Konica Minolta 621D Service Manual

621D
WHEEL LOADER

ASN JEEO135501

PARTS CATALOG

Publication Part Number: 7-8571NA

BD01E101

Photograph may show installation of optional equipment.

This unit first became available in March, 2003

TABLE OF CONTENTS
GENERAL INFORMATION
SECTION 2 – ENGINE
SECTION 3 – FUEL SYSTEM
SECTION 4 – ELECTRICAL SYSTEM
SECTION 5 – TRACKS / STEERING
SECTION 6 – POWER TRAIN
SECTION 7 – BRAKES
SECTION 8 – HYDRAULICS
SECTION 9 – CHASSIS/ATTACHMENTS
INDEX

.

Issued January 2003 (Revised August 2004) • 7-8571NA • Bur

Copyright © 2004 CNH America LLC. All Rights Reserved.

TABLE OF CONTENTS

02-01 MOUNT, ENGINE
02-02 RADIATOR - MOUNTING
02-03 FAN - FAN BELT
02-04 COOLANT RECOVERY SYSTEM
02-05 COOLING SYSTEM - AIR COOLER
02-06 COOLING SYSTEM - MOTOR, DRIVE (MOUNTING)
02-07 COOLING SYSTEM - MOTOR, DRIVE (STANDARD FAN DRIVE)
02-08 COOLING SYSTEM - MOTOR, DRIVE (REVERSIBLE FAN DRIVE)
02-09 VALVE ASSY - FAN
02-10 AIR CLEANER - AIR INTAKE PARTS
02-10A AIR CLEANER ASSY
02-11 MUFFLER - EXHAUST SYSTEM
02-12 MUFFLER - EXHAUST SYSTEM - IF USED
02-13 MUFFLER - EXHAUST SYSTEM - STANDARD/ASPIRATOR SPARK ARRESTER
02-13A MUFFLER - SPARK ARRESTER/ASPIRATOR
02-14 ENGINE
02-15 ENGINE, OIL
02-16 OIL PUMP - ENGINE
02-16A TURBO OUTLET
02-17 OIL FILTERS - ENGINE
02-18 OIL FILTER AND COOLER
02-19 OIL PUMP, PAN
02-20 OIL PUMP, PAN - DRAIN LINE
02-21 BREATHER - ENGINE
02-22 TURBOCHARGER SYSTEM
02-23 TURBOCHARGER
02-24 WATER PUMP
02-25 WATER PUMP - CONTROL
02-26 CYLINDER BLOCK
02-27 CYLINDER BLOCK
02-28 CYLINDER BLOCK
02-29 FLYWHEEL HOUSING
02-30 GEAR COVER - REAR HOUSING
02-31 FRONT GEAR COVER
02-31A GEAR COVER - PLATE
02-32 CYLINDER HEAD - COVERS
02-33 CYLINDER HEAD - VALVE MECHANISM
02-34 CYLINDER HEAD
02-35 MANIFOLD - INTAKE
02-36 MANIFOLD - EXHAUST
02-37 CAMSHAFT
02-38 CRANKSHAFT
02-39 CRANKSHAFT - PULLEY
02-40 FLYWHEEL - ENGINE
02-41 CONNECTING ROD
02-42 PISTONS - CONNECTING ROD
02-43 COOLING SYSTEM - ENGINE
02-44 THERMOSTAT - ENGINE COOLING SYSTEM
02-45 ENGINE - LIFT HOOK
02-46 ENGINE - BLOCK HEATER
03-01 CONTROLS - THROTTLE, FOOT

TABLE OF CONTENTS

03-02 PEDAL ASSY - THROTTLE, FOOT
03-03 FUEL LINES - FILTER, IN-LINE FUEL
03-04 FUEL TANK FILLER - SENDER
03-05 FUEL PUMP
03-06 FUEL INJECTION PUMP
03-07 FUEL INJECTION SYSTEM - PUMP MOUNTING
03-08 FUEL INJECTION SYSTEM - FUEL, SUPPLY
03-09 FUEL INJECTION SYSTEM - DRAIN LINE
03-10 FUEL INJECTION SYSTEM
03-11 FUEL INJECTION SYSTEM - INJECTOR
03-12 FUEL INJECTION SYSTEM - TURBOCHARGER, PIPES AND CONNECTIONS
03-13 FUEL FILTER
04-01 STARTER - BOSCH
04-01A STARTER - DENSO
04-02 ALTERNATOR - IF USED
04-03 ALTERNATOR - IF USED
04-04 PANEL, CONTROL
04-05 PANEL, CONTROL
04-06 HARNESS, FRONT (Z BAR LOADER)
04-07 HARNESS, FRONT (XT LOADER)
04-07A HARNESS, FRONT (XT LOADER) - IF USED
04-08 HARNESS - PEDESTAL
04-09 HARNESS - CAB ROOF
04-10 HARNESS - HOOD
04-11 HARNESS - CAB, MAIN
04-12 HARNESS - CANOPY ROOF
04-13 HARNESS - CANOPY, MAIN
04-14 HARNESS - TRANSMISSION
04-15 HARNESS - ENGINE
04-16 HARNESS - ENGINE - GRID HEATER
04-17 HARNESS, REAR CHASSIS - IF USED
04-17A HARNESS - REAR CHASSIS - IF USED
04-17B HARNESS - REAR CHASSIS - IF USED
04-18 MOUNTING - LAMP, FRONT
04-19 LAMP ASSY - LAMP, FRONT
04-20 BATTERY - CABLES - BOSCH STARTER
04-20A BATTERY - CABLES - DENSO STARTER - IF USED
04-20B BATTERY MOUNTING
04-21 LAMP - LICENSE PLATE
04-22 LAMP ASSY, FRONT AND REAR
04-23 MOUNTING - LAMPS, REAR COMBINATION
04-23A LAMP ASSY - LAMPS, REAR COMBINATION
04-24 BEACON ASSY, ROTATING - MOUNTING
04-25 MOUNTING - BACKUP ALARM
04-26 CANOPY, ROPS - WIPER, FRONT
04-27 CAB - WIPER, FRONT
04-27A CAB - WIPER, REAR
04-28 HARNESS - CIGAR LIGHTER
04-28A HARNESS - CIGAR LIGHTER
04-29 RADIO - MOUNTING -12 VOLT
04-30 RADIO - MOUNTING - 24 VOLT REMOTE

TABLE OF CONTENTS

04-31 RADIO - MOUNTING
04-32 RADIO - MOUNTING
05-01 STEERING WHEEL - COLUMN
05-02 VALVE ASSY - STEERING CONTROL
05-03 HYDRAULICS - STEERING
05-04 HYDRAULICS - STEERING
05-05 HYDRAULICS - STEERING
05-06 HYDRAULICS - STEERING
05-07 HYDRAULICS - STEERING, AUXILIARY
05-07A HYDRAULICS - STEERING, AUXILIARY
05-07B HYDRAULICS - STEERING, AUXILIARY
05-08 PRIORITY VALVE - STEERING, AUXILIARY
05-09 PUMP - STEERING, AUXILIARY
05-10 CYLINDER ASSY - STEERING
06-01 HYDRAULICS - TRANSMISSION
06-02 MOUNTING - TRANSMISSION
06-03 TRANSMISSION FILL TUBE - GAUGE, SIGHT
06-04 TRANSMISSION - CONVERTER, COVER AND INPUT SHAFT
06-05 TRANSMISSION - INPUT SHAFT
06-06 TRANSMISSION ASSY - HOUSING
06-07 TRANSMISSION ASSY - HOUSING TUBES
06-08 TRANSMISSION - CLUTCH ASSY, FIRST
06-09 TRANSMISSION - CLUTCH ASSY, SECOND
06-10 TRANSMISSION - CLUTCH ASSY, THIRD
06-11 TRANSMISSION - CLUTCH ASSY, FOURTH
06-12 TRANSMISSION - CLUTCH ASSY, FORWARD
06-13 TRANSMISSION - CLUTCH ASSY, REVERSE
06-14 TRANSMISSION - SHAFT, OUTPUT
06-15 TRANSMISSION - POWER TAKE OFF
06-16 TRANSMISSION - VALVE PLATES
06-17 TRANSMISSION - VALVE, CONTROL
06-18 TRANSMISSION - VALVE, CONTROL
06-19 TRANSMISSION - VALVE, REGULATOR AND OIL PUMP
06-20 TRANSMISSION - SENSOR, SPEED AND PUMP COVER
06-21 TRANSMISSION - FILTER, OIL AND FILLER COVER
06-21A COVER - TRANSMISSION
06-22 AXLE, FRONT - MOUNTING
06-22A AXLE, FRONT - HOUSING
06-22B AXLE, FRONT - DIFFERENTIAL CARRIER
06-22C AXLE, FRONT - DIFFERENTIAL
06-22D AXLE, FRONT - BRAKE
06-22E AXLE, FRONT - HUB, PLANETARY
06-23 AXLE, REAR - MOUNTING
06-23A AXLE, REAR - HOUSING
06-23B AXLE, REAR - DIFFERENTIAL CARRIER
06-23C AXLE, REAR - DIFFERENTIAL
06-23D AXLE, REAR - BRAKE
06-23E AXLE, REAR - HUB, PLANETARY
06-23F AXLE, REAR - HUB, PLANETARY
06-24 AXLE, REAR - STOP- NEED XLATIONS
06-25 DRIVE SHAFT - ENGINE

TABLE OF CONTENTS

06-26 DRIVE SHAFT
06-27 DRIVE SHAFT, FRONT - BEARING, SUPPORT AND LUBE LINE
06-28 DRIVE SHAFT - CENTER AND REAR
06-29 WHEELS
06-30 WHEELS
07-01 BRAKE, PARKING
07-02 BRAKE PEDALS
07-03 BRAKE PUMP
07-04 HYDRAULICS - BRAKE, MAIN
07-05 HYDRAULICS - BRAKE, MAIN
07-05A HYDRAULICS - BRAKE, MAIN - IF USED
07-05B HYDRAULICS - BRAKE, MAIN - IF USED
07-06 ACCUMULATOR - BRAKE
07-07 HYDRAULICS - BRAKE, MAIN
07-07A HYDRAULICS - BRAKE MAIN - AXLES - IF USED
07-08 VALVE ASSY - BRAKE
08-01 RESERVOIR
08-01A HYDRAULICS - RESERVOIR TO HYDRAULIC PUMP
08-02 HYDRAULIC OIL COOLER
08-02A HYDRAULIC LINES - COOLER WITHOUT BYPASS
08-02B HYDRAULICS - BYPASS
08-03 HYDRAULICS - FILTER, OIL
08-04 HYDRAULICS - LOADER LIFT (Z BAR LOADER) - IF USED
08-04A HYDRAULICS - LOADER LIFT (Z BAR LOADER)- IF USED
08-04B CYLINDER ASSY - LOADER LIFT (Z BAR LOADER)
08-04C HYDRAULICS - LOADER LIFT (XT LOADER) - IF USED
08-04D HYDRAULICS - LOADER LIFT (XT LOADER) - IF USED
08-04E CYLINDER ASSY - LOADER LIFT (XT LOADER)
08-04F CYLINDER ASSY - LOADER LIFT XR
08-05 HYDRAULICS - LOADER BUCKET (Z BAR LOADER) - IF USED
08-05A HYDRAULICS - LOADER BUCKET (Z BAR LOADER) - IF USED
08-05B HYDRAULICS - LOADER BUCKET (XT LOADER) - IF USED
08-05C HYDRAULICS - LOADER BUCKET (XT LOADER) - RIGHT SIDE - IF USED
08-05D HYDRAULICS - LOADER BUCKET (XT LOADER) - LEFT SIDE - IF USED
08-05E CYLINDER ASSY - LOADER BUCKET (Z BAR LOADER)
08-05F CYLINDER ASSY - LOADER BUCKET (XT LOADER) - IF USED
08-05G CYLINDER ASSY - LOADER BUCKET (XT LOADER) - IF USED
08-05H CYLINDER ASSY - LOADER BUCKET (XR LOADER)
08-06 HYDRAULICS - LOADER AUXILIARY (Z BAR LOADER) - IF USED
08-06A HYDRAULICS - LOADER AUXILIARY (XT LOADER) - IF USED
08-06B HYDRAULICS - LOADER AUXILIARY (XT LOADER) - IF USED
08-06C HYDRAULICS - LOADER AUXILIARY XR
08-06D HYDRAULICS - LOADER AUXILIARY (XT LOADER) - IF USED
08-06E HYDRAULICS - LOADER AUXILIARY (XT LOADER) - IF USED
08-07 HYDRAULICS - COUPLER LOCKING
08-08 HYDRAULICS - COUPLER (Z BAR LOADER)
08-08A HYDRAULICS - COUPLER (XT LOADER)
08-09 HYDRAULICS - RIDE CONTROL
08-09A HYDRAULICS - RIDE CONTROL - IF USED
08-09B HYDRAULICS - NON- RIDE CONTROL
08-09C HYDRAULICS - RIDE CONTROL - IF USED

TABLE OF CONTENTS

08-09D VALVE ASSY - RIDE CONTROL DIRECTIONAL - IF USED
08-09E ACCUMULATOR - RIDE CONTROL- IF USED
08-09F VALVE ASSY - RIDE CONTROL DIRECTIONAL
08-10 VALVE, CONTROL - MOUNTING, TWO SPOOL
08-10A VALVE ASSY - LOADER CONTROL, TWO SPOOL
08-10B VALVE ASSY - LOADER CONTROL, TWO SPOOL
08-10C VALVE SECTION - BUCKET/BOOM SPOOLS (TWO SPOOL VALVE) (Z-BAR/XT

LOADER)
08-11 VALVE, CONTROL - MOUNTING, THREE SPOOL
08-11A VALVE ASSY - LOADER CONTROL, THREE SPOOL
08-11B VALVE ASSY - LOADER CONTROL, THREE SPOOL
08-11C VALVE SECTION - BUCKET/BOOM/OPTIONAL SPOOLS (3 SPOOL VALVE) (Z-BAR/XT

LOADER)
08-12 VALVE, CONTROL - MOUNTING, FOUR SPOOL
08-12A VALVE ASSY - LOADER CONTROL, FOUR SPOOL
08-12B VALVE ASSY - LOADER CONTROL, FOUR SPOOL
08-13 VALVE ASSY - PISTON AXIS
08-14 VALVE ASSY - LOADER CONTROL
08-15 HYDRAULICS - LOADER CONTROL, REMOTE
08-15A LOADER CONTROL - JOYSTICK CONTROL
08-15B VALVE ASSY - JOYSTICK CONTROL
08-15C VALVE ASSY - JOYSTICK CONTROL
08-16 HYDRAULICS - LOADER CONTROL, REMOTE
08-16A LOADER CONTROL - JOYSTICK WITH SINGLE LEVER
08-16B VALVE ASSY - JOYSTICK WITH SINGLE LEVER
08-17 HYDRAULICS - LOADER CONTROL, REMOTE
08-17A LOADER CONTROL - JOYSTICK WITH DUAL LEVER
08-17B VALVE ASSY - JOYSTICK WITH DUAL LEVER
08-18 LOADER CONTROL - TWO LEVER
08-18A VALVE ASSY - TWO LEVER LOADER CONTROL
08-19 LOADER CONTROL - THREE LEVER
08-19A VALVE ASSY - 3 LEVER LOADER CONTROL
09-01 CONTROL - RETURN-TO-DIG (Z BAR LOADER)
09-02 CONTROL - RETURN-TO-DIG (XT LOADER)
09-03 CONTROLS - BUCKET HEIGHT AND RETURN-TO-TRANSPORT (Z-BAR)
09-04 CONTROLS - BUCKET HEIGHT RETURN-TO-TRANSPORT (XT)
09-04A CONTROLS - RTD,RTT, AND HGT -XT- TIER II
09-05 FRAME - LOADER LIFT (Z BAR LOADER) - IF USED
09-05A FRAME - LOADER LIFT (Z BAR LOADER) - IF USED
09-06 FRAME - LOADER LIFT XR
09-06A FRAME - LOADER LIFT XR - IF USED
09-06B FRAME - LOADER LIFT AND LINKAGE/ CYLINDERS XT - IF USED
09-06C FRAME - LOADER LIFT AND LINKAGE/ CYLINDERS XT- IF USED
09-07 BUCKETS - ATTACHMENT (Z BAR LOADER)
09-07A BUCKETS - ATTACHMENT (Z BAR LOADER)
09-08 BUCKETS - ATTACHMENT (XT LOADER)
09-08A BUCKETS - ATTACHMENT (XT LOADER)
09-09 LOADER BUCKET - WITH TEETH, SEGMENTS AND SKID PADS/COUPLERS
09-10 LOADER BUCKET - WITH BOLT ON EDGE AND SKID PADS/COUPLERS
09-11 BUCKET - LOADER
09-11A BUCKET - LOADER

TABLE OF CONTENTS

09-11B BUCKET - LOADER
09-11C BUCKET - LOADER
09-11D BUCKET - LOADER
09-12 FRAME, REAR - PIVOT - IF USED
09-12A FRAME, REAR - IF USED
09-12B CHASSIS - PIVOT
09-13 FRAME- TOOLBOX
09-14 FRAME, REAR - COVERS
09-14A FRAME, REAR - COVERS
09-15 COUNTERWEIGHTS
09-15A COUNTERWEIGHTS - IF USED
09-15B COUNTERWEIGHTS - IF USED
09-15C COUNTERWEIGHTS/HITCH - IF USED
09-16 HOOD
09-17 INSULATION - HOOD
09-18 COVERS - BATTERY BOX - IF USED
09-18A COVERS - BATTERY BOX - IF USED
09-18B COVERS - BATTERY BOX - WIDE FENDERS - IF USED
09-19 FENDERS, REAR
09-19A FENDERS, REAR - IF USED
09-20 FENDERS, REAR- WIDE - IF USED
09-20A FENDERS, REAR- WIDE - IF USED
09-21 FENDERS, REAR
09-22 FENDERS, FRONT
09-23 FENDERS, FRONT
09-24 FENDERS, REAR - STEPS
09-24A FENDERS, REAR - STEPS - IF USED
09-25 FENDERS, REAR - STEPS
09-25A FENDERS, REAR - STEPS - IF USED
09-26 FRAME, FRONT (Z BAR LOADER)
09-26A FRAME, FRONT (Z BAR LOADER) - IF USED
09-27 FRAME, FRONT (XT LOADER)
09-28 FRAME, FRONT (XT LOADER) -IF USED
09-29 FRAME, FRONT- PIN TETHER MOUNTING
09-30 CAB/CANOPY - MOUNTING, GLASS, AND REAR LIGHT POD
09-31 COVERS - CAB AND CANOPY, LOWER
09-32 COVERS - CAB OR CANOPY - WITHOUT AIR CONDITIONING
09-33 CANOPY - SUNVISOR - MIRROR, REAR VIEW
09-34 CAB - INTERIOR TRIM
09-35 CAB - INSULATION
09-36 WRIST SUPPORT
09-36A CAB - PANELS AND STORAGE RIGHT SIDE
09-36B CAB - PANELS AND STORAGE - BACK AND LEFT SIDE
09-36C CAB - RIGHT SIDE ACCESS AND FILTER
09-37 PEDESTAL - COVERS
09-38 CAB - PLENUMS, DUCTS AND LOUVERS
09-39 CAN BE USED AS EXTRA SHEET
09-40 CAB - WINDOW, RIGHT-HAND
09-41 CAB - WINDOW, LEFT-HAND
09-42 CAB - DOOR
09-43 WINDOW CATCH

TABLE OF CONTENTS

09-44 CAB - HEATER AND AIR CONDITIONING DUCTS
09-45 HEATER CORE MOUNTING
09-46 HEATING HOSES
09-46A COVERS - DRIVE BELT (WITHOUT AIR CONDITIONING)
09-47 AIR CONDITIONING
09-48 AIR CONDITIONING HOSES
09-48A COVERS - DRIVE BELT (WITH AIR CONDITIONING)
09-49 AIR CONDITIONING - CONDENSER
09-50 AIR CONDITIONING - COMPRESSOR MOUNTING
09-50A AIR CONDITIONING - COMPRESSOR
09-51 CANOPY, ROPS - COVERS
09-52 CANOPY - COVERS - VANDAL GUARD
09-53 CANOPY, ROPS - MOUNTING
09-54 DECALS
09-55 DECALS - SPECIAL PAINT
09-56 DECALS
09-57 DECALS - COMMON TO MODEL
09-58 DECALS - EUROPE
09-59 DECALS - ENGLISH
09-60 DECALS - FRENCH CANADIAN
09-61 DECALS - LATIN AMERICAN SPANISH
09-62 DECALS - GERMAN / AUSTRIAN
09-63 DECALS - ITALIAN
09-64 WHEEL CHOCK
09-65 LICENSE PLATE LIGHT
09-66 TRANSPORT OPTION (Z BAR LOADER)
09-67 TRANSPORT OPTION (XT LOADER)
09-68 TRANSPORT OPTION (XT LOADER)

NOTES

GENERAL INFORMATION

PROPRIETARY NOTICE

The contents of this manual are proprietary data of
this company. Reproduction or use of any part for
other than the operation and maintenance of our
equipment is permissible only if expressly authorized
in writing.

Additional copies may be obtained from your dealer.
Address requests for copies to your Dealer and refer
to the publication part number appearing on the
bottom of the rear catalog cover or on the title page.

COMPANY POLICY

Company policy, which is one of continuous
improvement, reserves the right to change prices
and to make changes in design and specification at
any time without notice and without obligation to
modify units previously built.

All data given in this book is subject to production
variations. Dimensions and weights are approximate
only and the illustrations do not necessarily show
machines in standard condition. For exact
information about any particular machine please
consult your dealer.

OWNER ASSISTANCE

We want you to be completely satisfied with your
investment. Normally any problems with your
equipment will be handled by your dealer's Service
Department; however, misunderstandings can occur.
If your problem has not been handled to your
satisfaction, we suggest the following:

1. Contact the owner or General Manager of the
dealership, explain the problem, and request
assistance. When additional assistance is
needed, your dealer has direct access to our
office.

2. Provide your dealer with:

● Your Name, Address, and Telephone number

● Machine Model and Serial Number

● Dealership Name and Address

● Machine purchase date and amount of use

● Nature of problem

Be aware that your problem will likely be resolved in
the dealership using the dealer's facilities,
equipment, and personnel. So it is important that
your initial contact be with the dealer.

PARTS AND ACCESSORIES

Genuine parts and accessories have been
specifically designed for these machines.

We would like to point out that “non-genuine” parts
and accessories have NOT been examined and
released by the Company. The installation and or use
of such products could have negative effects upon
the design characteristics of your machine and
thereby affect its safety. The company is not liable for
any damage caused by the use of “non-genuine”
parts and accessories.

IMPROVEMENTS

We are continually striving to improve our products.
We reserve the right to make improvements or
changes when it becomes practical and possible to
do so, without incurring any obligation to make
changes or additions to the equipment sold
previously.

MODEL CODES

The range of machines listed may not be available in
all countries or markets therefore, for the latest
information consult your local dealer.

SPARE PARTS

To maintain operating efficiency, use original spare
parts.

When ordering parts, give the following information:

● Machine Model

● Machine and Engine Serial Numbers

● Part Number from the Parts Catalog

I

II

HOW TO USE YOUR PARTS CATALOG

1. Figure Number

2. Sequence Code within the Figure Number

3. Page Number within the Sequence Code

4. Date of Printing (month / year)

5. Figure Description

6. General information regarding the figure

7. Parts supplied in repair kits per symbol reference

8. Figure call-out of the part number (REF)

9. Technical specifications relating to the part indicated

10. Figure call-out includes bracketed items, the included items may also be listed in the additional description
area

11. Orientation - Arrow indicates front of the machine

12. Footnote - Additional information relating to the part number. In this example, 08-20 equals another figure that
this part is shown on

13. Part Number

NSS = Not Serviced Separately (Non-serviced parts)
Bracketed numbers = not available as service parts in this market

14. Not Available as service part in this market

15. YR/SN

Year

Before 01/85 = Part valid for production January 1985 and before
From 01/85 = Part valid for production from January 1985 and after
BTW 01/85 & 02/02 = Part valid for machines produced between January 1985 and February 2002.

Serial Number (P.I.N.)

BSN JJC0268800 = Part valid for serial number JJC0268800 and below
ASN JJC0268800 = Part valid for serial number JJC0268800 and above
BTW JJC0178000 & JJC0179000 = Part valid for serial numbers between JJC0178000 & JJC0179000

16. Total Quantity of the Part referred to in the page. The quantity can be replaced by the following indications:

AR = As Required
X = As required

17. Part Description

18. Additional description of the part to help confirm identification

19. Figure Notes

20. Model Number(s)

RIGHT-HAND AND LEFT-HAND

The reference to right-hand and left-hand in this
catalog is identified by the operator standing at the
rear of the basic unit (without rear attachment),
looking toward the front of the machine (in normal
forward travel).

For pages covering any machine attachments,
right-hand and left-hand are defined by the operator
sitting in the position for proper operation of the
attachment.

DIMENSIONS

Metric and U.S. hardware dimensions do not show
the numeric designations of standard coarse threads.
A number following a semi colon (;) is the class or
grade of hardware. A comma (,) represents the
decimal point (.) used in U.S. dimensions.

III

EXPLANATION OF ABBREVIATIONS

AC Alternating Current
adj adjustable
amp ampere
AR As required

ASN

blkhd bulkhead
br branch

BSN

BTW between

cc cubic centimetre
cl class
cmprsn compression
cn pt cone point
cp pt cup point
CRS Chrome Alloy Steel
CST Carbon Steel
cu yd cubic yard

DC Direct Current
deg degree
dg pt dog point
dia diameter
dr type drive type

fc face
fc sl face seal
fem female
fem PT female pipe thread
fl flare
flat pt flat point
ft feet or foot

ga gauge
gal gallon or gallons
gpm gallons per minute
gr grade

hd head
hdg pt half dog point
hp horsepower
ID inside diameter
in inch or inches
Incl. Includes
inv fl inverted flare

Kkilo
kg kilogram
km/h kilometers per hour

Serial number and after
P.I.N. and after

before Serial number
before P.I.N.

Llitre
lb pounds
lb-ft pound-foot
lg long
LH left-hand
LH thd left-hand thread

M (prefix) metric thread size
mmetre
ml milliliter
mm millimetre

NF National Fine
No. number
NPT National Pipe Thread
NS National Super Fine

OD outside diameter
ohm electrical unit of resistance
Or O-ring
ORB O-ring boss
ORFS O-ring face seal
ov cntr over center
ov pt oval point
oz ounce

Ppitch
psi pounds per square inch
pt pint
PT pipe thread

rd round
rd holes round holes
RH right-hand
RH thd right-hand thread
rpm revolutions per minute

sl self-locking
sq square
SST Stainless Steel
st self-tapping
strk stroke
sw swivel

Tteeth
thk thick
tpr taper
tube OD tube outside diameter

V volt or volts
W watt or watts
X as required
yd yard

IV

SECTION INDEX

02-01 MOUNT, ENGINE
02-02 RADIATOR - MOUNTING
02-03 FAN - FAN BELT
02-04 COOLANT RECOVERY SYSTEM
02-05 COOLING SYSTEM - AIR COOLER
02-06 COOLING SYSTEM - MOTOR, DRIVE (MOUNTING)
02-07 COOLING SYSTEM - MOTOR, DRIVE (STANDARD FAN DRIVE)
02-08 COOLING SYSTEM - MOTOR, DRIVE (REVERSIBLE FAN DRIVE)
02-09 VALVE ASSY - FAN
02-10 AIR CLEANER - AIR INTAKE PARTS
02-10A AIR CLEANER ASSY
02-11 MUFFLER - EXHAUST SYSTEM
02-12 MUFFLER - EXHAUST SYSTEM - IF USED
02-13 MUFFLER - EXHAUST SYSTEM - STANDARD/ASPIRATOR SPARK ARRESTER
02-13A MUFFLER - SPARK ARRESTER/ASPIRATOR
02-14 ENGINE
02-15 ENGINE, OIL
02-16 OIL PUMP - ENGINE
02-16A TURBO OUTLET
02-17 OIL FILTERS - ENGINE
02-18 OIL FILTER AND COOLER
02-19 OIL PUMP, PAN
02-20 OIL PUMP, PAN - DRAIN LINE
02-21 BREATHER - ENGINE
02-22 TURBOCHARGER SYSTEM
02-23 TURBOCHARGER
02-24 WATER PUMP
02-25 WATER PUMP - CONTROL
02-26 CYLINDER BLOCK
02-27 CYLINDER BLOCK
02-28 CYLINDER BLOCK
02-29 FLYWHEEL HOUSING
02-30 GEAR COVER - REAR HOUSING
02-31 FRONT GEAR COVER
02-31A GEAR COVER - PLATE
02-32 CYLINDER HEAD - COVERS
02-33 CYLINDER HEAD - VALVE MECHANISM
02-34 CYLINDER HEAD
02-35 MANIFOLD - INTAKE
02-36 MANIFOLD - EXHAUST
02-37 CAMSHAFT
02-38 CRANKSHAFT
02-39 CRANKSHAFT - PULLEY
02-40 FLYWHEEL - ENGINE
02-41 CONNECTING ROD
02-42 PISTONS - CONNECTING ROD
02-43 COOLING SYSTEM - ENGINE
02-44 THERMOSTAT - ENGINE COOLING SYSTEM
02-45 ENGINE - LIFT HOOK
02-46 ENGINE - BLOCK HEATER

02-01

MOUNT, ENGINE

p1 05/04

02-01

MOUNT, ENGINE

REF FN PART NUMBER YR/SN QTY DESCRIPTION

1 627-12040 8 BOLT M12 x 40; 10.9
2 896-11016 4 WASHER 17,5 x 30 x 4 mm
3 8602303 1 MOUNT, ENGINE Rear Right
4 827-16120 4 SCREW M16 x 120; 10.9
5 496-81025 8 WASHER ,656 x 2,5 x ,188
5 227809A1 4 WASHER No Longer Used; Order 496-81025
6 361811A1 4 ISOLATOR
8 832-10416 4 NUT M16
9 8602304 1 MOUNT, ENGINE Rear Left
12 86990587 1 BRACKET Flywheel Housing
13 896-11012 14 WASHER 13,5 x 24 x 3mm
14 627-12040 8 BOLT M12 x 40; 10.9

87402787 1 SUPPORT Front Engine; No Longer Used; Not

Illustrated

896-15012 4 WASHER 13,5 x 28 x 4mm; No Longer Used; Not

Illustrated

827-12080 4 SCREW M18 x 80; 10.9; No Longer Used; Not

Illustrated

p1 05/04

621D

02-02

RADIATOR - MOUNTING

p1 08/04

02-02

RADIATOR - MOUNTING

REF FN PART NUMBER YR/SN QTY DESCRIPTION

347611A3 1 RADIATOR Incl. 1 - 6
1 403767A1 1 TANK Upper
2 403768A1 1 TANK Bottom
3 403769A1 1 CHANNEL Left Side
4 403770A1 1 RADIATOR Right Side
5 254409A1 X SEAL
6 A170241 1 CAP, RADIATOR 15 psi
7 627-8025 6 BOLT M8 x 25; 10.9
8 892-11008 6 WASHER M8
9 381963A1 2 SEAL 450 ML (17-11/16 IN); Cut From 187874C2;

Upper And Lower

10 381962A1 2 SEAL 537 ml (21-1/8 in); Cut From 198573C2;

Upper And Lower

11 381938A1 2 SEAL 652 ml (25-11/16 in); Cut From 198573C2;

Upper And Lower
12 86991195 1 HOSE 254 mm lg; Engine; Bottom
13 214-1440 3 CLAMP 2-1/16 - 3
14 86991251 1 PIPE 2.25 in; Coolant; Bottom
15 393632A1 2 CLAMP U-Bolt Assy
16 380125A2 1 HOSE 312 mm lg
17 254026A1 2 CLAMP
18 381232A1 1 HOSE 86 mm lg
19 382189A1 2 CLAMP U-Bolt Assy
20 382188A2 2 PLATE
21 L115548 3 CLAMP
22 214-1436 5 CLAMP 1-13/16 - 2-3/4
23 86991261 1 PIPE 326.5 mm lg; Coolant; Top
24 8501025 2 HOSE 110 mm lg; Coolant; Split
25 217-133 1 STEM
26 214-1410 1 CLAMP 9/16 - 1-1/16
27 86991260 1 HOSE 448 mm lg; Remote Coolant Drain
28 218-1255 1 NUT 3/4
29 218-755 1 CAP 1/2 tube; 3/4 thrd
30 87402554 1 TUBE 675 mm lg; Coolant Top
31 217-1035 1 FITTING 1/2 - 14m x 3/8 - 18 NPF
32 J911901 1 VALVE, CHECK Coolant

p1 08/04

621D

02-02

RADIATOR - MOUNTING

p2 08/04

02-02

RADIATOR - MOUNTING

REF FN PART NUMBER YR/SN QTY DESCRIPTION

33 217-191 1 CONNECTOR 1/4 id
34 217-130 1 ELBOW 1/4 id
35 87404891 1 HOSE 1280 mm lg
36 829-1408 1 NUT M10
37 214-1704 2 CLAMP
38 435437A1 4 STRAP
39 515-22127 1 CLAMP

p2 08/04

621D

02-03

FAN - FAN BELT

p1 08/04

02-03

FAN - FAN BELT

REF FN PART NUMBER YR/SN QTY DESCRIPTION

1 399708A1 1 GUARD
2 627-8030 4 SCREW M8 x 30; 10.9
3 892-11008 4 WASHER M8
4 895-15008 4 WASHER 9 x 20 x 1,6 mm
5 496-21053 1 WASHER 17/32 x 1-1/16 x 1/8
6 232-2448 1 NUT
7 371887A1 1 FAN Incl. 7A - 7B
7A 8604699 1 FAN 28 in.; ECS Molded
7B 8604700 1 HUB Fan
8 8602680 1 BELT Without Air Conditioning; Not Illustrated
9 87403165 1 BELT Air Conditioning Compressor
10 87403839 1 KIT Air Conditioning Pulley; Includes (1) Air

Conditioning Pulley, (4) Screws
11 87403769 1 BELT Drive Belt; Includes (1) Belt, (1) Idler
12 87403837 1 PULLEY ASSY. Air Conditioning Drive; Includes (1)

Air Conditioning Drive Pulley, (4) Screws
13 87403838 1 KIT Air Conditioning Drive Support; Includes (1) Fan

Support, (4) Screws
14 844-8020 4 BOLT M8 x 20; 8,8
15 844-10025 4 SCREW M10 x 25; 8,8
16 844-8045 4 SCREW M8 x 45; 8,8

p1 08/04

621D

02-04

COOLANT RECOVERY SYSTEM

p1 08/04

02-04

COOLANT RECOVERY SYSTEM

REF FN PART NUMBER YR/SN QTY DESCRIPTION

1 103846A1 1 CONTAINER
2 1547924C1 1 CAP
3 627-8020 4 BOLT M8 x 20; 10.9
4 895-15008 8 WASHER 9 x 20 x 1,6 mm
5 832-10408 4 NUT M8
6 86990727 1 GUARD Fan
7 A171099 3 CLAMP
8 396120A1 1 HOSE 495 mm (19-1/2 in); Cut From 31-2855;

Reservoir Drain
9 515-23143 5 CLAMP 9/16 ID
10 366664A1 1 HOSE 2260 mm (89 in); Cut From 31-2855; Coolant

Recovery
11 198824C1 1 GROMMET 1/2 ID
12 86983596 1 SHROUD
13 383541A1 2 FOAM
14 627-8030 10 SCREW M8 x 30; 10.9
15 895-25008 6 WASHER 9 x 24 x 2 mm
16 892-11008 10 WASHER M8

p1 08/04

621D

02-05

COOLING SYSTEM - AIR COOLER

p1 08/04

02-05

COOLING SYSTEM - AIR COOLER

REF FN PART NUMBER YR/SN QTY DESCRIPTION

1 347613A1 1 COOLER
2 86983212 1 TUBE Turbo To Air Cooler
3 86983213 1 TUBE Air Cooler To Intake
4 8501051 2 HOSE 140 mm ( 5 1/2 in ); Charge Air
5 86983214 2 HOSE (METRES)
6 892-11008 2 WASHER M8
7 627-8016 2 BOLT M8 x 16; 10.9
8 895-15010 6 WASHER 11 x 24 x 2 mm
9 386040R1 2 SPRING Poppet Return
10 561-703 2 SCREW M8 10 x 16; 12.9; Elbow
11 381934A1 2 SEAL Charge Air
12 86983215 2 FOAM Charge Air
13 86984661 4 FOAM Cover Plate
14 8500167 2 SEAL Air Tubes
15 L115549 8 CLAMP

p1 08/04

621D

02-06

COOLING SYSTEM - MOTOR, DRIVE (MOUNTING)

p1 08/04

02-06

COOLING SYSTEM - MOTOR, DRIVE (MOUNTING)

REF FN PART NUMBER YR/SN QTY DESCRIPTION

1 400337A1 1 MOTOR, HYDRAULIC Fan Drive; Standard or

Reversible; Incl. Ref 2, 3; With M12 Drain Port On

Top; No Longer Available, Order 87426773 Motor,

Ref 7; Also Order 700-378 Elbow and 87427292

Hose On Figure 07-05
2 8604520 1 SEAL Shaft Fan Pump; Not Illustrated
3 8604978 1 KIT Seal; Not Illustrated
4 627-10035 2 SCREW M10 x 35; 10.9
5 895-11010 4 WASHER 11 x 20 x 2 mm
6 832-10410 2 NUT M10
7 87426773 1 MOTOR, HYDRAULIC Fan Drive; Standard or

Reversible; Includes 87426795 Seal Kit; With M14

Drain Port On Side

87426795 1 KIT, SEALS Seal; Not Illustrated

p1 08/04

621D

02-07

COOLING SYSTEM - MOTOR, DRIVE (STANDARD FAN DRIVE)

p1 08/04

02-07

COOLING SYSTEM - MOTOR, DRIVE (STANDARD FAN DRIVE)

REF FN PART NUMBER YR/SN QTY DESCRIPTION

1 8605141 1 VALVE, PRESSURE RELIEF See Figure 02-10;

Replaces 429361A2 Valve Used In Production
2 700-306 1 ELBOW 90 deg; 1 fc sl x M22 Or; Incl. 3, 4
3 238-6016 1 O-RING 5/8 ID x 1/16; Face Seal
4 637-63193 1 O-RING 19,3 ID x 2,2; Boss Seal
5 701-361 1 ELBOW 90 deg; Incl. 6
6 238-6016 1 O-RING 5/8 ID x 1/16; Face Seal
7 700-162 2 CONNECTOR, HYD. 13/16 fc sl x M22 Or; Incl. 8, 9
8 637-63193 1 O-RING 19,3 ID x 2,2 mm; Boss Seal
9 238-6014 1 O-RING 1/2 ID x 1/16; Face Seal
10 440832A1 1 HOSE ASSY. 2249 mm; Forward
11 700-326 1 ELBOW 90 deg; 13/16 fc sl x M22 ORB; Incl. 12, 13
12 238-6014 1 O-RING 1/2 ID x 1/16; Face Seal
13 637-63193 1 O-RING 19,3 ID x 2,2; Boss Seal
14 700-103 1 CONNECTOR, HYD. 1 fc sl x M22 Or; Incl. 15, 16
15 637-63193 1 O-RING 19,3 ID x 2,2 mm; Boss Seal
16 238-6016 1 O-RING 5/8 ID x 1/16; Face Seal
17 376179A2 1 HOSE ASSY. 1935 mm; Reverse
18 400337A1 1 MOTOR, HYDRAULIC Fan Drive; Includes 8604978

Seal Kit, 8604520 Shaft Seal; M12 Drain Port On

Top; No Longer Available, Order 87426773 Motor

(Ref 18A), 700-378 Elbow (Ref 33), and 87427292

Hose On Figure 07-05
18A 87426773 1 MOTOR, HYDRAULIC Fan Drive; Includes

87426795 Seal Kit; M14 Drain Port On Side
19 408003A3 1 HOSE ASSY. 809 mm; Valve Supply
20 407750A1 1 BRACKET
21 827-8090 2 BOLT M8 x 90; 10.9
22 895-11008 4 WASHER 9 x 16 x 1,6 mm
23 832-10408 2 NUT M8
24 827-12050 2 SCREW M12 x 50; 10.9
25 896-15012 4 WASHER 13,5 x 28 x 4 mm
26 832-10412 2 NUT M12
27 700-387 1 ELBOW 45 deg; Incl. 28, 29
28 238-6018 1 O-RING 1-3/16 x 1/16; Face Seal
29 637-64236 1 O-RING 23,6 ID x 2,9; Boss Seal

p1 08/04

621D

02-07

COOLING SYSTEM - MOTOR, DRIVE (STANDARD FAN DRIVE)

p2 08/04

02-07

COOLING SYSTEM - MOTOR, DRIVE (STANDARD FAN DRIVE)

REF FN PART NUMBER YR/SN QTY DESCRIPTION

30 700-303 1 ELBOW 90 deg; 9/16 fc sl x M12 Or; Incl. 31, 32;

Used With 400337A1 Motor (Ref 18); If Used
31 238-6011 1 O-RING 5/16 x 1/16; Face Seal
32 637-63093 1 O-RING 9,3 ID x 2,2; Boss Seal
33 700-378 1 ELBOW 90 deg; 9/16 fc sl x M12 Or; Incl. 34, 35;

Used With 87426773 Motor (Ref 18A); If Used
34 637-63113 1 O-RING 11,3 ID x 2,2; Boss Seal
35 238-6011 1 O-RING 5/16 ID x 1/16; Face Seal

p2 08/04

621D

02-08

COOLING SYSTEM - MOTOR, DRIVE (REVERSIBLE FAN DRIVE)

p1 08/04

02-08

COOLING SYSTEM - MOTOR, DRIVE (REVERSIBLE FAN DRIVE)

REF FN PART NUMBER YR/SN QTY DESCRIPTION

1 8605147 1 VALVE Pressure Relief; See Figure 02-09;

Replaces 445495A1 Valve Used In Production
2 700-306 1 ELBOW 90 deg; 1 fc sl x M22 Or; Incl. 3, 4
3 238-6016 1 O-RING 5/8 ID x 1/16; Face Seal
4 637-63193 1 O-RING 19,3 ID x 2,2; Boss Seal
5 701-361 1 ELBOW 90 deg; Incl. 6
6 238-6016 1 O-RING 5/8 ID x 1/16; Face Seal
8 700-162 1 CONNECTOR, HYD. 13/16 fc sl x M22 Or; Incl. 8, 9
9 637-63193 1 O-RING 19,3 ID x 2,2 mm; Boss Seal
10 238-6014 1 O-RING 1/2 ID x 1/16; Face Seal
11 440832A1 1 HOSE ASSY. 1626,5 mm; Forward
12 700-326 2 ELBOW 90 deg; 13/16 fc sl x M22 Orb; Incl. 12, 13
13 238-6014 1 O-RING 1/2 ID x 1/16; Face Seal
14 637-63193 1 O-RING 19,3 ID x 2,2; Boss Seal
15 700-103 1 CONNECTOR, HYD. 1 fc sl x M22 Or; Incl. 15, 16
16 637-63193 1 O-RING 19,3 ID x 2,2 mm; Boss Seal
17 238-6016 1 O-RING 5/8 ID x 1/16; Face Seal
18 376179A2 1 HOSE ASSY. 1935 mm; Reverse
19 700-387 1 ELBOW 45 deg; Incl. 20, 21
20 238-6018 1 O-RING 3/4 ID x 1/16; Face Seal
21 637-64236 1 O-RING 23,6 ID x 2,9; Boss Seal
22 400337A1 1 MOTOR, HYDRAULIC Fan Drive; Includes 8604978

Seal Kit, 8604520 Shaft Seal; M12 Drain Port On

Top; No Longer Available, Order 87426773 Motor

(Ref 22A), 700-378 Elbow (Ref 34) and 87427292

Hose On Figure 07-05
22A 87426773 1 MOTOR, HYDRAULIC Fan Drive; Includes

87426795 Seal Kit; M14 Drain Port On Side
23 408003A3 1 HOSE ASSY. 809 mm; Valve Supply
24 407750A1 1 BRACKET
25 827-8120 3 BOLT M8 x 120; 10.9
26 895-11008 3 WASHER 9 x 17 x 1,6 mm
27 832-10408 3 NUT M8
28 827-12050 2 SCREW M12 x 50; 10.9
29 896-15012 4 WASHER 13,5 x 28 x 4 mm
30 832-10412 2 NUT M12

p1 08/04

621D

02-08

COOLING SYSTEM - MOTOR, DRIVE (REVERSIBLE FAN DRIVE)

p2 08/04

02-08

COOLING SYSTEM - MOTOR, DRIVE (REVERSIBLE FAN DRIVE)

REF FN PART NUMBER YR/SN QTY DESCRIPTION

31 700-303 1 ELBOW 90 deg; 9/16 fc sl x M12 Or; Incl 32, 33;

Used With 400337A1 Motor (Ref 22); If Used
32 238-6011 1 O-RING 5/16 ID x 1/16; Face Seal
33 637-63093 1 O-RING 9,2 ID x 2,2; Boss Seal
34 700-378 1 ELBOW 90 deg; 9/16 fc sl x M14 Or; Incl. 35, 36;

Used With 87426773 Motor (Ref 22A); If Used
35 637-63113 1 O-RING 11,3 ID x 2,2; Boss Seal
36 238-6011 1 O-RING 5/16 x 1/16; Face Seal
37 382375A2 1 SWITCH Rocker; Fan Reverser

p2 08/04

621D

02-09

VALVE ASSY - FAN

p1 08/04

02-09

VALVE ASSY - FAN

REF FN PART NUMBER YR/SN QTY DESCRIPTION

REF INSTRUCTION STANDARD FAN DRIVE
8605141 1 VALVE, PRESSURE RELIEF Models With Standard

Fan Drive; Incl. Ref 1 - 5; Replaces 429361A2

Valve Used In Production
1 NSS 1 NOT SERVICED SEPARATELY Body
2 8605073 1 VALVE, CHECK Includes 1542830C2 Seal Kit

1542830C2 1 KIT, GASKET Seal; Includes (4) O-Rings, (1)

Backup Ring, Which Are Not Serviced Separately
3 86984141 1 VALVE, PRESSURE RELIEF Includes 1542830C2

Seal Kit

1542830C2 1 KIT, GASKET Seal; Includes (4) O-Rings, (1)

Backup Ring, Which Are Not Serviced Separately
4 218-5209 1 PLUG Hex Socket; 9/16 Or; Incl. Ref 5
5 237-6006 1 O-RING 15/32 ID x 5/64

REF INSTRUCTION REVERSIBLE FAN DRIVE
8605147 1 VALVE PRESSURE RELIEF; Models With

Reversible Fan Drive; Incl. Ref 6 - 14; Replaces

445495A1 Valve Used In Production
6 NSS 1 NOT SERVICED SEPARATELY Body
7 8605152 1 VALVE, PRESSURE RELIEF Includes 1542830C2

Seal Kit

1542830C2 1 KIT, GASKET Seal; Includes (4) O-Rings, (1)

Backup Ring, Which Are Not Serviced Separately
8 8605066 1 VALVE, PRESSURE RELIEF Solenoid Cartridge;

Includes 329483A1 Seal Kit

329483A1 1 KIT, GASKET Seal; Includes (3) O-Rings, (4)

Backup Rings, Which Are Not Serviced Separately
9 8605069 1 COIL Electronic
10 8605053 1 VALVE, PRESSURE RELIEF Bi-Directional;

Includes 1542833C1 Seal Kit

1542833C1 1 PACKAGE, SEALS

11 8605150 1 VALVE, PILOT Directional, Relief Cartridge;

Includes 124639A1 Seal Kit

124639A1 1 KIT, GASKET Seal; Includes (4) O-Rings, (6)

Backup Rings, Which Are Not Serviced Separately

p1 08/04

621D

02-09

VALVE ASSY - FAN

p2 08/04

02-09

VALVE ASSY - FAN

REF FN PART NUMBER YR/SN QTY DESCRIPTION

12 8605151 1 VALVE, PILOT Directional, Relief Cartridge;

Includes 124639A1 Seal Kit

124639A1 1 KIT, GASKET Seal; Includes (4) O-Rings, (6)

Backup Rings, Which Are Not Serviced Separately
13 218-5207 1 PLUG Hex Socket; 7/16 Or; Incl. Ref 14
14 237-6004 1 O-RING 23/64 ID x 5/64

p2 08/04

621D

02-10

AIR CLEANER - AIR INTAKE PARTS

p1 08/04

02-10

AIR CLEANER - AIR INTAKE PARTS

REF FN PART NUMBER YR/SN QTY DESCRIPTION

1 8602956 1 BRACKET Air Cleaner; If Used; Not Illustrated
1A 87451676 1 SUPPORT Air Cleaner; If Used
2 390319A1 2 BRACKET
3 390318A1 1 CLEANER ASSY. See Figure 02-11A
4 87433573 1 ANGLE Inlet Screen
5 397116A1 1 TUBE
6 895-15010 8 WASHER 11 x 24 x 2 mm
7 827-10040 4 SCREW M10 x 40; 10.9
8 832-10410 4 NUT M10
9 827-12050 2 SCREW M12 x 50; 10.9
10 896-11012 4 WASHER 13,5 x 24 x 3 mm
11 832-10412 2 NUT M12
12 214-1480 1 CLAMP 4-5/8 - 5-1/2
13 214-1472 1 CLAMP 4-1/16 - 5
14 L127771 3 CLAMP
15 87400957 1 TUBE, AIR INTAKE
16 8602478 1 HOSE Air Cleaner
17 8605492 1 TUBE, AIR INTAKE CCV Valve; Replaced 87400959
18 8604749 1 HOSE 480 mm; Crankcase Vent
19 214-1416 2 CLAMP
20 87433574 1 SCREEN Inlet
21 896-15008 8 WASHER 9 x 21 x 2.5 mm
22 627-8035 3 SCREW M8 x 35; 10.9

p1 08/04

621D

02-10A

AIR CLEANER ASSY

p1 08/04

02-10A

AIR CLEANER ASSY

REF FN PART NUMBER YR/SN QTY DESCRIPTION

390318A1 1 CLEANER ASSY. Incl. 1 - 6
1 8604708 1 BODY Body
2 8602985 1 FILTER, ELEMENT Primary; Outer
3 8602986 1 FILTER, ELEMENT Secondary; Inner
4 8604711 1 COVER
5 8604231 1 VALVE Evacuator
6 8604713 1 DECAL

p1 08/04

621D

02-11

MUFFLER - EXHAUST SYSTEM

p1 08/04

02-11

MUFFLER - EXHAUST SYSTEM

REF FN PART NUMBER YR/SN QTY DESCRIPTION

REF INSTRUCTION NO LONGER AVAILABE SEE

FIGURES 02-13A, 02-13B
1 388283A1 1 MUFFLER Standard
1A 373393A1 1 MUFFLER Spark Arrester
2 86991785 1 BRACKET
3 896-15008 7 WASHER 9 x 21 x 2,5 mm
4 627-8020 4 BOLT M8 x 20; 10.9
5 827-12130 2 BOLT M12 x 130; 10.9
6 896-15012 2 WASHER 13,5 x 28 x 4 mm
7 299456A1 1 COLLAR CLAMP
8 86983217 1 TUBE
9 J903652 1 CLAMP
10 87409308 1 BRACKET
11 896-11010 3 WASHER 11 x 21 x 2,5 mm
12 627-10025 3 SCREW M10 x 25; 10.9
13 408195A1 1 PIPE, EXHAUST SYSTEM Plate
14 895-18010 4 WASHER 11 x 18 x 1,6 mm; Not Illustrated
15 832-10406 4 NUT M10; Not Illustrated
16 87425898 1 PLATE Muffler Mounting

p1 08/04

621D

02-12

MUFFLER - EXHAUST SYSTEM - IF USED

9

7

8

p1 08/04

1A

1

3

16

4

3

16

11

2

3

10

4

5

5

BS04F162

6

02-12

MUFFLER - EXHAUST SYSTEM - IF USED

REF FN PART NUMBER YR/SN QTY DESCRIPTION

REF INSTRUCTION NO LONGER AVAILABE; SEE

FIGURES 02-13, 02-13A
1 388283A1 1 MUFFLER Standard
1A 373393A1 1 MUFFLER Spark Arrester
2 299456A1 1 COLLAR CLAMP
3 86983216 1 TUBE
4 J903652 1 CLAMP
5 87428705 1 BRACKET
6 86991866 1 BRACKET
7 896-15008 4 WASHER 9 x 21 x 2,5 mm
8 896-15012 3 WASHER 13,5 x 28 x 4 mm
9 627-8025 4 BOLT M8 x 25
10 896-15010 3 WASHER 11 x 24 x 3 mm; Use With Spark Arrester
11 827-12130 2 BOLT M12 x 130
12 627-10025 3 SCREW M10 x 25; 10.9
13 408195A1 1 PIPE, EXHAUST SYSTEM Not Illustrated
14 895-18010 4 WASHER 11 x 18 x 1,6 mm; Not Illustrated
15 832-10406 4 NUT M10; Not Illustrated
16 87425898 2 PLATE Muffler

p1 08/04

621D

02-13

MUFFLER - EXHAUST SYSTEM - STANDARD/ASPIRATOR SPARK ARRESTER

p1 09/04

02-13

MUFFLER - EXHAUST SYSTEM - STANDARD/ASPIRATOR SPARK ARRESTER

REF FN PART NUMBER YR/SN QTY DESCRIPTION

REF MOUNTING FOR STD & ASPIRATOR MUFFLERS;

TIER II MODELS
1 388283A1 1 Standard
1A 87451543 1 Spark Arrestor & Aspirated
2 299456A1 1 Muffler
3 86983217 1 Exhaust
4 J903652 1 V Band
5 87409308 1 Muffler; Rear
6 87452053 1 Muffler; Front
7 896-15008 4 9 x 21 x 2,5 mm
8 896-15012 3 13,5 x 28 x 4 mm
9 627-8025 4 M8 x 25; 10.9
10 896-15010 3 11 x 24 x 3 mm; Use With Spark Arrester
11 827-12130 2 M12 x 130
12 627-10025 3 M10 x 25; 10.9
13 87425898 2 Muffler
14 408195A1 1 Components Not Service Separately
15 408196A1 1 Exhaust Stack Backing
16 832-10410 4 M10, 8
17 895-18010 4 11 x 18 x 1,6 mm; Not Illustrated

p1 09/04

621D

02-13A

MUFFLER - SPARK ARRESTER/ASPIRATOR

p1 09/04

02-13A

MUFFLER - SPARK ARRESTER/ASPIRATOR

REF FN PART NUMBER YR/SN QTY DESCRIPTION

1 87451543 1 MUFFLER Spark Arrestor & Aspiratedar
2 90-7639T1 1 CLAMP Valve
3 895-11008 1 WASHER 9 x 16 x 1.6mm
4 832-10408 2 NUT M8; 8
5 627-8025 1 BOLT M8 x 25; 10.9
6 87433700 1 VALVE, CHECK 2 - 1-1/4 in.
7 87450402 1 HOSE Check Valve To Air Cleaner
8 515-24349 3 CLAMP 34.9mm; M10 Bolt
9 82016818 1 HOSE, FLEXIBLE Connector Engine Air Cleaner

Aspirator Tube; 405mm ( 16 in )
10 832-10410 1 NUT M10; 8
11 627-10030 1 SCREW M10 x 30; 10.9
12 214-1436 2 CLAMP Type F #36
13 214-1420 2 CLAMP Type F #20
14 896-11008 2 WASHER 9 x 17 x 2mm
15 827-8045 1 BOLT M8 x 45; 10.9

p1 09/04

621D

ENGINE

02-14

p1 08/04

02-14

ENGINE

REF FN PART NUMBER YR/SN QTY DESCRIPTION

1 {87433688} 1 - ASSY

p1 08/04

621D

02-15

ENGINE, OIL

p1 09/04

02-15

ENGINE, OIL

REF FN PART NUMBER YR/SN QTY DESCRIPTION

1 2852122 1 TUBE, RIGID
2 2852413 1 DIPSTICK
3 4899036 1 PLUG
4 4897330 1 PLUG - ASSY
5 4895610 1 O-RING
6 2852377 1 NECK FILLER
7 2852134 2 SCREW
8 2852135 1 GASKET
9 98429552 1 CAP, INTRODUCTION

p1 09/04

621D

02-16

OIL PUMP - ENGINE

p1 08/04

02-16

OIL PUMP - ENGINE

REF FN PART NUMBER YR/SN QTY DESCRIPTION

1 4897481 1 PUMP, ENGINE OIL
2 4899090 4 SCREW M8 x 30

p1 08/04

621D

02-16A

TURBO OUTLET

p1 06/04

02-16A

TURBO OUTLET

REF FN PART NUMBER YR/SN QTY DESCRIPTION

1 J918685 1 PIPE Turbo Outlet Air Transfer
2 J883284 1 SEAL Turbo Outlet
3 J069053 1 CLAMP Turbo Outlet
4 217-402 1 PLUG 1/8-27 NPTF

p1 06/04

621D

02-17

OIL FILTERS - ENGINE

p1 08/04

02-17

OIL FILTERS - ENGINE

REF FN PART NUMBER YR/SN QTY DESCRIPTION

1 87803261 1 FILTER, ENGINE OIL

p1 08/04

621D

02-18

OIL FILTER AND COOLER

p1 08/04

02-18

OIL FILTER AND COOLER

REF FN PART NUMBER YR/SN QTY DESCRIPTION

1 4899019 15 SCREW M8X35
2 4892774 1 HEAT EXCHANGER - ASSY
3 4895043 1 PLUG
4 4896404 1 HOUSING
5 4895045 1 SPRING, VALVE
6 4899035 1 O-RING
7 4896410 1 VALVE, HYDRAULIC
8 4893391 1 CONNECTOR, HYD.
9 4896407 1 RADIATOR
10 4895742 1 GASKET
11 4896409 1 GASKET

p1 08/04

621D

02-19

OIL PUMP, PAN

p1 08/04

02-19

OIL PUMP, PAN

REF FN PART NUMBER YR/SN QTY DESCRIPTION

1 4899020 2 SCREW M8X20
2 4899091 18 SCREW
3 4898301 1 GASKET - ASSY
4 {2852309} 1
5 {2852313} 1
6 4847102 1 PLUG
7 4897858 1 SPACER
8 4897861 1 GASKET
9 2852310 1 STRAINER ASSY. 21.8X2.6MM

p1 08/04

621D

02-20

OIL PUMP, PAN - DRAIN LINE

p1 08/04

02-20

OIL PUMP, PAN - DRAIN LINE

REF FN PART NUMBER YR/SN QTY DESCRIPTION

1 87426452 1 FITTING 90 deg; Incl. 2, 3
2 218-1251 1 NUT, LOCK 7/8
3 218-756 1 CAP 7/8
4 86990586 1 HOSE, FLEXIBLE

p1 08/04

621D

02-21

BREATHER - ENGINE

p1 08/04

02-21

BREATHER - ENGINE

REF FN PART NUMBER YR/SN QTY DESCRIPTION

1 2852531 1 BREATHER
2 2852028 1 GASKET
3 4899110 3 SCREW

p1 08/04

621D

02-22

TURBOCHARGER SYSTEM

p1 08/04

02-22

TURBOCHARGER SYSTEM

REF FN PART NUMBER YR/SN QTY DESCRIPTION

1 87426452 1 FITTING 90 deg, Adj; Incl. 2, 3
2 238-6016 1 O-RING 5/8 ID x 1/16, Face Seal
3 637-63193 1 O-RING 19,3 ID x 2,2, Boss Seal
4 86990586 1 HOSE, FLEXIBLE Remote Oil Drain Hose
5 218-1251 1 NUT, LOCK 5/8
6 218-756 1 CAP 5/8
23 347613A1 1 COOLER Charge Air
25 86983214 2 HOSE (METRES) Intake
26 8500167 2 SEAL Seal, Charge Air Tubes
27 86983212 1 TUBE Charge Air Turbo
28 86983213 1 TUBE Charge Air Intake Tube
29 8501051 1 HOSE 76 x 140; Charge Air
30 86983215 2 FOAM Charge Air Seal
31 86984661 2 FOAM Cover
32 381934A1 2 SEAL Charge Air
33 895-15010 6 WASHER 11 x 24 x 2 mm
34 386040R1 2 SPRING
35 561-703 2 SCREW M8 x 16
36 L115549 2 CLAMP
41 627-8016 2 BOLT M8 x 16
42 892-11008 2 WASHER 8 mm, Spring Lock

p1 08/04

621D

02-23

TURBOCHARGER

p1 08/04

02-23

TURBOCHARGER

REF FN PART NUMBER YR/SN QTY DESCRIPTION

1 4899086 4 NUT
2 4895132 1 GASKET
3 2852375 1 TURBOCHARGER
4 4895098 1 PLUG
5 4899087 1 O-RING
6 4895141 4 TUBE, RIGID
7 4899098 1 NUT
7 2852407 4 COLLAR CLAMP

p1 08/04

621D

02-24

WATER PUMP

p1 08/04

02-24

WATER PUMP

REF FN PART NUMBER YR/SN QTY DESCRIPTION

1 4891252 1 PUMP, WATER
2 2852047 1 GASKET
3 4899031 2 SCREW M8X25

p1 08/04

621D

02-25

WATER PUMP - CONTROL

p1 08/04

02-25

WATER PUMP - CONTROL

REF FN PART NUMBER YR/SN QTY DESCRIPTION

1 2852398 1 TENSIONER, BELT
2 2852396 1 TENSIONER, BELT
3 2852397 1 ROLLER, SHIFTER
4 4898546 1 BELT

p1 08/04

621D

02-26

CYLINDER BLOCK

p1 08/04

02-26

CYLINDER BLOCK

REF FN PART NUMBER YR/SN QTY DESCRIPTION

1 2830076 1 CYLINDER BLOCK - ASSY
2 4899026 14 DOWEL
3 4895039 3 PLUG
4 4895038 6 PLUG
5 4895228 3 PLUG
6 4891353 14 SCREW M12X120
7 4895040 1 BUSHING

p1 08/04

621D

02-27

CYLINDER BLOCK

p1 08/04

02-27

CYLINDER BLOCK

REF FN PART NUMBER YR/SN QTY DESCRIPTION

1 4896153 6 PLUG
2 4895605 2 PLUG M14X1.5 - ASSY
3 4899115 1 O-RING
4 4899009 2 PLUG M10X1.5 - ASSY
5 4899072 1 O-RING
6 4895392 2 PLUG M18X1.5 - ASSY
7 4895393 1 O-RING
8 4895049 2 DOWEL
9 4895180 12 TAPPET
10 2852202 6 NOZZLE, LUB. OIL JET
11 4894218 6 SCREW

p1 08/04

621D

02-28

CYLINDER BLOCK

p1 08/04

02-28

CYLINDER BLOCK

REF FN PART NUMBER YR/SN QTY DESCRIPTION

1 4899032 14 SCREW M10X25
2 2852729 1 REINFORCEMENT

p1 08/04

621D

02-29

FLYWHEEL HOUSING

p1 08/04

02-29

FLYWHEEL HOUSING

REF FN PART NUMBER YR/SN QTY DESCRIPTION

1 4899026 2 DOWEL
2 {2852325} 2 M10X1.5X80
3 2852326 11 SCREW M10X1.5X40
4 4895378 1 PLUG
5 2852329 1 O-RING
6 2852327 5 SCREW M12X80
7 2852324 3 SCREW
8 4890833 1 GASKET
9 2852323 2 SCREW
10 2852328 1 COVER
11 4895358 1 COVER
12 2852025 1 COVER
13 2852100 3 SCREW M8X20

p1 08/04

621D

02-30

GEAR COVER - REAR HOUSING

p1 09/04

02-30

GEAR COVER - REAR HOUSING

REF FN PART NUMBER YR/SN QTY DESCRIPTION

1 4899026 2 DOWEL
2 4899091 4 SCREW
3 4899093 5 SCREW
4 4899073 1 SCREW
5 2852320 1 COVER - ASSY
6 {4899126} 1 D=22
7 2852517 1 O-RING
8 4895355 2 SCREW M5X17
9 2852515 1 PIN - ASSY
10 2852759 1 RING

p1 09/04

621D

02-31

FRONT GEAR COVER

p1 08/04

02-31

FRONT GEAR COVER

REF FN PART NUMBER YR/SN QTY DESCRIPTION

1 4897026 1 COVER
2 4899078 5 SCREW
3 4899063 8 SCREW M8X30
4 4890832 1 GASKET
5 4891209 2 DOWEL

p1 08/04

621D

02-31A

GEAR COVER - PLATE

p1 08/04

02-31A

GEAR COVER - PLATE

REF FN PART NUMBER YR/SN QTY DESCRIPTION

1 2852175 1 COVER
2 4896897 1 GASKET
3 4899037 2 SCREW

p1 08/04

621D

02-32

CYLINDER HEAD - COVERS

p1 08/04

02-32

CYLINDER HEAD - COVERS

REF FN PART NUMBER YR/SN QTY DESCRIPTION

1 4895360 6 BUSHING
2 2830281 4 SCREW
3 4895214 6 SCREW
4 2852032 4 COVER
5 2830775 1 BAFFLE ASSY.
6 2852033 6 GASKET
7 2830784 1 COVER - ASSY

p1 08/04

621D

02-33

CYLINDER HEAD - VALVE MECHANISM

p1 08/04

02-33

CYLINDER HEAD - VALVE MECHANISM

REF FN PART NUMBER YR/SN QTY DESCRIPTION

1 4895195 6 ROCKER ARM - ASSY
2 4895361 12 ROD, PUSH
3 4895193 6 SCREW
4 4892860 6 SCREW
5 4895363 2 RING
6 4895364 2 WASHER
7 4895196 1 ROCKER ARM - ASSY
8 4895365 2 SPACER
9 4895198 2 NUT
10 4895199 2 SCREW
11 4895200 1 ROCKER ARM - ASSY
12 4895204 1 SUPPORT

p1 08/04

621D

02-34

CYLINDER HEAD

p1 08/04

02-34

CYLINDER HEAD

REF FN PART NUMBER YR/SN QTY DESCRIPTION

2830923 1 GASKET Not Illustrated
1 4892861 6 SCREW
2 4892859 14 SCREW
3 4895768 1 CYLINDER HEAD - ASSY
4 4895183 24 COTTER, ROCKER ARM
5 4895188 6 VALVE, ENG EXHAUST, STD
6 4895187 6 VALVE, ENGINE, INLET, STD
7 4895347 12 CUP
8 4895215 12 SPRING
9 4895184 12 CUP
10 4899009 1 PLUG M10X1.5 - ASSY
11 4899072 1 O-RING
12 4895179 3 PLUG
13 4897178 6 VALVE SEAT
14 4897179 6 VALVE SEAT
15 2830922 1 GASKET 1.25
16 4895078 5 PLUG

p1 08/04

621D

02-35

MANIFOLD - INTAKE

p1 08/04