SECTION - FRAME & ATTACHING PARTS
Undercarriage Prep Installation SEE DETAIL F SEE DETAIL E 0 SEE DETAIL D 4 EXHST BRK (OPTIONAL) - BATTERY CABLE SEE DETAIL C UP GND- TO FRAME GROUND ON - BATTERY CABLE HORNS 8 8 5 RT HDLT GND TO FRONT BUMPER HARNESS DETAIL C AXLE LK PWR TO AXLE OSCILLATION CYLINDER VALVE 5 9 5 DETAIL D DETAIL F DETAIL E PAC4 - Series IV Highway Speed Excavators 8080400
Undercarriage Prep Installation D SEE DETAIL G B A DIFF LK TO REAR AXLE C F E F E D FUEL LVL TO FUEL LEVEL SENDER C B 5 A 8 8 5 4 AC CLUTCH AC CLUTCH OUT TO A/C AIR DRYER SEE DETAIL A 8 DETAIL B TRV ALM TO FRONT TRAVEL ALARM 9 9 SEE DETAIL B SECTION B-B CAN H TO POWER UNIT HARNESS BULKHEAD SCR CAN-G TO POWER UNIT HARNESS BULKHEAD RC 44 PWR- TO BULKHEAD MOUNT ON CAB FRONT BATT 5 TO BULKHEAD ON CAB FRONT BATT TO BULKHEAD ON CAB FRONT NOX CAN H TO SCR FRAME MODULE ON CAB FRONT 99 H TO 99 CONNECTOR IN CAB CONSOLE CAN H TO CAN CONNECTOR AT CAB FRONT RC 44 PWR- TO RC CONTROLLER ON CAB FRONT 5 RMT PWR TO STEER VALVE SOLENOID STR LEFT TO STEER VALVE SOLENOID DETAIL A IAT/HUM GND TO AIR INTAKE TUBE SENSOR STR RIGHT TO STEER VALVE SOLENOID 4 SECTION A-A 8080400 Series IV Highway Speed Excavators - PAC4
Undercarriage Prep Installation THIS LOCATION XL400IV & XL500IV ONLY UP PWR TO CENTER PIN 99 L TO CENTER PIN SECTION E-E DR MTR ENG TO REAR OF TRANSFER CASE ALL WHL TO FRONT OF TRANSFER CASE (ONLY ON VEHICLES WITH FRONT DRIVE AXLE) SECTION D-D R T/BRK R TAIL GND TO REAR FENDER LIGHT HARNESS MKR LTS TO LICENSE PLATE LIGHT MKR LTS ALM/MKR GND TO ID LIGHT BAR L T/BRK R TAIL GND TO REAR FENDER LIGHT HARNESS SECTION F-F HYD FILTER SW TO HYD FILTER SWITCH UP KEY IGN DRYER FUL GND AXLE LOCK PWR DIG BRAKE VLV DIG BRAKE SGN POST SCR SGN TO SCR TEMP SENSOR CONNECTOR TRV ALM TO REAR TRAVEL ALARM NOX IGN PWR TO NOX SENSOR MODULE PRE SCR SGN TO SCR TEMP SENSOR CONNECTOR 8 5 DEF LVL SGN TO ADBLUE TANK DEF PRS VLV SUP TO ADBLUE PRESSURE CONTROL VALVE DEF PUMP SUPPLY TO ADBLUE PUMP SECTION C-C 4 DIG BRAKE VLV TO BRAKE VALVES PAC4-4 Series IV Highway Speed Excavators 8080400
Undercarriage Prep Installation 0 9 0 4 5 0 0 0 04 XL400IV & XL500IV REAR VIEW XL400IV & XL500IV REAR VIEW After (& including) S/N s: XL400IV - 4000005 (4x); 4000008 (4x) XL500IV - 5000008 (x4) 5 0 9 0 4 XL00IV REAR VIEW GRAY CONNECTOR TO VEC BOX BLACK CONNECTOR TO VEC BOX DIG BRAKE VLV TO T-CASE PUMP START SWITCH TERMINAL GREEN CONNECTOR TO VEC BOX DRYER/FUL GND TO T-CASE PUMP GROUND TERMINAL V BAT V BAT FUSE 0 AMP ATO FUSE V BAT FUSE TO STUD ON BATTERY CABLE JUMPER BLUE CONNECTOR TO VEC BOX DETAIL G 8080400 Series IV Highway Speed Excavators -5 PAC44
Undercarriage Prep Installation Item Part Number Qty. Description Rev. 94040 ECCO 80 TRAVEL ALARM, (standard; includes items thru 8) Note: Optional travel alarms can be found on page -8. 80880 UNDERCARRIAGE FRAME WELDMENT, (XL00IV 4x) 80880 UNDERCARRIAGE FRAME WELDMENT, (XL00IV 4x4) 8080 UNDERCARRIAGE FRAME WELDMENT, (XL400IV & XL500IV x4) 80808 UNDERCARRIAGE FRAME WELDMENT, (XL400IV & XL500IV x) 80804 UNDERCARRIAGE FRAME WELDMENT, (XL400 X4 W/RAILGEAR) 480 SUPPORT CLAMP, / 4 494 A/R LOOM, /4, (gray) 5 009 SERIAL PLATE 4004 WHIZ LOK SCREW, 5/-8X-/4, (qty 4 for XL00IV) 400 4 WHIZ-LOK NUT, 5/-8 8 40 WHIZ-LOK NUT, /4-0 9 8005 SUPPORT CLAMP, -/4 0 80809 LICENSE PLATE LIGHT, (no longer available. For service order 80809S kit, located at the end of parts list.) 80889 UNDERCARRIAGE HARNESS 80909 4 WHIZ-LOK SCREW, /8-X-/ 809 HORN 4 8584094 4 SUPPORT CLAMP, 9/ 5 858450 9 SUPPORT CLAMP, -/ 85940 SUPPORT CLAMP, 9/ 88000 HEX HD CAPSCREW, /4-0X/4, GR5 8 880005 5 HEX HD CAPSCREW, /4-0X, GR5 9 88504 FLAT WASHER, #8 0 88005 ROUND HD MACHINE SCREW, #8-X, GR8 8840 4 DRIVE SCREW, #4X5/ 88500 HEX NUT, #8-804809 SELF-TAPPING SCREW, #0-4X/4 4 885500 LOCKWASHER, #8 5 88500 FLAT WASHER, /4 809058 WEATHER PACK SHROUD 80909 WEATHER PACK PIN 8 8090 WEATHER PACK SEAL 9 9044 SUPPORT CLAMP, /4 0 9054 CUSHION CLAMP, 804 DIG BRAKE RELAY 80809S Ref LICENSE PLATE LIGHT KIT, (includes items 0 thru 04. Modification of electrical connection is necessary, as well as drilling new mounting holes into frame) 0 800 LICENSE PLATE LIGHT 0 88009 ROUND HD MACHINE SCREW, #0-4X-/4, GR8 0 88505 HEX NUT, #0-4 04 88505 FLAT WASHER, #0 - Series IV Highway Speed Excavators 8080400
Undercarriage Prep Installation Item Part Number Qty. Description Rev. 8080400 Series IV Highway Speed Excavators -
Front Bumper & Headlights Installation 9 4 4 SEE DETAIL B 5 DETAIL B 9 4 4 SEE DETAIL A 5 DETAIL A 8 8 5 0 4 5 TOP VIEW OF BUMPER HARDWARE PAC5490-8 Series IV Highway Speed Excavators 8080400
Front Bumper & Headlights Installation DETAIL C 8 TH RET AMB TMP SGN DETAIL C 8080400 Series IV Highway Speed Excavators -9 PAC5500
Front Bumper & Headlights Installation Item Part Number Qty. Description Rev. 09409 FRONT BUMPER WELDMENT, (yellow) 094089 BUMPER BRACKET 404 8 WHIZ-LOK NUT, /- 4 8048048 BUMPER FRAME MOUNT 5 8048049 BUMPER SUPPORT BRACKET 808 HEADLIGHT, (includes bulb) 8084 HEADLIGHT BULB, 4V 80905 4 WHIZ-LOK SCREW, /8-X 8 88009 0 HEX HD CAPSCREW, /-X, GR5 9 8840 CARRIAGE BOLT, /8-X 0 884 8 CARRIAGE BOLT, /-X-/4 8850008 0 HEX NUT, /- 8850 HEX LOCKNUT, /8-88550 0 LOCKWASHER, / 4 885004 FLAT WASHER, /8 5 88500 0 FLAT WASHER, / 9009 8 HEX HEAD DRILL SCREW, /4-0X 8080 AMBIENT AIR TEMPERATURE SENSOR MOUNT 8 808 AMBIENT AIR TEMPERATURE SENSOR -0 Series IV Highway Speed Excavators 8080400
Front Bumper & Headlights Installation Item Part Number Qty. Description Rev. 8080400 Series IV Highway Speed Excavators -
Undercarriage Mirror & Grab Rail Installation 0 4 4 5 TOP VIEW SHOWING RIGHT HAND MIRROR MOUNT SEE DETAIL B 4 5 8 0 USE HARDWARE FURNISHED WITH MIRROR. PLACE NYLON WASHER BETWEEN MIRROR BRACKET AND MIRROR MOUNT 4 5 SEE DETAIL A 4 9 5 5 DETAIL A 8 SPLIT BUSHING SLIPS BETWEEN MIRROR LOOP AND TWIST BRACKET, (BOTTOM TWIST BRACKET ONLY) DETAIL B PAC40 - Series IV Highway Speed Excavators 8080400
Undercarriage Mirror & Grab Rail Installation Item Part Number Qty. Description Rev. 00 PIVOT BOLT MOUNT 4004 8 WHIZ-LOK SCREW, 5/-8X-/4 400 WHIZ--LOK NUT, 5/-8 4 8 MIRROR MOUNT 5 8085 GRAB RAIL 8089 MIRROR 8080 MIRROR MOUNT LOOP 8 80885 SPLIT BUSHING 9 808 MIRROR, R/H 0 8958 TWIST BRACKET 8989 4 CONVEX MIRROR 8800 HEX HD CAPSCREW, /8-X-/4, GR5 8850 HEX LOCKNUT, /8-4 88505 5/-8, (ny-lok) 5 88500 8 FLAT WASHER, 5/ 908 WHIZ-LOK SCREW, 5/-8X 8080400 Series IV Highway Speed Excavators -
Upperstructure Mirror Installation 4 SEE DETAIL A 8 9 5 DETAIL A PAC400-4 Series IV Highway Speed Excavators 8080400
Upperstructure Mirror Installation Item Part Number Qty. Description Rev. 405 WHIZ-LOK NUT, /8-8095 SIDE VIEW MIRROR 80099 MIRROR MOUNT 4 809 CAB MIRROR MOUNT 5 80909 WHIZ-LOK SCREW, /8-X-/ 8008 UPPER MIRROR BRACKET 880 SOCKET HD CAPSCREW, /8-X-/4 8 88500 HEX NUT, /8-9 88550 LOCKWASHER, /8 8045 A/R MIRROR MOUNT KIT, (includes items, & 5 thru 9) 8080400 Series IV Highway Speed Excavators -5
Engine Cover Installation 5 5 4 0 0 0 4 8 9 9 8 9 0 5 PAC45 - Series IV Highway Speed Excavators 8080400
Engine Cover Installation Item Part Number Qty. Description Rev. 405 5 WHIZ-LOK NUT, /8-800094 5 WHIZ-LOK SCREW, /8-X/4 80484 FRONT HINGE SHIM 4 8080 ENGINE ENCLOSURE, (includes items 4 thru 0) 5 8085 TRANSMISSION COVER, (includes louver) 80909 WHIZ-LOK SCREW, /8-X-/ 88005 4 HEX HD CAPSCREW, /8-X, GR5 8 880 BUTTON HD SCREW, /8-X/4 9 885004 FLAT WASHER, /8 0 885005 FLAT WASHER, / 8080 COVER BRACKET PLATE, L.H. 808 COVER BRACKET PLATE, R.H. 80905 WHIZ-LOK SCREW, /8-X 4 8048409 DRAW LATCH 5 80548 LOUVER, (use 94090 glue to mount) 8084 FRONT ENGINE ENCLOSURE, (includes item 9) 80848 ENGINE ENCLOSURE LID 8 80849 ENGINE ENCLOSURE BASE, (inlcudes louver) 9 805454 SCREEN GRILL 0 8084 CAM LOCK, (uses key 94440) 8080400 Series IV Highway Speed Excavators -
Front Fender Installation 4 4 4 5 8 SEE DETAIL A 8 BETWEEN ITEM & BOTTOM PLATE OF FRAME 4 9 5 0 4 9 0 BRACKETS AT REAR OF FENDERS SIDE VIEW OF LH FRONT FENDER DETAIL A 5 PLACES - SHIMMING OF LEFT HAND FENDER PAC490-8 Series IV Highway Speed Excavators 8080400
Front Fender Installation Item Part Number Qty. Description Rev. 4004 9 WHIZ-LOK SCREW, 5/-8X-/4 400 9 WHIZ-LOK NUT, 5/-8 405 WHIZ-LOK NUT, /8-4 8084 A/R FENDER SHIM 5 8080 FENDER BRACE 80808 FENDER BRACE 80809 FENDER BRACE 8 8085 FENDER BRACE 9 804800 5 FENDER SPACER 0 80844 FENDER BRACKET 808040 LH FRONT FENDER WELDMENT 80808 RH FRONT FENDER WELDMENT 80809 LH REAR FRONT FENDER WELDMENT 4 80909 9 WHIZ-LOK SCREW, /8-X-/ 5 8840 ROUND HD CARRIAGE BOLT, 5/-8X/4 8850005 HEX NUT, 5/-8 885500 LOCKWASHER, 5/ 8 88500 FLAT WASHER, 5/ 9 885004 FLAT WASHER, /8 0 88500 5 FLAT WASHER, / 99 5 WHIZ-LOK SCREW, /8-X-/4 800 4 WHIZ-LOK SCREW, /4-0X/ 8089 ACCESS PANEL 80804 ACCESS PANEL, (for machines equipped with engine block heater) 8080400 Series IV Highway Speed Excavators -9
Rear Fender Assembly, XL00IV 8 4 4 9 8 5 4 0 9 4 0 PAC4800-0 Series IV Highway Speed Excavators 8080400
Rear Fender Assembly, XL00IV Item Part Number Qty. Description Rev. 4448 LH REAR FENDER MOUNT 4449 RH REAR FENDER MOUNT 405 WHIZ-LOK NUT, /8-4 80890 REAR FENDER 5 8048 RH FENDER BRACE 80484 LH FENDER BRACE 80905 4 WHIZ-LOK SCREW, /8-X 8 88004 8 HEX HD CAPSCREW,/-X-/4, GR5, (torque to 5-0 lb-ft) 9 88009 8 HEX HD CAPSCREW, 5/8-X-/4, GR5 0 8850 HEX LOCKNUT, /8-88508 8 HEX LOCKNUT, /- 885505 8 LOCKWASHER, 5/8 88500 FLAT WASHER, / 4 885 8 FLAT WASHER, 5/8 8080400 Series IV Highway Speed Excavators -
Rear Fender Assembly, XL400IV & XL500IV 4 9 4 9 4 4 4 8 8 8 5 0 5 4 0 5 8 PAC480 - Series IV Highway Speed Excavators 8080400
Rear Fender Assembly, XL400IV & XL500IV Item Part Number Qty. Description Rev. 4448 4 LH REAR FENDER MOUNT 4449 4 RH REAR FENDER MOUNT 405 WHIZ-LOK NUT, /8-4 80890 REAR FENDER 5 8048 RH FENDER BRACE 80484 LH FENDER BRACE 80480 FRONT REAR FENDER 8 80905 4 WHIZ-LOK SCREW, /8-X 9 88004 HEX HD CAPSCREW, /-X-4, GR5, (torque to 5-0 lb-ft) 0 88009 HEX HD CAPSCREW, 5/8-X-/4 8850 HEX LOCKNUT, /8-88508 HEX LOCKNUT, /- 885505 LOCKWASHER, 5/8 4 88500 FLATWASHER, / 5 885 FLAT WASHER, 5/8 8080400 Series IV Highway Speed Excavators -
Rear Fender Assembly, XL400IV (with railgear) 4 8 5 8 9 4 4 0 5 8 SEE DETAIL A DETAIL A PAC50-4 Series IV Highway Speed Excavators 8080400
Rear Fender Assembly, XL400IV (with railgear) Item Part Number Qty. Description Rev. 8048050 4 FENDER BRACKET Not Used 49 8 CONDUIT 4 80890 REAR FENDER (rear) 5 8048 R.H. FENDER BRACE 8048 L.H. FENDER BRACE 80480 REAR FENDER (front) 8 80905 4 WHIZ-LOK SCREW, /8-X 9 88004 HEX HD CAPSCREW, /-X-4, GR5, (torque to 5-0 lb-ft) 0 88009 HEX HD CAPSCREW, 5/8-X-/4 8850 HEX LOCKNUT, /8-88508 HEX LOCKNUT, /- 885505 LOCKWASHER, 5/8 4 88500 FLATWASHER, / 5 885 FLAT WASHER, 5/8 8080400 Series IV Highway Speed Excavators -5
Front Steps Installation 8 0 9 0 5 0 4 8 0 9 0 5 SEE DETAIL A 4 0 DETAIL A PAC5540 - Series IV Highway Speed Excavators 8080400
Front Steps Installation Item Part Number Qty. Description Rev. 405 4 WHIZ-LOK NUT, /8-805 4 CAP PLATE 80 4 CAP PLATE 4 8004 4 STEP SUPPORT 5 8080 4 STEP ANGLE 808408 A/R STEP SHIM 8080 STAIR TREAD, 8.5 8 8088 STAIR TREAD, 4 9 808 STAIR TREAD, 5.5 0 80905 WHIZ-LOK SCREW, /8-X 80909 9 WHIZ-LOK SCREW, /8-X-/ 8850 HEX LOCKNUT, /8-885004 FLAT WASHER, /8 8080400 Series IV Highway Speed Excavators -
Front Steps (Extended) Installation 8 9 5 0 4 5 4 5 8 9 4 SEE DETAIL A 0 5 4 5 4 4 5 DETAIL A PAC590-8 Series IV Highway Speed Excavators 8080400
Front Steps (Extended) Installation Item Part Number Qty. Description Rev. 405 40 WHIZ-LOK NUT, /8-805 4 CAP PLATE 80 4 CAP PLATE 4 8004 4 STEP SUPPORT 5 8080 4 STEP ANGLE 808408 A/R STEP SHIM 8080 4 STAIR TREAD, 8.5 8 8088 STAIR TREAD, 4 9 808 STAIR TREAD, 5.5 0 808095 4 STEP EXTENSION PLATE Not Used Not Used 80905 WHIZ-LOK SCREW, /8-X 4 80909 9 WHIZ-LOK SCREW, /8-X-/ 5 8850 HEX LOCKNUT, /8-885004 4 FLAT WASHER, /8 8080400 Series IV Highway Speed Excavators -9
Rear Step Installation 5 4 NOTE: OPTIONAL L.H. STEP USES SAME MOUNTING HARDWARE AS SHOWN. PAC5550-0 Series IV Highway Speed Excavators 8080400
Rear Step Installation Item Part Number Qty. Description Rev. 80485044 R.H. REAR STEP ASSY, (includes items thru ) 8048504 L.H. REAR STEP ASSY, (optional; includes items thru ) 88009 4 HEX HD CAPSCREW, 5/8-X, GR5 8850 4 HEX LOCKNUT, 5/8-80480 R.H. REAR STEP WELDMENT, (used with 80485044 only) 80480 L.H. REAR STEP WELDMENT, (used with 8048504 only 4 8088 4 STAIR TREAD, 4 5 405 WHIZ-LOK NUT, /8-80905 WHIZ-LOK SCREW, /8-X 8080400 Series IV Highway Speed Excavators -
Battery Box Steps Installation PAC55 - Series IV Highway Speed Excavators 8080400
Battery Box Steps Installation Item Part Number Qty. Description Rev. 808504 BATTERY BOX STEPS ASSY, (includes qty. of item, items thru & qty. of item ) - 405 0 WHIZ-LOK NUT, /8-8080 STAIR TREAD, 8.5 8084 L.H. STEP PLATE 4 8085 R.H. STEP PLATE 5 80805 L.H. STEP PLATE 8088 STAIR TREAD, 44 80905 8 WHIZ-LOK SCREW, /8-X 8 80909 WHIZ-LOK SCREW, /8-X-/ 9 885004 FLAT WASHER, /8 0 80849 NYLON SPACER, /4X/ 8080400 Series IV Highway Speed Excavators -
Battery Box Steps (Extended) Installation A 8 A 5 9 4 5 4 5 5 4 5 0 4 SECTION A-A PAC5400-4 Series IV Highway Speed Excavators 8080400
Battery Box Steps (Extended) Installation Item Part Number Qty. Description Rev. 80850 BATTERY BOX STEPS ASSY, (includes qty. of item, items thru, qty. 0 of item, qty. 4 of item, qty. of item 4 & item 5) - 405 0 WHIZ-LOK NUT, /8-805 CAP PLATE 80 CAP PLATE 4 8004 STEP SUPPORT 5 8080 STAIR TREAD, 8.5 8084 L.H. STEP PLATE 8085 R.H. STEP PLATE 8 80805 L.H. STEP PLATE 9 8088 STEP EXTENDER PLATE 0 8089 STEP EXTENDER PLATE 8088 STAIR TREAD, 44 80905 WHIZ-LOK SCREW, /8-X 80909 WHIZ-LOK SCREW, /8-X-/ 4 885004 5 FLAT WASHER, /8 5 8850 HEX LOCKNUT, /8-80849 NYLON SPACER, /4X/ 8080400 Series IV Highway Speed Excavators -5
Mudflap Installation 4 5 9 4 5 9 5 0 PAC590 - Series IV Highway Speed Excavators 8080400
Mudflap Installation Item Part Number Qty. Description Rev. FRONT MUDFLAP INSTALLATION, (includes items thru 5) 80 MUDFLAP 848009 BACKING BAR 88000 8 HEX HD CAPSCREW, /4-0X-/4, GR5 4 88500 8 FLAT WASHER, /4 5 88504 8 HEX LOCKNUT, /4-0 REAR MUDFLAP INSTALLATION, (includes items thru ) 80855 REAR MUDFLAP, (XL00IV 4x only) 8085 REAR MUDFLAP, (XL00IV 4x4, XL400IV x4 & XL500IV x4 only) 8 80489 REAR MUDFLAP, (XL400IV x & XL500IV x only) 9 8084 BACKING BAR 0 84859 CLOSE LINK 88000 HEX HD CAPSCREW, /4-0X/4, GR5 88504 HEX LOCKNUT, /4-0 88005 4 HEX HD CAPSCREW, 5/-8X-/4, GR5 4 8800 4 HEX HD CAPSCREW, 5/-8X-/4, GR5 5 88505 8 HEX LOCKNUT, 5/-8 88500 8 FLAT WASHER, 5/ 8080400 Series IV Highway Speed Excavators -
Sheet Metal Covers Installation 5 8 9 (XL00IV) (XL400IV & XL500IV) 4 PAC48-8 Series IV Highway Speed Excavators 8080400
Sheet Metal Covers Installation Item Part Number Qty. Description Rev. 405 WHIZ-LOK NUT, /8-808 FUEL TANK COVER 8080 BATTERY BOX COVER 4 808 FUEL TANK COVER BRACKET 5 808805 DECK COVER WELDMENT, (XL00IV only) 80805 DECK COVER WELDMENT, (XL400IV & XL500IV only) 80905 0 WHIZ-LOK SCREW, /8-X, (qty for XL00IV only) 80905 WHIZ-LOK SCREW, /8-X, (qty for XL400IV & XL500IV only) 8840 ROUND HD CARRIAGE BOLT, /8-X 8 88005 8 HEX HD CAPSCREW, /8-X, GR5, (XL400IV & XL500IV only) 9 885004 8 FLAT WASHER, /8, (XL400IV & XL500IV only) 8080400 Series IV Highway Speed Excavators -9
Upperstructure Covers Installation 4 4 9 40 8 9 9 4 8 9 9 9 8 9 9 5 5 9 0 5 8 5 8 4 4 REAR DOOR 0 4 0 8 9 8 9 40 PAC8-40 Series IV Highway Speed Excavators 8080400
Upperstructure Covers Installation Item Part Number Qty. Description Rev. 0808 COVER SUPPORT ANGLE 8840 ROUND HD CARRIAGE BOLT, /8-X 0950 9 SCREW, 5/-8X/4 4 OIL COOLER COVER, (includes the following items) 80409 GROMMET 805454 SCREEN GRILL 5 Ref VALVE COVER ASSY, (see page -4 for details) INSIDE VALVE COVER, (yellow) Ref LEFT FRONT DOOR, (see page -44 for details) 8 08 TOP COVER 9 0 CAB BELLYPAN 0 000 4 HINGE COVER WELDMENT 808 VALVE TRAY BELLYPAN 555 STRIKER PLATE 444 HANDRAIL 4 4004 NYLON SLEEVE 5 440 LEFT COVER SUPPORT 8009 STRIKER PLATE 400 44 WHIZ-LOK NUT, 5/-8 8 405 WHIZ-LOCK NUT, /8-9 8004 WHIZ-LOCK SCREW, /-X/4 0 800094 5 WHIZ-LOCK SCREW, /8-X/4 8088 8 GASKET, /4X/ THICK 804048 COVER SUPPORT BRACKET 80500 STRUT BRACKET 4 80905 0 WHIZ-LOK SCREW, /8-X 5 8800 HEX HD CAPSCREW, /4-0X-/, GR5 8800 HEX HD CAPSCREW, /8-x-/4, GR5 88504 HEX JAM NUT 8 88500 FLAT WASHER, /4 9 885004 4 FLAT WASHER, /8 0 8854 4 ROLL PIN, /X-/4 908 SCREW, 5/-8X 80008 DOOR PROP 880 COTTER PIN, /X 4 Ref REAR DOOR, L.H., (w/o air conditioner), (see page -4 for details) Ref REAR DOOR, L.H., (w/air conditioner), (see page -4 for details) 5 800 AR SHIM, LATCH BRACKET 80540 COVER GUIDE 844 HOOD STOP CABLE 8 80909 4 WHIZ-LOK SCREW, /8-X-/ 9 8850 4 HEX LOCKNUT, /8-40 88550 LOCKWASHER, /8 8080400 Series IV Highway Speed Excavators -4
Valve Cover PAC9-4 Series IV Highway Speed Excavators 8080400
Valve Cover Item Part Number Qty. Description Rev. 4 VALVE COVER, (includes all items), (yellow) C VALVE COVER SHELL, (not available for service) 80050 HINGE 805 GAS PROP, 0#, (not illustrated) 4 8054 NON-SKID STAIR TREAD 5 80405 BALL STUD, 0MM 004 LATCH ASSY 94440 LATCH KEY 804095 GAS PROP BRACKET 8 80484 9 HEX SHEET METAL SCREW, #X/4 9 8808 SOCKET BUTTON HD CAPSCREW, /4-0X 0 8850 FLAT WASHER, /4 885004 HEX LOCKNUT, /4-0 80484 PLASTIC PLUG, / 8080400 Series IV Highway Speed Excavators -4
Left Front Door 4 5 PAC -44 Series IV Highway Speed Excavators 8080400
Left Front Door Item Part Number Qty. Description Rev. 04 FRONT LEFT DOOR ASSY, (w/o Air Conditioner), (includes all items), (yellow) D 80545 DOOR 80544 HINGE ASSY (tapered) 8808 4 SOCKET BUTTON HD CAPSCREW, /4-0X 4 8850 4 FLAT WASHER, /4 5 885004 4 HEX LOCKNUT, /4-0 8054 RUBBER STRIP, (not illustrated) 8080400 Series IV Highway Speed Excavators -45
Rear Door, L.H. 5 4 9 0 8 P/N 09 08 0 0 0 0 04 05 0 0 09 P/N 95 PAC00-4 Series IV Highway Speed Excavators 8080400
Rear Door, L.H. Item Part Number Qty. Description Rev. 09 REAR DOOR, L.H., (w/o air conditioner), (includes all items), (yellow) C 8054 DOOR 88505 4 FLAT WASHER, #8 804840 4 HEX LOCKNUT, #8-4 88005 4 SOCKET BUTTON HD CAPSCREW, #8-X/4 5 8054 LATCH 94440 LATCH KEY 80545 4 TRIM-LOK 80544 HINGE ASSY 8 8808 4 SOCKET BUTTON HD CAPSCREW, /4-0X 9 8850 4 FLAT WASHER, /4 0 88504 4 HEX LOCKNUT, /4-0 95 REAR DOOR, L.H., (w/air conditioner), (includes all items), (yellow) C 0 8054 DOOR 0 88505 4 FLAT WASHER, #8 0 804840 4 HEX LOCKNUT, #8-04 80544 HINGE 05 80548 LOUVER, (use 94090 glue to mount) 0 8054 LATCH 94440 LATCH KEY 0 88005 4 SOCKET BUTTON HD CAPSCREW, #8-X/4 08 80545 4 TRIM-LOK 09 8808 4 SOCKET BUTTON HD CAPSCREW, /4-0X 0 8850 4 FLAT WASHER, /4 885004 4 HEX LOCKNUT, /4-0 8080400 Series IV Highway Speed Excavators -4
Swing Bearing Installation Components ATTACHED TO OIL COOLER BOX 9 4 5 8 0 (ITEM TO ITEM ) (ITEM TO ITEM 4) 4 5 9 0 8 SET BACKLASH TO.05-.05 ON HIGH TOOTH OF GEAR AS MARKED BY VENDOR GLUE COVER TO CHASSIS 4 PAC85-48 Series IV Highway Speed Excavators 8080400
Swing Bearing Installation Components Item Part Number Qty. Description Rev. 400 VENT 80409 ADAPTER 9044 SUPPORT CLAMP 4 800094 WHIZ-LOCK SCREW, /8-X/4 5 405 WHIZ-LOCK NUT, /8-8454 HOSE ASSY 800 0 HEX HD CAPSCREW, /4-0X/4, GR5, (loctite & torque to 40-5 lb-ft) 8 Ref SWING TRANSMISSION ASSY, (see page 9- for details) 9 9004 0 HARDENED WASHER 0 5480 GREASE HOSE 84989 HOSE ASSY 800 BULKHEAD ADAPTER 8800 LUBE FITTING, STRAIGHT, /8 4 8840 MALE ELBOW, 45 DEGREES, /8X/4 TUBE 5 85040 8 GREASE CARTRIDGE, #, (4.5 oz.) 88404 MALE ELBOW, 90 DEGREES, /8X/4 TUBE 804400 SWING BEARING 8 800 FLAT HD CAPSCREW, 5/8-X-/4, (loctite & torque to 00-5 lb-ft) 9 80400 BEARING COVER 0 440459 AR BETASEAL PRIMERLESS ADHESIVE 804 40 FLAT HD CAPSCREW, 5/8-X-/, (loctite & torque to 00-5 lb-ft) 80905 WHIZ-LOK SCREW, /8-X 80405 COVER 4 80400 GASKET 8080400 Series IV Highway Speed Excavators -49
Counterweight & Swing Light Installation 5 NOTE: XL400IV & 500IV FRAME ILLUSTRATED. 4 SHIM EACH HOLE AS REQUIRED 8 8 9 PAC09-50 Series IV Highway Speed Excavators 8080400
Counterweight & Swing Light Installation Item Part Number Qty. Description Rev. 9094 SWING LIGHT ASSY 800094 4 WHIZ-LOCK SCREW, /8-X/4 44 SWING LIGHT MOUNT PLATE 4 5000 4 NUT, #0 5 4848 COUNTERWEIGHT,,000#, XL00IV, (yellow) 484 COUNTERWEIGHT, 8,850# XL400IV, (yellow) 484 COUNTERWEIGHT, 5,500#, XL500IV, (yellow) 804 A/R COUNTERWEIGHT SHIM 44059 SPECIAL WASHER, (square), (qty 4 required for XL00IV) 8 880 HEX HD CAPSCREW, -8X, GR5, (loctite & torque to 545-595 lb-ft), (qty 4 required for XL00IV) 9 44040 A/R LOCTITE, (# red) 8080400 Series IV Highway Speed Excavators -5
Boom Installation Components 5 TO L.H. HOIST CYLINDER 4 4 TO R.H. HOIST CYLINDER 8 0 9 5 PAC0-5 Series IV Highway Speed Excavators 8080400
Boom Installation Components Item Part Number Qty. Description Rev. 8800 HEX HD CAPSCREW, /-X-/, GR5, (lubricate & torque to 8- lb-ft) 80089 SPECIAL WASHER 80500 PIN WELDMENT, (apply #850 anti-seize lubrication to stop end of pin) 4 88404 MALE ELBOW, 90 DEGREES, /8X/4 TUBE 5 800 PIN WELDMENT, (apply #850 anti-seize lubrication to stop end of pin) 5490 LOCATOR PLATE 8004 WHIZ-LOK SCREW, /-X/4 8 8004 PIN WELDMENT, (apply #850 anti-seize lubrication to stop end of pin) 9 8800 LUBE FITTING, STRAIGHT, /8 0 800 BULKHEAD ADAPTER 5480 GREASE HOSE 849898 GREASE HOSE 8808 LUBE FITTING, 45 DEGREES, /8 4 8890 CONNECTOR 5 Ref BOOM CRADLE WELDMENT, (see page - for details) Ref HOIST CYLINDER ASSY, (see page 9- for details) 8080400 Series IV Highway Speed Excavators -5
Boom Rest Installation NOTE: IF MACHINE IS EQUIPPED WITH TELESTICK BOOM, SEE PAGE -4 FOR BOOM REST INFORMATION. 5 SEE DETAIL A 4 DETAIL A PAC550-54 Series IV Highway Speed Excavators 8080400
Boom Rest Installation Item Part Number Qty. Description Rev. 404 WHIZ-LOK NUT, /- 80808 HOSE SUPPORT WELDMENT 88 0 HEX HD CAPSCREW, /-X, GR8 4 9004 0 HARD WASHER, /X-/X.095 5 80800 BOOM REST 8080400 Series IV Highway Speed Excavators -55
Upperstructure Cab Installation Components 8 5 4 PAE0440-5 Series IV Highway Speed Excavators 8080400
Upperstructure Cab Installation Components Item Part Number Qty. Description Rev. Ref OPERATORS CAB, (see page - for details) 889904 4 PUSH PLUG, / 88894 4 STUD, 5/8-X4-/4, GR5 4 805 4 SPECIAL WASHER 5 80800 4 SHOCK MOUNT 88500 4 HEX LOCKNUT, 5/8-, (loctite & torque to 40-55 lb-ft) 4404 A/R LOCTITE, (#4 blue) 8 4404 A/R CAULK 8080400 Series IV Highway Speed Excavators -5
Undercarriage Cab Installation Components & Heater Plumbing 4 5 9 4 DETAIL A SEE DETAIL A 9 8 0 DETAIL B 0 SEE DETAIL B PAC5050-58 Series IV Highway Speed Excavators 8080400
Undercarriage Cab Installation Components & Heater Plumbing 4 HEATER INLET HEATER OUTLET 5 4 5 (BLACK) FROM HEATER OUTLET TO BOTTOM RADIATOR TUBE (RED) FROM HEATER INLET TO WATER VALVE CONNECT TO CAB HARNESS CAB GND HTR POT SGN B V ACC 4 (RED) FROM WATER VALVE TO PORT ON FRONT OF ENGINE 5 8 9 ON INSIDE OF CAB 0 0 8 LEFT FRONT CORNER OF CAB 8080400 Series IV Highway Speed Excavators -59 PAC500
Undercarriage Cab Installation Components & Heater Plumbing Item Part Number Qty. Description Rev. 4404 AR LOCTITE, (#4 BLUE) 4404 AR DOW INDUSTRIAL SILICONE CAULK, (#) 400 WHIZ-LOK NUT, 5/-8 4 80800 4 SHOCK MOUNT 5 80805 HORN BUTTON 88990 4 PUSH-IN PLASTIC PLUG 805 4 SPECIAL WASHER 8 8085 STEERING WHEEL 9 80405 DIAGNOSTIC CONNECTOR BRACKET 0 8048 CAB FRONT COVER WITH SEAL 85940 SUPPORT CLAMP, 9/ 8089 HEATER CONTROL VALVE, (v) Ref UNDERCARRIAGE CAB ASSY, (see page -40 for details) 4 A/R HEATER HOSE, (red) 5 A/R HEATER HOSE, (black) 809 GROUND CABLE 88 HOSE CLAMP 8 88000 4 HEX HD CAPSCREW, /4-0X-/, GR5 9 88005 HEX HD CAPSCREW, /-4X-/4, GR5 0 8800 4 ROUND HD MACHINE SCREW, #4-40X/8, GR8 88005 4 ROUND HD MACHINE SCREW, #- 885004 4 HEX NUT, #4-40 885008 4 HEX NUT, #- 4 88500 HEX LOCKNUT, /-4, (hand torque to 44-54 lb-ft) 5 88500 4 HEX LOCKNUT, 5/8-, (hand torque to 40-55 lb-ft) 88505 HEX LOCKNUT, 5/-8 885500 4 LOCKWASHER, #4 8 8855005 4 LOCKWASHER, # 9 8855009 4 LOCKWASHER, /4 0 8850 4 FLAT WASHER, #4 8850 4 FLAT WASHER, # 8850 4 FLAT WASHER, /4 88894 4 STUD, 5/8-X4-/4, GR5-0 Series IV Highway Speed Excavators 8080400
Undercarriage Cab Installation Components & Heater Plumbing Item Part Number Qty. Description Rev. 8080400 Series IV Highway Speed Excavators -
Power Unit Installation SEE DETAIL A 5 5 DETAIL A 4 8 PAC4900 - Series IV Highway Speed Excavators 8080400
Power Unit Installation Item Part Number Qty. Description Rev. 400 WHIZ-LOK NUT, 5/-8 805 SPECIAL WASHER Ref POWER UNIT ASSY, (see page 4- for details) 4 85940 SUPPORT CLAMP, / 5 88005 HEX HD CAPSCREW, 5/8-X4, GR5 8850 HEX LOCKNUT, 5/8-885 FLAT WASHER, 5/8 8 908 WHIZ-LOK SCREW, 5/-8X 8080400 Series IV Highway Speed Excavators -
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