SECTION 4 -ENGINE & ATTACHING PARTS

SECTION 4 -ENGINE & ATTACHING PARTS

ENGINE & ATTACHING PARTS Power Unit Assembly 49 46 9 40 44 50 61 11 14 5 51 60 20 27 45 41 21 0 7 7 12 16 4 20 27 45 52 58 VIEW SHOWING TUBE ASSEMBLY AT MAIN PUMP FOR MACHINES EQUIPPED WITH HOSE AT MAIN PUMP, SEE PAGE 8-6 FOR DETAILS. 15 59 4 8 47 110 111 112 11 101 102 10 104 105 106 107 108 109 10 26 29 4 45 1 2 MUFFLER SUPPORT COMPONENTS ARE LOCATED ON PAGE 4-6 PAE1522 4-2 Series III Rough Terrain Excavators 80644001

Power Unit Assembly 0 6 1 4 1 48 18 19 2 22 42 2 6 24 62 6 64 25 5 55 56 54 8 9 17 28 5 57 MUFFLER SUPPORT COMPONENTS ARE LOCATED ON PAGE 4-6 PAE152 80644001 Series III Rough Terrain Excavators 4-

Power Unit Assembly Item Part Number Qty. Description Rev. Consult Factory Ref POWER UNIT ASSY, (includes items 1 thru 64 & all items on page 4-6) T 1 1400129 1 FAN CLUTCH 2 206008 1 FAN 144064 A/R LOCTITE, (#242 blue) 4 1440404 A/R LOCTITE, (#545 purple) 5 14404082 A/R LOCTITE, (#565 white) 6 249212 1 MUFFLER CLAMP, 7 802220 FLAT WASHER, M10 8 88591204 1 O-RING 9 80899 2 LORD MOUNT 10 Ref MAIN HYDRAULIC PUMP, (see page 9-8 for details) 11 8048052 1 ALTERNATOR 12 8048055 1 STARTER 1 88591209 1 O-RING 14 8048108 4 HEX HD CAPSCREW, M10X1.5X110, (torque to 2-6 lb-ft) 15 876056 1 VITON O-RING, (lubricate lightly) 16 804827 STUD, M10X1.5X45MM, (torque to 40-45 lb-ft) 17 80486016 1 FRONT ENGINE MOUNT 18 Ref DRIVE BELT, (A/C equipped), (see page 6-44 for details) 8048056 1 DRIVE BELT, (no A/C equipped) 19 8077001 1 ENGINE, 17HP, (domestic) 8077129 1 ENGINE, 17HP, (export) 20 8077006 8 HEX HD CAPSCREW, 16-2.0X65, GR10.9, (torque to 17-180 lb-ft) 21 8077007 1 FLYWHEEL COUPLER 22 8077008 1 MUFFLER 8077100 1 CATALYTIC MUFFLER, (optional) 2 8077009 1 EXHAUST TAILPIPE 24 8077010 1 EXHAUST TUBE 25 7714014 1 WHIZ-LOK NUT, 1/2-1 26 807706 1 SUCTION ELBOW 27 80776002 2 REAR ENGINE MOUNT 28 80774025 1 OIL PRESSURE SENDER 29 80919 1 O-RING 0 8191011 16 LOCKWASHER, M8 1 819101 6 LOCKWASHER, M10 2 8191021 6 HEX HD CAPSCREW, 10-1.50X0, GR8.8, (torque to 2-6 lb-ft) 80774042 1 BELT TENSIONER IDLER 4 819100 HEX LOCKNUT, M10X1.5, (torque to 2-6 lb-ft) 5 80771024 1 TUBE MOUNT BRACKET 6 8191045 4 HEX HD CAPSCREW, 8-1.25X0, GR8.8, (torque to 16-20 lb-ft) 7 8191046 12 SOCKET HD CAPSCREW, M8X1.25X20, (torque to 16-20 lb-ft) 8 8191067 4 HEX HD CAPSCREW, M14-2X45MM, (torque to 87-9 lb-ft) 9 8077049 1 TUBE PORT COVER 40 819025 4 HEX HD CAPSCREW, 6-1.00X25, GR8.8, (torque to 4 lb-ft) 41 86521144 1 SUPPORT CLAMP, 1/16 42 8688127 1 MUFFLER CLAMP, 4 4 88201096 4 HEX HD CAPSCREW, 5/8-11X1-/4, GR5, (torque to 140-155 lb-ft) 44 88551009 4 LOCKWASHER, 1/4 45 88551015 12 LOCKWASHER, 5/8 4-4 Series III Rough Terrain Excavators 80644001

Power Unit Assembly Item Part Number Qty. Description Rev. 46 8077045 1 TUBE 47 88662418 1 ELBOW, 45 DEGREES, (includes item 8) 48 88662429 1 ELBOW, 90 DEGREES, (includes item 1) 49 8077046 1 TUBE, (w/heating flange) 50 88561001 4 FLAT WASHER, /16 51 90027470 4 HARDENED WASHER, /8 52 848497 1 WORM CLAMP 5 86671187 1 HOSE CLAMP 54 8668122 1 TY-WRAP 55 88201069 1 HEX HD CAPSCREW, 1/2-1X2, GR5 56 88561111 1 FLAT WASHER, 1/2 57 8048127 1 SLOBBER HOSE ASSY 58 82092119 2 FUEL HOSE 59 771089 1 MINI-CHECK COUPLING, (includes item 15) 60 8048054 1 PULLEY 61 8077151 1 O-RING 62 80484255 1 V-CLAMP 6 80484254 1 NUT 64 8048425 1 BOLT 101 819101 2 LOCKWASHER, M10 102 8191027 2 HEX HD CAPSCREW, 10-1.5X5, GR8.8, (torque to 2-6 lb-ft) 10 80776042 1 TUBE SUPPORT WELDMENT 104 Ref PUMP TUBE ASSY, (no longer available; order 8075022S Tube Replacement Kit on page 8-6) 105 8251291 1 CLAMP COVER PLATE 106 825004 1 CLAMP SET 107 88201046 2 HEX HD CAPSCREW, /8-16X-/4, GR5 108 8852106 2 HEX LOCKNUT, /8-16 109 88561004 2 FLAT WASHER, /8 110 88551015 4 LOCKWASHER, 5/8 111 87804 1 O-RING 112 84712740 2 FLANGE HALF 11 88201098 4 HEX HD CAPSCREW, 5/8-11X2-1/4, GR5, (torque to 140-155 lb-ft) 808407 1 ENGINE BLOCK HEATER, (optional, not illustrated; uses cord 778950) 808428 A/R ENGINE DIAGNOSTIC TOOL 80774017 1 ENGINE FILTER KIT, (includes the following items) 80774016 1 OIL FILTER 80774012 1 FILTER ELEMENT 80774010 1 SAFETY ELEMENT 808484 1 FUEL FILTER 80774018 1 PRE-FUEL FILTER SCREEN 80644001 Series III Rough Terrain Excavators 4-5

ENGINE & ATTACHING PARTS Muffler Support Components 2 8 19 5 1 7 6 1 9 10 4 12 15 16 MACHINES PRIOR TO THE S/N S LISTED BELOW ARE ENCOURAGED TO UPGRADE TO THE MUFFLER SUPPORT SET-UP SHOWN ON THIS PAGE BY ORDERING MUFFLER SUPPORT KIT, P/N 8077504. XL00III - 00000742 XL10III - 10000002 XL400III - 400000088 XL410III - 410000010 XL500III - 500000005 XL510III - 510000005 XL520III - 520000002 1 9 11 ALL MACHINES FOLLOWING THE SERIAL NUMBERS LISTED (INCLUDING S/N S SHOWN) WERE EQUIPPED WITH THE COMPONENTS SHOWN ON 14 17 2 18 PAE5800 4-6 Series III Rough Terrain Excavators 80644001

Muffler Support Components Item Part Number Qty. Description Rev. 1 144064 A/R LOCTITE, (242 blue) 2 800094 8 WHIZ-LOK SCREW, /8-16X/4 8067014 2 U-BOLT 4 8077016 2 WHIZ-LOK SCREW, M8X1.25X20MM 5 8077124 2 U-BOLT 6 80776020 1 TAIL PIPE BRACKET WELDMENT 7 8077608 1 MUFFLER BRACKET 8 80776044 1 HEAT SHIELD WELDMENT 9 819101 8 LOCKWASHER, M10 10 8191024 2 HEX HD CAPSCREW, 12-1.75X90, GR8.8, (loctite & torque to 2-6 lb-ft) 11 8191027 6 HEX HD CAPSCREW, 10-1.5X5, GR8.8 12 8820106 2 HEX HD CAPSCREW, /8-16X1-1/4, GR5 1 88521006 4 HEX LOCKNUT, /8-16 14 88521008 4 LOCKNUT, 1/2-1 15 88551011 2 LOCKWASHER, /8 16 88561004 2 FLAT WASHER, /8 17 88561006 4 FLAT WASHER, 1/2 18 80771217 1 BRACE PLATE 19 8026012 8 WHIZ-LOK SCREW, 1/4-20X1/2 8077504 Ref MUFFLER SUPPORT KIT, (includes all items) B 80644001 Series III Rough Terrain Excavators 4-7

Air Cleaner Installation 9 5 7 6 8 16 11 12 4 10 1 2 1 14 15 (TO TURBOCHARGER) TURBO II PRECLEANER TURBO III PRECLEANER 9 101 102 10 9 8 104 105 106 107 110 111 8 108 109 112 NOTE: PRECLEANER IS OPTIONAL. PAD0202 4-8 Series III Rough Terrain Excavators 80644001

Air Cleaner Installation Item Part Number Qty. Description Rev. 1 9002771 1 HOSE CLAMP 2 8077011 1 AIR INTAKE TUBE 0952572 1 AIR INTAKE ELBOW 4 8871217 1 COUPLING, 1/8, (max torque to 18 lb-in) 5 808151 1 TUBE FITTING, 90 DEGREES 6 8077604 1 AIR CLEANER MOUNT PLATE 7 771400 4 WHIZ-LOK SCREW, 5/16-18X5/8 8 8077015 1 CONNECTOR TUBE 80776009 1 CONNECTOR TUBE, (for machines equipped with precleaner only) 9 8077014 1 AIR INLET HOOD 8029006 1 TURBO II PRECLEANER, (includes items 101 thru 112), (for complete precleaner replacement, order 8077152) 8077152 1 TURBO III PRECLEANER 10 86871176 HOSE CLAMP, (max torque to 40 lb-in) 11 Ref AIR CLEANER ASSY, (see page 4-10 for details) 12 AR NYLON TUBING, 1/4 1 8077048 4 WHIZ-LOK SCREW, M8-1-1/4X12, (max torque to 15 lb-ft) 14 90027187 TY-RAP 15 8077012 1 AIR INTAKE ADAPTER 16 9141025 1 T-BOLT BAND CLAMP 101 867417 1 CAPTURE NUT 102 80294001 1 CAP ASSY 10 80294002 1 CAP STUD W/NUT, (includes item 101) 104 8029400 1 INTAKE SCREEN 105 80294004 1 BODY ASSY 106 8674178 1 SUPPORT WASHER 107 80294005 1 SPINNER ASSY (filter) 108 80294006 4 NUT 109 8674180 4 MOUNTING BOLT 110 80294007 1 BOTTOM ASSY 111 80294008 VENT SPACER 112 80294009 1 CLAMP 80644001 Series III Rough Terrain Excavators 4-9

Air Cleaner Assembly PAD1111 4-10 Series III Rough Terrain Excavators 80644001

Air Cleaner Assembly Item Part Number Qty. Description Rev. 807701 1 AIR CLEANER ASSEMBLY, (includes all items) A 1 1 BODY, (not available for service) 2 80774010 1 SAFETY ELEMENT 80774011 1 VACUATOR VALVE 4 80774012 1 PRIMARY ELEMENT 5 8077401 1 COVER 6 778154 1 FILTER RESTRICTION INDICATOR 80644001 Series III Rough Terrain Excavators 4-11

Cooling Unit Installation 1 2 SEE DETAIL A 1 2 4 17 15 16 6 7 14 5 6 7 26 27 5 27 28 26 27 27 4 2 11 12 1 10 8 9 21 22 18 19 20 2 TO OVERFLOW BOTTLE TO RADIATOR PORT 29 0 46 47 44 DETAIL A 25 19 20 24 TO FRONT OF ENGINE 45 48 1 2 NOTE: HOSES CONNECTING TO OIL COOLER CAN BE FOUND ON PAGE 8-16 4 5 41 7 TO CAB HEATER WATER PORTS (UNDER CAB) 50 51 52 49 TO LOWER RADIATOR TUBE NIPPLE 42 7 41 8 9 40 6 7 PAD0212 4-12 Series III Rough Terrain Excavators 80644001

Cooling Unit Installation Item Part Number Qty. Description Rev. 1 8048048 4 CHARGE AIR HOSE 2 8899115 8 SPRING CLAMP 8077021 1 CHARGE AIR TUBE 4 8077022 1 CHARGE AIR TUBE 5 807702 1 UPPER RADIATOR TUBE 6 8048109 4 RADIATOR TUBE COUPLING 7 85071128 8 HOSE CLAMP, 1-9/16X2-1/2 8 8077019 1 FAN SHROUD 9 916018 8 WHIZ-LOK SCREW, 5/16-18X1 10 9114122 1 SUPPORT CLAMP, 5/8 11 8077020 2 COOLING UNIT SUPPORT 12 88201065 2 HEX HD CAPSCREW, 1/2-1X1, GR5 1 7714014 6 WHIZ-LOK NUT, 1/2-1 14 8077028 1 LOWER RADIATOR TUBE 15 8077027 1 FORMED HOSE 16 86971172 2 HOSE CLAMP 17 84717192 1 PUSH-LOK FITTING 18 80771020 1 TANK PIVOT BRACKET 19 771400 6 WHIZ-LOK SCREW, 5/16-18X5/8 20 7714006 6 WHIZ-LOK NUT, 5/16-18 21 820114 1 HEX HD CAPSCREW, 1/2-1X8, GR8 22 8852108 1 HEX LOCKNUT, 1/2-1 2 85841150 SUPPORT CLAMP 24 804820 1 SURGE TANK, (includes item 5) 25 80771019 1 TANK SUPPORT WELDMENT 26 272040 AR HOSE, /8 27 8688106 8 HOSE CLAMP 28 82092118G 1 OVERFLOW HOSE 29 802204 2 WHIZ-LOK SCREW, 1/2-1X/4 0 8077017 1 COOLING UNIT ASSY, (includes items 44 thru 52) A 1 8098051 1 OVERFLOW TANK 2 88561002 4 FLAT WASHER, 1/4 8820100 4 HEX HD CAPSCREW, 1/4-20X/4, GR5 4 8077102 1 OVERFLOW TANK BRACKET 5 88261016 4 BUTTON HD CAPSCREW, 1/4-20X/4 6 820995 AR HEATER HOSE, BLACK 7 86671187 6 HOSE CLAMP 8 771279 1 CLAMP SET 9 77117 1 COVER PLATE 40 8820102 1 HEX HD CAPSCREW, 5/16-18X1-/4, GR5 41 820988 AR HEATER HOSE, RED 42 80774126 1 HEATER CONTROL VALVE KIT, (w/jumper harness) 4 80481144 1 IN-LINE ORIFICE 44 80774001 1 RADIATOR 45 80774002 1 HYDRAULIC OIL COOLER 46 8077400 1 CHARGE AIR COOLER 47 80774004 1 MOUNTING BRACKET 48 80774005 1 MOUNTING BRACKET 49 80774006 1 DRAINCOCK, 1/4 NPTX90 DEGREES 4-1 Series III Rough Terrain Excavators 80644001

Cooling Unit Installation Item Part Number Qty. Description Rev. 50 80774007 16 HEX NUT, /8-16, (zinc) 51 80774008 16 FLANGE HD CAPSCREW, /8-16X1.25, (zinc) 52 80774009 2 FLAT WASHER, /8, (zinc) 5 80484259 1 SURGE TANK CAP 4-14 Series III Rough Terrain Excavators 80644001

Cooling Unit Installation Item Part Number Qty. Description Rev. 80644001 Series III Rough Terrain Excavators 4-15

Double Gear Pump Installation SEE DETAIL A 2 7 10 1 4 5 11 8 2 6 9 SEE DETAIL A PAD1502 4-16 Series III Rough Terrain Excavators 80644001

Double Gear Pump Installation Item Part Number Qty. Description Rev. 1 144064 A/R LOCTITE, (#242 blue) 2 1440404 A/R LOCTITE, (#545 purple) 8077106 1 GEAR PUMP 4 819101 2 LOCKWASHER, M10 5 8191040 2 SOCKET HD CAPSCREW, M10X0, (loctite & torque to 2-6 lb-ft) 6 8866208 1 STRAIGHT CONNECTOR, (includes item 9) 7 8866245 2 ELBOW, 90 DEGREES, (includes item 10) 8 86671112 1 PUMP GASKET 9 88591210 1 O-RING 10 88591206 2 O-RING 11 802220 2 FLAT WASHER, M10 80644001 Series III Rough Terrain Excavators 4-17

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