 10.5 metre lift height - 768740 9803/3630 to 1185999

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 9803/3740 on

70 Series Integral Brakes (3 Piece Axles)

Side Engined over 10.5 metre lift height - 1186000 9803/3730 to 1507999

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)

-

9803/5100

70 Series Integral Brakes (3 Piece Axles)

-

Loadalls

Rough Terrain Fork Lifts 921, 926, 930, 940 - 600001 on

1-8

9803/8610-14

1-8


Section 1 - General Information About This Manual Applicable Machines Machines

Table 5. Transfer Gearbox Procedures Service Manual

Procedures Section G

Backhoe Loaders Midi

9803/9400

The drop box is part of the rear axle drive head. K Rear Axle Procedures ( T 1-6)

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

Loadalls

1-9

9803/8610-14

1-9


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!

1-10

9803/8610-14

1-10


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.

The two types of fasteners can be readily identified by colour and part number suffix. K Table 6. Fastener Types ( T 1-11).

Torque settings are given for the following conditions:

Fastener Type

Table 6. Fastener Types Colour Part No. Suffix

Note: Dacromet fasteners are lubricated as part of the plating process, do not lubricate.

Condition 1 – Un-lubricated fasteners – Zinc fasteners – Yellow plated fasteners

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

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.

– Lubricated zinc and yellow plated fasteners – Where there is a natural lubrication. For example, cast iron components

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. 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.

1-11

Fig 1. Torque settings for these bolts are determined by the application. Refer to the relevant procedure for the required settings.

9803/8610-14

1-11


Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 7. Torque Settings - UNF Grade 'S' Fasteners Hexagon (A/F) Condition 1

Bolt Size 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 Hexagon (A/F) Condition 1

Bolt Size ISO Metric Thread

1-12

Condition 2

mm

mm

Nm

kgf m

lbf ft

Condition 2 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

9803/8610-14

1-12


Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 9. Metric Grade 10.9 Fasteners Hexagon (A/F) Condition 1

Bolt Size ISO Metric Thread

mm

mm

Nm

kgf m

Condition 2 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 Hexagon (A/F) Condition 1

Bolt Size

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

1-13

9803/8610-14

1-13


Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 11. Torque Settings - Rivet Nut Bolts/Screws Bolt Size 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

1-14

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

9803/8610-14

1-14


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 Hexagon (A/F) Size

1-15

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 Port Hexagon (A/F)

SAE Tube Size

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

9803/8610-14

1-15


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.

BSP Hose Size in.

1-16

Note: Dimension 2-D will vary depending upon the torque applied.

Table 15. BSP Hose - Torque Settings Hexagon (A/F) mm

Nm

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

9803/8610-14

kgf m

lbf ft

1-16


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

1-17

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

9803/8610-14

1-17


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)

1-18

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

9803/8610-14

1-18


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. For lists of tools required for a given axle or gearbox see the relevant transmission 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.

Part Number

Description

Used In Section

Tool Detail Reference

-

Torque measuring tool - Wheel hub seals

A

K Fig 4. ( T 1-21)

445/04700

Shim Kit

E

K Fig 5. ( T 1-21)

459/70378

Spacer Kit

E

K Fig 6. ( T 1-22)

459/70379

Spacer Kit

E

K Fig 7. ( T 1-22)

823/10420

Thrust washer kit

F

K Fig 8. ( T 1-23)

823/10547

Spacer Kit

F

K Fig 9. ( T 1-23)

921/M0229 Shim Kit

D

K Fig 10. ( T 1-23)

921/M0103 Spacer Kit

D

K Fig 11. ( T 1-24)

921/52100

Spacer Kit

D

K Fig 12. ( T 1-24)

892/00174

Measuring cup

D

K Fig 13. ( T 1-24)

892/00179

Bearing press

A, E

K Fig 14. ( T 1-25)

892/00182

Bearing pad driver

892/00224

Impulse extractor

892/00225

Adaptor for extractor

892/00295

End float setting tool

F

K Fig 17. ( T 1-25)

892/00333

Heavy duty socket - 19mm

A

K Fig 18. ( T 1-25)

892/00812

Drive coupling spanner

D, E, F

K Fig 19. ( T 1-25)

892/00819

Heavy duty socket - 15mm

D

-

892/00891

Wheel hub seal dolly

A

K Fig 32. ( T 1-29)

B

K Fig 16. ( T 1-25) -

892/00912

Heavy duty socket - 46mm

G

-

892/00914

Heavy duty socket - 55mm

G

-

892/00915

Reaction block fixture

G

K Fig 20. ( T 1-26)

892/00918

Setting tool kit

D, E, F

K Fig 21. ( T 1-26)

892/01064

Adaptor spanner

E

K Fig 22. ( T 1-26)

892/01065

Holding fixture

E

K Fig 23. ( T 1-26)

1-19

9803/8610-14

1-19


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. ( T 1-26)

892/01076

Support bracket

E

K Fig 25. ( T 1-27)

892/01077

Selector shaft lock screw

E

K Fig 26. ( T 1-27)

892/01078

Mainshaft adjuster

E

K Fig 27. ( T 1-27)

892/01079

Ring socket spanner - mainshaft setting ring

E

K Fig 28. ( T 1-27)

892/01080

Ring socket spanner - layshaft setting ring

E

K Fig 29. ( T 1-27)

892/01082

Assembly cradle

F

K Fig 31. ( T 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. ( T 1-29)

892/01237

Park brake lock-up tool

D

K Fig 30. ( T 1-27)

921/01900

Shim Kit

D

K Fig 34. ( T 1-31)

921/02200

Shim Kit

E

K Fig 35. ( T 1-31)

921/51700

Shim Kit

E

K Fig 36. ( T 1-31)

921/52100

Shim Kit

D

K Fig 37. ( T 1-32)

921/52600

Spacer Kit

E, F

K Fig 38. ( T 1-32)

921/52620

Spacer (13.70mm service use)

E, F

K Fig 39. ( T 1-32)

921/52627

Spacer (14.20 mm service use)

D

K Fig 40. ( T 1-32)

921/53300

Spacer Kit

D

K Fig 41. ( T 1-33)

921/53400

Spacer Kit

D, E

K Fig 42. ( T 1-33)

921/53700

Shim Kit

F

K Fig 43. ( T 1-34)

992/04800

Flange spanner

E, F

K Fig 44. ( T 1-34)

993/59300

Pressure test adaptor and clamp

F

K Fig 45. ( T 1-34)

993/59400

End float setting tool

E

K Fig 46. ( T 1-35)

993/59500

Impulse extractor adapter

B

K Fig 16. ( T 1-25)

993/70100

End float setting tool kit

F

K Fig 47. ( T 1-36)

993/70111

Breakback torque wrench

D, E, F

K Fig 48. ( T 1-37)

997/11000

Support bracket

D

K Fig 49. ( T 1-37)

998/10738

Adaptor spanner

F

K Fig 50. ( T 1-37)

998/M1374 M14 Stud (use with 998/M1375) 4 off required

A

K Fig 51. ( T 1-37)

998/M1375 Reaction plate

A

K Fig 51. ( T 1-37)

990/00083

E

K Fig 33. ( T 1-31)

1-20

End float setting tool

9803/8610-14

1-20


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 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.

1-21

9803/8610-14

1-21


Section 1 - General Information Service Tools Tool Detail Reference

747030-C1

747030-C1

Fig 6. 459/70378 Spacer Kit

Fig 7. 459/70379 Spacer Kit

Item

Description

Item

Description

1

823/10647 Spacer - 17.80mm thick

1

823/10679 Spacer - 2.20mm thick

2

823/10648 Spacer - 17.85mm thick

2

823/10680 Spacer - 2.25mm thick

3

823/10649 Spacer - 17.90mm thick

3

823/10681 Spacer - 2.30mm thick

4

823/10650 Spacer - 17.95mm thick

4

823/10682 Spacer - 2.35mm thick

5

823/10651 Spacer - 18.00mm thick

5

823/10683 Spacer - 2.40mm thick

6

823/10652 Spacer - 18.05mm thick

823/10684 Spacer - 2.45mm thick

7

823/10653 Spacer - 18.10mm thick

823/10685 Spacer - 2.50mm thick

8

823/10654 Spacer - 18.15mm thick

823/10686 Spacer - 2.55mm thick

9

823/10655 Spacer - 18.20mm thick

823/10687 Spacer - 2.60mm thick

10

823/10656 Spacer - 18.25mm thick

823/10688 Spacer - 2.65mm thick

11

823/10657 Spacer - 18.30mm thick

823/10689 Spacer - 2.70mm thick

12

823/10658 Spacer - 18.35mm thick

823/10690 Spacer - 2.75mm thick

13

823/10659 Spacer - 18.40mm thick

823/10691 Spacer - 2.80mm thick

14

823/10660 Spacer - 18.45mm thick

823/10692 Spacer - 2.85mm thick

15

823/10661 Spacer - 18.50mm thick

823/10693 Spacer - 2.90mm thick

16

823/10662 Spacer - 18.55mm thick

823/10694 Spacer - 2.95mm thick

17

823/10663 Spacer - 18.60mm thick

823/10695 Spacer - 3.00mm thick

18

823/10665 Spacer - 18.65mm thick

823/10696 Spacer - 3.05mm thick

19

823/10666 Spacer - 18.70mm thick

823/10697 Spacer - 3.10mm thick

20

823/10667 Spacer - 18.75mm thick

823/10698 Spacer - 3.15mm thick

21

823/10668 Spacer - 18.80mm thick

823/10699 Spacer - 3.20mm 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.

1-22

9803/8610-14

1-22


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 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

747030-C1

Fig 10. 921/M0229 Shim Kit

Note: After using a spacer, obtain a replacement to keep the set complete.

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.

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

1-23

9803/8610-14

1-23


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.

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

1-24

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.

C002510

Fig 13. 892/00174 Measuring Cup

9803/8610-14

1-24


Section 1 - General Information Service Tools Tool Detail Reference 892/00225

Adaptor

993/59500

Adaptor

Fig 17. 892/00295 End Float Setting Tool 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 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

1-25

9803/8610-14

1-25


Section 1 - General Information Service Tools Tool Detail Reference

Fig 22. 892/01064 Adaptor Spanner

Fig 20. 892/00915 Reaction Block Fixture

1

1a

1b 1c Fig 23. 892/01065 Holding Fixture

1d

1e

Fig 21. 892/00918 Setting Tool Kit Item

Description

1

892/00918 Setting Tool Kit

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)

A396960-C1

Fig 24. 892/01075 Support Bracket

Additional parts for 40 series drive heads only: 1d

998/11350 Adaptor

1e

998/11351 Sleeve (front axles) 998/11352 Sleeve (rear axles)

1-26

9803/8610-14

1-26


Section 1 - General Information Service Tools Tool Detail Reference

A396590

Fig 28. 892/01079 Ring Socket Spanner A396580-C1

Fig 25. 892/01076 Support Bracket

A395350

A396600

Fig 26. 892/01077 Selector Shaft Lock Screw

Fig 29. 892/01080 Ring Socket Spanner

A396510

Fig 27. 892/01078 Mainshaft Adjuster Fig 30. 892/01237 Park Brake Lock-Up Tool

1-27

9803/8610-14

1-27


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

160.0

R1 2

1.0

49

48

2

25.0

20.0 TYP 9 PLACES

R1 09 .

0

9

R137.0

263.6

153.2 60.7

140.1

R125 .0 9

600.0 325.6 REF 216.6

51.8

168.0 107.3 73.2 REF

10.0

R6 2

.0

==

30

2.9 53.2 95.0 118.7

TYP 9 PLACES 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.

1-28

9803/8610-14

1-28


Section 1 - General Information Service Tools Tool Detail Reference

A

5 1 6

8, 9

7

10

2 3 4

B

15 19,20 13 14 16

C 18 17 21

8

Fig 32. 892/01092 Wheel Hub Service Kit A

Bearing Puller

B

Bearing Press

C

Seal Dolly Comprises of:

1

998/10623

Puller beam - 1off

2

998/1067

Clamp plates - 1off

3

1315/3731Z

Bolt M16 x 220 - 2off

4

1370/0601Z

Nut M16 - 2off

5

998/10614

Reaction tube - 1off

6

998/10624

Modified wheel stud - 2off

1-29

9803/8610-14

1-29


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

(1)

998/10608

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

9803/8610-14

1-30


Section 1 - General Information Service Tools Tool Detail Reference

747030-C1

Fig 33. 990/00083 End Float Setting Tool

Fig 36. 921/51700 Shim Kit

747030-C1

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

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

Fig 34. 921/01900 Shim Kit Item

Item

Note: After using a shim, obtain a replacement to keep the set complete.

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.

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Section 1 - General Information Service Tools Tool Detail Reference

747030-C1

Fig 37. 921/52100 Shim Kit

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 921/52620 Spacer - 13.70mm thick

Item

Description

23

1

921/52108 Shim - 0.2mm thick

24

921/52621 Spacer - 13.75mm thick

2

921/52106 Shim - 0.25mm thick

25

921/52622 Spacer - 13.80mm thick

3

921/52107 Shim - 0.3mm thick

26

921/52623 Spacer - 13.85mm thick

4

921/52104 Shim - 0.5mm thick

27

921/52624 Spacer - 13.90mm thick

5

921/52105 Shim - 1.0mm 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 shim, obtain a replacement to keep the set complete

Note: After using a spacer, obtain a replacement to keep the set complete.

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

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C002510

Fig 39. 921/52620 Spacer (service use)

C002510

Fig 40. 921/52627 Spacer (service use)

9803/8610-14

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Section 1 - General Information Service Tools Tool Detail Reference

747030-C1

747030-C1

Fig 41. 921/53300 Spacer Kit

Fig 42. 921/53400 Spacer Kit

Item

Description

Item

Description

1

921/53322 Spacer - 13.550mm thick

1

921/52628 Spacer - 12.600 mm thick

2

921/53323 Spacer - 13.575mm thick

2

829/30405 Spacer - 12.625 mm thick

3

921/53324 Spacer - 13.600mm thick

3

921/52629 Spacer - 12.650 mm thick

4

921/53325 Spacer - 13.625mm thick

4

829/30406 Spacer - 12.675 mm thick

5

921/53301 Spacer - 13.650mm thick

5

921/52630 Spacer - 12.700 mm thick

6

921/53302 Spacer - 13.675mm thick

6

829/30407 Spacer - 12.725 mm thick

7

921/53303 Spacer - 13.700mm thick

7

921/52601 Spacer - 12.750 mm thick

8

921/53304 Spacer - 13.725mm thick

8

829/30408 Spacer - 12.775 mm thick

9

921/53305 Spacer - 13.750mm thick

9

921/52602 Spacer - 12.800 mm thick

10

921/53306 Spacer - 13.775mm thick

10

829/30409 Spacer - 12.825 mm thick

11

921/53307 Spacer - 13.800mm thick

11

921/52603 Spacer - 12.850 mm thick

12

921/53308 Spacer - 13.825mm thick

12

829/30410 Spacer - 12.875 mm thick

13

921/53309 Spacer - 13.850mm thick

13

921/52604 Spacer - 12.900 mm thick

14

921/53310 Spacer - 13.875mm thick

14

829/30411 Spacer - 12.925 mm thick

15

921/53311 Spacer - 13.900mm thick

15

921/52605 Spacer - 12.950 mm thick

16

921/53312 Spacer - 13.925mm thick

16

829/30412 Spacer - 12.975 mm thick

17

921/53313 Spacer - 13.950mm thick

17

921/52606 Spacer - 13.000 mm thick

18

921/53314 Spacer - 13.975mm thick

18

829/30413 Spacer - 13.025 mm thick

19

921/53315 Spacer - 14.000mm thick

19

921/52607 Spacer - 13.050 mm thick

20

921/53316 Spacer - 14.025mm thick

20

829/30414 Spacer - 13.075 mm thick

21

921/53317 Spacer - 14.050mm thick

21

921/52608 Spacer - 13.100 mm thick

22

921/53318 Spacer - 14.075mm thick

22

829/30415Spacer - 13.125 mm thick

23

921/53319 Spacer - 14.100mm thick

23

921/52609 Spacer - 13.150 mm thick

24

921/53320 Spacer - 14.125mm thick

24

829/30416 Spacer - 13.175 mm thick

25

921/53321 Spacer - 14.150mm thick

25

921/52610 Spacer - 13.200 mm thick

Note: After using a spacer, obtain a replacement to keep the set complete.

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

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9803/8610-14

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