JCB JS210, JS220 (JCB Engine) Tracked Excavator Service Repair Manual Instant Download

Service Manual JS 210, JS220 - JCB Engine Service Manual - JS 210, JS220 - JCB Engine Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section J - Track and Running Gear Section K - Engine Publication No. 9813/2400-2 World Class Customer Support Copyright 2007 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 India Limited, 23/7, Mathura Road, Ballabgarh - 121004, Haryana (India), Tel 0129 4299000 Fax 0129 2309051

Section 1 General Information Service Manual - JS 210, JS220 - JCB Engine Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section J - Track and Running Gear Section K - Engine Publication No. 9813/2400-2 World Class Customer Support Copyright 2007 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 India Limited, 23/7, Mathura Road, Ballabgarh - 121004, Haryana (India), Tel 0129 4299000 Fax 0129 2309051

Section 1 - General Information Contents Contents Introduction About this Manual ...................................................................................... 1-1 Machine Model and Serial Number .......................................................1-1 Using the Service Manual .....................................................................1-1 Section Numbering ................................................................................1-1 Left Side, Right Side ..............................................................................1-2 Cross References ..................................................................................1-2 Machine Description .................................................................................. 1-3 The JCB Tracked Excavator ..................................................................1-3 Intended Use .........................................................................................1-3 Component Location .............................................................................1-4 Identifying Your Machine ........................................................................... 1-7 Machine Identification Plate ..................................................................1-7 Component Identification Plates ............................................................1-8 Page No. Torque Settings Zinc Plated Fasteners and Dacromet Fasteners ....................................... 1-9 Introduction ............................................................................................1-9 Bolts and Screws ...................................................................................1-9 Hydraulic Connections ............................................................................. 1-13 'O' Ring Face Seal System ..................................................................1-13 'Torque Stop' Hose System .................................................................1-16 Service Tools Numerical List .......................................................................................... 1-17 Tool Detail Reference .............................................................................. 1-20 Section B - Body and Framework ........................................................1-20 Section C - Electrics ............................................................................1-24 Section E - Hydraulics .........................................................................1-25 Section K - Engine ...............................................................................1-39 Service Consumables Sealing and Retaining Compounds ......................................................... 1-41 Terms and Definitions Colour Coding .......................................................................................... 1-43 Hydraulic Schematic Colour Codes .....................................................1-43 1-i 1-i

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Section 1 - General Information Introduction About this Manual Machine Model and Serial Number specifications of the machine and the descriptions contained in this publication. This manual provides information for the following model(s) in the JCB machine range: Finally, please remember above all else safety must come first! JCB JS220 from serial number 2163177 to 2168079. JCB JS210LC with JCB Dieselmax Engine from serial number 2163079 to 2163161. JCB JS210LC from serial number 2163079 to 2168079. Section Numbering T11-005 The manual is compiled in sections, the first three are numbered and contain information as follows: General Information - includes torque settings and service tools. Care and Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc. Maintenance - includes service schedules and recommended lubricants for all the machine. 1 Using the Service Manual T11-004 This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training by JCB Technical Training Department. 2 3 These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated with the maintenance and repair of hydraulic earthmoving equipment. The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for example: The illustrations in this publication are for guidance only. Where the machines differ, the text and/or the illustration will specify. Attachments Body and Framework, etc. A B General warnings in Section 2 are repeated throughout the manual, as well as specific warnings. Read all safety statements regularly, so you do not forget them. Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of each alphabetically coded section. Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt. Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry threads, hence for lubricated threads may be reduced by one third. The manufacturer's policy is one of continuous improvement. The right to change the specification of the machine without notice is reserved. No responsibility will be accepted for discrepancies which may occur between 1-1 1-1 9813/2400-2

Section 1 - General Information Introduction About this Manual Left Side, Right Side In this manual, 'left' A and 'right' B mean your left and right when you are seated correctly in the machine. B A Cross References T1-004_2 In this publication, page cross references are made by presenting the subject title printed in bold, italic and underlined. It is preceeded by the 'go to' symbol. The number of the page upon which the subject begins, is indicated within the brackets. For example: K K Cross References ( T T 1-2). 1-2 1-2 9813/2400-2

Section 1 - General Information Introduction Machine Description Machine Description The JCB Tracked Excavator The JCB Tracked Excavator is a self propelled machine comprising a tracked undercarriage and a revolving upper structure which incorporates a boom, dipper, bucket and swing mechanism. It is mainly used for digging below ground level with bucket motions towards the machine. The upper structure can swing 360 degrees and discharge material while the tracked undercarriage remains stationary. Intended Use The machine is intended to be used under normal conditions for the applications described in this manual. If the machine is used for other purposes or in dangerous environments, for example in a flammable atmosphere or in areas with dust containing asbestos, special safety regulations must be followed and the machine must be equipped for use in these environments. The machine is primarily designed for excavating with a bucket, without movement of the undercarriage during the work cycle. An excavator work cycle normally comprises excavating, elevating, swinging and discharging of material. An excavator can also be used for object or material handling/transportation provided it meets the lifting regulations. 1-3 1-3 9813/2400-2

Section 1 - General Information Introduction Machine Description Component Location Primary Fuel Filter/Sedimenter 25 Main Fuel Filter/Sedimenter 26 Note: The illustration(s) show a typical machine model; your machine may look different from the model shown. Battery 27 Bucket 1 Air Pre Cleaner (option) 28 Bucket Link 2 Air Filter 29 Dipper Link 3 Track Plate 30 Bucket Ram 4 Track Gearbox 31 Dipper 5 Lower Roller 32 Tipping Ram 6 Upper Roller 33 Boom 7 Recoil Spring 34 Boom Ram 8 Idler Wheel 35 Operators Cab 9 Front Attachment Pin 36 Hydraulic Pump 10 Engine Oil Pan 37 Counterweight 11 Remote Engine Oil Filter 38 Slew Ring 12 Slew Motor/Gearbox 13 Main Valve Block 14 Hydraulic Oil Tank 15 Hydraulic Tank Breather 16 Pilot Oil Filter 17 Return Filter 18 Suction Filter 19 Drain Line Filter 20 Plexus Filter 21 Breaker In-line Filter 22 Fuel Tank 23 Engine Fuel Filter/Sedimenter 24 1-4 1-4 9813/2400-2

Section 1 - General Information Introduction Machine Description 14 13 15 16 11 10 12 Fig 1. 1-5 1-5 9813/2400-2

Section 1 - General Information Introduction Machine Description 24,25,26 19 21 18 23 20 17 38 22 37 36 27 28 29 35 33 30 36 34 36 32 31 Fig 2. 1-6 1-6 9813/2400-2

Section 1 - General Information Introduction Identifying Your Machine Identifying Your Machine Machine Identification Plate Typical Product Identification Number (PIN) Your machine has a data plate, located on the outside the cab as shown at A. The machine serial number is inscribed at B which is the frameK K Fig 3. ( T T 1-7). 1 2 3 C 4 JCB JS102 01474000 baseplate of the rear World Manufacturer Code (JCB) 1 Machine Type and Model (JS102 = JS330 Tracked) 2 Randomly Generated Check Letter 3 Machine Serial Number (01474000) 4 Fig 3. K K Fig 4. ( T T 1-7) Fig 4. 1-7 1-7 9813/2400-2

Section 1 - General Information Introduction Identifying Your Machine Component Identification Plates Typical Engine Identification Number Each JCB Engine has a unique identification number stamped on the main engine block, as shown A. When ordering replacement parts, always quote the complete engine serial number. K K Fig 5. ( T T 1-8). D021990 Fig 5. 1-8 1-8 9813/2400-2

Section 1 - General Information 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 K Table 1. Fastener Types ( T T 1-9). Torque settings are given for the following conditions: Condition 1 Table 1. Fastener Types Colour Un-lubricated fasteners Zinc fasteners Yellow plated fasteners Fastener Type Zinc and Yellow Dacromet Part No. Suffix Golden finish 'Z' (e.g. 1315/3712Z) Condition 2 Mottled silver finish 'D' (e.g. 1315/3712D) 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 6. 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. 1-9 1-9 9813/2400-2

Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 2. Torque Settings - UNF Grade 'S' Fasteners Hexagon (A/F) in. Nm 7/16 11.2 1/2 22.3 9/16 40.0 5/8 64.0 3/4 98.00 13/16 140.0 15/16 196.0 1 1/8 343.0 1 15/16 547.0 1 1/2 814.0 1 7/8 1181.0 2 1/4 1646.0 Bolt Size Condition 1 kgf m 1.1 2.3 4.1 6.5 10.0 14.3 20.0 35.0 55.8 83.0 120.4 167.8 Condition 2 kgf m 1.0 2.0 3.7 5.8 9.0 12.8 18.0 31.5 50.2 74.6 108.4 151.0 in. 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1 1/8 1 1/4 mm 6.3 7.9 9.5 11.1 12.7 14.3 15.9 19.0 22.2 25.4 31.7 38.1 lbf ft 8.3 16.4 29.5 47.2 72.3 103.2 144.6 253.0 403.4 600.4 871.1 1214.0 Nm 10.0 20.0 36.0 57.0 88.0 126.0 177.0 309.0 492.0 732.0 1063.0 1481.0 lbf ft 7.4 14.7 26.5 42.0 64.9 92.9 130.5 227.9 362.9 539.9 784.0 1092.3 Table 3. Torque Settings - Metric Grade 8.8 Fasteners Hexagon (A/F) Bolt Size Condition 1 Condition 2 ISO Metric Thread M5 M6 M8 M10 M12 M16 M20 M24 M30 M36 mm 5 6 8 10 12 16 20 24 30 36 mm 8 10 13 17 19 24 30 36 46 55 Nm 5.8 9.9 24.0 47.0 83.0 205.0 400.0 690.0 1372.0 2399.0 kgf m 0.6 1.0 2.4 4.8 8.5 20.9 40.8 70.4 139.9 244.6 lbf ft 4.3 7.3 17.7 34.7 61.2 151.2 295.0 508.9 1011.9 1769.4 Nm 5.2 9.0 22.0 43.0 74.0 184.0 360.0 621.0 1235.0 2159.0 kgf m 0.5 0.9 2.2 4.4 7.5 18.8 36.7 63.3 125.9 220.0 lbf ft 3.8 6.6 16.2 31.7 54.6 135.7 265.5 458.0 910.9 1592.4 1-10 1-10 9813/2400-2

Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 4. Metric Grade 10.9 Fasteners Hexagon (A/F) Bolt Size Condition 1 Condition 2 ISO Metric Thread M5 M6 M8 M10 M12 M16 M20 M24 M30 M36 mm 5 6 8 10 12 16 20 24 30 36 mm 8 10 13 17 19 24 30 36 46 55 Nm 8.1 13.9 34.0 67.0 116.0 288.0 562.0 971.0 1930.0 3374.0 kgf m 0.8 1.4 3.5 6.8 11.8 29.4 57.3 99.0 196.8 344.0 lbf ft 6.0 10.2 25.0 49.4 85.5 212.4 414.5 716.9 1423.5 2488.5 Nm 7.3 12.5 30.0 60.0 104.0 259.0 506.0 874.0 1737.0 3036.0 kgf m 0.7 1.3 3.0 6.1 10.6 26.4 51.6 89.1 177.1 309.6 lbf ft 5.4 9.2 22.1 44.2 76.7 191.0 373.2 644.6 1281.1 2239.2 Table 5. Metric Grade 12.9 Fasteners Hexagon (A/F) Bolt Size Condition 1 Condition 2 ISO Metric Thread M5 M6 M8 M10 M12 M16 M20 M24 M30 M36 mm 5 6 8 10 12 16 20 24 30 36 mm 8 10 13 17 19 24 30 36 46 55 Nm 9.8 16.6 40.0 80.0 139.0 345.0 674.0 1165.0 2316.0 4049.0 kgf m 1.0 1.7 4.1 8.1 14.2 35.2 68.7 118.8 236.2 412.9 lbf ft 7.2 12.2 29.5 59.0 102.5 254.4 497.1 859.2 1708.2 2986.4 Nm 8.8 15.0 36.0 72.0 125.0 311.0 607.0 1048.0 2084.0 3644.0 kgf m 0.9 1.5 3.7 7.3 12.7 31.7 61.9 106.9 212.5 371.6 lbf ft 6.5 11.1 26.5 53.1 92.2 229.4 447.7 773.0 1537.1 2687.7 1-11 1-11 9813/2400-2

Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 6. Torque Settings - Rivet Nut Bolts/Screws Bolt Size ISO Metric Thread mm M3 3 M4 4 M5 5 M6 6 M8 8 M10 10 M12 12 Nm 1.2 3.0 6.0 10.0 24.0 48.0 82.0 kgf m 0.1 0.3 0.6 1.0 2.5 4.9 8.4 lbf ft 0.9 2.0 4.5 7.5 18.0 35.5 60.5 Table 7. Torque Settings - Internal Hexagon Headed Cap Screws (Zinc) Bolt Size ISO Metric Thread M3 2.0 M4 6.0 M5 11.0 M6 19.0 M8 46.0 M10 91.0 M12 159.0 M16 395.0 M18 550.0 M20 770.0 M24 1332.0 Nm kgf m 0.2 0.6 1.1 1.9 4.7 9.3 16.2 40.0 56.0 79.0 136.0 lbf ft 1.5 4.5 8.0 14.0 34.0 67.0 117.0 292.0 406.0 568.0 983.0 1-12 1-12 9813/2400-2

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 8. Torque Settings - BSP Adaptors BSP Adaptor Size in. mm 1/4 19.0 3/8 22.0 1/2 27.0 5/8 30.0 3/4 32.0 1 38.0 1 1/4 50.0 Hexagon (A/F) Nm 18.0 31.0 49.0 60.0 81.0 129.0 206.0 kgf m 1.8 3.2 5.0 6.1 8.2 13.1 21.0 lbf ft 13.0 23.0 36.0 44.0 60.0 95.0 152.0 Table 9. Torque Settings - SAE Connections Hexagon (A/F) mm 15.9 20.0 - 28.0 19.1 46.0 - 54.0 22.2 95.0 - 105.0 27.0 130.0 - 140.0 1 1/16 - 12 31.8 1 5/16 - 12 38.1 1 5/8 47.6 SAE Tube Size 4 6 8 10 12 16 20 SAE Port Thread Size 7/16 - 20 9/16 - 18 3/4 - 16 7/8 - 14 Nm kgf m 2.0 - 2.8 4.7 - 5.5 9.7 - 10.7 13.2 - 14.3 19.4 - 21.4 29.6 - 31.6 28.5 - 38.7 lbf ft 16.5 - 18.5 34.0 - 40.0 69.0 - 77.0 96.0 - 104.0 141.0 - 155.0 216.0 - 230.0 210.0 - 280.0 190.0 - 210.0 290.0 - 310.0 280.0 - 380.0 1-13 1-13 9813/2400-2

Section 1 - General Information Torque Settings Hydraulic Connections Hoses Screwed into Adaptors Fig 7. Hoses 7-B screwed into adaptors 7-A seal onto an `O' ring 7-C which is compressed into a 45 seat machined into the face of the adaptor port. Note: Dimension 7-D will vary depending upon the torque applied. Table 10. BSP Hose - Torque Settings Hexagon (A/F) mm 14.0 14.0 - 16.00 19.0 24.0 - 27.0 22.0 33.0 - 40.0 27.0 44.0 - 50.0 30.0 58.0 - 65.0 32.0 84.0 - 92.0 38.0 115.0 - 126.0 50.0 189.0 - 200.0 55.0 244.0 - 260.0 BSP Hose Size in. 1/8 1/4 3/8 1/2 5/8 3/4 1 1 1/4 1 1/2 Nm kgf m 1.4 - 1.6 2.4 - 2.7 3.4 - 4.1 4.5 - 5.1 5.9 - 6.6 8.6 - 9.4 11.7 - 12.8 19.3 - 20.4 24.9 - 26.5 lbf ft 10.3 - 11.8 17.7 - 19.9 24.3 - 29.5 32.4 - 36.9 42.8 - 47.9 61.9 - 67.8 84.8 - 92.9 139.4 - 147.5 180.0 - 191.8 1-14 1-14 9813/2400-2

Section 1 - General Information Torque Settings Hydraulic Connections Adaptors into Component Connections with Bonded Washers Table 11. BSP Adaptors with Bonded Washers - Torque Settings BSP Size Nm in. 1/8 20.0 1/4 34.0 3/8 75.0 1/2 102.0 5/8 122.0 3/4 183.0 1 203.0 1 1/4 305.0 1 1/2 305.0 kgf m 2.1 3.4 7.6 10.3 12.4 18.7 20.7 31.0 31.0 lbf ft 15.0 25.0 55.0 75.0 90.0 135.0 150.0 225.0 225.0 1-15 1-15 9813/2400-2

Section 1 - General Information Torque Settings Hydraulic Connections 'Torque Stop' Hose System Fig 8. `Torque Stop' Hoses 8-B screwed into adaptors 8-A seal onto an 'O' ring 8-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 8-D, which acts as a physical stop. Note: Minimum dimension 8-E fixed by shoulder 8-D. Table 12. BSP `Torque Stop' Hose - Torque Settings BSP Hose Size Hexagon (A/F) in. mm 1/8 14.0 1/4 19.0 3/8 22.0 1/2 27.0 5/8 30.0 3/4 32.0 1 38.0 1 1/4 50.0 1 1/2 55.0 Nm 14.0 27.0 40.0 55.0 65.0 95.0 120.0 189.0 244.0 kgf m 1.4 2.7 4.1 5.6 6.6 9.7 12.2 19.3 24.9 lbf ft 10.0 20.0 30.0 40.0 48.0 70.0 89.0 140.0 180.0 1-16 1-16 9813/2400-2

Section 1 - General Information Service Tools Numerical List The tools listed in the table are special tools required for carrying out the procedures described in this manual. These tools are available from JCB Service. details of all tools, including the content of kits and sets, refer to Tool Detail Reference, Section 1. 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. Some tools are available as kits or sets, the part numbers for parts within such kits or sets are not listed here. For full Part Number 993/68100 - 892/00842 892/00843 892/00845 892/00846 892/00847 892/00848 892/00849 926/15500 992/12300 992/12400 992/12800 992/12801 4104/1310 892/00281 892/00298 892/00285 892/00284 892/01174 331/22966 - - - - - Description See Section Slide Hammer Kit - see Tool Detail Reference (Section 1) for content Rivet Nut Tool - see Tool Detail Reference (Section 1) Glass Lifter Folding Stand for Holding Glass Cartridge Gun Glass Extractor (Handles) Nylon Spatula Wire Starter Braided Cutting Wire Rubber Spacer Blocks 12V Mobile Oven 240V Static Oven (2 Cartridge) Cut-Out Knife 'L' Blades Hand Cleaner AVO Meter (not illustrated) Fluke Meter Hyd. Oil Temperature Probe Digital Tachometer DLA Kit Pump Drive Alignment Tool (not illustrated) Male Adapters - BSP x BSP - see Tool Detail Reference (Section 1) Male Adapters - BSP x NPT (USA only) - see Tool Detail Reference (Section 1) Pressure Test Points - Adaptors - see Tool Detail Reference (Section 1) Pressure Test Points - 'T' Adaptors - see Tool Detail Reference (Section 1) 'T' Adaptors - see Tool Detail Reference (Section 1) B B B B B B B B B B B B B B B C C C C C E E E E E E 1-17 1-17 9813/2400-2

Section 1 - General Information Service Tools Numerical List Part Number Description See Section - - - - - 892/00334 Female Blanking Caps - see Tool Detail Reference (Section 1) Male Cone Blanking Caps - see Tool Detail Reference (Section 1) Female Connectors - see Tool Detail Reference (Section 1) Bonded Washers - see Tool Detail Reference (Section 1) Ram Protection Sleeves - see Tool Detail Reference (Section 1) Ram Seal Fitting Tool Hexagon Spanners - see Tool Detail Reference (Section 1) Piston Seal Assembly Tool Hydraulic Flow Test Equipment - see Tool Detail Reference (Section 1) Hydraulic Circuit Pressure Test Kit - see Tool Detail Reference (Section 1) for content Hydraulic Hand Pump Equipment - see Tool Detail Reference (Section 1) Spool Clamp Spool Clamp ARV Extractor Test Block for A.R.V. Valve Spool Seal Fitting Tool Gauge Gauge Gauge Connector Hose Ram Jigs - see Tool Detail Reference (Section 1) Ram Piston Nut Spanners - see Tool Detail Reference (Section 1) Socket Box Wrench Nut Adapter Seal Ring Tool Stopper Bearing Rig Inserting Seal Ring and Correction Jig - see Tool Detail Reference (Section 1) Jig for Pulling Out, Press-fitting Bushing - see Tool Detail Reference (Section 1) Jig for Press-fitting Wiper Ring - see Tool Detail Reference (Section 1) Jig for Inserting Cylinder Head - see Tool Detail Reference (Section 1) Seal Ring and Connector Jig - see Tool Detail Reference (Section 1) Bush Removal Jig - see Tool Detail Reference (Section 1) Bush Fitting Jig - see Tool Detail Reference (Section 1) Wiper Ring Fitting Jig - see Tool Detail Reference (Section 1) Wiper Ring Fitting Jig - see Tool Detail Reference (Section 1) E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E 892/01027 - - - 992/10100 892/00039 992/02800 331/31069 892/00891 892/00346 892/00279 892/00280 892/00347 892/00254 - - - - - - - - - - - - - - - - 1-18 1-18 9813/2400-2

Section 1 - General Information Service Tools Numerical List Part Number Description See Section 892/00041 De-glazing Tool K 1-19 1-19 9813/2400-2

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Section 1 - General Information Service Tools Tool Detail Reference Tool Detail Reference Section B - Body and Framework Note: Not all service tools are illustrated. Fig 9. 993/68100 Slide Hammer Kit 993/68101 993/68102 993/68103 993/68104 993/68105 993/68106 Slide Hammer End Stops Adaptor - M20 x 5/8" UNF Adaptor - M20 x 1" UNF Adaptor - M20 x M20 Adaptor - M20 x M24 993/68107 993/68108 993/68109 993/68110 993/68111 Bar - M20 x M20 X 800 mm Adaptor - M20 x 7/8" UNF Adaptor - M20 x M12 Adaptor - M20 x 5/8" UNF (Shoulder) Adaptor - M20 x 1/2" UNF 1 2 3 4 5 6 7 8 9 10 11 826/01099 826/01101 826/01102 826/01103 826/01104 826/01105A - M6 x 16 mm Rivet Nut M6 x 19 mm Rivet Nut M8 x 18 mm Rivet Nut M8 x 21 mm Rivet Nut M10 x 23 mm Rivet Nut M10 x 26 mm Rivet Nut Installation Tool available from: Bollhoff Fastenings Ltd (www.bollhof.com) 1 2 Fig 10. Rivet Nut Tool 1-20 1-20 9813/2400-2

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