SECTION 1 - FRAME & ATTACHING PARTS

FRAME & ATTACHING PARTS

Series IV Highway Speed Excavators 808040011-2

Undercarriage Prep Installation

PAC4713

SEE DETAIL “F”

SEE DETAIL “E”11

SEE DETAIL “D”

4

SEE DETAIL “C”

HORNS

8131825

RT HDLT GNDTO FRONTBUMPERHARNESSEXHST BRK

(OPTIONAL) “-” BATTERYCABLE

UP GND-1TO FRAME GROUNDON “-” BATTERY CABLE

DETAIL “C”

DETAIL “F”

67

29

DETAIL “E”

615

DETAIL “D”

1215AXLE LK PWR

TO AXLE OSCILLATION

CYLINDER VALVE

2

30


80804001 Series IV Highway Speed Excavators 1-3


PAC4721

F

F

E

E

DIFF LKTO REAR AXLE

D

D

C

CFUEL LVLTO FUEL

LEVEL SENDER

SEE DETAIL “G” B

B

A

A

81825

1262728

DETAIL “B”

6714

TRV ALMTO FRONTTRAVEL ALARM

679 6

79

SEE DETAIL “B” SECTION B-B

6716

AC CLUTCHAC CLUTCH OUTTO A/C AIR DRYER

SEE DETAIL “A”

CAN HTO POWER UNITHARNESS BULKHEAD

SCR CAN-G1TO POWER UNITHARNESS BULKHEAD

DETAIL “A”

RMT PWRTO STEER VALVE

SOLENOID

STR LEFTTO STEER VALVE

SOLENOID

IAT/HUM GNDTO AIR INTAKETUBE SENSOR

STR RIGHTTO STEER VALVESOLENOID

RC 44 PWR-1TO BULKHEAD MOUNT

ON CAB FRONT

NOX CAN HTO SCR FRAME MODULE ON CAB FRONT

BATT 5TO BULKHEAD

ON CAB FRONT

BATT 1TO BULKHEAD

ON CAB FRONT

1939 HTO 1939 CONNECTORIN CAB CONSOLE

CAN HTO CAN CONNECTORAT CAB FRONT

RC 44 PWR-2TO RC CONTROLLERON CAB FRONT

SECTION A-A67

14

6715

6715




36

THIS LOCATIONXL4100IV & XL5100IV ONLY

SECTION E-E

UP PWR 1TO CENTER PIN

1939 LTO CENTER PIN

DR MTR ENGTO REAR OF

TRANSFER CASESECTION D-D

ALL WHLTO FRONT OF TRANSFER

CASE (ONLY ON VEHICLESWITH FRONT DRIVE AXLE)

R T/BRK RTAIL GND

TO REAR FENDERLIGHT HARNESS

MKR LTSTO LICENSE

PLATE LIGHT

SECTION F-F

MKR LTSALM/MKR GNDTO ID LIGHT BAR

367

L T/BRK RTAIL GNDTO REAR FENDERLIGHT HARNESS

TRV ALMTO REAR TRAVEL ALARMHYD FILTER SW

TO HYD FILTERSWITCH

UP KEY IGNDRYER FUL GNDAXLE LOCK PWR

DIG BRAKE VLVDIG BRAKE SGN

81725

31

SECTION C-C

DIG BRAKE VLVTO BRAKE VALVES

714

DEF PUMP SUPPLYTO ADBLUE PUMP

DEF PRS VLV SUPTO ADBLUE PRESSURECONTROL VALVE

DEF LVL SGNTO ADBLUE TANK

PRE SCR SGNTO SCR TEMPSENSOR CONNECTOR

NOX IGN PWRTO NOX SENSORMODULE

POST SCR SGNTO SCR TEMP

SENSOR CONNECTOR

PAC4731




PAC4741

1019202224

521

XL4100IV & XL5100IVREAR VIEW

101102103104

XL4100IV & XL5100IVREAR VIEW

XL3100IVREAR VIEW

521

1019202224

23

12V BAT12V BAT FUSE

10 AMP ATO FUSE

12V BAT FUSETO STUD ON

BATTERY CABLEJUMPER BLUE CONNECTOR

TO VEC BOX DETAIL “G”

BLACK CONNECTORTO VEC BOX

GRAY CONNECTORTO VEC BOX

GREEN CONNECTORTO VEC BOX

DIG BRAKE VLVTO T-CASE PUMP

START SWITCHTERMINAL

DRYER/FUL GNDTO T-CASE PUMPGROUND TERMINAL

After (& including) S/N’s:XL4100IV - 4100000765 (4x2); 4160000081 (4x2)

XL5100IV - 5100000618 (6x4)



Undercarriage Prep InstallationItem Part Number Qty. Description Rev.

1 91403420 1 ECCO 830 TRAVEL ALARM, (standard; includes items 26 thru 28)Note: Optional travel alarms can be found on page 12-128.

2 80886011 1 UNDERCARRIAGE FRAME WELDMENT, (XL3100IV 4x2)80886012 1 UNDERCARRIAGE FRAME WELDMENT, (XL3100IV 4x4)80786017 1 UNDERCARRIAGE FRAME WELDMENT, (XL4100IV & XL5100IV 6x4)80786018 1 UNDERCARRIAGE FRAME WELDMENT, (XL4100IV & XL5100IV 6x6)80786047 1 UNDERCARRIAGE FRAME WELDMENT, (XL4100 6X4 W/RAILGEAR)

3 24861170 2 SUPPORT CLAMP, 11/164 71492134 A/R LOOM, 3/4, (gray)5 77023029 1 SERIAL PLATE6 77143004 16 WHIZ LOK SCREW, 5/16-18X1-1/4, (qty 14 for XL3100IV)7 77143006 14 WHIZ-LOK NUT, 5/16-188 77143013 6 WHIZ-LOK NUT, 1/4-209 80673025 2 SUPPORT CLAMP, 2-1/4

10 80783109 1 LICENSE PLATE LIGHT, (no longer available. For service order 80783109S kit, located at the end of parts list.)

11 80783189 1 UNDERCARRIAGE HARNESS12 80973096 4 WHIZ-LOK SCREW, 3/8-16X1-1/213 83303239 1 HORN14 85841094 4 SUPPORT CLAMP, 9/1615 85841150 9 SUPPORT CLAMP, 1-1/216 85941017 1 SUPPORT CLAMP, 29/3217 88201003 1 HEX HD CAPSCREW, 1/4-20X3/4, GR518 88201005 5 HEX HD CAPSCREW, 1/4-20X1, GR519 88561104 2 FLAT WASHER, #820 88301075 2 ROUND HD MACHINE SCREW, #8-32X1, GR821 88341012 4 DRIVE SCREW, #4X5/1622 88501610 2 HEX NUT, #8-3223 80483093 1 SELF-TAPPING SCREW, #10-24X3/424 88551006 2 LOCKWASHER, #825 88561002 6 FLAT WASHER, 1/426 80963058 1 WEATHER PACK SHROUD27 80963069 2 WEATHER PACK PIN28 80963066 2 WEATHER PACK SEAL29 91043147 1 SUPPORT CLAMP, 3/430 91053413 1 CUSHION CLAMP, 1”31 83303243 1 DIG BRAKE RELAY

80783109S Ref LICENSE PLATE LIGHT KIT, (includes items 101 thru 104. Modification of electrical connection is necessary, as well as drilling new mounting holes into frame)

101 82173007 1 LICENSE PLATE LIGHT102 88301097 2 ROUND HD MACHINE SCREW, #10-24X1-1/4, GR8103 88521605 2 HEX NUT, #10-24104 88561105 2 FLAT WASHER, #10



Undercarriage Prep InstallationItem Part Number Qty. Description Rev.



Front Bumper & Headlights Installation

PAC5491

2

71214

5DETAIL “B”

616

1

616

SEE DETAIL “A”

SEE DETAIL “B”

91214

5

71214

DETAIL “A”

10

38 8 15 13 11

4

15

13

11

91214

TOP VIEW OF BUMPER HARDWARE

VIEW OF ITEM 6 HEADLIGHT KIT

19

20



Front Bumper & Headlights Installation

PAC5500

17

DETAIL “C”

DETAIL “C”

18 TH RETAMB TMP SGN



Front Bumper & Headlights InstallationItem Part Number Qty. Description Rev.

1 0940179 1 FRONT BUMPER WELDMENT, (yellow)2 0940189 2 BUMPER BRACKET3 77143014 8 WHIZ-LOK NUT, 1/2-134 80481048 2 BUMPER FRAME MOUNT5 80481049 2 BUMPER SUPPORT BRACKET6 80783436S 2 LED HEADLIGHT REPLACEMENT KIT, (includes qty. 1 of items 19 & 20)

Note: The original halogen headlights have been replaced by LED headlights. When replacing the halogen headlights, the 80783436S LED headlight replacement kit must be used. Once replaced, items 19 & 20 can be ordered for service separately, as needed. One kit replaces one light. If both lights are being replaced, order two kits.

7 80973025 4 WHIZ-LOK SCREW, 3/8-16X18 88201069 10 HEX HD CAPSCREW, 1/2-13X2, GR59 88411062 2 CARRIAGE BOLT, 3/8-16X1

10 88411112 8 CARRIAGE BOLT, 1/2-13X1-1/411 88501008 10 HEX NUT, 1/2-1312 88521206 6 HEX LOCKNUT, 3/8-1613 88551013 10 LOCKWASHER, 1/214 88561004 6 FLAT WASHER, 3/815 88561006 20 FLAT WASHER, 1/216 90027319 8 HEX HEAD DRILL SCREW, 1/4-20X117 80781202 1 AMBIENT AIR TEMPERATURE SENSOR MOUNT18 80783223 1 AMBIENT AIR TEMPERATURE SENSOR19 80783441 2 HEADLIGHT MOUNTING BRACKET20 80783436 2 LED HEADLIGHT



Front Bumper & Headlights InstallationItem Part Number Qty. Description Rev.



Undercarriage Mirror & Grab Rail Installation

PAC4760

11

1415164

TOP VIEW SHOWING RIGHT HANDMIRROR MOUNT

DETAIL “B”

SPLIT BUSHING SLIPS BETWEENMIRROR LOOP AND TWISTBRACKET, (BOTTOM TWIST

BRACKET ONLY)

1

10

6

7

11

SEEDETAIL “B”

11USE HARDWARE FURNISHED WITHMIRROR. PLACE NYLON WASHER

BETWEEN MIRROR BRACKET ANDMIRROR MOUNT

141516

810

DETAIL “A”

1215

13

8

2

4

11

9

SEEDETAIL “A”

141516

5

2

3



Undercarriage Mirror & Grab Rail InstallationItem Part Number Qty. Description Rev.

1 77023013 1 PIVOT BOLT MOUNT2 77143004 8 WHIZ-LOK SCREW, 5/16-18X1-1/43 77143006 1 WHIZ--LOK NUT, 5/16-184 77383672 2 MIRROR MOUNT5 80383265 1 GRAB RAIL6 80383269 1 MIRROR7 80383270 1 MIRROR MOUNT LOOP8 80383285 2 SPLIT BUSHING9 80383336 1 MIRROR, R/H

10 83953128 3 TWIST BRACKET11 86983693 4 CONVEX MIRROR12 88201036 1 HEX HD CAPSCREW, 3/8-16X1-1/4, GR513 88521206 1 HEX LOCKNUT, 3/8-1614 88521305 3 5/16-18, (ny-lok)15 88561003 8 FLAT WASHER, 5/1616 91363018 3 WHIZ-LOK SCREW, 5/16-18X1



Upperstructure Mirror Installation

PAC4700

2

4

2

3

SEE DETAIL “A”

15

6 789

DETAIL “A”



Upperstructure Mirror InstallationItem Part Number Qty. Description Rev.

1 77143015 2 WHIZ-LOK NUT, 3/8-162 80363195 2 SIDE VIEW MIRROR3 80763099 1 MIRROR MOUNT4 80363197 1 CAB MIRROR MOUNT5 80973096 2 WHIZ-LOK SCREW, 3/8-16X1-1/26 80761038 1 UPPER MIRROR BRACKET7 88211072 2 SOCKET HD CAPSCREW, 3/8-16X1-1/48 88501620 2 HEX NUT, 3/8-169 88551107 2 LOCKWASHER, 3/8

80364215 A/R MIRROR MOUNT KIT, (includes items 1, 3 & 5 thru 9)



Engine Cover Installation

PAC4775

��

�

��

��

��

��

�

��

�

�

��

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Engine Cover InstallationItem Part Number Qty. Description Rev.

1 77143015 5 WHIZ-LOK NUT, 3/8-162 80303094 5 WHIZ-LOK SCREW, 3/8-16X3/43 80481142 1 FRONT HINGE SHIM4 80783103 1 ENGINE ENCLOSURE, (includes items 14 thru 20)5 80783115 1 TRANSMISSION COVER, (includes louver)6 80973096 2 WHIZ-LOK SCREW, 3/8-16X1-1/27 88201035 4 HEX HD CAPSCREW, 3/8-16X1, GR58 88261027 2 BUTTON HD SCREW, 3/8-16X3/49 88561004 6 FLAT WASHER, 3/8

10 88561005 3 FLAT WASHER, 7/1611 80781220 1 COVER BRACKET PLATE, L.H.12 80781222 1 COVER BRACKET PLATE, R.H.13 80973025 6 WHIZ-LOK SCREW, 3/8-16X114 80484091 3 DRAW LATCH15 80514168 2 LOUVER, (use 91164090 glue to mount)16 80784227 1 FRONT ENGINE ENCLOSURE, (includes item 19)17 80784228 1 ENGINE ENCLOSURE LID18 80784229 1 ENGINE ENCLOSURE BASE, (inlcudes louver)19 80514154 1 SCREEN GRILL20 80784271 1 CAM LOCK, (uses key 91144470)



Front Fender Installation

PAC4790

11

12

13

3

14

15161718

3

12

1022

2

31419

56

8

SEE DETAIL “A”

3414

BETWEEN ITEM 6 & BOTTOMPLATE OF FRAME

1

11

7

20

9

421

SIDE VIEW OFLH FRONT FENDER

BRACKETS AT REAROF FENDERS

DETAIL “A”5 PLACES - SHIMMING OF

LEFT HAND FENDER

23



Front Fender InstallationItem Part Number Qty. Description Rev.

1 77143004 9 WHIZ-LOK SCREW, 5/16-18X1-1/42 77143006 9 WHIZ-LOK NUT, 5/16-183 77143015 11 WHIZ-LOK NUT, 3/8-164 80381427 A/R FENDER SHIM5 80383107 1 FENDER BRACE6 80383108 1 FENDER BRACE7 80383109 1 FENDER BRACE8 80383251 1 FENDER BRACE9 80481030 5 FENDER SPACER

10 80781144 2 FENDER BRACKET11 80786040 1 LH FRONT FENDER WELDMENT12 80786028 1 RH FRONT FENDER WELDMENT13 80786029 1 LH REAR FRONT FENDER WELDMENT14 80973096 9 WHIZ-LOK SCREW, 3/8-16X1-1/215 88411036 2 ROUND HD CARRIAGE BOLT, 5/16-18X3/416 88501005 2 HEX NUT, 5/16-1817 88551010 2 LOCKWASHER, 5/1618 88561003 2 FLAT WASHER, 5/1619 88561004 2 FLAT WASHER, 3/820 88561006 5 FLAT WASHER, 1/221 91163196 5 WHIZ-LOK SCREW, 3/8-16X1-3/422 80263012 4 WHIZ-LOK SCREW, 1/4-20X1/223 80781197 1 ACCESS PANEL

80786042 1 ACCESS PANEL, (for machines equipped with engine block heater)



Rear Fender Assembly, XL3100IV

PAC4800

413

81

2

13

11

9 1214

3 76 10

77 7 10

5

314 12 9

1

2

1311

4

8

13



Rear Fender Assembly, XL3100IVItem Part Number Qty. Description Rev.

1 4341248 2 LH REAR FENDER MOUNT2 4341249 2 RH REAR FENDER MOUNT3 77143015 2 WHIZ-LOK NUT, 3/8-164 80383290 2 REAR FENDER5 80481113 1 RH FENDER BRACE6 80481114 1 LH FENDER BRACE7 80973025 4 WHIZ-LOK SCREW, 3/8-16X18 88201074 8 HEX HD CAPSCREW,1/2-13X3-1/4, GR5, (torque to 25-30 lb-ft)9 88201096 8 HEX HD CAPSCREW, 5/8-11X1-3/4, GR5

10 88521306 2 HEX LOCKNUT, 3/8-1611 88521308 8 HEX LOCKNUT, 1/2-1312 88551015 8 LOCKWASHER, 5/813 88561006 16 FLAT WASHER, 1/214 88561113 8 FLAT WASHER, 5/8



Rear Fender Assembly, XL4100IV & XL5100IV

PAC4810

7

914

1

21412

4

12

10 13 15

86

118

3

8

8 5 11

1015

131

21

2

14

12

914

7

4



Rear Fender Assembly, XL4100IV & XL5100IVItem Part Number Qty. Description Rev.

1 4341248 4 LH REAR FENDER MOUNT2 4341249 4 RH REAR FENDER MOUNT3 77143015 2 WHIZ-LOK NUT, 3/8-164 80383290 2 REAR FENDER5 80481113 1 RH FENDER BRACE6 80481114 1 LH FENDER BRACE7 80483026 2 FRONT REAR FENDER8 80973025 4 WHIZ-LOK SCREW, 3/8-16X19 88201074 16 HEX HD CAPSCREW, 1/2-13X3-14, GR5, (torque to 25-30 lb-ft)

10 88201096 16 HEX HD CAPSCREW, 5/8-11X1-3/411 88521306 2 HEX LOCKNUT, 3/8-1612 88521308 16 HEX LOCKNUT, 1/2-1313 88551015 16 LOCKWASHER, 5/814 88561006 32 FLATWASHER, 1/215 88561113 16 FLAT WASHER, 5/8



Rear Fender Assembly, XL4100IV (with railgear)

PAC15120

7 4

7

101315

11

3

3

SEE DETAIL ‘A’

DETAIL ‘A’

4

8 5

68

1 1

91214

811



Rear Fender Assembly, XL4100IV (with railgear)Item Part Number Qty. Description Rev.

1 80486050 4 FENDER BRACKET2 Not Used3 71492131 28” CONDUIT4 80383290 2 REAR FENDER (rear)5 80481233 1 R.H. FENDER BRACE6 80481222 1 L.H. FENDER BRACE7 80483026 2 REAR FENDER (front)8 80973025 4 WHIZ-LOK SCREW, 3/8-16X19 88201074 16 HEX HD CAPSCREW, 1/2-13X3-14, GR5, (torque to 25-30 lb-ft)

10 88201096 16 HEX HD CAPSCREW, 5/8-11X1-3/411 88521306 2 HEX LOCKNUT, 3/8-1612 88521308 16 HEX LOCKNUT, 1/2-1313 88551015 16 LOCKWASHER, 5/814 88561006 32 FLATWASHER, 1/215 88561113 16 FLAT WASHER, 5/8



Front Steps Installation

PAC5540

168

10

16910

5

71

10

111

1112

3

1112132

4

111

1112

4

1112132

3SEE DETAIL “A”

DETAIL “A”

168

10

16910

5

7110

13



Front Steps InstallationItem Part Number Qty. Description Rev.

1 77143015 24 WHIZ-LOK NUT, 3/8-162 80271315 4 CAP PLATE3 80271316 4 CAP PLATE4 80273104 4 STEP SUPPORT5 80381220 4 STEP ANGLE6 80381408 A/R STEP SHIM7 80383101 2 STAIR TREAD, 18.5”8 80383287 2 STAIR TREAD, 24”9 80383311 2 STAIR TREAD, 15.5”

10 80973025 21 WHIZ-LOK SCREW, 3/8-16X111 80973096 19 WHIZ-LOK SCREW, 3/8-16X1-1/212 88521206 16 HEX LOCKNUT, 3/8-1613 88561004 7 FLAT WASHER, 3/8



Front Steps (Extended) Installation

168

13

168

13

113

113 5

77

113

113

10

4 3

2

141516

141516

113

113

113

10

113

1415

4

2

16

3

SEE DETAIL ‘A’

DETAIL ‘A’

1415

16913

5

7

7 16913

PAC15390



Front Steps (Extended) InstallationItem Part Number Qty. Description Rev.

1 77143015 40 WHIZ-LOK NUT, 3/8-162 80271315 4 CAP PLATE3 80271316 4 CAP PLATE4 80273104 4 STEP SUPPORT5 80381220 4 STEP ANGLE6 80381408 A/R STEP SHIM7 80383101 4 STAIR TREAD, 18.5”8 80383287 2 STAIR TREAD, 24”9 80383311 2 STAIR TREAD, 15.5”

10 80781095 4 STEP EXTENSION PLATE11 Not Used12 Not Used13 80973025 37 WHIZ-LOK SCREW, 3/8-16X114 80973096 19 WHIZ-LOK SCREW, 3/8-16X1-1/215 88521206 16 HEX LOCKNUT, 3/8-1616 88561004 4 FLAT WASHER, 3/8



Rear Step Installation

PAC5550

1

23

4

56

NOTE: OPTIONAL L.H. STEP USES SAME MOUNTING HARDWARE AS SHOWN.



Rear Step InstallationItem Part Number Qty. Description Rev.

80485044 1 R.H. REAR STEP ASSY, (includes items 3 thru 6) 180485043 1 L.H. REAR STEP ASSY, (optional; includes items 3 thru 6) 1

1 88201097 4 HEX HD CAPSCREW, 5/8-11X2, GR52 88521210 4 HEX LOCKNUT, 5/8-113 80486027 1 R.H. REAR STEP WELDMENT, (used with 80485044 only)

80486026 1 L.H. REAR STEP WELDMENT, (used with 80485043 only4 80383287 4 STAIR TREAD, 24”5 77143015 16 WHIZ-LOK NUT, 3/8-166 80973025 16 WHIZ-LOK SCREW, 3/8-16X1



Battery Box Steps Installation

PAC5531



Battery Box Steps InstallationItem Part Number Qty. Description Rev.

80785104 1 BATTERY BOX STEPS ASSY,(includes qty. 12 of item 1, items 2 thru 6 & qty. 12 of item 7)

-

1 77143015 20 WHIZ-LOK NUT, 3/8-162 80383101 2 STAIR TREAD, 18.5”3 80781164 1 L.H. STEP PLATE4 80781165 1 R.H. STEP PLATE5 80781205 1 L.H. STEP PLATE6 80783168 2 STAIR TREAD, 44”7 80973025 18 WHIZ-LOK SCREW, 3/8-16X18 80973096 2 WHIZ-LOK SCREW, 3/8-16X1-1/29 88561004 2 FLAT WASHER, 3/8

10 80783249 2 NYLON SPACER, 3/4X1/2



Battery Box Steps (Extended) Installation

PAC15400

1

1

16

A

SECTION A-A

A

12

1314

113

1315

1315

112

112

131415

131415

112

7

11

10

5

2

43

9

8

6



Battery Box Steps (Extended) InstallationItem Part Number Qty. Description Rev.

80785107 1 BATTERY BOX STEPS ASSY,(includes qty. 12 of item 1, items 2 thru 11, qty. 10 of item 12, qty. 14 of item 13, qty. 3 of item 14 & item 15)

-

1 77143015 20 WHIZ-LOK NUT, 3/8-162 80271315 2 CAP PLATE3 80271316 3 CAP PLATE4 80273104 3 STEP SUPPORT5 80383101 3 STAIR TREAD, 18.5”6 80781164 1 L.H. STEP PLATE7 80781165 1 R.H. STEP PLATE8 80781205 1 L.H. STEP PLATE9 80781238 2 STEP EXTENDER PLATE

10 80781239 1 STEP EXTENDER PLATE11 80783168 3 STAIR TREAD, 44”12 80973025 16 WHIZ-LOK SCREW, 3/8-16X113 80973096 16 WHIZ-LOK SCREW, 3/8-16X1-1/214 88561004 5 FLAT WASHER, 3/815 88521206 12 HEX LOCKNUT, 3/8-1616 80783249 2 NYLON SPACER, 3/4X1/2



Mudflap Installation

PAC5920

12345

679

141516

9131516

101112



Mudflap InstallationItem Part Number Qty. Description Rev.

FRONT MUDFLAP INSTALLATION, (includes items 1 thru 5)1 77383307 2 MUDFLAP2 83481009 2 BACKING BAR3 88201006 8 HEX HD CAPSCREW, 1/4-20X1-1/4, GR54 88561002 8 FLAT WASHER, 1/45 88521204 8 HEX LOCKNUT, 1/4-20

REAR MUDFLAP INSTALLATION, (includes items 6 thru 16)6 80383355 2 REAR MUDFLAP, (XL3100IV 4x2 only)7 80383356 2 REAR MUDFLAP, (XL3100IV 4x4, XL4100IV 6x4 & XL5100IV 6x4 only)8 80483192 2 REAR MUDFLAP, (XL4100IV 6x6 & XL5100IV 6x6 only)9 80381433 2 BACKING BAR

10 83483597 2 CLOSE LINK11 88201003 2 HEX HD CAPSCREW, 1/4-20X3/4, GR512 88521304 2 HEX LOCKNUT, 1/4-2013 88201025 4 HEX HD CAPSCREW, 5/16-18X2-1/4, GR514 88201027 4 HEX HD CAPSCREW, 5/16-18X2-3/4, GR515 88521205 8 HEX LOCKNUT, 5/16-1816 88561003 8 FLAT WASHER, 5/16



Sheet Metal Covers Installation

PAC4821

5689

(XL3100IV)

(XL4100IV & XL5100IV)

127

46

137



Sheet Metal Covers InstallationItem Part Number Qty. Description Rev.

1 77143015 12 WHIZ-LOK NUT, 3/8-162 80781163 1 FUEL TANK COVER3 80781206 1 BATTERY BOX COVER4 80781173 1 FUEL TANK COVER BRACKET5 80886015 1 DECK COVER WELDMENT, (XL3100IV only)

80786035 1 DECK COVER WELDMENT, (XL4100IV & XL5100IV only)6 80973025 10 WHIZ-LOK SCREW, 3/8-16X1, (qty for XL3100IV only)

80973025 2 WHIZ-LOK SCREW, 3/8-16X1, (qty for XL4100IV & XL5100IV only)7 88411062 12 ROUND HD CARRIAGE BOLT, 3/8-16X18 88201035 8 HEX HD CAPSCREW, 3/8-16X1, GR5, (XL4100IV & XL5100IV only)9 88561004 8 FLAT WASHER, 3/8, (XL4100IV & XL5100IV only)



Upperstructure Covers Installation

4

26

29

13

2438

296

3916 1731

243829

39192218

31

1120

5

317

233635 37

40

29

29

381725

281415

3

17317

21

1217

3

173

24

17

30

283233

101

2

18

26

9

7

21

27

34

29 40

296

PAC1832

REARDOOR



Upperstructure Covers InstallationItem Part Number Qty. Description Rev.

1 0182086 2 COVER SUPPORT ANGLE2 88411062 1 ROUND HD CARRIAGE BOLT, 3/8-16X13 0791506 39 SCREW, 5/16-18X3/44 1671262 1 OIL COOLER COVER, (includes the following items)

80471069 3 GROMMET80514154 1 SCREEN GRILL

5 Ref VALVE COVER ASSY, (see page 1-42 for details)6 1671267 1 INSIDE VALVE COVER, (yellow)7 Ref LEFT FRONT DOOR, (see page 1-44 for details)8 1671308 1 TOP COVER9 1671310 1 CAB BELLYPAN

10 2600301 4 HINGE COVER WELDMENT11 3380682 1 VALVE TRAY BELLYPAN12 3576535 1 STRIKER PLATE13 3641644 1 HANDRAIL14 4100114 3 NYLON SLEEVE15 4341202 3 LEFT COVER SUPPORT16 80771097 1 STRIKER PLATE17 77143006 44 WHIZ-LOK NUT, 5/16-1818 77143015 3 WHIZ-LOCK NUT, 3/8-1619 80223034 2 WHIZ-LOCK SCREW, 1/2-13X3/420 80303094 5 WHIZ-LOCK SCREW, 3/8-16X3/421 80383368 28” GASKET, 3/4X1/2 THICK22 80471048 1 COVER SUPPORT BRACKET23 80571003 1 STRUT BRACKET24 80973025 30 WHIZ-LOK SCREW, 3/8-16X125 88201011 2 HEX HD CAPSCREW, 1/4-20X2-1/2, GR526 88201036 13 HEX HD CAPSCREW, 3/8-16x1-1/4, GR527 88521204 2 HEX JAM NUT28 88561002 6 FLAT WASHER, 1/429 88561004 24 FLAT WASHER, 3/830 88631542 4 ROLL PIN, 1/2X1-3/431 91363018 7 SCREW, 5/16-18X132 80771008 2 DOOR PROP33 88631303 2 COTTER PIN, 1/16X134 Ref REAR DOOR, L.H., (w/o air conditioner), (see page 1-46 for details)

Ref REAR DOOR, L.H., (w/air conditioner), (see page 1-46 for details)35 80771022 AR SHIM, LATCH BRACKET36 80541016 1 COVER GUIDE37 77383144 1 HOOD STOP CABLE38 80973096 4 WHIZ-LOK SCREW, 3/8-16X1-1/239 88521306 4 HEX LOCKNUT, 3/8-1640 88551011 7 LOCKWASHER, 3/8



Valve Cover

PAC2191



Valve CoverItem Part Number Qty. Description Rev.

1671264 1 VALVE COVER, (includes all items), (yellow) C11 1 VALVE COVER SHELL, (not available for service)2 80773050 1 HINGE3 80363153 1 GAS PROP, 130#, (not illustrated)4 80514162 3 NON-SKID STAIR TREAD5 80374105 1 BALL STUD, 10MM6 7300364 1 LATCH ASSY

91144470 1 LATCH KEY7 80374095 1 GAS PROP BRACKET8 80484162 9 HEX SHEET METAL SCREW, #1X3/49 88261018 6 SOCKET BUTTON HD CAPSCREW, 1/4-20X1

10 88561107 12 FLAT WASHER, 1/411 88521004 6 HEX LOCKNUT, 1/4-2012 80484161 2 PLASTIC PLUG, 1/2



Left Front Door

PAC2211

2

3

45

1



Left Front DoorItem Part Number Qty. Description Rev.

1671304 1 FRONT LEFT DOOR ASSY, (includes all items), (yellow) D1 80514175 1 DOOR2 80514224 1 HINGE ASSY (tapered)3 88261018 4 SOCKET BUTTON HD CAPSCREW, 1/4-20X14 88561107 4 FLAT WASHER, 1/45 88521004 4 HEX LOCKNUT, 1/4-206 80514173 1 RUBBER STRIP, (not illustrated)



Rear Door, L.H.

111

101

110

102 103

104

105

106

107

109

9

10

8

7

12

3

4

5

PAC2201

P/N 1671309

P/N 1671295



Rear Door, L.H.Item Part Number Qty. Description Rev.

1671309 1 REAR DOOR, L.H., (w/o air conditioner), (includes all items), (yellow) C1 80514163 1 DOOR2 88561105 4 FLAT WASHER, #83 80484160 4 HEX LOCKNUT, #8-324 88261005 4 SOCKET BUTTON HD CAPSCREW, #8-32X3/45 80514166 1 LATCH

91144470 1 LATCH KEY6 Not Used7 80514164 1 HINGE ASSY8 88261018 4 SOCKET BUTTON HD CAPSCREW, 1/4-20X19 88561107 4 FLAT WASHER, 1/4

10 88521104 4 HEX LOCKNUT, 1/4-20

1671295 1 REAR DOOR, L.H., (w/air conditioner), (includes all items), (yellow) C101 80514167 1 DOOR102 88561105 4 FLAT WASHER, #8103 80484160 4 HEX LOCKNUT, #8-32104 80514164 1 HINGE105 80514168 1 LOUVER, (use 91164090 glue to mount)106 80514166 1 LATCH

91144470 1 LATCH KEY107 88261005 4 SOCKET BUTTON HD CAPSCREW, #8-32X3/4108 Not Used109 88261018 4 SOCKET BUTTON HD CAPSCREW, 1/4-20X1110 88561107 4 FLAT WASHER, 1/4111 88521004 4 HEX LOCKNUT, 1/4-20



Swing Bearing Installation Components

13

4

25

6

79

8

10

1113

12

14

16

17

18

1920

21

15

2422

23

PAC1851

GLUE COVER TO CHASSIS

(ITEM 12 TO ITEM 14)

ATTACHED TO OIL COOLER BOX

SET BACKLASH TO .015-.056 ON HIGH TOOTH OF GEAR AS MARKED BY VENDOR

(ITEM 12 TO ITEM 16)



Swing Bearing Installation ComponentsItem Part Number Qty. Description Rev.

1 77343070 1 VENT2 80243019 1 ADAPTER3 91043147 1 SUPPORT CLAMP4 80303094 1 WHIZ-LOCK SCREW, 3/8-16X3/45 77143015 1 WHIZ-LOCK NUT, 3/8-166 84716547 1 HOSE ASSY7 83201017 10 HEX HD CAPSCREW, 3/4-10X3/4, GR5, (loctite & torque to 340-365 lb-ft)8 Ref SWING TRANSMISSION ASSY, (see page 9-64 for details)9 90027473 10 HARDENED WASHER

10 2754860 1 GREASE HOSE11 84719896 1 HOSE ASSY12 80623016 2 BULKHEAD ADAPTER13 88671001 2 LUBE FITTING, STRAIGHT, 1/814 88743021 1 MALE ELBOW, 45 DEGREES, 1/8X1/4 TUBE15 85041302 18 GREASE CARTRIDGE, #2, (14.5 oz.)16 88743041 1 MALE ELBOW, 90 DEGREES, 1/8X1/4 TUBE17 80443001 1 SWING BEARING18 80323011 32 FLAT HD CAPSCREW, 5/8-11X3-3/4, (loctite & torque to 200-215 lb-ft)19 80413010 1 BEARING COVER20 14404579 AR BETASEAL PRIMERLESS ADHESIVE21 80433131 40 FLAT HD CAPSCREW, 5/8-11X2-1/2, (loctite & torque to 200-215 lb-ft)22 80973025 2 WHIZ-LOK SCREW, 3/8-16X123 80471053 1 COVER24 80473060 1 GASKET



Counterweight & Swing Light Installation, XL3100IV

6

1

3 4

2

5

7

1089

78910

PAC16140

SHIM EACH HOLEAS REQUIRED



Counterweight & Swing Light Installation, XL3100IVItem Part Number Qty. Description Rev.

1 2920194 2 SWING LIGHT ASSY2 80303094 4 WHIZ-LOCK SCREW, 3/8-16X3/43 4341111 2 SWING LIGHT MOUNT PLATE4 5220600 4 NUT, #105 4821468 1 COUNTERWEIGHT, 6000#, (yellow)6 80341133 A/R COUNTERWEIGHT SHIM7 Order Kit 8 SPECIAL WASHER, (square) 8 Order Kit 4 HEX HD CAPSCREW, 1-8X3-1/2, GR5,

(loctite & torque to 625-675 lb-ft)9 14404102 A/R LOCTITE, (#277 red)

10 Order Kit 4 LOCKWASHER, 1”, (wedge-style)

80804015 1 COUNTERWEIGHT MOUNTING KIT, (includes items 6 (qty. 8), 7, 8 & 10



Counterweight & Swing Light Installation, XL4100IV & XL5100IV

6

7

89

78

1 2

3 4

5

PAC2091

SHIM EACH HOLEAS REQUIRED



Counterweight & Swing Light Installation, XL4100IV & XL5100IVItem Part Number Qty. Description Rev.

1 2920194 2 SWING LIGHT ASSY2 80303094 4 WHIZ-LOCK SCREW, 3/8-16X3/43 4341111 2 SWING LIGHT MOUNT PLATE4 5220600 4 NUT, #105 4821467 1 COUNTERWEIGHT, 8,850# XL4100IV, (yellow)

4821466 1 COUNTERWEIGHT, 15,500#, XL5100IV, (yellow)6 80341133 A/R COUNTERWEIGHT SHIM7 4740569 6 SPECIAL WASHER, (square)8 88201137 6 HEX HD CAPSCREW, 1-8X3, GR5, (loctite & torque to 545-595 lb-ft)9 14404102 A/R LOCTITE, (#277 red)



Boom Installation Components

5

12

15

4 7 6

16

910821

12

11

32

1

13

14

PAC2101

TO R.H. HOIST CYLINDER

TO L.H. HOIST CYLINDER



Boom Installation ComponentsItem Part Number Qty. Description Rev.

1 88201067 6 HEX HD CAPSCREW, 1/2-13X1-1/2, GR5, (lubricate & torque to 68-73 lb-ft)2 80321089 6 SPECIAL WASHER3 80526006 2 PIN WELDMENT, (apply #8522012 anti-seize lubrication to stop end of pin)4 88743041 2 MALE ELBOW, 90 DEGREES, 1/8X1/4 TUBE5 80326011 2 PIN WELDMENT, (apply #8522012 anti-seize lubrication to stop end of pin)6 3576490 1 LOCATOR PLATE7 80223034 2 WHIZ-LOK SCREW, 1/2-13X3/48 80626014 2 PIN WELDMENT, (apply #8522012 anti-seize lubrication to stop end of pin)9 88671001 2 LUBE FITTING, STRAIGHT, 1/8

10 80623016 2 BULKHEAD ADAPTER11 2754860 1 GREASE HOSE12 84719898 1 GREASE HOSE13 88671018 2 LUBE FITTING, 45 DEGREES, 1/814 88691302 2 CONNECTOR15 Ref BOOM CRADLE WELDMENT, (see page 2-2 for details)16 Ref HOIST CYLINDER ASSY, (see page 9-2 for details)



Boom Rest Installation

PAC5510

SEE DETAIL “A”

2

DETAIL “A”

1

34

1

5

NOTE: IF MACHINE IS EQUIPPED WITHTELESTICK BOOM, SEE PAGE 3-64FOR BOOM REST INFORMATION.



Boom Rest InstallationItem Part Number Qty. Description Rev.

1 77143014 2 WHIZ-LOK NUT, 1/2-132 80786038 1 HOSE SUPPORT WELDMENT3 86121186 10 HEX HD CAPSCREW, 1/2-13X2, GR84 90027471 10 HARD WASHER, 1/2X1-1/16X.0955 80786030 1 BOOM REST



Upperstructure Cab Installation Components

PAE0440

37

4

5

6

28

1



Upperstructure Cab Installation ComponentsItem Part Number Qty. Description Rev.

1 Ref OPERATORS CAB, (see page 6-2 for details)2 88991024 4 PUSH PLUG, 1/23 88681394 4 STUD, 5/8-11X4-3/4, GR54 77381205 4 SPECIAL WASHER5 80383060 4 SHOCK MOUNT6 88521010 4 HEX LOCKNUT, 5/8-11, (loctite & torque to 140-155 lb-ft)7 14403364 A/R LOCTITE, (#242 blue)8 14404173 A/R CAULK



Undercarriage Cab Installation Components & Heater Plumbing

SEE DETAIL “A”

32

13

1334

7

25

DETAIL “B”

1924

DETAIL “A”26

29

18

10

10

SEE DETAIL “B”

PAC5050



Undercarriage Cab Installation Components & Heater Plumbing

PAC5060

5

8

21232831

9

20222730

17

14

15

311

1626

1417

12

1417

1517

HEATERINLET

HEATEROUTLET

(BLACK) FROM HEATER OUTLETTO BOTTOM RADIATOR TUBE

(RED) FROM HEATER INLETTO WATER VALVE

(RED) FROM WATER VALVE TOPORT ON FRONT OF ENGINE

CONNECT TO CAB HARNESS

LEFT FRONT CORNER OF CAB

ON INSIDEOF CAB

CAB GNDHTR POT SGN B12V ACC



Undercarriage Cab Installation Components & Heater PlumbingItem Part Number Qty. Description Rev.

1 14403364 AR LOCTITE, (#242 BLUE)2 14401473 AR DOW INDUSTRIAL SILICONE CAULK, (#732)3 77143006 1 WHIZ-LOK NUT, 5/16-184 80383060 4 SHOCK MOUNT5 80383065 1 HORN BUTTON6 88991023 4 PUSH-IN PLASTIC PLUG7 77381205 4 SPECIAL WASHER8 80383335 1 STEERING WHEEL9 80461205 1 DIAGNOSTIC CONNECTOR BRACKET

10 80483111 1 CAB FRONT COVER WITH SEAL11 85941017 1 SUPPORT CLAMP, 29/3212 80783119 1 HEATER CONTROL VALVE, (12v)13 Ref UNDERCARRIAGE CAB ASSY, (see page 6-40 for details)14 A/R HEATER HOSE, (red)15 A/R HEATER HOSE, (black)16 83673109 1 GROUND CABLE17 86671187 6 HOSE CLAMP18 88201007 4 HEX HD CAPSCREW, 1/4-20X1-1/2, GR519 88201053 1 HEX HD CAPSCREW, 7/16-14X1-3/4, GR520 88301023 4 ROUND HD MACHINE SCREW, #4-40X3/8, GR821 88301056 4 ROUND HD MACHINE SCREW, #6-3222 88501604 4 HEX NUT, #4-4023 88501608 4 HEX NUT, #6-3224 88521007 1 HEX LOCKNUT, 7/16-14, (hand torque to 44-54 lb-ft)25 88521010 4 HEX LOCKNUT, 5/8-11, (hand torque to 140-155 lb-ft)26 88521205 1 HEX LOCKNUT, 5/16-1827 88551003 4 LOCKWASHER, #428 88551005 4 LOCKWASHER, #629 88551009 4 LOCKWASHER, 1/430 88561102 4 FLAT WASHER, #431 88561103 4 FLAT WASHER, #632 88561107 4 FLAT WASHER, 1/433 88681394 4 STUD, 5/8-11X4-3/4, GR5



Undercarriage Cab Installation Components & Heater PlumbingItem Part Number Qty. Description Rev.



Power Unit Installation

PAC4900

2567

2567

148DETAIL “A”

SEE DETAIL “A”

3



Power Unit InstallationItem Part Number Qty. Description Rev.

1 77143006 1 WHIZ-LOK NUT, 5/16-182 77381205 6 SPECIAL WASHER3 Ref POWER UNIT ASSY, (see page 4-2 for details)4 85941016 1 SUPPORT CLAMP, 1/25 88201105 6 HEX HD CAPSCREW, 5/8-11X4, GR56 88521210 6 HEX LOCKNUT, 5/8-117 88561113 6 FLAT WASHER, 5/88 91363018 1 WHIZ-LOK SCREW, 5/16-18X1



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