PARTS CATALOGUE

AF 50D
FORKLIFT TRUCKS

Action Construction Equipment Ltd.

4th Floor, Pinnacle, Surajkund, NCR-121009
E-mail:-marketing@[Link]
 GENERAL INFORMATION
Machine Identification
Each ACE Machine is identified with a serial number.
Chassis & Engine also have serial numbers.

Ordering parts

When ordering parts, the order should specify the part

description, Part Numbers, Quantity and Serial number

of Machine. Quality ACE parts are available from our

dealers throughout India.

How to use this parts catalogue.

This part catalogue includes illustrations of assembly

which make up the machine.

Index provided in beginning of parts catalogue should

be used to determine the page number on which specific
systems are illustrated the page number on which specific
systems are illustrated. Quantity of parts for each model is
mentioned in separate coloumn which indicate the total
number of that item used in that particular assembly and
total number used in machine.
INDEX
INDEX
INDEX
INDEX
FIGURE NO. 1

ENGINE ASSY. COMPLETE

PAGE NO.
1
 FIGURE NO. 1

ENGINE ASSY. COMPLETE

SR NO. DESCRIPTION PART NO. QTY.

1. Engine 4805 BS-III 905803032300 1

- Engine LR108G65 90580108G650 1

2. Hose Turbo Charger to Inter Cooler Pipe 180501130000 1

3. Hose Air Cleaner to Tubro Charger 180501120000 1

4. Hose Inter Cooler to Inter Manifold 180501160000 1

4A. Hose Intercooler Pipe to Intercooler 180501150000 1

5. Bolt Hex-M10X120, GR - 8.8 901101012240 4

6. Plate 1 180301011000 4

7. Engine Rubber Lower 903051235000 4

8. Coller Ø13 903051271000 4

9. Engine Rubber Upper 903051234000 4

10. Plate 2 180301012000 4

11. Nut Nylock M10 901221000000 4

12. Engine MTG LH AF 50 D 180501010100 1

- Engine MTG RH AF 50 D 180501010300 1

13. Air Cleaner Holding Plate 180342041080 1

14. Hose Air Cleaner to Pipe 180501030000 1

15. Hose Clamp 4" 955400801000 2

16. Nut Hex M10 Gr-8 901201002000 2

17. Spring Washer B-10 901611000000 2

PAGE NO.
2
FIGURE NO. 2

COOLING SYSTEM DIESEL

PAGE NO.
3
 FIGURE NO. 2

COOLING SYSTEM DIESEL

SR NO. DESCRIPTION PART NO. QTY.

1. Radiator Automatic Assy. 180501040000 1

2. Bolt Hex-M8X45,GR 8.8. 901100812090 4

3. Washer Plain M8 901600800000 4

4. Washer spring M8 901610800000 4

5. Hex Nut M8 901200812000 4

6. Rubber Gromet 18301040500 4

7. Hose Clamp Ø25 955400250350 4

8. Hose Engine to Radiator 180501040200 1

9. Hose Radiator to Engine 180501040100 1

PAGE NO.
4
FIGURE NO. 3

FUEL SYSTEM DIESEL

PAGE NO.
5
 FIGURE NO. 3

FUEL SYSTEM DIESEL

ITEM
DESCRIPTION PART NO. QTY.
NO.

1. Cover Tank Plate 180501100100 1

2. Tank Cover Gasket 180308020200 1

3. Bolt M8x25 901500812050 8

4. Washer Spring M8 901610800000 8

5. Loose Hose 180308000200 1

6. Hose Clamp 1" 955400250350 2

7. Fuel Intake Cap 180307040370 1

8. Drain Plug 100083301900 1

9. Loose Hose 180308000200 1

10. Hose Clamp 1" 955400250350 2

11. Hose Air Cleaner Pipe to Turbo Charger 180501120000 1

12. Hose Clamp 3" 955400600800 2

PAGE NO.
6
FIGURE NO. 4

EXHAUST SYSTEM DIESEL

Horizontal Silencer Vertical Silencer

PAGE NO.
7
 FIGURE NO. 4

EXHAUST SYSTEM DIESEL

ITEM
DESCRIPTION PART NO. QTY.
NO.

1. Silencer Assy Horizontal 18501110000 1

- Silencer Assy Vertical 180501300000 1

2. Gromet for silencer 180301040500 2

3. Bolt M10x40 901101012080 2

4. Washer 10 901601000000 2

5. Nut M10 91201000000 2

PAGE NO.
8
FIGURE NO. 5

ELECTRIC SYSTEM

PAGE NO.
9
 FIGURE NO. 5

ELECTRIC SYSTEM

ITEM
DESCRIPTION PART NO. QTY.
NO.

1. Battery 88AH 424583100100 1

2. Battery Lead -VE. 180309010200 1

3. Battery Lead +VE. 180309010300 1

4. Fuse Box 180302010020 1

5. Buzzer 12V 180302010400 1

6. Horn 12V 180302010300 1

7. Rear Light Mid 180302011100 1

8. Rear Light LH/RH 180302011000 2

9. Harness Assy. 180517020000 1

10. Ignition Switch. 180302010500 1

PAGE NO.
10
FIGURE NO. 6

METER BOARD ASSY.

1. INSTRUMENT CLUSTER UNIT

2. COMBINATION SWITCH

PAGE NO.
11
 FIGURE NO. 6

METER BOARD ASSY.

ITEM
DESCRIPTION PART NO. QTY.
NO.

1. Instrument cluster unit 180304031200 1

2. Combination switch 180302010200 1

PAGE NO.
12
FIGURE NO. 7

DRIVE AXLE ASSY

PAGE NO.
13
 FIGURE NO. 7

DRIVE AXLE ASSY

ITEM
DESCRIPTION PART NO. QTY.
NO.

A Front Axle Assy. 180503020000 1

1. Housing axle COQ212000100 1

2. Breather air COQ210200100 1

3. Drum brake COQ213230100 2

4. Retainer oil seal COQ213240100 2

5. Hub front COQ213250100 2

6. Bearing GB2978400000 2

7. Nut bearing GBT119120000 4

8. Washer bearing COQ213260100 2

9. Shaft driver COQ213270100 2

10. Packing COQ213280100 2

11. Bolt reamer COQ213290100 24

12. Seal oil COQ212010100 2

13. Shim COQ212020100 2

14. Nut COQ212030100 12

15. Bolt COQ212040100 12

16. Nut COQ212050100 12

17. Nut COQ212060100 12

18. Nut COQ212070100 12

19. Bearing taper GB2978400000 2

20. Seal oil COQ212080100 2

21. Bolt COQ212090100 14

22. Bolt COQ213200100 4

23. Flug COQ213210100 3

24. COQ210310100 1

25. COQ210320100 1

PAGE NO.
14
FIGURE NO. 8

FRONT WHEEL ASSY SINGLE DRIVE

PAGE NO.
15
 FIGURE NO. 8

FRONT WHEEL ASSY SINGLE DRIVE

ITEM
DESCRIPTION PART NO. QTY.
NO.

1. Solid Tyre (300X15) 185082400500 2

- Pnumatic Tyre (300X15) 185082400200 2

- Non Marking Tyre (300X15) 185082400800 2

2. Rim Front 180538015200 2

PAGE NO.
16
FIGURE NO. 9

FRONT WHEEL ASSY DUAL DRIVE

PAGE NO.
17
 FIGURE NO. 9

FRONT WHEEL ASSY DUAL DRIVE

ITEM
DESCRIPTION PART NO. QTY.
NO.

1. Solid Tyre (300X15) 185082400500 4

- Pnumatic Tyre (300X15) 185082400200 4

- Non Marking Tyre (300X15) 185082400800 4

2. Rim Front Outer 8.00-15 180538015100 2

3. Rim Front 180538015200 2

PAGE NO.
18
FIGURE NO. 10

WHEEL BRAKE

PAGE NO.
19
 FIGURE NO. 10

WHEEL BRAKE
ITEM
DESCRIPTION PART NO. QTY.
NO.

A Wheel brake assy. L.H COQ210100100 1

Wheel brake assy. R.H COQ210110100 1

B Wheel cylinder assy. COQ210110100 2

Lever brake R.H COQ212310100 1

1. Lever brake L.H COQ212320100 1

2. Brakeshoe COQ212330100 2

3. Brake plate COQ212340100 2

4. Spring COQ212350100 4

5. Strut COQ212360100 2

6. Pin COQ212370100 2

7. Hook COQ212380100 2

8. Board COQ212390100 2

9. Shim GB9718500000 2

10. Pin GB9176000000 2

11. Hook COQ212400100 2

12. Lever COQ212410100 2

13. Spring COQ212420100 2

14. Adjuster COQ212430100 1

Adjuster COQ212440100 1

15. Rubber COQ212450100 2

16. Brake shoe COQ212460100 2

17. Pin COQ212470100 2

18. Spring COQ212480100 2

19. Cable R COQ212490100 1

Cable L COQ212500100 1

20. Board COQ212510100 2

PAGE NO.
20
FIGURE NO. 10

WHEEL BRAKE

PAGE NO.
21
 FIGURE NO. 10

WHEEL BRAKE
ITEM
DESCRIPTION PART NO. QTY.
NO.

21. Bolt GB5783860000 8

22. Washer GB9387000000 8

23. Shank COQ212520100 4

24. Spring COQ212530100 4

25. Sleeve COQ212540100 8

26. Pin COQ212550100 4

27. Pin COQ212560100 2

28. Washer lock COQ212570100 4

29. Snap COQ212580100 4

30. Bushing COQ212590100 2

31. Bolt GB2176000000 4

32. 8 Washer GB9387000000 4

33. Pin COQ212600100 4

34. Pin COQ212610100 2

35. Body COQ212620100 2

36. Cover dust COQ212630100

37. Rod 4

38. Piston COQ212650100 4

Piston 4

39. Cup piston COQ212660100 4

40. Spring COQ212670100 2

41. Screw bleader COQ212680100 2

42. Cup screw COQ212690100 2

43. Snap COQ212710100 4

44. Seat tube COQ212720100 2

PAGE NO.
22
FIGURE NO. 11

REDUCTION & DIFFERENTIAL

PAGE NO.
23
 FIGURE NO. 11

REDUCTION & DIFFERENTIAL

ITEM
DESCRIPTION PART NO. QTY.
NO.

A Differential assy. 162483300100 1

1. Case, differential 162483300200 1

2. Case, cross L.H. 162483300300 1

3. Nut 162483300400 12

4. Bolt 162483300500 12

5. Bolt 162483300600 2

6. Washer 162483300700 2

7. Iron, slik 162483300800 2

8. Plate, lock 162483300900 2

9. Nut 162483301000 2

10. Bearing, taper roller 162483301100 2

11. Shims 162483301200 1

12. Gear, Pinion 162483301300 2

13. Shaft, cross 162483301400 1

14. Gear, spiral vevel 162483301500 1

15. Ring, thruet 162483301600 4

16. Bearing, tape roller 162483301700 1

17. Bolt 162483301800 16

18. Nut 162483301900 1

19. Shim, lock 162483302000 1

20. Shaft 162483302100 1

21. Plate 162483302200 1

22. Shim 162483302300 1

PAGE NO.
24
FIGURE NO. 11

REDUCTION & DIFFERENTIAL

PAGE NO.
25
 FIGURE NO. 11

REDUCTION & DIFFERENTIAL

ITEM
DESCRIPTION PART NO. QTY.
NO.

23. Bolt 162483302400 6

24. Washer 162483302500 6

25. Shim 162483302600 1

26. Bearing, taper roller 162483302700 1

27. Nut, lock 162483302800 1

28. Gear, output 162483302900 1

29. Plate 162483303000 1

30. Seal, oil 162483303100 1

31. Seat, bearing 162483303200 1

32. O-ring 162483303300 1

33. O-ring 162483303400 1

34. Bearing, taper roller 162483303500 1

35. Shim 162483303600 1

36. Gear, piion 162483303700 4

37. Case, cross R.h 162483303800 1

38. Bolt 162483303800 1

39. Nut 162483303900 4

40. Pin 162483304000 4

41. Cover, bearing 162483304100 4

42. Cover, bearing 162483304200 2

43. Washer 162483304300 14

44. Pin 162483304400 14

45. Pin 162483304500 2

PAGE NO.
26
FIGURE NO. 12

TRANSMISSION (TORQUE CONVERTOR ASSY.)

PAGE NO.
27
 FIGURE NO. 12

TRANSMISSION (TORQUE CONVERTOR ASSY.)

ITEM
DESCRIPTION PART NO. QTY.
NO.

A Transmission sub assy. 162480400100 1

1. Case, tor-com 162480400200 1

2. Oil filter 162480400300 1

3. Bolt 162480400400 4

4. Washer 162480400500 21

5. Cover 162480400600 1

6. Shim 162480400700 1

7. Bolt 162480400800 3

- Bolt 162480400900 10

- Bolt 1624804001000 2

8. Shim 1624804001100 1

9. Pin 1624804001200 2

10. Plug 1624804001300 2

11. Pin 1624804001400 2

12. Piston 1624804001500 2

13. Spring 1624804001600 1

14. Spring 1624804001700 1

15. Shim 1624804001800 1

16. Cover 1624804001900 1

17. Bolt 1624804002000 2

18. Clutch, hydrolic 1624804002100 1

19. Cover 1624804002200 1

20. Bolt 1624804002300 1

21. Washer 1624804002400 1

22. Charging pump 1624804002500 1

23. Shaft, turbo 1624804002600 1

PAGE NO.
28
FIGURE NO. 13

TRANSMISSION (CLUTCH ASSY.)

PAGE NO.
29
 FIGURE NO. 13

TRANSMISSION (CLUTCH ASSY.)

ITEM
DESCRIPTION PART NO. QTY.
NO.

A Transmission clutch sub assy. 162480402700 1

1. Case transmission 162480402800 1

2. Plug 162480402900 2

3. Plug 162480403000 12

4. Washer 162480403100 8

5. Bolt 162480403200 4

6. Control valve assy. 162480403300 1

7. Bolt 162480403400 1

8. Bolt 162480403500 3

9. Plug 162480403600 1

10. Plug 162480403700 4

11. Dipstick 162480403800 1

12. Pipe oil fil 162480403900 1

13. Shim 162480404000 1

14. Clutch 162480404100 1

15. Pipe 162480404200 1

16. O-ring seal 162480404300 1

17. O-ring seal 162480404400 1

18. Snap ring 162480404500 1

19. Clutch 162480404600 1

20. Clip 162480404700 1

21. Bolt 162480404800 1

22. Washer 162480404900 1

23. Plate 162480405000 1

24. Washer 162480405100 2

25. Bolt 162480405200 2

PAGE NO.
30
FIGURE NO. 13

TRANSMISSION (CLUTCH ASSY.)

PAGE NO.
31
 FIGURE NO. 13

TRANSMISSION (CLUTCH ASSY.)

ITEM
DESCRIPTION PART NO. QTY.
NO.

26. Bearing 162480405300 2

27. Gear 162480405400 1

28. Snap ring 162480405500 1

29. Bearing 162480405600 1

30. Gear 162480405700 1

31. Bearing 162480405800 1

PAGE NO.
32
FIGURE NO. 14

HYDRALIC CLUTCH (TORQUE CONVERTOR TYPE)

PAGE NO.
33
 FIGURE NO. 14

HYDRALIC CLUTCH (TORQUE CONVERTOR TYPE)

ITEM
DESCRIPTION PART NO. QTY.
NO.

A Clutch hydraulic COC210400100 1

1. Shift input COC210410100 1

2. Ring seal COC214010100 3

3. 40 Snap ring GB8941860000 1

4. 308 bearing GB2768200000 1

5. Thrust COC214020100 1

6. Gear reverse COC214030100 1

7. Ring thrust COC214040100 2

8. 50 Snap ring GB8941860000 4

9. Snap ring COC214050100 2

10. Spring COC214060100 2

11. Ring seal COC214070100 2

12. Piston COC214080100 2

13. Plate separator COC214090100 12

14. Ring seal COC215010100 2

15. Plate friction assy. COC210500100 12

16. Plate seperator COC215020100 2

17. Snap ring COC215030100 2

18. 1 Gear forward COC215040100 1

19. Ring thrust COC215050100 1

20. 310 Bearing GB2768200000 1

21. Ring COC215060100 1

22. Needle bearing COC215070100 2

23. Plug COC215080100 2

24. Plug COC215090100 2

25. Body GB3077700000 2

PAGE NO.
34
FIGURE NO. 15

HYDRAULIC CLUTCH 2

PAGE NO.
35
 FIGURE NO. 15

HYDRAULIC CLUTCH 2
ITEM
DESCRIPTION PART NO. QTY.
NO.

A Clutch 162484300100 1

1. Shaft assy. 162484300200 1

2. Sing seal 162484300300 1

3. Gear, forward 162484300400 1

4. Piston 162484300500 1

5. Ring, thrust 162484300600 1

6. Bearing 162484300700 1

7. Snap, ring 162484300800 2

8. Spring 162484300900 1

9. Seat, spring 162484301000 1

10. Ring, thrust 162484301100 1

11. Needle, bearing 162484301200 1

12. Plate, friction assy. 162484301300 6

13. Plate, seperator 162484301400 6

14. Plate, end 162484301500 1

15. Ring, seal 162484301600 1

16. Snap, ring 162484301700 1

17. Ring, seal 162484301800 2

18. Plug 162484301900 1

19. Snap, ring 162484302000 1

20. Bearing 162484302100 1

21. Plug 162484302200 1

22. Body 162484302300 1

PAGE NO.
36
FIGURE NO. 16

INCHING CONTROL VALVE (TRANSMISSION)

PAGE NO.
37
 FIGURE NO. 16

INCHING CONTROL VALVE (TRANSMISSION)

ITEM
DESCRIPTION PART NO. QTY.
NO.

A Control valve assy. 162441300100 1

1. Control, valve 162441300200 1

2. Gasket 162441300300 1

3. Body, valve 162441300400 1

4. Plug 162441300500 1

5. Washer 162441300600 1

6. Spring 162441300700 1

7. Ball steel 162441300800 1

8. Plug 162441300900 4

9. Bolt 162441301000 7

10. Washer, lock 162441301100 7

11. Piston 162441301200 1

12. Spring 162441301300 1

13. Spring 162441301400 1

14. Stopper 162441301500 1

15. Spring 162441301600 1

16. Spring 162441301700 1

17. Spring 162441301800 1

18. Spring 162441301900 1

19. Selector 162441302000 1

20. Washer 162441302100 1

21. Plunger 162441302200 1

22. Spring 162441302300 1

PAGE NO.
38
FIGURE NO. 16

INCHING CONTROL VALVE (TRANSMISSION)

PAGE NO.
39
 FIGURE NO. 16

INCHING CONTROL VALVE (TRANSMISSION)

ITEM
DESCRIPTION PART NO. QTY.
NO.

23. Plunger 162441302400 1

24. Washer 162441302500 1

25. Snap, ring 162441302600 1

26. Seal, oil 162441302700 2

- Seal, oil 162441302800 2

27. Plug 162441302900 1

28. Reverse lamp switch 162441303000 2

29. Shim 162441303100 2

30. Bolt 162441303200 1

31. Washer 162441303300 1

32. Plunger 162441303300 1

PAGE NO.
40
FIGURE NO. 17

CHARGING PUMP (TRANSMISSION)

PAGE NO.
41
 FIGURE NO. 17

CHARGING PUMP (TRANSMISSION)

ITEM
DESCRIPTION PART NO. QTY.
NO.

23. Bolt 162483302400 6

24. Washer 162483302500 6

25. Shim 162483302600 1

26. Bearing, taper roller 162483302700 1

27. Nut, lock 162483302800 1

28. Gear, output 162483302900 1

29. Plate 162483303000 1

30. Seal, oil 162483303100 1

31. Seat, bearing 162483303200 1

32. O-ring 162483303300 1

33. O-ring 162483303400 1

34. Bearing, taper roller 162483303500 1

35. Shim 162483303600 1

36. Gear, piion 162483303700 4

37. Case, cross R.h 162483303800 1

38. Bolt 162483303800 1

39. Nut 162483303900 4

40. Pin 162483304000 4

41. Cover, bearing 162483304100 4

42. Cover, bearing 162483304200 2

43. Washer 162483304300 14

44. Pin 162483304400 14

45. Pin 162483304500 2

PAGE NO.
42
FIGURE NO. 18

DRIVE UNIT MOUNT TORQUE CONVERTOR TYPE

PAGE NO.
43
 FIGURE NO. 18

DRIVE UNIT MOUNT TORQUE CONVERTOR TYPE

ITEM
DESCRIPTION PART NO. QTY.
NO.

1. Bolt GB5785860000 12

2. Washer GB9387000000 23

3. Bolt M10 GB5782860000 10

4. Drive unit sub assy. 1

5. Bolt M10 GB5785860000 12

6. Washer GB9387000000 12

7. O-ring GB3452192000 1

8. Reduction & differential LH0101110000 4

PAGE NO.
44
FIGURE NO. 19

STEERING SYSTEM

PAGE NO.
45
 FIGURE NO. 19

STEERING SYSTEM

ITEM
DESCRIPTION PART NO. QTY.
NO.

1. Steering Column 180304030300 1

2. Spring Washer M6 901610600000 4

3. Screw M6x15 901560612030 4

4. Union Joint 180304040000 1

5. M10X1 Nipple, Grease GB1152820000 1

6. Boot for Steering 180304031300 1

7. Internal circlip Ø37 930371501000 2

8. Bolt Hex M10x50 901101012100 4

9. Spring washer M10 901611000000 4

10. Screw Hex M12x25 901501212050 2

11. Spring washer M12 901611200000 2

12. Shaft 180304020200 1

13. Bolt M6x35 GB5782860000 4

14. Washer C0E012030100 4

15. Insert 180304030260 4

16. Rubber gromet for steering bkt 180304030330 4

17. Tilting bolt 180304030700 1

18. Spacer steering bkt 180304030500 1

19. Locking nut 180304030800 1

20. Handle with cover 180304030900 1

21. Washer M10 GB9685000000 1

22. Bolt M10x15 GB5782860000 1

23. Washer C0E012090100 2

24. Lock Bolt 180304031000 2

PAGE NO.
46
FIGURE NO. 19

STEERING SYSTEM

PAGE NO.
47
 FIGURE NO. 19

STEERING SYSTEM

ITEM
DESCRIPTION PART NO. QTY.
NO.

25. Washer M8 GB9387000000 1

26. Bolt M8x35 GB5782860000 1

27. Steering wheel assy. 180304030400 1

28. 20 Snap ring GB8941860000 1

29. Bearing 6904-Z 180304030370 1

30. Arbor 180304030350 1

31. Hex nut M16 901201612000 1

32. Steering Unit Assembly 50D 180510010000 1

33. Lower Column 180304020100 1

34. Grommet 180304030330 4

35. Bearing 6904-Z 180304030370 1

36. Shim C0E012110100 1

37. Dash Board Assy. 180304030100 1

PAGE NO.
48
FIGURE NO. 20

STEERING AXLE ASSY.

PAGE NO.
49
 FIGURE NO. 20

STEERING AXLE ASSY.

ITEM
DESCRIPTION PART NO. QTY.
NO.
A Steering Axle assy. 180505000000 1
1. Left steering knuckle COW210400100 1
2. Oil cup JBT794021995 5
3. Steering axle body COW210000100 1
4. Steering cylinder COW210200100 1
5. Oil cup JBT794021995 1
6. Lock pin COW212000100 2
7. Shim GB9718500000 2
8. Washer GB9387000000 2
9. Nut GB6173200000 2
10. Right steering knuckle COW2103001001 1
11. Bearing GB2908400000 2
12. Bearing GB2908200000 4
13. Dust ring GBT1070831989 4
14. King pin steering knuckle COW212010100 2
15. Hub COW212020100 2
16. Hub Bolt COW212030100 10
17. Hub Bolt COW212040100 10
18. Nut GBT617120000 10
19. Oil seal GBT987711998 2
20. Bearing GB2978400000 2
21. Bearing GB2978400000 2
22. Nut GB8128800000 4
23. Shim GB8588800000 2
24. Hub cover COW212050100 2
25. Shim COW212060100 2
26. Seal ring GBT1070831989 4
27. Bolt GB5782200000 2

PAGE NO.
50
FIGURE NO. 20

STEERING AXLE ASSY.

PAGE NO.
51
 FIGURE NO. 20

STEERING AXLE ASSY.

ITEM
DESCRIPTION PART NO. QTY.
NO.

28. Nut GB6172120000 2

29. Shim COW212070100 2

30. Shim COW212080100 2

31. Shim COW212090100 2

32. Bracket COW212100100 2

33. Spacer COW212110100 2

34. Bolt GB5782860000 4

35. Shim GB9387000000 4

36. Shim GB9718500000 4

37. Shim COW212120100 4

38. Pin GB8797600000 8

39. Snap ring GB8931860000 4

40. Bearing GB9163900000 4

41. Pin clevis COW212130100 4

42. Connection rod COW212140100 2

43. Pin COW212150100 2

44. Shim COW212160100 8

PAGE NO.
52
FIGURE NO. 21

STEERING WHEEL

PAGE NO.
53
 FIGURE NO. 21

STEERING WHEEL
ITEM
DESCRIPTION PART NO. QTY.
NO.

1. Solid Tyre 7X12 182082400500 2

- Pnumatic Tyre (7X12) 182082400200 2

- Non Marking Tyre 7X12 182082400700 2

2. Rim Rear 180535012200 2

PAGE NO.
54
FIGURE NO. 22

STEERING CYLINDER

PAGE NO.
55
 FIGURE NO. 22

STEERING CYLINDER
ITEM
DESCRIPTION PART NO. QTY.
NO.

A Steering Cylinder Assy. 180510010000 1

1. Piston Rod Assy. COW210310100 1

2. Bearing COW210320100 2

3. O-ring seal GB3452188000 2

4. Cylinder Body COW210330100 1

5. Retainer COW210340100 1

6. O-ring seal GB3452188000 1

7. Cylinder Cover COW210350100 1

8. Yx-ring seal COW210360100 2

9. Snap ring COW210370100 2

10. Dust ring COW210380100 2

11. Snap ring COW210390100 2

12. O-ring seal GB3452188000 2

PAGE NO.
56
FIGURE NO. 23

TRANSMISSION CONTROL INCHING ASSY

PAGE NO.
57
 FIGURE NO. 23

TRANSMISSION CONRTOL INCHING ASSY

ITEM
DESCRIPTION PART NO. QTY.
NO.

1. Knob Assy. 180301070100 1

2. Hex Nut-M10 901201000000 1

3. Rod Assy. 180301070200 1

4. Bracket Up 180301070300 1

5. Bolt Hex M8x25 901100812050 4

6. Spring washer M8 901610800000 5

7. Bolt Hex 6x16 901100612030 2

8. Spring washer M6 901610600000 2

9. Shaft Assy 180301070400 2

10. Link Rod 50D 180501070500 1

11. Pin 8*18 180301070600 2

12. Split Pin- 3.2x20 900400300040 2

13. Spring Washer M-8. 901610800000 2

14. Bracket Lower 180301070700 1

15. Boss Assy 180301070800 1

16. Link AF 50D 180512040000 1

17. Nut Hex M8 901200812010 1

18. Elbow RH 180301070910 2

19. Hex Nut M8 901200800000 2

20. Elbow LH 180301070930 1

PAGE NO.
58
FIGURE NO. 24

ACCELERATOR PEDAL

PAGE NO.
59
 FIGURE NO. 24

ACCELERATOR PEDAL
ITEM
DESCRIPTION PART NO. QTY.
NO.

1. Accelerator Pedal unit 180301080620 1

2. Pedal roller 180301080400 1

3. Spacer 180301080230 3

4. Split pin 3.2x20 900400300040 3

5. Pan head bolt M12x60 180301080640 1

6. Hex nut M12 901201212000 1

7. Bolt M6x20 901100612040 2

8. Hex nut M6 901200600000 2

9. Plain washer M6 901600600000 2

10. Pedal rod assy 180301080200 1

11. Spring 180301080300 1

12. Washer Plain M10 901601000000 1

13. Split pin 3.2x20 900400300040 1

14. Mounting plate assy. 180501080100 1

15. Accelerator cable assy. 180330220000 1

16. Bolt M10x16 901101012030 2

17. Washer plan M10 901601000000 2

PAGE NO.
60
FIGURE NO.25

BRAKE & INCHING CONTROL

PAGE NO.
61
 FIGURE NO. 25

BRAKE & INCHING CONTROL

ITEM
DESCRIPTION PART NO. QTY.
NO.

1. Pedal Cover 180301091000 2

2. Inching Pedal Assy. 180511050000 1

3. Pin clevis 180301090730 4

4. Washer 8 901600800000 4

5. Split pin 3x20 900400300040 4

6. Fork RH 180301090740 1

7. Link assy. 180301090700 1

8. Fork LH 180301090740 1

9. Nut M8 901200812000 1

10. Bolt M10x35 901101012070 1

11. Washer Plain M10 901601000000 6

12. Brake Pedal Assy. 180511020000 1

13. Bushing 180301091300 5

14. Clip 180511200000 2

15. Bundy tube 1 180511180000 2

16. Master cylinder 180511110000 1

17. Bundy tube 2 180511190000 1

18. Bolt M10x25 901101022070 4

19. Bracket pedal assy 180511130000 1

20. Bush 1 assy. 180511150000 1

21. Bushing 180301070840 8

22. Bush Assy for FWD & REV 180511070000 1

23. Spring 180301090900 2

PAGE NO.
62
FIGURE NO. 25

BRAKE & INCHING CONTROL

PAGE NO.
63
 FIGURE NO. 25

BRAKE & INCHING CONTROL

ITEM
DESCRIPTION PART NO. QTY.
NO.

24. Pedal pin assy 180511080000 1

25. Bolt M6x15 901100612030 2

26. Washer 6 901610600000 2

27. Inching link assy 180511060000 2

28. Washer 8 901600800000 2

29. Split pin 2x20 90040030040 2

30. Shaft assy 180511090000 1

31. Nut M10 901201000000 3

32. Nut M8 901200800000 1

33. Bolt M10x35 901101012070 3

34. Washer 8 901600800000 1

35. Pin clevis 900400300040 1

36. DISTRIBUTOR TEE BIG. 101212400600 1

PAGE NO.
64
FIGURE NO. 26

BRAKE LEVER

PAGE NO.
65
 FIGURE NO. 26

BRAKE LEVER
ITEM
DESCRIPTION PART NO. QTY.
NO.

1. Bracket 180301100100 1

2. Rubber stopper 180301101600 1

3. Fork assy. 180301100400 1

4. Hand knob 180301101000 1

5. Bracket 180301101400 1

6. Pin shaft 180301101500 2

7. Washer 8 901600800000 3

8. External circlip 930101001000 3

9. Spacer 180301100200 2

10. Bolt M10x45 901501012090 1

11. Washer 10 901611000000 6

12. Nut M10 901201000000 1

13. Lever pviot brkt 180301101800 2

14. Lift brk assy 180301101700 1

15. Pin 8x45 180301101600 1

16. Small fork 180301101200 1

17. Aduster screw 180301100500 1

18. Ball Ø6 180301100700 1

19. Spring 180301100800 2

20. Washer 8 180301101100 1

21. Nut M8 901200800000 1

22. Over head 180301100900 1

23. Threaded bush 180301100600 1

24. Bolt M10x40 901501012080 2

PAGE NO.
66
FIGURE NO. 27

CHASSIS & COUNTER WEIGHT

PAGE NO.
67
 FIGURE NO. 27

CHASSIS & COUNTER WEIGHT

ITEM
DESCRIPTION PART NO. QTY.
NO.

1. Chassis Assy. 180506000000 1

2. Bolt M30x200 901103012300 2

3. Washer spring M30 901613000000 2

4. Washer plain M30 180306050000 2

5. Counter weight 180514010000 1

6. Cap Counter WT. 180306030000 2

7. Toe Pin 50D 180514020000 1

8. Axle Mounting Clamp 180545320000 2

9. Washer Plain M20 901612000000 4

10. Bolt M20x85 901102023170 4

PAGE NO.
68
FIGURE NO. 28

PUMP MOUNTING (DIESEL)

5 4
6

9 8
7

PAGE NO.
69
 FIGURE NO. 28

PUMP MOUNTING (DIESEL)

ITEM
DESCRIPTION PART NO. QTY.
NO.

1. Hydraulic Pump 40CC 180509050000 1

2. Pump Coupling 50D 180509170000 1

3. Propeller Shaft 101086100100 1

4. Bolt M12x50 901101212100 2

5. Spring Washer M12 901611200000 2

6. Washer Plain M12 901601200000 2

7. Bolt 3/8, L=30 902100312060 8

8. Washer Plain 901601200000 8

9. Washer Spring 901611200000 8

PAGE NO.
70
FIGURE NO. 29

HOOD, FLOOR BOARD & SEAT

PAGE NO.
71
 FIGURE NO. 29

HOOD, FLOOR BOARD & SEAT

ITEM
DESCRIPTION PART NO. QTY.
NO.
1. Bolt M16x35 901501622070 4

2. Washer Spring M16 901611600000 4

3. Washer Plain M16 901601600000 4

4. Lower Plate Assy 180507020000 1

5. Bolt M10 901501012030 6

6. Washer Spring M10 901611000000 6

7. Washer Plain M10 901601000000 6

8. Upper Hood Assy 180507050000 1

9. Floor Board 180515010000 1

10. Floor Mat 50D 180516010000 1

11. Battery Mtg Clamp 180309030000 1

12. Metalic Bonnet 180527000000 1

13. Battery Mtg Plate 180309020000 1

14. Shock Absorber 180307060600 1

15. Nut M8 901200812000 2

16. Washer Spring M8 901610800000 2

17. Washer Plain M8 901600800000 8

18. Bolt M10x40 901501012080 8

19. Washer Spring M10 901611000000 8

20. Washer Plain M10 901601000000 8

21. Driver Seat 180513050000 1

22. Hinge 180307060400 2

23. Bolt M10 901101012090 2

24. Washer Spring M10 901611000000 2

25. Washer Plain M10 901201000000 2

26. Bonnet Mtg Brkt 180508010700 1

PAGE NO.
72
FIGURE NO. 29

HOOD, FLOOR BOARD & SEAT

PAGE NO.
73
 FIGURE NO. 29

HOOD, FLOOR BOARD & SEAT

ITEM
DESCRIPTION PART NO. QTY.
NO.
27. Battery Mtg Clamp 180309030000 2

28. Pin 180307050640 1

29. Radiator Cover 180501060000 1

30. Locking Bolt M10 180307070100 2

31. Floor Board Front 180515000000 1

32. Floor Board Back 180516000000 1

33. Bolt HEX-M8X25,GR 8.8 901100812050 4

34. Bracket Lock Handle 180307050670 1

35. Nut M6 901200612000 2

36. Washer Plain M6 901600600000 2

37. Bracket 180307050620 1

38. Hook 180307050610 1

39. Bush 180307050630 1

40. Spring 180307050660 1

41. Washer Plain M10 901601000000 1

42. Pin 180307050640 1

43. Battery Mtg Plate 180517030000 1

44. Bolt M10x20 901101012040 4

45. Washer M10 901601012030 4

PAGE NO.
74
FIGURE NO. 30

INSULATOR & MAT

PAGE NO.
75
 FIGURE NO. 30

INSULATOR & MAT

ITEM
DESCRIPTION PART NO. QTY.
NO.
1. Rubber, Floor Board 180301110400 1

2. Rubber, Floor Board 180301110400 1

3. Bonnet Bend Rubber 180301110100 1

4. Heat Insulator 180527000100 1

5. Radiator Cover Rubber 180301110200 1

6. Radiator Cover 180501060000 1

7. Foam Pad 180306020000 2

PAGE NO.
76
FIGURE NO. 31

TORQUE CONVERTER OIL COOLING SYSTEM

PAGE NO.
77
 FIGURE NO. 31

TORQUE CONVERTER OIL COOLING SYSTEM

ITEM
DESCRIPTION PART NO. QTY.
NO.
1. Hose Radiator to Transmission 180502040000 1

2. Hose Transmission to Radiator 180502030000 1

3. ELBOW M20X1.5 & BSP 1/2" 180502050000 1

4. Hose Clamp 955400250350 3

PAGE NO.
78
FIGURE NO. 32

HYDRAULIC SYSTEM MAST 3.0M & 3.6M STD

PAGE NO.
79
 FIGURE NO. 32

HYDRAULIC SYSTEM MAST 3.0M & 3.6M STD

ITEM
DESCRIPTION PART NO. QTY.
NO.

1. Hose Clamp Ø25 955400250350 4

2. Lift Cylinder Clamp 180312120000 2

3. Cable Tie 10'' 996200000194 2

4. LP Hose 919972101570 2

5. T For Cylinder Return 180312190100 1

6. LP Hose 180308000200 1

7. Dowty Seal 925082000100 3

8. Connector BSP 3/4"- BSP 3/4" 180545170000 1

9. Hose inbetween 180545140000 1

10. Lifting Cylinder T-Joint 180530070000 1

11. Clamp 955400250350 3

12. Hose CV to FV 180545260000 1

13. Flow valve 180545130000 1

14. Lifting Cylinder AF 50D 3.0 MTR STD 905421101500 2

- Lifting Cylinder AF50D 3.6 MTR STD 905361118000 2

PAGE NO.
80
FIGURE NO. 33

FORK AND CARRIAGE ASSY 3.0M/3.6M STD

PAGE NO.
81
 FIGURE NO. 33

FORK AND CARRIAGE ASSY 3.0M/3.6M STD

ITEM
DESCRIPTION PART NO. QTY.
NO.

1. Fork L-1200mm 185022100500 2

- Fork Set L-1500 185022100600 1

- Fork Set L-1800 180546010000 1

- Fork Set L-2000 185022100700 1

2. Backrest 180545050000 1

3. Washer Plain M14 901611400000 8

4. Bolt M14x30 901501413070 8

5. Bolt M12x30 901501413070 8

6. Carriage Assy. (3.0M STD & 3.6M STD) 180530020000 1

7. Side Roller 180545080000 4

8. Spacer 180312022000 8

9. Washer plain M12 901611200000 8

10. Roller Ø123 180545060000 6

11. Circlip Ø50 930502002000 6

PAGE NO.
82
FIGURE NO. 34

MAST ASSY. OF 3.0M & 3.6M STD

PAGE NO.
83
 FIGURE NO. 34

MAST OF 3.0M & 3.6M STD

ITEM
DESCRIPTION PART NO. QTY.
NO.

1. Outer Mast 3.0M STD 180530011000 1

- Outer Mast 3.6M STD 180536011000 1

2. Pin 180545042000 2

3. Washer plain M12 901611200000 2

4. Bolt M12x20 901501212040 2

5. Mast Mounting Bearing 180545310000 2

6. Mast Clamp 180545320000 2

7. Bolt M20x85 901102013170 4

8. Washer plain M20 901612000000 4

9. Roller Ø123 180545060000 4

10. External circlip Ø50 93050200200 4

11. Grease Nipple 901300800000 2

12. Bush 180531010100 8

13. Side Roller 180545080000 4

14. Washer Plain M12 901611200000 8

15. Bolt M12x55 901501212100 8

16. Clearence Pad 180312032300 2

17. Clearence Shim 180312032400 2

18. Mast Inner 3.0M STD 180530010100 1

- Mast Inner 3.6M STD 180536010100 1

PAGE NO.
84
FIGURE NO. 35

HYDRAULIC SYSTEM FOR MAST 3.0M FFL

PAGE NO.
85
 FIGURE NO. 35

HYDRAULIC SYSTEM FOR MAST 3.0M FFL

ITEM
DESCRIPTION PART NO. QTY.
NO.

1. Adopter Center Cylinder 180545150000 1

2. Clip 180310318000 2

3. Bolt M8x15 901500812030 2

4. Washer Spring M8 901610800000 2

5. Pipe Lifting Cylinder 180538026000 1

6. Hose Pipe to C Cylinder 180545240000 1

7. Hose CV to FV 180545260000 1

8. Flow valve 180545130000 1

9. Hose inbetween 180545140000 1

10. Connector BSP 3/4" BSP 3/4" 180545170000 1

11. Dowety 925082000100 4

12. T Joint Lifting Cylinder 180545230000 1

13. Lifting Cylinder LH 905301115000 1

13-A Lifting Cylinder RH 905311115000 1

14. Centre Cylinder 904511078000 1

15. Adopter for Lifting Cylinder 180538025000 1

PAGE NO.
86
FIGURE NO. 36

FORK AND CARRIAGE ASSY 3.0M FFL

PAGE NO.
87
 FIGURE NO. 36

FORK AND CARRIAGE ASSY 3.0M FFL

ITEM
DESCRIPTION PART NO. QTY.
NO.

1. Fork-1200mm 185022100500 2

- Fork Set L-1500 185022100600 1

- Fork Set L-1800 180546010000 1

- Fork Set L-2000 185022100700 1

2. Backrest 180545050000 1

3. Washer Plain M14 901611400000 8

4. Bolt M14x30 901501413070 8

5. Bolt M12x30 901501413070 8

6. Carriage Assy. 180538030100 1

7. Side Roller 180545080000 4

8. Spacer 180312022000 8

9. Washer plain M12 901611200000 8

10. Roller Ø123 180545060000 6

11. Snap ring Ø50 930502002000 6

PAGE NO.
88
FIGURE NO. 37

MAST ASSY. OF 3.0M FFL

PAGE NO.
89
 FIGURE NO. 37

MAST ASSY. OF 3.0M FFL

ITEM
DESCRIPTION PART NO. QTY.
NO.

1. Outer Mast 180538010100 1

2. Pin 180545042000 2

3. Washer Plain M12 901611200000 2

4. Bolt M12x20 901501212040 2

5. Mast Mounting Bearing 180545310000 2

6. Mast Clamp 180545320000 2

7. Bolt M20x85 901102013170 4

8. Washer Plain M20 901612000000 4

9. Roller Ø123 180545060000 4

10. External circlip Ø50 93050200200 4

11. Grease nipple 901300800000 2

12. Bush 180531010100 8

13. Side Roller 180545080000 4

14. Washer M12 901611200000 8

15. Bolt M12x55 901501212100 8

16. Clearence Pad 180312032300 2

17. Clearence Shim 180312032400 2

18. Mast Inner 180538020100 1

PAGE NO.
90
FIGURE NO. 38

HYDRAULIC SYSTEM MAST 4.5M/6.0M FFL

17

18
8 15 16

4 12 11
23

22 13

10
2
9

3
7
19
20
21

6
15

PAGE NO.
91
 FIGURE NO. 38

HYDRAULIC SYSTEM MAST 4.5M/6.0M FFL

ITEM
DESCRIPTION PART NO. QTY.
NO.

1. Lifting Cylinder 4.5M FFL 905421101500 2

- Lifting Cylinder 6.0M FFL 905422001600 2

2. Centre Cylinder 4.5M FFL 904511078000 1

- Centre Cylinder 6.0M FFL 905422101600 1

3. Center Cylinder Tube Assy. 180545180000 1

4. Centre Cylinder Clamp 180545100000 1

5. Adopter Center Cylinder 180545150000 1

6. Hose Inbetween Lifting Cylinder 180545140000 1

7. Connector BSP 3/4"- BSP 3/4" 180545170000 1

8. Flow Valve 180545130000 1

9. Lift Cylinder U Bolt 180545110000 2

10. Lift Cylinder Clamp 180312120000 2

11. Bolt M12x45 901501212090 2

12. Hex nut M12 901201200000 2

13. Hex nut M10 901201002000 4

14. T-Joint for Flow Valve 180545200000 1

15. Adopter T joint for lifting cylinder 180545230000 1

16. Hose from Lifting Cylinder to T joint 919972101570 2

17. Bolt M16x90 901501612180 2

18. Washer M16 901611600000 2

19. Bolt M12x30 901501212060 2

20. Washer plain M12 901601212030 2

21. Spring washer 901611200000 2

22. Bolt M10x40 901501012080 2

23. Spring washer M10 901611000000 2

PAGE NO.
92
FIGURE NO. 39

FORK AND CARRIAGE ASSY. 4.5M/6.0M FFL

PAGE NO.
93
 FIGURE NO. 39

FORK AND CARRIAGE ASSY. 4.5M/6.0M FFL

ITEM
DESCRIPTION PART NO. QTY.
NO.

1. Fork-1200mm 185022100500 2

- Fork Set L-1500 185022100600 1

- Fork Set L-1800 180546010000 1

- Fork Set L-2000 185022100700 1

2. Backrest 180545050000 1

3. Washer M14 901611400000 8

4. Bolt M14x30 901501413070 8

5. Bolt M12x30 901501413070 8

6. Carriage Assy. 4.5M/6.0M FFL 180545041000 1

7. Side Roller 180545080000 4

8. Spacer 180312022000 8

9. Washer Plain M12 901611200000 8

10. Roller Ø123 180545060000 6

11. Snap ring Ø50 930502002000 6

PAGE NO.
94
FIGURE NO. 40

MAST OF 4.5M & 6.0M FFL

PAGE NO.
95
 FIGURE NO. 40

MAST OF 4.5M & 6.0M FFL

ITEM
DESCRIPTION PART NO. QTY.
NO.

1. Outer Mast 4.5M FFL 180545011000 1

- Outer Mast 6.0M FFL 180539010100 1

2. Mid Mast 4.5M FFL 180545021000 1

- Mid Mast 6.0M FFL 180539020100 1

3. Inner Mast 4.5M FFL 180545031000 1

- Inner Mast 6.0M FFL 180539030100 1

4. Side Roller 180545080000 8

5. Bush 180312022000 16

6. Bolt M12x55 901501212100 16

7. Washer spring M12 901611200000 18

8. Grease Nipple 901300800000 2

9. Roller Ø123 180545060000 8

10. External circlip Ø50 930502002000 8

11. Mast Mounting Bearing 180545310000 2

12. Mast Clamp 180545320000 2

13. Washer Plain M20 901612000000 4

14. Bolt M20-1.5x85 901102023170 4

15. Mast pin 180545042000 2

16. Bolt M12x20 901101212070 2

17. Clearence Pad Shim 180312032400 4

18. Clearence Pad 180312032300 4

PAGE NO.
96
FIGURE NO. 41

FORK AND PIN TYPE CARRIAGE ASSY.

PAGE NO.
97
 FIGURE NO. 41

FORK AND PIN TYPE CARRIAGE ASSY.

ITEM
DESCRIPTION PART NO. QTY.
NO.

1. Pin Type Fork 180536022010 2

2. Backrest 180545050000 1

3. Washer M14 901611400000 8

4. Bolt M14x30 901501413070 8

5. Bolt M12x30 901501413070 8

6. Dual pin type carriage 180536022000 1

7. Side Roller 180545080000 4

8. Spacer 180312022000 8

9. Washer M12 901611200000 8

10. Roller Ø123 180545060000 6

11. Snap Ring Ø50 930502002000 6

12. Fork Holding Brkt 180536022070 2

PAGE NO.
98
FIGURE NO. 42

HYDRAULIC SYSTEM

PAGE NO.
99
 FIGURE NO. 42

HYDRAULIC SYSTEM
ITEM
DESCRIPTION PART NO. QTY.
NO.

1. Adopter [Link] Inlet 180509070000 1

2. Adopter [Link] Outlet 180509080000 1

3. Hose [Link] to Pump 180509060000 1

4. Hose CV to [Link] 50 D 180509100000 2

5. Hose CV to FV 50D 180545260000 1

6. Hose CV to Tilt Cyl. tube 180509110000 2

7. Hose Tilt CY. tube to Tilt Cyl. 180509120000 4

8. Hose ST. unit to [Link] 1 50 D 180509130000 1

9. Hose ST. unit to [Link] 2 50 D 180509140000 1

10. Hose ST. unit to tank return 180509150000 1

11. Hose Control valve(CV) return 180509160000 1

12. Hose pump to CV 180509180000 1

13. Adopter return line filter 180509010400 2

14. Return line filter 180509010300 1

15. Tilt cylinder tube assy. 180507030100 1

16. Hose clamp 955400250350 1

17. Connector BSP 1''-3/4'' 701000005600 1

18. Connector 3/4" - 3/4" 701001010400 1

19. Adopter BSP 3/4-BSP 3/8 180523010000 2

20. Connector BSP 3/8 - BSP 3/8 925090110110 1

21. Connector BSP 1/4"-BSP 1/4" 180308050320 1

22. Connector G3/8-G1/2 925092000300 3

PAGE NO.
100
FIGURE NO. 43

HYDRAULIC OIL TANK

PAGE NO.
101
 FIGURE NO. 43

HYDRAULIC OIL TANK

ITEM
DESCRIPTION PART NO. QTY.
NO.

1. Breather Cum Dip Stick 180308020300 1

2. Tank Cover Assy 180509010100 1

3. Gasket 180308020200 1

4. Bolt M8x20 901100812050 8

5. Washer spring M8 901610800000 8

6. Stainer 180308020400 1

PAGE NO.
102
FIGURE NO. 44

VALVE CONTROL LINKAGE (4 SPOOL)

PAGE NO.
103
 FIGURE NO. 44

VALVE CONTROL LINKAGE (4 SPOOL)

ITEM
DESCRIPTION PART NO. QTY.
NO.

1. Control Valve (4 spool) 180003431600 1

2. Washer M10 901601000000 4

3. Nut M10 901201000000 4

4. Mtg Brckt 180523030000 1

5. Connector link 180523040000 4

6. Pin Ø5x20 180308031000 8

7. Split Pin 900400300040 8

8. Joint 180523020000 4

9. Bolt M10x25 901101012050 4

10. Knob 180308030510 4

11. Lever Lift 180308030100 1

12. Shim 8 901600800000 4

13. Shim 12 901601200000 4

14. Rubber 8

15. Bolt M12x60 901101212120 4

16. Nut M12 901201012000 4

17. Washer M12 901611200000 4

18. Bush 4

19. Bolt M6x15 901100612030 1

20. Washer M6 901610600000 1

21. Pin Assy 180523060000 1

22. Shim 180308030200 3

23. Bush 180523050000 3

24. Lever tilt 180308030200 1

25. Lever third 180308030300 1

26. Lever four 180308030400 1

PAGE NO.
104
FIGURE NO. 45

VALVE CONTROL LINKAGE (3 SPOOL)

PAGE NO.
105
 FIGURE NO. 45

VALVE CONTROL LINKAGE (3 SPOOL)

ITEM
DESCRIPTION PART NO. QTY.
NO.

1. Control Valve (3 spool) 180003331600 1

2. Washer M10 901601000000 4

3. Nut M10 901201000000 4

4. Mtg Brckt 180523030000 1

5. Connector link 180523040000 3

6. Pin Ø5x20 180308031000 6

7. Split Pin 900400300040 6

8. Joint 180523020000 3

9. Bolt M10x25 901101012050 4

10. Knob 180308030510 3

11. Lever Lift 180308030100 1

12. Shim 8 901600800000 3

13. Shim 12 901601200000 4

14. Rubber 8

15. Bolt M12x60 901101212120 4

16. Nut M12 901201012000 4

17. Washer M12 901611200000 4

18. Bush 4

19. Bolt M6x15 901100612030 1

20. Washer M6 901610600000 1

21. Pin Assy 180523060000 1

22. Shim 180308030200 3

23. Bush 180523050000 3

24. Lever tilt 180308030200 1

25. Lever third 180308030300 1

PAGE NO.
106
FIGURE NO. 46

VALVE CONTROL LINKAGE (2 SPOOL)

PAGE NO.
107
 FIGURE NO. 46

VALVE CONTROL LINKAGE (2 SPOOL)

ITEM
DESCRIPTION PART NO. QTY.
NO.

1. Control Valve (2 spool) 180003231600 1

2. Washer M10 901601000000 4

3. Nut M10 901201000000 4

4. MTG brckt 180523030000 1

5. Connector link 180523040000 2

6. Pin Ø5x20 180308031000 6

7. Split pin 900400300040 6

8. Joint 180523020000 2

9. Bolt M10x25 901101012050 4

10. Knob 180308030510 2

11. Lever Lift 180308030100 1

12. Shim 8 901600800000 2

13. Shim 12 901601200000 4

14. Rubber 8

15. Bolt M12x60 901101212120 4

16. Nut M12 901201012000 4

17. Washer M12 901611200000 4

18. Bush 4

19. Bolt M6x15 901100612030 1

20. Washer M6 901610600000 1

21. Pin Assy 180523060000 1

22. Shim 180308030200 2

23. Bush 180523050000 2

24. Lever tilt 180308030200 1

PAGE NO.
108
ENGINE MODEL
MAKE - MAHINDRA
MODEL - 4805 TC
FIGURE NO. 47

Valve Housing Cover

PAGE NO.
109
 FIGURE NO. 47

Valve Housing Cover

ITEM
DESCRIPTION PART NO. QTY.
NO.

1 VALVE Housing Cover 006005759F91 1

2 CAP Oil Filler 005553100R92 1

3 OILSEAL Filler Cap 005553101R2 2

4 BOLT Flanged M8 x 1.25 x 95.0 000020791E05 9

5 GASKET Cover to Cylinder Head 000020608E05 1

6 HOSE PCV CAP TO OIL SEPERATOR 006013552H1 1

7 HOSE OIL SEPERATOR TO FRONT COVER 006013553H1 1

8 HOSE OIL SEPERATOR TO AIR 79HP BHL 006013554H1 1

9 BRACKET OIL SEPERATOR BHL 006013989H1 1

10 OIL SEPERATOR (PCV FOR ROTARY) 006002227B1 1

PAGE NO.
110
FIGURE NO. 48

EXHAUST SYSTEM

PAGE NO.
111
 FIGURE NO. 48

EXHAUST SYSTEM
ITEM
DESCRIPTION PART NO. QTY.
NO.

1 MANIFOLD Exhaust 006012717H1 1

2 STUD M8 x 28 Exhaust Manifold 006002649F1 8

3 NUT CLEVELOC Exhaust Manifold M8 006000856F1 8

4 GASKET Exhaust Manifold Mounting 006000264F1 4

5 GASKET Turbocharger Mounting 0024018 1

6 TURBOCHARGER 006015640H1 1

7 STUD Turbocharger Mounting 006000823F1 4

8 NUT Turbocharger Mounting 006000856F1 4

9 PIPE Lub. Oil TC Inlet 006013551H1 1

10 BOLT Banjo M10 x 1.25 006001299B1 1

11 BOLT Banjo M10 x 1 001081723R1 1

12 WASHER Copper 000000017 4

13 PIPE Lub. Oil TC Outlet 006013502F1 1

14 BOLT Banjo M16 000020704E05 1

15 WASHER Copper 006009296F1 2

16 CLIP 005552915R91 1

17 ADAPTOR M18 006007441F1 1

18 WASHER M18 005552905R1 2

19 GASKET TC Turbine (Ex. Pipe to Turbine) 006013846F1 1

20 ELBOW TC Outlet 006015649H1 1

21 STUD M8 x 28 Elbow TC Outlet Mounting 006002649F1 4

22 NUT Flanged 006000856F1 4

PAGE NO.
112
FIGURE NO. 49

AIR INTAKE SYSTEM

PAGE NO.
113
 FIGURE NO. 49

AIR INTAKE SYSTEM

ITEM
DESCRIPTION PART NO. QTY.
NO.

1 INTAKE Manifold 006008634H1 1

2 STUD for Intake Manifold - M8 x 40 000020265E05 4

3 NUT Flanged for Intake Manifold - M8 x 1.25 000020777E05 9

4 GASKET Intake Manifold Mounting 000020609E05 4

5 GASKET INTAKE MANIFOLD RIGID MTG. 000020247E05 2

6 ELBOW Venturi 006013550H1 1

7 BOLT Flanged - M8 x 25 2030900000 1

8 BOLT Flanged - M8 x 1.25 x 30 2030600000 5

9 NUT Flanged - M8 006000663F1 3

10 ALUMINIUM Venturi 006005495F91 1

11 STICKER EPA - 8560 ‡ 1

12 CLAMP Constant Pressure (Medium) 006000631F1 3

13 HOSE IC Outlet to Venturi E006007234F1 1

A SUB-ASSEMBLY TC to IC Consists of E006008648F91 1

12 CLAMP Constant Pressure (Medium) ‡ 2

14 HOSE Silicon IC Inlet ‡ 1

15 PIPE TC to IC ‡ 1

16 HOSE Silicon TC Outlet ‡ 1

17 BRACKET Maxifuse Mounting 005559255B1 2

PAGE NO.
114
FIGURE NO. 50

EGR SYSTEM

PAGE NO.
115
 FIGURE NO. 50

EGR SYSTEM
ITEM
DESCRIPTION PART NO. QTY.
NO.
1 PIPE VACUUM PUMP OIL INLET 006013549H1 1
2 BOLT Banjo M10 x 1.5 Alternator Lubrication 006005670F1 1
3 BOLT Banjo M10 x 1 001081723R1 1
4 PIPE Lub. Outlet Alternator 006008185F1 1
5 ALTERNATOR 006014851H1 1
6 Tensioner Assembly Alternator 006013548H91 1
7 BOLT M10 x 1.5 x 130 006000554H1 1
8 NUT M10 x 1.5 005554365R1 1
9 WASHER M10 000022079RD 5
10 BOLT M10 x 40 000016631P04 1
11 BRACKET Alternator 006009348F1 1
12 NUT M10 x 1.5 005554365R1 1
13 TUBE RUBBER - Altenator to Reservoir E006007897F1 1
14 VACUUM RESERVOIR 006003985C1 1
15 BRACKET Modulator Mounting E006007208F1 1
16 BOLT Bracket Modulator Mounting M8 x 16 000020308E05 2
17 EGR Vacuum Modulator E007700817B91 1
18 BOLT M6 x 16 000020311E05 4
19 TUBE RUBBER - Modulator to Intake Pipe E006007898F1 1
20 EGR Valve 006017165H91 1
21 BOLT M8 x 30 000020306E05 2
22 NUT M8 x 1.25 000020777E05 2
23 GASKET EGR Pipe 006003982C1 4
24 BRACKET EGR Support 006013547H1 1
25 BOLT M8X1.25X30 000020306E05 2
26 PIPE EGR VALVE TO VENTURI 006013544H1 1
27 NUT Flanged 000020777E05 2
28 GASKET Exhaust Manifold to EGR Pipes E006006816F1 1

PAGE NO.
116
FIGURE NO. 50

EGR SYSTEM

PAGE NO.
117
 FIGURE NO. 50

EGR SYSTEM
ITEM
DESCRIPTION PART NO. QTY.
NO.
29 BOLT Allen M8 x 25 006002715B1 6
30 NUT M8 000020777E05 2
31 PIPE EGR COOLER TO EGR VALVE 006013543H1 1
32 EGR COOLER 006015518C1 1
33 PIPE CRANKCASE TO EGR COOLER 006013545H1 1
34 CLIP 005552915R91 6
35 PIPE EGR COOLER TO WATER PUMP 006013546H1 1
36 BRACKET ASSEMBLY EGR Cooler 006007574F91 1
PIPE EXHAUST MANIFOLD TO EGR
37 006013542H1 1
COOLER
38 HOSE EGR Cooler Pipe 006005659F1 2
39 TUBE RUBBER - Reservoir to Modulator E006007742F1 1
40 TUBE RUBBER - Modulator to Valve E006007028F1 1
41 STUD M8 006000823F1 2
42 NUT Cleveloc 006000856F1 2
43 GUARD Alternator 006007746F1 1
44 BOLT M8 x 20 000020307E05 2
45 BOLT M16 x 2 x 40 000010583P03 1
46 WASHER Spring Lock 001082015R2 1
BOLT Alternator Tensioner Bracket Mtg. M10 x
47 000020324E05 2
16
48 SLEEVE Alternator Tensioner Bracket 006009338F1 1
49 WASHER Copper Lub. Inlet Alternator 000000017 4
50 CLIP Alternator Outlet Pipe 000020708E05 1
51 BOLT Banjo M16 000020704E05 1
52 WASHER Copper M16 000020706E05 2
53 WASHER Spring M10 000022273RD 2
54 WASHER PLAIN 000051632D01 3
55 WASHER Plain M8 001121799R1 5
56 CLIP Cable 000708114R3 1

PAGE NO.
118
FIGURE NO. 51

CYLINDER HEAD ASSEMBLY

PAGE NO.
119
 FIGURE NO. 51

CYLINDER HEAD ASSEMBLY

ITEM
DESCRIPTION PART NO. QTY.
NO.

A CYLINDER HEAD Assembly Consisting Of : 006005365F91 1

1 CYLINDER HEAD ‡ 1

2 PLUG Expansion 30 x 2.0 x 42 000020299E05 7

3 PLUG Expansion 25 x 2.0 x 34 000020298E05 8

4 GUIDE Valve 000020024E05 8

5 VALVE Stem Seal 000020345E05 8

6 RING VALVE SEAT Exhaust 000020052E05 4

7 RING VALVE SEAT Intake 000020069E05 4

8 INJECTOR 006000541F1 4

9 WASHER 006006562F1 4

10 BANJO 0000000KT 4

11 NUT Flanged M8 x 1.25 Grade 8 000020777E05 4

12 WASHER - Clamp Nozzle Holder 000020289E05 4

13 CLAMP Nozzle Holder 000020571E05 4

14 STUD M8 x 1.25 x 45 000020266E05 4

15 DUMMY Glow Plug 006000548F1 4

16 PLUG Hex. M10 x 1.0 000020786E05 2

17 BRACKET Engine Lifting Rear 006013992H1 1

18 BOLT M8 x 16 Hex. Hd. Rear Lifting Eye 000020308E05 2

19 BOLT Cylinder Head Mounting M14 x 2 x 134 006000812F1 10

Grade 12.9

20 STUD for Pedestal Rocker Arm M8 x 1.25 x 70 006000659F1 4

Grade 10.9

21 STUD M8 x 1.25 x 80 Grade 10.9 006000662F1 4

PAGE NO.
120
FIGURE NO. 52

VALVE TRAIN

PAGE NO.
121
 FIGURE NO. 52

VALVE TRAIN
ITEM
DESCRIPTION PART NO. QTY.
NO.

1 CAMSHAFT 006003113F1 1

CAMSHAFT THRUST PLATE 000020798E05 1

KEY WOODRUFF 000020270E05 1

GEAR CAMSHAFT(FINISHED)-DIN9 FOR 75 M06002568F1 1

2 TAPPET 006002300D1 8

3 PUSH ROD Valve 000020107E05 8

A ARM ROCKER Cpte. Consists of : 000020172E05 4

4 SCREW Adjusting 000020062E05 8

5 PLUG Tapper 000020799E05 8

6 RING Seeger 000022034RD 8

7 WASHER Valve Lever Shaft 000022033RD 8

8 NUT M8 x 1 000020796E05 8

B ROCKER ARM INTAKE Assembly consists of 000020843E05 4

9 ROCKER ARM Intake 000020823E05 4

10 BUSH For Rocker Arm 000020341E05 4

11 SHAFT Rocker Arm 000020064E05 8

12 PEDESTAL Rocker Arm 000020031E05 8

ROCKER ARM EXHAUST Assembly consists

C 000020844E05 4
of

10 BUSH For Rocker Arm 000020341E05 4

13 ROCKER ARM Exhaust 000020823E05 4

NUT Flanged for Pedestal M8 x 1.25 Class

14 006000663F1 8
10-M94981

15 VALVE LOCK - Half 006000002F1 16

16 RETAINER Upper for Valve Spring 006000077F1 8

17 VALVE Spring 005557570R1 8

PAGE NO.
122
FIGURE NO. 53

CRANKCASE FRONT COVER

PAGE NO.
123
 FIGURE NO. 53

CRANKCASE FRONT COVER

ITEM
DESCRIPTION PART NO. QTY.
NO.

1 BOLT Main Drive Pulley M14 x 1.5 x 5 006005215B1 1

2 WASHER Main Drive Pulley 006005197F1 1

3 PULLEY Hydraulic Pump Splined - Single Groove 006008485F91 1

4 GREASE SEAL for Front Cover 006000876F1 1

4a PLUG M14 x 1.5 Hex Socket Pipe 000020787E05 1

A FRONT COVER Sub - Assembly Consists of 006008669F91 1

5 GREASE Nipple M6 007600185C1 1

6 FRONT COVER 006006925F1 1

7 O RING 28.25X2.62 NBR 000020381E05 1

8 ROLLER Bearing (35 x 62 x 14) 006000565F1 1

9 SPACER Hydraulic Pump Brg 000020118E05 1

10 ROLLER Bearing (35 x 72 x 17) 006000566F1 1

11 CIRCLIP Internal 72 mm 000704385R1 1

12 OIL SEAL Front 000020369E05 1

13 GEAR Hydraulic Pump 006005061F1 1

* PLUG (M10 x 1 Hex. Socket Pipe) 000020786E05 1

14 SPIDER Hydraulic Pump 006000598F1 1

15 GEAR Idler Assembly With Bush 006000879F91 1

16 GEAR Idler 006000530F1 1

17 BUSH for Idler Gear 000020339E05 1

18 SHAFT Idler Gear 006005610C1 1

19 BOLT Flanged Hex. Head M8 x 1.25 x 35 006006762F1 3

20 BOLT Flanged Hex. Head M8 x 1.25 x 45 000020254E05 20

PAGE NO.
124
FIGURE NO. 53

CRANKCASE FRONT COVER

PAGE NO.
125
 FIGURE NO. 53

CRANKCASE FRONT COVER

ITEM
DESCRIPTION PART NO. QTY.
NO.

21 GASKET OIL FILL TUBE 006014645H1 1

22 OIL FILL TUBE FRONT COVER 006013555H1 1

23 BOLT Flanged Hex. Head M8 x 1.25 x 20 000020307E05 4

24 PIPE Lubrication 006004882F1 1

25 WASHER 000000017 4

26 BOLT Banjo (M10 x1) 001081723R1 2

27 BEARING Housing 006003610F1 1

28 BOLT M8 x 25 000020309E05 4

29 PLATE EPA ‡ 1

30 CLIP Cable 000708117R2 1

31 CAP OIL FILLING 000020629E05 1

32 O RING OIL FILLING CAP 000020628E05 1

PAGE NO.
126
FIGURE NO. 54

CRANKCASE WITH OIL PAN

PAGE NO.
127
 FIGURE NO. 54

CRANKCASE WITH OIL PAN

ITEM
DESCRIPTION PART NO. QTY.
NO.

A CRANKCASE Assembly Consists of : 006005364F91 1

1 CRANKCASE ‡ 1

2 CAP Main Bearing Rear ‡ 1

3 CAP Main Bearing Front ‡ 4

4 BOLT Main Bearing Cap 006004569F1 10

5 PLUG Expansion 36 x 2.0 x 50 006002987C1 2

6 PLUG Expansion 006000015F1 4

7 BUSH Camshaft Front 000020300E05 1

8 BUSH Camshaft Rear 000020903E05 4

9 PLUG M14 x 1.5 Hex. Socket Pipe 000020787E05 6

10 PIN Dowel 8.0M 6 x 12 000020279E05 2

11 PIN SEALING for fuel timing hole 000020751E05 1

12 ADAPTER Oil Gallery 000020808E05 1

13 SLEEVE Location 000020507E05 2

14 PLUG Expansion 30 x 2.0 x 42 000020299E05 1

15 PLUG Expansion 56 x 2.0 x 80 000020301E05 1

PIN DOWEL 12.5 H8 - for Flywheel Housing to

16 005551963R1 1
Crankcase

17 PISTON COOLING JET Assembly (Ball Type) 006000571F91 4

18 BOLT Flanged M6 x 30 Full Threaded 000020818E05 4

19 GASKET for Piston Cooling Jet Assembly 000020779E05 4

20 BOLT Flanged M8 x 1.25 x 145 Grade 8.8 006000130F1 25

21 SEALING for pipe union 000020286E05 1

22 DRAIN PLUG 006000110F1 1

23 BOLT Flanged Hex. Head M8 x 1.25 x 50 000020255E05 4

PAGE NO.
128
FIGURE NO. 54

CRANKCASE WITH OIL PAN

PAGE NO.
129
 FIGURE NO. 54

CRANKCASE WITH OIL PAN

ITEM
DESCRIPTION PART NO. QTY.
NO.

24 OIL PAN 006011223H1 1

25 GASKET Water Drain Plug Housing 000020495E05 1

26 HOUSING Water Drain / Heater Plug 006000385F1 1

27 BOLT M8 x 20 000020307E05 2

28 PLUG for Block Heater / Water Drain 006000519F1 1

29 DIPSTICK 006008674F1 1

30 O‘RING for Dipstick 000020664E05 1

31 BRACKET Maxifuse Mounting 005559255B1 1

32 BOLT M6 000020797E05 1

33 WASHER Plain M6 000016559R2 1

34 WASHER COPPER 005552905R1 1

35 CONNECTOR DIPSTICK GUIDE PIPE 006008672F1 1

36 PIPE DIPSTICK 006018860H91 1

MOTOR STARTER-LUCAS 005558084R91 1

PAGE NO.
130
FIGURE NO. 55

PISTON, KINER, CONNECTING ROD & CRANKSHAFT

PAGE NO.
131
 FIGURE NO. 55

PISTON, KINER, CONNECTING ROD & CRANKSHAFT

ITEM
DESCRIPTION PART NO. QTY.
NO.

1 GEAR Oil pump drive 000020368E05 1

2 BOLT Hex. Head M10 x 1 x 20 000020884E05 4

A RING SET Piston Consists of 1

3 RING Piston TOP 006001421F1 4

4 RING Piston 2nd 006001422F1 4

5 RING Oil Control 006001423F1 4

B PISTON with Pin Consists of 1

6 PISTON 006014552D1 4

7 PIN PISTON 006011425H1 4

8 CIRCLIP Piston Pin 006001420F1 8

C ASSEMBLY Connecting Rod each Consist of E006012262H91 1

9 CAP Connecting Rod 006001313F1 4

10 BUSH Connecting Rod 006006803F1 4

11 BOLT Connecting Rod 006001387F1 8

12 CONNECTING ROD without Cap 006001312F1 4

13 BEARING Shell Connecting Rod Upper & Lower 006004886F1 8

14 BEARING MAIN JOURNAL Top 006004887F1 5

15 BEARING MAIN JOURNAL Bottom 006004888F1 5

16 THRUST WASHER (With Lug) 000020889E05 2

17 THRUST WASHER (Without Lug) 000020890E05 2

18 PIN Dowel 8.0 M6 x 18 DIN 7 000020281E05 1

19 GEAR Crankshaft 006000871F1 1

20 CRANKSHAFT 006017195C1 1

21 CYLINDER LINER WITH GRADING ID 96-BS3A 006010411C1 4

22 O' RING Cylinder Liner 006014461C1 8

PAGE NO.
132
FIGURE NO. 56

LUBE OIL PUMP

PAGE NO.
133
 FIGURE NO. 56

LUBE OIL PUMP

ITEM
DESCRIPTION PART NO. QTY.
NO.

1 OIL PUMP Assembly 006004090F92 1

2 SLEEVE Location 14 x 15 000020275E05 2

3 BOLT Flanged Hex. Head M6 x 1 x 16 000020311E05 2

4 WASHER Spring Lock M6 001233808R1 2

5 STRAINER Suction 006000195F1 1

6 GASKET for Oil Cooler Pipe Flange 000021720E11 1

7 BOLT Flanged Hex. Head M10 x 1.5 x 65 000020302E05 2

PAGE NO.
134
FIGURE NO. 57

LUBE OIL COOLER AND PIPING

PAGE NO.
135
 FIGURE NO. 57

LUBE OIL COOLER AND PIPING

ITEM
DESCRIPTION PART NO. QTY.
NO.

1 OIL FILTER (Factory Fitted) 006002508F1 1

1 OIL FILTER - (Use for Service) 006008803F1 1

2 OIL Cooler 12 Plate 006000756F1 1

3 PIPE Crankcase to Oil Cooler 006007600F1 1

4 BOLT Allen M6 x 16 000013345P04 2

5 BOLT Flanged M8 x 1.25 x 95.0 000020791E05 2

6 BOLT Flanged Hex. Head M8 x 1.25 x 45 000020254E05 1

7 BRACKET Oil Filter 006002819C1 1

8 GASKET Oil Filter Bracket 008000046F1 1

9 CONNECTING Plug For 12 Plate Oil Cooler 006000757F1 1

10 CLIP PIPE [Link] Pump - Worm Type 005552915R91 3

11 HOSE Crankcase to Oil Cooler 006007496F1 1

12 PIPE Oil Cooler to Water Pump 006007597F1 1

13 CLIP Hose 005556668R91 2

14 HOSE Oil Cooler to Water Pump 000020754E05 1

15 GASKET Oil Coller Pipe Flange 000021720E11 1

PAGE NO.
136
FIGURE NO. 58

COOLING SYSTEM

PAGE NO.
137
 FIGURE NO. 58

COOLING SYSTEM
ITEM
DESCRIPTION PART NO. QTY.
NO.

1 BOLT Flanged M8 x 1.25 x 20 000020307E05 3

2 FAN Metallic E006000892F1 1

3 NUT Flanged M8 x 1.25 Grade 8 000020777E05 3

4 WASHER Spring Lock 5/16" 001082011R2 3

5 FAN Adaptor 006015668H1 1

6 BELT - 1185 mm 006007029F1 1

7 PULLEY - Water Pump & Fan Drive 006015137H1 1

8 WATER PUMP Assembly Consists of 006015185H91 1

9 ADAPTOR ‡ 1

10 BOLT Flanged Hex. Head M8 x 1.25 x 30 000020306E05 3

11 HOUSING Water Pump Bearing ‡ 1

12 O’Ring ‡ 1

13 SPINDLE Water Pump ‡ 1

14 SEAL Water Pump ‡ 1

15 IMPELLER ‡ 1

16 STUD M8 x 1.25 x 45 000020266E05 3

17 CLIP Hose 006004797F1 2

18 HOSE Bypass for Water Pump 006006097D1 1

19 THERMOSTAT Housing 006007686F1 1

20 GASKET Thermostat Housing 000021920E14 1

21 SENSOR TEMP Alt Part # 005551425R2 005551426R2 1

22 WASHER Insert Temperature 005550766R3 1

PAGE NO.
138
FIGURE NO. 58

COOLING SYSTEM

PAGE NO.
139
 FIGURE NO. 58

COOLING SYSTEM
ITEM
DESCRIPTION PART NO. QTY.
NO.

23 BOLT M8 x 75 Thermostat Housing 006007297F1 3

24 TEMPERATURE Sensor KSB E007700921B91 1

25 THERMOSTAT Assembly 006004365F91 1

26 GASKET Thermostat 000020320E05 1

27 COVER Thermostat 000021915E14 1

28 BOLT Flanged Hex. Head M6 x 1 x 20 000020312E05 4

29 WASHER M10 Temp. Sensor KSB 006009551F1 1

30 BRACKET ENG LIFT FRONT 006013993H1 1

PAGE NO.
140
FIGURE NO. 59

RADIATOR AND INTERCOOLER

PAGE NO.
141
 FIGURE NO. 59

RADIATOR AND INTERCOOLER

ITEM
DESCRIPTION PART NO. QTY.
NO.
1 Radiator & Intercooler Assembly Consists of E006006477F91 1
2 Radiator Assembly E006008643F91 1
3 Thrash Guard Radiator E006007575F1 1
4 CAP Radiator E006008221F1 1
5 Radiator E006007706F1 1
6 Bolt M6 x 16 Thrash Guard Mounting 000022206RD 4
7 Washer Plain M6 000016559R2 4
8 Washer Spring M6 001233808R1 4
9 Drain Plug E006008222F1 1
10 Cowl Radiator E006007715F1 1
11 Intercooler Assembly Consists of E006008636F91 1
12 Trash Guard Intercooler E006007576F1 1
13 Intercooler E006007714F1 1
14 Bolt M6 x 16 Trash Guard Mounting 000022206RD 4
15 Washer Plain M6 000016559R2 4
16 Washer Spring M6 001233808R1 4
17 Bolt M8 x 20 Intercooler Mounting 000020307E05 4
18 Nut M8 Intercooler Mounting 000020777E05 2
19 Bolt M8 x 20 Radiator Mounting 000020307E05 4
20 Hose Thermostat to Radiator E006007227F1 1
21 Hose Radiator to Water Pump E006007429F1 1
22 Clip Hose Radiator 006004797F1 4
23 Surge Tank Assembly E006008515F91 1
24 Cap Surge Tank 006002259C1 1
25 Tube Surge Tank 006002261C1 1
26 Clip Surge Tank Tube 006004939C1 2
27 Surge TANK (Bottle) 006008392F1 1
28 Bracket Surge Tank 006008383F1 1
29 Bolt for Surge Tank Bracket M6 x 16 000020311E05 2
30 Washer Plain M6 000016559R2 2
31 Nut M6 000020796E05 2

PAGE NO.
142
FIGURE NO. 60

FLYWHEEL & REAR OIL SEAL

PAGE NO.
143
 FIGURE NO. 60

FLYWHEEL & REAR OIL SEAL

ITEM
DESCRIPTION PART NO. QTY.
NO.

A ASSEMBLY FLYWHEEL Consisting of : 006005681H91 1

1 RING GEAR ‡ 1

2 FLYWHEEL ‡ 1

4 PIN Dowel 000020269E05 1

5 BOLT M14 X 1.5 X 50 HEX (Flywheel Mtg Bolt) 000020305E05 6

6 PIN Dowel 005551963R1 2

7 PIN Dowel 8.0 M6 x 16 000020280E05 2

8 RETAINER Rear Oil Seal 000020541E05 1

9 BOLT Flanged Hex. Head M8 x 1.25 x 25 000020309E05 8

10 OIL SEAL Crankshaft Rear 006003835C1 1

PAGE NO.
144
FIGURE NO. 61

FIP, NOZZLES AND PIPINGS

PAGE NO.
145
 FIGURE NO. 61

FIP, NOZZLES AND PIPINGS

ITEM
DESCRIPTION PART NO. QTY.
NO.
1 GEAR Rotary FIP 006005226F1 1
2 GASKET FIP Mounting 006000222F1 1
3 STUD ROTARY FIP Mounting 006000557F1 3
4 WASHER PLAIN 120393 3
5 WASHER 5/16’’ Springlock 001082011R2 3
6 NUT FLANGED M8 x 1.25 grades 2077700000 3
7 BOLT BANJO 001232932R1 2
8 WASHER 000020710E05 4
9 PIPE Fuel Filter to FIP Inlet 006002766F1 1
PIPE LUBE OIL DRAIN VACUUM PUM TO FEED
10 006013539H1
PUMP

13 PIPE O/F Tank side 006000922F1 1

14 PIPE O/F FIP side 006000920F1 1
15 BANJO BOLT 000020704E05 1
16 BRACKET For Fuel Filter E006015370H1 1
17 BOLT M8X1.25X30 000020306E05 2
18 FLANGE HEX NUT M8X1 000020777E05 2
19 BOLT Hex. M10 X 1.5 X 20 000020565E05 2
20 GEAR FUEL FEED PUMP 006013534H1 1
21 HOUSING FEED PUMP 006013535H1 1
22 GASKET HOUSING FEED PUMP 000703851R1 1
23 FUEL FEED PUMP MECHANICAL 006013536H1 1
GASKET FUEL FEED PUMP 006013537H1 1
24 SCREW M5 x 20 001121502R1 2
25 U-CLAMP Top Plate 006002413F1 2
26 WASHER PLAIN 000020706E05 2
27 Z-CLAMP 006002449F1 1

PAGE NO.
146
FIGURE NO. 61

FIP, NOZZLES AND PIPINGS

PAGE NO.
147
 FIGURE NO. 61

FIP, NOZZLES AND PIPINGS

ITEM
DESCRIPTION PART NO. QTY.
NO.
28 BOLT Flanged M6 x 1 x 16 000020311E05 1
29 WASHER Spring Lock M6 001233808R1 1
30 NUT M6 x 1 001233807R1 1
31 FUEL Spill Pipe 006000639F1 1
32 CLIP CABLE 000708114R3 1
33 BOLT Flanged M8 x 1.25 000020308E05 1
34 FIP 006017943H1 1
BRACKET ROTARY FIP SUPPORT 006000814F1 1
35 HIGH PRESSURE Pipe Set 006013532H1 1
36 BOLT M6 x 16 000022206RD 1
37 CLAMP High Pressure Pipe 000022201RD 1
38 CLAMP High Pressure Pipe 000022202RD 1
39 WASHER Spring M6 001233808R1 1
40 NUT M6 x 1 Hex. 001233807R1 1
41 FUEL FILTER WITH WATER SEPARATOR 006007776F91 1
FUEL FILTER INSERT 006008904B1 1
WATER SENSOR 006008905B1 1
42 HOSE FEED PUMP TO MAIN FILTER 006013538H1 1

PAGE NO.
148
ENGINE MODEL
LR4108
FIGURE NO. 62

CYLINDER HEAD ASSEMBLY

PAGE NO.
150
 FIGURE NO. 62

CYLINDER HEAD ASSEMBLY

ITEM
DESCRIPTION PART NO. QTY.
NO.

Cylinder head assy. 4RTF01000000 1

Cylinder head with valve assembly 4R0101HJ0000 1

Rocker shaft assembly 4R0102000000 1

Valve rotocap assembly R01300Y00000 4

Rocker arm assembly R01025000000 8

1. Screw plug Z3/8" LR0102090000 2

2. Rocker shaft 4R0102010000 1

3. Bolt M10x85 GB227688ZnD0 4

4. Washer 10 GB84876ZnD00 8

5. Nut M10 GB5476ZnD000 8

6. Adjusting screw, rocker arm R01020800000 8

7. Nut M10 GB92376ZnD00 4

8. Rubber sealing ring R01001700000 4

9. Nut M10 GB5276ZnD000 4

10. Stud, rocker shaft seat R01001600000 4

11. Screw M6x16 GB7576000000 1

12. Nut M6 GB5276ZnD000 1

13. Seat, rocker shaft(oil feed) R01020500000 1

14. Spring, rocker shaft R01020200000 3

15. Seat, rocker shaft R01020600000 3

16. Washer, rocker shaft R01020400000 2

17. Spring, rocker shaft end R01020300000 2

18. Retaining ring 25 GB8947600000 2

19. Bush, rocker arm R010252A0000 8

20. Valve cap R01000600000 8

PAGE NO.
151
FIGURE NO. 62

CYLINDER HEAD ASSEMBLY

PAGE NO.
152
 FIGURE NO. 62

CYLINDER HEAD ASSEMBLY

ITEM
DESCRIPTION PART NO. QTY.
NO.

21. Valve collet R01000500000 16

22. Retainer, valve spring R010004Y0000 8

23. Oil hood, valve R010019Y0000 4

24. Upper seat, valve rotocap R010301Y0000 4

25. Thrust washer, valve rotocap spring R01030200000 4

26. Spring, valve rotocap R01030400000 4

27. Lower seat, valve R01030300000 4

28. Spacer, inlet valve spring R010015Y0000 4

29. Rocker arm R01025100000 8

30. Valve spring R010003y0000 8

31. Bolt, cylinder head R010007A1000 18

32. Washer, cylinder head bolt R01001200000 18

33. Nut M8 GB5276ZnD000 4

34. Spherical washer 8 GB84976ZnD00 4

35. Stud, clamp plate R01001800000 4

36. Clamp plate, injector R01000800000 4

37. Cover, cap, side water outlet RT0100210000 1

38. Gasket, thermostat 6RTIIIR5300040 1

39. Screw plug 1/2" YTQ021187000 1

40. Bolt M10x20 GB2176ZnD000 8

41. Spring washer 10 GB9376000000 8

42. Cylinder head mechanical assembly 4R010100Y000 1

42.1 Cylinder head 4R0101010000 1

42.2 Bowl plug 10 R01010700000 4

42.3 Valve guide R01010400000 8

PAGE NO.
153
FIGURE NO. 62

CYLINDER HEAD ASSEMBLY

PAGE NO.
154
 FIGURE NO. 62

CYLINDER HEAD ASSEMBLY

ITEM
DESCRIPTION PART NO. QTY.
NO.

42.4 Bowl plug 24 R01010800000 4

42.5 Bowl plug 42 R01010500000 1

42.6 Seat ring, inlet valve R010102Y0000 4

42.7 Seat ring, exhaust valve R01010300000 4

42.8 Bowl plug 35 R01010600000 3

43 Gasket, thermostat LH4110010011A 1

43.1 Gasket, thermostat RW4110010011 1

44. Inlet valve R010001Y0000 1

45. Exhaust valve R01000200000 1

46. Gasket water return adaptor R01000200000 1

47. Cover, water return hole 6RTIII01002600 1

48. Hoisting ear R01000900000 2

49. Hoisting sleeve LH0101090000 4

50. Injector stud bolt LH0101110000 4

51. Water outlet gasket(Front) R01002400000 1

52. Water outlet cover(Cover) 4R0100023FE0 1

PAGE NO.
155
FIGURE NO. 63

CYLINDER BLOCK ASSEMBLY

PAGE NO.
156
 FIGURE NO. 63

CYLINDER BLOCK ASSEMBLY

ITEM
DESCRIPTION PART NO. QTY.
NO.

Cylinder block assy. 4RAT02000000 1

1. Cylinder block mechanical assembly 4RAT02010000 1

Cylinder block mechanical assembly 4RAT30201000 1

1.1 Camshaft block R01000200000 1

1.2-1 Cylinder block 4RBAQ0201001FE 1

1.2-2 Cylinder block 4RBAT0201001FEZ 1

1.2-3 Cylinder block RW4110Q020101 1

1.3 Bowl plug Ø50 LH0101110000 1

1.4 Camshaft bearing R02010700000 4

1.5 Plug 60 QSB144640000 1

1.6 Cap, rear main bearing LR0201110000 1

1.7 Washer, main bearing bolt R02010500000 10

1.8 Bolt, main bearing R02010400000 10

1.9 Cap, locating main bearing LR0201030000 1

1.10 Mian bearing cap LR0201020000 3

1.11 Screw plug Z 1/8" YTQ021187000 4

2. Dowel, cylinder block upper front face R02002300000 1

3. Gasket, push rod chamber cover 4R0200090000 1

4. Cover, front push rod chamber 4R020008A000 1

5. Sealing washer R01001700000 4

6. Nut 10 GB92376ZnD00 4

7. Stud, push rod chamber cover R02001100000 4

8. Dowel, cylinder block top face R02002100000 3

Drain pipe assembly, crankcase

9. LR0203000000 1
ventilation

10-1 Cylinder liner RAZ102000100 4

PAGE NO.
157
FIGURE NO. 63

CYLINDER BLOCK ASSEMBLY

PAGE NO.
158
 FIGURE NO. 63

CYLINDER BLOCK ASSEMBLY

ITEM
DESCRIPTION PART NO. QTY.
NO.

10-2 Cylinder liner RBA020001000 4

10-3 Cylinder liner RW1100200010 4

11. Sealing ring, cylinder liner Ra0200023000 12

12. Hollow dowel, cylinder block rear face R02001500000 2

13. Nozzle, rear oil sealing R02000400000 1

14. Drain cock assy, radiator LR0204000000 1

14.1 Clamp LR020402A000 1

14.2 Handle LR0204010000 1

14.3 Water valve LR0204500000 1

14.4 Cotter pin 2.5x20 GB9186000000 1

15. Thrust shell(top/bottom), main bearing LR0200434400 1

16. Drain tube, main oil passage relief valve R02001200000 1

17. Bottom shell, main bearing R02004142000 4

18. Dowel, cylinder block bottom face R02002700000 2

19. Screw plug Z3/8" LR0102090000 2

20. Gasket, feeding water adaptor R02001700000 1

21. Cover plate 6RTIII02002800 1

22. Feeding water adaptor, oil cooler LR0202000000 1

23. Spring washer 10 GB9376000000 4

24. Bolt M10x25 GB217ZnD000 4

25. Connector, oil pressure sensor 6RQ202000000 1

26. Piston cooling nozzle RW0202000000 4

27. Nozzle bolt RW0200030000 4

28. Gasket 6RAZL0200060 4

29. Spring washer BII0490000000 4

PAGE NO.
159
FIGURE NO. 64

CAMSHAFT ASSY.

PAGE NO.
160
 FIGURE NO. 64

CAMSHAFT ASSY.
ITEM
DESCRIPTION PART NO. QTY.
NO.

Camshaft assy. 4R030000Y000 1

1. Push rod R03000300000 8

2. Tappet R03000200000 8

3. Camshaft 4R030001Y000 1

4. Semi-circular key 6x22 GB1099790000 1

5. Thrust, camshaft R03000400000 1

6. Bolt M8x20 GB2176Y00000 2

PAGE NO.
161
FIGURE NO. 65

CRANKSHAFT AND FLYWHEEL ASSY.

PAGE NO.
162
 FIGURE NO. 65

CRANKSHAFT AND FLYWHEEL ASSY.

ITEM
DESCRIPTION PART NO. QTY.
NO.

Crankshaft and flywheel assy. 4RTF04000000 1

1. Crankshaft jaw 5404417A0000 1

2. Plate, crankshaft jaw LR0400070000 1

3. Crankshaft pulley 4RG104000310 1

4. Semi-circular key 10x38 GB1099720000 2

5. Crankshaft assembly. L4R04023IHJ0 1

5.1 Screw plug Z 1/8" LR0201090000 4

5.2-1 Crankshaft L4R0403IHJ00 1

5.2-2 Crankshaft 4RC040001000 1

6. Retaining ring 4RTF04001000 1

7. Flywheel assembly 4RTF04001001 1

Flywheel assembly 4RT304010030 1

8. Pin 14gax30 GB1197600000 1

9. Washer, flywheel bolt R04000500000 1

10. Bearing 803030000000 1

11. Flywheel bolt LR0400090000 7

12. Flywheel assembly 4RG304010000 1

13. FLywheel ring 4RG304010001 1

PAGE NO.
163
FIGURE NO. 66

PISTON AND CONNECTING ROD ASSY.

PAGE NO.
164
 FIGURE NO. 66

PISTON AND CONNECTING ROD ASSY.

ITEM
DESCRIPTION PART NO. QTY.
NO.

Piston and connecting rod assembly RA0500000000 1

1. Bolt, connecting rod RA0501040000 8

2. Shell, connecting rod RZ0500050000 8

3. Connecting rod mechanical assy. RA0501000000 4

3.1 Cap, connecting rod RA0501020000 4

3.2 Dowel LR0501050000 4

3.3 Body, connecting rod RA0501010000 4

3.4 Bush, connecting rod R050103A0000 4

4. Retaining ring 36 GB8937600000 8

5. Piston pin RA0500040000 4

6-1 Piston RA0500010000 4

6-2 Piston RC050001Y100 4

6-3 Piston RB0500011000 4

6-4 Piston RCB050001000 4

6-5 Piston LR1100500010 4

7-1 Piston wreath RA0500023020 4

7-2 Piston wreath RAZL050002302 4

7-3 Piston wreath RB0500023020 4

7-4 Piston wreath RW110050002302 4

7-5 Piston wreath RBZL050002302 4

PAGE NO.
165
FIGURE NO. 67

GEAR TRAIN ASSY.

PAGE NO.
166
 FIGURE NO. 67

GEAR TRAIN ASSY.

ITEM
DESCRIPTION PART NO. QTY.
NO.

Gear tain assy. RT0600001000 1

1. Plug RT0600270000 1

2. Sealing ring RT0600190000 1

3. Driving gear shaft, hydrolic pump LRT060024100 1

4. Gasket, hydrolic pump LRT060029000 1

5. Cap board RT060029000 1

6. Spring washer 8 GB9796000000 4

7. Bolt M8x30 GB2276ZnD000 4

8. Bolt M12x55 GB2276880000 1

9. Spring washer 12 GB9376000000 1

10. Retaining ring, camshaft gear R06000400000 1

11. Air compressor gear R060021A0000 1

12. Retaining ring 25 GB8947600000 1

13. Thrust plate, hydrolic pump gear RT0600261000 1

14. Driving gear, hydrolic pump RT061101A000 1

15. Driving gear push, hydrolic pump RT0611020000 1

16. Driving splined sleeve, hydrolic pump RT0600250000 1

17. Retaining ring 25 GB8947600000 1

18. Bolt M10x30 GB2176000000 5

19. Thrust plate washer, hydrolic pump RT0600320000 3

20. Camshaft gear R060003A0000 1

21. Bolt M10x65 GB2276880000 2

22. Locking washer R06003100000 1

PAGE NO.
167
FIGURE NO. 67

GEAR TRAIN ASSY.

PAGE NO.
168
 FIGURE NO. 67

GEAR TRAIN ASSY.

ITEM
DESCRIPTION PART NO. QTY.
NO.

23. Thrust plate, idle gear R06001100000 1

24. Idle gear shaft R06000900000 1

25. Crankshaft gear LR060001A000 1

26. Idle gear assembly R060100A000 1

27. Driving gear, oil pump R060002A2000 1

28. Injection pump gear LR060005A000 1

29. Bolt M8x30 GB2276880000 4

30. Retaining plate, injection pump gear LR0600070000 1

31. Screw, lubrication oil passages R06000231000 2

32. Washer, overflow fuel pipe adaptor srew R32000200000 6

33. Fix plate, oil supply pipe RT0602230000 2

34. Oil pipe assembly, timing gear RT0602000000 1

35. Screw, lubrication oil passages R06001200000 1

36. Screw, lubrication oil passages RT0600220000 1

37. Cylindrical head screws M5x12 GB6576000000 2

38. Timing plate, injection pump LR0600080000 1

39. Hub injection pump gear LR0600060000 1

40. Washer, elbow adaptor 540245300000 2

PAGE NO.
169
FIGURE NO. 68

SUMP ASSY. (III)

PAGE NO.
170
 FIGURE NO. 68

SUMP ASSY. (III)

ITEM
DESCRIPTION PART NO. QTY.
NO.

Sump assy. 4RG120700000 1

1. Gasket sump 4RG107000400 1

2. Sump 4RG120700010 1

3. Spring washer 1 GB9376000000 23

4. Bolt M10x35 GB217688ZnD0 23

5. O-seal ring 35x3.1 YTQ020286000 1

6. Oil drain plug assy. 6RQJ07010000 1

7. Sleeve, dipstick 4RG307030000 1

8. Dipstick assembly 4RG307040000 1

9. Screw plug NPT 1/2" YTQ021186000 1

PAGE NO.
171
FIGURE NO. 69

TIMING GEAR CHAMBER ASSY.

PAGE NO.
172
 FIGURE NO. 69

TIMING GEAR CHAMBER ASSY.

ITEM
DESCRIPTION PART NO. QTY.
NO.
Timing gear chamber assy. 4RTF08000000 1
1. Washer 10 GB84876ZnD00 33
2. Bolt M10x70 GB2276ZnD000 7
3. Pin 8gax16 GB1197600000 2
4. Gasket, inspection hole cover R08000500000 1
5. Inspection hole cover R08000400000 1
6. Bolt M8x35 GB2176ZnD000 2
7. Washer 8 GB84876ZnD000 9
8. Bolt M8x22 GB2176ZnD000 5
9. Oil sealing 65x90x12 LR0801500000 1
10. Bolt M10x60 GB2276ZnD000 2
11. Bolt M10x90 GB2176ZnD000 2
12. Bolt M8x18 GB2176ZnD000 4
13. Cover plate RT0600280000 1
14. Gasket, hydrolic pump LRT060029000 1
15. Bolt M10x50 GB2276ZnD000 2
16. Cover assembly, timing gear chamber 3RTF080100A0 1
16.1 Screw plug 3RTF08010500 1
16.2 Washer 18 GB9576000000 1
16.3 Cover assembly, timing gear chamber 3RTF08010100 1
16.4 Oil filter R08010210000 1
17. Gasket, timing gear chamber cover RT0800030000 1
18. Timing gear chamber RT0800011000 1
19. Sealing plate, air compressor R08001100000 1
20. Screen R08000800000 1
21. Cover, oil filter R08001500000 1
Gasket, timing gear chamber
22. RT0800020000 1
RT0800020000
23. Bolt M10x30 GB2176ZnD000 18

PAGE NO.
173
FIGURE NO. 70

FLYWHEEL HOUSING ASSY. (I)

PAGE NO.
174
 FIGURE NO. 70

FLYWHEEL HOUSING ASSY. (I)

ITEM
DESCRIPTION PART NO. QTY.
NO.

Flywheel housing assy. 4RTF09000010 1

Flyhweel housing assy. 4RG140900000 1

1. Intermediate plate 4RTF09000910 1

2. o-seal ring LR0900080000 1

3. Oil seal 105x130x12 LR0901000000 1

4. Flywheel housing 4RTF09000120 1

Flywheel housing 4RG140900010 1

5. Washer 10 GB9376000000 7

6. Bolt M10x30 GB2176000000 7

7. Cover plate, gear shaft hole 4RTF09000400 1

PAGE NO.
175
FIGURE NO. 71

FLYWHEEL HOUSING ASSY. (II)

PAGE NO.
176
 FIGURE NO. 71

FLYWHEEL HOUSING ASSY. (II)

ITEM
DESCRIPTION PART NO. QTY.
NO.

Flywheel housing assy. 4RT309000020 1

1. Oil seal 105x130x12 LR0901000000 1

2. O-ring LR0900080000 1

3. Bolt M14x50 GB5782860000 8

4. Washer 14 GB9387000000 8

5. Flywheel housing 4RT30900012A 1

6. Intermediate plate 4RTF09000910 1

7. Observation port cover 4RG109000300 1

8. Washer 6 GB9387000000 2

9. Bolt M6x12 GB5781860000 2

10. Screw M4x10 GB6785000000 2

11. Pointer 4RG109000400 1

12. Bolt M10x30 GB5783860000 7

13. Washer 10 GB9387000000 7

14. Washer 16 GB9387000000 2

15. Bolt M16x90 GB5782860000 2

PAGE NO.
177
FIGURE NO. 72

CYLINDER HEAD HOOD ASSY.

PAGE NO.
178
 FIGURE NO. 72

CYLINDER HEAD HOOD ASSY.

ITEM
DESCRIPTION PART NO. QTY.
NO.

Cylinder head hood assy. L4R110000000 1

1. Hood, cylinder head 4RT62110100A1 1

2. Sealing gasket, cylinder head hood L4R110001000 1

3. Cover, oil filter 4RG111030000 1

PAGE NO.
179
FIGURE NO. 73

CRANKCASE VENTILATION ASSY.

PAGE NO.
180
 FIGURE NO. 73

CRANKCASE VENTILATION ASSY.

ITEM
DESCRIPTION PART NO. QTY.
NO.

Crankcase ventilation assy. 4RG112000010 1

1. Exhaust pipe, ventilation 6RG612030100 1

2. Connecting rubber hose 4R1200030000 2

3. Hoop JK1A00000000 4

4. Gasket, push rod chamber cover 4R0200090000 1

Oil-air seperator and rear push rod

5. 4RG112010010 1
chamber cover assemblt

6. Rubber hose R12000200000 2

7. Upper oil return pipe, crankcase R12000110000 1

8. Hoop JK0000000000 4

PAGE NO.
181
FIGURE NO. 74

INTAKE TUBE ASSY. (I)

PAGE NO.
182
 FIGURE NO. 74

INTAKE TUBE ASSY. (I)

ITEM
DESCRIPTION PART NO. QTY.
NO.

Intake manifold assy. 4RTF22000010 1

Intake manifold assy. 4RT722000000 1

1. Bolt M10x16 GB2176ZnD000 8

2. Spring washer 10 GB9376000000 20

3. Rear cover, intake manifold 4RG222020000 1

4. Gasket, intake manifold 4RG122000200 3

5. Intake manifold 4RG122000100 1

6. End cover, intake manifold 4RG122000400 1

7. Connecting tube, intake manifold 4RTF22000500 1

8. Bolt M10x25 GB2176ZnD000 4

9. Bolt M10x35 GB2176ZnD000 8

10. Gasket, intake manifold R22000300000 4

11. Name plate LR070009A000 1

12. Rivet 4x6 GB8277600000 4

13. Screw plug air intake 4GB8277600000 1

14. Washer 160620000000 1

15. Connecting tube air intake 4RG122201020 1

16. Connecting tube air intake 4RG822000700 1

17. Connecting tube air intake 4RG122010000 1

PAGE NO.
183
FIGURE NO. 74

MUFFLER ASSY. (II) / EXHAUST TUBE ASSY. (III)

PAGE NO.
184
 FIGURE NO. 75

MUFFLER ASSY. (II) / EXHAUST TUBE ASSY. (III)

ITEM
DESCRIPTION PART NO. QTY.
NO.

1. Exhaust manifold 4R2300010000 1

2. Exhaust manifold gasket LR230002A000 4

3. Washer 10 GB9718500000 11

4. Bolt M10x35 GB5781860000 8

5. Exhaust bend 4RT323000400 1

6. Bolt M10x30 GB5781860000 3

7. Bend gasket LR230003A000 1

8. Bolt M8x25 551201020000 1

9. Bolt M8x25 Gb5781890000 1

10. Washer 8 GB9386000000 1

11. Nut M8 GB6170860000 1

12. Clamp with bracket assy. 551201040000 1

13. Thrust washer 551201031000 2

14. Exhaust cap with rock arm 551201051000 1

15. Washer 8 GB971850000 2

16. Clevis pin 551201032000 1

17. Cotter pin 3.2x16 GB9186000000 2

18. Exhaust bend 4RG323000400

PAGE NO.
185
FIGURE NO. 76

ZHB INJECTION PUMP ASSY.

PAGE NO.
186
 FIGURE NO. 76

ZHB INJECTION PUMP ASSY.

ITEM
DESCRIPTION PART NO. QTY.
NO.

1. Nut ZHBF61001600 1

2. Spring washer 14 Gb9387000000 1

3. Woodruff key ZHB039000000 1

4. Body, fuel injection pump ZHBF40000000 1

5. Plunger pair ZHE9540Z0010 4

6. Washer ZHB025000000 4

7. Delivery valve pair ZHF600000000 4

8. Washer, fuel outlet valve seat ZHB024000000 4

9. Spring, fuel outlet valve BII207A000000 4

10. Volume reducer BII2080000000 4

11. Sealing ring ZHB017000000 4

12. Delivery valve holder ZHBF61002900 4

13. Washer BII0440000000 4

14. Air-vent screw BII0532000000 2

15. Washer 8120F0104200 1

16. Screw plug ZHBF61001500 1

17. Washer BII0440000000 2

18. Screw plug ZHB038000000 2

19. Gasket, feed pump BII019A000000 1

20. Spring washer 6 GB9387000000 3

21. Bolt M6x16 GB5783860000 3

PAGE NO.
187
FIGURE NO. 77

FEED PUMP ASSY.

PAGE NO.
188
 FIGURE NO. 77

FEED PUMP ASSY.

ITEM
DESCRIPTION PART NO. QTY.
NO.

1. Feed pump assy. BII0603A00000 1

2. Pipe joint bolt 16110B000000 1

3. Washer 160060000000 4

4. Feed pump valve 16123D000000 2

5. Spring feed pump valve BII0690000000 2

6. Washer 160620000000 2

7. Outlet pipe joint seat BII0680000000 1

8. Pipe joint bolt 16110B000000 1

PAGE NO.
189
FIGURE NO. 78

TA GOVERNOR ASSY.

PAGE NO.
190
 FIGURE NO. 78

TA GOVERNOR ASSY.

ITEM
DESCRIPTION PART NO. QTY.
NO.

1. Governor assy. TA1300000000 1

2. Screw plug ZHB038000000 1

3. Washer BII0440000000 1

4. Washer 161590000000 1

5. Breather seat TA0001900000 1

6. Washer 421915500000 1

7. Breather assy. TA0006000000 1

8. Bush, stop shaft TA0000200000

9. Torsion spring TA0000500000

10. Stop handle TA0000400000

11. Washer 6 GB9387000000 2

12. Nut M6 GB6170860000 1

13. Washer BII0440000000 1

14. Stop screw, control rod TA00008A0000 1

15. Nut M6 GB6170860000 1

16. Washer 6 GB9387000000 1

17. Screw TII0750000000 1

PAGE NO.
191
FIGURE NO. 79

FUEL INJECTOR ASSY.

PAGE NO.
192
 FIGURE NO. 79

FUEL INJECTOR ASSY.

ITEM
DESCRIPTION PART NO. QTY.
NO.

Fuel injector assy. R32000000000 1

1. Protection cap, fuel inlet hole PB86J0000800 1

2. Case, injector PB86J0000100 1

3. Protecting plug, fuel return hole PB86J0000310 1

4. Pressure adjusting shims PB86J00011026 As required

5. Spring, injector PB86J0000200 1

6. Spring retainer PB86J0000600 1

7. Connecting plate assembly PB86J0001000 1

Dowel pin, injector PB86J00007A0 2

Connecting plate PB86J0000500 1

Dowel pin, nozzle PB86J0002800 2

Dowel pin, nozzle PB86J00007A0 2

8. Nozzle ZCK150J43000A 1

ZCK150J42T0001
Needle 1
A

Nozzle body ZCK150J4300002 1

9. Nut, injector PB86J0000400 1

10. Protecting sleeve, injector PB86J0000900 1

11. Washer, injector R32000100000 1

PAGE NO.
193
FIGURE NO. 80

FUEL FILTER INSTALLATION ASSY.

PAGE NO.
194
 FIGURE NO. 80

FUEL FILTER INSTALLATION ASSY.

ITEM
DESCRIPTION PART NO. QTY.
NO.

1. Bolt, fuel pipe C0810A001100 1

2. Washer C0810A000900 7

3. Filter seat CX0708S00100 1

4. Washer 10 GBT931987000 2

5. Bolt M10x28 GBT578320000 2

6. Air-bleed screw plug C0708S00500 1

7. Spring washer C0506B001700 1

8. Bolt, fuel pipe 541842700000 1

9. Fuel filter CX0708S00000 2

10. Screw plug C0708S100040 2

11. Sealing washer C07080000000 2

12. Fuel filter assy. 2CX0708S0000 1

PAGE NO.
195
FIGURE NO. 81

FUEL INJECTION PIPES ASSY. (I) /

FUEL LOW PRESSURE PIPES INSTALLATION ASSY. (I)

PAGE NO.
196
 FIGURE NO. 81

FUEL INJECTION PIPES ASSY. (I) /

FUEL LOW PRESSURE PIPES INSTALLATION ASSY. (I)
ITEM
DESCRIPTION PART NO. QTY.
NO.

Fuel injection pipes assy. L4R340000A00 1

Clamp assy, for 3 fuel injection pipes R34060000000 2

Clamp assy, for 2 fuel injection pipes R34070000000 1

Fuel low pressure pipes assy. 4RTF35000020 1

Fuel low pressure pipes assy. 4RG835000000 1

1. Screw M4x10 GB6576ZnD000 3

2. Clamp plate R34060100000 2

3. Rubber pad R34060200000 4

4. Base weldment, clamp R34065000000 2

5. Fuel injection pipe assembly, cylinder No. 1 L4R340100A00 1

6. Clamp plate R34070100000 1

7. Fuel injection pipe assembly, cylinder No. 2 L2R340200A00 1

8. Rubber pad R34070200000 2

9. Base weldment, clamp R34075000000 1

10. Fuel injection pipe assembly, cylinder No. 3 L4R340300A00 1

11. Fuel injection pipe assembly, cylinder No. 4 L4R340400A00 1

12. Fuel return pipe, fuel injector 4RTF35040000 1

Fuel return pipe, fuel injector 4RG12350600A 1

13. Fuel return pipe, fuel injector RT3505000000 1

Fuel return pipe, fuel injector 4RG123507000 1

Fuel supply pipe assembly, No.

14. 3RTII35010000 1
4(L=650mm)

Fuel supply pipe assembly, No.

15. 4RTII35040000 2
3(L=650mm)

PAGE NO.
197
FIGURE NO. 82

FUEL INJECTION PIPES ASSY. (II) /

FUEL LOW PRESSURE PIPES INSTALLATION ASSY. (II)

PAGE NO.
198
 FIGURE NO. 82

FUEL INJECTION PIPES ASSY. (II) /

FUEL LOW PRESSURE PIPES INSTALLATION ASSY. (II)
ITEM
DESCRIPTION PART NO. QTY.
NO.

1. Fuel supply pipe assembly, No. 3 4RTII35040000 1

2. Tie band ZDW150600000 2

3. Adaptor, bend pipe 8120F1512800 2

4. Fuel supply pipe assembly, No. 4 3RTII35010000 1

5. Fuel return pipe, fuel injector 4RG1235010000 1

Fuel injection pipe assembly, cylinder No.

6. L4R340400A00 1
4

Fuel injection pipe assembly, cylinder No.

7. L4R340300A00 1
3

Fuel injection pipe assembly, cylinder No.

8. L4R340200A00 1
2

Fuel injection pipe assembly, cylinder No.

9. L4R340100A00 1
1

Screw M4x10 GB6576ZnD000 3

Clamp plate R34060100000 2

Rubber pad R34060200000 2

Base weldment, clamp R34065000000 2

Clamp plate R34070100000 1

Rubber pad R34070200000 2

Base weldment, clamp R34075000000 1

PAGE NO.
199
FIGURE NO. 83

OIL PUMP INSTALLATION ASSY. /

OIL SUCTION STRAINER ASSY.

PAGE NO.
200
 FIGURE NO. 83

OIL PUMP INSTALLATION ASSY. /

OIL SUCTION STRAINER ASSY.
ITEM
DESCRIPTION PART NO. QTY.
NO.

1. Oil pump assy. 4RHZQ4100000 1

2. Flat ket C5x12 GB1096790000 1

3. Spring washer 12 GB9376000000 1

4. Nut M12 GB5276000000 1

5. Spring washer 10 GB9376000000 2

6. Bolt M10x30 GB2176000000 2

7. O-rubber sealing ring R41000100000 2

8. Pressure relies valve LR4121000000 1

9. Oil saction strainer 4RG144200000 1

10. Spring washer 10 GB8487600000 1

11. Spring washer 10 GB9376000000 1

12. Bolt M10x20 GB2176000000 1

13. Gasket oil suction pipe flange R42000100000 1

14. Spring washer 8 GB9376000000 2

15. Bolt M8x25 GB2176000000 2

PAGE NO.
201
FIGURE NO. 84

OIL FILTER ASSY.

PAGE NO.
202
 FIGURE NO. 84

OIL FILTER ASSY.

ITEM
DESCRIPTION PART NO. QTY.
NO.

1. Bottom gasket R43000100000 1

2. Oil filter bottom 4RTF43010010 1

3. Spring washer 10 GB9376000000 4

4. Bolt M10x40 GB2276000000 3

5. Bolt M10x80 GB2276000000 1

6. Oil cooler assy. 4RG2245010011 1

7. Oil filter JX1008L00000 1

PAGE NO.
203
FIGURE NO. 85

WATER PUMP INSTALLATION ASSY. /

FAN AND PULLEY ASSY.

PAGE NO.
204
 FIGURE NO. 85

WATER PUMP INSTALLATION ASSY. /

FAN AND PULLEY ASSY.
ITEM
DESCRIPTION PART NO. QTY.
NO.

Water pump assy. 6RTF51000100 1

Fan and pulley assy. 4RT352000000 1

1. Gasket, water pump housing 6RTF510003AZ 1

2. Water pump assy. 4RT125100000 1

3. Spring washer 10 GB9376000000 6

4. Bolt M10x30 GB2176000000 4

5. Belt pulley, water pump 3R5200020000 1

6. Spring washer 12 GB9576000000 1

7. Nut M8x1 GB5976000000 1

8. Pin 3x25 GB9176000000 1

9. Fan 6RTIII52010000 1

10. Spring washer 8 GB9376000000 4

11. Bolt M8x20 GB2176000000 4

12. Blet A1340 4RG352000100 1

13. Bearing GB2788200000 2

14. IIF17 Water seal II17000000000 1

PAGE NO.
205
FIGURE NO. 86

THERMOSTAT ASSY.

PAGE NO.
206
 FIGURE NO. 86

THERMOSTAT ASSY.
ITEM
DESCRIPTION PART NO. QTY.
NO.

Thermostat assy. 4RTF53000000 1

1. Bolt M8x25 GB2176ZnD000 2

2. Spring washer 8 GB9376000000 2

3. Cap, thermostat 4RTF53000100 1

4. Gasket, thermostat cap 4R5300020000 1

5. Thermostat 103382X00000 1

6. Thermostat housing 4RTF53010000 1

Thermostat body 4RTF53010100 1

Bypass connector R51010200000 1

7. Gasket, thermostat housing 4R5300040000 1

8. Spring washer 10 GB9376000000 2

9. Bolt M10x35 GB2176ZnD000 2

10. Hose 4R5300030000 1

11. Hoop, rubber hose JK1X00000000 2

PAGE NO.
207
FIGURE NO. 87

RADIATOR INSTALLATION ASSY.

PAGE NO.
208
 FIGURE NO. 87

RADIATOR INSTALLATION ASSY.

ITEM
DESCRIPTION PART NO. QTY.
NO.

1. Hose engine to radiator 180501040200 1

2. Hose clamp Ø45 955400450600 4

3. Hose radiator to engine 180501040100 1

4. Radiator assy AF 50D 180501040000 1

5. Radiator cover AF 50D 180501060000 1

6. Gromet for radiator 180304030250 1

7. Bolt Hex-M10X35,GR 8.8. 901101012070 4

8. Washer Spring 10 901611000000 4

9. Hex Nut M10 901201002000 4

10. Washer 10 901601000000 4

PAGE NO.
209
FIGURE NO. 89

STARTER INSTALLATION ASSY. /

ALTERNATOR AND BRACKET ASSY.

PAGE NO.
210
 FIGURE NO. 89

STARTER INSTALLATION ASSY. /

ALTERNATOR AND BRACKET ASSY.
ITEM
DESCRIPTION PART NO. QTY.
NO.

Starter installation assy. 6RQ261000000 1

1. Spring washer 12 GB9376000000 3

2. Bolt M12x35 GB2176ZnD000 3

3. Starter QD154E00WX00 1

Starter QD263E00WX00 1

Alternator and bracket assy. 6RTF62000000 1

4. Washer 8 GB84876ZnD00 4

5. Bolt M8 R62000200000 1

6. Bolt M8x35 GB227688Zn00 1

7. Adusting bracket, alternator 6RTF620001AB 1

Adusting bracket, alternator 4RG126200011 1

8. Nut M8 GB5276ZnD000 2

9. Alternator 6R6201000000 1

Alternator (24V, 500W) 4RG126201000 1

PAGE NO.
211