This service manual section provides information on servicing the crankshaft and related components on a backhoe loader. It includes identification of parts, technical specifications, operation descriptions, removal and installation instructions, and check/inspection procedures. Proper cleaning and installation of the crankshaft oil seal is critical to prevent oil leakage. Removal and installation of the crankshaft requires carefully following all steps while ensuring components remain clean and undamaged.
Jcb 3 cx compact backhoe loader service repair manual (sn from 2495456 and up)fusefjskekkmem
This service manual provides instructions for servicing a JCB 3CX Compact backhoe loader. It contains sections covering the machine systems including the engine, fuel system, cooling system, brake system, hydraulic system and electrical system. The specific section summarized discusses servicing procedures for the engine crankshaft, including how it is lubricated by engine oil, how to check its condition by inspecting the bearing surfaces and diameters, and ensuring the oilways are clear.
Jcb 3 cx backhoe loader service repair manual sn from 2442701 to 2451000fusefjskekkmem
This service manual section provides information on servicing the crankshaft and related components on a backhoe loader. It includes identification of parts, technical specifications, operation descriptions, removal and installation instructions, and check/inspection procedures. Proper cleaning and installation of the crankshaft oil seal is critical to prevent oil leakage. Removal and installation of the crankshaft requires carefully following all steps while ensuring components remain clean and undamaged.
Caterpillar cat 140 h motor grader (prefix 126) service repair manual (126000...fusefjskekkmem
The document provides instructions for disassembling and assembling the final drive of a 140H Motor Grader. It lists 24 steps for disassembly, removing components like the sun gear shaft, planetary carrier, gear assemblies, ring gear, drive shaft, and seals. It then lists 30 steps for assembly, installing these components in reverse order, noting specifics like torque specifications and tool requirements.
Caterpillar cat 140 g motor grader (prefix 5md) service repair manual (5md000...fjjsefkksemme
This service repair manual provides instructions for disassembling and assembling various components of a 140G motor grader, including:
1) Removing and installing brake and wheel spindle housings, which includes releasing air pressure and removing nuts, guards, and air lines.
2) Removing and installing tandem housings, which are attached to the final drive housing with nuts.
3) Removing and installing drive sprockets by removing nuts with a tool and ensuring proper preload on bearings.
Caterpillar cat 303 e cr mini hydraulic excavator (prefix hhm) service repair...yhhjjkfkseme
The document provides instructions for removing and installing the fuel injection pump on a Caterpillar 303E CR Mini Hydraulic Excavator. The removal procedure involves removing the solenoid, speed control plate bolts, start spring, injection pump bolts, and recording the number and thickness of shims under the pump. For installation, the same number and thickness of shims are reused and the pump is installed by aligning the control rack pin in the notch and inserting the rack pin into the thrust lever groove. Tightening the bolts completes the installation.
Caterpillar cat 140 g motor grader (prefix 72v) service repair manual (72v042...fusefjskekkmem
This document provides instructions for removing and installing a camshaft on a Caterpillar 3306 engine. It describes in detail:
1) Marking the gears to ensure proper timing when reinstalling the camshaft.
2) Removing the camshaft bolts and carefully pulling out the camshaft.
3) Cleaning and lubricating the camshaft lobes and bearings before reinstalling.
4) Aligning the timing marks and installing the camshaft bolts to complete the process.
Caterpillar cat 140 h motor grader (prefix 8jm) service repair manual (8jm000...yhhjjkfkseme
This document provides instructions for removing and assembling the fuel injection pump housing and governor from a Caterpillar 3306 engine. It describes 10 steps to remove the components, including disconnecting fuel lines and other connections, removing mounting bolts and nuts, and lifting out the assembly. It then describes 8 steps to disassemble the housing further. The assembly section outlines 9 steps, including installing bearings in the proper locations and depths, inserting the camshaft, washer, and snap ring. Proper cleaning and lubrication of parts is emphasized throughout.
This service manual provides instructions for servicing components of the 6TFT and 6TST engines, including the engine, body and framework, operator station, fuel and exhaust systems, cooling system, brakes, steering, driveline, hydraulic system, electrical system, fasteners, and consumable products. The manual contains sections on general information, component identification, and procedures for removing and installing parts. Safety precautions are provided throughout regarding safe operation and maintenance of the machine.
Jcb 3 cx compact backhoe loader service repair manual (sn from 2495456 and up)fusefjskekkmem
This service manual provides instructions for servicing a JCB 3CX Compact backhoe loader. It contains sections covering the machine systems including the engine, fuel system, cooling system, brake system, hydraulic system and electrical system. The specific section summarized discusses servicing procedures for the engine crankshaft, including how it is lubricated by engine oil, how to check its condition by inspecting the bearing surfaces and diameters, and ensuring the oilways are clear.
Jcb 3 cx backhoe loader service repair manual sn from 2442701 to 2451000fusefjskekkmem
This service manual section provides information on servicing the crankshaft and related components on a backhoe loader. It includes identification of parts, technical specifications, operation descriptions, removal and installation instructions, and check/inspection procedures. Proper cleaning and installation of the crankshaft oil seal is critical to prevent oil leakage. Removal and installation of the crankshaft requires carefully following all steps while ensuring components remain clean and undamaged.
Caterpillar cat 140 h motor grader (prefix 126) service repair manual (126000...fusefjskekkmem
The document provides instructions for disassembling and assembling the final drive of a 140H Motor Grader. It lists 24 steps for disassembly, removing components like the sun gear shaft, planetary carrier, gear assemblies, ring gear, drive shaft, and seals. It then lists 30 steps for assembly, installing these components in reverse order, noting specifics like torque specifications and tool requirements.
Caterpillar cat 140 g motor grader (prefix 5md) service repair manual (5md000...fjjsefkksemme
This service repair manual provides instructions for disassembling and assembling various components of a 140G motor grader, including:
1) Removing and installing brake and wheel spindle housings, which includes releasing air pressure and removing nuts, guards, and air lines.
2) Removing and installing tandem housings, which are attached to the final drive housing with nuts.
3) Removing and installing drive sprockets by removing nuts with a tool and ensuring proper preload on bearings.
Caterpillar cat 303 e cr mini hydraulic excavator (prefix hhm) service repair...yhhjjkfkseme
The document provides instructions for removing and installing the fuel injection pump on a Caterpillar 303E CR Mini Hydraulic Excavator. The removal procedure involves removing the solenoid, speed control plate bolts, start spring, injection pump bolts, and recording the number and thickness of shims under the pump. For installation, the same number and thickness of shims are reused and the pump is installed by aligning the control rack pin in the notch and inserting the rack pin into the thrust lever groove. Tightening the bolts completes the installation.
Caterpillar cat 140 g motor grader (prefix 72v) service repair manual (72v042...fusefjskekkmem
This document provides instructions for removing and installing a camshaft on a Caterpillar 3306 engine. It describes in detail:
1) Marking the gears to ensure proper timing when reinstalling the camshaft.
2) Removing the camshaft bolts and carefully pulling out the camshaft.
3) Cleaning and lubricating the camshaft lobes and bearings before reinstalling.
4) Aligning the timing marks and installing the camshaft bolts to complete the process.
Caterpillar cat 140 h motor grader (prefix 8jm) service repair manual (8jm000...yhhjjkfkseme
This document provides instructions for removing and assembling the fuel injection pump housing and governor from a Caterpillar 3306 engine. It describes 10 steps to remove the components, including disconnecting fuel lines and other connections, removing mounting bolts and nuts, and lifting out the assembly. It then describes 8 steps to disassemble the housing further. The assembly section outlines 9 steps, including installing bearings in the proper locations and depths, inserting the camshaft, washer, and snap ring. Proper cleaning and lubrication of parts is emphasized throughout.
This service manual provides instructions for servicing components of the 6TFT and 6TST engines, including the engine, body and framework, operator station, fuel and exhaust systems, cooling system, brakes, steering, driveline, hydraulic system, electrical system, fasteners, and consumable products. The manual contains sections on general information, component identification, and procedures for removing and installing parts. Safety precautions are provided throughout regarding safe operation and maintenance of the machine.
Caterpillar cat m316 d wheeled excavator (prefix w6a) service repair manual (...fujsjefjwerkskemm
This document provides instructions for removing and installing an idler gear on a Caterpillar C6.6 engine. It describes the required tools and steps to:
1) Lock the camshaft and crankshaft in position, remove bolts, and remove the standard or heavy-duty idler gear.
2) Clean and inspect the idler gear components, install the idler gear while aligning timing marks, install bolts, and check end play and backlash.
3) Ensure the number one piston is at top dead center before installing the idler gear in the correct position and alignment.
Caterpillar cat 140 g motor grader (prefix 72v) service repair manual (72v000...fusefjskekkmem
The document provides instructions for disassembling and assembling a transmission for a 140G motor grader. The key steps include:
1) Removing the transmission by draining fluids, disconnecting lines and hoses, and lifting it out of the machine.
2) Disassembling the transmission further by removing covers, links, plates and sleeves to access the internal components.
3) Reassembling the transmission involves installing components in reverse order and refilling fluids. Precise torques and clearances are specified.
Caterpillar cat 303.5 e2 cr mini hydraulic excavator (prefix cr9) service rep...fusefjskekkmem
This document provides instructions for removing and installing fuel injection lines and nozzles on a Caterpillar 303.5E2 CR Mini Hydraulic Excavator. The lines and nozzles are removed by disconnecting clamps and removing retaining nuts and bolts. They are installed by reversing the removal process and tightening to the specified torques. Additional sections provide instructions for removing and installing the governor, camshaft, and disassembling the governor components using the required tools.
Jcb 527 58 t4 f telescopic handler service repair manual (sn from 2330671 and...ufjjsjefkksemm
This service manual provides instructions for servicing and maintaining a Loadall rough terrain variable reach truck. The manual contains sections covering the machine, attachments, body and framework, operator station, HVAC system, engine, fuel and exhaust systems, cooling system, driveline, hydraulic system, electrical system, fasteners and fixings, and consumable products. The engine section provides detailed removal and installation instructions for components like the camshaft, tappets, rocker assembly, oil sump, and grid heater. Safety precautions are outlined throughout and torque specifications are provided for fasteners.
Jcb 536 t70 lp telescopic handler service repair manual sn 2336575 and upfiskefjskemem
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks. It contains sections on machine systems and components including the engine, fuel system, cooling system, brakes, hydraulics, and electrical systems. Specific models covered include 526-56, 531-70, 533-105, 535-95, 536-60, and others. Safety warnings are provided throughout and procedures for removal and installation are described in detail with torque specifications.
Jcb 550 140 telescopic handler service repair manual sn from 2902000 onwardsfisjejfskemmd
This service manual provides instructions for servicing the loadall rough terrain variable reach truck. It contains sections on the machine systems including the engine, fuel system, cooling system, brake system, hydraulic system and electrical system. The section summarized focuses on servicing the engine valves and connecting rod big-end bearings. It provides removal and installation instructions, component identification diagrams, and technical specifications for the valves and instructions to check the big-end bearings for wear. Safety information is also provided to ensure the work is performed correctly.
Jcb js130 excavator service repair manual sn from 2373080 to 2375080fiskefjskemem
The document provides a service manual for excavator tracks. It includes sections on track components, measuring wear using technical data tables, adjusting tracks, removing and installing tracks, and storing tracks. Procedures are provided for measuring link rail surface wear, track pitch/internal pin and bush wear, and bush external wear to determine wear percentages and maintenance requirements.
Jcb tm220 telescopic wheeled loader service repair manual sn from 2679851 to ...fujsjefjwerkskemm
This service manual provides instructions for servicing the rocker and fittings on the TM180 and TM220 loader engines. The document describes how to remove and install the rocker assembly, disassemble and assemble the rocker arms, and remove and install the rocker cover. Technical specifications are also provided for rocker shaft dimensions, tappet clearances, and tappet dimensions. The operation of the hydraulic tappets is explained, along with difficult operating conditions that could cause play.
Jcb 560 80 tier 4 telescopic handler service repair manual sn from 2460601 on...fusefjjskekemm
The document provides instructions for servicing fuel injectors and related components on JCB Loadall vehicles. It begins with an introduction to fuel injectors and their purpose. The main sections include checking injector operation using leak-off tests, removing and installing individual injectors, removing and installing injector seals, and removing and installing the common fuel rail assembly. Torque specifications are provided for reinstalling components.
Caterpillar cat m318 d wheeled excavator (prefix w8p) service repair manual (...fdjjsekksemxs
This document provides instructions for removing and installing an idler gear on a Caterpillar C6.6 diesel engine. It describes:
1) The required tools and preparation steps, which include locking the camshaft and crankshaft, removing covers, and ensuring the valves are closed.
2) The removal procedure, which involves marking components, loosening rocker arms, and tilting the idler gear during removal.
3) The installation procedure, such as cleaning parts, aligning timing marks, and lubricating before sliding the hub into the idler gear. Precise timing of the camshaft and crankshaft is required.
Jcb 325 t skid steer loader service repair manual sn from 2476302 to 2477300fujsjefjskekmem
This service manual provides instructions for servicing JCB skid steer loaders and their components. It contains sections on machine systems and components including the engine, fuel system, cooling system, brakes, hydraulics and electrical system. The section summarized here provides instructions for removing and installing the crankshaft from the engine. It describes cleaning and inspecting the crankshaft, lists the required tools and consumables, and outlines the step-by-step removal and installation procedures. Precautions are given such as allowing the engine to cool before working on it and using lifting devices due to the heavy weight of components.
Jcb 2 t st hydrostatic dumper service repair manualfujsjefjwerkskemm
This service manual provides information for maintaining and servicing JCB machines with Kubota engines. The document includes sections on safety procedures, technical specifications for Kubota D1703 and V2203-M engines, component identification diagrams, and an explanation of the four-stroke engine cycle. Safety warnings cover hot components, turning the engine, high pressure washing, and working with fuel, oil and other fluids.
Liebherr er 942 hydraulic excavator service repair manualudjjfkkskemm
The document is a service manual that provides technical data, maintenance guidelines, and information on systems for hydraulic excavators models ER 900-942. It covers general information, tools, the engine, coupling and splitterbox, hydraulic system, hydraulic components, electrical system, swing gear, swing ring, travel gear, track components, undercarriage and uppercarriage attachments, cab heater and air conditioning. The manual is intended to assist with maintenance and repairs for the excavator models.
Jcb js115 t2 excavator service repair manual sn 2397465 and upudjjfkkskemm
The document provides maintenance instructions for steel tracks on excavators. It includes procedures to check track components for wear, measure critical dimensions, and compare measurements to tolerance charts to determine replacement needs. Key components like links, pins, bushes and the sprocket are to be inspected, with links also checked for distortion. Measurements of dimensions like track tension, pin pitch and bush diameter indicate wear percentages and guide maintenance decisions.
Jcb 540 v140 telescopic handler service repair manual sn from 2460601 onwardsudjjfkkskemm
This service manual provides instructions for servicing the Loadall rough terrain variable reach truck. It contains sections on the machine systems including the engine, fuel system, cooling system, brake system, hydraulic system and electrical system. The section summarized focuses on servicing the engine valves and connecting rod big-end bearings. It provides removal and installation instructions, component identification diagrams, and technical specifications for the valves and instructions to check the big-end bearings for wear.
Jcb 540 200 telescopic handler service repair manual sn from 2902000 onwardsudjjfkkskemm
This service manual provides information on servicing the Loadall rough terrain variable reach truck. It contains instructions that were originally provided by the manufacturer and covers systems like the engine, brakes, hydraulics, and electrical systems. The manual instructs technicians to study it before operating or maintaining the machine to prevent injury or death. It also contains sections on safety, maintenance procedures, technical specifications, and the removal and installation of components.
Jcb 540 170 telescopic handler service repair manual sn from 2460601 onwardsudjjfkkskemm
This service manual provides instructions for servicing the Loadall rough terrain variable reach truck. It contains sections on the machine systems including the engine, fuel system, cooling system, brake system, hydraulic system and electrical system. The section summarized focuses on servicing the engine valves and connecting rod big-end bearings. It provides removal and installation instructions, component identification diagrams, and technical specifications for the valves and instructions to check the big-end bearings for wear.
Jcb 535 95 tier 4 telescopic handler service repair manual sn from 2460601 on...udjjfkkskemm
This service manual provides instructions for servicing the components of a Loadall rough terrain variable reach truck, including the fuel injection system. The document covers removal and installation procedures for fuel injectors, injector seals, the common fuel rail, and the high pressure fuel injection pump. Safety information is provided throughout regarding working on the fuel system and the need to relieve pressure before conducting repairs.
Jcb 536 60 tier 4 telescopic handler service repair manual sn from 2460601 on...udjjfkkskemm
This document provides service and repair instructions for fuel injectors on JCB Loadall vehicles. It begins with an introduction to the injector components and operation. The main sections provide procedures for checking injector operation with diagnostic tools, removing and installing individual injectors, and removing and installing injector seals in the cylinder head. The summary highlights that the document contains procedures for inspecting and replacing fuel injectors and their seals.
Jcb 526 56 telescopic handler service repair manual sn 2336575 and upudjjfkkskemm
This service manual provides information for servicing and repairing Loadall rough terrain variable reach trucks. It contains instructions for machine components, attachments, body and framework, operator station, heating and air conditioning, engine, fuel and exhaust systems, cooling system, brake system, steering system, driveline, hydraulic system, and electrical system. The manual instructs technicians on removal and installation of components like the engine, and provides torque specifications and other technical details.
Jcb 250 skid steer loader service repair manual sn from 2675500 to 2675700udjjfkkskemm
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 parts, applying sealant, installing bearing shells and bolts, and torquing bolts to specified values. Special tools like templates and torque wrenches are needed to correctly complete the process.
Jcb 250 skid steer loader service repair manual sn from 2478301 to 2478700udjjfkkskemm
This service manual provides instructions for servicing JCB skid steer loaders and their components. It contains sections on machine systems and components including the engine, fuel system, cooling system, brakes, driveline, hydraulics, and electrical system. The section summarized here provides instructions for removing and installing the crankshaft from the engine. It describes cleaning and inspecting the crankshaft, lists the required tools and consumables, and outlines the step-by-step removal and installation procedures.
Caterpillar cat m316 d wheeled excavator (prefix w6a) service repair manual (...fujsjefjwerkskemm
This document provides instructions for removing and installing an idler gear on a Caterpillar C6.6 engine. It describes the required tools and steps to:
1) Lock the camshaft and crankshaft in position, remove bolts, and remove the standard or heavy-duty idler gear.
2) Clean and inspect the idler gear components, install the idler gear while aligning timing marks, install bolts, and check end play and backlash.
3) Ensure the number one piston is at top dead center before installing the idler gear in the correct position and alignment.
Caterpillar cat 140 g motor grader (prefix 72v) service repair manual (72v000...fusefjskekkmem
The document provides instructions for disassembling and assembling a transmission for a 140G motor grader. The key steps include:
1) Removing the transmission by draining fluids, disconnecting lines and hoses, and lifting it out of the machine.
2) Disassembling the transmission further by removing covers, links, plates and sleeves to access the internal components.
3) Reassembling the transmission involves installing components in reverse order and refilling fluids. Precise torques and clearances are specified.
Caterpillar cat 303.5 e2 cr mini hydraulic excavator (prefix cr9) service rep...fusefjskekkmem
This document provides instructions for removing and installing fuel injection lines and nozzles on a Caterpillar 303.5E2 CR Mini Hydraulic Excavator. The lines and nozzles are removed by disconnecting clamps and removing retaining nuts and bolts. They are installed by reversing the removal process and tightening to the specified torques. Additional sections provide instructions for removing and installing the governor, camshaft, and disassembling the governor components using the required tools.
Jcb 527 58 t4 f telescopic handler service repair manual (sn from 2330671 and...ufjjsjefkksemm
This service manual provides instructions for servicing and maintaining a Loadall rough terrain variable reach truck. The manual contains sections covering the machine, attachments, body and framework, operator station, HVAC system, engine, fuel and exhaust systems, cooling system, driveline, hydraulic system, electrical system, fasteners and fixings, and consumable products. The engine section provides detailed removal and installation instructions for components like the camshaft, tappets, rocker assembly, oil sump, and grid heater. Safety precautions are outlined throughout and torque specifications are provided for fasteners.
Jcb 536 t70 lp telescopic handler service repair manual sn 2336575 and upfiskefjskemem
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks. It contains sections on machine systems and components including the engine, fuel system, cooling system, brakes, hydraulics, and electrical systems. Specific models covered include 526-56, 531-70, 533-105, 535-95, 536-60, and others. Safety warnings are provided throughout and procedures for removal and installation are described in detail with torque specifications.
Jcb 550 140 telescopic handler service repair manual sn from 2902000 onwardsfisjejfskemmd
This service manual provides instructions for servicing the loadall rough terrain variable reach truck. It contains sections on the machine systems including the engine, fuel system, cooling system, brake system, hydraulic system and electrical system. The section summarized focuses on servicing the engine valves and connecting rod big-end bearings. It provides removal and installation instructions, component identification diagrams, and technical specifications for the valves and instructions to check the big-end bearings for wear. Safety information is also provided to ensure the work is performed correctly.
Jcb js130 excavator service repair manual sn from 2373080 to 2375080fiskefjskemem
The document provides a service manual for excavator tracks. It includes sections on track components, measuring wear using technical data tables, adjusting tracks, removing and installing tracks, and storing tracks. Procedures are provided for measuring link rail surface wear, track pitch/internal pin and bush wear, and bush external wear to determine wear percentages and maintenance requirements.
Jcb tm220 telescopic wheeled loader service repair manual sn from 2679851 to ...fujsjefjwerkskemm
This service manual provides instructions for servicing the rocker and fittings on the TM180 and TM220 loader engines. The document describes how to remove and install the rocker assembly, disassemble and assemble the rocker arms, and remove and install the rocker cover. Technical specifications are also provided for rocker shaft dimensions, tappet clearances, and tappet dimensions. The operation of the hydraulic tappets is explained, along with difficult operating conditions that could cause play.
Jcb 560 80 tier 4 telescopic handler service repair manual sn from 2460601 on...fusefjjskekemm
The document provides instructions for servicing fuel injectors and related components on JCB Loadall vehicles. It begins with an introduction to fuel injectors and their purpose. The main sections include checking injector operation using leak-off tests, removing and installing individual injectors, removing and installing injector seals, and removing and installing the common fuel rail assembly. Torque specifications are provided for reinstalling components.
Caterpillar cat m318 d wheeled excavator (prefix w8p) service repair manual (...fdjjsekksemxs
This document provides instructions for removing and installing an idler gear on a Caterpillar C6.6 diesel engine. It describes:
1) The required tools and preparation steps, which include locking the camshaft and crankshaft, removing covers, and ensuring the valves are closed.
2) The removal procedure, which involves marking components, loosening rocker arms, and tilting the idler gear during removal.
3) The installation procedure, such as cleaning parts, aligning timing marks, and lubricating before sliding the hub into the idler gear. Precise timing of the camshaft and crankshaft is required.
Jcb 325 t skid steer loader service repair manual sn from 2476302 to 2477300fujsjefjskekmem
This service manual provides instructions for servicing JCB skid steer loaders and their components. It contains sections on machine systems and components including the engine, fuel system, cooling system, brakes, hydraulics and electrical system. The section summarized here provides instructions for removing and installing the crankshaft from the engine. It describes cleaning and inspecting the crankshaft, lists the required tools and consumables, and outlines the step-by-step removal and installation procedures. Precautions are given such as allowing the engine to cool before working on it and using lifting devices due to the heavy weight of components.
Jcb 2 t st hydrostatic dumper service repair manualfujsjefjwerkskemm
This service manual provides information for maintaining and servicing JCB machines with Kubota engines. The document includes sections on safety procedures, technical specifications for Kubota D1703 and V2203-M engines, component identification diagrams, and an explanation of the four-stroke engine cycle. Safety warnings cover hot components, turning the engine, high pressure washing, and working with fuel, oil and other fluids.
Liebherr er 942 hydraulic excavator service repair manualudjjfkkskemm
The document is a service manual that provides technical data, maintenance guidelines, and information on systems for hydraulic excavators models ER 900-942. It covers general information, tools, the engine, coupling and splitterbox, hydraulic system, hydraulic components, electrical system, swing gear, swing ring, travel gear, track components, undercarriage and uppercarriage attachments, cab heater and air conditioning. The manual is intended to assist with maintenance and repairs for the excavator models.
Jcb js115 t2 excavator service repair manual sn 2397465 and upudjjfkkskemm
The document provides maintenance instructions for steel tracks on excavators. It includes procedures to check track components for wear, measure critical dimensions, and compare measurements to tolerance charts to determine replacement needs. Key components like links, pins, bushes and the sprocket are to be inspected, with links also checked for distortion. Measurements of dimensions like track tension, pin pitch and bush diameter indicate wear percentages and guide maintenance decisions.
Jcb 540 v140 telescopic handler service repair manual sn from 2460601 onwardsudjjfkkskemm
This service manual provides instructions for servicing the Loadall rough terrain variable reach truck. It contains sections on the machine systems including the engine, fuel system, cooling system, brake system, hydraulic system and electrical system. The section summarized focuses on servicing the engine valves and connecting rod big-end bearings. It provides removal and installation instructions, component identification diagrams, and technical specifications for the valves and instructions to check the big-end bearings for wear.
Jcb 540 200 telescopic handler service repair manual sn from 2902000 onwardsudjjfkkskemm
This service manual provides information on servicing the Loadall rough terrain variable reach truck. It contains instructions that were originally provided by the manufacturer and covers systems like the engine, brakes, hydraulics, and electrical systems. The manual instructs technicians to study it before operating or maintaining the machine to prevent injury or death. It also contains sections on safety, maintenance procedures, technical specifications, and the removal and installation of components.
Jcb 540 170 telescopic handler service repair manual sn from 2460601 onwardsudjjfkkskemm
This service manual provides instructions for servicing the Loadall rough terrain variable reach truck. It contains sections on the machine systems including the engine, fuel system, cooling system, brake system, hydraulic system and electrical system. The section summarized focuses on servicing the engine valves and connecting rod big-end bearings. It provides removal and installation instructions, component identification diagrams, and technical specifications for the valves and instructions to check the big-end bearings for wear.
Jcb 535 95 tier 4 telescopic handler service repair manual sn from 2460601 on...udjjfkkskemm
This service manual provides instructions for servicing the components of a Loadall rough terrain variable reach truck, including the fuel injection system. The document covers removal and installation procedures for fuel injectors, injector seals, the common fuel rail, and the high pressure fuel injection pump. Safety information is provided throughout regarding working on the fuel system and the need to relieve pressure before conducting repairs.
Jcb 536 60 tier 4 telescopic handler service repair manual sn from 2460601 on...udjjfkkskemm
This document provides service and repair instructions for fuel injectors on JCB Loadall vehicles. It begins with an introduction to the injector components and operation. The main sections provide procedures for checking injector operation with diagnostic tools, removing and installing individual injectors, and removing and installing injector seals in the cylinder head. The summary highlights that the document contains procedures for inspecting and replacing fuel injectors and their seals.
Jcb 526 56 telescopic handler service repair manual sn 2336575 and upudjjfkkskemm
This service manual provides information for servicing and repairing Loadall rough terrain variable reach trucks. It contains instructions for machine components, attachments, body and framework, operator station, heating and air conditioning, engine, fuel and exhaust systems, cooling system, brake system, steering system, driveline, hydraulic system, and electrical system. The manual instructs technicians on removal and installation of components like the engine, and provides torque specifications and other technical details.
Jcb 250 skid steer loader service repair manual sn from 2675500 to 2675700udjjfkkskemm
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 parts, applying sealant, installing bearing shells and bolts, and torquing bolts to specified values. Special tools like templates and torque wrenches are needed to correctly complete the process.
Jcb 250 skid steer loader service repair manual sn from 2478301 to 2478700udjjfkkskemm
This service manual provides instructions for servicing JCB skid steer loaders and their components. It contains sections on machine systems and components including the engine, fuel system, cooling system, brakes, driveline, hydraulics, and electrical system. The section summarized here provides instructions for removing and installing the crankshaft from the engine. It describes cleaning and inspecting the crankshaft, lists the required tools and consumables, and outlines the step-by-step removal and installation procedures.
Jcb 9 tst dumper service repair manual sn from grm0011 to grm9989udjjfkkskemm
This service manual provides instructions for servicing the braking system of dumpers. It contains information on health and safety when working on the brakes, technical specifications, component identification, troubleshooting, and bleeding the brakes. The braking system uses mineral oil and contains separate front and rear brake circuits for safety. Adjustment is generally not needed as the brakes are self-adjusting, but bleeding may be required if the brake lines leak fluid.
Jcb 9 tft dumper service repair manual sn from hrm1382 to hrm4003udjjfkkskemm
This service manual provides instructions for servicing the braking system of dumpers. It contains information on health and safety when working on the brakes, technical specifications, component identification, troubleshooting, and bleeding the brakes. The braking system uses mineral oil and contains separate front and rear brake circuits for safety. Adjustment is generally not needed as the brakes are self-adjusting, but bleeding may be required if the brake lines leak fluid.
Jcb 5 cx backhoe loader service repair manual sn from 2509500 and upudjjfkkskemm
This service manual provides instructions for servicing the crankshaft on a backhoe loader. The crankshaft is a core component that connects the pistons to the flywheel. Key steps in servicing the crankshaft include cleaning it and inspecting the journals for wear. The crankshaft needs to be removed to service other engine components like the main bearings. Proper installation requires cleaning surfaces, installing new cooling jets, lubricating bearings, and fitting thrust washers in the correct orientation. Following the removal and installation procedures helps ensure the crankshaft operates properly.
Jcb 4 cx backhoe loader service repair manual sn from 2442701 to 2451000udjjfkkskemm
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Jcb 3 cx backhoe loader service repair manual sn from 2442701 to 2451000udjjfkkskemm
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2. 15 - Engine
12 - Crankshaft
00 - General
15 - 73 9813/6900-6 15 - 73
00 - General
Introduction .................................................... 15-73
Technical Data ............................................... 15-74
Component Identification ............................... 15-75
Operation ....................................................... 15-76
Check (Condition) .......................................... 15-77
Remove and Install ....................................... 15-78
Introduction
Figure 285.
B
A
A Crankcase
B Crankshaft
3. 15 - Engine
12 - Crankshaft
00 - General
15 - 74 9813/6900-6 15 - 74
Technical Data
Table 100.
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
4. 15 - Engine
12 - Crankshaft
00 - General
15 - 75 9813/6900-6 15 - 75
Component Identification
Figure 286.
B
A
A Crankcase
B Crankshaft
5. 15 - Engine
12 - Crankshaft
00 - General
15 - 76 9813/6900-6 15 - 76
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 287.
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
6. 15 - Engine
12 - Crankshaft
00 - General
15 - 77 9813/6900-6 15 - 77
Check (Condition)
1. Check the main bearing surfaces for damage and
excessive wear.
Figure 288.
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 289.
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 290.
D
C
C J-jets
D Fixing screws
7. 15 - Engine
12 - Crankshaft
00 - General
15 - 78 9813/6900-6 15 - 78
Remove and Install
Consumables
Description Part No. Size
Cleaner/Degreaser
- General purpose
solvent based parts
cleaner
4104/1557 0.4 L
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.
8. 15 - Engine
12 - Crankshaft
00 - General
15 - 79 9813/6900-6 15 - 79
Figure 291.
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 292.
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:
9. 15 - Engine
12 - Crankshaft
00 - General
15 - 80 9813/6900-6 15 - 80
Figure 293.
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 294.
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:
10. 15 - Engine
12 - Crankshaft
00 - General
15 - 81 9813/6900-6 15 - 81
Figure 295.
C
B
A
A
A
H
A Thrust washers B Crankshaft
C Rear main bearing H Oil slot - thrust washers
6.1. Slide 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 101. Torque Values
Item Nm
F 24
11. 15 - Engine
12 - Crankshaft
03 - Main Bearing
15 - 82 9813/6900-6 15 - 82
03 - Main Bearing
Introduction .................................................... 15-82
Check (Condition) .......................................... 15-83
Remove and Install ....................................... 15-83
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 296.
A
B
A Main bearing
B Crankshaft
12. 15 - Engine
12 - Crankshaft
03 - Main Bearing
15 - 83 9813/6900-6 15 - 83
Check (Condition)
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
Refer to: PIL 15-12-00.
13. 15 - Engine
12 - Crankshaft
06 - Front Oil Seal
15 - 84 9813/6900-6 15 - 84
06 - Front Oil Seal
Remove and Install
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 297.
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 298.
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
298.
14. 15 - Engine
12 - Crankshaft
06 - Front Oil Seal
15 - 85 9813/6900-6 15 - 85
Figure 298.
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
299.
Dimension: -0.5 -0/+0.5mm
Figure 299.
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.
15. 15 - Engine
12 - Crankshaft
06 - Front Oil Seal
15 - 86 9813/6900-6 15 - 86
After Installation
1. Install the crankshaft pulley, refer to (PIL
15-12-12).
2. Install the drive belt, refer to (PIL 15-18).
16. 15 - Engine
12 - Crankshaft
09 - Rear Oil Seal
15 - 87 9813/6900-6 15 - 87
09 - Rear Oil Seal
Remove and Install
Special Tools
Description Part No. Qty.
Crankshaft Rear Oil
Seal Installation Tool
892/01156 1
Crankshaft Rear Oil
Seal Alignment Tool
892/01158 1
Note: The flywheel hub and crankshaft rear oil seal
need to be replaced as a pair.
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 flywheel, refer to (PIL 15-54).
Remove
1. Use a suitable lever behind the lip of the seal
to carefully prise out the rear oil seal from the
counterbore in the flywheel housing. Take care
not to scratch or damage the counterbore or the
flywheel hub. Damaged or dirty sealing faces will
cause the oil seal to fail.
Figure 300. 24mm Hub
A
C B
A Crankshaft rear oil seal
B Flywheel housing
C Flywheel hub
Figure 301. 15mm Hub
A
C E
B
A Crankshaft rear oil seal
B Flywheel housing
C Flywheel hub
E Fixing bolt
Install (24mm Hub)
1. Make sure that the counterbore and the flywheel
hub are clean and free from damage and
corrosion.
17. 15 - Engine
12 - Crankshaft
09 - Rear Oil Seal
15 - 88 9813/6900-6 15 - 88
Figure 302.
B
A
D
D
C
A Crankshaft rear oil seal B Flywheel housing
C Flywheel hub D Oil seal alignment tool
2. To prevent the seal lip rolling over and becoming
damaged, make sure that you use the oil seal
alignment tool to initially install the oil seal on to
the flywheel hub. Locate the alignment tool over
the end of the hub, then carefully push the oil seal
over the alignment tool and on to the crankshaft
diameter. Make sure that the oil seal is installed
the correct way around.
Special Tool: Crankshaft Rear Oil Seal
Installation Tool (Qty.: 1)
Special Tool: Crankshaft Rear Oil Seal Alignment
Tool (Qty.: 1)
3. Apply lubricant P80 around the seal outer rubber
diameter.
4. Dismantle the oil seal installation tool. Bolt the
centre body to the flywheel hub, using the two
flywheel bolts. Assemble the outer sleeve on to
the centre body and install the screw.
Figure 303.
A
B
C
F
E
F
H
G
J
H
G
A Crankshaft rear oil seal B Flywheel housing
C Outer sleeve E Oil seal installation tool
F Flywheel bolts G Centre body
H Flywheel hub J Screw
5. 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 tolerance specified.
Length/Dimension/Distance: 0.5mm
6. Remove the oil seal installation tool.
Install (15mm Hub)
1. Make sure that the counterbore and the hub are
clean and free from damage.
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19. 15 - Engine
12 - Crankshaft
09 - Rear Oil Seal
15 - 89 9813/6900-6 15 - 89
Figure 304.
B
A
D
D
C
A Crankshaft rear oil seal B Flywheel housing
C Flywheel hub D Oil seal alignment tool
2. Install the new hub on to the crankshaft gear and
install the old hub on the outside of the new hub
to create a double thickness flywheel hub, install
the fixing bolt as shown at A. Do not touch the
PTFE seal lips of the crankshaft oil seal.
3. Make sure that you use the oil seal alignment tool
to initially install the oil seal on to the flywheel
hub to prevent damage to the seal lip. Locate the
alignment tool over the end of the hub, carefully
push the oil seal over the alignment tool as far
on to the crankshaft hub as possible. Make sure
that the seal is installed the correct way around.
Special Tool: Crankshaft Rear Oil Seal
Installation Tool (Qty.: 1)
Special Tool: Crankshaft Rear Oil Seal Alignment
Tool (Qty.: 1)
4. Apply the lubricant P80 around the seal outer
rubber diameter.
5. Dismantle the oil seal installation tool. Use the
two flywheel bolts to attach the centre body on to
the flywheel hub. Assemble the outer sleeve on
to the centre body include the extension ring and
install the screw.
Figure 305.
A
B
C1 C2
F
G
H
J
K
L
K
J
A Crankshaft rear oil seal B Flywheel housing
C1 New hub C2 Old hub
F Flywheel bolts G Oil seal installation tool
H Extension ring J Centre body
K Outer sleeve L Screw
6. Turn the screw to push the seal into position in
the counterbore so that the screw will not turn.
20. 15 - Engine
12 - Crankshaft
09 - Rear Oil Seal
15 - 90 9813/6900-6 15 - 90
7. Remove the oil seal installation tool, remove the
old hub and install the fixing bolt. Repeat steps 5
and 6 to fully install the rear oil seal.
8. Remove the oil seal installation tool.
After Installation
1. Install the flywheel, refer to (PIL 15-54).
Table 102. Torque Values
Item Nm
E 47
21. 15 - Engine
12 - Crankshaft
12 - Pulley
15 - 91 9813/6900-6 15 - 91
12 - Pulley
Remove and Install
Special Tools
Description Part No. Qty.
Torque Wrench
(10-100Nm)
993/70111 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).
Remove
1. Remove the fixing bolts and withdraw the pulley
from the crankshaft.
Figure 306.
A
B
A
A Crankshaft pulley
B Fixing bolts (x3)
2. The bolts must not be reused. Discard the bolts.
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. Renew the fixing bolts. Tighten the new bolts in
three stages to the correct torque value.
Special Tool: Torque Wrench (10-100Nm) (Qty.:
1)
4. The bolts are tightened using a torque and
angle method. Refer to Fasteners and Fixings,
General, Introduction (PIL 72-00).
Figure 307.
C
C Angle gauge (obtain locally)
After Replacement
1. Install the drive belt. Refer to (PIL 15-18).
Table 103.
Item Torque Value
(Nm)
Torque Angle
(Degrees)
2 (1st stage) 30N·m
2 (2nd stage) 75N·m
2 (Final stage) 180°