section 4 - engine & attaching parts -...

SECTION 4 - ENGINE & ATTACHING PARTS

- 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


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



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



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



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



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




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)




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




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)




Air Cleaner Assembly

PAC0561



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



Power Steering Reservoir Assembly

PAC0541



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



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



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



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



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



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



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



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



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



Oil Cooler & Hoses

PAC0601

11

1

5

12

2

13

3

14

4

8

9

5

6

7

8

9

5

12

14

10



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)



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



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)



Air Dryer & Adapter Assemblies

1

3

24

56

202203

204

205

201

PAC1641PAC1532_hundreds

PAC1540



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



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)



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)



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)



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)



Remote Air Braking Valve Assembly

1

7

910

2

5

8

3

6

4

PAC0300



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



Air Tank Assemblies

128

38

58

68

49

1011

278

101102111

110111

103111

104112113114

105106107108111

109111

201202208

203208

205208209

206208

204210211212

202207208

PAC1561PAC1571PAC3910



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



Relay Valve Assemblies

2101214

251114

1

9

8

15

314

21413

614

71114

5

414

101

104

103

102 105106

107

PAC1582PAC1591




207

201

202

209

203

204

206208

205208

308

307313

306

310313

301

302303313

304

314

305

312

309313

308

311313

PAC1601PAC1631




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



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



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




Air Fitting Assemblies

1112

6

8912

312

1213

512

1 7

1012

412

14

2312

106

103

104107

101107

102

105107

PAC1622PAC1651



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 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 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 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 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)



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