SECTION 5 - DRIVE TRAIN - MyGradall.com

1 SECTION 5 - DRIVE TRAINDRIVE TRAINS eries IV Highway Speed Excavators808040015-2 Transfer Case InstallationPAC 5 8 1 3 DRIVE TRAIN80804001 Series IV Highway Speed Excavators5-3 Transfer Case InstallationItemPart HD CAPSCREW, 3/8-16X1, GR52804830324 BEARING STRAP, (includes item 3)3804830338 BEARING STRAP SCREW4807831781 ELECTRIC MOTOR PUMP, (includes items 18 thru 20)5807830941 DRIVESHAFT, (transmission to transfer case), (includes items 102 & 103)6 RefTRANSFER CASE ASSY, (see page 5-6 for details)7847217021 HOSE ASSY, (ORFS 45 degree female swivel at motor pump)847229691 HOSE ASSY, (JIC 45 degree female swivel at motor pump)8847217031 HOSE ASSY9868812874 WASHER10882011054 HEX HD CAPSCREW, 5/8-11X4, GR511885212104 HEX LOCKNUT, 5/8-1112885611134 FLAT WASHER, 5/813886620191 JIC STRAIGHT CONNECTOR, (includes item 16),(If ordering this part, you must order 84722969 hose assembly, item 7)14886624301 STRAIGHT CONNECTOR, (includes item 17) 424 HYDRAULIC TRACTOR FLUID16885912051O-RING17885912061O-RING1 8807841741 PUMP SOLENOID, 24V19807841721 TERMINAL WIRE20807841731 GROUND WIRE21771430154 WHIZ-LOK NUT, 3/8-1610180384375A/RUNIVERSAL JOINT KIT, (includes brackets and hardware)

2 102807842081 SLIP YOKE ASSY103807842091 YOKE SHAFTDRIVE TRAINS eries IV Highway Speed Excavators808040015-4 Transfer Case AssemblyPAC 5 8 2 3 $ % Before S/N sXL3100IV - 3120000340 (4x2); 3140000367 (4x4)XL4100IV - 4100000665 (6x4); 4160000075 (6x6)XL5100IV - 5100000608 (6x4 & 6x6) DRIVE TRAIN80804001 Series IV Highway Speed Excavators5-5 Transfer Case AssemblyItemPart FITTING, 45 DEGREES2 RefTRAVEL MOTOR, (see page 9-82 for details)3 RefCOUNTERBALANCE VALVE ASSY, (see page 9-110 for details) MOUNT68320100616 HEX HD CAPSCREW, 3/4-10X2, GR8, (torque to 260-285 lb-ft)7832010483 HEX HD CAPSCREW, 3/8-16X5-1/4, GR88847216731 HOSE ASSY, (see note at bottom of page)9847216741 HOSE ASSY, (see note at bottom of page)

3 10868812274 LORD MOUNT118856110911 FLAT WASHER, 3/8128855101616 LOCKWASHER, 3/413885911361O-RING14886624361 ELBOW, 90 DEGREES, (includes item 16)15886626642 FLANGE KIT, (includes item 34)16885912071O-RING17885912042O-RING188 85912061O-RING19837630561 VITON O-RING, (lubricate lightly)20771330891 MINI-CHECK COUPLING, (includes item 19)21886623711 ELBOW, 90 DEGREES, (swivel nut)22 RefPROPEL ANTI-CAVITATION VALVE, (see page 9-112 for details)23807812081 VALVE MOUNT PLATE24847217911 HOSE ASSY25847217921 HOSE ASSY26882010372 HEX HD CAPSCREW, 3/8-16X1-1/2, GR527882010452 HEX HD CAPSCREW, 3/8-16X3-1/2, GR528886623011 STRAIGHT CONNECTOR, (includes item 17)29886624861 ELBOW, 90 DEGREES, (includes item 17)30886624871 ELBOW, 90 DEGREES, (includes item 18)311 TRANSFER CASE, (4x2 & 6x4 machines only), (see page 5-8 for details)1 TRANSFER CASE, (4x4 & 6x6 machines only), (see page 5-12 for details)32885213067 HEX LOCKNUT, 3/8-1633886628161 ADAPTER, 45 DEGREES, (replaces 90 degree elbow on older machines)34889912212O-RINGNOTE.

4 Prior to ordering item 8 or 9, check manufacturer of hose. If the hose is a Gates manufactured hose, item 15 flange kit must also be ordered for proper installation at travel motor. If the hose is manufactured by Parker, no additional kit is S/N sXL3100IV - 3120000340 (4x2); 3140000367 (4x4)XL4100IV - 4100000665 (6x4); 4160000075 (6x6)XL5100IV - 5100000608 (6x4 & 6x6) DRIVE TRAINS eries IV Highway Speed Excavators808040015-6 Transfer Case AssemblyPAC140601031461211162227293220 DETAIL A 23151718192612133711165612213419241016 SEEDETAIL A 14353033253682832111626 After (& including) S/N sXL3100IV - 3120000340 (4x2); 3140000367 (4x4)XL4100IV - 4100000665 (6x4).

5 4160000075 (6x6)XL5100IV - 5100000608 (6x4 & 6x6) DRIVE TRAIN80804001 Series IV Highway Speed Excavators5-7 Transfer Case AssemblyItemPart FITTING, 45 DEGREES2 RefTRAVEL MOTOR, (see page 9-82 for details)3 RefCOUNTERBALANCE VALVE ASSY, (see page 9-110 for details) MOUNT68320100616 HEX HD CAPSCREW, 3/4-10X2, GR8, (torque to 260-285 lb-ft)7832010483 HEX HD CAPSCREW, 3/8-16X5-1/4, GR88847225211 HOSE ASSY9847225201 HOSE ASSY10868812274 LORD MOUNT118856110911 FLAT WASHER, 3/8128855101616 LOCKWASHER, 3/413885911361O-RING14886624361 ELBOW, 90 DEGREES, (includes item 35)15847127384 FLANGE CLAMP HALF16885213067 HEX LOCKNUT, 3/8-1617885510128 LOCKWASHER, 7/1618832011558 HEX HD CAPSCREW, 7/16-14X1-3/4, GR819910831062O-RING20886628161 ADAPTER, 45 DEGREES21771330891 MINI-CHECK COUPLING, (includes item 34)22 RefPROPEL ANTI-CAVITATION VALVE, (see page 9-112 for details)23807812081 VALVE MOUNT PLATE24847217911 HOSE ASSY25847217921 HOSE ASSY26882010372 HEX HD CAPSCREW, 3/8-16X1-1/2, GR527882010452 HEX HD CAPSCREW, 3/8-16X3-1/2, GR528886623011 STRAIGHT CONNECTOR, (includes item 32)29886624861 ELBOW, 90 DEGREES, (includes item 32)30886624871 ELBOW, 90 DEGREES, (includes item 33)

6 31886623711 ELBOW, 90 DEGREES, (swivel nut)32885912042O-RING33885912061O-RING34 837630561 VITON O-RING, (lubricate lightly)35885912071O-RING361 TRANSFER CASE, (4x2 & 6x4 machines only), (see page 5-8 for details)1 TRANSFER CASE, (4x4 & 6x6 machines only), (see page 5-12 for details)After (& including) S/N sXL3100IV - 3120000340 (4x2); 3140000367 (4x4)XL4100IV - 4100000665 (6x4); 4160000075 (6x6)XL5100IV - 5100000608 (6x4 & 6x6) DRIVE TRAINS eries IV Highway Speed Excavators808040015-8 Transfer Case, XL3100IV (4X2), XL4100IV & XL5100IV (6X4)PA C 6 6 6 0 AABBFRONT VIEWREAR VIEW123456877910111213141015161718192021 22232425262729283031327333435343536 SIGNALFULLY ROADPART IA L ENG AGE DFULLY REMOTEITEM 33 OPENOPENCLOSEDITEM 36 OPENCLOSEDCLOSEDDRIVE TRAIN80804001 Series IV Highway Speed Excavators5-9 Transfer Case, XL3100IV (4X2), XL4100IV & XL5100IV (6X4)

7 PA C 6 6 7 0373839404142394041424344454647484950515 2394053545539405657585960394061625657586 3394056575853546465646667 SECTION A-A6810697071727374757617777855 SECTION B-BDRIVE TRAINS eries IV Highway Speed Excavators808040015-10 Transfer Case, XL3100IV (4X2), XL4100IV & XL5100IV (6X4)ItemPart CASE, (4X2 & 6X4 machines only), (includes all items)B1807841481 STREET ELBOW2807841421 HEX PIPE PLUG3807841431 BREATHER4807841621 FLAT WASHER, 1/45807841631 HEX HD CAPSCREW6807841601 HOSE CLAMP7807840921 HOSE ASSY88078413319 SCREW, 3/8-16X1-1/49807841511 RUN TEE10807841553 HEX PLUG11807841281 MAGNETIC PLUG12807841502 PLUG138078414412 FLAT WASHER, 3/8148078413712 HEX HD CAPSCREW, 3/8-16X5-1/215807841021 ACCESS COVER16807841326 SCREW, 3/8-16X1178078414012 WASHER188078414911 HEX FLANGE SCREW, 3/8-16X3/419807841151 OIL PASSAGE PLATE20807841571 STRAINER21807841581 ELBOW228078413410 SCREW.

8 3/8-16X1-1/223807841591 ELBOW24807841171 DIPSTICK TUBE25807841161 DIPSTICK26807841541 STRAIGHT CONNECTOR27807841611 HOSE CLAMP28807840931 HOSE ASSY298078414518 NUT, 3/8-1630807841531 REDUCER BUSHING31807841312 HARDENED DOWEL32807841521 TEE33807842341 SWITCH KIT, (normally closed; gold), (includes switch & items 34 & 35)342 SWITCH BALL352 SWITCH GASKET36807842351 SWITCH KIT, (normally open; silver), (includes switch & items 34 & 35)37807841082 YOKE SPACER38807841001 SEAL RETAINER39807841226 BEARING CONE40807841216 BEARING CUP41807841041 GEAR AND SHAFT ASSY - INPUT42807841641 SNAP RING43807841251 ROLLER BEARING44807841241 INNER BEARING45807841031 SHIFT COLLAR46VA0000S47041 BALL BEARING47VA0000S47151 INTERNAL SNAP RING48807841461 EXTERNAL SNAP RINGDRIVE TRAIN80804001 Series IV Highway Speed Excavators5-114980784147A/REXTERNAL SNAP RING50807841201 PLANETARY PAD51807841071 PLANETARY INPUT SHAFT52807840991 REAR HOUSING53807841182 YOKE WASHER54807841272 LOCKNUT55807841091 SHIFT FORK5680784110A/RSHIM.

9 005 THICK5780784111A/RSHIM, .007 THICK5880784112A/RSHIM, .020 THICK59807841191 DISCONNECT ASSY60807841231 DISCONNECT BUSHING61807841061 GEAR AND SHAFT ASSY - OUTPUT62807841051 GEAR AND SHAFT ASSY63807841011 BEARING COVER64807840972 YOKE65807840942 INPUT SEAL66807840951 OIL SEAL - OUTPUT67807840961 OIL SEAL SLEEVE68807841411 SOCKET HD CAPSCREW, 5/16-18X169807841391 WASHER, 5/1670807841141 SHIFT PISTON71807841261O-RING72807841131 SHIFT CYLINDER73807841383 SOCKET HD CAPSCREW, 1/4-20X2-3/474807840891 SWITCH ADAPTER75807841561O-RING76807841351 HEX HD CAPSCREW, 3/8-16X1-3/477807841301 RETURN SPRING78807840881 SHIFT SHAFT Transfer Case, XL3100IV (4X2)

10 , XL4100IV & XL5100IV (6X4)ItemPart TRAINS eries IV Highway Speed Excavators808040015-12 Transfer Case, XL3100IV (4X4), XL4100IV & XL5100IV (6X6)PA C 6 6 8 01234576101112108910 CCFRONT VIEW131415161718192021222324252627282930 123536313435363233 AAREAR VIEWSIGNALFULLY ROADPA RT I AL E N G AG E DFULLY REMOTEITEM 34 OPENOPENCLOSEDITEM 12 OPENCLOSEDCLOSEDDRIVE TRAIN80804001 Series IV Highway Speed Excavators5-13 Transfer Case, XL3100IV (4X4), XL4100IV & XL5100IV (6X6)PA C 6 6 9 0373839404142394043444546474950515253485 4394055563739405758596061394062685758596 3394057585955566465646667 SECTION A-A6933707172737475767729787980 SECTION B-BSECTION C-C64666760 DRIVE TRAINS eries IV Highway Speed Excavators808040015-14 Transfer Case, XL3100IV (4X4), XL4100IV & XL5100IV (6X6)ItemPart CASE, (4X4 & 6X6 machines only), (includes all items)