SECTION 4 - ENGINE & ATTACHING PARTS - …

1 SECTION 4 - ENGINE & ATTACHING PARTS - ENGINE & ATTACHING PARTSS eries III Highway Speed Excavators808540014-2 Power Unit Assembly12412813512798363837151781278993 1431721431721421719131201311688192111216 6171161641431725213115416731332 4 5 13 9212989951334765020531211321551251301367 99912613021332301351154163 1211913021300350 13123133156102113347750 80 89 9111318015 22401402402 DETAIL A USE ITEM 135TO SHIM CYLINDERON TO .020 GAP BETWEENADJUSTMENT SCREW & NUT AFTER NOT A PORTA & BPORT B SEE DETAIL A FOR MACHINES EQUIPPED WITHEXHAUST BRAKE OPTION ONLYTO EXHAUSTBRAKECYLINDER50150250350450550250 6 BEFORE S/N sXL3100 III - 3120000191 (4X2) & 3140000295 (4X4);XL4100 III - 4100000392 (6X4) & 4160000043 (6X6);XL5100 III - 5100000577 (6X4 & 6X6)PA C 3 9 9 2- ENGINE & ATTACHING PARTS80854001 Series III Highway Speed Excavators4-3 Power Unit Assembly8223 3915942 60102160 1133593107114666153109561465881341087172 114026162 BREATHER SUPPLIEDWITH TRANSMISSIONREVERSESWITCHSEE DETAIL VIEW CCLAMP AND HARDWAREFOR PILOT SUPPLY HOSE18335873908915815710988134159 30 31108252728 25 9711787 491478640 POSITIVEBATTERYCABLENEGATIVEBATTERYCABLE TRANSMISSIONCOOLER LINEDETAIL B SEE DETAIL B DETAIL C 17 85100175176177178 SPEED SENSOR UNDER YOKENOTE: INSTALL SENSOR UNTIL MAGNET ENDOF SENSOR TOUCHES GEAR, THEN BACKOFF 1/2 TURN.

2 TORQUE NUT TO 20 C 3 8 7 0- ENGINE & ATTACHING PARTSS eries III Highway Speed Excavators808540014-4 Power Unit Assembly 31108161 3110916157507513946867107104141145169146 71401702916217149142171139 63138416413416210814617359P/S PRESSUREENG HARNESSP/S SUCTION HOSEAIR LINE TO RUNTEE ON GOVERNERROUTE TO P/SRESERVOIR ONUNDERCARRIAGEHAND TORQUE NUTTO 70-80 SUPPLIEDW/ALTERNATOR23844974222323234931 111159161 TOPORT "Y"TOPORT "Z"DETAIL E "H"TO SLAVEVLV H NEUTRALSWITCHTOPORT "X"TO SLAVEVLV L "L"4470 43115 MOUNT TOREAR OF P/UMOUNT TOFRONT OF COUNTERSHAFTPTO AIR FITTINGS179 24174 SEEDETAIL F 1104887468683152122132 5413711049691164947 DETAIL D "Z""Y""X"SEE DETAIL D SEE DETAIL E 31118511388402245101 DETAIL F "B RES 1"PORT 2A TO AIRCOMPRESSORPAC3881 PAC3890- ENGINE & ATTACHING PARTS80854001 Series III Highway Speed Excavators4-5 Power Unit AssemblyPAC 3 9 0 2103 SPICER 2-PLATE PER INSTRUCTIONSINCLUDED WITH CLUTCH KITGAP BETWEEN CLUTCHRELEASE FINGERS & THROW-OUT BEARING HOUSINGMUST BE MAINTAINED.

3 DONOT PRELOAD SIDE, (SMALLERDIAMETER SURFACE),TOWARDS TRANSMISSION(4) INTERMEDIATED PLATE 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 TAP 4 INTERMEDIATE PLATE PINS. PINS ARE TO TOUCHFLYWHEEL.* INSTALL TRANSMISSION* ADJUST RELEASE BEARING TO .500 DIM. USING ADJUSTER WITH LOCKNUT GREASE FITTINGFROM TROWOUT BEARINGAND INSTALL IN ITEM # ENGINE & ATTACHING PARTSS eries III Highway Speed Excavators808540014-6 Power Unit AssemblyItemPart FactoryRefPOWER UNIT ASSY, XL3100 III,(includes items 1 thru 179 & items 350 & 351)FConsult FactoryRefPOWER UNIT ASSY w/EXHAUST BRAKE, XL3100 III,(includes items 1 thru 179, 350 & 351 & items 400 thru 402)FConsult FactoryRefPOWER UNIT ASSY, XL4100 III & XL5100 III,(includes items 1 thru 179 & items 300 & 301)FConsult FactoryRefPOWER UNIT ASSY w/EXHAUST BRAKE, XL4100 III & XL5100 III,(includes items 1 thru 179, 300 & 301 & items 400 thru 402)

4 F109033441 VENT LINE BRACKET2807810661 TOP PTO BRACKET3807810651 LOWER PTO BRACKET414001291 FAN CLUTCH520600381 FAN627205991 RADIATOR HOSE727548681 SUCTION PILOT PUMP HOSE ASSY8 RefTRAVEL MOTOR ASSY, (see page 9-98 for details)9 RefCOUNTERSHAFT PTO ASSY, (see page 9-110 for details)10 RefPTO ASSY, (see page 9-106 for details)1149233231 ENGINE HARNESS12120012344 HARDENED WASHER, 3/81314403364A/RLOCTITE, (#242 blue)1414403416A/RDI-ELECTRIC GREASE15A/RMOTOR OIL, (consult Operator Manual for spec)1614404043A/RLOCTITE, (#545 purple)1714404082A/RLOCTITE, (#565 white)1814404102A/RLOCTITE, (#277 red)1914404825A/RHYDRAULIC FLUID2014404967A/RTRANSMISSION OIL, (synthetic)2114405342A/RLOCTITE, #518, RED22 A/RNYLON TUBING, 1/4, BLACK23 A/RNYLON TUBING, 3/8, BLACK24771330891 MINI-CHECK COUPLING, (includes item 174)25771331361 CLAMP SET26771331371 COVER PLATE27771333061 STACK BOLT28771333901 SAFETY CLIP29771430031 WHIZ-LOK SCREW, 5/16-18X5/830771430041 WHIZ-LOK SCREW, 5/16-18X1-1/431771430066 WHIZ-LOK NUT, 5/16-1832802230358 FLANGE SCREW, 1/2-13X3/4, GR8, (loctite & hand torque to 68-78 lb-ft)33802332203 HARDENED WASHER, M1034803030468 HEX HD CAPSCREW, M16-2X35, (loctite & hand torque to 32-37 lb-ft)35803711062 SPACER BRACKET36803814651 CLUTCH LEVER37 RefSLAVE CYLINDER, (see page 5-6 for details)

5 38803830701 ROD END39803831471 PUSH FITTING, 1/4X3/840803831512 TUBE FITTING, 90 DEGREES, 1/8X1/4 TUBE41803831651 TUBE FITTING, 90 DEGREES, 1/4X1/4 TUBE- ENGINE & ATTACHING PARTS80854001 Series III Highway Speed Excavators4-742803831661 TUBE FITTING, 90 DEGREES, 1/4X3/8 TUBE43803831761 TUBE FITTING, 1/8X1/4X1/444803831781 TUBE FITTING, 3/8X3/4X1/445803831821 TUBE FITTING, 1/4X1/4X1/846803831881 TUBE FITTING, 1/8X1/4X1/447803832061 TUBE FITTING, 1/8X3/848803832071 TUBE FITTING, 1/8X3/8X3/849803832085 TUBE FITTING, 90 DEGREES, 1/8X3/850803833996 LORD MOUNT51804810951 MOUNTING PLATE52807860161 PTO BRACKET53 RefTRANSMISSION ASSY, (see page 5-8 for details)54804830361 SUCTION ELBOW55804830501 PILOT BEARING56804830521 ALTERNATOR57804830541 PULLEY58804830551 STARTER59804830561 DRIVE BELT, (w/o undercarriage air conditioner)804830571 DRIVE BELT, (w/undercarriage air conditioner)60804830801 ADAPTER61804830901 POSITIVE BATTERY CABLE62804830911 NEGATIVE BATTERY CABLE63804830991 ADAPTER, M2664804831001 ADAPTER, M1265804831021 HEX HD CAPSCREW, M16-22X25, GR866804831084 HEX HD CAPSCREW, , (hand torque to 38-43 lb-ft)67804831091 RADIATOR TUBE COUPLING68804831101 LOWER RADIATOR TUBE69804831121 DUAL PORT, 90 DEGREES70804831181 ELBOW, 90 DEGREES, 71804831271 SLOBBER HOSE72804832261 EXHAUST ADAPTER73804832373 STUD, AIR VALVE ASSY, (see page 4-46 for details)

6 75804860161 FRONT ENGINE MOUNT76804860171 ENGINE MOUNT, MOUNT, BRACKET79804860511 TRANSMISSION SUPPORT WELDMENT80805330171 PILOT/POWER STEERING PUMP81 RefCLUTCH ASSY, (see page 5-2 for details)8280783002 XXX1 REVERSE LIGHT SWITCH ASSY83807830031HI-LO RANGE SWITCH ASSY84807830041 NEUTRAL START SWITCH ASSY8580975004S1 SPEED SENSOR ASSY, (includes items 175 thru 178)-86 A/RNYLON TUBING, 1/4, RED87 A/RNYLON TUBING, 3/8, RED88831910075 HEX HD CAPSCREW, , , M10 Power Unit AssemblyItemPart ENGINE & ATTACHING PARTSS eries III Highway Speed Excavators808540014-890831910303 HEX LOCKNUT, , (hand torque to 32-42 lb-ft)91831910402 SOCKET HD CAPSCREW, HD CAPSCREW, , HD CAPSCREW, , (hand torque to 32-37 lb-ft)94831910674 HEX HD CAPSCREW, M14-2X45958319108210 SOCKET HD CAPSCREW, , (hand torque to 32-37 lb-ft)

7 96832011268 HEX HD CAPSCREW,3/8-16X2-1/2, GR897836631191 CLAMP SET98836816881 TUBE SPACER, 3-3/899836835162 RUBBER STOP100836870601 SEAL101845210541 GOVERNOR102847127421 HOSE NIPPLE103847168991 HOSE ASSY104847210221 HOSE ASSY107850711283 HOSE CLAMP108858411505 SUPPORT CLAMP, 1-1/2109859410164 SUPPORT CLAMP, 1/2110859410172 SUPPORT CLAMP, 29/32111859410181 SUPPORT CLAMP, 211286641304A/ROPEN GEAR LUBE113866711121 PILOT/POWER STEERING PUMP GASKET114869711721 HOSE CLAMP115869836481 BRASS ELBOW, 90 DEGREES, 1/8116869836501 BRASS ELBOW, 90 DEGREES117882010231 HEX HD CAPSCREW, 5/16-18X1-3/4, GR5118882010282 HEX HD CAPSCREW, 5/16-18x3, GR5119882010384 HEX HD CAPSCREW, 3/8-16X1-3/4, GR5120886814434 HEX HD CAPSCREW, 1/2-13X2-3/4, GR5, (loctite & hand torque to 68-78 lb-ft)121882010942 HEX HD CAPSCREW, 5/8-11X1-1/4, GR5122882010964 HEX HD CAPSCREW, 5/8-11X1-3/4, GR5, (hand torque to 140-155 lb-ft)123882011114 HEX HD CAPSCREW, 3/4-10X2, GR5, (loctite & hand torque to 240-265 lb-ft)124882510431 SOCKET HD SHOULDER BOLT, 1/2X2-1/2, (10-24 thread)125882610292 SOCKET BUTTON HD CAPSCREW, 3/8-16X1126885010062 HEX NUT, 3/8-16127885014102 HEX JAM NUT, 5/16-18128885212061 HEX LOCKNUT, 3/8-16129885510104 LOCKWASHER, 5/161308855101116 LOCKWASHER, 3/8131885510138 LOCKWASHER, 1/2132885510156 LOCKWASHER, 5/8133885510164 LOCKWASHER, 3/4134885610035 FLAT WASHER, 5/1613588561006A/RFLAT WASHER, 1/2136885611092 FLAT WASHER, 3/8137885911151O-RING138886621071 ELBOW, 90 DEGREES, (swivel nut)139886623041 CONNECTOR, (includes item 169)

8 140886623051 CONNECTOR, (includes item 170), (hand torque to 105-110 lb-ft) Power Unit AssemblyItemPart ENGINE & ATTACHING PARTS80854001 Series III Highway Speed Excavators4-9141886623091 CONNECTOR, (includes item 169)142886623292 ELBOW, 90 DEGREES, (includes item 171)143886623304 ELBOW, 90 DEGREES, (includes item 172)145886623751 ELBOW, 90 DEGREES, (swivel nut)146886624302 CONNECTOR, (includes item 173), (hand torque to 52-54 lb-ft)147886913001 BIJUR CONNECTOR, 3/4148887112101 PIPE COUPLER, 1/8149887112511 SQUARE HD PIPE PLUG, 1/4150887430001 MALE ADAPTER, 1/8X1/4 TUBE151887430101 MALE ADAPTER, 1/4X1/4 TUBE152887430142 MALE ADAPTER, 1/2X3/8 TUBE153900274704 HARDENED WASHER, 3/8154900274716 HARDENED WASHER, 1/2155900274722 HARDENED WASHER156900274734 HARDENED WASHER, 7/16157910331331 HEX NUT, NUT, , (hand torque to 15-22 lb-ft)159910431474 SUPPORT CLAMP, 3/4160910831551 TRUCK VALVE161913630183 WHIZ-LOK SCREW, 5/16-18X1162809730503 SUPPORT CLAMP163831910802 SOCKET HD CAPSCREW, ASSY, (torque nuts on hose ends to 27-29 lb-ft)166886623381 BRANCH TEE, (includes item 171)

9 167882010684 HEX HD CAPSCREW, 1/2-13X1-3/4, GR5168885210084 HEX LOCKNUT, 1/2-13169885912072O-RING170885912091O-RI NG171885912043O-RING172885912054O-RING17 3885912062O-RING174837630561 VITON O-RING, (lubricate lightly)175809730171 SPEED SENSOR176809630581 WEATHERPACK SHROUD, (2-wire)177809630662 CABLE SEAL, 16GA., (gray)178809630692 MALE TERMINAL PIN179807740421 BELT TENSIONER IDLER180 Consult FactoryRefENGINE181803843991 CLUTCH BRAKE, (supplied w/transmission)182833840921 CLUTCH RELEASE BEARING, (supplied w/transmission)300 RefMAIN HYDRAULIC PUMP ASSY, (see page 9-44 for details)301807810671 PUMP BRACKET350 RefMAIN HYDRAULIC PUMP ASSY, (see page 9-44 for details)351808810391 PUMP BRACKET400804831291 TUBE FITTING, SWIVEL, Power Unit AssemblyItemPart ENGINE & ATTACHING PARTSS eries III Highway Speed Excavators808540014-10401804831301 TUBE FITTING, 90 DEGREES402 RefENGINE AIR VALVE ASSY, EXHAUST BRAKE, (see page 4-46 for details)501886623482 RUN TEE, (includes item 502)502885912064O-RING503804812131 LOCKING PLATE504847211521 HOSE ASSY, (torque nuts on hose to 75-79 lb-ft)

10 505847211511 HOSE ASSY, (torque nuts on hose to 75-79 lb-ft)506886623312 ELBOW, 90 DEGREES, (includes item 502)80383428A/RENGINE DIAGNOSTIC TOOL804841331 ENGINE FILTER KIT, (includes one of each of the following)804841171 AIR FILTER ELEMENT804841161 AIR FILTER SAFETY ELEMENT803843841 FUEL FILTER803843851 OIL FILTER803840451 TRANSMISSION FILTER773838191 FUEL/WATER SEPARATOR, (mounted on boom rest) Power Unit AssemblyItemPart ENGINE & ATTACHING PARTS80854001 Series III Highway Speed Excavators4-11 Power Unit AssemblyItemPart ENGINE & ATTACHING PARTSS eries III Highway Speed Excavators808540014-12 Air Cleaner AssemblyPAC0561- ENGINE & ATTACHING PARTS80854001 Series III Highway Speed Excavators4-13 Air Cleaner AssemblyItemPart CLEANER ASSY, (includes items 1 thru 9)1839541081 CUP ASSY2839541091 BAFFLE ASSY3836712901 VACUATOR VALVE4839541101 CLAMP ASSY5839541111O-RING6804841231 FINNED SLEEVE7804841171 ELEMENT8804841161 SAFETY ELEMENT91 BODY ASSY10803833891 WARNING DECAL11839530742 MOUNTING BAND12885010052 HEX NUT, 5/16-1813771430064 WHIZ-LOK NUT, 5/16-1814771430034 WHIZ