SECTION 5 - DRIVE TRAIN - MyGradall.commygradall.com/pdf/parts_manuals/80804001_Section_5...14 88662436 1 ELBOW, 90 DEGREES, (includes item 16) 15 88662664 2 FLANGE KIT, (includes

SECTION 5 - DRIVE TRAIN

DRIVE TRAIN

Series IV Highway Speed Excavators 808040015-2

Transfer Case Installation

15

DIG BRAKE VLVDRYER/FUL GND

69

101112

(LARGE WASHERGOES ON TOP OF

MOUNT)

235

8

81316

PUMP “OUT” TO FRONTOF TRANSFER CASE

SEE DETAIL “A”1

21 4

71417

PUMP “IN” TO REAROF TRANSFER CASE

7

DR MTR ENGREV PWR

DR MTR ENGTRV OUTPUT

DIG BRAKE VLVT-CASE PUMP STARTSWITCH TERMINAL

SEE DETAIL “A”

18

HAND TORQUE TO15 LB-IN



19

20

101

102

DRIVESHAFTKIT

DRIVESHAFT COMPONENTS

103

PAC5813

DRIVE TRAIN

80804001 Series IV Highway Speed Excavators 5-3

Transfer Case InstallationItem Part Number Qty. Description Rev.

1 88201035 4 HEX HD CAPSCREW, 3/8-16X1, GR52 80483032 4 BEARING STRAP, (includes item 3)3 80483033 8 BEARING STRAP SCREW4 80783178 1 ELECTRIC MOTOR PUMP, (includes items 18 thru 20)5 80783094 1 DRIVESHAFT, (transmission to transfer case), (includes items 102 & 103)6 Ref TRANSFER CASE ASSY, (see page 5-6 for details)7 84721702 1 HOSE ASSY, (ORFS 45 degree female swivel at motor pump)

84722969 1 HOSE ASSY, (JIC 45 degree female swivel at motor pump)8 84721703 1 HOSE ASSY9 86881287 4 WASHER

10 88201105 4 HEX HD CAPSCREW, 5/8-11X4, GR511 88521210 4 HEX LOCKNUT, 5/8-1112 88561113 4 FLAT WASHER, 5/813 88662019 1 JIC STRAIGHT CONNECTOR, (includes item 16),

(If ordering this part, you must order 84722969 hose assembly, item 7)14 88662430 1 STRAIGHT CONNECTOR, (includes item 17)15 80533031 10.5qt 424 HYDRAULIC TRACTOR FLUID16 88591205 1 O-RING17 88591206 1 O-RING18 80784174 1 PUMP SOLENOID, 24V19 80784172 1 TERMINAL WIRE20 80784173 1 GROUND WIRE21 77143015 4 WHIZ-LOK NUT, 3/8-16

101 80384375 A/R UNIVERSAL JOINT KIT, (includes brackets and hardware)102 80784208 1 SLIP YOKE ASSY103 80784209 1 YOKE SHAFT

DRIVE TRAIN


Transfer Case Assembly

PAC5823

��

��

��

�

��

��

��

��

��

��

��

�

�

�

��

��

$��%�

�

��

��

��

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Before S/N’sXL3100IV - 3120000340 (4x2); 3140000367 (4x4)XL4100IV - 4100000665 (6x4); 4160000075 (6x6)

XL5100IV - 5100000608 (6x4 & 6x6)

DRIVE TRAIN


Transfer Case AssemblyItem Part Number Qty. Description Rev.

1 80383166 1 TUBE FITTING, 45 DEGREES2 Ref TRAVEL MOTOR, (see page 9-80 for details)3 Ref COUNTERBALANCE VALVE ASSY, (see page 9-108 for details)4 80786036 1 R.H. MOUNT5 80786037 1 L.H. MOUNT6 83201006 16 HEX HD CAPSCREW, 3/4-10X2, GR8, (torque to 260-285 lb-ft)7 83201048 3 HEX HD CAPSCREW, 3/8-16X5-1/4, GR88 84721673 1 HOSE ASSY, (see note at bottom of page)9 84721674 1 HOSE ASSY, (see note at bottom of page)

10 86881227 4 LORD MOUNT11 88561109 11 FLAT WASHER, 3/812 88551016 16 LOCKWASHER, 3/413 88591136 1 O-RING14 88662436 1 ELBOW, 90 DEGREES, (includes item 16)15 88662664 2 FLANGE KIT, (includes item 34)16 88591207 1 O-RING17 88591204 2 O-RING18 88591206 1 O-RING19 83763056 1 VITON O-RING, (lubricate lightly)20 77133089 1 MINI-CHECK COUPLING, (includes item 19)21 88662371 1 ELBOW, 90 DEGREES, (swivel nut)22 Ref PROPEL ANTI-CAVITATION VALVE, (see page 9-110 for details)23 80781208 1 VALVE MOUNT PLATE24 84721791 1 HOSE ASSY25 84721792 1 HOSE ASSY26 88201037 2 HEX HD CAPSCREW, 3/8-16X1-1/2, GR527 88201045 2 HEX HD CAPSCREW, 3/8-16X3-1/2, GR528 88662301 1 STRAIGHT CONNECTOR, (includes item 17)29 88662486 1 ELBOW, 90 DEGREES, (includes item 17)30 88662487 1 ELBOW, 90 DEGREES, (includes item 18)31 1 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)32 88521306 7 HEX LOCKNUT, 3/8-1633 88662816 1 ADAPTER, 45 DEGREES, (replaces 90 degree elbow on older machines)34 88991221 2 O-RING

NOTE: 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 required.

Before S/N’sXL3100IV - 3120000340 (4x2); 3140000367 (4x4)XL4100IV - 4100000665 (6x4); 4160000075 (6x6)XL5100IV - 5100000608 (6x4 & 6x6)

DRIVE TRAIN


Transfer Case Assembly

PAC14060

1031

46

12

11162227

2932

20

DETAIL “A”

23

151718192

61213

37

1116

56

12

21341

9

24

10

16

SEEDETAIL “A”

1435

3033

25

36

8

283211

1626

After (& including) S/N’sXL3100IV - 3120000340 (4x2); 3140000367 (4x4)XL4100IV - 4100000665 (6x4); 4160000075 (6x6)

XL5100IV - 5100000608 (6x4 & 6x6)

DRIVE TRAIN


Transfer Case AssemblyItem Part Number Qty. Description Rev.

1 80383166 1 TUBE FITTING, 45 DEGREES2 Ref TRAVEL MOTOR, (see page 9-80 for details)3 Ref COUNTERBALANCE VALVE ASSY, (see page 9-108 for details)4 80786036 1 R.H. MOUNT5 80786037 1 L.H. MOUNT6 83201006 16 HEX HD CAPSCREW, 3/4-10X2, GR8, (torque to 260-285 lb-ft)7 83201048 3 HEX HD CAPSCREW, 3/8-16X5-1/4, GR88 84722521 1 HOSE ASSY9 84722520 1 HOSE ASSY

10 86881227 4 LORD MOUNT11 88561109 11 FLAT WASHER, 3/812 88551016 16 LOCKWASHER, 3/413 88591136 1 O-RING14 88662436 1 ELBOW, 90 DEGREES, (includes item 35)15 84712738 4 FLANGE CLAMP HALF16 88521306 7 HEX LOCKNUT, 3/8-1617 88551012 8 LOCKWASHER, 7/1618 83201155 8 HEX HD CAPSCREW, 7/16-14X1-3/4, GR819 91083106 2 O-RING20 88662816 1 ADAPTER, 45 DEGREES21 77133089 1 MINI-CHECK COUPLING, (includes item 34)22 Ref PROPEL ANTI-CAVITATION VALVE, (see page 9-110 for details)23 80781208 1 VALVE MOUNT PLATE24 84721791 1 HOSE ASSY25 84721792 1 HOSE ASSY26 88201037 2 HEX HD CAPSCREW, 3/8-16X1-1/2, GR527 88201045 2 HEX HD CAPSCREW, 3/8-16X3-1/2, GR528 88662301 1 STRAIGHT CONNECTOR, (includes item 32)29 88662486 1 ELBOW, 90 DEGREES, (includes item 32)30 88662487 1 ELBOW, 90 DEGREES, (includes item 33)31 88662371 1 ELBOW, 90 DEGREES, (swivel nut)32 88591204 2 O-RING33 88591206 1 O-RING34 83763056 1 VITON O-RING, (lubricate lightly)35 88591207 1 O-RING36 1 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 TRAIN


Transfer Case, XL3100IV (4X2), XL4100IV & XL5100IV (6X4)

PAC6660

A

A

B

B

FRONT VIEW

REAR VIEW

1 2 3

45

6

8

7

7

9

10

1112

1314

10

15

16

1718

19

20

2122

23

24

25

26

27

29

28

303132

7

333435

343536

SIGNALFULLY ROAD

PARTIAL ENGAGEDFULLY REMOTE

ITEM 33OPENOPEN

CLOSED

ITEM 36OPEN

CLOSEDCLOSED

DRIVE TRAIN



PAC6670

373839

40 41 42 39 40 41 42 43 44 45 46 47 48

49

50

51

52

3940

535455

39

40565758

59

60

3940

61

62

565758

6339

40

565758

53

54

6465

646667

SECTION A-A

68

10

6970 71

72

73

7475

7617

77

78

55

SECTION B-B

DRIVE TRAIN


Transfer Case, XL3100IV (4X2), XL4100IV & XL5100IV (6X4)Item Part Number Qty. Description Rev.

80783072 1 TRANSFER CASE, (4X2 & 6X4 machines only), (includes all items) B1 80784148 1 STREET ELBOW2 80784142 1 HEX PIPE PLUG3 80784143 1 BREATHER4 80784162 1 FLAT WASHER, 1/45 80784163 1 HEX HD CAPSCREW6 80784160 1 HOSE CLAMP7 80784092 1 HOSE ASSY8 80784133 19 SCREW, 3/8-16X1-1/49 80784151 1 RUN TEE

10 80784155 3 HEX PLUG11 80784128 1 MAGNETIC PLUG12 80784150 2 PLUG13 80784144 12 FLAT WASHER, 3/814 80784137 12 HEX HD CAPSCREW, 3/8-16X5-1/215 80784102 1 ACCESS COVER16 80784132 6 SCREW, 3/8-16X117 80784140 12 WASHER18 80784149 11 HEX FLANGE SCREW, 3/8-16X3/419 80784115 1 OIL PASSAGE PLATE20 80784157 1 STRAINER21 80784158 1 ELBOW22 80784134 10 SCREW, 3/8-16X1-1/223 80784159 1 ELBOW24 80784117 1 DIPSTICK TUBE25 80784116 1 DIPSTICK26 80784154 1 STRAIGHT CONNECTOR27 80784161 1 HOSE CLAMP28 80784093 1 HOSE ASSY29 80784145 18 NUT, 3/8-1630 80784153 1 REDUCER BUSHING31 80784131 2 HARDENED DOWEL32 80784152 1 TEE33 80784234 1 SWITCH KIT, (normally closed; gold), (includes switch & items 34 & 35)34 2 SWITCH BALL35 2 SWITCH GASKET36 80784235 1 SWITCH KIT, (normally open; silver), (includes switch & items 34 & 35)37 80784108 2 YOKE SPACER38 80784100 1 SEAL RETAINER39 80784122 6 BEARING CONE40 80784121 6 BEARING CUP41 80784104 1 GEAR AND SHAFT ASSY - INPUT42 80784164 1 SNAP RING43 80784125 1 ROLLER BEARING44 80784124 1 INNER BEARING45 80784103 1 SHIFT COLLAR46 VA0000S4704 1 BALL BEARING47 VA0000S4715 1 INTERNAL SNAP RING48 80784146 1 EXTERNAL SNAP RING

DRIVE TRAIN


49 80784147 A/R EXTERNAL SNAP RING50 80784120 1 PLANETARY PAD51 80784107 1 PLANETARY INPUT SHAFT52 80784099 1 REAR HOUSING53 80784118 2 YOKE WASHER54 80784127 2 LOCKNUT55 80784109 1 SHIFT FORK56 80784110 A/R SHIM, .005 THICK57 80784111 A/R SHIM, .007 THICK58 80784112 A/R SHIM, .020 THICK59 80784119 1 DISCONNECT ASSY60 80784123 1 DISCONNECT BUSHING61 80784106 1 GEAR AND SHAFT ASSY - OUTPUT62 80784105 1 GEAR AND SHAFT ASSY63 80784101 1 BEARING COVER64 80784097 2 YOKE65 80784094 2 INPUT SEAL66 80784095 1 OIL SEAL - OUTPUT67 80784096 1 OIL SEAL SLEEVE68 80784141 1 SOCKET HD CAPSCREW, 5/16-18X169 80784139 1 WASHER, 5/1670 80784114 1 SHIFT PISTON71 80784126 1 O-RING72 80784113 1 SHIFT CYLINDER73 80784138 3 SOCKET HD CAPSCREW, 1/4-20X2-3/474 80784089 1 SWITCH ADAPTER75 80784156 1 O-RING76 80784135 1 HEX HD CAPSCREW, 3/8-16X1-3/477 80784130 1 RETURN SPRING78 80784088 1 SHIFT SHAFT


DRIVE TRAIN



PAC6680

123

45

7

6

10

11

12

10

89

10

C

C

FRONT VIEW

1314

15 16 17 18 19

20

21

22

23

24

252627

28

2930

123536

31

343536

32

33

A

A

REAR VIEW

SIGNALFULLY ROAD

PARTIAL ENGAGEDFULLY REMOTE

ITEM 34OPENOPEN

CLOSED

ITEM 12OPEN

CLOSEDCLOSED

DRIVE TRAIN



PAC6690

373839

40 41 42 39 40 43 44 45 46 47 49 50 51

52

53

48

54

3940

555637

39

40575859

60

61

3940

62

68

575859

6339

40

575859

55

56

6465

646667

SECTION A-A

69

33

7071 72

73

74

7576

7729

78

79

80

SECTION B-B

SECTION C-C

646667

60

DRIVE TRAIN



80783073 1 TRANSFER CASE, (4X4 & 6X6 machines only), (includes all items) B1 80784148 1 STREET ELBOW2 80784143 1 BREATHER3 80784142 1 HEX PIPE PLUG4 80784162 1 FLAT WASHER, 1/45 80784163 1 HEX HD CAPSCREW, 1/4-20X1/26 80784160 1 HOSE CLAMP7 80784092 1 HOSE ASSY8 80784128 1 MAGNETIC PLUG9 80784150 2 PLUG

10 80784133 19 SCREW, 3/8-16X1-1/411 80784151 1 RUN TEE12 80784235 2 SWITCH KIT, (normally open; silver), (includes switch & items 35 & 36)13 80784144 12 FLAT WASHER, 3/814 80784137 12 HEX HD CAPSCREW, 3/8-16X5-1/215 80784152 1 TEE16 80784131 2 HARDENED DOWEL17 80784153 1 REDUCER BUSHING18 80784093 1 HOSE ASSY19 80784145 18 NUT, 3/8-1620 80784161 1 HOSE CLAMP21 80784154 1 STRAIGHT CONNECTOR22 80784116 1 DIPSTICK23 80784117 1 DIPSTICK TUBE24 80784159 1 ELBOW25 80784134 10 SCREW, 3/8-16X1-1/226 80784158 1 ELBOW27 80784157 1 O-RING28 80784115 1 OIL PASSAGE PLATE29 80784140 12 WASHER30 80784149 11 HEX FLANGE SCREW, 3/8-16X3/431 80784132 6 SCREW, 3/8-16X132 80784102 1 ACCESS COVER33 80784155 3 HEX PLUG34 80784234 1 SWITCH KIT, (normally closed; gold), (includes switch & items 35 & 36)35 3 BALL36 3 SWITCH GASKET37 80784108 2 YOKE SPACER38 80784100 1 SEAL RETAINER39 80784122 6 BEARING CONE40 80784121 6 BEARING CUP41 80784104 1 GEAR AND SHAFT ASSY - INPUT42 80784098 1 FRONT HOUSING43 80784129 1 SNAP RING44 80784164 1 SNAP RING45 80784125 1 ROLLER BEARING46 80784124 1 INNER RACE BEARING47 80784103 1 SHIFT COLLAR48 80784107 1 PLANETARY INPUT SHAFT

DRIVE TRAIN


49 VA0000S4704 1 BALL BEARING50 VA0000S4715 1 INTERNAL SNAP RING51 80784146 1 EXTERNAL SNAP RING52 80784147 A/R EXTERNAL SNAP RING53 80784120 1 PLANETARY PAD54 80784099 1 REAR HOUSING55 80784118 2 YOKE WASHER56 80784127 2 LOCKNUT57 80784110 A/R SHIM, .005 THICK58 80784111 A/R SHIM, .007 THICK59 80784112 A/R SHIM, .020 THICK60 80784119 1 DISCONNECT ASSY61 80784123 1 DISCONNECT BUSHING62 80784106 1 GEAR AND SHAFT ASSY - OUTPUT63 80784101 1 BEARING COVER64 80784097 3 YOKE65 80784094 1 INPUT SEAL66 80784095 2 OIL SEAL - OUTPUT67 80784096 2 OIL SEAL SLEEVE68 80784105 1 GEAR AND SHAFT ASSY69 80784141 1 SOCKET HD CAPSCREW70 80784139 1 WASHER, 5/1671 80784114 1 SHIFT PISTON72 80784126 1 O-RING73 80784113 1 SHIFT CYLINDER74 80784138 3 SOCKET HD CAPSCREW, 1/4-20X2-3/475 80784089 1 SWITCH ADAPTER76 80784156 1 O-RING77 80784135 1 HEX HD CAPSCREW, 3/8-16X1-3/478 80784130 1 RETURN SPRING79 80784088 1 SHIFT SHAFT80 80784109 1 SHIFT FORK


DRIVE TRAIN


Front Axle Installation

PAC5830

3 4

SEE DETAIL “A”

A

A

2

1

4

3

12PORT 2 PORT 1 PORT 3 PORT 4

7 FROM PORT C4 ONVALVE TO PORT 2ON CYLINDER

67

6

FROM PORT C3 ONVALVE TO PORT 4ON CYLINDERFROM PORT C2 ON

VALVE TO PORT 1ON CYLINDER

FROM PORT C1 ONVALVE TO PORT 3

ON CYLINDER

SECTION A-A

DETAIL “A”

1

11

8

10

SEE DETAIL “B”DETAIL “B”

213

59

BETWEEN FRAMEAND VALVE BLOCK

DRIVE TRAIN


Front Axle InstallationItem Part Number Qty. Description Rev.

1 77143013 2 WHIZ-LOK NUT, 1/4-202 77381588 2 FRONT SPRING PIN3 80383097 2 STABILIZER CYLINDER ASSY, (no service parts available for this component)

77364083 4 STABILIZER CYLINDER PIN CLIP4 Ref STABILIZER VALVE ASSY, (see page 9-24 for details)5 83201181 4 HEX HD CAPSCREW, 7/16-14X2-3/4, GR86 84721175 2 HOSE ASSY7 84721176 2 HOSE ASSY8 88201012 2 HEX HD CAPSCREW, 1/4-20X2-3/4, GR59 88521007 4 HEX LOCKNUT, 7/16-14

10 88551009 2 LOCKWASHER, 1/411 88561002 2 FLAT WASHER, 1/412 88662401 4 STRAIGHT FITTING, (includes o-ring)13 88671001 2 LUBE FITTING, STRAIGHT, 1/8

DRIVE TRAIN


Front Steer Axle - Axle Assembly, XL3100IV (4X2), XL4100IV & XL5100IV (6X4)

PAC0710

THIS PAGE APPLIES TO THE FOLLOWING MACHINES:

XL3100IV (4x2) - Before S/N 3120000295XL4100IV (6x4) - Before S/N 4100000606, excluding 4100000561, 4100000562, 4100000564, 4100000565, 4100000566 & 4100000587XL5100IV (6x4) - Before S/N 5100000604, excluding 5100000596 & 5100000602

IF YOUR S/N DOES NOT FALL WITHIN THE RANGES SHOWN ABOVE, SEE PAGE 5-26.

DRIVE TRAIN


Front Steer Axle - Axle Assembly, XL3100IV (4X2), XL4100IV & XL5100IV (6X4)Item Part Number Qty. Description Rev.

0280192 1 FRONT AXLE, (includes items 1 thru 7)1 Ref STEERING KNUCKLE & AXLE BEAM, (see page 5-20 for details)2 Ref BRAKE SHOE ASSY, (see page 5-22 for details)3 80484212 2 INNER BEARING NUT4 80514203 2 LOCKWASHER5 80514204 2 PIERCED LOCK RING6 80514205 2 OUTER BEARING NUT7 Ref WHEEL & DRUM ASSY, (see page 5-24 for details)8 86681356 4 U-BOLT9 86683039 2 CLIP SEAT

10 Ref SPRING ASSY, (see page 5-48 for details)11 80381020 2 SPRING SEAT12 86681572 8 FLAT WASHER13 77383580 8 HEX HIGH NUT, 3/4-16, (torque to 300-310 lb-ft)14 88671018 6 LUBE FITTING, 45 DEGREES, 1/815 86981645 2 DOWEL PIN16 80381435 2 AXLE SPACER17 80781001 2 STEERING STOP SPACER18 86883257 2 HOSE ASSY

80684202 1 WHEEL BEARING NUT KIT, (includes items 3 thru 6)

DRIVE TRAIN


Front Steer Axle - Steering Components, XL3100IV (4X2), XL4100IV & XL5100IV (6X4)

PAC0722




DRIVE TRAIN


Front Steer Axle - Steering Components, XL3100IV (4X2), XL4100IV & XL5100IV (6X4)Item Part Number Qty. Description Rev.

1 6 FLAT WASHER2 6 CAPSCREW3 2 GREASE FITTING4 2 CAP5 2 GASKET6 2 BUSHING7 1 KEY, (upper)8 2 NUT9 1 SHIM, (.015)

1 SHIM, (.005)1 SHIM, (.030)1 SHIM, (.010)

10 80514068 1 STEERING ARM, L.H. 80514069 1 STEERING ARM, R.H.

11 83091206 1 NUT12 80514060 1 AXLE CENTER13 1 KEY, (lower)14 80514061 1 STOP SCREW15 80514062 1 NUT16 77374021 1 ADAPTER17 77374022 1 HARDENED WASHER18 1 BEARING/SEAL ASSY19 83073948 2 COTTER20 1 NUT21 83073948 1 COTTER22 80514064 1 TIE ROD ARM, R.H.

80514065 1 TIE ROD ARM, L.H.23 77374027 2 KEY24 1 CAPSCREW25 86981433 1 TIE ROD END ASSY, R.H., (includes items 19 & 20)

86981435 1 TIE ROD END ASSY, L.H., (includes items 19 & 20)26 83072667 1 NUT27 80514066 1 TIE ROD & CLAMP ASSY, (includes items 24 thru 26)28 1 KING PIN29 80514053 1 STEERING KNUCKLE ASSY, L.H., (includes item 6)

80514054 1 STEERING KNUCKLE ASSY, R.H., (includes item 6)30 2 OIL SEAL ASSY31 83072667 1 NUT

NOTE: QUANTITIES SHOWN ABOVE ARE FOR ONE WHEEL END ONLY. ONLY ITEMS WITH PART NUMBERS LISTED ARE AVAILABLE FOR SERVICE.

80384506 1 KING PIN KIT, (includes items 1 thru 9, 13, 18, 28 & 30)

NOTE: QUANTITIES OF PARTS IN KING PIN KIT ARE ENOUGH TO SERVICE BOTH WHEEL ENDS.

DRIVE TRAIN


Front Steer Axle - Service Brakes, XL3100IV (4X2), XL4100V & XL5100IV (6X4)

PAC0730

1

23

4

5

7

6

8293536

27

26 24 23

222825

2120 19

39

1415 16 17

1615

18

12

13

11

10

30

3132

829

33

34




DRIVE TRAIN


Front Steer Axle - Service Brakes, XL3100IV (4X2), XL4100V & XL5100IV (6X4)Item Part Number Qty. Description Rev.

80514043 1 BRAKE ASSY, L.H., (includes all items except items 17, 19, 20, 21, 23, 24 & 27)80514044 1 BRAKE ASSY, R.H., (includes all items except items 17, 19, 20, 21, 23, 24 & 27)

1 80484010 1 CAMSHAFT, L.H.80384111 1 CAMSHAFT, R.H.

2 80684171 1 SPECIAL WASHER3 85403197 2 SEAL4 83071693 1 CAM BUSHING5 80684087 2 BRAKE SHOE ANCHOR PIN6 83683832 2 BUSHING7 80684088 2 SPRING8 77374045 2 BRAKE SHOE (with lining), (includes item 29)9 85403198 1 O-RING

10 80514045 1 L.H. BRAKE CHAMBER BRACKET ASSY, (includes items 11 & 33)80514046 1 R.H. BRAKE CHAMBER BRACKET ASSY, (includes items 11 & 33)

11 83071693 1 CAM BUSHING12 80514048 1 DUST SHIELD13 80514049 6 CAPSCREW14 85403196 1 FLAT WASHER15 80684164 2 FLAT WASHER16 80684165 2 FLAT WASHER17 80514047 1 AUTO SLACK ADJUSTER18 86984005 1 SNAP RING19 77374008 1 BRAKE CHAMBER ASSY20 83684545 2 FLAT WASHER21 77374010 2 NUT22 80484012 4 CAPSCREW23 83481440 7 LOCKNUT24 83683836 14 HARDENED WASHER25 80514201 1 BRAKE SPIDER ASSY, L.H., (includes items 3, 4, 6 & 9)

80514202 1 BRAKE SPIDER ASSY, R.H., (includes items 3, 4, 6 & 9)26 80684072 1 RETURN SPRING27 77374012 7 CAPSCREW28 77374032 1 GREASE FITTING29 77374050 2 BRAKE SHOE (no lining)30 80514050 1 BRAKE SPRING PIN31 83683919 2 RETAINER32 77384860 2 ROLLER33 80684077 1 GREASE SEAL34 80514051 1 PIN CLIP35 80514052 1 PIN36 80384410 1 COTTER PIN

77374043 A/R BRAKE SHOES (with lining) & HARDWARE KIT,*includes qty. 2 of items 5 thru 8, 31 & 32*includes qty. 1 of items 26

DRIVE TRAIN


Front Steer Axle - Disc Wheel & Rims, XL3100IV (4X2), XL4100IV & XL5100IV (6X4)

PAC0740




DRIVE TRAIN


Front Steer Axle - Disc Wheel & Rims, XL3100IV (4X2), XL4100IV & XL5100IV (6X4)Item Part Number Qty. Description Rev.

80514053 1 HUB & DRUM ASSY, L.H., (includes items 9 & 15 thru 21)80514054 1 HUB & DRUM ASSY, R.H., (includes items 9 & 15 thru 21)

1 TIRE & RIM, (contact Gradall for ordering information)2 80684092 4 HEX HD CAPSCREW3 80684093 4 HARDENED WASHER4 77374038 1 LUBE FITTING5 80514072 1 CAP6 80484009 8 HEX HD CAPSCREW7 77374013 8 FLAT WASHER8 83684983 1 DRIVE FLANGE ASSY, (includes item 10)9 80514198 1 OIL SEAL

10 83684985 1 FELT RETAINER11 77384905 1 OUTER WHEEL NUT12 80484211 1 LOCKWASHER13 80484212 1 INNER BEARING NUT14 25000804 1 OUTER BEARING CONE15 83481594 10 NUT ASSY16 80514216 1 HUB17 25000801 1 OUTER BEARING CUP18 83071487 1 INNER BEARING CUP19 80514215 1 BRAKE DRUM20 80384371 10 WHEEL STUD21 25000802 1 INNER BEARING CONE

DRIVE TRAIN


Front Steer Axle (20,000lb) - Axle Assembly, XL3100IV (4X2), XL4100IV & XL5100IV (6X4)

PAC15340


XL3100IV (4x2) - After (& including) S/N 3120000295XL4100IV (6x4) - After (& including) S/N 4100000606, including 4100000561, 4100000562, 4100000564, 4100000565, 4100000566 & 4100000587XL5100IV (6x4) - After (& including) S/N 5100000604, including 5100000596 & 5100000602


DRIVE TRAIN


Front Steer Axle (20,000lb) - Axle Assembly, XL3100IV (4X2), XL4100IV & XL5100IV (6X4)Item Part Number Qty. Description Rev.

80485139 Ref FRONT AXLE ASSY, (w/disc wheels), (includes all items) A180483284 1 FRONT AXLE, (includes items 1 thru 7)

1 Ref STEERING KNUCKLE & AXLE BEAM, (see page 5-28 for details)2 Ref BRAKE SHOE ASSY, (see page 5-30 for details)3 80484212 2 INNER BEARING NUT4 80514203 2 LOCKWASHER5 80514204 2 PIERCED LOCK RING6 80514205 2 OUTER BEARING NUT7 Ref WHEEL & DRUM ASSY, (see page 5-32 for details)8 86681356 4 U-BOLT9 86683039 2 CLIP SEAT

10 Ref SPRING ASSY, (see page 5-48 for details)11 80381020 2 SPRING SEAT12 86681572 8 FLAT WASHER13 77383580 8 HEX HIGH NUT, 3/4-16, (torque to 300-310 lb-ft)14 88671018 6 LUBE FITTING, 45 DEGREES, 1/815 86981645 2 DOWEL PIN16 80381435 2 AXLE SPACER17 80781001 2 STEERING STOP SPACER18 86883257 2 HOSE ASSY

80684202 1 WHEEL BEARING NUT KIT, (includes items 3 thru 6)

DRIVE TRAIN


Front Steer Axle (20,000lb) - Steering Components, XL3100IV (4X2), XL4100IV & XL5100IV (6X4)

PAC15350




DRIVE TRAIN


Front Steer Axle (20,000lb) - Steering Components, XL3100IV (4X2), XL4100IV & XL5100IV (6X4)Item Part Number Qty. Description Rev.

1 6 FLAT WASHER2 6 CAPSCREW3 2 GREASE FITTING4 2 CAP5 2 GASKET6 2 BUSHING7 1 KEY, (upper)8 2 NUT9 1 SHIM, (.015)

1 SHIM, (.005)1 SHIM, (.030)1 SHIM, (.010)

10 80484195 1 STEERING ARM, L.H. 86983313 1 STEERING ARM, R.H.

11 83091206 1 NUT12 80484197 1 AXLE CENTER13 1 KEY, (lower)14 86981554 1 STOP SCREW15 80514062 1 NUT16 77374021 1 ADAPTER17 77374022 1 HARDENED WASHER18 1 BEARING/SEAL ASSY19 86984034 2 COTTER20 1 NUT21 83073948 1 COTTER22 86981556 1 TIE ROD ARM, L.H.

86981553 1 TIE ROD ARM, R.H.23 77374027 2 KEY24 1 CAPSCREW25 86981435 1 TIE ROD END ASSY, L.H., (includes items 19 & 20)

86981433 1 TIE ROD END ASSY, R.H., (includes items 19 & 20)26 83072667 1 NUT27 80484203 1 TIE ROD & CLAMP ASSY, (includes items 24 thru 26)28 1 KING PIN29 86984032 1 STEERING KNUCKLE ASSY, L.H., (includes item 6)

86984031 1 STEERING KNUCKLE ASSY, R.H., (includes item 6)30 2 OIL SEAL ASSY31 83483432 1 NUT

NOTE: QUANTITIES SHOWN ABOVE ARE FOR ONE WHEEL END ONLY. ONLY ITEMS WITH PART NUMBERS LISTED ARE AVAILABLE FOR SERVICE.

90203230 1 KING PIN KIT, (includes items 1 thru 9, 13, 18, 28 & 30)NOTE: QUANTITIES OF PARTS IN KING PIN KIT ARE ENOUGH TO SERVICE BOTH WHEEL ENDS.

DRIVE TRAIN


Front Steer Axle (20,000lb) - Service Brakes, XL3100IV (4X2), XL4100IV & XL5100IV (6X4)

PAC15360

1

23

4

5

7

6

8293536

27

26 24 23

222825

2120 19

39

1415

16 1716

1518

12

13

11

10

30

3132

829

33

34




DRIVE TRAIN


Front Steer Axle (20,000lb) - Service Brakes, XL3100IV (4X2), XL4100IV & XL5100IV (6X4)Item Part Number Qty. Description Rev.

80684279 1 BRAKE ASSY, L.H., (includes all items except items 17, 19, 20, 21, 23, 24 & 27)80684280 1 BRAKE ASSY, R.H., (includes all items except items 17, 19, 20, 21, 23, 24 & 27)

1 80484204 1 CAMSHAFT, L.H.86984004 1 CAMSHAFT, R.H.

2 80684171 1 SPECIAL WASHER3 85403197 2 SEAL4 80684170 1 CAM BUSHING5 83683822 2 BRAKE SHOE ANCHOR PIN6 83683832 2 BUSHING7 83683826 2 SPRING8 80384128 2 BRAKE SHOE (with lining), (includes item 29)9 85403198 1 O-RING

10 80484205 1 L.H. BRAKE CHAMBER BRACKET ASSY, (includes items 11 & 33)80484206 1 R.H. BRAKE CHAMBER BRACKET ASSY, (includes items 11 & 33)

11 83071693 1 CAM BUSHING12 80484277 1 DUST SHIELD13 80684082 6 CAPSCREW14 85403196 1 FLAT WASHER15 80684164 2 FLAT WASHER16 80684165 2 FLAT WASHER17 80684166 1 SLACK ADJUSTER, L.H.

80684167 1 SLACK ADJUSTER, R.H.18 86984005 1 SNAP RING19 77374008 1 BRAKE CHAMBER ASSY20 83684545 2 FLAT WASHER21 77374010 2 NUT22 80484012 4 CAPSCREW23 83481440 7 LOCKNUT24 83683836 14 HARDENED WASHER25 80484207 1 BRAKE SPIDER ASSY, L.H., (includes items 3, 4, 6 & 9)

80484208 1 BRAKE SPIDER ASSY, R.H., (includes items 3, 4, 6 & 9)26 80684072 1 RETURN SPRING27 77374012 7 CAPSCREW28 77374032 1 GREASE FITTING29 80384129 2 BRAKE SHOE (no lining)30 86881554 1 BRAKE SPRING PIN31 83683919 2 RETAINER32 77384860 2 ROLLER33 80684077 1 GREASE SEAL34 80514051 1 PIN CLIP35 80514052 1 PIN36 80384410 1 COTTER PIN

80484280 A/R BRAKE SHOES (with lining) & HARDWARE KIT,*includes qty. 2 of items 5 thru 8, 31 & 32*includes qty. 1 of items 26

DRIVE TRAIN


Front Steer Axle (20,000lb) - Disc Wheel & Rims, XL3100IV (4X2), XL4100IV & XL5100IV (6X4)

PAC15370




DRIVE TRAIN


Front Steer Axle (20,000lb) - Disc Wheel & Rims, XL3100IV (4X2), XL4100IV & XL5100IV (6X4)Item Part Number Qty. Description Rev.

80484213 1 HUB & DRUM ASSY, (includes items 9 & 15 thru 21)1 TIRE & RIM, (contact Gradall for ordering information)2 80684092 4 HEX HD CAPSCREW3 80684093 4 HARDENED WASHER4 77374038 1 LUBE FITTING5 80514072 1 CAP6 80484009 8 HEX HD CAPSCREW7 77374013 8 FLAT WASHER8 83684983 1 DRIVE FLANGE ASSY, (includes item 10)9 80514198 1 OIL SEAL

10 83684985 1 FELT RETAINER11 77384905 1 OUTER WHEEL NUT12 80484211 1 LOCKWASHER13 80484212 1 INNER BEARING NUT14 25000804 1 OUTER BEARING CONE15 80484008 10 NUT16 80514216 1 HUB17 25000801 1 OUTER BEARING CUP18 83071487 1 INNER BEARING CUP19 80514215 1 BRAKE DRUM20 80484214 10 WHEEL STUD21 25000802 1 INNER BEARING CONE

DRIVE TRAIN


Front Drive Axle - Axle Assembly, XL3100IV (4X4), XL4100IV & XL5100IV (6X6)

PAC0820

DRIVE TRAIN


Front Drive Axle - Axle Assembly, XL3100IV (4X4), XL4100IV & XL5100IV (6X6)Item Part Number Qty. Description Rev.

80383422 1 FRONT DRIVE AXLE (includes items 1 thru 5)1 Ref HOUSING ASSY, (see page 5-36 for details)2 Ref DIFFERENTIAL CARRIER ASSY, (see page 5-38 for details)3 Ref STEERING COMPONENTS, (see page 5-42 for details)4 Ref FRONT SERVICE BRAKES, (see page 5-44 for details)5 Ref FRONT DISC WHEELS & RIMS, (see page 5-46 for details)6 80383423 4 U-BOLT7 86881336 2 CLIP SEAT8 Ref SPRING ASSY, (see page 5-48 for details)9 86681572 8 FLAT WASHER

10 77383580 8 HEX HIGH NUT, 3/4-16, (torque to 300-310 lb-ft)11 88711252 2 SQUARE HD PIPE PLUG, 3/812 80386116 1 CYLINDER MOUNT WELDMENT, L.H.13 83683173 2 HOSE ASSY14 80386115 1 CYLINDER MOUNT WELDMENT, R.H.15 83201062 8 HEX HD CAPSCREW, 5/8-11X2-1/4, GR8, (loctite & torque to 200-215 lb-ft)16 90027472 8 HARDENED WASHER, 5/8

DRIVE TRAIN


Front Drive Axle - Housing Assembly, XL3100IV (4X4), XL4100IV & XL5100IV (6X6)

PAC0750

DRIVE TRAIN


Front Drive Axle - Housing Assembly, XL3100IV (4X4), XL4100IV & XL5100IV (6X6)Item Part Number Qty. Description Rev.

1 80384141 1 HOUSING ASSY, (includes items 8 thru 10)2 83684055 2 MAGNETIC PLUG3 83071503 1 BREATHER ASSY4 80984109 8 HEX HD CAPSCREW, (short)

80684021 4 HEX HD CAPSCREW, (long)5 83081182 12 FLAT WASHER6 83684055 4 TRUNNION PLUG7 80684023 4 BUSHING8 83684963 2 OIL SEAL ASSY9 80684024 2 THRUST WASHER

10 83684935 2 BUSHING

DRIVE TRAIN


Front Drive Axle - Differential Assembly, XL3100IV (4X4), XL4100IV & XL5100IV (6X6)

PAC0760

DRIVE TRAIN


Front Drive Axle - Differential Assembly, XL3100IV (4X4), XL4100IV & XL5100IV (6X6)Item Part Number Qty. Description Rev.

80384368 1 DIFFERENTIAL CARRIER ASSY, (includes all items)1 80984185 1 DRIVE PINION NUT2 80384366 1 INPUT YOKE ASSY, (includes item 3)3 80384367 1 DEFLECTOR4 77384018 1 OIL SEAL5 80684028 1 OUTER BEARING CONE6 77104306 1 OUTER BEARING CUP7 77384642 8 HEX HD CAPSCREW8 80684040 8 FLAT WASHER9 80684030 1 PINION BEARING CAGE ASSY, (includes items 6 & 11)

10 AR SPACER, (0.344 thick) AR SPACER, (0.345 thick) AR SPACER, (0.346 thick) AR SPACER, (0.347 thick) AR SPACER, (0.348 thick) AR SPACER, (0.354 thick) AR SPACER, (0.358 thick) AR SPACER, (0.359 thick) AR SPACER, (0.360 thick) AR SPACER, (0.361 thick) AR SPACER, (0.362 thick)

11 83091306 1 INNER BEARING CUP12 77204028 1 INNER BEARING CONE13 80384133 1 DRIVE GEAR & PINION SET, (7.17 ratio)14 83483557 1 BEARING15 91024040 1 SNAP RING16 AR SHIM, (.003 thick)

AR SHIM, (.005 thick) AR SHIM, (.010 thick) AR SHIM, (.020 thick)

17 80684036 1 DIFFERENTIAL CARRIER & CAP ASSY, (includes items 18, 19 & 39)18 83687009 4 FLAT WASHER19 83687010 4 HEX HD CAPSCREW20 91084100 2 LOCK PIN21 83687012 2 BEARING ADJUSTER RING22 77204041 2 DIFFERENTIAL BEARING CUP23 77204042 2 DIFFERENTIAL CONE24 80684037 1 DIFFERENTIAL CASE & NEST ASSY, (includes items 25 thru 32)25 80684038 1 DIFFERENTIAL CASE ASSY, (includes items 26 & 27)26 80684039 16 HEX HD CAPSCREW27 80684040 16 FLAT WASHER28 80684041 2 THRUST WASHER29 80684042 2 SIDE GEAR30 83483418 4 PINION THRUST WASHER31 80684043 4 PINION GEAR32 80684044 1 DIFFERENTIAL SPIDER33 80684045 12 HEX HD CAPSCREW34 83081182 12 FLAT WASHER35 80984021 12 HEX NUT

DRIVE TRAIN


36 86881678 1 FLAT WASHER37 80684047 1 THRUST SCREW38 80684048 1 JAM NUT39 80984183 4 BALL

83684999 AR PINION BEARING SPACER KIT, (includes item 10) 83687001 AR DIFFERENTIAL CASE TO GEAR BOLT KIT, (includes 33, 34 & 35) 80684026 AR DIFFERENTIAL KIT, (includes items 28 thru 32) 77384849 AR HARDWARE KIT, (includes item 16)

Front Drive Axle - Differential Assembly, XL3100IV (4X4), XL4100IV & XL5100IV (6X6) (Continued)Item Part Number Qty. Description Rev.

DRIVE TRAIN


Front Drive Axle - Differential Assembly, XL3100IV (4X4), XL4100IV & XL5100IV (6X6) (Continued)Item Part Number Qty. Description Rev.

DRIVE TRAIN


Front Drive Axle - Steering Components, XL3100IV (4X4), XL4100IV & XL5100IV (6X6)

PAC0770

13

3

21

33

36

3434

13

35 3231

3029 26

2728

2120

1918

2223

24

25

4

5

6

7

8

9

10

1112

1415

16 17

DRIVE TRAIN


Front Drive Axle - Steering Components, XL3100IV (4X4), XL4100IV & XL5100IV (6X6)Item Part Number Qty. Description Rev.

1 80984109 8 HEX HD CAPSCREW, (short) 80684021 4 HEX HD CAPSCREW, (long)

2 83081182 12 FLAT WASHER3 77384624 1 OIL SEAL SLEEVE, OUTER4 80384488 1 SPINDLE ASSY, (includes items 3, 22, 23 & 24)5 80684051 1 STEERING KNUCKLE, L.H.

80684052 1 STEERING KNUCKLE, R.H.6 80684053 AR SHIM, (.003 thick)

80684054 AR SHIM, (.005 thick) 80684055 AR SHIM, (.010 thick)

7 83684953 2 GREASE SEAL8 80684058 1 STEERING ARM, UPPER L.H.

80684059 1 STEERING ARM, UPPER R.H.9 86984059 12 FLAT WASHER

10 80684056 12 CAPSCREW11 83081182 4 FLAT WASHER12 77384852 4 CAPSCREW13 77104365 2 GREASE FITTING14 83481440 2 LOCKNUT15 83081182 2 FLAT WASHER16 80684076 1 BRAKE CHAMBER BRACKET, L.H.

80684075 1 BRAKE CHAMBER BRACKET, R.H.17 80684078 1 BRAKE CHAMBER18 83684972 1 SPECIAL SCREW19 1 TIE ROD END NUT20 83073458 1 COTTER21 83684973 1 NUT22 80684024 1 THRUST WASHER23 77384626 1 OIL SEAL SLEEVE, INNER24 83684963 1 OIL SEAL ASSY25 80384489 1 AXLE SHAFT ASSY, L.H.

80384490 1 AXLE SHAFT ASSY, R.H.26 83684966 1 TIE ROD & END ASSY, (includes items 19 & 27 thru 32)27 1 TIE ROD ASSY, (includes items 28 thru 31)28 1 TIE ROD29 2 HEX HD CAPSCREW30 2 CLAMP31 2 HEX NUT32 80684065 1 TIE ROD END, L.H.

80684066 1 TIE ROD END, R.H.33 80684067 1 STEERING KNUCKLE CAP, LOWER34 80684060 4 CAPSCREW35 83081090 2 FLAT WASHER36 80984121 1 THRUST BEARING

NOTE: QUANTITIES SHOWN ARE FOR ONE WHEEL END ONLY.

DRIVE TRAIN


Front Drive Axle - Service Brake, XL3100IV (4X4), XL4100IV & XL5100IV (6X6)

31

2

5

2223

6

7 89

10

1213

11

1415

16

17

18

202425

2223

21

19

4

26

2827

SEE FIGURE FOR STEERING

COMPONENTS.

PAC0780

DRIVE TRAIN


Front Drive Axle - Service Brake, XL3100IV (4X4), XL4100IV & XL5100IV (6X6)Item Part Number Qty. Description Rev.

80384125 1 BRAKE ASSY, L.H., (includes items 1, 3, 4, 5, 6, 7, 13 & 17 thru 26) 80384126 1 BRAKE ASSY, R.H., (includes items 1, 3, 4, 5, 6, 7, 13 & 17 thru 26)

1 80684068 1 CAMSHAFT, R.H. 80684069 1 CAMSHAFT, L.H.

2 83071523 1 RETAINER, OUTER3 80684070 2 GREASE SEAL4 77384857 1 GREASE FITTING5 80684071 1 BRAKE SPIDER ASSY, (includes items 3, 4, 7 & 20)6 86983442 1 RETURN SPRING7 80684073 1 CAM BUSHING8 77384861 1 CAMSHAFT BRACKET9 80684086 4 FLAT WASHER

10 80684085 4 CAPSCREW11 77384862 1 RETAINER ASSY12 77384863 4 TAPPING SCREW13 77384858 2 FLAT WASHER14 80684080 1 AUTO SLACK ADJUSTER15 80684172 2 FLAT WASHER16 83481443 1 SNAP RING17 80684082 6 CAPSCREW18 80684083 1 DUST SHIELD, (upper l.h. & lower r.h.)

80684084 1 DUST SHIELD, (lower l.h. & upper r.h.)19 83683822 2 BRAKE SHOE ANCHOR PIN20 83683832 2 BUSHING21 83683826 2 SPRING22 80384128 2 BRAKE SHOE (with lining), (includes item 23)23 80384129 2 BRAKE SHOE (no lining)24 83683919 2 RETAINER25 77384860 2 ROLLER26 86881554 2 RETURN SPRING PIN27 83683836 12 HARDENED WASHER28 80684049 12 CAPSCREW


80484280 A/R BRAKE SHOES (with lining) & HARDWARE KIT,*includes qty. 2 of items 19 thru 22*includes qty. 1 of items 6, 24 & 25

DRIVE TRAIN


Front Drive Axle - Disc Wheels & Rims, XL3100IV (4X4), XL4100IV & XL5100IV (6X6)

PAC0792

DRIVE TRAIN


Front Drive Axle - Disc Wheels & Rims, XL3100IV (4X4), XL4100IV & XL5100IV (6X6)Item Part Number Qty. Description Rev.

1 TIRE & RIM, (contact Gradall for ordering information)2 80684092 4 HEX HD CAPSCREW3 80384260 4 HARDENED WASHER4 83684981 1 LUBE FITTING5 83684982 1 CAP6 80984109 8 HEX HD CAPSCREW, (short)7 83081182 8 FLAT WASHER8 80384371 10 WHEEL STUD9 80684099 1 OIL SEAL

10 77104445 1 INNER BEARING CONE11 83684986 1 OUTER WHEEL NUT12 83684987 1 LOCKWASHER13 83684988 1 INNER WHEEL NUT14 86984028 1 BEARING CONE15 80484008 10 OUTER WHEEL NUT16 80384370 1 HUB & CUP ASSY, (includes items 17 & 18)17 1 OUTER BEARING CUP18 1 INNER BEARING CUP19 80384372 1 BRAKE DRUM20 83684983 1 DRIVE FLANGE ASSY21 83684984 1 DRIVE FLANGE FELT22 83684985 1 DRIVE FLANGE RETAINER


DRIVE TRAIN


Front Steer/Drive Axle - Spring Assembly

PAC0800

DRIVE TRAIN


Front Steer/Drive Axle - Spring AssemblyItem Part Number Qty. Description Rev.

80383233 1 FRONT SPRING ASSY, (includes items 7 thru 17) B1 83201181 4 HEX HD CAPSCREW, 7/16-14X2-3/4, GR82 88671001 2 LUBE FITTING3 77381588 2 PIN4 88521007 4 HEX LOCKNUT, 7/16-145 80381016 2 MOUNT BRACKET6 80386007 1 MOUNT BRACKET7 80384116 1 BUSHING8 80384117 2 CLAMP9 80384119 4 SPACER

10 1 HEX NUT11 80384118 2 CLAMP12 80384121 4 HEX HD CAPSCREW, (includes item 14)13 80384122 1 RIVET14 4 HEX NUT15 80384124 1 HEX HD CAPSCREW, (includes item 10)16 80384420 1 LEAF#117 80384421 1 LEAF#2

DRIVE TRAIN


Rear Axle Installation, XL3100IV

PAC5840

34

3

10

53

10

5

3

4

67

8

67

9

TORQUE BOLTS IN A 4-STAGE,CRISS-CROSS PATTERN

STAGE 1 - 150-185 LB-FTSTAGE 2 - 280-315 LB-FTSTAGE 3 - 470-505 LB-FTSTAGE 4 - 560-595 LB-FT

4

2 3

1

DRIVE TRAIN


Rear Axle Installation, XL3100IV

SEEDETAIL “B”

SEEDETAIL “A”

DETAIL “A”

DETAIL “B”1

2

TO L.H. & R.H. SPRINGBRAKE CHAMBERS

TO L.H. & R.H. SERVICEBRAKE CHAMBERS

AIR LINE 13TO AXLE DIFFERENTIAL LOCKON FRONT AXLE

VIEW SHOWING AIR LINELOCATION IN FRONT OF CAB

PAC5850

DRIVE TRAIN


Rear Axle Installation, XL3100IVItem Part Number Qty. Description Rev.

1 A/R BLACK NYLON TUBING, 3/82 A/R BLACK NYLON TUBING, 1/23 77383118 16 HARDENED WASHER, 7/84 77383119 8 HIGH NUT, 7/8-145 80381219 2 REAR AXLE MOUNTING PLATE6 80483032 4 BEARING STRAP7 80483033 8 BEARING STRAP SCREW, (torque to 115-135 lb-ft)8 80783097 1 DRIVESHAFT, (transfer case to rear axle)9 Ref REAR AXLE ASSY, (see page 5-54 for details)

10 83201173 8 HEX HD CAPSCREW, 7/8-14X9, GR8

DRIVE TRAIN


Rear Axle Installation, XL3100IVItem Part Number Qty. Description Rev.

DRIVE TRAIN


Rear Axle Assembly, XL3100IV

PAC5860

3

16

5

4

4

5

SERVICE BRAKE(TOP)

SPRING BRAKE(TOP)

SERVICE BRAKE(BOTTOM)

SPRING BRAKE(BOTTOM)

DRIVE TRAIN


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

1 14403126 31pt. GEAR OIL, 80W902 14403649 A/R LITHIUM GREASE, #23 80383153 1 TUBE FITTING, 90 DEGREES, 1/4X3/84 80383154 2 TUBE FITTING, 90 DEGREES, 3/8X3/85 80383155 2 TUBE FITTING, 90 DEGREES, 3/8X1/26 80883022 1 REAR AXLE, XL3100IV, (includes all items on page 5-56 thru 5-64) B

DRIVE TRAIN


Rear Axle - Axle Housing, XL3100IV

PAC6260

1

2

3

1817

19

16

910

11

45

68

713

15

12 14

DRIVE TRAIN


Rear Axle - Axle Housing, XL3100IVItem Part Number Qty. Description Rev.

1 80384134 1 HOUSING ASSY2 77384016 1 INDICATOR PLUG3 83071503 1 BREATHER4 83073466 2 INNER WHEEL BEARING NUT5 80684140 2 LOCKWASHER6 83073302 2 OUTER WHEEL BEARING NUT7 86984540 1 AXLE SHAFT, L.H.8 83683355 1 WHEEL BEARING KIT, (kit contains parts for two wheel assemblies),

(includes items 9 thru 15)9 83683357 2 INNER OIL SEAL

10 86984028 2 BEARING CONE11 80984200 2 OUTER BEARING CONE12 80984421 2 AXLE SHAFT GASKET13 83091186 16 AXLE SHAFT DOWEL14 83071409 16 LOCKWASHER (star)15 83483432 16 HEX NUT16 83073451 2 MAGNETIC PLUG17 83081182 12 FLAT WASHER18 80984109 8 HEX HD CAPSCREW, (short)

80984108 4 HEX HD CAPSCREW, (long)19 86984539 1 AXLE SHAFT, R.H.

DRIVE TRAIN


Rear Axle - Differential, XL3100IV

PAC6270

DRIVE TRAIN


Rear Axle - Differential, XL3100IVItem Part Number Qty. Description Rev.

80884006 1 DIFFERENTIAL CARRIER, (includes items 1 thru 37)1 80984112 1 HEX NUT2 80884007 1 YOKE & DEFLECTOR ASSY, (includes item 3)3 80684121 1 DEFLECTOR4 77384641 1 OIL SEAL5 83954016 1 OUTER BEARING CONE6 80684160 1 OUTER BEARING CUP7 83687005 8 HEX HD CAPSCREW8 80684040 8 FLAT WASHER9 83954018 1 PINION BEARING CAGE ASSY, (includes items 6 & 12)

10 80984189 AR SHIM, (.002 THICK)80984190 AR SHIM, (.005 THICK)80984191 AR SHIM, (.008 THICK)80984192 AR SHIM, (.020 THICK)

11 80984193 AR SPLIT SPACER KIT, (includes the following thicknesses) AR SPACER (0.250 THICK) AR SPACER (0.251 THICK) AR SPACER (0.252 THICK) AR SPACER (0.253 THICK) AR SPACER (0.254 THICK) AR SPACER (0.256 THICK) AR SPACER (0.260 THICK) AR SPACER (0.261 THICK) AR SPACER (0.262 THICK) AR SPACER (0.263 THICK) AR SPACER (0.264 THICK)

12 80684161 1 INNER BEARING CUP13 83954020 1 INNER BEARING CONE14 80684162 1 RING GEAR & PINION SET, (7.17)15 83954022 1 PINION ROLLER BEARING16 83954023 1 LOCK RING17 80384136 1 DIFFERENTIAL CARRIER & CAP ASSY, (includes items 18, 19 & 21)18 77384648 4 FLAT WASHER19 77384647 4 HEX HD CAPSCREW20 83954025 2 BEARING ADJUSTING RING21 80984183 4 BALL22 83384039 2 BEARING CUP23 86984028 2 BEARING CONE24 83954097 1 DIFFERENTIAL CASE & NEST ASSY, (includes items 25 thru 33)25 80984018 1 DIFFERENTIAL CASE ASSY, (includes items 26 & 27)26 83954028 12 HEX HD CAPSCREW27 83081182 12 FLAT WASHER28 77384634 1 DIFFERENTIAL KIT, (includes items 29 thru 33)29 77384741 2 THRUST WASHER30 77384742 2 SIDE GEAR31 77384745 1 SPIDER32 77384744 4 PINION33 77384743 4 THRUST WASHER34 83483441 2 COTTER PIN

DRIVE TRAIN


35 80984020 12 HEX HD CAPSCREW36 83081182 12 FLAT WASHER37 80984021 12 HEX NUT38 83081170 1 FLAT WASHER

Rear Axle - Differential, XL3100IV (Continued)Item Part Number Qty. Description Rev.

DRIVE TRAIN


Rear Axle - Differential, XL3100IV (Continued)Item Part Number Qty. Description Rev.

DRIVE TRAIN


Rear Axle - Service Brake, XL3100IV

PAC6280

DRIVE TRAIN


Rear Axle - Service Brake, XL3100IVItem Part Number Qty. Description Rev.

1 86984005 1 SNAP RING2 80684165 AR FLAT WASHER3 80684164 AR FLAT WASHER4 80984194 1 AUTOMATIC SLACK ADJUSTER, L.H.

80683112 1 AUTOMATIC SLACK ADJUSTER, R.H.5 80314103 1 BRAKE CHAMBER ASSY6 85403196 1 FLAT WASHER7 83954010 1 SPIDER ASSY, (includes items 14, 15 & 30)8 85403198 1 O-RING9 80884001 1 BRACKET ASSY, L.H., (includes items 36 & 37)

80884002 1 BRACKET ASSY, R.H., (includes items 36 & 37)10 83684543 4 HEX HD CAPSCREW11 86981562 4 FLAT WASHER12 83684545 2 FLAT WASHER13 83481440 2 LOCKNUT14 83071688 1 GREASE SEAL15 80684170 1 BUSHING16 77384447 2 ROLLER17 80684171 1 SPECIAL WASHER18 80684173 1 CAMSHAFT, L.H.

80684174 1 CAMSHAFT, R.H.19 77384914 1 BRAKE SHOES (with lining) & HARDWARE KIT, (includes two brake shoes w/

lining & items 16, 22, 23 & 27 thru 30)20 83954009 6 HEX HD CAPSCREW21 83684070 4 BUSHING22 83684085 1 RETURN SPRING23 83684086 2 SPRING PIN24 80384139 8 HEX HD CAPSCREW25 83683836 16 HARDENED WASHER26 86683065 4 LOCKNUT27 86984005 4 SNAP RING28 80684172 4 FLAT WASHER29 80984197 2 BRAKE SHOE ANCHOR PIN30 83684081 2 BUSHING31 80384140 1 DUST SHIELD ASSY32 86881560 1 YOKE PIN33 80384409 1 CLEVIS34 80384410 1 COTTER PIN35 83684981 1 GREASE FITTING36 85403197 1 SEAL37 83071693 1 CAM BUSHING

QUANTITIES SHOWN ARE FOR ONE BRAKE ASSY. WHEN REPLACING BRAKE LINING IT IS RECOMMENDED TO REPLACE

ALL LININGS AT THE SAME TIME.

DRIVE TRAIN


Rear Axle - Disc Wheel & Rim, XL3100IV

PAC6290

DRIVE TRAIN


Rear Axle - Disc Wheel & Rim, XL3100IVItem Part Number Qty. Description Rev.

80884030 1 HUB & DRUM ASSY, WEBB, (includes items 5 thru 10)1 1 TIRE & RIM ASSY, (contact Gradall for ordering information)2 85403068 Ref VALVE STEM EXTENSION, 6”, (inside dual tires - not illustrated)3 80484111 10 OUTER WHEEL NUT4 80484035 1 BRAKE DRUM5 77384841 1 HUB, 10 STUD OUTBOARD6 77384843 8 DRIVE STUD, 5/8-187 80484036 10 WHEEL STUD8 83071793 1 INNER BEARING CUP9 83071572 1 OUTER BEARING CUP

DRIVE TRAIN


Rear Axle Installation, XL4100IV & XL5100IV

PAC5871

2

SEEDETAIL “A”

SEEDETAIL “B”

5

SEEDETAIL “C”

7

A

A

34

6

14151617

18 19

101

DRIVESHAFTKIT

DRIVE TRAIN


Rear Axle Installation, XL4100IV & XL5100IV

PAC5880

1218

9DETAIL “B”

1

13

11DETAIL “A”

10

SECTION A-A

13

11

1

DETAIL “C”

FRONT OF CAB

3/8” AIR LINE 32 FROMINTERAXLE DIFFERENTIALLOCK ON FRONT-REAR AXLE

3/8” AIR LINE 13 FROMDIFFERENTIAL LOCK ON

FRONT-REAR AXLE

DRIVE TRAIN


Rear Axle Installation, XL4100IV & XL5100IVItem Part Number Qty. Description Rev.

1 24601563 6 FLEX LOCKNUT, 5/8-112 A/R BLACK NYLON TUBING, 3/8”3 80483032 4 BEARING STRAP4 80483033 8 BEARING STRAP SCREW5 80783086 2 TORQUE ROD, (6X4 machines only)

80683225 2 TORQUE ROD, (6X6 machines only), (includes bushing 80684264)6 80783095 1 DRIVESHAFT, (transfer case to tandem axle), (includes items 18 & 19)7 Ref REAR AXLE ASSY, (see page 5-70 for details)8 83201094 2 HEX HD CAPSCREW, 5/8-11X8, GR89 83481177 2 TORQUE ROD MOUNT

10 83683114 A/R THRUST WASHER11 86641154 4 HEX HD CAPSCREW, 5/8-11X3-1/212 86683062 4 TORQUE ROD SPACER13 88561113 4 FLAT WASHER, 5/814 83683112 4 SADDLE PLATE ASSY, (includes items 15 thru 17)15 83683743 8 HARDENED WASHER16 80983054 8 HEX NUT, (torque to 305 lb-ft)17 80983055 8 STUD18 80784212 1 SLIP YOKE ASSY19 80784213 1 TUBE YOKE

80384375 A/R UNIVERSAL JOINT KIT, (includes brackets and hardware)

DRIVE TRAIN


Rear Axle Installation, XL4100IV & XL5100IVItem Part Number Qty. Description Rev.

DRIVE TRAIN


Rear Axle Assembly, XL4100IV & XL5100IV

PAC5891

25

8

23

13

3

12

38

25

7

7

1

3 25

8

14

1

3

8

2521

13

20

SERVICE BRAKE(TOP)


SPRING BRAKE(TOP) B


B

SERVICE BRAKE(TOP)


A

A

SPRING BRAKE(TOP)


16 1011 17

1826

15282930

SECTION B-B

DRIVE TRAIN


Rear Axle Assembly, XL4100IV & XL5100IV

PAC5900

22

925

24

8

45

19

22

45

19

6

25

8

22

24

4519

SECTION A-A

DRIVE TRAIN


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

1 14403126 65pt GEAR OIL 80W902 14403649 A/R LITHIUM GREASE, #23 A/R BLACK NYLON TUBING, 3/8”4 77143004 3 WHIZ-LOK SCREW, 5/16-18X1-1/45 77143006 3 WHIZ-LOK NUT, 5/16-186 80383142 1 TUBE FITTING, 3/8X3/87 80383153 2 TUBE FITTING, 1/4X3/88 80383154 6 TUBE FITTING, 3/8X3/89 80383167 1 TUBE FITTING, 3/8X3/8

10 80483032 4 BEARING STRAP11 80483033 8 BEARING STRAP SCREW12 80483187 1 HOSE ASSY13 80483188 2 HOSE ASSY14 80483190 1 HOSE ASSY15 80683054 2 EQUALIZER BEAM, (includes items 26 thru 30)16 80783081 1 REAR TANDEM AXLE, (includes all items on pages 5-74 thru 5-88)17 80783096 1 DRIVESHAFT, TANDEM INTER-AXLE18 80983113 1 BEAM END KIT19 83481325 3 MOUNTING BAR20 83683111 2 BEAM PIVOT PIN21 83683173 1 HOSE ASSY22 85841150 3 SUPPORT CLAMP, 1-1/223 86883256 1 HOSE ASSY24 86886048 2 SUPPORT BRACKET25 86983650 6 BRASS FITTING, 90 DEGREES26 80684136 4 BAR PIN END BUSHING27 Not Used28 83683745 4 SEAL29 83683746 2 BUSHING SEAL30 80684134 2 LUBE FITTING

DRIVE TRAIN


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

DRIVE TRAIN


Rear Axle - Forward Housing, XL4100IV & XL5100IV (6X4 & 6X6)

PAC6200

1

2

3

1817

19

16

910

11

45

6

713 15

1412

8

21

20

22

DRIVE TRAIN


Rear Axle - Forward Housing, XL4100IV & XL5100IV (6X4 & 6X6)Item Part Number Qty. Description Rev.

1 80484030 1 HOUSING ASSY, (includes items 20 thru 22)2 77384016 1 INDICATOR PLUG3 80514221 1 BREATHER & TUBE KIT4 83073466 2 INNER WHEEL BEARING NUT5 80684140 2 LOCKWASHER6 83073302 2 OUTER WHEEL BEARING NUT7 86984540 1 AXLE SHAFT, L.H.8 83683355 1 WHEEL BEARING KIT, (kit contains parts for two wheel assemblies),


10 86984028 2 BEARING CONE11 80984200 2 OUTER BEARING CONE12 80984421 2 AXLE SHAFT GASKET13 83091186 16 AXLE SHAFT DOWEL14 83071409 16 LOCKWASHER, (star)15 83483432 16 HEX NUT16 83073451 2 MAGNETIC PLUG17 83081182 12 FLAT WASHER18 80984109 9 HEX HD CAPSCREW, (short)

80984108 3 HEX HD CAPSCREW, (long)19 86984539 1 AXLE SHAFT, R.H.20 80984409 1 BEAM HANGER BRACKET, L.H.21 80984410 1 BEAM HANGER BRACKET, R.H.22 80684141 1 TORQUE ROD BRACKET

DRIVE TRAIN


Rear Axle - Rear Housing, XL4100IV & XL5100IV (6X4 & 6X6)

PAC6210

1

2

3

1817

19

16

21

20

22

13

910

11

45

6

713

15

14128

DRIVE TRAIN


Rear Axle - Rear Housing, XL4100IV & XL5100IV (6X4 & 6X6)Item Part Number Qty. Description Rev.

1 80484018 1 HOUSING ASSY, (includes items 20 thru 22)2 77384016 1 INDICATOR PLUG3 80514221 1 BREATHER & TUBE KIT4 83073466 2 INNER WHEEL BEARING NUT5 80684140 2 LOCKWASHER6 83073302 2 OUTER WHEEL BEARING NUT7 86984540 1 AXLE SHAFT, L.H.8 83683355 1 WHEEL BEARING KIT, (kit contains parts for two wheel assemblies),


10 86984028 2 BEARING CONE11 80984200 2 OUTER BEARING CONE12 80984421 2 AXLE SHAFT GASKET13 83091186 16 AXLE SHAFT DOWEL14 83071409 16 LOCKWASHER (star)15 83483432 16 HEX NUT16 83073451 2 MAGNETIC PLUG17 83081182 12 FLAT WASHER18 80984109 8 HEX HD CAPSCREW, (short)

80984108 4 HEX HD CAPSCREW, (long)19 86984539 1 AXLE SHAFT, R.H.20 80984409 1 BEAM HANGER BRACKET, L.H.21 80984410 1 BEAM HANGER BRACKET, R.H.22 80684141 1 TORQUE ROD BRACKET

DRIVE TRAIN


Rear Axle - Forward Differential Assembly, XL4100IV & XL5100IV (6X4 & 6X6)

PAC6220

DRIVE TRAIN


Rear Axle - Forward Differential Assembly, XL4100IV & XL5100IV (6X4 & 6X6)Item Part Number Qty. Description Rev.

80784071 1 DIFFERENTIAL CARRIER ASSY, (includes all items except 99), (STD., 7.17)1 80984112 1 HEX NUT2 80884007 1 YOKE & DEFLECTOR ASSY, (includes item 3)3 80684121 1 DEFLECTOR4 77384642 7 HEX HD CAPSCREW5 80684040 7 FLAT WASHER6 80784069 1 SHIELD, FILTER7 80514212 1 SEAL8 83954018 1 PINION BEARING CAGE ASSY, (includes item 14)9 83954039 1 DOWEL PIN

10 83954040 AR SHIM, (.003 thick)83954041 AR SHIM, (.005 thick83954042 AR SHIM, (.010 thick)

11 83954036 1 SPRING12 83954037 1 RELIEF VALVE13 80684147 2 O-RING14 80684148 1 BEARING CUP15 80984113 1 OUTER BEARING CONE16 86881678 5 FLAT WASHER17 80984172 1 OIL PUMP18 80984173 6 HEX HD CAPSCREW19 77374013 6 FLAT WASHER20 80984174 1 INPUT SHAFT21 80484026 1 THRUST WASHER22 83954049 1 DIFFERENTIAL SIDE GEAR23 83954051 8 HEX HD CAPSCREW24 80684093 8 HARDENED WASHER25 80484027 1 INTER-AXLE DIFFERENTIAL CASE & NEST ASSY,

(includes items 23, 24 & 26 thru 29)26 80984175 1 INTER-AXLE DIFFERENTIAL CASE ASSY, (includes items 23 & 24)27 83384010 1 SPIDER28 83954053 4 PINION29 83954052 4 THRUST WASHER30 83954054 1 LOCK RING31 80484025 1 CLUTCH COLLAR32 83954057 1 DIFFERENTIAL SIDE GEAR33 83954056 1 SHIFT FORK34 77104332 1 BEARING CONE35 77104333 1 BEARING CUP36 83954059 1 ADAPTER37 83954058 1 OIL FILTER38 80514211 1 DIFFERENTIAL CARRIER & CAP ASSY, (includes items 71 thru 73)39 80984177 1 HEX HD CAPSCREW40 83954093 1 HEX JAM NUT41 83954090 1 SHAFT42 83384177 1 SPRING43 83954060 1 SCREEN ASSY44 83954070 1 SENSOR SWITCH45 80984178 1 SPRING

DRIVE TRAIN


46 80984179 1 SHAFT47 80984180 1 PISTON48 80684150 1 O-RING49 80684151 1 COVER50 83954085 1 CLUTCH COLLAR51 80984182 1 SHIFT FORK52 83954096 1 ADJUSTING RING, L.H.53 77104444 1 BEARING CUP, L.H.54 77104445 1 INNER BEARING CONE55 83954097 1 DIFFERENTIAL CASE & NEST ASSY, (includes items 56, 57, 59, 63, 66

& kit 77384634)56 80984018 1 DIFFERENTIAL CASE ASSY, (includes items 57 & 66)57 83954028 12 HEX HD CAPSCREW58 83081182 12 FLAT WASHER59 77384741 2 THRUST WASHER60 77384742 2 SIDE GEAR61 77384745 1 SPIDER62 77384744 4 PINION63 77384743 4 THRUST WASHER64 80684124 1 RING GEAR & PINION SET, (STD., 7.17)65 80984020 12 HEX HD CAPSCREW66 83687011 1 LOCK PIN67 80984021 12 HEX NUT68 86984028 2 BEARING CONE69 83384039 1 BEARING CUP, R.H.70 83954025 1 BEARING ADJUSTING RING, R.H.71 77384647 4 HEX HD CAPSCREW72 77384648 4 FLAT WASHER73 80984183 4 BALL74 83954062 1 BEARING CONE75 83384053 1 BEARING CUP76 86984067 AR SHIM, (.003 thick)

86984068 AR SHIM, (.005 thick)86984069 AR SHIM, (.010 thick)

77 83954063 1 SPACER78 83954064 1 DRIVEN GEAR79 83954065 1 PINION BEARING SPACER KIT, (includes the following shim thicknesses)

2 SPACER, (.451 thick) 2 SPACER, (.452 thick) 2 SPACER, (.453 thick) 2 SPACER, (.454 thick) 2 SPACER, (.459 thick) 2 SPACER, (.462 thick) 2 SPACER, (.466 thick) 2 SPACER, (.470 thick) 2 SPACER, (.474 thick) 2 SPACER, (.478 thick) 2 SPACER, (.482 thick) 2 SPACER, (.483 thick)

Rear Axle - Forward Differential Assembly, XL4100IV & XL5100IV (6X4 & 6X6) (Continued)Item Part Number Qty. Description Rev.

DRIVE TRAIN


2 SPACER, (.484 thick) 2 SPACER, (.485 thick) 2 SPACER, (.486 thick)

80 83091278 1 BEARING CUP81 80484024 1 BEARING CONE82 83954066 1 PINION WASHER83 83954068 1 COVER84 83954069 5 HEX HD CAPSCREW85 80684093 5 HARDENED WASHER86 80984184 1 PINION NUT87 83954100 1 THRU SHAFT & BEARING CAGE ASSY, (includes items 88 thru 91,

94 thru 96 & 98)88 83954101 1 THRU SHAFT89 83954102 1 BEARING CAGE ASSY, (includes item 90)90 90202067 2 BEARING CUP91 86984096 2 BEARING CONE92 83954103 4 HEX HD CAPSCREW93 91084100 1 COTTER PIN94 80514213 1 SNAP RING KIT, (includes the following snap ring thicknesses)

AR SNAP RING, (.155 thick) AR SNAP RING, (.158 thick) AR SNAP RING, (.161 thick) AR SNAP RING, (.164 thick) AR SNAP RING, (.167 thick) AR SNAP RING, (.170 thick) AR SNAP RING, (.173 thick) AR SNAP RING, (.176 thick) AR SNAP RING, (.179 thick) AR SNAP RING, (.182 thick)

95 83954104 1 SNAP RING SPACER96 83954105 1 SEAL97 80784070 1 YOKE98 80984185 1 DRIVE PINION NUT99 Ref AXLE SHAFT, (see page 5-74 for details)

100 80684155 1 SHIFT ASSY101 80984177 1 HEX HD CAPSCREW102 77384881 1 O-RING103 83081170 1 FLAT WASHER

77384634 1 DIFFERENTIAL KIT, (includes items 59 thru 63)83954038 1 CAGE & SEAL ASSY, (includes items 7 & 8)

Rear Axle - Forward Differential Assembly, XL4100IV & XL5100IV (6X4 & 6X6) (Continued)Item Part Number Qty. Description Rev.

DRIVE TRAIN


Rear Axle - Rear Differential Assembly, XL4100IV & XL5100IV (6X4 & 6X6)

PAC6230

DRIVE TRAIN


Rear Axle - Rear Differential Assembly, XL4100IV & XL5100IV (6X4 & 6X6)Item Part Number Qty. Description Rev.

80784072 1 DIFFERENTIAL CARRIER ASSY, (includes all items except item 28)1 80984112 1 HEX NUT2 80884007 1 YOKE & DEFLECTOR ASSY, (includes item 3)3 80684121 1 DEFLECTOR4 77384641 1 OIL SEAL5 80984113 1 OUTER BEARING CONE6 80684148 1 BEARING CUP7 77384642 8 HEX HD CAPSCREW8 77384643 8 FLAT WASHER9 83954018 1 PINION BEARING CAGE ASSY, (includes items 6 & 12)

10 80984189 AR SHIM, (.002 thick)80984190 AR SHIM, (.005 thick)80984191 AR SHIM, (.008 thick)80984192 AR SHIM, (.020 thick)

11 80984193 1 SPLIT SPACER KIT, (includes the following thicknesses) AR SPACER, (.250 thick) AR SPACER, (.251 thick) AR SPACER, (.252 thick) AR SPACER, (.253 thick) AR SPACER, (.254 thick) AR SPACER, (.256 thick) AR SPACER, (.260 thick) AR SPACER, (.261 thick) AR SPACER, (.262 thick) AR SPACER, (.263 thick) AR SPACER, (.264 thick)

12 80984115 1 INNER BEARING CUP13 80984116 1 INNER BEARING CONE14 83954128 1 RING GEAR & PINION SET, (includes item 1)15 83954022 1 PINION ROLLER BEARING16 83954023 1 LOCK RING17 83954024 1 DIFFERENTIAL CARRIER & CAP ASSY, (includes items 18, 19 & 39)18 77384648 4 FLAT WASHER19 77384647 4 HEX HD CAPSCREW20 83954025 2 BEARING ADJUSTING RING21 91084100 2 COTTER PIN22 83384039 2 BEARING CUP23 86984028 2 BEARING CONE24 83954026 1 DIFFERENTIAL CASE & NEST ASSY, (includes items 25 thru 33)25 83954027 1 DIFFERENTIAL CASE ASSY, (includes items 26 & 27)26 83954028 12 HEX HD CAPSCREW27 83081182 12 FLAT WASHER28 Ref AXLE SHAFT, (see page 5-76 for details)29 77384741 2 THRUST WASHER30 77384742 2 SIDE GEAR31 77384745 1 SPIDER32 77384744 4 PINION33 77384743 4 THRUST WASHER34 83954029 1 BOLT, NUT & WASHER KIT, (includes items 35, 36 & 37)

DRIVE TRAIN


35 80984020 12 HEX HD CAPSCREW36 83081182 12 FLAT WASHER37 80984021 12 HEX NUT38 83081170 1 FLAT WASHER39 80984183 4 BALL

77384634 1 DIFFERENTIAL KIT, (includes items 29 thru 33)

Rear Axle - Rear Differential Assembly, XL4100IV & XL5100IV (6X4 & 6X6) (Continued)Item Part Number Qty. Description Rev.

DRIVE TRAIN


Rear Axle - Rear Differential Assembly, XL4100IV & XL5100IV (6X4 & 6X6) (Continued)Item Part Number Qty. Description Rev.

DRIVE TRAIN


Rear Axle - Service Brake, XL4100IV & XL5100IV (6X4 & 6X6)

PAC6240

DRIVE TRAIN


Rear Axle - Service Brake, XL4100IV & XL5100IV (6X4 & 6X6)Item Part Number Qty. Description Rev.

1 86683836 16 HEX NUT2 80684164 AR FLAT WASHER3 80684165 AR FLAT WASHER4 80984194 2 AUTOMATIC SLACK ADJUSTER,

(L. H. on forward-rear axle, R.H. on rear-rear axle)80683112 2 AUTOMATIC SLACK ADJUSTER,

(R. H. on forward-rear axle, L.H. on rear-rear axle)5 80683105 1 BRACKET ASSY, (R.H. on forward-rear axle), (includes items 6 & 7)

80683119 1 BRACKET ASSY, (R.H. on rear-rear axle), (includes items 6 & 7)80683104 1 BRACKET ASSY, (L.H. on forward-rear axle), (includes items 6 & 7)80683118 1 BRACKET ASSY, (L.H. on rear-rear axle), (includes items 6 & 7)

6 85403197 1 SEAL7 83071693 1 CAM BUSHING8 80984196 1 BRAKE CHAMBER9 80384409 1 CLEVIS

10 86881560 1 YOKE PIN11 80384410 1 COTTER PIN12 83684545 2 FLAT WASHER13 83481440 2 LOCKNUT14 83684543 4 HEX HD CAPSCREW15 80684086 4 FLAT WASHER16 80384140 1 DUST SHIELD, (forward rear)

80484037 1 DUST SHIELD, (rear rear)17 83954009 6 HEX HD CAPSCREW18 80684171 2 SPECIAL WASHER19 83954010 1 SPIDER ASSY, (includes items 20, 21 & 22)20 80684170 1 BUSHING21 83684081 2 BUSHING22 83071688 1 GREASE SEAL23 85403198 1 O-RING24 77384914 1 BRAKE SHOES (with lining) & HARDWARE KIT, (includes two brake shoes w/

lining & items 21, 26 thru 30, 34 & 35)25 83684070 2 BUSHING26 77384447 2 ROLLER27 86984005 5 SNAP RING28 80684172 4 FLAT WASHER29 83071417 4 FELT30 80984197 2 BRAKE SHOE ANCHOR PIN31 85031342 2 HEX HD CAPSCREW, 3/8-16X3/4, GR5, (head drilled for lock wire)32 80684172 1 SPECIAL WASHER33 80684173 1 CAMSHAFT, (L.H. on forward rear axle), (R.H. on rear rear axle)

80684174 1 CAMSHAFT, (R.H. on forward rear axle), (L.H. on rear rear axle)34 83684085 1 RETURN SPRING35 83684086 2 SPRING PIN36 80384139 16 HEX HD CAPSCREW37 83683836 32 HARDENED WASHER

DRIVE TRAIN


Rear Axle - Disc Wheel & Rim, XL4100IV & XL5100IV (6X4 & 6X6)

PAC6250

DRIVE TRAIN


Rear Axle - Disc Wheel & Rim, XL4100IV & XL5100IV (6X4 & 6X6)Item Part Number Qty. Description Rev.

80484106 1 HUB & DRUM ASSY, ARVINMERITOR, (includes items 3 thru 9)1 1 TIRE & RIM ASSY, (contact Gradall for ordering information)2 85403068 1 VALVE STEM EXTENSION, 3”, (inside dual tires, not illustrated)3 80484111 10 OUTER WHEEL NUT4 80484110 1 BRAKE DRUM5 80484107 1 HUB6 80484108 8 DRIVE STUD, 5/8-187 80484109 10 WHEEL STUD8 83384039 1 INNER BEARING CUP9 83071500 1 OUTER BEARING CUP

DRIVE TRAIN


All-Wheel Drive Components Installation

PAC5910

1

34

5

34 2

3/8” AIR LINE 14 FROM FITTINGON FRONT OF TRANSFER CASE

FRONT OF CAB

DRIVE TRAIN


All-Wheel Drive Components InstallationItem Part Number Qty. Description Rev.

1 A/R BLACK NYLON TUBING, 3/8”2 80383166 1 TUBE FITTING, 1/4X3/83 80483032 4 BEARING STRAP4 80483033 8 BEARING STRAP SCREW5 80783098 1 DRIVESHAFT, (transfer case to front drive axle)

DRIVE TRAIN


This Page Intentionally Left Blank

Documents

SECTION 5 - DRIVE TRAIN - MyGradall.commygradall.com/pdf/parts_manuals/80804001_Section_5...14 88662436 1 ELBOW, 90 DEGREES, (includes item 16) 15 88662664 2 FLANGE KIT, (includes