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521D, 621D, 721D

Tier II
Wheel loaders

CARES MANUEL
Machine Location
Job Code manual

Cre 9-88990
 Copyright ©

Copyright  2003 CNH France S.A.

Printed in France
Cre 9-88990 September 2003
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TABLE OF CONTENTS 0-1

Page
Jobe Code

GENERAL 1
Description of CARES system machine locations and job codes 1-1
Machine location and prime part 1-2
Job codes 1-3
Job time 1-3
Troubleshooting time 1-4
Welding time 1-4
No job time provided (open box) 1-4
Definition of terms used 1-5
Service codes 1-6
Request for supplementary Job Code or modification of time allowed 1-8

ENGINE 2
MAINTENANCE xxxxxx
TROUBLESHOOTING xxxxxx
REMOVAL AND INSTALLATION OR OVERHAUL xxxxxx
RADIATOR & COOLING HOSES 020411
SHROUDS AND SCREENS 020413
FAN, BELT 020415
WATER PUMP AND HOUSING 020417
WATER MANIFOLDS, OUTLETS, THERMOSTATS 020419
AIR CLEANER AND PRECLEANERS 020421
AIR INTAKE HOSES AND TUBES 020423
TURBOCHARGER 020425
INTAKE MANIFOLDS, AFTERCOOLER 020427
COLD STARTING AIDS 020429
EXHAUST MUFFLERS AND EXTENSIONS 020431
EXHAUST MANIFOLDS AND PIPES 020433
VALVE COVER AND BREATHERS 020441
ROCKER ARM ASSEMBLY AND PUSH RODS 020443
CYLINDER HEADS 020445
VALVES, SEATS AND GUIDES 020447
SLEEVES, PISTONS AND RINGS 020451
CONNECTING RODS, BEARINGS AND CONNECTING ROD PINS 020455
CRANKSHAFT PULLEY, TIMING COVER AND SEAL 020461
TIMING GEARS 020463
CAMSHAFT, BUSHINGS AND LIFTERS 020465
CRANKSHAFT, MAIN BEARINGS AND SEALS 020467
ENGINE BLOCK CASTING 020468
FLYWHEEL AND HOUSING 020469
OIL PAN AND DIPSTICK 020471
OIL PUMP 020473
HEAT EXCHANGERS, OIL FILTER AND BASE 020475
EXTERNAL LUBRIFICATION TUBES AND HOSES 020477

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TABLE OF CONTENTS 0-2

FUEL SYSTEM 3
MAINTENANCE xxxxxx
TROUBLESHOOTING xxxxxx
FUEL TANK 030411
FUEL LINES, TUBES AND HOSES 030413
FUEL TRANSFER (LIFT) PUMP 030415
FUEL COOLERS 030417
FUEL FILTERS 030421
FUEL INJECTION PUMP 030431
FUEL INJECTOR LINES 030433
FUEL INJECTORS 030435
FUEL SHUTOFF AND THROTTLE 030443

ELECTRICAL SYSTEM 4
TROUBLESHOOTING xxxxxx
R&I OR OVERHAUL xxxxxx
CHASSIS WIRING 040120
ENGINE WIRING 040140
CAB/OPERATOR COMPARTMENT WIRING 040170
CIRCUIT BREAKERS/RELAYS 040510
FUSES 040520
IGNITION/KEY SWITCH 041512
FUEL SHUTOFF CONTROL 041513
MACHINE FUNCTION CONTROLS 041515
POWER RELAYS 041531
ENGINE OIL PRESSURE 042011
BATTERY VOLTAGE 042014
MACHINE FUNCTIONS 042015
HORN 042031
STARTER MOTOR 042510
BATTERY CIRCUIT 042550
ALTERNATOR CIRCUIT 043010
REGULATOR AND RECTIFIER 043030
HEADLIGHT CIRCUIT 043510
STOPLIGHT/TAILLIGHT CIRCUIT 043520
TURN SIGNAL/HAZARD (FLASHER) LIGHT CIRCUIT 043530
WORK LIGHT CIRCUIT 043550
DOME/PANEL LIGHT CIRCUIT 043560
SAFETY (BEACON) LIGHT CIRCUIT 043570
BLOWER MOTOR CIRCUIT (HEATER/AIR CONDITIONER) 044010
WIPER MOTOR CIRCUIT 044020
AUXILIARY MOTOR CIRCUIT 044050
BACKUP ALARM CIRCUIT 044510
COLD START AIDS 044550
RADIO/SOUND SYSTEM 044570
OPERATOR CONVENIENCE AND ACCESSORIES 044580
HEIGHT (LIFT) CONTROL CIRCUIT 046031
BUCKET (RETURN-TO-DIG) CONTROL CIRCUIT 046032
TRANSMISSION CONTROL CIRCUIT 046039
ENGINE - ELECTRONIC FUEL CONTROL 046041
MACHINE FUNCTION MONITORS 047011

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TABLE OF CONTENTS 0-3

STEERING SYSTEM 5
TROUBLESHOUTING xxxxxx
STEERING WHEEL AND COLUMNS 050110
ARTICULATION PIVOTS 050550
AUXILIARY STEERING PUMP 050723
PUMP TO VALVE LINES 050733
RETURN LINES 050735
COOLING SYSTEM 050737
MAIN RELIEF VALVE 050741
STEERING CONTROL VALVE (HAND PUMP) 050743
CIRCUIT RELIEF VALVE 050745
FLOW/PRESSURE DIVIDER VALVES 050747
CHECK VALVES 050749
VALVE TO CYLINDER LINES 050751
AUXILIARY STEERING LINES 050755
STEERING CYLINDERS 050761
OIL COOLER 050771

POWERTRAIN 6
MAINTENANCE xxxxxx
TROUBLESHOOTING xxxxxx
REMOVAL & INSTALLATION OR OVERHAUL xxxxxx
TORQUE CONVERTERS 061010
POWERSHIFT TRANSMISSION RESERVOIR AND FILTERS 062311
POWERSHIFT PUMPS 062313
POWERSHIFT TRANSMISSION HYDRAULIC LINES/FITTINGS 062315
POWERSHIFT TRANSMISSION CONTROL VALVE 062317
TRANSMISSION OIL COOLER 062319
POWERSHIFT TRANSMISSION CLUTCH PACKS 062321
SHAFTS/BEARINGS/BUSHINGS 062323
POWERSHIFT TRANSMISSION HOUSING 062335
DIFFERENTIAL AND AXLES SHAFTS/BEARINGS 063111
DIFFERENTIAL AND AXLES GEARS 063113
DIFFERENTIAL AND AXLE HOUSINGS 063119
PLANETARY CARRIER 063121
PLANETARY GEARS 063123
PLANETARY HOUSING 063127
DRIVE SHAFT 063161
UNIVERSAL JOINTS (DRIVE LINES ONLY) 063163
HUBS/WHEELS/TIRES 063170

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TABLE OF CONTENTS 0-4

BRAKES 7
MAINTENANCE xxxxxx
TROUBLESHOOTING xxxxxx
HYDRAULIC BRAKE/FAN PUMP 071031
HYDRAULIC BRAKE LINES 071041
BRAKE CONTROL VALVE 071053
ACCUMULATOR 071067
BRAKE ADJUSTERS/ACTUATORS 071071
BRAKE PLATES AND PADS 071073
BRAKE ROTORS 071075
PEDALS/LEVERS 071081
PARKING BRAKE LINKAGE 071085

HYDRAULIC SYSTEM 8
MAINTENANCE xxxxxx
TROUBLESHOOTING xxxxxx
HYDRAULIC RESERVOIR 084111
HYDRAULIC FILTERS 084113
BREATHERS AND RELIEFS (HYDRAULIC RESERVOIR) 084115
MAIN SYSTEM PUMP 084121
PUMP INLET LINES 084131
PUMP TO VALVE CIRCUIT LINES 084133
RETURN CIRCUIT LINES 084135
MAIN RELIEF VALVE 084141
CONTROL VALVE (DIRECTIONAL FLOW) 084143
CIRCUIT RELIEF VALVES 084145
POWER ASSIST CONTROL VALVE (PILOT CONTROL) 084146
FLOW/PRESSURE DIVIDER VALVES 084147
CONTROL VALVES - OPTIONS 084148
LIFT CIRCUIT LINES 084151
BUCKET CIRCUIT LINES 084153
AUXILIARY/COUPLER CIRCUIT LINES 084157
POWER ASSIST CIRCUIT LINES (PILOT LINES) 084159
LIFT CYLINDER 084161
BUCKET CIYLINDER 084163
HYDRAULIC MOTOR (COOLING SYSTEM) 084170
ACCUMULATORS 084183
EQUIPMENT CONTROL LEVERS 084191
EQUIPMENT CONTROL LINKAGE 084193
RETURN-TO-DIG AND HEIGHT CONTROL 084195

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TABLE OF CONTENTS 0-5

CHASSIS/ATTACHMENTS 9
MAINTENANCE xxxxxx
TROUBLESHOOTING xxxxxx
MAIN FRAME/CHASSIS 090111
MOUNTING & SUSPENSION ENGINE/TRANSMISSION/AXLE/CAB 090115
COUNTERWEIGHTS, DRAWBAR 090117
HOOD AND SIDE PANELS 090131
SHROUD AND GRILLE 090132
FENDERS/STEPS/HANDRAILS 090133
GUARDS/SHIELDS/TRIM 090135
LOCKUP KIT/BATTERY BOX/SAFETY EQUIPMENT 090136
PAINT AND DECALS 090137
LUBRIFICATION SYSTEM 090151
CAB FRAME AND HARDWARE 090311
CAB DOORS AND WINDOWS 090313
PRESSURIZER/FILTER 090314
CAB HEATER AND DEFROSTER 090315
AIR CONDITIONING SYSTEM 090317
OPERATOR CONSOLE, INSTRUMENT PANEL AND STEERING COLUMN 090318
INTERIOR INSULATION/HEADLINER/FLOORMAT/TRIM 090319
ROPS 090321
SEAT AND SUPPORTS 090331
SEAT BELT 090333
LOADER BUCKETS AND TEETH 094111
LOADER LIFT PINS, BUSHINGS AND LINKS 094121
LOADER BUCKET LINKAGE, PINS AND BUSHING 094123
LIFT ARMS 094131
LOADER BUCKET LINKAGE 094133

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GENERAL 1-1
Description of CARES system machine locations and job codes
08 41 21 A

The 1st and 2nd digits indicate the The 7th element is an alphabet
machine locations and correspond to that refers to the work codes
the chapters in the service manuals and the working hours

The 3rd and 4th digits indicate

The 5th and 6th digits indicate
the main components
the sub-assemblies
or assemblies

a) Machine location code

084121

08 = Hydraulic system
41 = Hydraulic pumps
21 = Main system pump

NOTE: The machine location codes are given on table of contents.

b) Job code

084121A
08 = Hydraulic system
41 = Hydraulic pumps
21 = Main system pump
A = Main system pump, R&I

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GENERAL 1-2
Machine location and prime part
The machine location must be specified on the warranty claim form; It shows the location of the "Prime part" on
the machine.
The "Prime part" refers to the part that caused the breakdown.
Example:

Machine location
XXXX XXXX XXXX XXXX Job code

Main relief valve 084141

Main relief valve assembly, R & I ........................... 0.9 0.9 0.9 084141A

Main relief valve assembly, Overhaul...................... 1.3 1.3 1.3 084141B

If the "Prime part" is a nut, a bolt, an O-ring, a gasket, a seal or other hardware item, select the machine
location corresponding to the location of the component which the item is a part of, or to which it is attached. For
example, if a bolt on a connecting rod is broken, the bolt would be listed as the "Prime part" and the machine
location of the connecting rod would be used.
CAUTION!
Never use the job codes given below to refer to the machine locations:

Removal
Maintenance Troubleshooting
and installation or overhaul

020401 020402 020403

030401 030402 040003
060001 040002 060003
070001 050002
080001 060002
090001 070002
080002
090002

Codes ending in ...01 (MAINTENANCE), ...02 (TROUBLESHOOTING), ...03 (REMOVAL AND INSTALLATION
OR OVERHAUL) are for job codes only and are never machine locations since they cannot indicate a location
for the "Prime part" which caused the breakdown.

Service codes
Service codes are specified on the warranty claim to identify "How" and "Why" the "Prime part" caused the
breakdown. Only the approved service codes listed on page 1-6 may be used.

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GENERAL 1-3
Job codes
The job code (a six digit number followed by an alphabetical character) must be specified on the warranty claim
form in order to be reimbursed for labour costs. Selection of job codes should cover all repairs performed in
correcting the problem. The job code can be different from the machine location code but most of the time it will
be the same.
Example:

Machine location
XXXX XXXX XXXX XXXX Job code

Timing gears 020463

Crankshaft gear, R & I ............................................ 6.3 6.6 7.6 020463A

Job time
The CARES manuals have been designed so that the warranty claim forms can be completed with one job code
for each "Prime part".
When a job time is given, it covers all operations necessary to perform the jobs it prescribes. The job
time includes the Removal and Installation of all parts or components that may have been removed to
access the defective part or component.
Job time (labour hours) in the column under the machine models to which the job code applies, is given in hours
and tenths of hours.

*** indicates that the job code does not apply to this particular model.

open box (no indication of time) means a time has not been determined for this model but the job code
is applicable.
Because the manuals are written in this style, there is the occasional warranty claim form that will combine
(overlap) two job codes which include the R & I of the same part in each job time given.
The system will approve and pay the hours requested under a job code as long as the requested hours do not
exceed the given job time.
As a result, when two job codes are combined, the removal and installation should be deducted from one of the
two job codes. The number of hours obtained in this way should be entered on the warranty claim form.
Example:
Installation of a short engine block and valve grind. The corresponding job codes 020403B and 020447B both
include the R & I of the cylinder head. The request for a 721D wheel loader should therefore be:
020403B 020447B Total
25.1 + 2.8 = 29.7
The indication of the time 2.8 hours under the 020447B code corresponds to its own time, or 11.5 hours, from
which the 8.7 hours of the 020445A code corresponding to the R & I of the cylinder head have been deducted.

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GENERAL 1-4
Troubleshooting time
Troubleshooting is a specific job. Times are listed in various sections of the manual for the hook-up of the test
instruments and the proper running of the test requires.
Only is in specific cases is troubleshooting included as part of the job time. For example, R & I of the main relief
valve includes pressure testing and adjusting just as R & I of the secondary relief valve includes hand-pumping
and adjusting. If troubleshooting time is included, it will be noted in the job description.

Welding time
With the flat rate times, welding (when performed by the dealership) is the only additional time to be considered.
All requests for welding must be accompanied with a job code.
A request for welding is to be made by picking the job code for the component or part of which the welding was
performed and then adding the letter "W" as a second alphabetical character to the job code.
Example:
The job code for the counterweight is 090117A. Welding would be requested under job code 090117AW and
labour calculated using the following guidelines:

No job time provided (open box)

A repair request should always be accompanied by a job code. However, if no indication of time is given, it must
be calculated considering:
1 That a highly qualified mechanic has performed the repairs, in the dealership’s "certified" shop.
2 Include in the job time, cleaning of the area to be repaired and the actual repair job including associated
problems encountered.
3 Troubleshooting performed should be requested by the appropriate troubleshooting job code.

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GENERAL 1-5
Definition of terms used
R & I (Removal and Installation)
This term refers to the Removal of an existing part or component and the Installation of this same part or
component or of a different part or component. This term also includes the R & I of all parts or components
necessary to gain access to the part or component determined.
Example:

Machine location
XXXX XXXX XXXX XXXX Job code

Radiator & cooling hoses 020411

Radiator assembly, R & I .......................................... 4.0 4.0 4.0 020411G

Replacement
This term indicates the removal of an existing part and the installation of a new or different part.
Example:

Machine location
XXXX XXXX XXXX XXXX Job code

Cylinder head 020445

Cylinder head, Replace........................................... 7.1 8.4 9.6 020445B

Overhaul
This term includes:
The removal and installation of a component.
Complete disassembly.
Checking for the absence of any trace of wear or damage.
Cleaning all the parts.
Complete assembly and checking all tolerances.
Replacing the related filter cartridges.
Renewing all oils and lubricants used.
Replacing all seals, gaskets, O-rings, etc.
The proper running in of new parts and all the adjustments, where necessary.
Example:

Machine location
XXXX XXXX XXXX XXXX Job code

Main system pump 084121

Main system pump, Overhaul

(Includes Job Code 084121A) .......................................... 4.5 4.5 4.5 084121B

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SERVICE CODES (Alphabetical) 1-6

Abnormal noise .................................................... 065 Not sealing properly ............................................. 225
Adjustment (why?) ............................................... 010 Notched (rubber parts, tyres) ............................... 265
Appearance (describe, visual consequences) ..... 015 Obstructed (describe) .......................................... 040
Assembly ............................................................. 005 Off-centre when rotating....................................... 345
Backfire (engine injection).................................... 210 Open circuit (electrical) ........................................ 228
Backlash (describe) ............................................. 020 Ovalization ........................................................... 120
Banging................................................................ 065 Overspeeding (travel motor) ................................ 320
Blistered ............................................................... 035 Parts unscrewed .................................................. 135
Blocked (describe) ............................................... 040 Parts which have been dropped .......................... 135
Bonding/assembly................................................ 005 Pinched (cable, piping, seals) .............................. 180
Brazed.................................................................. 365 Pin-holes .............................................................. 235
Broken.................................................................. 365 Pitted.................................................................... 240
Buckling (rod)....................................................... 050 Porosity ................................................................ 235
Burned ................................................................. 055 Pre-delivery after leaving the factory
Chipped/nicked (chains, gearing) ........................ 070 (between zeo and five hours only)................... 555
Clamping/retaining - poor/none............................ 075 Pressure high ....................................................... 245
Clogging (where?)................................................ 255 Pressure low ........................................................ 250
Condensation (electricity, diesel oil, oil) ............... 220 Roughness (engine)............................................. 150
Contaminated (describe)...................................... 090 Rubbing................................................................ 170
Corroded .............................................................. 260 Rupture ................................................................ 045
Cracked (describe, cast parts, blocks)................. 095 Rusted.................................................................. 260
Cracked (pipes, hoses) ........................................ 030
Scratched (rubber parts, tyres) ............................ 265
Cracked................................................................ 365
Seized .................................................................. 270
Crushed ............................................................... 080
Separation
Cut through (flexible parts)................................... 105
(paint, chromium plated parts, tyres) ............... 140
Deep grooves (hydraulic motor)........................... 155 Service modification programme
Does not engage (mechanical) .............................110 (implementation note only) .............................. 275
Does not return (mechanical)................................115 Sheared ............................................................... 280
Elongated............................................................. 120 Shifting difficult (mechanical) ............................... 285
Elongation (belts, chains)..................................... 310 Short circuit (electrical, electronic) ....................... 290
End play ............................................................... 125 Short shipment
Erratic/fluctuating ................................................. 130 (machines assembled on site only) ................. 950
Faulty connection (electricity, electronic) ............. 085 Slipping ................................................................ 295
Field survey.......................................................... 136 Slow lowering ....................................................... 100
Flaking Soft consistency ................................................... 300
(paint, chromium plated parts, tyres) ............... 140 Spongey consistency ........................................... 300
Folded, bent ......................................................... 025 Squeezed out (circuit seals)................................. 230
Forgotten part ...................................................... 231 Sticking/binding .................................................... 305
Fraying (belt)........................................................ 145 Stripped/pulled out (threaded items) .................... 315
Surging (travel motor) .......................................... 320
Glazing (engine)................................................... 150
Swollen (pipes, hoses) ......................................... 030
Grazed (rubber parts, tyres)................................. 265
Temperature too high ........................................... 325
High fuel consumption (motor)............................. 160
Temperature too low ............................................ 330
High oil consumption (motor) ............................... 165
Tension (belts, chains) ......................................... 310
Humidity (electricity, diesel oil, oil) ....................... 220
Torn (flexible parts) .............................................. 105
Incorrect alignment Torque high (engine, hydraulic motor) ................. 335
(by how much? Mechanical consequences).... 205 Torque low (engine, hydraulic motor) ................... 340
Interference.......................................................... 170 Turned.................................................................. 345
Internal leaks (hydraulic)...................................... 060 Twisted ................................................................. 350
Jumped out of its groove (circuit seals) ............... 230 Vibrations (describe) (welds)................................ 355
Jumps out of gear ................................................ 175
Wear/worn (describe)........................................... 360
Knotted (cable, piping, seals)............................... 180 Welded ................................................................. 365
Laminating (rolled parts) ...................................... 185 Would not hold charge (electricity)....................... 370
Leak ..................................................................... 100
Length (describe) ................................................. 195
Loose ................................................................... 200
Marked ................................................................. 025
Misfiring (engine injection) ................................... 210
Mismachined (how?)............................................ 215

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SERVICE CODES (Numerical) 1-7

Assembly ............................................................. 005 Loose ................................................................... 200
Bonding/assembly................................................ 005 Incorrect alignment
Adjustment (why?) ............................................... 010 (by how much? Mechanical consequences).... 205
Appearance (describe, visual consequences) ..... 015 Misfiring (engine injection) ................................... 210
Backlash (describe) ............................................. 020 Backfire (engine injection).................................... 210
Marked ................................................................. 025 Mismachined (how?) ............................................ 215
Folded, bent ......................................................... 025 Condensation (electricity, diesel oil, oil) ............... 220
Cracked (pipes, hoses) ........................................ 030 Humidity (electricity, diesel oil, oil) ....................... 220
Swollen (pipes, hoses)......................................... 030 Not sealing properly ............................................. 225
Blistered ............................................................... 035 Open circuit (electrical) ........................................ 228
Blocked (describe) ............................................... 040 Squeezed out (circuit seals)................................. 230
Obstructed (describe) .......................................... 040 Jumped out of its groove (circuit seals) ............... 230
Rupture ................................................................ 045 Forgotten part ...................................................... 231
Buckling (rod)....................................................... 050 Porosity ................................................................ 235
Burned ................................................................. 055 Pin-holes .............................................................. 235
Internal leaks (hydraulic)...................................... 060 Pitted.................................................................... 240
Abnormal noise .................................................... 065 Pressure high ....................................................... 245
Banging................................................................ 065 Pressure low ........................................................ 250
Chipped/nicked (chains, gearing) ........................ 070 Clogging (where?)................................................ 255
Clamping/retaining - poor/none............................ 075 Corroded .............................................................. 260
Crushed ............................................................... 080 Rusted.................................................................. 260
Faulty connection (electricity, electronic) ............. 085 Notched (rubber parts, tyres) ............................... 265
Contaminated (describe)...................................... 090 Grazed (rubber parts, tyres)................................. 265
Cracked (describe, cast parts, blocks)................. 095 Scratched (rubber parts, tyres) ............................ 265
Slow lowering....................................................... 100 Seized .................................................................. 270
Leak ..................................................................... 100 Service modification programme
Torn (flexible parts) .............................................. 105 (implementation note only) .............................. 275
Cut through (flexible parts)................................... 105 Sheared ............................................................... 280
Does not engage (mechanical) .............................110 Shifting difficult (mechanical) ............................... 285
Does not return (mechanical)................................115 Short circuit (electrical, electronic) ....................... 290
Elongated............................................................. 120 Slipping ................................................................ 295
Ovalization ........................................................... 120 Soft consistency ................................................... 300
End play ............................................................... 125 Spongey consistency ........................................... 300
Erratic/fluctuating ................................................. 130 Sticking/binding .................................................... 305
Parts unscrewed .................................................. 135 Elongation (belts, chains)..................................... 310
Parts which have been dropped .......................... 135 Tension (belts, chains) ......................................... 310
Field survey.......................................................... 136 Stripped/pulled out (threaded items) .................... 315
Separation Overspeeding (travel motor) ................................ 320
(paint, chromium plated parts, tyres) ............... 140 Surging (travel motor) .......................................... 320
Flaking Temperature too high ........................................... 325
(paint, chromium plated parts, tyres) ............... 140 Temperature too low ............................................ 330
Fraying (belt)........................................................ 145 Torque high (engine, hydraulic motor) ................. 335
Glazing (engine)................................................... 150 Torque low (engine, hydraulic motor) ................... 340
Roughness (engine)............................................. 150 Off-centre when rotating....................................... 345
Deep grooves (hydraulic motor)........................... 155 Turned.................................................................. 345
High fuel consumption (motor)............................. 160 Twisted ................................................................. 350
High oil consumption (motor) ............................... 165 Vibrations (describe) (welds)................................ 355
Rubbing................................................................ 170 Wear/worn (describe)........................................... 360
Interference.......................................................... 170 Brazed.................................................................. 365
Jumps out of gear ................................................ 175 Broken.................................................................. 365
Knotted (cable, piping, seals)............................... 180 Cracked................................................................ 365
Pinched (cable, piping, seals) .............................. 180 Welded ................................................................. 365
Laminating (rolled parts) ...................................... 185 Would not hold charge (electricity)....................... 370
Length (describe) ................................................. 195 Pre-delivery after leaving the factory
(between zeo and five hours only)................... 555
Short shipment
(machines assembled on site only) ................. 950

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REQUEST FOR SUPPLEMENTARY JOB CODE OR MODIFICATION OF

TIME ALLOWED 1-8
Reference number of form used : .........................................................
Model concerned : .........................................................
Machine location : .........................................................

Request to add a job code

Closest existing job code: ......................................................................................................................................
................................................................................................................................................................................

Description of the job code requested: ..................................................................................................................

................................................................................................................................................................................

Estimated time for the requested job code: ...........................................................................................................

................................................................................................................................................................................

Request for changing the time allowed

IMPORTANT: All requests for modifications must be supported by copies of the job cards, and details of time
spent, etc.
Job code : .................................................
Time allowed : .................................................
Time requested : .................................................
Case store or dealer _____________________________ Complete this form and send it to:
Town __________________________________________
Phone No. ______________________________________ CNH FRANCE
17, Rue des Tournelles
Signature ______________________________________
B.P. 306
Date ___________________________________________ 60803 CREPY-EN-VALOIS Cedex
FRANCE
Attn: Product Support Manager
for the machine concerned

The Product Support Manager is authorized to study all requests for modification of time spent, concerning a
given job code. Attach all the documents necessary for studying the case: workshop job cards, details of
time spent, etc.

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DIESEL ENGINE 2-1
Machine

521D

621D

721D
Location
Job Code
NOTE : All engine repair Job Codes include run-in
procedures, adjustments, cleaning and painting if
necessary.
MAINTENANCE xxxxxx
Filter Element - Engine Oil, Replace 0.3 0.3 0.3 020401A
Filter Element - Air Cleaner, Replace 0.2 0.2 0.2 020401B

TROUBLESHOOTING xxxxxx
Run Engine Until It Reaches Operating Temperature
(Includes Visual Inspection and Checking All 0.3 0.3 0.3 020402A
Instrument Panel Indicators)
Stall Speed, Test (Includes Checking Low & High
0.4 0.4 0.4 020402B
Rpm; Also Includes Job Code 020402A)
Loosen Injector Line Fitting to Determine Loss of
0.4 0.5 *** 020402C
Power In Engine Cylinders (All)
Check Intake System for Air Restriction or Intake Air
0.4 0.4 0.4 020402D
Leaks
Cooling System, Pressure Test 0.3 0.3 0.3 020402E
Troubleshoot Engine (Includes : Compression,
0.8 0.8 0.8 020402F
Crankcase and Boost Pressure Checks)
Engine Diagnostic Test with Service Tool (Includes
*** *** 1.0 020402G
Tool Connection & Diagnostic)

REMOVAL AND INSTALLATION OR OVERHAUL xxxxxx

NOTE : For units with air conditioning, use Job Code

090001A if necessary along with Job Codes in this
area.

Engine assembly, R&I (Includes R&I of any item or

5.2 5.5 6.5 020403A
components necessary to access engine)
Short block assembly, R&I (Includes : Engine, R&I.
Studs and fittings, R&I. Check all engine
specifications and tolerances. Filter elements, 20.7 22.5 25.1 020403B
replace. Do run-in procedres & adjustments.
Cleaning and painting.)
Engine assembly, Overhaul (Includes : Engine, R&I
complete disassembly. Cleaning all components and
passages. Assemble to all specifications and 27.1 33.9 35.9 020403C
tolerances. Do run-in procedres & adjustments.
Cleaning and painting.)

Cre 9-88990 Issued 09-03

 Copyright ©
DIESEL ENGINE 2-2
Machine

521D

621D

721D
Location
Job Code

COOLING SYSTEM
RADIATOR & COOLING HOSES 020411
Radiator cap, R&I 0.1 0.1 0.1 020411A
Coolant Lines, Upper Radiator Hose (One), R&I 0.4 0.4 0.4 020411B
Coolant Lines, Upper Radiator Tube (Between
0.6 0.6 0.6 020411C
Hoses), R&I
Coolant Lines, Lower Radiator Hose (One), R&I 0.5 0.5 .05 020411D
Coolant Lines, Lower Radiator Tube (Between
1.5 1.5 1.5 020411E
Hoses), R&I
Mounting Bracket/Wrapper & Hardware for Radiator,
4.0 4.0 4.0 020411F
R&I
Radiator Assembly, R&I (Includes : Hood, Hoses, &
4.0 4.0 4.0 020411G
Lines R&I. Drain & Re-Fill)
Bottom or Top Tank of Radiator, R&I (Includes Job
5.0 5.0 5.0 020411H
Code 020411G)
Radiator Core, R&I 5.5 5.5 5.5 020411I
Cooling System Frame, R&I (Includes Removing
020411J
Cooling System & Hood R&I)
Drain Hose/Cap Plug or Shutoff Valve for Cooling
0.4 0.4 0.4 020411K
System, R&I
Coolant Recovery Reservoir, R&I 0.4 0.4 0.4 020411L

SHROUDS AND SCREENS 020413

Radiator Fan Shroud, R&I (Includes Hood, R&I) 5.3 5.3 5.3 020413A
Radiator Fan Guard, R&I 1.0 1.0 1.0 020413B
Drive Belt Guard, R&I 0.2 0.2 0.2 020413C

FAN, BELT 020415

Drive Belt, R&I (Alternator, Water Pump, Air
0.3 0.3 0.3 020415A
Conditioning)
Belt Tensioner Assembly, R&I 0.4 0.4 0.4 020415B
Bracket for Belt Tensioner, R&I 0.4 0.4 0.4 020415C
Radiator Fan, R&I 1.0 1.0 1.0 020415D
Belt Idler Pulley, R&I 0.7 0.7 0.7 020415E

NOTE : For cooling fan & brake system pump refer

to machine location 071031.

WATER PUMP AND HOUSING 020417

Drive Pulley/Hub for Water Pump, R&I 0.7 0.7 0.7 020417A
Water Pump, R&I (Includes Replacing Gaskets) 0.7 0.7 0.7 020417B

WATER MANIFOLDS, OUTLETS, THERMOSTATS 020419

Thermostat, R&I (Includes Replacing Gaskets) 0.7 0.7 0.7 020419A
Thermostat Housing, R&I (Includes Replacing
0.7 0.7 0.7 020419B
Gaskets)
Water Inlet Housing, R&I (Includes Replacing
0.5 0.5 0.5 020419C
Gaskets)

Cre 9-88990 Issued 09-03

 Copyright ©
DIESEL ENGINE 2-3
Machine

521D

621D

721D
Location
Job Code

INTAKE SYSTEM SYSTEM

AIR CLEANER AND PRECLEANERS 020421
Air Cleaner Inlet Tube or Precleaner, R&I 0.3 0.3 0.3 020421A
Air Cleaner Cover, R&I (Includes Retaining
0.2 0.2 0.2 020421B
Hardware)
Air Cleaner Dust Valve (Evacuator), R&I 0.1 0.1 0.1 020421C
Air Cleaner Assembly, R&I (Includes Mounting Band
0.6 0.6 0.6 020421D
& Hardware)
Mounting Bracket for Air Cleaner, R&I 0.5 0.5 *** 020421E
Mounting Bracket for Air Cleaner or Muffler, R&I *** *** 0.7 020421F

AIR INTAKE HOSES AND TUBES 020423

Hoses and/or Tubes Between Air Cleaner &
0.3 0.3 0.3 020423A
Turbocharger, R&I

TURBOCHARGER 020425
Turbocharger, R&I (Includes Replacing Gasket) 1.1 1.4 1.4 020425A
Turbocharger, Overhaul
2.5 2.9 2.9 020425B
(Includes Job Code 020425A)
Actuator, R&I (Turbo Wastegate) (Includes
0.9 0.9 0.9 020425C
Adjustments)
Tube, R&I (Wastegate Actuator) 0.3 0.3 0.3 020425D

INTAKE MANIFOLDS, AFTERCOOLER 020427

Cover for Intake Manifold, R&I (Includes Replacing
0.9 *** *** 020427A
Gasket)
Aftercooler, R&I (Charge Air) *** *** 1.0 020427B
Charge Air Aftercooler Tube, R&I *** 0.4 020427C
Charge Air Aftercooler Connecting Hose, R&I *** *** 0.3 020427D

COLD STARTING AIDS 020429

NOTE : For cold start electrical system, refer to

machine location 044550.

EXHAUST SYSTEM
EXHAUST MUFFLERS AND EXTENSIONS 020431
Extension Pipe for Exhaust, R&I 0.3 0.3 0.3 020431A
Muffler, R&I 0.3 0.3 0.3 020431B
Mounting Bracket for Muffler, R&I 0.3 0.3 0.3 020431C

EXHAUST MANIFOLDS AND PIPES 020433

Exhaust Manifold Assembly, R&I (Includes
2.0 2.1 2.1 020433A
Turbocharger, R&I)

Cre 9-88990 Issued 09-03

 Copyright ©
DIESEL ENGINE 2-4
Machine

521D

621D

721D
Location
Job Code

CYLINDER HEADS AND VALVES

VALVE COVER AND BREATHERS 020441
Valve Cover for Cylinder Head, R&I (One) 0.3 0.3 1.3 020441A
Valve Cover for Cylinder Head, R&I (All) 0.5 0.7 *** 020441B
Injector Wiring Support, R&I (Includes Job Codes
*** *** 2.2 020441C
040140B & 020441A)

ROCKER ARM ASSEMBLY AND PUSH RODS 020443

Rocker Arm Assembly & Push Rods, R&I (One
1.1 1.1 2.1 020443A
Cylinder)
Rocker Arm Assembly & Push Rods, R&I (All
2.3 3.7 5.2 020443B
Cylinders)
Rocker Arm Assembly, Overhaul (One Cylinder,
2.2 2.2 3.2 020443C
Includes Job Code 020443A)
Rocker Arm Assembly, Overhaul (All Cylinders,
3.0 4.8 6.3 020443D
Includes Job Code 020443B)

CYLINDER HEADS 020445

Cylinder Head, R&I (Includes : Cleaning Head,
6.4 7.8 8.7 020445A
Replacing Gaskets, Adjusting Valves)
Cylinder Head, Replace (Includes : Transfer of Parts,
7.1 8.4 9.6 020445B
Job Code 020445A)
Expansion Plug for Cylinder Head, Replace 020445C

VALVES, SEATS AND GUIDES 020447

Valves and Springs, R&I (Includes Job Code
7.0 8.3 9.5 020447A
020445A)
Grind Valve Face and Valve Seat (Includes Job Code
8.3 10.3 11.5 020447B
020447A)
Cylinder Head, Overhaul (Includes : Grinding Valve
Face & Seats, Test Springs, Replace Valve Guides & 9.8 12.5 13.6 020447C
Seat Inserts (Where Necessary))
Valve Seal, Valve Spring, or Retainer, R&I 020447D

Cre 9-88990 Issued 09-03

 Copyright ©
DIESEL ENGINE 2-5
Machine

521D

621D

721D
Location
Job Code

SLEEVES, PISTONS AND RODS

SLEEVES, PISTONS AND RINGS 020451
Replace Rings on Piston (One), (Includes : Remove
Glaze From Sleeve, Checking Piston & Cylinder 12.8 15.0 17.9 020451A
Tolerances)
Replace Rings on Piston (All), (Includes : Remove
Glaze From Sleeve, Checking Piston & Cylinder 14.3 1.70 19.9 020451B
Tolerances)
Piston (One), R&I (Includes : Checking Piston &
12.8 15.0 17.9 020451C
Cylinder Tolerances, Fitting Piston Pin)
Piston (All), R&I (Includes : Checking Piston &
15.0 17.8 20.7 020451D
Cylinder Tolerances, Fitting Piston Pin)
Cylinder Bore (One), Over Size (Includes : Fitting &
020451E
Assembling Oversize Piston)
Cylinder Bore (All), Over Size (Includes : Fitting &
020451F
Assembling Oversize Piston)

CONNECTING RODS, BEARINGS AND CONNECTING ROD PINS 020455

Connecting Rod Bearing, R&I (One) 7.5 8.0 8.2 020455A
Connecting Rod Bearing, R&I (All) 9.0 9.8 10.0 020455B
Connecting Rod Assembly, R&I (One) 12.8 15.0 17.9 020455C
Connecting Rod Assembly, R&I (All) 13.9 16.8 19.7 020455D

CRANKSHAFT, CAMSHAFT AND TIMING TRAIN

CRANKSHAFT PULLEY, TIMING COVER AND SEAL 020461
Crankshaft Pulley, R&I 0.5 0.5 0.5 020461A
Crankshaft Oil Seal (Front), R&I (Includes Replacing
1.5 1.5 1.5 020461B
Wear Sleeve & Job Code 020461A)
Cover for Accessory Drive, R&I 0.3 0.3 0.3 020461C
Timing Gear Housing, R&I 8.0 8.5 9.0 020461D
Timing Pin for Camshaft Gear, R&I (Includes
0.3 0.3 *** 020461E
Housing & O-Ring)

TIMING GEARS 020463

Camshaft Gear, R&I (Includes Replacing Thrust
6.3 6.6 7.6 020463A
Flange)

CAMSHAFT, BUSHINGS AND LIFTERS 020465

Camshaft and Tappets, R&I 8.7 18.1 9.9 020465A
Lifters, R&I 9.6 19.2 10.7 020465B

CRANKSHAFT, MAIN BEARINGS AND SEALS 020467

Crankshaft Oil Seal, R&I (Rear) (Includes R&I
6.2 6.5 7.5 020467A
Carrier & Gasket)
Crankshaft Assembly and Main Bearings,R&I
10.0 11.3 12.3 020467B
(Includes Checking All Tolerances)

Cre 9-88990 Issued 09-03

 Copyright ©
DIESEL ENGINE 2-6
Machine

521D

621D

721D
Location
Job Code
ENGINE BLOCK CASTING 020468
Engine block casting, R&I (Includes : Components,
studs and fitting , R&I (from old block to new block).
Check and set all engine specifications and 25.8 30.1 31.5 020468A
tolerances. Filter element, replace. Run-in procedure.
Clean and paint.
Expansion Plugs, R&I 020468B

FLYWHEEL AND HOUSING 020469

Flywheel, R&I 5.7 6.0 7.0 020469A
Ring gear on flywheel, R&I 6.2 6.5 7.5 020469B
Flywheel housing, R&I 6.0 6.3 7.3 020469C

LUBRIFICATION SYSTEM
OIL PAN AND DIPSTICK 020471
Oil level dipstick, R&I 0.1 0.1 0.1 020471A
Dipstick tube, R&I 0.4 0.4 0.4 020471B
Filler Tube - Oil, R&I 0.4 0.4 0.4 020471C
Drain Hose/Cap for Engine Oil, R&I 0.3 0.3 0.3 020471D
Oil Drain Line/Fitting, R&I (at Oil Pan) 2.5 2.5 2.5 020471E
Oil Pan Assembly, R&I (Includes Fuel tank, R&I)) 4.5 4.6 4.8 020471F
Block Reinforcement between Block and Pan, R&I
4.8 5.0 5.2 020471G
(Includes Job Code 020461D

OIL PUMP 020473

Oil Inlet Tube and Screen, R&I (Includes Job Code
4.7 4.8 5.0 020473A
020471E)
Oil Pump Assembly, R&I (Includes Job Code
2.1 2.2 2.2 020473B
020461D)
Oil Pump Drive Gear on Crankshaft, R&I (Includes
020473C
Job Code 020461D)

HEAT EXCHANGERS, OIL FILTER AND BASE 020475

Engine Oil Cooler, R&I (Includes Replacing Gasket) 0.9 1.1 1.1 020475A
Reilef Valve assembly for Oil Pump, R&I 0.3 0.3 0.3 020475B

EXTERNAL LUBRIFICATION TUBES AND HOSES 020477

Oil Supply Line to Turbocharger, R&I 0.4 0.4 0.4 020477A
Oil Drain Line From Turbocharger, R&I 0.4 0.4 0.4 020477B

Cre 9-88990 Issued 09-03

 Copyright ©
FUEL SYSTEM 3-1
Machine

521D

621D

721D
Location
Job Code
MAINTENANCE xxxxxx
Fuel Filter, Replace 0.3 0.3 0.3 030401A
Inline Fuel Filter, Replace 0.4 0.4 0.4 030401B

TROUBLESHOOTING xxxxxx
Fuel Injection Pump, Check and Adjust Timing 1.0 1.0 *** 030402A
Electronic Fuel Injection, Check and Adjust *** *** 1.0 030402A

FUEL TANK, LINES AND TRANSFER PUMP

FUEL TANK 030411
Fuel Tank Cap, R&I 0.1 0.1 0.1 030411A
Drain Plug, R&I 0.3 0.3 0.3 030411B
Fuel Tank Plate, R&I 0.5 0.5 0.5 030411C
Fuel Tank Belt/Strap, R&I 0.7 0.7 0.7 030411D
Fuel Tank, R&I (Includes Job Codes 030311C&D) 2.0 2.0 2.0 030411E

FUEL LINES, TUBES AND HOSES 030413

Fitting - Fuel Tank, R&I 0.8 0.8 0.8 030413A
Fuel Tank Breather, R&I 0.3 0.3 0.3 030413B
Fuel Line - Fuel Tank Outlet, R&I 0.9 0.9 0.9 030413C
Fuel Line, at Inlet of Lift Pump, R&I 0.3 0.3 *** 030413D
Fuel Return Line, Pump to Tee, R&I 0.3 0.3 0.3 030413E
Fuel Return Line at Tank, R&I 0.3 0.3 0.3 030413F
Fuel Line, Filter Head to Pump, R&I 0.3 0.3 0.3 030413G
Fuel Return Line, Injectors to Pump, R&I 1.2 1.4 *** 030413H
Fuel Line, Injection Pump to Fuel Rail, R&I *** *** 0.3 030413I
Fuel Line, Water Separator to Electronic Controller,
*** *** 0.3 030413J
R&I
Fuel Line, at Electronic Control Unit - Injection Pump,
*** *** 0.3 030413K
R&I
Fuel Rail, R&I *** *** 1.4 030413L
Pressure Control Valve, R&I (One, on Fuel Rail) *** *** 0.3 030413M
Return Fuel Pressure Limiter, R&I *** *** 0.3 030413N

FUEL TRANSFER (LIFT) PUMP 030415

Fuel Lift Pump, R&I 0.4 0.4 0.4 030415A

FUEL COOLERS 030417

Fuel Cooler, R&I 1.0 1.0 1.0 030417A

FUEL FILTER SYSTEM

FUEL FILTERS 030421
Adapter for Fuel Filter, R&I (Includes Job Code
0.4 0.4 0.4 030421A
030401A)
Support for Fuel Filter, R&I (Includes Job Code
0.7 0.7 0.7 030421B
030401A)

Cre 9-88990 Issued 09-03

 Copyright ©
FUEL SYSTEM 3-2
Machine

521D

621D

721D
Location
Job Code

FUEL INJECTION SYSTEM

FUEL INJECTION PUMP 030431
Connectors for Fuel Injection Lines, R&I (One)
0.3 0.3 *** 030431A
(Includes Replacing Washer)
Throttle Arm, R&I 0.4 0.4 *** 030431B
Fuel Injection Pump, R&I 2.3 2.5 1.3 030431C
Drive Gear for Injection Pump, R&I 1.0 1.0 1.4 030431D
Fuel Pressure for Regulating Valve Module, R&I *** *** 0.5 030431E

FUEL INJECTOR LINES 030433

Clamp Assembly for Injector Lines, R&I 0.3 0.3 0.3 030433A
Fuel Injector Line (#1 Cylinder) , R&I (Includes
0.5 0.5 0.3 030433B
Replacing Seal)
Fuel Injector Line (#2 Cylinder) , R&I (Includes
0.5 0.5 0.3 030433C
Replacing Seal)
Fuel Injector Line (#3 Cylinder) , R&I (Includes
0.4 0.4 0.3 030433D
Replacing Seal)
Fuel Injector Line (#4 Cylinder) , R&I (Includes
0.4 0.4 0.3 030433E
Replacing Seal)
Fuel Injector Line (#5 Cylinder) , R&I (Includes
*** 0.4 0.3 030433F
Replacing Seal)
Fuel Injector Line (#6 Cylinder) , R&I (Includes
*** 0.4 0.3 030433G
Replacing Seal)
Fuel Injector Line (All Cylinders) , R&I (Includes
1.0 1.5 1.5 030433H
Replacing Seal)

FUEL INJECTORS 030435

Fuel Injectors (One), R&I (Includes Replacing Seal &
0.6 0.7 1.9 030435A
Job Code 030435C on 721D)
Fuel Injectors (All), R&I (Includes Replacing Seal &
1.5 2.0 3.5 030435B
Job Code 030435C on 721D)
*** *** 0.4 030435C
Fuel Connector, Replace (One, Fuel Line to Injector)

NOTE : For injector harness, refer to machine

location 040140

FUEL SYSTEM CONTROLS

FUEL SHUTOFF AND THROTTLE 030443
Foot Throttle Pedal, R&I 0.8 0.8 0.8 030443A
Throttle Linkage From Foot Pedal, R&I 0.6 0.6 *** 030443B
Throttle Cable, R&I 1.0 1.0 *** 030443C
Throttle Cable Bracket, R&I 0.4 0.4 *** 030443D

NOTE : For fuel electrical system, refer to machine

location 041513, 046041.

Cre 9-88990 Issued 09-03

 Copyright ©
ELECTRICAL SYSTEM 4-1
Machine

521D

621D

721D
Location
Job Code
TROUBLESHOOTING xxxxxx
Battery, Check & Test (Hydrometer and Load Test) 0.5 0.5 0.5 040002A
Charge System, Check & Test (Includes Job Code
0.7 0.7 0.7 040002B
040002A)
Starting System, Check & Test (Includes Job Code
0.7 0.9 0.9 040002C
040002A)
Troubleshoot Electrical Circuits With Multi-Meter
1.0 1.0 1.0 040002D
(Includes Ground Circuit Test)
Electronic System Diagnostic Test - Service Tool
1.0 1.0 1.0 040002E
(Includes Tool Connection)
Download Electronic Software 0.3 0.3 0.3 040002F

R&I OR OVERHAUL xxxxxx

Wire Harness, Repair
040003A
(Includes Connectors/Terminals)

WIRING & HARNESSES

CHASSIS WIRING 040120
Front Chassis Harness, R&I 3.0 3.0 3.0 040120A
Rear Chassis Harness, R&I 3.0 3.0 3.0 040120B
Hood Harness, R&I 0.4 0.4 0.4 040120C
Relay Harness, R&I 0.7 0.7 0.7 040120D

ENGINE WIRING 040140

Engine Harness, R&I 2.5 2.5 2.5 040140A
Injector Harness, R&I (Includes Job Code 020441A) *** *** 1.7 040140B

CAB/OPERATOR COMPARTMENT WIRING 040170

Junction Stud for Cab Power, R&I 1.0 1.0 1.0 040170A
Main Cab Harness, R&I 040170B
Cab Roof Harness, R&I 3.0 3.0 3.0 040170C
Steering Pedestal Harness, R&I 2.0 2.0 2.0 040170D

CIRCUIT BREAKERS FUSES, RELAYS

CIRCUIT BREAKERS/RELAYS 040510
Relay/Circuit Breaker, R&I (Power Panel) 0.1 0.1 0.1 040510A

FUSES 040520
Fuse, R&I 0.1 0.1 0.1 040520A

Cre 9-88990 Issued 09-03

 Copyright ©
ELECTRICAL SYSTEM 4-2
Machine

521D

621D

721D
Location
Job Code

SWITCHES & CONTROLS

IGNITION/KEY SWITCH 041512
Ignition/Key Switch, R&I 0.5 0.5 0.5 041512A

FUEL SHUTOFF CONTROL 041513

Solenoid - Fuel Shutoff, R&I 0.8 0.8 *** 041513A

MACHINE FUNCTION CONTROLS 041515

Cooling Fan Reverser Switch, R&I 0.4 0.4 0.4 041515A
Cooling Fan Reversing Solenoid, R&I 0.5 0.5 0.5 041515B

POWER RELAYS
POWER RELAYS 041531
Power Relay, R&I 0.6 0.6 0.6 041531A

INSTRUMENTATION, GAUGES AND SENDERS

NOTE : Refer to instrument cluster machine location

047011 for indicators, gauges and displays.

ENGINE OIL PRESSURE 042011

BATTERY VOLTAGE 042014

MACHINE FUNCTIONS 042015

AUDIBLE WARNING DEVICES

HORN 042031
Horn, R&I 0.3 0.3 0.3 042031A
NOTE : For horn switch refer to machine location
043530.

ELECTRIC STARTER AND BATTERY CIRCUIT

STARTER MOTOR 042510
Starter Motor, R&I 0.9 0.9 0.9 042510A
Starter Drive, R&I (Includes Job Code 042510A) 1.4 1.4 1.4 042510B
Starter Motor, Overhaul (Includes Job Code
2.5 2.5 2.5
042510B) 042510C
Relay - Starter Motor, R&I 0.5 0.5 0.5 042510D
Relay - Neutral Start, R&I 0.2 0.2 0.2 042510E
Terminal Block at Relay Panel, R&I 0.6 0.6 0.6 042510F

Cre 9-88990 Issued 09-03

 Copyright ©
ELECTRICAL SYSTEM 4-3
Machine

521D

621D

721D
Location
Job Code
BATTERY CIRCUIT 042550
Battery, R&I (One) 0.5 0.5 0.5 042550A
Battery, R&I (All) 0.9 0.9 0.9 042550B
Jumper Cable Between Batteries, R&I 0.5 0.5 0.5 042550C
Battery Cable - Positive, R&I 0.5 0.5 0.5 042550D
Battery Cable - Negative, R&I (Battery to Master
0.5 0.5 0.5
Disconnect) 042550E
Battery Cable - Master Disconnect to Chassis, R&I 0.2 0.2 0.2 042550F
Master Disconnect Switch, R&I 0.6 0.6 0.6 042550G

ELECTRIC CHARGING COMPONENTS

ALTERNATOR CIRCUIT 043010
Alternator, R&I 0.7 0.7 0.7 043010A
Pulley for Alternator, R&I (Includes Job Code
0.9 0.9 0.9 043010B
043010A)
Alternator, Overhaul (Includes Job Code 043010A &
1.9 1.9 1.9 043010C
043010B)

REGULATOR AND RECTIFIER 043030

Voltage Regulator and Brush Holder, R&I 0.5 0.5 0.5 043030A

ELECTRIC LIGHT CIRCUIT

HEADLIGHT CIRCUIT 043510
Headlight Assembly, R&I 0.3 0.3 0.3 043510A
Sealed Beam - Headlight, R&I 0.3 0.3 0.3 043510B
Switch - Lamp, R&I 0.4 0.4 0.4 043510C

STOPLIGHT/TAILLIGHT CIRCUIT 043520

Lens, R&I 0.2 0.2 0.2 043520A
Bulb, R&I 0.2 0.2 0.2 043520B
Stoplight /Taillight Assembly, R&I 0.5 0.5 0.5 043520C
Switch - Stop Lights, R&I 0.8 0.8 0.8 043520D

TURN SIGNAL/HAZARD (FLASHER) LIGHT CIRCUIT 043530

Lens, R&I 0.2 0.2 0.2 043530A
Bulb, R&I 0.2 0.2 0.2 043530B
Turn Signal & Hazard Light Assembly, R&I 0.5 0.5 0.5 043530C
Switch - Turn Signal - Dimmer - Horn, R&I 0.8 0.8 0.8 043530D
Switch - Four-Way Flasher, R&I 0.4 0.4 0.4 043530E
Module - Flasher, R&I 0.5 0.5 0.5 043530F

WORK LIGHT CIRCUIT 043550

Floodlight Assembly, R&I 0.3 0.3 0.3 043550A
Sealed Beam, R&I 0.3 0.3 0.3 043550B

Cre 9-88990 Issued 09-03

 Copyright ©
ELECTRICAL SYSTEM 4-4
Machine

521D

621D

721D
Location
Job Code
DOME/PANEL LIGHT CIRCUIT 043560
Lens, R&I 0.2 0.2 0.2 043560A
Bulb, R&I 0.2 0.2 0.2 043560B
Dome Light Assembly, R&I 0.4 0.4 0.4 043560C

SAFETY (BEACON) LIGHT CIRCUIT 043570

Lens, R&I 0.3 0.3 0.3 043570A
Bulb, R&I 0.3 0.3 0.3 043570B
Beacon Assembly, R&I 0.7 0.7 0.7 043570C
Switch, R&I 0.4 0.4 0.4 043570D

ELECTRIC MOTORS
BLOWER MOTOR CIRCUIT (HEATER/AIR CONDITIONER) 044010
Operator Switch – Cab Blower Motor, R&I 0.4 0.4 0.4 044010A
Speed Resistor/Thermal Fuse – Cab Blower Motor,
0.5 0.5 0.5 044010B
R&I
Cab Blower Motor, R&I (Includes Fan & Housing) 3.0 3.0 3.0 044010C
Operator Thermostat Control - Air Conditioning, R&I 1.0 1.0 1.0 044010D
Wire Harness - Air Conditioner, R&I 044010E
Electric Clutch - Air Conditioning Compressor, R&I 2.3 2.3 2.3 044010F
Low Pressure Switch - Air Conditioning, R&I 0.5 0.5 0.5 044010G
High Pressure Switch - Air Conditioning, R&I 0.5 0.5 0.5 044010H

WIPER MOTOR CIRCUIT 044020

Switch - Front Wiper Motor/Washer, R&I 0.5 0.5 0.5 044020A
Switch - Rear Wiper Motor/Washer, R&I 0.4 0.4 0.4 044020B
Wiper Motor Assembly - Front, R&I 1.5 1.5 1.5 044020C
Wiper Motor Assembly - Rear, R&I 2.0 2.0 2.0 044020D
Windshield Washer Pump and Reservoir, R&I 0.4 0.4 0.4 044020E
Wiper Arm, R&I 0.2 0.2 0.2 044020F

AUXILIARY MOTOR CIRCUIT 044050

Motor - Auxiliary Steering Pump, R&I 3.1 3.1 3.1 044050A
Relay - Auxiliary Steering, R&I 0.5 0.5 0.5 044050B
Module - Auxiliary Steering, R&I 0.5 0.5 0.5 044050C
Pressure Switch - Auxiliary Steering, R&I 0.5 0.5 0.5 044050D

ELECTRIC ACCESSOIRIES/ATTACHMENTS
BACKUP ALARM CIRCUIT 044510
Backup Alarm, R&I 0.4 0.4 0.4 044510A
Disable Switch, R&I 0.5 0.5 0.5 044510B

Cre 9-88990 Issued 09-03

 Copyright ©
ELECTRICAL SYSTEM 4-5
Machine

521D

621D

721D
Location
Job Code
COLD START AIDS 044550
Ether Start Switch, R&I 0.4 0.4 0.4 044550A
Cold Start ECU & Temperature Sensor, R&I 0.4 0.4 *** 044550B
Intake Air / (Grid) Heater, R&I (Includes Job Code
020427A on 721D) 0.6 0.6 1.5 044550C
Block Heater, R&I 0.7 0.7 0.7 044550D
Fuel Heater, R&I (Includes Filter cartridge R&I) *** *** 0.4 044550E

RADIO/SOUND SYSTEM 044570

Radio, R&I 1.0 1.0 1.0 044570A
Speaker, R&I 0.5 0.5 0.5 044570B
Antenna, R&I 0.4 0.4 0.4 044570C
Converter, R&I (24V to 12V) 0.5 0.5 0.5 044570D
Wire Harness, R&I 1.5 1.5 1.5 044570E

OPERATOR CONVENIENCE AND ACCESSORIES 044580

Element - Cigar Lighter, R&I 0.1 0.1 0.1 044580A
Cigar Lighter Outlet, R&I 0.5 0.5 0.5 044580B
Auxilliary Power Outlet, R&I 0.5 0.5 0.5 044580C

ELECTRO-HYDRAULIC CONTROLS
HEIGHT (LIFT) CONTROL CIRCUIT 046031
Height Controls - Proximity Switch, R&I 0.4 0.4 0.4 046031A
Height Controls - Detent Coil, R&I 0.5 0.5 0.5 046031B
Operator Control Switch, R&I (Height Controls) 0.4 0.4 0.4 046031C
Return to Travel Controls - Proximity Switch, R&I 0.4 0.4 0.4 046031D
Return to Travel Controls - Detent Coil, R&I 0.5 0.5 0.5 046031E
Operator Control Switch, R&I (Return to Travel) 0.4 0.4 0.4 046031F
Operator Control Switch, R&I (Quick Attachment) 0.4 0.4 0.4 046031G
Pin Engage Solenoid, R&I 0.4 0.4 0.4 046031H
Ride Control Switch, R&I 0.4 0.4 0.4 046031I
Ride Control Valve Solenoid, R&I 0.5 0.5 0.5 046031J

BUCKET (RETURN-TO-DIG) CONTROL CIRCUIT 046032

Proximity Switch, R&I 0.5 0.5 0.5 046032A
Detent Coil, R&I 0.5 0.5 0.5 046032B
Operator Control Switch, R&I 0.4 0.4 0.4 046032C

Cre 9-88990 Issued 09-03

 Copyright ©
ELECTRICAL SYSTEM 4-6
Machine

521D

621D

721D
Location
Job Code
TRANSMISSION CONTROL CIRCUIT 046039
Transmission Harness - Solenoids at Transmission
1.5 1.5 1.5 046039A
Control Valve, R&I
Coil/Solenoid - Transmission Control Valve, R&I 1.0 1.0 1.0 046039B
Transmission Shift Control Lever, R&I 0.8 0.8 0.8 046039C
Switch - Declutch, R&I (Hand Control) 0.4 0.4 0.4 046039D
Switch - Declutch at Brake, R&I 0.8 0.8 0.8 046039E
Switch - Transmission Enable, R&I 0.5 0.5 0.5 046039F
Transmission Electronic Control Module, R&I (Ecm) 0.5 0.5 0.5 046039G
Engine Speed Sensor, R&I 0.5 0.5 0.5 046039H
Turbine Speed Sensor, R&I 0.5 0.5 0.5 046039I
Intermediate Speed Sensor, R&I 0.5 0.5 0.5 046039J
Output Speed Sensor, R&I 0.5 0.5 0.5 046039K
Downshift Button, R&I 0.4 0.4 0.4 046039L
Auto Shift Switch, R&I (Operator) 0.4 0.4 0.4 046039M
F-N-R Control Switch, R&I 0.5 0.5 0.5 046039N
Thermostat Switch, R&I 0.5 0.5 0.5 046039O
Time Delay Module, R&I 1.2 1.2 1.2 046039P
Solenoid - Parking Brake, R&I 0.5 0.5 0.5 046039K
Operator Switch - Parking Brake, R&I 0.4 0.4 0.4 046039R

ENGINE - ELECTRONIC FUEL CONTROL 046041

Controller - Engine Fuel System, R&I (Includes
*** *** 1.0 046041A
Software Download)
Sensor - Accumulator Pressure/Temperature, R&I *** *** 0.4 046041B
Sensor - Engine Speed/Rpm, R&I *** *** 0.4 046041C
Sensor - Engine Timing, R&I *** *** 0.4 046041D
Sensor - Engine Intake Temperature & Pressure, R&I *** *** 0.4 046041E
Sensor - Fuel Temperature, R&I *** *** 0.4 046041F
Sensor - Fuel High Pressure, R&I *** *** 0.4 046041G
Sensor - Engine Oil Temperature, R&I *** *** 0.4 046041H
Sensor - Throttle Pedal Position, R&I *** *** 0.5 046041I

ELECTRONIC SYSTEMS
MACHINE FUNCTION MONITORS 047011
Instrument Cluster, R&I (Machine Monitoring) 0.6 0.6 0.6 047011A
Up/Down Count Switch, R&I 0.4 0.4 0.4 047011B
Program/Reset Switch, R&I 0.4 0.4 0.4 047011C
Sender - Engine Coolant Temperature, R&I 0.6 0.6 0.6 047011D
Switch - Transmission Filter Maintenance, R&I 0.5 0.5 0.5 047011E
Sender - Fuel Level, R&I 1.0 1.0 1.0 047011F
Sender - Engine Oil Pressure, R&I 0.4 0.4 0.4 047011G
Sensor - Transmission Oil Temperature, R&I 0.5 0.5 0.5 047011H
Sensor - Torque Converter Temperature, R&I 0.5 0.5 0.5 047011I
Switch - Engine Air Filter, R&I 0.3 0.3 0.3 047011J
Switch - Brake System Warning Pressure, R&I 0.4 0.4 0.4 047011K
Switch - Brake Lamp, R&I 0.6 0.6 0.6 047011L
Switch - Hydraulic Filter Restriction, R&I 0.4 0.4 0.4 047011M
Sender - Hydraulic Oil Temperature, R&I 0.5 0.5 0.5 047011N
Sender - Engine Coolant Level Indicator, R&I 0.4 0.4 0.4 047011O

Cre 9-88990 Issued 09-03

 Copyright ©
STEERING SYSTEM 5-1
Machine

521D

621D

721D
Location
Job Code
TROUBLESHOUTING xxxxxx
Test/Adjust Steering System Pressure 0.8 0.8 0.8 050002A

STEERING CONTROLS
STEERING WHEEL AND COLUMNS 050110
Steering Wheel, R&I 0.4 0.4 0.4 050110A
Steering Column, R&I (Includes Pivot Bushings) 1.3 1.3 1.3 050110B
Tilt Latch Assembly for Steering Column, R&I
1.6 1.6 1.6 050110C
(Position Adjustment)
Isolator Coupling, R&I 1.5 1.5 1.5 050110D
Pedestal for Steering Column/Brake Pedals, R&I 4.0 4.0 4.0 050110E

ARTICULATION PIVOTS 050550

Articulation Pivot Pin - Upper, R&I 1.2 1.2 1.2 050550A
Articulation Pivot Pin -Lower, R&I 1.9 1.9 1.9 050550B
Articulation Pivot Bearing - Upper, R&I 5.0 5.0 5.0 050550C
Articulation Pivot Bearing - Lower, R&I 5.0 5.0 5.0 050550D
Articulation Pivot Bearing Seal - Upper, R&I 2.1 2.1 2.1 050550E
Articulation Pivot Bearing Seal - Lower, R&I 2.1 2.1 2.1 050550F

STEERING HYDRAULIC SYSTEM

MAIN STEERING PUMP

NOTE : For repairs in this area, refer to machine

location 084121.

AUXILIARY STEERING PUMP 050723

Auxiliary Steering Pump Assembly, R&I 1.9 1.9 1.9 050723A
Auxiliary Steering Pump Assembly, Overhaul
3.0 3.0 3.0 050723B
(Includes Job Code 050723A)

STEERING HYDRAULIC LINES

PUMP TO VALVE LINES 050733
Fitting at Loader Valve, R&I 1.0 1.0 1.0 050733A
Pressure Test Coupling, R&I (Quick Disconnect
0.4 0.4 0.4 050733B
Fitting)
Line – Loader Valve to Steering Valve (Hand Pump),
1.0 1.0 1.0 050733C
R&I
Fitting at Inlet of Steering Valve (Hand Pump), R&I 1.3 1.3 1.3 050733D
Signal Line - Loader Valve - Steering Valve, R&I 1.3 1.3 1.3 050733E
Fitting for Signal Line, R&I 0.5 0.5 0.5 050733F

RETURN LINES 050735

Fitting at Outlet of Steering Valve (Hand Pump), R&I 0.5 0.5 0.5 050735A
Return Line From Steering Control Valve, R&I 0.7 0.7 0.7 050735B

Cre 9-88990 Issued 09-03

 Copyright ©
STEERING SYSTEM 5-2
Machine

521D

621D

721D
Location
Job Code
COOLING SYSTEM 050737
Line – Fan Motor Drive to Hydraulic Oil Cooler, R&I 2.0 2.0 2.0 050737A
Line - Hydraulic Oil Cooler to Filter, R&I 2.0 2.0 2.0 050737B
Line - Fan Drive to Filter, R&I (Used Without Cooler) 2.0 2.0 2.0 050737C

STEERING VALVES
MAIN RELIEF VALVE 050741

NOTE : For repairs in this area, refer to machine

location 084141.

STEERING CONTROL VALVE (HAND PUMP) 050743

Steering Control Valve, R&I 1.5 1.5 1.5 050743A
Steering Control Valve, Overhaul (Includes Job Code
2.9 2.9 2.9 050743B
050743A)

CIRCUIT RELIEF VALVE 050745

Steering Circuit Relief Valve, R&I 0.5 0.5 0.5 050745A
Steering Circuit Relief Valve, Overhaul (Includes
1.0 1.0 1.0 050745B
050745A)

FLOW/PRESSURE DIVIDER VALVES 050747

Auxiliary Steering Priority Valve, R&I 0.9 0.9 0.9 050747A
Auxiliary Steering Priority Valve, Overhaul (Includes
2.0 2.0 2.0 050747B
Job Code 050747A)
Load Sense Shuttle Valve, R&I 050747C

CHECK VALVES 050749

Check Valve for Auxiliary Steering, R&I 1.0 1.0 1.0 050749A
Check Valve for Auxiliary Steering, Overhaul
2.5 2.5 2.5 050749B
(Includes Job Code 050749A)

STEERING HYDRAULIC LINES (VALVE TO CYLINDER OR ACTUATOR)

VALVE TO CYLINDER LINES 050751
Fitting at Work Port of Hand Pump, R&I (One) 0.5 0.5 0.5 050751A
Line at Work Port of Hand Pump, R&I (One) 0.6 0.6 0.6 050751B
Intermediate Line, R&I (One) 0.6 0.6 0.6 050751C
Line at Steering Cylinder, R&I (One) 0.5 0.5 0.5 050751D
Fitting at Steering Cylinder, R&I (One) 0.4 0.4 0.4 050751E

AUXILIARY STEERING LINES 050755

Fitting at Auxiliary Steering Pump, R&I (One) 0.9 0.9 0.9 050755A
Line - Auxiliary Steering Pump to Auxiliary Valve, R&I 1.0 1.0 1.0 050755B
Fitting at Auxiliary Steering Valve, R&I (One) 0.8 0.8 0.8 050755C
Line - Auxiliary Valve to Steering Hand Pump, R&I 1.0 1.0 1.0 050755D
Line - Auxiliary Steering Valve to Filter, R&I (One) 1.0 1.0 1.0 050755E
Signal Line - Auxiliary Steering Valve to Steering
1.5 1.5 1.5 050755F
Valve, R&I (Hand Pump)

Cre 9-88990 Issued 09-03

 Copyright ©
STEERING SYSTEM 5-3
Machine

521D

621D

721D
Location
Job Code

STEERING CYLINDERS / ACTUATORS

STEERING CYLINDERS 050761
Steering Cylinder, R&I 1.0 1.0 1.0 050761A
Steering Cylinder, Overhaul (Includes Job Code
2.4 2.4 2.4 050761B
050761A)

STEERING HEAT EXCHANGERS

OIL COOLER 050771
Hydraulic System Oil Cooler, R&I 2.0 2.0 2.0 050771A

Cre 9-88990 Issued 09-03

 Copyright ©
POWERTRAIN 6-1
Machine

521D

621D

721D
Location
Job Code
MAINTENANCE xxxxxx
Drain & Fill Oil In Transmission 0.4 0.4 0.4 060001A
Drain & Fill Oil In Axle 0.4 0.4 0.4 060001B
Drain & Fill Oil In Planetary 0.4 0.4 0.4 060001C
Transmission Filter, Replace 0.3 0.3 0.3 060001D

TROUBLESHOOTING xxxxxx
Converter Stall Speed Test 0.4 0.4 0.4 060002A
Check Operation of Clutch Cutout 0.3 0.3 0.3 060002B
Test Transmission Pressures 1.0 1.0 1.0 060002C

REMOVAL & INSTALLATION OR OVERHAUL xxxxxx

Powershift Transmission, R&I (Includes Job Code
14.5 14.5 14.5 060003A
090311D)
Complete Powershift Transmission, Overhaul
35.5 35.5 35.5 060003B
(Includes Job Code 060003A)
Axle Assembly - Front, R&I 3.8 3.8 3.8 060003C
Axle Assembly - Rear, R&I 4.4 4.4 4.4 060003D
Axle Assembly - Front, Overhaul (Includes Job Code
14.3 14.3 14.3 060003E
060003C)
Axle Assembly - Rear, Overhaul (Includes Job Code
15.4 15.4 15.4 060003F
060003D)
Differential Assembly - Front, R&I (Includes Job
5.5 5.5 5.5 060003G
Code 060003C)
Differential Assembly - Rear, R&I (Includes Job Code
6.0 6.0 6.0 060003H
060003D)
Differential Assembly - Front, Overhaul (Includes Job
9.5 9.5 9.5 060003I
Code 060003G)
Differential Assembly - Rear, Overhaul (Includes Job
10.0 10.0 10.0 060003J
Code 060003H)

NOTE : Axle assembly overhaul complete (Includes

: brakes, differential and planetaries).

TORQUE CONVERTERS
TORQUE CONVERTERS 061010
Torque Converter, R&I (Includes Job Code 060003A) 16.2 16.2 16.2 061010A

HYDRAULIC SYSTEM FOR POWERSHIFT TRANSMISSION

POWERSHIFT TRANSMISSION RESERVOIR AND FILTERS 062311
Filler Tube - Transmission, R&I 0.7 0.7 0.7 062311A
Sight Gauge/Hose, R&I 0.5 0.5 0.5 062311B

POWERSHIFT PUMPS 062313

Charge Pump Assembly for Powershift
20.0 20.0 20.0 062313A
Transmission, R&I (Includes Job Codes 061010A)
Charge Pump/ Pressure Regulator Assembly for
Powershift Transmission, Overhaul (Includes Job 23.0 23.0 23.0 062313B
Code 062313A)

Cre 9-88990 Issued 09-03

 Copyright ©
POWERTRAIN 6-2
Machine

521D

621D

721D
Location
Job Code
POWERSHIFT TRANSMISSION HYDRAULIC LINES/FITTINGS 062315
Fitting - Inlet/Outlet of Transmission, R&I (One) 1.0 1.0 1.0 062315A
Line - Transmission to Cooler, R&I 2.0 2.0 2.0 062315B
Line - Cooler to Transmission, R&I 2.0 2.0 2.0 062315C

POWERSHIFT TRANSMISSION CONTROL VALVE 062317

Transmission Control Valve Assembly, R&I 2.3 2.3 2.3 062317A
Transmission Control Valve Assembly, Complete
5.6 5.6 5.6 062317B
Overhaul (Includes Job Code 062317A)
Torque Converter Control Pressure Relief, R&I
1.0 1.0 1.0 062317C
(Located In Transmission Housing)

TRANSMISSION OIL COOLER 062319

Transmission Oil Cooler, R&I (Includes Hood, R&I) 1.5 1.5 1.5 062319A

POWERSHIFT CLUTCHES AND SHAFTS

POWERSHIFT TRANSMISSION CLUTCH PACKS 062321

NOTE : For repairs in this machine location, refer to

Job Codes 060003A or 060003B.

POWERSHIFT TRANSMISSION
SHAFTS/BEARINGS/BUSHINGS 062323
Oil Seal for Output Shaft, R&I 2.0 2.0 2.0 062323A

NOTE : For other repairs in this machine location,

refer to Job Codes 060003A or 060003B.

POWERSHIFT GEARS AND HOUSINGS

POWERSHIFT TRANSMISSION HOUSING 062335
Breather - Transmission Housing, R&I 0.9 0.9 0.9 062335A

NOTE : For repairs in this machine location, refer to

Job Codes 060003A or 060003B.

DIFFERENTIAL AND AXLES

DIFFERENTIAL AND AXLES SHAFTS/BEARINGS 063111
Axle Shaft/Sun Gear, R&I 3.0 3.0 3.0 063111A
Oil Seal - Differential Pinion, R&I 2.0 2.0 2.0 063111B

NOTE : For repairs in these machine locations, refer

to 060003 Job Codes.

DIFFERENTIAL AND AXLES GEARS 063113

NOTE : For repairs in this machine location, refer to

060003 Job Codes.

Cre 9-88990 Issued 09-03

 Copyright ©
POWERTRAIN 6-3
Machine

521D

621D

721D
Location
Job Code
DIFFERENTIAL AND AXLE HOUSINGS 063119
Front Axle Housing, Replace 12.0 12.0 12.0 063119A
Rear Axle Pivot Pin End Cap, R&I 1.0 1.0 1.0 063119B
Rear Axle Pivot Pin, R&I (Includes Job Code
2.0 2.0 2.0 063119C
063119B)
Rear Axle Housing, Replace 12.5 12.5 12.5 063119D
Breather - Axle Housing, R&I 0.3 0.3 0.3 063119E

PLANETARIES
PLANETARY CARRIER 063121
Planetary Carrier Assembly, R&I (One) 3.0 3.0 3.0 063121A
Planetary Carrier Assembly, Overhaul (One)
4.5 4.5 4.5 063121B
(Includes Job Code 063121A)

PLANETARY GEARS 063123

Ring Gear, R&I 3.2 3.2 3.2 063123A

PLANETARY HOUSING 063127

Housing - Planetary (Wheel Hub), R&I 4.5 4.5 4.5 063127A
Oil Seal - Wheel Hub, Replace 4.8 4.8 4.8 063127B
Flange/Ouput Shaft - Axle Wheel End, R&I 4.5 4.5 4.5 063127C

DRIVE LINES
DRIVE SHAFT 063161
Drive Shaft - Engine, R&I 1.0 1.0 1.0 063161A
Drive Shaft - Front, R&I 1.3 1.3 1.3 063161B
Drive Shaft - Center, R&I 0.8 0.8 0.8 063161C
Drive Shaft - Rear, R&I 0.8 0.8 0.8 063161D
Drive Shaft Support Bearing, R&I 0.9 0.9 0.9 063161E

UNIVERSAL JOINTS (DRIVE LINES ONLY) 063163

Universal Joint - Engine, R&I (Includes Job Code
1.4 1.4 1.4 063163A
063161A)
Universal Joint - Front, R&I (Includes Job Code
1.9 1.9 1.9 063163B
063161B)
Universal Joint - Center, R&I (Includes Job Code
1.4 1.4 1.4 063163C
063161C)
Universal Joint - Rear, R&I (Includes Job Code
1.4 1.4 1.4 063163D
063161D)

HUBS/WHEELS/TIRES 063170
Wheel & Tire Assembly, R&I (One) 0.6 0.6 0.6 063170A

OPERATOR CONTROLS - TRANSMISSION

NOTE : Refer to machine location 046039.

Cre 9-88990 Issued 09-03

 Copyright ©
BRAKES 7-1
Machine

521D

521D

721D
Location
Job Code
MAINTENANCE xxxxxx
Remove Air From Brake System 0.5 0.5 0.5 070001A

TROUBLESHOOTING xxxxxx
Test Brake Pressure 0.3 0.3 0.3 070002A
Adjust Brake Pressure (Includes Job Code 070002A) 0.5 0.5 0.5 070002B
Flowmeter Test (Hydraulic Brake Pump) 1.0 1.0 1.0 070002C
Test and Recharge Accumulator (One) 0.5 0.5 0.5 070002D
Test and Recharge Accumulator (Both) 0.8 0.8 0.8 070002E
Accumulator Charging Valve, R&I 0.7 0.7 0.7 070002F

BRAKE PUMPS
HYDRAULIC BRAKE/FAN PUMP 071031
Hydraulic Pump, R&I (For Hydraulic Brakes and
0.5 0.5 0.5 071031A
Cooling System Fan Drive)
Hydraulic Pump, Reseal (Includes Job Code
1.0 1.0 1.0 071031B
071031A)

NOTE : At pump cooling lines, refer to machine

location 050737.

BRAKE LINES
HYDRAULIC BRAKE LINES 071041
Fitting on Reservoir, R&I 0.4 0.4 0.4 071041A
Line - Reservoir to Pump, R&I 0.5 0.5 0.5 071041B
Line - Pump to Brake Valve, R&I 0.6 0.6 0.6 071041C
Line - Between Brake Valve and Accumulator, R&I 0.5 0.5 0.5 071041D
Line - Brake Valve to Reservoir, R&I 0.6 0.6 0.6 071041E
Line - Brake Valve to (Tee-Fitting) on Axle, R&I 0.6 0.6 0.6 071041F
Line - (Tee-Fitting) to Wheel End, R&I (One) 0.4 0.4 0.4 071041G
Line - Between Brake Valve and Park Brake
0.5 0.5 0.5 071041H
Accumulator, R&I

BRAKE VALVES
BRAKE CONTROL VALVE 071053
Brake Valve, R&I 1.6 1.6 1.6 071053A
Brake Valve, Overhaul (Includes Job Code 071053A) 2.6 2.6 2.6 071053B

BRAKE CYLINDER/CHAMBER
ACCUMULATOR 071067
Accumulator (Service & Parking Brake), R&I 1.0 1.0 *** 071067A
Accumulator (Service & Parking Brake), Overhaul
2.0 2.0 *** 071067B
(Includes Job Code 071067A)
Accumulator (Service Brake), R&I *** *** 0.8 071067C
Accumulator (Parking Brake), Overhaul *** *** 0.6 071067D

Cre 9-88990 Issued 09-03

 Copyright ©
BRAKES 7-2
Machine

521D

521D

721D
Location
Job Code

BRAKE (PLATES, ROTORS, ACTUATORS)

BRAKE ADJUSTERS/ACTUATORS 071071
Caliper Assembly - Parking Brake, R&I 0.6 0.6 0.6 071071A
Caliper Assembly - Parking Brake, Overhaul
1.1 1.1 1.1 071071B
(Includes Job Code 071071A)

BRAKE PLATES AND PADS 071073

Axle Brake Plates/Discs and Piston Asssembly, R&I
3.9 3.9 3.9 071073A
(One Set – Includes Seals & Springs)
Pads - Parking Brake, R&I 0.8 0.8 0.8 071073B

BRAKE ROTORS 071075

Rotor - Parking Brake, R&I 2.0 2.0 2.0 071075A

OPERATOR CONTROLS
PEDALS/LEVERS 071081
Brake Pedal – Left, R&I 0.7 0.7 0.7 071081A
Brake Pedal - Right, R&I (Includes Shaft/Block) 0.9 0.9 0.9 071081B
Torsion Spring - Brake Pedal, R&I 0.5 0.5 0.5 071081C

PARKING BRAKE LINKAGE 071085

NOTE : Refer to machine location 046039 at

electrical park brake system.

Cre 9-88990 Issued 09-03

 Copyright ©
HYDRAULIC SYSTEM 8-1
Machine

521D

621D

721D
Location
Job Code
MAINTENANCE xxxxxx
Filter Elements - Hydraulic Oil, Replace 0.5 0.5 0.5 080001A
Drain & Fill Oil In Hydraulic Reservoir 0.5 0.5 0.5 080001B
Install Vacuum Pump on Hydraulic Reservoir 0.3 0.3 0.3 080001C
Install Portable Filter / Filter Oil In The Hydraulic
1.5 1.5 1.5 080001D
System (Includes Job Code 080001A)

TROUBLESHOOTING xxxxxx
Test & Adjust Main Relief Valve With Pressure
0.7 0.7 0.7 080002A
Gauge
Test & Adjust Secondary Relief Valve With Hand
0.7 0.7 0.7 080002B
Pump - ‘A” Port
Test & Adjust Secondary Relief Valve With Hand
0.7 0.7 0.7 080002C
Pump - ‘B’ Port
Test Pressure Combination / Regulating Valve With
0.8 0.8 0.8 080002D
Pressure Gauge (Pilot Assist)
Test & Adjust - Standby Pressures (High/Low) (Pfc -
0.9 0.9 0.9 080002E
Piston Pump Settings)
Test & Recharge Accumulator 0.8 0.8 0.8 080002F
Test Complete Hydraulic System With A Flowmeter
1.3 1.3 1.3 080002G
(Pump & Tee Test)
Isolation/Leak Test Hydraulic Cylinder 0.6 0.6 0.6 080002H

HYDRAULIC RESERVOIR AND FILTERS

HYDRAULIC RESERVOIR 084111
Drain Hose/Cap Plug for Reservoir, R&I (Includes
0.6 0.6 0.6 084111A
Job Code 080001D)
Fill Cap for Reservoir, R&I 0.1 0.1 0.1 084111B
Access Cover for Reservoir, R&I 0.3 0.3 0.3 084111C
Sight Gauge, R&I 0.4 0.4 0.4 084111D
Hydraulic Reservoir, R&I 084111E

HYDRAULIC FILTERS 084113

Filter Bypass Valve, R&I 084113A
Filter Head Assembly, R&I (Includes Replace Filters) 1.3 1.3 1.3 084113B

BREATHERS AND RELIEFS (HYDRAULIC RESERVOIR) 084115

Reservoir Relief, R&I 0.4 0.4 0.4 084115A

HYDRAULIC PUMPS
MAIN SYSTEM PUMP 084121
Main System Pump, R&I 3.0 3.0 3.0 084121A
Main System Pump, Overhaul (Includes Job Code
4.5 4.5 4.5 084121B
084121A)
Pilot Valve (Compensator) Assembly, R&I 084121C
Pilot Valve (Compensator) Assembly, Overhaul
084121D
(Includes Job Code 084121C)

NOTE : For cooling fan and brake system pump

refer to machine location 071031.

Cre 9-88990 Issued 09-03

 Copyright ©
HYDRAULIC SYSTEM 8-2
Machine

521D

621D

721D
Location
Job Code

HYDRAULIC LINES (BETWEEN RESERVOIR AND VALVE)

PUMP INLET LINES 084131
Line - Outlet of Reservoir to Main Pump, R&I 0.9 0.9 0.9 084131A
Fitting - Inlet of Main Pump, R&I 1.3 1.3 1.3 084131B

PUMP TO VALVE CIRCUIT LINES 084133

Fitting - Pump Outlet, R&I 1.0 1.0 1.0 084133A
Line - Pump Outlet to Loader Valve, R&I 1.3 1.3 1.3 084133B
Fitting - Inlet of Loader Valve, R&I 0.4 0.4 0.4 084133C
Pressure Test Coupling, R&I (Quick Disconnect
0.3 0.3 0.3 084133D
Fitting)

RETURN CIRCUIT LINES 084135

Fitting - Outlet of Loader Valve, R&I 1.0 1.0 1.0 084135A
Line - Outlet of Loader Valve to Filter, R&I 1.2 1.2 1.2 084135B
Manifold at Filter Head, R&I 0.5 0.5 0.5 084135C
Fitting at Filter Head, R&I 0.5 0.5 0.5 084135D
Line - Outlet of Filter Head to Reservoir, R&I 1.5 1.5 1.5 084135E
Signal Line - Pump Compensator, R&I (One) 1.0 1.0 1.0 084135F
Fitting - Pump Compensator Line, R&I (One) 1.0 1.0 1.0 084135G

COOLING CIRCUIT LINES

NOTE : For repairs, refer to machine location
050737.

HYDRAULIC VALVES
MAIN RELIEF VALVE 084141
Main Relief Valve, R&I (Includes Job Code 080002A) 0.9 0.9 0.9 084141A
Main Relief Valve, Overhaul (Includes Job Code
1.3 1.3 1.3 084141B
084141A)

CONTROL VALVE (DIRECTIONAL FLOW) 084143

Loader Control Valve, R&I 3.1 3.1 3.1 084143A
O-Rings Between Valve Sections, Replace (Includes
3.9 3.9 3.9 084143B
Job Code 084143A)
Valve Section - One Section, Overhaul (Includes Job
4.4 4.4 4.4 084143C
Code 084143B)
Valve Section - Two Sections, Overhaul (Includes
5.4 5.4 5.4 084143D
Job Code 084143B)
Valve Section - Three Sections, Overhaul (Includes
6.4 6.4 6.4 084143E
Job Code 084143B)

Cre 9-88990 Issued 09-03

 Copyright ©
HYDRAULIC SYSTEM 8-3
Machine

521D

621D

721D
Location
Job Code
CIRCUIT RELIEF VALVES 084145
Circuit Relief Valve - ‘A’ Port, R&I (Includes Job Code
1.0 1.0 1.0 084145A
080002B)
Circuit Relief Valve - ‘B’ Port, R&I (Includes Job Code
1.0 1.0 1.0 084145B
080002C)
Circuit Relief Valve - ‘A’ Port, Overhaul (Includes Job
1.4 1.4 1.4 084145C
Code 084145A)
Circuit Relief Valve - ‘B’ Port , Overhaul (Includes Job
1.4 1.4 1.4 084145D
Code 084145B)
Ride Control Relief (Selector) Valve, R&I (One) 1.5 1.5 1.5 084145E
Ride Control Relief (Selector) Valve, Overhaul
1.8 1.8 1.8 084145F
(Includes Job Code 084145E)

POWER ASSIST CONTROL VALVE (PILOT CONTROL) 084146

Operator Control Valve - Power Assist, R&I (Hand
1.7 1.7 1.7 084146A
Control Valve)
Operator Control Valve - Power Assist, Overhaul
2.6 2.6 2.6 084146B
(Includes Job Code 084146A)
Auxiliary Control Valve - Power Assist, R&I 1.4 1.4 1.4 084146C
Auxiliary Control Valve - Power Assist, Overhaul
2.1 2.1 2.1 084146D
(Includes Job Code 084146C)

FLOW/PRESSURE DIVIDER VALVES 084147

Pressure Regulator Valve, R&I (Hydraulic Power
0.9 0.9 0.9 084147A
Assist)
Pressure Regulator Valve, Overhaul (Hydraulic
1.4 1.4 1.4 084147B
Power Assist) (Includes Job Code 084147A)

CONTROL VALVES - OPTIONS 084148

Cooling Fan Reversing Valve, R&I 2.0 2.0 2.0 084148A
Ride Control Valve, R&I (One) 1.2 1.2 1.2 084148B
Ride Control Valve, Overhaul (Includes Job Code
1.5 1.5 1.5 084148C
084143F)
Solenoid Valve, R&I - Locking Attachment Coupler 0.7 0.7 0.7 084148D

HYDRAULIC LINES (BETWEEN VALVE AND RESERVOIR)

LIFT CIRCUIT LINES 084151
Fitting at Control Valve, R&I 0.9 0.9 0.9 084151A
Line at Control Valve, R&I 1.0 1.0 1.0 084151B
Intermediate Line Between Control Valve and Lift
1.0 1.0 1.0 084151C
Cylinders, R&I
Line at Lift Cylinder - Rod End, R&I 0.7 0.7 0.7 084151D
Line at Lift Cylinder - Closed End, R&I 0.5 0.5 0.5 084151E
Fitting at Lift Cylinder, R&I 0.3 0.3 0.3 084151F
Line Between Ride Control Valve & Lift Circuit, R&I 1.0 1.0 1.0 084151G
Line Between Ride Control Valve & Accumulator, R&I 1.0 1.0 1.0 084151H
Line Between Ride Control Valve & Loader Valve,
1.0 1.0 1.0 084151I
R&I (Also Bleed Off Line)
Line Between Loader Valve & Filter, R&I 1.0 1.0 1.0 084151J

Cre 9-88990 Issued 09-03

 Copyright ©
HYDRAULIC SYSTEM 8-4
Machine

521D

621D

721D
Location
Job Code
BUCKET CIRCUIT LINES 084153
Fitting at Control Valve, R&I 0.9 0.9 0.9 084153A
Line at Control Valve, R&I 1.3 1.3 1.3 084153B
Intermediate Line to Closed End of Bucket Cylinder,
0.7 0.7 0.7 084153C
R&I
Line at Bucket Cylinder - Rod End, R&I 0.7 0.7 0.7 084153D
Line at Bucket Cylinder - Closed End, R&I 0.8 0.8 0.8 084153E
Fitting at Bucket Cylinder, R&I 0.3 0.3 0.3 084153F

AUXILIARY/COUPLER CIRCUIT LINES 084157

Auxiliary Circuit Line, R&I (One) 1.0 1.0 1.0 084157A
Coupler Attach Circuit Line, R&I (One) 1.0 1.0 1.0 084157B

POWER ASSIST CIRCUIT LINES (PILOT LINES) 084159

Line - Loader Valve to Hand Control Valve, R&I 0.7 0.7 0.7 084159A
Line - Loader Valve to Pilot Accumulator, R&I 0.6 0.6 0.6 084159B
Fitting at Accumulator, R&I 1.0 1.0 1.0 084159C
Fitting at Operator Control Valve, R&I 0.4 0.4 0.4 084159D
Line - Operator Control Valve to Loader Valve, R&I 1.0 1.0 1.0 084159E
Return Line Control Valve to Reservoir, R&I 0.5 0.5 0.5 084159F
Fitting at Loader Valve, R&I 0.5 0.5 0.5 084159G

HYDRAULIC CYLINDERS
LIFT CYLINDER 084161
Lift Cylinder, R&I 1.6 1.6 1.6 084161A
Cylinder Seal Kit, Replace 2.0 2.0 2.0 084161B
Cylinder Tube, R&I (Includes Job Codes 084161A
3.2 3.2 3.2 084161C
and 084161B)

BUCKET CIYLINDER 084163

Bucket Cylinder 1.9 1.9 1.9 084163A
Cylinder Seal Kit, Replace 2.5 2.5 2.5 084163B
Cylinder Tube, R&I (Includes Job Codes 084163A
3.4 3.4 3.4 084163C
and 084163B)

HYDRAULIC MOTORS
HYDRAULIC MOTOR (COOLING SYSTEM) 084170
Cooling Fan Motor, R&I (At - Cooling Box) 2.5 2.5 2.5 084170A
Hydraulic Line, R&I - Hydraulic Fan Motor (One) 2.0 2.0 2.0 084170B

Cre 9-88990 Issued 09-03

 Copyright ©
HYDRAULIC SYSTEM 8-5
Machine

521D

621D

721D
Location
Job Code

HYDRAULIC ACCUMULATORS
ACCUMULATORS 084183
Accumulator - Hydraulic Power Assist, R&I 084183A
Accumulator - Hydraulic Power Assist, Overhaul
084183B
(Includes Job Code 084183A)
Accumulator - Ride Control, R&I (One) 1.0 1.0 1.0 084183C
Accumulator - Ride Control, Overhaul (Includes
2.0 2.0 2.0 084183D
Charging & Job Code 084183C)

HYDRAULIC EQUIPMENT CONTROLS

EQUIPMENT CONTROL LEVERS 084191
Operator Remote Control Lever Assembly, R&I 0.6 0.6 0.6 084191A

EQUIPMENT CONTROL LINKAGE 084193

Linkage Assembly - Operator Remote Lever, R&I 0.8 0.8 0.8 084193A
Dust Boot for Operator Control Lever, R&I 0.3 0.3 0.3 084193B

RETURN-TO-DIG AND HEIGHT CONTROL 084195

Bracket/Mount - Proximity Switch, R&I 0.4 0.4 0.4 084195A
Plate/Actuator for Height or Return-To-Travel, R&I 1.0 1.0 1.0 084195B
Cover - Proximity Switch, R&I 0.3 0.3 0.3 084195C

NOTE : For electrical components in height control

or return-to-dig circuits, go to machine locations
046031 or 046032.

Cre 9-88990 Issued 09-03

 Copyright ©
CHASSIS 9-1
Machine

521D

621D

721D
Location
Job Code
MAINTENANCE xxxxxx
Evacuate & Charge Air Conditioning System 1.2 1.2 1.2 090001A

TROUBLESHOOTING xxxxxx
Troubleshoot Air Conditioning System Using Leak
1.0 1.0 1.0 090002A
Detector & Manifold Gauges

MAIN FRAME/CHASSIS 090111

Chassis - Front Frame, Replace 090111A
Chassis - Rear Frame, Replace 090111B
Upper Pivot Pin - Main Frame, R&I 1.2 1.3 1.3 090111C
Lower Pivot Pin - Main Frame, R&I 1.5 2.0 2.0 090111D

MOUNTING & SUSPENSION ENGINE/TRANSMISSION/AXLE/CAB 090115

Engine Mount, R&I (One, Includes Rubber Cushion) 1.0 1.0 1.0 090115A
Engine Mount, R&I (All, Includes Rubber Cushion) 2.5 2.5 2.5 090115B
Transmission Mounting Bracket (Lower), R&I 1.0 1.0 1.0 090115C
Transmission Mounting Bracket (Upper), R&I 090115D
Isolator - Transmission Mount, R&I 0.7 0.7 0.7 090115E
Pivot Pin - Rear Axle, R&I 2.0 2.0 2.0 090115F
Rubber Cushion for Mounting Cab/Rops, R&I 1.0 1.0 1.0 090115G
Frame Articulation Stop for Bumper, R&I 0.3 0.3 0.3 090115H

COUNTERWEIGHTS, DRAWBAR 090117

Counterweight, R&I (One) 0.9 0.9 1.0 090117A

PROTECTIVE COVERING/APPEARANCE/CONVENIENCE
HOOD AND SIDE PANELS 090131
Hood, R&I 0.7 0.7 1.0 090131A
Hood Access Door, R&I (Cooling System) 0.4 0.4 0.4 090131B
Hood Latch/Lock Assembly, R&I 0.4 0.4 0.4 090131C
Hood Jack Assembly/Support, R&I 0.4 0.4 0.5 090131D
Hood Insulation, R&I 090131E

SHROUD AND GRILLE 090132

Grille, R&I 0.4 0.4 0.4 090132A
Fan Guard (Right), R&I 0.5 0.5 0.5 090132B
Fan Guard (Left), R&I *** *** 0.5 090132C

FENDERS/STEPS/HANDRAILS 090133
Fenders - Front, R&I 0.5 0.5 0.5 090133A
Fenders - Rear, R&I 0.4 0.4 0.4 090133B
Rear Fender Support, R&I (One Side) 0.5 0.5 0.5 090133C
Mud Flat, R&I (One) 0.3 0.3 0.3 090133D
Upper Platform Step, R&I 0.7 0.7 0.7 090133E
Step, R&I 0.3 0.3 0.3 090133F
Step Assembly, R&I (Includes Job Code 090133F) 0.4 0.4 0.4 090133G
Handrail, R&I 090133H

Cre 9-88990 Issued 09-03

 Copyright ©
CHASSIS 9-2
Machine

521D

621D

721D
Location
Job Code
GUARDS/SHIELDS/TRIM 090135
Guard/Mount for Headlight, R&I 0.5 0.5 0.5 090135A
Guard for Hydraulic Filters, R&I 0.2 0.2 0.2 090135B
Frame Access Cover, R&I 0.2 0.2 0.2 090135C

LOCKUP KIT/BATTERY BOX/SAFETY EQUIPMENT 090136

Safety Lock for Chassis Pivot, R&I 0.2 0.2 0.2 090136A
Cover for Battery Compartment, R&I 0.4 0.4 0.4 090136B
Tool Box, R&I 0.1 0.1 0.1 090136C

PAINT AND DECALS 090137

NOTE : When paint or decal Job Codes are used, a
detailed explanation telling (what, why and how
much) is required.
Painting 090137A
Decals, Replace 090137B

MAINTENANCE SYSTEMS
LUBRIFICATION SYSTEM 090151
Lube/Grease Lubrication Line, R&I 0.5 0.5 0.5 090151A
Fitting for Lube Line, R&I 0.2 0.2 0.2 090151B

CAB/PROTECTIVE STRUCTURES
CAB FRAME AND HARDWARE 090311
Cover Skirt/Panel for Cab - Lower Front, R&I 0.6 0.6 0.6 090311A
Cover Skirt/Panel for Cab - Lower Side, R&I 0.4 0.4 0.4 090311B
Door/Panel for Outside Access to Cab Air Filter or
0.4 0.4 0.4 090311C
Control Console, R&I
Cab Assembly, R&I 7.0 7.0 7.0 090311D
Cab Assembly, Replace (Includes Job Code
090311E
090311D)

CAB DOORS AND WINDOWS 090313

Handle - Cab Door, R&I 0.5 0.5 0.5 090313A
Latch - Cab Door, R&I 0.4 0.4 0.4 090313B
Window - Cab Door, R&I 1.1 1.1 1.1 090313C
Cab Door, R&I 0.8 0.8 0.8 090313D
Windshield – Center Section, R&I 3.0 3.0 3.0 090313E
Windshield – Side Section, R&I 2.5 2.5 2.5 090313F
Handle/Latch for Cab Window, R&I 0.6 0.6 0.6 090313G
Rear Window, R&I 0.9 0.9 0.9 090313H
Outside Mirror, R&I 0.2 0.2 0.2 090313I
Rear View Mirror, R&I 0.3 0.3 0.3 090313J

Cre 9-88990 Issued 09-03

 Copyright ©
CHASSIS 9-3
Machine

521D

621D

721D
Location
Job Code
PRESSURIZER/FILTER 090314
Cab Air Filter - Fresh Air, R&I 0.1 0.1 0.1 090314A
Cab Air Filter - Recirculation, R&I 0.2 0.2 0.2 090314B

CAB HEATER AND DEFROSTER 090315

Air Louver, R&I 0.1 0.1 0.1 090315A
Air Duct, R&I 0.5 0.5 0.5 090315B
Rear Blower Box Cover/Louver Plate, R&I 0.5 0.5 0.5 090315C
Plenum, R&I 0.4 0.4 0.4 090315D
Heater Core, R&I (Units Without Air Conditioning) 2.5 2.5 2.5 090315E
Heater Hose or Line, R&I (Engine to Heater Core) 1.5 1.5 1.5 090315F
Heater Control Valve, R&I 1.0 1.0 1.0 090315G
Cable - Heater Control Valve, R&I 1.1 1.1 1.1 090315H

AIR CONDITIONING SYSTEM 090317

NOTE : Job code - 090001A - is not included in

these air conditioning Job codes.
ADD - 090001A - one time per A/C system repair, If
necessary.
A/C compressor clutch refer to machine location
044010.
Drive Belt - Compressor, R&I 0.3 0.3 0.3 090317A
Compressor, R&I 0.8 0.8 0.8 090317B
Compressor, Overhaul (Includes Job Code 090317B) 090317C
Mounting Bracket – Compressor, R&I 0.8 0.8 0.8 090317D
Line - Cab to Compressor, R&I (Low Pressure) 0.6 0.6 0.6 090317E
Line - Compressor to Condenser, R&I (High
0.6 0.6 0.6 090317F
Pressure)
Line/Tube at Expansion Valve, R&I 0.4 0.4 0.4 090317G
Expansion Valve, R&I 1.5 1.5 1.5 090317H
Heater/Evaporator Core, R&I 2.5 2.5 2.5 090317I
Line - Receiver Drier to Cab, R&I 0.4 0.4 0.4 090317J
Receiver Drier, R&I 0.6 0.6 0.6 090317K
Condenser, R&I 0.6 0.6 0.6 090317L
Line - Condenser to Receiver Drier, R&I 0.5 0.5 0.5 090317M
Cover - Condenser Assembly, R&I 0.3 0.3 0.3 090317N
Swivel/Bracket - Condenser Assembly, R&I 0.8 0.8 0.8 090317O
Condensation Tray, R&I (Evaporator) 2.0 2.0 2.0 090317P
Drain Hose, R&I 0.2 0.2 0.2 090317Q

OPERATOR CONSOLE, INSTRUMENT PANEL AND STEERING COLUMN 090318

Pedestal Cover, R&I (Upper) 0.5 0.5 0.5 090318A
Transmission Shift Selector Cover, R&I 0.4 0.4 0.4 090318B
Steering Column Cover, R&I (Lower) 0.7 0.7 0.7 090318C
Steering Column Boot, R&I 0.5 0.5 0.5 090318D
Right Hand Control Console Cover, R&I 2.0 2.0 2.0 090318E
Rear Storage Console Cover, R&I 0.6 0.6 0.6 090318F

Cre 9-88990 Issued 09-03

 Copyright ©
CHASSIS 9-4
Machine

521D

621D

721D
Location
Job Code
INTERIOR INSULATION/HEADLINER/FLOORMAT/TRIM 090319
Headliner, R&I 1.5 1.5 1.5 090319A
Floormat, R&I 0.8 0.8 0.8 090319B
Cover - Rops Post, R&I 0.5 0.5 0.5 090319C
Cab Foam/Insulation, R&I (Acoustic & Insulating) 090319D
Sun Visor, R&I 0.2 0.2 0.2 090319E
Storage Strap, R&I 0.1 0.1 0.1 090319F
Ash Tray, R&I 0.1 0.1 0.1 090319G
Coat Hook, R&I 0.1 0.1 0.1 090319H

PROTECTIVE STRUCTURES
ROPS 090321
Rops Assembly, R&I 090321A
Rops, Replace (Includes Job Code 090321A) 090321B

SEAT AND SEAT BELTS

SEAT AND SUPPORTS 090331
Seat Assembly, R&I 1.0 1.0 1.0 090331A
Seat Cushions - Back, R&I 090331B
Seat Cushions - Seat, R&I 090331C
Arm Rest, R&I 0.4 0.4 0.4 090331D
Slide or Slide Tubes, R&I (Includes Bushings) 0.8 0.8 0.8 090331E
Seat Suspension Assembly, Overhaul (Includes Seat,
090331F
R&I)
Shock Absorber, R&I 090331G
Boot/Cover for Suspension, R&I 0.4 0.4 0.4 090331H
Wire Harness, R&I 0.8 0.8 0.8 090331I
Control Switch, R&I 0.7 0.7 0.7 090331J
Air Compressor, R&I 1.2 1.2 1.2 090331K
Air Spring, R&I 1.4 1.4 1.4 090331L
Air Line, R&I 0.6 0.6 0.6 090331M

SEAT BELT 090333

Seat Belts, R&I 0.3 0.3 0.3 090333A

LOADER GROUND ENGAGING/MATERIAL HANDLING COMPONENTS

LOADER BUCKETS AND TEETH 094111
Loader Bucket, R&I (Without Quick Attachment
1.1 1.1 1.1 094111A
Option)
Cutting Edge on Loader Bucket, R&I 094111B
Shanks - Loader Bucket Teeth, R&I (One) 0.4 0.4 0.4 094111C
Shanks - Loader Bucket Teeth, R&I (All) 2.0 2.0 2.0 094111D
Points - Loader Bucket Teeth, R&I (One) 0.3 0.3 0.3 094111E
Points - Loader Bucket Teeth, R&I (All) 1.9 1.9 1.9 094111F

Cre 9-88990 Issued 09-03

 Copyright ©
CHASSIS 9-5
Machine

521D

621D

721D
Location
Job Code

LOADER PINS, BUSHING AND LINKS

LOADER LIFT PINS, BUSHINGS AND LINKS 094121
Lift Frame Pivot Pin, R&I 2.5 2.5 2.5 094121A
Bushings for Pin In Job Code 094121A, R&I
3.5 3.5 3.5 094121B
(Includes Job Code 094121A)
Pivot Pin for Closed End of Lift Cylinder, R&I 2.0 2.0 2.0 094121C
Bushings for Pin In Job Code 094121C, R&I
3.0 3.0 3.0 094121D
(Includes Job Code 094121C)
Pin at Rod End of Lift Cylinder, R&I 2.0 2.0 2.0 094121E
Bushings for Pin In Job Code 094121E, R&I
3.0 3.0 3.0 094121F
(Includes Job Code 094121E)

LOADER BUCKET LINKAGE, PINS AND BUSHING 094123

Pin at Closed End of Bucket Cylinder, R&I 1.0 1.0 1.0 094123A
Bushings for Pin In Job Code 094123A, R&I
3.5 3.5 3.5 094123B
(Includes Job Code 094123A)
Pin at Rod End of Bucket Cylinder, R&I 1.0 1.0 1.0 094123C
Bushings for Pin In Job Code 094123C, R&I
3.0 3.0 3.0 094123D
(Includes Job Code 094123C)
Center Pivot Pin for Bellcrank, R&I 2.0 2.0 2.0 094123E
Bushings for Pin In Job Code 094123E, R&I
3.0 3.0 3.0 094123F
(Includes Job Code 094123E)
Pin - Mounting Bucket Link to Bellcrank, R&I 1.0 1.0 1.0 094123G
Bushings for Pin In Job Code 094123G, R&I(Includes
2.5 2.5 2.5 094123H
Job Code 094123G)
Pin for Mounting Bucket Link to Bucket, R&I 1.0 1.0 1.0 094123I
Bushings for Pin In Job Code 094123I, R&I (Includes
2.0 2.0 2.0 094123J
Job Code 094123I)

LOADER STRUCTURAL MEMBERS

LIFT ARMS 094131
Loader Lift Arms, R&I 7.0 7.0 7.0 094131A
LOADER BUCKET LINKAGE 094133
Link - Bellcrank to Bucket, R&I 1.5 1.5 1.5 094133A
Bellcrank, R&I 4.5 4.5 4.5 094133A

Cre 9-88990 Issued 09-03

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