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Jcb 260 t skid steer loader service repair manual sn from 2476302 to 2477300

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This service manual provides instructions for servicing skid steer loaders and their engines. It details removing and installing the engine bedplate, which acts as the main strength component and maintains alignment of internal engine parts. The multi-step procedure requires cleaning and applying sealant to the bedplate and crankcase mating surfaces, installing bearing shells and bolts, and torquing bolts to specified values. Special tools like templates and torque wrenches are needed to correctly complete the installation.

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SERVICE MANUAL SKIDSTEER LOADER 225T, 250, 250T, 260, 260T, 270, 270T, 280, 300, 300T, 320T, 325T, 330 EN - 9813/7450 - ISSUE 2 - 12/2017 This manual contains original instructions, verified by the manufacturer (or their authorized representative). Copyright 2017 © 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. www.jcb.com Foreword The Operator's Manual You and others can be killed or seriously injured if you operate or maintain the machine without first studying the Operator's Manual. You must understand and follow the instructions in the Operator's Manual. If you do not understand anything, ask your employer or JCB dealer to explain it. Do not operate the machine without an Operator's Manual, or if there is anything on the machine you do not understand. Treat the Operator's Manual as part of the machine. Keep it clean and in good condition. Replace the Operator's Manual immediately if it is lost, damaged or becomes unreadable. Contents 01 - Machine 03 - Attachments, Couplings and Load Handling 06 - Body and Framework 09 - Operator Station 12 - Heating, Ventilating and Air- Conditioning (HVAC) 15 - Engine 18 - Fuel and Exhaust System 21 - Cooling System 24 - Brake System 27 - Driveline 30 - Hydraulic System 33 - Electrical System 72 - Fasteners and Fixings 75 - Consumable Products 78 - After Sales
15 - Engine 09 - Bedplate 00 - General 15 - 67 9813/7450-2 15 - 67 00 - General Introduction .................................................... 15-67 Remove and Install ....................................... 15-68 Introduction The bedplate acts as the main strength component of the engine. it maintains the correct alignment and supports the weight of the internal components. Figure 145. 1 2 1 Bedplate 2 Crankcase
15 - Engine 09 - Bedplate 00 - General 15 - 68 9813/7450-2 15 - 68 Remove and Install Special Tools Description Part No. Qty. Template for Sealant Bedplate to Crankcase (4 Cyl) 892/12356 1 Torque Wrench (10-100Nm) 993/70111 1 Consumables Description Part No. Size Cleaner/Degreaser - General purpose solvent based parts cleaner 4104/1557 0.4L CAUTION This component is heavy. It must only be removed or handled using a suitable lifting method and device. Before Removal 1. This procedure requires service parts. Make sure you have obtained the correct service parts before you start, refer to Parts Catalogue. 2. Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work. 3. Remove the engine, refer to (PIL 15-00). 4. Remove the drive belt, refer to (PIL 15-18). 5. Remove the crankshaft pulley, refer to (PIL 15-12). 6. Remove the oil sump, refer to (PIL 15-45). 7. Disconnect and remove the fuel pipes from the injectors, refer to (PIL 18-96). 8. Remove the rocker cover, refer to (PIL 15-42). 9. Remove the fuel injectors, refer to (PIL 18-18). 10. Remove the rocker assembly including the push rods, refer to (PIL 15-42). 11. It is not necessary to remove the cylinder head assembly to remove the crankshaft. If however the cylinder head needs to be removed for other reasons (for piston and connecting rod removal for example) remove it now, refer to (PIL 15-06). 12. Remove the fuel injection pump, refer to (PIL 18-18). 13. Remove the starter motor, refer to (PIL 15-75). 14. Remove the high duty PTO (Power Take-Off) device (if installed). 15. Position the engine upside down in a suitable jig or fixture, supported at the front of the cylinder block. 16. Remove the flywheel, refer to (PIL 15-54). 17. Remove the flywheel housing, refer to (PIL 15-54). 18. Remove the fuel injection pump drive gear, refer to (PIL 15-51). 19. Remove the oil pump, refer to (PIL 15-60). 20. Remove the high duty PTO idler drive gear (if installed), refer to (PIL 15-51). 21. Remove the crankshaft drive gear, refer to (PIL 15-51). 22. Remove the camshaft, refer to (PIL 15-15). 23. Remove the rear timing case, refer to (PIL 15-51). 24. If the pistons and connecting rods have not been removed, undo and remove the main bearing caps, refer to (PIL 15-12).
15 - Engine 09 - Bedplate 00 - General 15 - 69 9813/7450-2 15 - 69 Figure 146. 51 18 18 18 18 18 9 11 4 8 12 X 13 18 3 7 62 10 P3 1-10 Main bearing bolts (x10) 11 Bedplate peripheral bolts (x16) 12 Bedplate 13 Crankcase 18 Upper bearing shell (x5) P3 O-ring (if installed) T1 Lifting bolts (obtain locally)
15 - Engine 09 - Bedplate 00 - General 15 - 70 9813/7450-2 15 - 70 Remove 1. Remove the bedplate peripheral bolts. 2. Progressively remove the main bearing bolts in reverse order starting at bolt 10. The bolts MUST NOT be re-used. Discard the bolts. 3. Install the four temporary lifting bolts. Carefully separate the bedplate from the crankcase. Use suitable lifting equipment (if the bedplate is lifted manually, two people will be required). DO NOT use a lever to separate the bedplate. 4. Remove and discard the O-ring. 5. Carefully remove the upper bearing shells from the bedplate, remove the bedplate. Figure 147. 18 18 18 18 18 T6 T6 T6 18 12 T6 P3 13 11 A (T5) V YY P2 51 9 4 8 3 7 62 10 T4 T4 W P2 B (T5) Y Y P2 X 1-10 Main bearing bolts 11 Bedplate peripheral bolts (x16) 12 Bedplate 13 Crankcase 18 Lower bearing shells (x5) A Left side template B Right side template T3 Angle Gauge (obtain locally)
15 - Engine 09 - Bedplate 00 - General 15 - 71 9813/7450-2 15 - 71 T4 Guide pins (x2 obtain locally) T5 Sealant template T6 Lifting bolts (x4 obtain locally) V Sealant template portion for removal W Bearing tab X Rear main bearing Y Bearing location tab P2 Anaerobic sealant P3 O-ring
15 - Engine 09 - Bedplate 00 - General 15 - 72 9813/7450-2 15 - 72 Before Installation 1. Clean off all traces of the old sealant compound from the crankcase and bedplate mating faces. 2. Use a suitable degreasing agent to carefully clean the main bearing saddles in the bedplate and crankcase. Take care not to block the oil ways or the piston cooling jets. Consumable: Cleaner/Degreaser - General purpose solvent based parts cleaner Important: Anaerobic sealant will not start to cure whilst it is open to the atmosphere, however when air is excluded (for instance when the two parts are put together) it will immediately start to harden. Make sure that all the necessary tools, bolts etc. are readily available prior to assembling the components. The parts must be installed and tightened to the correct torque value within 5 minutes (with a maximum permissible time of 15 minutes). Important: BEFORE installing the bedplate: DO NOT rotate the crankshaft. Make sure that the upper main bearing shells are flush with the bottom face of the crankcase. Install 1. The installation procedure is the opposite of the removal procedure. Additionally do the following steps. 2. Make sure that all items are clean and free from damage and corrosion. 3. Install the two guide pins T4 to the crankcase bedplate fixing holes as shown. 4. Install the four lifting bolts T6 to the bedplate as shown. 5. Install a new O-ring at the bedplate. 6. Use a suitable degreasing agent to clean both sides of the lower bearing shells. Assemble the lower bearing shells into the bedplate. Lubricate the lower bearing shells with clean engine oil. Note: Make sure that the location tab W engages in the slot as shown. Consumable: Cleaner/Degreaser - General purpose solvent based parts cleaner 7. Note: The sealant template T5 is used on the crankcase, NOT the bedplate. The sealant template T5 comprises of two pieces, A and B. Modify the template A by removing portion V. Special Tool: Template for Sealant Bedplate to Crankcase (4 Cyl) (Qty.: 1) 8. Locate the holes in the templates A and B using four fixing bolts at positions Y. Use the templates as a guide apply beads of sealant P2 around the crankcase/bedplate mating face as shown to the dimension specified. Length/Dimension/Distance: 1.5mm 9. Remove the four fixing bolts at positions Y. Remove the templates A and B, make sure you do not smudge the sealant. Discard the templates. 10. Add beads of sealant P2 around the four bolt holes at positions Y, so as to join the sealant beads as shown at X. 11. Make sure that the location guide pins T4 are in position in the crankcase. Assemble the bedplate to the crankcase use the alignment guide pins. 12. Note: The bedplate is heavy. Two people will be required to lift and rotate the bedplate safely on to the crankcase. Install new main bearing bolts 1-10. Tighten the bolts to the correct torque value in pairs, starting in the centre and working outwards (in sequence 1-10) to the 1st stage pre- torque. Special Tool: Torque Wrench (10-100Nm) (Qty.: 1) 13. Install the bedplate peripheral bolts. Tighten the bolts to the correct torque value. 14. After installation and tightening the bedplate peripheral bolts, further tighten the main bearing bolts in pairs, starting in the centre and working outwards (in sequence 1-10) to the 2nd stage pre-torque. 15. Finally, angle tighten the main bearing bolts in pairs, starting in the centre and working outwards (in sequence 1-10) for the final stage torque. Use the torque and angle method, refer to Fasteners and Fixings, General, Introduction (PIL 72-00). Important: If the parts have not been tightened to the correct torque value within the maximum 15 minute time period, then the parts must be separated, thoroughly cleaned and fresh sealant applied. After Installation 1. Check that the crankshaft can be freely rotated by hand. Remove the bedplate lifting bolts T6. 2. Carry out the procedures listed, Before removal in reverse order. Table 54. Torque Table Item Torque Value 1-10 (1st Stage) 50N·m 1-10 (2nd Stage) 115N·m
15 - Engine 12 - Crankshaft 00 - General 15 - 76 9813/7450-2 15 - 76 Technical Data Table 55. Main bearing journal diameter (x4) - min 87.98mm - max 88mm Main rear bearing journal diameter (x1) - min 99.98mm - max 100mm Connecting rod bearing journal diameter - min 72.98mm - max 73mm Maximum wear and ovality on journals (1) Crankshaft induction hardness 55 HRc min on surface Thrust washer width - min 2.44mm - max 2.5mm Crankshaft end float - min 0.05mm - max 0.28mm (1) No visible damage/wear or marks
15 - Engine 12 - Crankshaft 00 - General 15 - 77 9813/7450-2 15 - 77 Component Identification Figure 148. B A A Crankcase B Crankshaft
15 - Engine 12 - Crankshaft 00 - General 15 - 78 9813/7450-2 15 - 78 Operation Lubrication Oil is fed from the main gallery via five drillings, one to each of the main bearings. A groove around the diameter of the upper main bearing shell allows oil transfer to cross drillings in the crankshaft to feed each of the big end bearings. Crankshaft gear is 'splash' lubricated. Front and rear crankshaft oil seals prevent oil leakage from, and dirt ingress to, the engine. Figure 149. 1 Main gallery 2 Drillings (x5) 3 Main bearings 4 Big end bearings 5 Cross drillings 6 Crankshaft gear 7 Crankshaft oil seal 8 Crankshaft oil seal
15 - Engine 12 - Crankshaft 00 - General 15 - 79 9813/7450-2 15 - 79 Check (Condition) 1. Check the main bearing surfaces for damage and excessive wear. Figure 150. A A Main bearing shells 2. Measure the crankshaft diameters to confirm they are within service limits, refer to Technical Data (PIL 15-12). Figure 151. B B Crankshaft 3. Check that the oil-way cross drillings in the crankshaft are clear and free from debris. Blocked or restricted oil-ways will cause oil starvation at the big end bearings. 4. Check that the piston cooling J-jets are clear. If the J-jets cannot be cleared remove the fixing screws. Remove theJ-jets and discard them. 5. Install new J-jets. Figure 152. D C C J-jets D Fixing screws
15 - Engine 12 - Crankshaft 00 - General 15 - 80 9813/7450-2 15 - 80 Remove and Install Consumables Description Part No. Size Cleaner/Degreaser - General purpose solvent based parts cleaner 4104/1557 0.4L CAUTION This component is heavy. It must only be removed or handled using a suitable lifting method and device. Before Removal 1. This procedure requires service parts. Make sure you have obtained the correct service parts before you start, refer to Parts Catalogue. 2. Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work. 3. Remove the engine, refer to (PIL 15-00). 4. Remove the drive belt, refer to (PIL 15-18). 5. Remove the crankshaft pulley, refer to (PIL 15-12). 6. Remove the oil sump, refer to (PIL 15-45). 7. Disconnect and remove the fuel pipes from the injectors, refer to (PIL 18-96). 8. Remove the rocker cover, refer to (PIL 15-42). 9. Remove the fuel injectors, refer to (PIL 18-18). 10. Remove the rocker assembly including the push rods, refer to (PIL 15-42). 11. It is not necessary to remove the cylinder head assembly to remove the crankshaft. If however the cylinder head needs to be removed for other reasons (for piston and connecting rod removal for example) remove it now, refer to (PIL 15-06). 12. Remove the fuel injection pump, refer to (PIL 18-18). 13. Remove the starter motor, refer to (PIL 15-75). 14. Remove the high duty PTO device (if installed). 15. Position the engine upside down in a suitable jig or fixture, supported at the front of the cylinder block. 16. Remove the flywheel, refer to (PIL 15-54). 17. Remove the flywheel housing, refer to (PIL 15-54). 18. Remove the fuel injection pump drive gear, refer to (PIL 15-51). 19. Remove the oil pump, refer to (PIL 15-60). 20. Remove the high duty PTO idler drive gear (if installed), refer to (PIL 15-51). 21. Remove the crankshaft drive gear, refer to (PIL 15-51). 22. Remove the camshaft, refer to (PIL 15-15). 23. Remove the rear timing case, refer to (PIL 15-51). 24. If the pistons and connecting rods have not been removed, undo and remove the main bearing caps, refer to (PIL 15-12). 25. Remove the bedplate, refer to (PIL 15-09). Remove 1. Remove the thrust washers between the crankshaft and crankcase rear main bearing.
15 - Engine 12 - Crankshaft 00 - General 15 - 81 9813/7450-2 15 - 81 Figure 153. C B A A A Thrust Washers B Crankshaft C Rear main bearing 2. Put labels on the thrust washers to make sure that they are installed in the correct positions during assembly. 3. Use suitable lifting equipment to carefully lift the crankshaft from the crankcase (if the crankshaft is lifted manually, two people will be required). 4. Carefully lift out the bearing shells. Figure 154. D D Main bearing shells 5. It is recommended that the bearing shells are replaced. If however they are to be used again, put label on the shells to make sure that they are installed in their original positions during assembly. 6. Inspect the crankshaft and main bearings etc. for damage and excessive wear. Refer to Check Condition (PIL 15-12). Before Installation 1. Clean off all traces of the old sealant compound from the crankcase and bedplate mating faces. 2. Use a suitable degreasing agent to carefully clean the main bearing saddles in the bedplate and crankcase. Take care not to block the oil ways or the piston cooling jets. Consumable: Cleaner/Degreaser - General purpose solvent based parts cleaner Important: Cleanliness is of the utmost importance. Blocked oil-ways or oil jets will cause engine failure. Before you install the crankshaft make sure that ALL oil-ways and jets are clear and free from debris. Install 1. The installation procedure is the opposite of the removal procedure. Additionally do the following steps. 2. Make sure that all items are clean and free from damage and corrosion. 3. If removed or a new crankcase is being installed then install cooling J jets as follows:
15 - Engine 12 - Crankshaft 00 - General 15 - 82 9813/7450-2 15 - 82 Figure 155. F E E J jets (x4) F Fixing screws 3.1. Insert the cooling jets into the crankcase. 3.2. Note: There are different types of cooling jets installed depending on the engine application. The jets are colour coded. 3.3. Be sure to install the correct jets. Refer to the relevant parts catalogue for the correct cooling jet identification. 3.4. Tighten the retaining screws to the correct torque value. 4. Install the upper bearing shells as follows: Figure 156. D G D Main bearing shells G Bearing location tab 4.1. Use a suitable degreasing agent to make sure that the surface of the upper bearing shells are clean. Consumable: Cleaner/Degreaser - General purpose solvent based parts cleaner 4.2. Assemble the bearing shells into the crankcase bearing saddles. Make sure that the location tab engages into the slot as shown. 4.3. Important: Make sure that the oil-way holes in the bearing saddles align with the holes in the bearing shell. If the holes are even partially misaligned the piston cooling oil jet will be restricted, causing the engine to fail. 4.4. Lubricate the upper bearing shells with clean engine oil. 5. Use suitable lifting equipment (if the crankshaft is lifted manually, two people will be required), to carefully lower the crankshaft into the crankcase. DO NOT rotate the crankshaft, the bearing shells can become dislodged, refer to step 4. 6. Install the thrust washers as follows:
15 - Engine 12 - Crankshaft 00 - General 15 - 83 9813/7450-2 15 - 83 Figure 157. C B A A A H A Thrust washers B Crankshaft C Rear main bearing H Oil slot - thrust washers 6.1. ºÝºÝߣ the thrust washers between the crankshaft and the crankcase rear main bearing. 6.2. Make sure that they are installed in the correct positions, with the two slots facing outwards from the bearing saddle. 6.3. If necessary, push the crankshaft forward and then backwards to obtain clearance to install the thrust washers. 6.4. DO NOT rotate the crankshaft, the bearing shells can become dislodged, refer to step 4. 7. Check that the crankshaft end float is within service limits, refer to Technical Data (PIL 15-12). Table 56. Torque Values Item Nm F 24
15 - Engine 12 - Crankshaft 03 - Main Bearing 15 - 84 9813/7450-2 15 - 84 03 - Main Bearing Introduction .................................................... 15-84 Check (Condition) .......................................... 15-85 Remove and Install ....................................... 15-85 Introduction In a piston engine, the main bearings are the bearings on which the crankshaft rotates. The bearings hold the crankshaft in place and prevent the forces created by the piston and transmitted to the crankshaft by the connecting rods from dislodging the crankshaft, instead forcing the crank to convert the reciprocating movement into rotation. Figure 158. A B A Main bearing B Crankshaft
15 - Engine 12 - Crankshaft 03 - Main Bearing 15 - 85 9813/7450-2 15 - 85 Check (Condition) (For: JCB Tier 4i /T4F <55kW Engine 4 Cyl) 1. Check the bearing shell surfaces for signs of damage and excessive wear. 2. Measure the crank pin diameters to confirm they are within service limits. Refer to: PIL 15-12-00. 3. Renew any parts that are worn or not within the specified tolerances. Remove and Install (For: JCB Tier 4i /T4F <55kW Engine 4 Cyl) Special Tools Description Part No. Qty. Torque Wrench (10-100Nm) 993/70111 1 Before Removal This procedure requires service parts. Make sure you have obtained the correct service parts before you start. Refer to Parts Catalogue. 1. Make the machine safe. Refer to: PIL 01-03. 2. Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work. 3. Remove the engine from the machine. Refer to: PIL 15-00-00. 4. Disconnect and remove the fuel pipes from the injectors. Refer to: PIL 18-96-00. 5. Remove the rocker cover. Refer to: PIL 15-42-06. 6. Remove the fuel injectors. Refer to: PIL 18-18-03. 7. Drain the oil from the engine. Refer to: PIL 15-21-00. 8. Remove the oil sump. Refer to: PIL 15-45-00. 9. Position the engine upside down in a suitable jig or fixture, supported at the front of the crankcase. The connecting rod and the big-end bearing cap have been fracture split and must be kept together as a set. Care must be taken to avoid contamination and or damage to the fracture split surfaces. Remove 1. It is recommended that the big-end bearing caps are removed in pairs, cylinders 1 and 4 and cylinders 2 and 3. Rotate the crankshaft so that the big-end bearing caps on cylinders 2 and 3 are positioned as shown.
15 - Engine 12 - Crankshaft 03 - Main Bearing 15 - 86 9813/7450-2 15 - 86 2. Remove the bolts and lift off the big-end bearing caps from the connecting rods. The bolts must not be re-used, discard the bolts. Figure 159. X 1 2 1 Big-end bearing caps 2 Big-end bearing cap bolts X Cast notch 2.1. Make sure that the tool is kept in inline with the bolt to avoid damaging the screw thread. 3. Lift out the bearing shells from the bearing caps. Carefully rotate the crank to disengage from the connecting rods and get access to the upper bearing shells. Lift out the upper bearing shells. It is recommended that the bearing shells are renewed. If they are to be reused, label the bearing shells to make sure that they are installed in their original positions on assembly. Figure 160. 4 3 Z 1 2 6 5 1 Big-end bearing cap 2 Bolts 3 Connecting rod 4 Piston 5 Piston rings 6 Big end bearing shells Z Fracture split surfaces 4. Carefully rotate the crankshaft to position the big- end bearing caps of cylinders 1 and 4. Make sure that the crank does not foul the connecting rods of cylinders 2 and 3. Remove the bearing caps and bearing shells as described in previous steps. 5. Inspect the big-end bearings for signs of damage and excessive wear. Install 1. The installation procedure is the opposite of the removal procedure. Additionally do the following steps. 2. Make sure that all items are clean and free from damage and corrosion. 3. Install the upper bearing shell to the connecting rod. Lubricate the bearing shell with clean engine oil. 4. Install the lower bearing shell to the big-end bearing cap. Lubricate the bearing shell with
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15 - Engine 12 - Crankshaft 03 - Main Bearing 15 - 87 9813/7450-2 15 - 87 clean engine oil. Install the big-end bearing cap to the connecting rod. Make sure that the cast notch on the bearing cap faces to the front of the engine. Use compressed air to clean the fracture surfaces before assembly. 5. Install new big end bearing cap bolts. Tighten the new bolts in three stages to the correct torque value. Special Tool: Torque Wrench (10-100Nm) (Qty.: 1) 5.1. Make sure that the tool is kept in inline with the bolt to avoid damaging the screw thread. 5.2. The bolts are tightened using a torque and angle method. Refer to: PIL 72-00-00. Figure 161. 0° +90° Y Figure 162. T3 T3 Angle gauge (obtain locally) After Installation 1. The after installation procedure is the opposite of the before removal procedure. Table 57. Torque Table Item Torque Value (Nm) Angle (de- grees) 2 (1st Stage) 35 2 (2nd Stage) 65 2 (Final Stage) 90
15 - Engine 12 - Crankshaft 06 - Front Oil Seal 15 - 88 9813/7450-2 15 - 88 06 - Front Oil Seal Remove and Install (For: JCB Tier 4i /T4F <55kW Engine 4 Cyl) Special Tools Description Part No. Qty. Crankshaft Front Oil Seal Installation Tool 892/01157 1 Before Removal 1. This procedure requires service parts. Make sure you have obtained the correct service parts before you start, refer to Parts Catalogue. 2. Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work. 3. Get access to the engine. 4. Remove the drive belt, refer to (PIL 15-18). 5. Remove the crankshaft pulley, refer to (PIL 15-12-12). Remove 1. Use a suitable lever behind the lip of the seal, carefully prise out the oil seal from the counterbore in the crankcase. Take care not to scratch or damage the counterbore or the crankshaft hub. Damaged or dirty sealing faces will cause the oil seal to fail. Figure 163. C A B A Crankshaft oil seal B Crankcase C Crankshaft hub Install 1. Make sure that the counterbore and the crankshaft hub are clean and free from damage and corrosion. Use a suitable degreasing agent to clean all traces of oil and grease from the counterbore. Important: The oil seal has a special coating and MUST be installed dry without lubricant. 2. Dismantle the seal installation tool. Bolt the centre body to the crankshaft hub, using the bolts. Refer to Figure 164. Special Tool: Crankshaft Front Oil Seal Installation Tool (Qty.: 1) 3. Install the oil seal on to the centre body. Make sure that the seal is installed the correct way around. Assemble the outer sleeve on to the centre body and install the screw. Refer to Figure 164.
15 - Engine 12 - Crankshaft 06 - Front Oil Seal 15 - 89 9813/7450-2 15 - 89 Figure 164. F D G H B G F C A E A Crankshaft oil seal B Crankcase C Crankshaft hub D Seal installation tool E Fixing bolts (x3) F Centre body G Outer sleeve H Screw 4. Turn the screw to push the seal squarely into the counterbore until the outer sleeve comes up against the front edge of the counterbore. When correctly installed, the front face of the seal should be flush with the edge of the counterbore within the specified tolerance. Refer to Figure 165. Dimension: -0.5 -0/+0.5mm Figure 165. B G F C A A Crankshaft oil seal B Crankcase C Crankshaft hub F Centre body G Outer sleeve 5. Remove the seal installation tool.

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Jcb 260 t skid steer loader service repair manual sn from 2476302 to 2477300

  • 1. SERVICE MANUAL SKIDSTEER LOADER 225T, 250, 250T, 260, 260T, 270, 270T, 280, 300, 300T, 320T, 325T, 330 EN - 9813/7450 - ISSUE 2 - 12/2017 This manual contains original instructions, verified by the manufacturer (or their authorized representative). Copyright 2017 © 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. www.jcb.com Foreword The Operator's Manual You and others can be killed or seriously injured if you operate or maintain the machine without first studying the Operator's Manual. You must understand and follow the instructions in the Operator's Manual. If you do not understand anything, ask your employer or JCB dealer to explain it. Do not operate the machine without an Operator's Manual, or if there is anything on the machine you do not understand. Treat the Operator's Manual as part of the machine. Keep it clean and in good condition. Replace the Operator's Manual immediately if it is lost, damaged or becomes unreadable. Contents 01 - Machine 03 - Attachments, Couplings and Load Handling 06 - Body and Framework 09 - Operator Station 12 - Heating, Ventilating and Air- Conditioning (HVAC) 15 - Engine 18 - Fuel and Exhaust System 21 - Cooling System 24 - Brake System 27 - Driveline 30 - Hydraulic System 33 - Electrical System 72 - Fasteners and Fixings 75 - Consumable Products 78 - After Sales
  • 2. 15 - Engine 09 - Bedplate 00 - General 15 - 67 9813/7450-2 15 - 67 00 - General Introduction .................................................... 15-67 Remove and Install ....................................... 15-68 Introduction The bedplate acts as the main strength component of the engine. it maintains the correct alignment and supports the weight of the internal components. Figure 145. 1 2 1 Bedplate 2 Crankcase
  • 3. 15 - Engine 09 - Bedplate 00 - General 15 - 68 9813/7450-2 15 - 68 Remove and Install Special Tools Description Part No. Qty. Template for Sealant Bedplate to Crankcase (4 Cyl) 892/12356 1 Torque Wrench (10-100Nm) 993/70111 1 Consumables Description Part No. Size Cleaner/Degreaser - General purpose solvent based parts cleaner 4104/1557 0.4L CAUTION This component is heavy. It must only be removed or handled using a suitable lifting method and device. Before Removal 1. This procedure requires service parts. Make sure you have obtained the correct service parts before you start, refer to Parts Catalogue. 2. Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work. 3. Remove the engine, refer to (PIL 15-00). 4. Remove the drive belt, refer to (PIL 15-18). 5. Remove the crankshaft pulley, refer to (PIL 15-12). 6. Remove the oil sump, refer to (PIL 15-45). 7. Disconnect and remove the fuel pipes from the injectors, refer to (PIL 18-96). 8. Remove the rocker cover, refer to (PIL 15-42). 9. Remove the fuel injectors, refer to (PIL 18-18). 10. Remove the rocker assembly including the push rods, refer to (PIL 15-42). 11. It is not necessary to remove the cylinder head assembly to remove the crankshaft. If however the cylinder head needs to be removed for other reasons (for piston and connecting rod removal for example) remove it now, refer to (PIL 15-06). 12. Remove the fuel injection pump, refer to (PIL 18-18). 13. Remove the starter motor, refer to (PIL 15-75). 14. Remove the high duty PTO (Power Take-Off) device (if installed). 15. Position the engine upside down in a suitable jig or fixture, supported at the front of the cylinder block. 16. Remove the flywheel, refer to (PIL 15-54). 17. Remove the flywheel housing, refer to (PIL 15-54). 18. Remove the fuel injection pump drive gear, refer to (PIL 15-51). 19. Remove the oil pump, refer to (PIL 15-60). 20. Remove the high duty PTO idler drive gear (if installed), refer to (PIL 15-51). 21. Remove the crankshaft drive gear, refer to (PIL 15-51). 22. Remove the camshaft, refer to (PIL 15-15). 23. Remove the rear timing case, refer to (PIL 15-51). 24. If the pistons and connecting rods have not been removed, undo and remove the main bearing caps, refer to (PIL 15-12).
  • 4. 15 - Engine 09 - Bedplate 00 - General 15 - 69 9813/7450-2 15 - 69 Figure 146. 51 18 18 18 18 18 9 11 4 8 12 X 13 18 3 7 62 10 P3 1-10 Main bearing bolts (x10) 11 Bedplate peripheral bolts (x16) 12 Bedplate 13 Crankcase 18 Upper bearing shell (x5) P3 O-ring (if installed) T1 Lifting bolts (obtain locally)
  • 5. 15 - Engine 09 - Bedplate 00 - General 15 - 70 9813/7450-2 15 - 70 Remove 1. Remove the bedplate peripheral bolts. 2. Progressively remove the main bearing bolts in reverse order starting at bolt 10. The bolts MUST NOT be re-used. Discard the bolts. 3. Install the four temporary lifting bolts. Carefully separate the bedplate from the crankcase. Use suitable lifting equipment (if the bedplate is lifted manually, two people will be required). DO NOT use a lever to separate the bedplate. 4. Remove and discard the O-ring. 5. Carefully remove the upper bearing shells from the bedplate, remove the bedplate. Figure 147. 18 18 18 18 18 T6 T6 T6 18 12 T6 P3 13 11 A (T5) V YY P2 51 9 4 8 3 7 62 10 T4 T4 W P2 B (T5) Y Y P2 X 1-10 Main bearing bolts 11 Bedplate peripheral bolts (x16) 12 Bedplate 13 Crankcase 18 Lower bearing shells (x5) A Left side template B Right side template T3 Angle Gauge (obtain locally)
  • 6. 15 - Engine 09 - Bedplate 00 - General 15 - 71 9813/7450-2 15 - 71 T4 Guide pins (x2 obtain locally) T5 Sealant template T6 Lifting bolts (x4 obtain locally) V Sealant template portion for removal W Bearing tab X Rear main bearing Y Bearing location tab P2 Anaerobic sealant P3 O-ring
  • 7. 15 - Engine 09 - Bedplate 00 - General 15 - 72 9813/7450-2 15 - 72 Before Installation 1. Clean off all traces of the old sealant compound from the crankcase and bedplate mating faces. 2. Use a suitable degreasing agent to carefully clean the main bearing saddles in the bedplate and crankcase. Take care not to block the oil ways or the piston cooling jets. Consumable: Cleaner/Degreaser - General purpose solvent based parts cleaner Important: Anaerobic sealant will not start to cure whilst it is open to the atmosphere, however when air is excluded (for instance when the two parts are put together) it will immediately start to harden. Make sure that all the necessary tools, bolts etc. are readily available prior to assembling the components. The parts must be installed and tightened to the correct torque value within 5 minutes (with a maximum permissible time of 15 minutes). Important: BEFORE installing the bedplate: DO NOT rotate the crankshaft. Make sure that the upper main bearing shells are flush with the bottom face of the crankcase. Install 1. The installation procedure is the opposite of the removal procedure. Additionally do the following steps. 2. Make sure that all items are clean and free from damage and corrosion. 3. Install the two guide pins T4 to the crankcase bedplate fixing holes as shown. 4. Install the four lifting bolts T6 to the bedplate as shown. 5. Install a new O-ring at the bedplate. 6. Use a suitable degreasing agent to clean both sides of the lower bearing shells. Assemble the lower bearing shells into the bedplate. Lubricate the lower bearing shells with clean engine oil. Note: Make sure that the location tab W engages in the slot as shown. Consumable: Cleaner/Degreaser - General purpose solvent based parts cleaner 7. Note: The sealant template T5 is used on the crankcase, NOT the bedplate. The sealant template T5 comprises of two pieces, A and B. Modify the template A by removing portion V. Special Tool: Template for Sealant Bedplate to Crankcase (4 Cyl) (Qty.: 1) 8. Locate the holes in the templates A and B using four fixing bolts at positions Y. Use the templates as a guide apply beads of sealant P2 around the crankcase/bedplate mating face as shown to the dimension specified. Length/Dimension/Distance: 1.5mm 9. Remove the four fixing bolts at positions Y. Remove the templates A and B, make sure you do not smudge the sealant. Discard the templates. 10. Add beads of sealant P2 around the four bolt holes at positions Y, so as to join the sealant beads as shown at X. 11. Make sure that the location guide pins T4 are in position in the crankcase. Assemble the bedplate to the crankcase use the alignment guide pins. 12. Note: The bedplate is heavy. Two people will be required to lift and rotate the bedplate safely on to the crankcase. Install new main bearing bolts 1-10. Tighten the bolts to the correct torque value in pairs, starting in the centre and working outwards (in sequence 1-10) to the 1st stage pre- torque. Special Tool: Torque Wrench (10-100Nm) (Qty.: 1) 13. Install the bedplate peripheral bolts. Tighten the bolts to the correct torque value. 14. After installation and tightening the bedplate peripheral bolts, further tighten the main bearing bolts in pairs, starting in the centre and working outwards (in sequence 1-10) to the 2nd stage pre-torque. 15. Finally, angle tighten the main bearing bolts in pairs, starting in the centre and working outwards (in sequence 1-10) for the final stage torque. Use the torque and angle method, refer to Fasteners and Fixings, General, Introduction (PIL 72-00). Important: If the parts have not been tightened to the correct torque value within the maximum 15 minute time period, then the parts must be separated, thoroughly cleaned and fresh sealant applied. After Installation 1. Check that the crankshaft can be freely rotated by hand. Remove the bedplate lifting bolts T6. 2. Carry out the procedures listed, Before removal in reverse order. Table 54. Torque Table Item Torque Value 1-10 (1st Stage) 50N·m 1-10 (2nd Stage) 115N·m
  • 8. 15 - Engine 12 - Crankshaft 00 - General 15 - 76 9813/7450-2 15 - 76 Technical Data Table 55. Main bearing journal diameter (x4) - min 87.98mm - max 88mm Main rear bearing journal diameter (x1) - min 99.98mm - max 100mm Connecting rod bearing journal diameter - min 72.98mm - max 73mm Maximum wear and ovality on journals (1) Crankshaft induction hardness 55 HRc min on surface Thrust washer width - min 2.44mm - max 2.5mm Crankshaft end float - min 0.05mm - max 0.28mm (1) No visible damage/wear or marks
  • 9. 15 - Engine 12 - Crankshaft 00 - General 15 - 77 9813/7450-2 15 - 77 Component Identification Figure 148. B A A Crankcase B Crankshaft
  • 10. 15 - Engine 12 - Crankshaft 00 - General 15 - 78 9813/7450-2 15 - 78 Operation Lubrication Oil is fed from the main gallery via five drillings, one to each of the main bearings. A groove around the diameter of the upper main bearing shell allows oil transfer to cross drillings in the crankshaft to feed each of the big end bearings. Crankshaft gear is 'splash' lubricated. Front and rear crankshaft oil seals prevent oil leakage from, and dirt ingress to, the engine. Figure 149. 1 Main gallery 2 Drillings (x5) 3 Main bearings 4 Big end bearings 5 Cross drillings 6 Crankshaft gear 7 Crankshaft oil seal 8 Crankshaft oil seal
  • 11. 15 - Engine 12 - Crankshaft 00 - General 15 - 79 9813/7450-2 15 - 79 Check (Condition) 1. Check the main bearing surfaces for damage and excessive wear. Figure 150. A A Main bearing shells 2. Measure the crankshaft diameters to confirm they are within service limits, refer to Technical Data (PIL 15-12). Figure 151. B B Crankshaft 3. Check that the oil-way cross drillings in the crankshaft are clear and free from debris. Blocked or restricted oil-ways will cause oil starvation at the big end bearings. 4. Check that the piston cooling J-jets are clear. If the J-jets cannot be cleared remove the fixing screws. Remove theJ-jets and discard them. 5. Install new J-jets. Figure 152. D C C J-jets D Fixing screws
  • 12. 15 - Engine 12 - Crankshaft 00 - General 15 - 80 9813/7450-2 15 - 80 Remove and Install Consumables Description Part No. Size Cleaner/Degreaser - General purpose solvent based parts cleaner 4104/1557 0.4L CAUTION This component is heavy. It must only be removed or handled using a suitable lifting method and device. Before Removal 1. This procedure requires service parts. Make sure you have obtained the correct service parts before you start, refer to Parts Catalogue. 2. Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work. 3. Remove the engine, refer to (PIL 15-00). 4. Remove the drive belt, refer to (PIL 15-18). 5. Remove the crankshaft pulley, refer to (PIL 15-12). 6. Remove the oil sump, refer to (PIL 15-45). 7. Disconnect and remove the fuel pipes from the injectors, refer to (PIL 18-96). 8. Remove the rocker cover, refer to (PIL 15-42). 9. Remove the fuel injectors, refer to (PIL 18-18). 10. Remove the rocker assembly including the push rods, refer to (PIL 15-42). 11. It is not necessary to remove the cylinder head assembly to remove the crankshaft. If however the cylinder head needs to be removed for other reasons (for piston and connecting rod removal for example) remove it now, refer to (PIL 15-06). 12. Remove the fuel injection pump, refer to (PIL 18-18). 13. Remove the starter motor, refer to (PIL 15-75). 14. Remove the high duty PTO device (if installed). 15. Position the engine upside down in a suitable jig or fixture, supported at the front of the cylinder block. 16. Remove the flywheel, refer to (PIL 15-54). 17. Remove the flywheel housing, refer to (PIL 15-54). 18. Remove the fuel injection pump drive gear, refer to (PIL 15-51). 19. Remove the oil pump, refer to (PIL 15-60). 20. Remove the high duty PTO idler drive gear (if installed), refer to (PIL 15-51). 21. Remove the crankshaft drive gear, refer to (PIL 15-51). 22. Remove the camshaft, refer to (PIL 15-15). 23. Remove the rear timing case, refer to (PIL 15-51). 24. If the pistons and connecting rods have not been removed, undo and remove the main bearing caps, refer to (PIL 15-12). 25. Remove the bedplate, refer to (PIL 15-09). Remove 1. Remove the thrust washers between the crankshaft and crankcase rear main bearing.
  • 13. 15 - Engine 12 - Crankshaft 00 - General 15 - 81 9813/7450-2 15 - 81 Figure 153. C B A A A Thrust Washers B Crankshaft C Rear main bearing 2. Put labels on the thrust washers to make sure that they are installed in the correct positions during assembly. 3. Use suitable lifting equipment to carefully lift the crankshaft from the crankcase (if the crankshaft is lifted manually, two people will be required). 4. Carefully lift out the bearing shells. Figure 154. D D Main bearing shells 5. It is recommended that the bearing shells are replaced. If however they are to be used again, put label on the shells to make sure that they are installed in their original positions during assembly. 6. Inspect the crankshaft and main bearings etc. for damage and excessive wear. Refer to Check Condition (PIL 15-12). Before Installation 1. Clean off all traces of the old sealant compound from the crankcase and bedplate mating faces. 2. Use a suitable degreasing agent to carefully clean the main bearing saddles in the bedplate and crankcase. Take care not to block the oil ways or the piston cooling jets. Consumable: Cleaner/Degreaser - General purpose solvent based parts cleaner Important: Cleanliness is of the utmost importance. Blocked oil-ways or oil jets will cause engine failure. Before you install the crankshaft make sure that ALL oil-ways and jets are clear and free from debris. Install 1. The installation procedure is the opposite of the removal procedure. Additionally do the following steps. 2. Make sure that all items are clean and free from damage and corrosion. 3. If removed or a new crankcase is being installed then install cooling J jets as follows:
  • 14. 15 - Engine 12 - Crankshaft 00 - General 15 - 82 9813/7450-2 15 - 82 Figure 155. F E E J jets (x4) F Fixing screws 3.1. Insert the cooling jets into the crankcase. 3.2. Note: There are different types of cooling jets installed depending on the engine application. The jets are colour coded. 3.3. Be sure to install the correct jets. Refer to the relevant parts catalogue for the correct cooling jet identification. 3.4. Tighten the retaining screws to the correct torque value. 4. Install the upper bearing shells as follows: Figure 156. D G D Main bearing shells G Bearing location tab 4.1. Use a suitable degreasing agent to make sure that the surface of the upper bearing shells are clean. Consumable: Cleaner/Degreaser - General purpose solvent based parts cleaner 4.2. Assemble the bearing shells into the crankcase bearing saddles. Make sure that the location tab engages into the slot as shown. 4.3. Important: Make sure that the oil-way holes in the bearing saddles align with the holes in the bearing shell. If the holes are even partially misaligned the piston cooling oil jet will be restricted, causing the engine to fail. 4.4. Lubricate the upper bearing shells with clean engine oil. 5. Use suitable lifting equipment (if the crankshaft is lifted manually, two people will be required), to carefully lower the crankshaft into the crankcase. DO NOT rotate the crankshaft, the bearing shells can become dislodged, refer to step 4. 6. Install the thrust washers as follows:
  • 15. 15 - Engine 12 - Crankshaft 00 - General 15 - 83 9813/7450-2 15 - 83 Figure 157. C B A A A H A Thrust washers B Crankshaft C Rear main bearing H Oil slot - thrust washers 6.1. ºÝºÝߣ the thrust washers between the crankshaft and the crankcase rear main bearing. 6.2. Make sure that they are installed in the correct positions, with the two slots facing outwards from the bearing saddle. 6.3. If necessary, push the crankshaft forward and then backwards to obtain clearance to install the thrust washers. 6.4. DO NOT rotate the crankshaft, the bearing shells can become dislodged, refer to step 4. 7. Check that the crankshaft end float is within service limits, refer to Technical Data (PIL 15-12). Table 56. Torque Values Item Nm F 24
  • 16. 15 - Engine 12 - Crankshaft 03 - Main Bearing 15 - 84 9813/7450-2 15 - 84 03 - Main Bearing Introduction .................................................... 15-84 Check (Condition) .......................................... 15-85 Remove and Install ....................................... 15-85 Introduction In a piston engine, the main bearings are the bearings on which the crankshaft rotates. The bearings hold the crankshaft in place and prevent the forces created by the piston and transmitted to the crankshaft by the connecting rods from dislodging the crankshaft, instead forcing the crank to convert the reciprocating movement into rotation. Figure 158. A B A Main bearing B Crankshaft
  • 17. 15 - Engine 12 - Crankshaft 03 - Main Bearing 15 - 85 9813/7450-2 15 - 85 Check (Condition) (For: JCB Tier 4i /T4F <55kW Engine 4 Cyl) 1. Check the bearing shell surfaces for signs of damage and excessive wear. 2. Measure the crank pin diameters to confirm they are within service limits. Refer to: PIL 15-12-00. 3. Renew any parts that are worn or not within the specified tolerances. Remove and Install (For: JCB Tier 4i /T4F <55kW Engine 4 Cyl) Special Tools Description Part No. Qty. Torque Wrench (10-100Nm) 993/70111 1 Before Removal This procedure requires service parts. Make sure you have obtained the correct service parts before you start. Refer to Parts Catalogue. 1. Make the machine safe. Refer to: PIL 01-03. 2. Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work. 3. Remove the engine from the machine. Refer to: PIL 15-00-00. 4. Disconnect and remove the fuel pipes from the injectors. Refer to: PIL 18-96-00. 5. Remove the rocker cover. Refer to: PIL 15-42-06. 6. Remove the fuel injectors. Refer to: PIL 18-18-03. 7. Drain the oil from the engine. Refer to: PIL 15-21-00. 8. Remove the oil sump. Refer to: PIL 15-45-00. 9. Position the engine upside down in a suitable jig or fixture, supported at the front of the crankcase. The connecting rod and the big-end bearing cap have been fracture split and must be kept together as a set. Care must be taken to avoid contamination and or damage to the fracture split surfaces. Remove 1. It is recommended that the big-end bearing caps are removed in pairs, cylinders 1 and 4 and cylinders 2 and 3. Rotate the crankshaft so that the big-end bearing caps on cylinders 2 and 3 are positioned as shown.
  • 18. 15 - Engine 12 - Crankshaft 03 - Main Bearing 15 - 86 9813/7450-2 15 - 86 2. Remove the bolts and lift off the big-end bearing caps from the connecting rods. The bolts must not be re-used, discard the bolts. Figure 159. X 1 2 1 Big-end bearing caps 2 Big-end bearing cap bolts X Cast notch 2.1. Make sure that the tool is kept in inline with the bolt to avoid damaging the screw thread. 3. Lift out the bearing shells from the bearing caps. Carefully rotate the crank to disengage from the connecting rods and get access to the upper bearing shells. Lift out the upper bearing shells. It is recommended that the bearing shells are renewed. If they are to be reused, label the bearing shells to make sure that they are installed in their original positions on assembly. Figure 160. 4 3 Z 1 2 6 5 1 Big-end bearing cap 2 Bolts 3 Connecting rod 4 Piston 5 Piston rings 6 Big end bearing shells Z Fracture split surfaces 4. Carefully rotate the crankshaft to position the big- end bearing caps of cylinders 1 and 4. Make sure that the crank does not foul the connecting rods of cylinders 2 and 3. Remove the bearing caps and bearing shells as described in previous steps. 5. Inspect the big-end bearings for signs of damage and excessive wear. Install 1. The installation procedure is the opposite of the removal procedure. Additionally do the following steps. 2. Make sure that all items are clean and free from damage and corrosion. 3. Install the upper bearing shell to the connecting rod. Lubricate the bearing shell with clean engine oil. 4. Install the lower bearing shell to the big-end bearing cap. Lubricate the bearing shell with
  • 19. Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.
  • 20. 15 - Engine 12 - Crankshaft 03 - Main Bearing 15 - 87 9813/7450-2 15 - 87 clean engine oil. Install the big-end bearing cap to the connecting rod. Make sure that the cast notch on the bearing cap faces to the front of the engine. Use compressed air to clean the fracture surfaces before assembly. 5. Install new big end bearing cap bolts. Tighten the new bolts in three stages to the correct torque value. Special Tool: Torque Wrench (10-100Nm) (Qty.: 1) 5.1. Make sure that the tool is kept in inline with the bolt to avoid damaging the screw thread. 5.2. The bolts are tightened using a torque and angle method. Refer to: PIL 72-00-00. Figure 161. 0° +90° Y Figure 162. T3 T3 Angle gauge (obtain locally) After Installation 1. The after installation procedure is the opposite of the before removal procedure. Table 57. Torque Table Item Torque Value (Nm) Angle (de- grees) 2 (1st Stage) 35 2 (2nd Stage) 65 2 (Final Stage) 90
  • 21. 15 - Engine 12 - Crankshaft 06 - Front Oil Seal 15 - 88 9813/7450-2 15 - 88 06 - Front Oil Seal Remove and Install (For: JCB Tier 4i /T4F <55kW Engine 4 Cyl) Special Tools Description Part No. Qty. Crankshaft Front Oil Seal Installation Tool 892/01157 1 Before Removal 1. This procedure requires service parts. Make sure you have obtained the correct service parts before you start, refer to Parts Catalogue. 2. Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work. 3. Get access to the engine. 4. Remove the drive belt, refer to (PIL 15-18). 5. Remove the crankshaft pulley, refer to (PIL 15-12-12). Remove 1. Use a suitable lever behind the lip of the seal, carefully prise out the oil seal from the counterbore in the crankcase. Take care not to scratch or damage the counterbore or the crankshaft hub. Damaged or dirty sealing faces will cause the oil seal to fail. Figure 163. C A B A Crankshaft oil seal B Crankcase C Crankshaft hub Install 1. Make sure that the counterbore and the crankshaft hub are clean and free from damage and corrosion. Use a suitable degreasing agent to clean all traces of oil and grease from the counterbore. Important: The oil seal has a special coating and MUST be installed dry without lubricant. 2. Dismantle the seal installation tool. Bolt the centre body to the crankshaft hub, using the bolts. Refer to Figure 164. Special Tool: Crankshaft Front Oil Seal Installation Tool (Qty.: 1) 3. Install the oil seal on to the centre body. Make sure that the seal is installed the correct way around. Assemble the outer sleeve on to the centre body and install the screw. Refer to Figure 164.
  • 22. 15 - Engine 12 - Crankshaft 06 - Front Oil Seal 15 - 89 9813/7450-2 15 - 89 Figure 164. F D G H B G F C A E A Crankshaft oil seal B Crankcase C Crankshaft hub D Seal installation tool E Fixing bolts (x3) F Centre body G Outer sleeve H Screw 4. Turn the screw to push the seal squarely into the counterbore until the outer sleeve comes up against the front edge of the counterbore. When correctly installed, the front face of the seal should be flush with the edge of the counterbore within the specified tolerance. Refer to Figure 165. Dimension: -0.5 -0/+0.5mm Figure 165. B G F C A A Crankshaft oil seal B Crankcase C Crankshaft hub F Centre body G Outer sleeve 5. Remove the seal installation tool.