- ENGINE & ATTACHING PARTS
Series III Highway Speed Excavators 808540014-2
Power Unit Assembly
124128135
127 98
36
38
37 151 78 1278993
143172 143
172
142171
9
13120131168
81921112
166171
16164
143172
52
131154167
31332
4 5 13 92129
8995 13
3476
502053
121132155
12513013679
99126130
21332
301351154
163 12119130
21300350
13123133156
1021
1334
7750
80 89 91113
180
15
22401402 402
DETAIL “A”
USE ITEM 135TO SHIM CYLINDER
ON MOUNT.
.015 TO .020 GAP BETWEENADJUSTMENT SCREW & LEVER.
TIGHTEN NUT AFTER ADJUSTING.DO NOT PRELOAD.
PORT “A”
PORTA & B
PORT “B”
SEE DETAIL “A”
FOR MACHINES EQUIPPED WITHEXHAUST BRAKE OPTION ONLY
TO EXHAUSTBRAKE
CYLINDER
501502
503
504505
502506
BEFORE S/N’sXL3100III - 3120000191 (4X2) & 3140000295 (4X4);XL4100III - 4100000392 (6X4) & 4160000043 (6X6);
XL5100III - 5100000577 (6X4 & 6X6)
PAC3992
- ENGINE & ATTACHING PARTS
80854001 Series III Highway Speed Excavators 4-3
Power Unit Assembly
82
23
39159
42
60102160
1133593
107 114
6
66153
10956
146588
134108
71
72
11
402
61
62
BREATHER SUPPLIEDWITH TRANSMISSION
REVERSESWITCH
SEE DETAIL VIEW CCLAMP AND HARDWAREFOR PILOT SUPPLY HOSE
1833587390
89158
157
109
88134
159
30 31108
252728
25 97117
87 49147
86
40
POSITIVEBATTERYCABLE
NEGATIVEBATTERYCABLE
TRANSMISSIONCOOLER LINE
DETAIL “B”
SEE DETAIL “B”
DETAIL “C”
17 85100175176177178
SPEED SENSOR UNDER YOKENOTE: INSTALL SENSOR UNTIL MAGNET END
OF SENSOR TOUCHES GEAR, THEN BACKOFF 1/2 TURN. TORQUE NUT TO 20 LB-FT.
PAC3870
- ENGINE & ATTACHING PARTS
Series III Highway Speed Excavators 808540014-4
Power Unit Assembly
31108161 31
109161
57
50
751394
6867107
104141145169
146
7140170
29162
17149
142171
139
63138
4164
134162
108
146173
59
P/S PRESSURE
ENG HARNESS
P/S SUCTION HOSE
AIR LINE TO RUNTEE ON GOVERNER
ROUTE TO P/SRESERVOIR ONUNDERCARRIAGE
HAND TORQUE NUTTO 70-80 LB-FT.NUT SUPPLIED
W/ALTERNATOR
23
84
49
7422
23
23
2349
31111159161
TOPORT "Y"
TOPORT "Z"
DETAIL “E”
"H"
TO SLAVEVLV “H”
NEUTRALSWITCH
TOPORT "X"
TO SLAVEVLV “L”
"L"
4470
43115
MOUNT TOREAR OF P/U
MOUNT TOFRONT OF P/U
R.H. COUNTERSHAFTPTO AIR FITTINGS
179
24174
SEEDETAIL “F”
110
4887
468683
152122132
54137
110 49 69116
49
47
DETAIL “D”
"Z"
"Y"
"X"
SEE DETAIL “D”
SEE DETAIL “E”
31118 51
1388
40
2245
101
DETAIL “F”"B RES 1"
PORT “2A”TO AIR
COMPRESSOR
PAC3881PAC3890
- ENGINE & ATTACHING PARTS
80854001 Series III Highway Speed Excavators 4-5
Power Unit Assembly
PAC3902
103
SPICER 2-PLATE CLUTCH.ASSEMBLE PER INSTRUCTIONSINCLUDED WITH CLUTCH KIT
GAP BETWEEN CLUTCHRELEASE FINGERS & THROW-OUT BEARING HOUSINGMUST BE MAINTAINED. DONOT PRELOAD BEARINGHOUSING.
RAISED SIDE, (SMALLERDIAMETER SURFACE),TOWARDS TRANSMISSION
(4) INTERMEDIATED PLATE PINS.SEE CLUTCH INSTALLATIONINSTRUCTIONS.
1
2
3
45
6
7
8
CLUTCH INSTALLATION INSTRUCTIONS:
* ASSEMBLE CLUTCH DISC OVER ALIGNMENT TOOL.
* INSTALL PRESSURE PLATE CAPSCREWS FINGER TIGHT.
* TIGHTEN CAPSCREW ONE TURN AT A TIME IN A CRISS-CROSSPATTERN AS INDICATED BY NUMBERS; TIGHTEN THE CAPSCREWS TO35-40 LB-FT.
* REMOVE ALIGNING TOOL.LIGHTLY TAP 4 INTERMEDIATE PLATE PINS. PINS ARE TO TOUCHFLYWHEEL.
* INSTALL TRANSMISSION
* ADJUST RELEASE BEARING TO .500 DIM. USING ADJUSTER RING.LOCK WITH LOCKNUT RING.
REMOVE GREASE FITTINGFROM TROWOUT BEARINGAND INSTALL IN ITEM #49.
148
150
55
96130
81
181
182
- ENGINE & ATTACHING PARTS
Series III Highway Speed Excavators 808540014-6
Power Unit AssemblyItem Part Number Qty. Description Rev.
Consult Factory Ref POWER UNIT ASSY, XL3100III,(includes items 1 thru 179 & items 350 & 351)
F
Consult Factory Ref POWER UNIT ASSY w/EXHAUST BRAKE, XL3100III,(includes items 1 thru 179, 350 & 351 & items 400 thru 402)
F
Consult Factory Ref POWER UNIT ASSY, XL4100III & XL5100III,(includes items 1 thru 179 & items 300 & 301)
F
Consult Factory Ref POWER UNIT ASSY w/EXHAUST BRAKE, XL4100III & XL5100III,(includes items 1 thru 179, 300 & 301 & items 400 thru 402)
F
1 0903344 1 VENT LINE BRACKET2 80781066 1 TOP PTO BRACKET3 80781065 1 LOWER PTO BRACKET4 1400129 1 FAN CLUTCH5 2060038 1 FAN6 2720599 1 RADIATOR HOSE7 2754868 1 SUCTION PILOT PUMP HOSE ASSY8 Ref TRAVEL MOTOR ASSY, (see page 9-98 for details)9 Ref COUNTERSHAFT PTO ASSY, (see page 9-110 for details)
10 Ref PTO ASSY, (see page 9-106 for details)11 4923323 1 ENGINE HARNESS12 12001234 4 HARDENED WASHER, 3/813 14403364 A/R LOCTITE, (#242 blue)14 14403416 A/R DI-ELECTRIC GREASE15 A/R MOTOR OIL, (consult Operator Manual for spec)16 14404043 A/R LOCTITE, (#545 purple)17 14404082 A/R LOCTITE, (#565 white)18 14404102 A/R LOCTITE, (#277 red)19 14404825 A/R HYDRAULIC FLUID20 14404967 A/R TRANSMISSION OIL, (synthetic)21 14405342 A/R LOCTITE, #518, RED22 A/R NYLON TUBING, 1/4, BLACK23 A/R NYLON TUBING, 3/8, BLACK24 77133089 1 MINI-CHECK COUPLING, (includes item 174)25 77133136 1 CLAMP SET26 77133137 1 COVER PLATE27 77133306 1 STACK BOLT28 77133390 1 SAFETY CLIP29 77143003 1 WHIZ-LOK SCREW, 5/16-18X5/830 77143004 1 WHIZ-LOK SCREW, 5/16-18X1-1/431 77143006 6 WHIZ-LOK NUT, 5/16-1832 80223035 8 FLANGE SCREW, 1/2-13X3/4, GR8, (loctite & hand torque to 68-78 lb-ft)33 80233220 3 HARDENED WASHER, M1034 80303046 8 HEX HD CAPSCREW, M16-2X35, (loctite & hand torque to 32-37 lb-ft)35 80371106 2 SPACER BRACKET36 80381465 1 CLUTCH LEVER37 Ref SLAVE CYLINDER, (see page 5-6 for details)38 80383070 1 ROD END39 80383147 1 PUSH FITTING, 1/4X3/840 80383151 2 TUBE FITTING, 90 DEGREES, 1/8X1/4 TUBE41 80383165 1 TUBE FITTING, 90 DEGREES, 1/4X1/4 TUBE
- ENGINE & ATTACHING PARTS
80854001 Series III Highway Speed Excavators 4-7
42 80383166 1 TUBE FITTING, 90 DEGREES, 1/4X3/8 TUBE43 80383176 1 TUBE FITTING, 1/8X1/4X1/444 80383178 1 TUBE FITTING, 3/8X3/4X1/445 80383182 1 TUBE FITTING, 1/4X1/4X1/846 80383188 1 TUBE FITTING, 1/8X1/4X1/447 80383206 1 TUBE FITTING, 1/8X3/848 80383207 1 TUBE FITTING, 1/8X3/8X3/849 80383208 5 TUBE FITTING, 90 DEGREES, 1/8X3/850 80383399 6 LORD MOUNT51 80481095 1 MOUNTING PLATE52 80786016 1 PTO BRACKET53 Ref TRANSMISSION ASSY, (see page 5-8 for details)54 80483036 1 SUCTION ELBOW55 80483050 1 PILOT BEARING56 80483052 1 ALTERNATOR57 80483054 1 PULLEY58 80483055 1 STARTER59 80483056 1 DRIVE BELT, (w/o undercarriage air conditioner)
80483057 1 DRIVE BELT, (w/undercarriage air conditioner)60 80483080 1 ADAPTER61 80483090 1 POSITIVE BATTERY CABLE62 80483091 1 NEGATIVE BATTERY CABLE63 80483099 1 ADAPTER, M2664 80483100 1 ADAPTER, M1265 80483102 1 HEX HD CAPSCREW, M16-22X25, GR866 80483108 4 HEX HD CAPSCREW, M10-1.5X110, (hand torque to 38-43 lb-ft)67 80483109 1 RADIATOR TUBE COUPLING68 80483110 1 LOWER RADIATOR TUBE69 80483112 1 DUAL PORT, 90 DEGREES70 80483118 1 ELBOW, 90 DEGREES, 71 80483127 1 SLOBBER HOSE72 80483226 1 EXHAUST ADAPTER73 80483237 3 STUD, M10-1.5X4574 Ref ENGINE AIR VALVE ASSY, (see page 4-46 for details)75 80486016 1 FRONT ENGINE MOUNT76 80486017 1 ENGINE MOUNT, R.H.77 80486018 1 ENGINE MOUNT, L.H.78 80486022 1 CYLINDER BRACKET79 80486051 1 TRANSMISSION SUPPORT WELDMENT80 80533017 1 PILOT/POWER STEERING PUMP81 Ref CLUTCH ASSY, (see page 5-2 for details)82 80783002XXX 1 REVERSE LIGHT SWITCH ASSY83 80783003 1 HI-LO RANGE SWITCH ASSY84 80783004 1 NEUTRAL START SWITCH ASSY85 80975004S 1 SPEED SENSOR ASSY, (includes items 175 thru 178) -86 A/R NYLON TUBING, 1/4, RED87 A/R NYLON TUBING, 3/8, RED88 83191007 5 HEX HD CAPSCREW, M8-1.25X16, GR8.889 83191013 15 LOCKWASHER, M10
Power Unit AssemblyItem Part Number Qty. Description Rev.
- ENGINE & ATTACHING PARTS
Series III Highway Speed Excavators 808540014-8
90 83191030 3 HEX LOCKNUT, M10-1.5, (hand torque to 32-42 lb-ft)91 83191040 2 SOCKET HD CAPSCREW, M10-1.5X3092 83191045 4 HEX HD CAPSCREW, M8-1.25X30, GR8.893 83191065 4 SOCKET HD CAPSCREW, M10-1.5X45, (hand torque to 32-37 lb-ft)94 83191067 4 HEX HD CAPSCREW, M14-2X4595 83191082 10 SOCKET HD CAPSCREW, M10-1.5X35, (hand torque to 32-37 lb-ft)96 83201126 8 HEX HD CAPSCREW,3/8-16X2-1/2, GR897 83663119 1 CLAMP SET98 83681688 1 TUBE SPACER, 3-3/899 83683516 2 RUBBER STOP
100 83687060 1 SEAL101 84521054 1 GOVERNOR102 84712742 1 HOSE NIPPLE103 84716899 1 HOSE ASSY104 84721022 1 HOSE ASSY107 85071128 3 HOSE CLAMP108 85841150 5 SUPPORT CLAMP, 1-1/2109 85941016 4 SUPPORT CLAMP, 1/2110 85941017 2 SUPPORT CLAMP, 29/32111 85941018 1 SUPPORT CLAMP, 2112 86641304 A/R OPEN GEAR LUBE113 86671112 1 PILOT/POWER STEERING PUMP GASKET114 86971172 1 HOSE CLAMP115 86983648 1 BRASS ELBOW, 90 DEGREES, 1/8116 86983650 1 BRASS ELBOW, 90 DEGREES117 88201023 1 HEX HD CAPSCREW, 5/16-18X1-3/4, GR5118 88201028 2 HEX HD CAPSCREW, 5/16-18x3, GR5119 88201038 4 HEX HD CAPSCREW, 3/8-16X1-3/4, GR5120 88681443 4 HEX HD CAPSCREW, 1/2-13X2-3/4, GR5, (loctite & hand torque to 68-78 lb-ft)121 88201094 2 HEX HD CAPSCREW, 5/8-11X1-1/4, GR5122 88201096 4 HEX HD CAPSCREW, 5/8-11X1-3/4, GR5, (hand torque to 140-155 lb-ft)123 88201111 4 HEX HD CAPSCREW, 3/4-10X2, GR5, (loctite & hand torque to 240-265 lb-ft)124 88251043 1 SOCKET HD SHOULDER BOLT, 1/2X2-1/2, (10-24 thread)125 88261029 2 SOCKET BUTTON HD CAPSCREW, 3/8-16X1126 88501006 2 HEX NUT, 3/8-16127 88501410 2 HEX JAM NUT, 5/16-18128 88521206 1 HEX LOCKNUT, 3/8-16129 88551010 4 LOCKWASHER, 5/16130 88551011 16 LOCKWASHER, 3/8131 88551013 8 LOCKWASHER, 1/2132 88551015 6 LOCKWASHER, 5/8133 88551016 4 LOCKWASHER, 3/4134 88561003 5 FLAT WASHER, 5/16135 88561006 A/R FLAT WASHER, 1/2136 88561109 2 FLAT WASHER, 3/8137 88591115 1 O-RING138 88662107 1 ELBOW, 90 DEGREES, (swivel nut)139 88662304 1 CONNECTOR, (includes item 169)140 88662305 1 CONNECTOR, (includes item 170), (hand torque to 105-110 lb-ft)
Power Unit AssemblyItem Part Number Qty. Description Rev.
- ENGINE & ATTACHING PARTS
80854001 Series III Highway Speed Excavators 4-9
141 88662309 1 CONNECTOR, (includes item 169)142 88662329 2 ELBOW, 90 DEGREES, (includes item 171)143 88662330 4 ELBOW, 90 DEGREES, (includes item 172)145 88662375 1 ELBOW, 90 DEGREES, (swivel nut)146 88662430 2 CONNECTOR, (includes item 173), (hand torque to 52-54 lb-ft)147 88691300 1 BIJUR CONNECTOR, 3/4148 88711210 1 PIPE COUPLER, 1/8149 88711251 1 SQUARE HD PIPE PLUG, 1/4150 88743000 1 MALE ADAPTER, 1/8X1/4 TUBE151 88743010 1 MALE ADAPTER, 1/4X1/4 TUBE152 88743014 2 MALE ADAPTER, 1/2X3/8 TUBE153 90027470 4 HARDENED WASHER, 3/8154 90027471 6 HARDENED WASHER, 1/2155 90027472 2 HARDENED WASHER156 90027473 4 HARDENED WASHER, 7/16157 91033133 1 HEX NUT, M5X.8158 91033134 1 HEX NUT, M10-1.5, (hand torque to 15-22 lb-ft)159 91043147 4 SUPPORT CLAMP, 3/4160 91083155 1 TRUCK VALVE161 91363018 3 WHIZ-LOK SCREW, 5/16-18X1162 80973050 3 SUPPORT CLAMP163 83191080 2 SOCKET HD CAPSCREW, M12-1.75X40164 84721545 1 HOSE ASSY, (torque nuts on hose ends to 27-29 lb-ft)166 88662338 1 BRANCH TEE, (includes item 171)167 88201068 4 HEX HD CAPSCREW, 1/2-13X1-3/4, GR5168 88521008 4 HEX LOCKNUT, 1/2-13169 88591207 2 O-RING170 88591209 1 O-RING171 88591204 3 O-RING172 88591205 4 O-RING173 88591206 2 O-RING174 83763056 1 VITON O-RING, (lubricate lightly)175 80973017 1 SPEED SENSOR176 80963058 1 WEATHERPACK SHROUD, (2-wire)177 80963066 2 CABLE SEAL, 16GA., (gray)178 80963069 2 MALE TERMINAL PIN179 80774042 1 BELT TENSIONER IDLER180 Consult Factory Ref ENGINE181 80384399 1 CLUTCH BRAKE, (supplied w/transmission)182 83384092 1 CLUTCH RELEASE BEARING, (supplied w/transmission)
300 Ref MAIN HYDRAULIC PUMP ASSY, (see page 9-44 for details)301 80781067 1 PUMP BRACKET350 Ref MAIN HYDRAULIC PUMP ASSY, (see page 9-44 for details)351 80881039 1 PUMP BRACKET
400 80483129 1 TUBE FITTING, SWIVEL, M12-1.5X1/8
Power Unit AssemblyItem Part Number Qty. Description Rev.
- ENGINE & ATTACHING PARTS
Series III Highway Speed Excavators 808540014-10
401 80483130 1 TUBE FITTING, 90 DEGREES402 Ref ENGINE AIR VALVE ASSY, EXHAUST BRAKE, (see page 4-46 for details)501 88662348 2 RUN TEE, (includes item 502)502 88591206 4 O-RING503 80481213 1 LOCKING PLATE504 84721152 1 HOSE ASSY, (torque nuts on hose to 75-79 lb-ft)505 84721151 1 HOSE ASSY, (torque nuts on hose to 75-79 lb-ft)506 88662331 2 ELBOW, 90 DEGREES, (includes item 502)
80383428 A/R ENGINE DIAGNOSTIC TOOL
80484133 1 ENGINE FILTER KIT, (includes one of each of the following)80484117 1 AIR FILTER ELEMENT80484116 1 AIR FILTER SAFETY ELEMENT80384384 1 FUEL FILTER80384385 1 OIL FILTER80384045 1 TRANSMISSION FILTER77383819 1 FUEL/WATER SEPARATOR, (mounted on boom rest)
Power Unit AssemblyItem Part Number Qty. Description Rev.
- ENGINE & ATTACHING PARTS
80854001 Series III Highway Speed Excavators 4-11
Power Unit AssemblyItem Part Number Qty. Description Rev.
- ENGINE & ATTACHING PARTS
Series III Highway Speed Excavators 808540014-12
Air Cleaner Assembly
PAC0561
- ENGINE & ATTACHING PARTS
80854001 Series III Highway Speed Excavators 4-13
Air Cleaner AssemblyItem Part Number Qty. Description Rev.
80483211 1 AIR CLEANER ASSY, (includes items 1 thru 9)1 83954108 1 CUP ASSY2 83954109 1 BAFFLE ASSY3 83671290 1 VACUATOR VALVE4 83954110 1 CLAMP ASSY5 83954111 1 O-RING6 80484123 1 FINNED SLEEVE7 80484117 1 ELEMENT8 80484116 1 SAFETY ELEMENT9 1 BODY ASSY
10 80383389 1 WARNING DECAL11 83953074 2 MOUNTING BAND12 88501005 2 HEX NUT, 5/16-1813 77143006 4 WHIZ-LOK NUT, 5/16-1814 77143003 4 WHIZ-LOK SCREW, 5/16-18X5/815 77383154 1 RESTRICTION INDICATOR16 83953075 1 AIR INLET HOOD
77383862 1 TURBO II PRECLEANER, (optional; not illustrated)17 77383792 1 BAND CLAMP18 83683510 1 HUMP HOSE19 77383791 2 BAND CLAMP20 80483150 1 INTAKE TUBE21 80483045 1 INTAKE ELBOW22 77383790 1 BAND CLAMP23 80683250 4 T-BOLT CLAMP24 80483048 2 CHARGE AIR HOSE, (small)25 3460507 1 CHARGE AIR TUBE, R.H.26 77383789 4 T-BOLT CLAMP27 77383787 2 CHARGE AIR HOSE, (large)28 3460508 1 CHARGE AIR TUBE, L.H.29 Ref CHARGE AIR COOLER, (see page 4-22 for details)30 88201022 2 HEX HD CAPSCREW, 5/16-18X1-1/2, GR531 88551010 2 LOCKWASHER, 5/16
- ENGINE & ATTACHING PARTS
Series III Highway Speed Excavators 808540014-14
Power Steering Reservoir Assembly
PAC0541
- ENGINE & ATTACHING PARTS
80854001 Series III Highway Speed Excavators 4-15
Power Steering Reservoir AssemblyItem Part Number Qty. Description Rev.
80383263 1 POWER STEERING RESERVOIR ASSY. (includes all items) C1 80384047 1 DIPSTICK2 80384096 1 FLANGE NUT3 80384049 1 WASHER4 80384095 1 SPRING5 80384094 1 RETAINER6 80384048 1 FILTER ELEMENT7 80384093 2 MOUNTING BRACKET8 1 RESERVOIR ASSY, (not available for service)9 80384097 1 COVER ASSY
- ENGINE & ATTACHING PARTS
Series III Highway Speed Excavators 808540014-16
Exhaust System
PAC0571
1
2
3
4
6
7
8
1
1
13
1
5
6
10
9
101
102
103104
104105
OPTIONAL RAIN CAP INSTALLATION COMPONENTS
11
12TO ENGINE
TURBO
- ENGINE & ATTACHING PARTS
80854001 Series III Highway Speed Excavators 4-17
Exhaust SystemItem Part Number Qty. Description Rev.
1 83713009 4 SEAL CLAMP2 1 EXHAUST ADAPTER, (see page 4-2, item 72, for details)3 86983493 1 FLEXIBLE TUBING4 80483152 1 EXHAUST TUBE5 80483121 2 MUFFLER CLAMP6 77143015 4 WHIZ-LOCK NUT, 3/8-167 80973025 4 WHIZ-LOK SCREW, 3/8-16X18 80483169 1 EXHAUST STACK9 77383946 1 MUFFLER CLAMP
10 77383778 1 MUFFLER11 80484252 1 TURBO CLAMP, 6 CYL. 12 80484253 1 BOLT13 80484254 1 NUT
80485127 Ref RAIN CAP INSTALLATION, (includes items 101 thru 105)101 80481254 1 EXHAUST STACK102 77173017 1 RAIN CAP103 88521305 1 HEX NUT, 5/16104 83681481 8 WASHER105 88201023 1 HEX HD CAPSCREW, 5/16-18X1-3/4, GR5
- ENGINE & ATTACHING PARTS
Series III Highway Speed Excavators 808540014-18
Fuel Tank & Lines, XL3100III
16
17
18
35
34
313233
18
22
21
30
30
30
30
30
20
20
19
153729
29
29
34
313233
18
111
2373839
13
10
2312
9
56
FUEL RETURNTO ENGINE
34
18
17
18
36
17
2122
18
172
2122
18
1829
28
17
17 8
FUEL SUPPLYTO ENGINE
14
2427
25
18
26
25
14
23
923
11
NOTE: ILLUSTRATION REPRESENTS A 4X4 MACHINE
40
PAC2482
- ENGINE & ATTACHING PARTS
80854001 Series III Highway Speed Excavators 4-19
Fuel Tank & Lines, XL3100IIIItem Part Number Qty. Description Rev.
1 80483193 1 FUEL TANK, (includes items 7 & 40)2 80881032 1 FORWARD END PLATE3 80386042 2 MOUNTING STRAP4 80383259 2 RUBBER INSULATOR5 2420020 1 FUEL SENDER, (includes item 6)6 85071058 1 GASKET7 83683030 1 VENTED CAP8 80881034 1 STEP BRACKET, R.H.9 80483106 2 HOSE BARB, 90 DEGREES
10 86683106 1 HOSE CLAMP11 80483075 2 HOSE BARB, 90 DEGREES12 AR HOSE, 3/813 AR HOSE, 5/1614 AR HOSE, 1/215 80486043 2 FUEL TANK SUPPORT16 80481178 1 REAR END PLATE17 80973025 32 WHIZ-LOK SCREW, 3/8-16X118 77143015 A/R WHIZ-LOCK NUT, 3/8-16, (quantity of 34 for 4x2; quantity of 42 for 4x4)19 88561004 6 FLAT WASHER, 5/1620 88521206 14 HEX LOCKNUT, 3/8-1621 83201092 7 HEX HD CAPSCREW, 5/8-11X2, GR8, (hand torque to 200-215 lb-ft)22 90027472 7 HARDENED WASHER, 5/823 83483497 4 HOSE CLAMP24 77383819 1 FUEL/WATER SEPARATOR, (includes drain cock)25 88662667 2 SQUARE HD PIPE PLUG, 3/826 83683377 1 MOUNTING BASE27 88201044 2 HEX HD CAPSCREW, 3/8-16X3-1/4, GR528 80881033 1 STEP BRACKET, L.H.29 80383101 4 STAIR TREAD, 18.530 80483043 A/R STEP WELDMENT, (quantity of 4 for 4x2; quantity of 5 for 4x4)31 80273104 2 STEP SUPPORT, (4x4 only)32 80271316 2 CAP PLATE, (4x4 only)33 80271315 2 CAP PLATE, (4x4 only)34 80973096 8 WHIZ-LOK SCREW, 3/8-16X1-1/2, (4x4 only)35 83201115 8 HEX HD CAPSCREW, 3/8-16X1-1/4, GR836 80481176 1 FORWARD STEP SUPPORT37 80483266 2 RUBBER STRIP38 80385057 Ref LOCKING FUEL CAP INSTALLATION, (optional),
(order the following 2 parts to install)B
84761066 1 LOCKING CAP, (apply AV 50 loctite to threads of fuel tank before installing)85641094 1 PADLOCK
39 80785065 Ref LOCKING FUEL CAP W/CHAIN INSTALLATION, (optional),(order the following 4 parts to install)
-
77143013 1 WHIZ-LOK NUT, 1/4-2080263012 1 WHIZ-LOK SCREW, 1/4-20X1/280686076 1 PADLOCK W/CHAIN84761066 1 LOCKING CAP, (apply AV 50 loctite to threads of fuel tank before installing)
40 80384098 1 VENT BREATHER
- ENGINE & ATTACHING PARTS
Series III Highway Speed Excavators 808540014-20
Fuel Tank & Lines, XL4100III & XL5100III
PAC0582
16
17
18
35
34
313233
18
22
21
30
30
30
30
30
20
20
19
152829
29
29
34
313233
18
111
2373637
13
10
2312
9
56
FUEL RETURNTO ENGINE
34
18
17
18
8
17
2122
18
172
2122
FUEL SUPPLYTO ENGINE
14
2427
25
18
26
25
14
23
923
11
NOTE: ILLUSTRATION REPRESENTS A 6X6 MACHINE
38
- ENGINE & ATTACHING PARTS
80854001 Series III Highway Speed Excavators 4-21
Fuel Tank & Lines, XL4100III & XL5100IIIItem Part Number Qty. Description Rev.
1 80483193 1 FUEL TANK, (includes items 7 & 38)2 80881032 1 FORWARD END PLATE3 80386042 2 MOUNTING STRAP4 80383259 2 RUBBER INSULATOR5 2420020 1 FUEL SENDER, (includes item 6)6 85071058 1 GASKET7 83683030 1 VENTED CAP8 80481176 1 FORWARD STEP SUPPORT9 80483106 2 HOSE BARB, 90 DEGREES
10 86683106 1 HOSE CLAMP11 80483075 2 HOSE BARB, 90 DEGREES12 AR HOSE, 3/813 AR HOSE, 5/1614 AR HOSE, 1/215 80486043 2 FUEL TANK SUPPORT16 80481178 1 REAR END PLATE17 80973025 24 WHIZ-LOK SCREW, 3/8-16X118 77143015 A/R WHIZ-LOCK NUT, 3/8-16, (quantity of 26 for 6x4; quantity of 34 for 6x6)19 88561004 6 FLAT WASHER, 5/1620 88521206 14 HEX LOCKNUT, 3/8-1621 83201092 7 HEX HD CAPSCREW, 5/8-11X2, GR8, (hand torque to 200-215 lb-ft)22 90027472 7 HARDENED WASHER, 5/823 83483497 4 HOSE CLAMP24 77383819 1 FUEL/WATER SEPARATOR, (includes drain cock)25 88662667 2 SQUARE HD PIPE PLUG, 3/826 83683377 1 MOUNTING BASE27 88201044 2 HEX HD CAPSCREW, 3/8-16X3-1/4, GR528 80483266 2 RUBBER STRIP29 80383101 4 STAIR TREAD, 18.530 80483043 A/R STEP WELDMENT, (quantity of 4 for 6x4; quantity of 5 for 6x6)31 80273104 2 STEP SUPPORT, (6x6 only)32 80271316 2 CAP PLATE, (6x6 only)33 80271315 2 CAP PLATE, (6x6 only)34 80973096 8 WHIZ-LOK SCREW, 3/8-16X1-1/2, (6x6 only)35 83201115 8 HEX HD CAPSCREW, 3/8-16X1-1/4, GR836 80385057 Ref LOCKING FUEL CAP INSTALLATION, (optional),
(order the following 2 parts to install)B
84761066 1 LOCKING CAP, (apply AV 50 loctite to threads of fuel tank before installing)85641094 1 PADLOCK
37 80785065 Ref LOCKING FUEL CAP W/CHAIN INSTALLATION, (optional),(order the following 4 parts to install)
-
77143013 1 WHIZ-LOK NUT, 1/4-2080263012 1 WHIZ-LOK SCREW, 1/4-20X1/280686076 1 PADLOCK W/CHAIN84761066 1 LOCKING CAP, (apply AV 50 loctite to threads of fuel tank before installing)
38 80384098 1 VENT BREATHER
- ENGINE & ATTACHING PARTS
Series III Highway Speed Excavators 808540014-22
Radiator & Coolers Assembly
PAC0590
3536
34
333536
21
2
6
5
22
18
17
14
8
15
4
71225
11
20
291
23
9
1413
3
303132
19
19
2
27
24
10
28
26
6
28
16
NOTE: FOR RADIATOR HOSES, SEE FIGURE
VIEW OF CHARGE AIR COOLER
MOUNTING
- ENGINE & ATTACHING PARTS
80854001 Series III Highway Speed Excavators 4-23
Radiator & Coolers AssemblyItem Part Number Qty. Description Rev.
3620075 1 RADIATOR & COOLERS ASSY, (includes items 1 thru 29) B1 80483177 1 RADIATOR, (includes item 29)2 80483039 1 CHARGE AIR COOLER3 80486035 1 FAN SHROUD4 80486036 1 AIR SEAL FRAME5 4341260 1 RADIATOR/CHARGE AIR COOLER MOUNT6 4341259 1 RADIATOR/CHARGE AIR COOLER MOUNT7 80383122 1 OIL COOLER8 77383825 1 OVERFLOW BOTTLE, (includes cap)
77384903 1 OVERFLOW BOTTLE CAP9 80483122 1 DRAIN COCK
10 80473061 4 RUBBER MOUNT11 88661110 2 MALE ELBOW, 90 DEGREES, 1/2X3/8 TUBE12 88201026 4 HEX HD CAPSCREW, 5/16-18X2-1/2, GR513 80303094 8 WHIZ-LOCK SCREW, 3/8-16X3/414 85941016 2 SUPPORT CLAMP, 1/215 80973025 6 WHIZ-LOK SCREW, 3/8-16X116 80483138 5 SOUNDPROOFING17 91363018 4 WHIZ-LOK SCREW, 5/16-18X118 77143006 4 WHIZ LOK NUT, 5/16-1819 80973042 2 FOAM STRIP20 84712745 1 PUSH LOK FITTING21 80483140 1 SOUNDPROOFING22 77383144 1 HOOD STOP CABLE23 80383219 1 SQ HD PIPE PLUG, 1/4NPT24 88561109 4 FLAT WASHER, 3/825 0100011 A/R LOCTITE, #242, (apply to item 12)26 77143015 4 WHIZ-LOCK NUT, 3/8-1627 88201041 4 HEX HD CAPSCREW, 3/8-16X2-1/2, GR528 80473062 8 REBOUND WASHER29 80974026 1 RADIATOR CAP, (14 psi)30 80483137 1 RECIRCULATION FLAP31 77143003 4 WHIZ-LOK SCREW, 5/16-18X5/832 88561004 4 FLAT WASHER, 7/1633 80483185 1 RECIRCULATION FLAP34 80483184 1 RECIRCULATION FLAP35 80303094 4 WHIZ-LOK SCREW, 3/8-16X3/436 88561109 4 FLAT WASHER, 3/8
- ENGINE & ATTACHING PARTS
Series III Highway Speed Excavators 808540014-24
Oil Cooler & Hoses
PAC0601
11
1
5
12
2
13
3
14
4
8
9
5
6
7
8
9
5
12
14
10
- ENGINE & ATTACHING PARTS
80854001 Series III Highway Speed Excavators 4-25
Oil Cooler & HosesItem Part Number Qty. Description Rev.
1 Ref TRANSMISSION FILTER, (see page 4-2 for details)2 77143004 3 WHIZ-LOK SCREW, 5/16-18X1-1/43 88551010 3 LOCKWASHER, 5/164 88501005 3 HEX NUT, 5/16-185 88743014 3 MALE ADAPTER, 1/2X3/8 TUBE6 88662105 1 ELBOW, 90 DEGREES, (swivel nut)7 88661110 1 MALE ELBOW, 90 DEGREES, 1/2X3/8 TUBE8 84717956 1 HOSE ASSY9 84718708 1 HOSE ASSY
10 Ref OIL COOLER, (see page 4-22 for details)11 Ref TRANSMISSION ASSY, (see page 5-8 for details)12 84719975 1 HOSE ASSY13 88662119 1 ELBOW, 45 DEGREES, (swivel nut)14 Ref CONNECTOR, (see page 4-22 for details)
- ENGINE & ATTACHING PARTS
Series III Highway Speed Excavators 808540014-26
Air Brake System Components
11
21
10
20
12
13
14
15
16
17
7
18
8
19
9
78
2223
1
2
3
4
5
6
NOTE: PRESTOMATIC TUBE FITTINGS REQUIRE SPECIAL CUTTING TOOL, 80383267, FOR CUTTING ALL AIR LINES.
PAC1660
- ENGINE & ATTACHING PARTS
80854001 Series III Highway Speed Excavators 4-27
Air Brake System ComponentsItem Part Number Qty. Description Rev.
1 Ref LOCKOUT AIR VALVE, (see page 6-66 for details)2 Ref PARKING BRAKE VALVE ASSY, (see page 6-86 for details)3 Ref DOUBLE CHECK VALVE ASSY, (see page 6-82 for details)4 Ref 4-WAY AIR VALVE ASSY, (see page 6-84 for details)5 Ref SPRING BRAKE CONTROL VALVE ASSY, (see page 6-84 for details)6 Ref FOOT PEDAL VALVE ASSY, (see page 6-82 for details)7 Ref FRONT AIR BRAKE CHAMBER, (XL3100III 4X2; XL4100III & XL5100III 6X4),
(see page 5-42 for details)Ref FRONT AIR BRAKE CHAMBER, (XL3100III 4X4; XL4100III & XL5100III 6X6),
(see page 5-62 for details)8 Ref HOSE ASSY, (XL3100III 4X2; XL4100III & XL5100III 6X4), (see page 5-
38 for details)Ref HOSE ASSY, (XL3100III 4X4; XL4100III & XL5100III 6X6), (see page 5-
54 for details)9 2 ADAPTER ASSY, (see page 4-28 for details)
10 1 REMOTE AIR BRAKING VALVE ASSY, (see page 4-34 for details)11 1 RELAY VALVE ASSY, (see page 4-38 for details)12 1 AIR TANK ASSY, (see page 4-36 for details)13 1 AIR TANK ASSY, (see page 4-36 for details)14 1 AIR VALVE ASSY, (see page 4-30 for details)15 1 AIR DRYER ASSY, (see page 4-28 for details)16 Ref REAR AIR BRAKE CHAMBER, (XL3100III), (see page 5-78 for details)
Ref REAR AIR BRAKE CHAMBER, (XL4100III & XL5100III), (see page 5-98 for details)
17 1 RELAY VALVE ASSY, (XL3100III), (see page 4-38 for details)1 RELAY VALVE ASSY, (XL4100III & XL5100III), (see page 4-38 for details)
18 1 RELAY VALVE ASSY, (XL3100III), (see page 4-38 for details)1 RELAY VALVE ASSY, (XL4100III & XL5100III), (see page 4-38 for details)
19 1 RELAY VALVE ASSY, (see page 4-38 for details)20 1 ADAPTER ASSY, (see page 4-28 for details)21 Ref GOVERNOR, (see page 4-2 for details)22 1 AIR FITTING ASSY, (see page 4-44 for details)23 1 AIR FITTING ASSY, (see page 4-44 for details)
- ENGINE & ATTACHING PARTS
Series III Highway Speed Excavators 808540014-28
Air Dryer & Adapter Assemblies
1
3
24
56
202203
204
205
201
PAC1641PAC1532_hundreds
PAC1540
- ENGINE & ATTACHING PARTS
80854001 Series III Highway Speed Excavators 4-29
Air Dryer & Adapter AssembliesItem Part Number Qty. Description Rev.
ADAPTER ASSY1 80383167 1 TUBE FITTING, 45 DEGREES, 3/8X3/82 80983038 1 ADAPTER, 45 DEGREES3 86883042 1 ANCHOR ELBOW4 14404082 AR LOCTITE, (#565 white)5 88201005 2 HEX HD CAPSCREW, 1/4-20X1, GR56 77143013 2 WHIZ-LOCK NUT, 1/4-20
101 80683005 1 AIR DRYER ASSY -X5103072 1 AIR DRYER ASSY, (optional) -
102 88201036 4 HEX HD CAPSCREW, 3/8-16X1-1/4, GR5103 88561004 4 FLAT WASHER, 3/8104 88521306 4 NYLON LOCKNUT, 3/8-16105 1 DESICCANT CARTRIDGE106 1 O-RING107 1 O-RING108 83953037 1 SAFETY VALVE
80684001 A/R DESICCANT CARTRIDGE KIT,(includes items 105 thru 107; 80683005 air dryer only)
80684285 A/R PURGE VALVE MAINTENANCE KIT
ADAPTER ASSY
201 86883042 1 ANCHOR ELBOW202 80383154 1 TUBE FITTING, 90 DEGREES, 3/8X3/8203 80983038 1 ADAPTER, 45 DEGREES204 88201006 2 HEX HD CAPSCREW, 1/4-20X1-1/4,GR5205 77143013 2 WHIZ-LOK NUT, 1/4-20
- ENGINE & ATTACHING PARTS
Series III Highway Speed Excavators 808540014-30
Air Valve Assembly
9 3
89
4
4 3
4
1
1011
2
6
5
7
5
6
21011
11415
121316
121316
PAC1552
Before S/N‘sXL3100III 3120000189 (4X2) & 3140000290 (4X4);XL4100III 4100000379 (6X4) & 4160000042 (6X6);
XL5100III 5100000576 (6X4 & 6X6)
- ENGINE & ATTACHING PARTS
80854001 Series III Highway Speed Excavators 4-31
Air Valve AssemblyItem Part Number Qty. Description Rev.
1 80383295 2 4-WAY AIR VALVE2 77383550 2 SUBBASE3 77383551 4 EXHAUST MUFFLER, 1/44 80383153 3 TUBE FITTING, 90 DEGREES, 1/4X3/8 TUBE5 80383221 2 SLOTTED PLUG FITTING, 1/86 80383222 4 SLOTTED PLUG FITTING, 1/87 80381201 1 AIR VALVE BRACKET8 86883118 1 STREET TEE, 1/49 80383190 2 TUBE FITTING, 1/4X3/8X3/8
10 77143016 4 WHIZ-LOCK SCREW, #10-24X3/4 LG11 77143017 4 WHIZ-LOCK NUT, #10-2412 77384789 2 SOLENOID, 12V13 80384406 2 SOLENOID NUT14 77143004 2 WHIZ-LOK SCREW, 5/16-18X1-1/415 77143006 2 WHIZ-LOK NUT, 5/16-1816 80484265 2 CONNECTOR, 12V
Before S/N’s XL3100III 3120000189 (4X2) & 3140000290 (4X4);XL4100III 4100000379 (6X4) & 4160000042 (6X6); XL5100III 5100000576 (6X4 & 6X6)
- ENGINE & ATTACHING PARTS
Series III Highway Speed Excavators 808540014-32
Air Valve Assembly
9
31314
814
9
101112
4
4
31314
101112
4
1
2
514
7
514
2
1
614
614
PORTS3 & 5
PORT 1
PORT 4
PORT 4
PORTS3 & 5
PORT 1
PORT 2
PORT 2
PORTS 12 & 14
PORTS 12 & 14
1718
151619
1516
PAC3951
After (& including) S/N’sXL3100III 3120000189 (4X2) & 3140000290 (4X4);XL4100III 4100000379 (6X4) & 4160000042 (6X6);
XL5100III 5100000576 (6X4 & 6X6)
- ENGINE & ATTACHING PARTS
80854001 Series III Highway Speed Excavators 4-33
Air Valve AssemblyItem Part Number Qty. Description Rev.
1 80383295 2 4-WAY AIR VALVE2 80783055 2 SUBBASE3 77383551 4 EXHAUST MUFFLER, 1/44 80383153 3 TUBE FITTING, 90 DEGREES, 1/4X3/8 TUBE5 80383221 2 SLOTTED PLUG FITTING, 1/86 80383222 4 SLOTTED PLUG FITTING, 1/87 80781062 1 AIR VALVE BRACKET8 86883118 1 STREET TEE, 1/49 80383190 2 TUBE FITTING, 1/4X3/8X3/8
10 88211035 4 SOCKET HD CAPSCREW, #10-24X1-3/411 77143017 4 WHIZ-LOCK NUT, #10-2412 88551007 4 LOCKWASHER, #1013 80383301 4 BRASS BUSHING14 14404082 A/R LOCTITE, (#565 white)15 77384789 2 SOLENOID, 12V16 80384406 2 SOLENOID NUT17 77143004 2 WHIZ-LOK SCREW, 5/16-18X1-1/418 77143006 2 WHIZ-LOK NUT, 5/16-1819 80484265 2 CONNECTOR, 12V
After (& including) S/N’sXL3100III 3120000189 (4X2) & 3140000290 (4X4);XL4100III 4100000379 (6X4) & 4160000042 (6X6); XL5100III 5100000576 (6X4 & 6X6)
- ENGINE & ATTACHING PARTS
Series III Highway Speed Excavators 808540014-34
Remote Air Braking Valve Assembly
1
7
910
2
5
8
3
6
4
PAC0300
- ENGINE & ATTACHING PARTS
80854001 Series III Highway Speed Excavators 4-35
Remote Air Braking Valve AssemblyItem Part Number Qty. Description Rev.
1 80383167 1 TUBE FITTING, 45 DEGREES, 3/8X3/82 86683293 1 DOUBLE CHECK VALVE3 85403220 1 REDUCING VALVE, (85 psi)4 80383141 1 TUBE FITTING, STRAIGHT, 1/4X3/8 TUBE5 86983655 1 HEX NIPPLE, 1/4X3/86 80383142 1 TUBE FITTING, STRAIGHT, 3/8X3/8 TUBE7 86983651 1 STREET TEE, 3/8X3/88 80383154 1 TUBE FITTING, 90 DEGREES, 3/8X3/89 77143004 1 WHIZ-LOK SCREW, 5/16-18X1-1/4
10 77143006 1 WHIZ-LOK NUT, 5/16-18
- ENGINE & ATTACHING PARTS
Series III Highway Speed Excavators 808540014-36
Air Tank Assemblies
128
38
58
68
49
1011
278
101102111
110111
103111
104112113114
105106107108111
109111
201202208
203208
205208209
206208
204210211212
202207208
PAC1561PAC1571PAC3910
- ENGINE & ATTACHING PARTS
80854001 Series III Highway Speed Excavators 4-37
Air Tank AssembliesItem Part Number Qty. Description Rev.
80485022 Ref AIR TANK ASSY 61 80383144 1 TUBE FITTING, STRAIGHT, 1/2X1/2 TUBE2 80383216 2 REDUCING BUSHING, 3/8X1/23 80383219 1 SQ HD PIPE PLUG, 1/4NPT4 86683296 1 AIR TANK5 86983772 1 HEX PLUG, 3/86 86671121 1 DRAIN COCK, 3/87 88661118 1 ELBOW, 90 DEGREES8 14404082 A/R LOCTITE, (#565 white)9 80483023 2 AIR TANK MOUNT
10 80973096 4 WHIZ-LOK SCREW, 3/8-16X1-1/211 77143015 4 WHIZ-LOCK NUT, 3/8-16
80485023 Ref AIR TANK ASSY 5
101 80383216 1 REDUCING BUSHING, 3/4X1/2 TUBE102 80383144 1 TUBE FITTING, STRAIGHT, 1/2X1/2 TUBE103 86983772 1 HEX PLUG, 3/8104 86683296 1 AIR TANK105 80383217 1 REDUCING BUSHING, 3/4X3/8 TUBE106 80383168 1 TUBE FITTING, 90 DEGREES, 3/8X1/2107 80383154 1 TUBE FITTING, 90 DEGREES, 3/8X3/8108 86983651 1 STREET TEE, 3/8X3/8109 80383219 1 SQUARE HD PIPE PLUG, 1/4110 86671121 1 DRAIN COCK, 3/8111 14404082 A/R LOCTITE, (#565 white)111 80483023 2 AIR TANK MOUNT112 80973096 4 WHIZ-LOK BOLT, 3/8-16X1-1/2113 77143015 4 WHIZ-LOCK NUT, 3/8-16
80485121 Ref AIR TANK ASSY, (used with power unit assemblies equipped w/exhaust brake only)
-
201 80383144 1 TUBE FITTING, STRAIGHT, 1/2X1/2 TUBE202 80383216 2 REDUCING BUSHING, 3/8X1/2203 80383219 1 PIPE PLUG, 1/4204 86683296 1 AIR TANK205 80383152 1 TUBE FITTING, 90 DEGREES, 1/4X1/4 TUBE206 86671121 1 DRAIN COCK, 3/8207 88661113 1 ELBOW, 90 DEGREES208 14404082 A/R LOCTITE, (#565 white)209 80383301 1 BRASS BUSHING210 80483023 2 AIR TANK MOUNT211 80973096 4 WHIZ-LOK BOLT, 3/8-16X1-1/2212 77143015 4 WHIZ-LOCK NUT, 3/8-16
- ENGINE & ATTACHING PARTS
Series III Highway Speed Excavators 808540014-38
Relay Valve Assemblies
2101214
251114
1
9
8
15
314
21413
614
71114
5
414
101
104
103
102 105106
107
PAC1582PAC1591
- ENGINE & ATTACHING PARTS
80854001 Series III Highway Speed Excavators 4-39
Relay Valve Assemblies
207
201
202
209
203
204
206208
205208
308
307313
306
310313
301
302303313
304
314
305
312
309313
308
311313
PAC1601PAC1631
- ENGINE & ATTACHING PARTS
Series III Highway Speed Excavators 808540014-40
Relay Valve Assemblies
401403410411 401
405410413
409408
414
402
401406
401410 401
404
401405
401407413
401403
401412
501503
501510 501
505
501511 509
508
502
513
501507
501504
501505
501506
501512
PAC3970PAC3980
- ENGINE & ATTACHING PARTS
80854001 Series III Highway Speed Excavators 4-41
Relay Valve AssembliesItem Part Number Qty. Description Rev.
80485017 Ref RELAY VALVE ASSY, (spring), (XL4100III & XL5100III),(includes items 1 thru 14)
A1
1 83683374 1 RELAY VALVE2 86683293 1 DOUBLE CHECK VALVE3 80383168 2 TUBE FITTING, 90 DEGREES, 3/8X1/24 86983772 2 HEX PLUG, 3/85 80383154 1 TUBE FITTING, 90 DEGREES, 3/8X3/86 80983038 1 TUBE FITTING, 45 DEGREES, 3/8X3/4 TUBE 7 80383215 1 REDUCING BUSHING, 1/2X3/88 77143006 4 WHIZ-LOK NUT, 5/16-189 80481084 1 BENT PLATE
10 86983655 1 HEX NIPPLE, 1/4X3/811 80383213 2 HEX NIPPLE, 3/812 80383142 1 TUBE FITTING, STRAIGHT, 3/8X3/8 TUBE13 80383186 1 SWIVEL NUT RUN TEE, 3/8X1/2 TUBE14 14404082 A/R LOCTITE, (#565 white)15 77143004 2 WHIZ-LOK SCREW, 5/16-18X1-1/4
80485033 Ref RELAY VALVE ASSY, (includes items 101 thru 106) 3101 83683374 1 RELAY VALVE102 80383153 1 TUBE FITTING, 90 DEGREES, 1/4X3/8 TUBE103 80383157 1 TUBE FITTING, 1/2X1/2 TUBE104 80383154 1 TUBE FITTING, 90 DEGREES, 3/8X3/8105 86983772 1 HEX PLUG, 3/8106 14404082 A/R LOCTITE, (#565 white)107 77143006 2 WHIZ-LOK NUT, 5/16-18
80485018 Ref RELAY VALVE ASSY, (rear service), (includes items 201 thru 208) 4201 83683374 1 RELAY VALVE202 80481084 1 BENT PLATE203 77143006 4 WHIZ-LOK NUT, 5/16-18204 80383157 1 TUBE FITTING, 90 DEGREES, 1/2X1/2 TUBE205 83683359 2 TUBE FITTING, 90 DEGREES, 3/8X3/4 TUBE206 86983772 2 HEX PLUG, 3/8207 80383153 1 TUBE FITTING, 90 DEGREES, 1/4X3/8 TUBE208 14404082 A/R LOCTITE, (#565 white)209 77143004 2 WHIZ-LOK SCREW, 5/16-18X1-1/4
80485019 Ref AIR VALVE ASSY, (front service), (XL4100III & XL5100III),(includes items 301 thru 313)
3
301 83683374 1 RELAY VALVE302 80383141 1 TUBE FITTING, STRAIGHT, 1/4X3/8 TUBE303 86883118 1 STREET TEE, 1/4304 80481084 1 BENT PLATE305 77143006 4 WHIZ-LOK NUT, 5/16-18306 80383142 1 TUBE FITTING, STRAIGHT, 3/8X3/8 TUBE
- ENGINE & ATTACHING PARTS
Series III Highway Speed Excavators 808540014-42
307 86683293 1 DOUBLE CHECK VALVE308 80383154 2 TUBE FITTING, 90 DEGREES, 3/8X3/8309 83683359 2 TUBE FITTING, 90 DEGREES, 3/8X3/4 TUBE310 86983655 1 HEX NIPPLE, 1/4X3/8311 86983772 1 HEX PLUG, 3/8312 80383193 1 STREET TEE, 1/2X1/2313 14404082 A/R LOCTITE, (#565 white)314 77143004 2 WHIZ-LOK SCREW, 5/16-18X1-1/4
80885017 Ref RELAY VALVE ASSY, (spring), (XL3100III), (includes items 401 thru 413) A1401 14404082 A/R LOCTITE, (#565 white)402 77143006 2 WHIZ-LOK NUT, 5/16-18403 80383142 2 TUBE FITTING, STRAIGHT, 3/8X3/8 TUBE404 80383143 1 TUBE FITTING, 3/8X1/2405 80383154 3 TUBE FITTING, 90 DEGREES, 3/8X3/8406 80383168 1 TUBE FITTING, 90 DEGREES, 3/8X1/2407 80383215 1 REDUCING BUSHING, 1/2X3/8408 80481084 1 BENT PLATE409 83683374 1 RELAY VALVE410 86683293 3 DOUBLE CHECK VALVE411 86983655 1 HEX NIPPLE, 1/4X3/8412 86983772 2 HEX PLUG, 3/8413 80383213 2 HEX NIPPLE, 3/8414 77143004 2 WHIZ-LOK SCREW, 5/16-18X1-1/4
80885018 Ref RELAY VALVE ASSY, (front service), (XL3100III), (includes items 501 thru 512) A501 14404082 A/R LOCTITE, (#565 white)502 77143006 2 WHIZ-LOK NUT, 5/16-18503 80383142 1 TUBE FITTING, STRAIGHT, 3/8X3/8 TUBE504 80383143 1 TUBE FITTING, 3/8X1/2505 80383154 2 TUBE FITTING, 90 DEGREES, 3/8X3/8506 80383155 1 TUBE FITTING, 90 DEGREES, 3/8X1/2507 80383193 1 TUBE FITTING508 80481084 1 BENT PLATE509 83683374 1 RELAY VALVE510 86683293 1 DOUBLE CHECK VALVE511 86983655 1 HEX NIPPLE, 1/4X3/8512 86983772 1 HEX PLUG, 3/8513 77143004 2 WHIZ-LOK SCREW, 5/16-18X1-1/4
Relay Valve AssembliesItem Part Number Qty. Description Rev.
- ENGINE & ATTACHING PARTS
80854001 Series III Highway Speed Excavators 4-43
Relay Valve AssembliesItem Part Number Qty. Description Rev.
- ENGINE & ATTACHING PARTS
Series III Highway Speed Excavators 808540014-44
Air Fitting Assemblies
1112
6
8912
312
1213
512
1 7
1012
412
14
2312
106
103
104107
101107
102
105107
PAC1622PAC1651
- ENGINE & ATTACHING PARTS
80854001 Series III Highway Speed Excavators 4-45
Air Fitting AssembliesItem Part Number Qty. Description Rev.
AIR FITTING ASSY1 86883118 1 STREET TEE, 1/42 80383179 1 RUN TEE, 3/8X3/83 80383215 2 REDUCING BUSHING, 1/2X3/84 80383218 1 REDUCING BUSHING, 1/2X1/45 80383165 1 TUBE FITTING, 90 DEGREES, 1/4X1/4 TUBE6 80383141 1 TUBE FITTING, STRAIGHT, 1/4X3/8 TUBE7 80483105 1 CROSS TEE, 1/28 86983655 1 HEX NIPPLE, 1/4X3/89 86683291 1 PR-2 VALVE, 65 PSI
10 80483104 1 BULKHEAD FITTING, 1/2X1/2 TUBE11 84521057 1 SAFETY VALVE, (150 psi)12 14404082 A/R LOCTITE, (#565 white)13 80993168 1 RUN TEE, 1/214 80383144 1 TUBE FITTING, STRAIGHT, 1/2X1/2 TUBE
AIR FITTING ASSY
101 80383215 1 BUSHING, 3/8X1/2102 80993168 1 RUN TEE, 1/2103 80383167 1 TUBE FITTING, 45 DEGREES, 3/8X3/8104 86683294 1 CHECK VALVE105 80483103 1 FITTING, 1/2X1/2106 80383144 1 STRAIGHT TUBE FITTING, 1/2X1/2 TUBE107 14404082 A/R LOCTITE, (#565 white)
- ENGINE & ATTACHING PARTS
Series III Highway Speed Excavators 808540014-46
Engine Air Valve Assemblies
9
7
5
6
3
5
1
248
1011
104 105
106
103
104
101
102
107
108109
110111
PAC0081PAC3920
Before S/N‘sXL3100III 3120000189 (4X2) & 3140000290 (4X4);XL4100III 4100000379 (6X4) & 4160000042 (6X6);
XL5100III 5100000576 (6X4 & 6X6)
- ENGINE & ATTACHING PARTS
80854001 Series III Highway Speed Excavators 4-47
Engine Air Valve AssembliesItem Part Number Qty. Description Rev.
ENGINE AIR VALVE ASSY1 80383295 1 4-WAY AIR VALVE2 77383550 1 SUBBASE3 77383551 1 EXHAUST MUFFLER, 1/44 77143017 2 WHIZ-LOCK NUT, #10-245 80383172 4 TUBE FITTING, 45 DEGREES, 1/4X3/86 80383222 1 SLOTTED PLUG FITTING, 1/87 80383139 1 TUBE FITTING, STRAIGHT, 1/8X1/48 77143016 2 WHIZ-LOCK SCREW, #10-24X3/4 LG9 80381152 1 VALVE BRACKET
10 80384492 1 SOLENOID11 80384406 1 SOLENOID NUT
ENGINE AIR VALVE ASSY, EXHAUST BRAKE, (used with power unit assemblies equipped w/exhaust brake only)
101 80383295 1 4-WAY AIR VALVE102 77383550 1 SUBBASE103 77383551 2 EXHAUST MUFFLER, 1/4104 80383140 2 TUBE FITTING, STRAIGHT, 1/4X1/4105 80383221 1 SLOTTED PLUG FITTING, 1/8106 80383222 2 SLOTTED PLUG FITTING, 1/8107 80381152 1 VALVE BRACKET108 77143016 2 WHIZ-LOK SCREW, #10-24109 77143017 2 WHIZ-LOCK NUT, #10-24110 80384492 1 SOLENOID111 80384406 1 SOLENOID NUT
Before S/N’s XL3100III 3120000189 (4X2) & 3140000290 (4X4);XL4100III 4100000379 (6X4) & 4160000042 (6X6); XL5100III 5100000576 (6X4 & 6X6)
- ENGINE & ATTACHING PARTS
Series III Highway Speed Excavators 808540014-48
Engine Air Valve Assemblies
55
21213
1415
4
11
10
6 5
17
139
PORT 4PORT 2
PORT 14
PORT 5 PORT 1 PORT 3
PORT 12
8
104 101105
102111112
113114
110
109
101103108 104
101103108
101106
PORT 4
PORT 2
PORT 5 PORT 1 PORT 3
PORT 12
107
PAC3930PAC3940
After (& including) S/N’sXL3100III 3120000189 (4X2) & 3140000290 (4X4);XL4100III 4100000379 (6X4) & 4160000042 (6X6);
XL5100III 5100000576 (6X4 & 6X6)
- ENGINE & ATTACHING PARTS
80854001 Series III Highway Speed Excavators 4-49
Engine Air Valve AssembliesItem Part Number Qty. Description Rev.
ENGINE AIR VALVE ASSY1 14404082 A/R LOCTITE, (#565 white)2 77143017 2 WHIZ-LOCK NUT, #10-243 77383551 1 EXHAUST MUFFLER, 1/44 80383151 1 TUBE FITTING, 90 DEGREES, 1/8X1/4 TUBE5 80383172 3 TUBE FITTING, 45 DEGREES, 1/4X3/86 80383173 1 TUBE FITTING, 45 DEGREES, 3/8X3/8, (swivel)7 80383222 1 SLOTTED PLUG FITTING, 1/88 80383295 1 4-WAY AIR VALVE9 80383301 1 BRASS BUSHING
10 80781063 1 AIR VALVE BRACKET11 80783055 1 SUBBASE12 88211035 2 SOCKET HD CAPSCREW, #10-24X1-3/413 88551007 2 LOCKWASHER, #1014 80384492 1 SOLENOID15 80384406 1 SOLENOID NUT
ENGINE AIR VALVE ASSY, EXHAUST BRAKE, (used with power unit assemblies equipped with exhaust brake only)
101 14404082 A/R LOCTITE, (#565 white)102 77143017 2 WHIZ-LOCK NUT, #10-24103 77383551 2 EXHAUST MUFFLER, 1/4104 80383140 2 TUBE FITTING, STRAIGHT, 1/4X1/4105 80383221 1 SLOTTED PLUG FITTING, 1/8106 80383222 2 SLOTTED PLUG FITTING, 1/8107 80383295 1 4-WAY AIR VALVE108 80383301 2 BRASS BUSHING109 80781063 1 AIR VALVE BRACKET110 80783055 1 SUBBASE111 88211035 2 SOCKET HD CAPSCREW, #10-24X1-3/4112 88551007 2 LOCKWASHER, #10113 80384492 1 SOLENOID114 80384406 1 SOLENOID NUT
After (& including) S/N’sXL3100III 3120000189 (4X2) & 3140000290 (4X4);XL4100III 4100000379 (6X4) & 4160000042 (6X6); XL5100III 5100000576 (6X4 & 6X6)