Gradall Excavator XL4100II Operators Parts Service Manual

Description

List of Files:
XL4100II Parts Manual 31200007 2004.pdf (260 Pages)
Contents:
31200007 XL4100II PARTS MANUAL
UPPERSTRUCTURE
Section 1 Introduction
Section 2 Boom Assemblies
Section 3 Cab & Related Components
Section 4 Hydraulic System Components
Section 5 Main Hydraulic Systems
Section 6 Pilot Hydraulic Systems
Section 7 Attachments
UNDERCARRRIAGE
Section 1 Introduction
Section 2 Undercarriage Assembly
Section 3 Drive Line Components
Section 4 Front Axle Assembly
Section 6 Air System
Section 7 Cab & Related Components
Section 8 Steering & Component Assemblies
OPTIONS
XL4100II Illustrated Parts Manual 31200030 2004.pdf (508 Pages)
XL4100II Illustrated Parts Manual 31200043.pdf (500 Pages)
XL4100II Illustrated Parts Manual 31200044 2004.pdf (500 Pages)
XL4100II Illustrated Parts Manual 31200046 2004.pdf (500 Pages)
XL4100II Illustrated Parts Manual 31200047 2004.pdf (504 Pages)
XL4100II Illustrated Parts Manual 31200048 2004.pdf (524 Pages)
XL4100II Illustrated Parts Manual 31200049 2004.pdf (524 Pages)
XL4100II Illustrated Parts Manual 31200053 2005.pdf (510 Pages)
XL4100II Illustrated Parts Manual 31200059 2005.pdf (506 Pages)
XL4100II Illustrated Parts Manual 31200063 2005.pdf (504 Pages)
XL4100II Illustrated Parts Manual 31200064 2005.pdf (526 Pages)
XL4100II Illustrated Parts Manual 31200065 2007.pdf (518 Pages)
XL4100II Illustrated Parts Manual 31200068 2005.pdf (510 Pages)
XL4100II Illustrated Parts Manual 31200081 2005.pdf (494 Pages)
XL4100II Illustrated Parts Manual 31200083 2005.pdf (502 Pages)
XL4100II Illustrated Parts Manual 31200088 2005.pdf (452 Pages)
XL4100II Illustrated Parts Manual 31200089 2005.pdf (474 Pages)
XL4100II Illustrated Parts Manual 31200092 2005.pdf (454 Pages)
XL4100II Illustrated Parts Manual 31200095 2005.pdf (444 Pages)
XL4100II Illustrated Parts Manual 31200098 2005.pdf (446 Pages)
XL4100II Illustrated Parts Manual 31200101 2005.pdf (436 Pages)
XL4100II Illustrated Parts Manual 31200103 2005.pdf (446 Pages)
XL4100II Illustrated Parts Manual 31200116 2005.pdf (438 Pages)
XL4100II Illustrated Parts Manual 31200117 2005.pdf (438 Pages)
XL4100II Illustrated Parts Manual 31200135 2005.pdf (440 Pages)
XL4100II Illustrated Parts Manual 31200138 2005.pdf (468 Pages)
XL4100II Illustrated Parts Manual 31200139 2005.pdf (472 Pages)
XL4100II Illustrated Parts Manual 31200145 2006.pdf (454 Pages)
XL4100II Illustrated Parts Manual 31200174 2005.pdf (450 Pages)
XL4100II Illustrated Parts Manual 31200178 2005.pdf (432 Pages)
XL4100II Illustrated Parts Manual 31200187 2005.pdf (458 Pages)
Contents:
31200187 XL4100II PARTS MANUAL
Effectivity Page
Table Of Contents
Section 1 Frame & Attaching Parts
Section 2 Boom
Section 3 Attachments
Section 4 Engine & Attaching Parts
Section 5 Drive Train
Section 6 Cab
Section 7 Controls
Section 8 Hydraulic Circuits
Section 9 Hydraulic Components
Section 10 Electrical
Section 11 Decals
Section 12 Options
Recommended Parts List
Part Number Index
XL4100II Illustrated Parts Manual 31200195 2005.pdf (446 Pages)
XL4100II Illustrated Parts Manual 31200196 2005.pdf (446 Pages)
Contents:
Service Kits
Section 1 Frame & Attaching Parts
Figure 1-1 Frame Assembly
Figure 1-2 Mirror & Grab Rails
Figure 1-3 Engine Cover
Figure 1-4 R.H. Fender & Mirrors
Figure 1-5 L.H. Fender
Figure 1-6 Rear Fender Assembly
Figure 1-7 Deck & Cover
Figure 1-8 Left Side Cover Assembly
Figure 1-9 Rotating Platform
Figure 1-10 Swing Bearing, Cradle & Hoist Cylinder Mounting & Lube System
Figure 1-11 Valve Cover
Section 2 Boom
Figure 2-1 Boom Cradle
Figure 2-2 Main Boom Assembly
Figure 2-3 Telescope Boom Assembly
Figure 2-4 Boom Roller Assemblies
Figure 2-5 Bucket Linkage
Section 3 Attachments
Figure 3-1 24” Excavating Buckets
Figure 3-2 48” Excavating Bucket
Figure 3-3 Fixed Thumb Grapple Assembly
Figure 3-4 24” Ditching Bucket
Figure 3-5 48” Ditching Bucket
Section 4 Engine & Attaching Parts
Figure 4-1 Engine Assembly, L.H. View
Figure 4-2 Engine Assembly, R.H. View
Figure 4-3 Air Cleaner Assembly
Figure 4-4 Power Steering Reservoir Assembly
Figure 4-5 Exhaust System
Figure 4-6 Fuel Tank & Lines
Figure 4-7 Radiator & Cooler Assemblies
Figure 4-8 Oil Cooler & Hoses
Figure 4-9 Air Brake System
Figure 4-10 Spring Brake Control Valve & Parking Brake Valve Assemblies
Figure 4-11 Lockout Air Valve, Air Dryer & Adapter Assemblies
Figure 4-12 Air Valve Assemblies
Figure 4-13 Air Valve & Double Check Valve Assemblies
Figure 4-14 Air Reservoir Assemblies
Figure 4-15 Relay Valve Assemblies
Figure 4-16 Foot Pedal Valve & Air Fitting Assembly
Figure 4-17 Air Valve Assemblies
Figure 4-18 Air Valve & Air Fitting Assemblies
Section 5 Drive Train
Figure 5-1 Clutch Assembly
Figure 5-2 Clutch Release Bearing
Figure 5-3 Slave Valve Assembly
Figure 5-4 Transmission – Slave Control Assembly
Figure 5-5 Transmission – Slave Valve w/Hoses
Figure 5-6 Transmission – Clutch Housing
Figure 5-7 Transmission – Shift Bar Housing
Figure 5-8 Transmission – Reverse Idler, Input Shaft & Drive Gear
Figure 5-9 Transmission – Mainshaft & Countershaft Gears
Figure 5-10 Transmission – Auxiliary Mainshaft
Figure 5-11 Transmission – Auxiliary Case Assembly
Figure 5-12 Transmission – Range Cylinder
Figure 5-13 Transmission – Auxiliary Countershaft & Auxiliary Drive Gear
Figure 5-14 Transmission – Master Shift Valve Assembly
Figure 5-15 Propeller Shaft
Figure 5-16 Front Axle – Axle Assembly, 6X4
Figure 5-17 Front Axle – Steering Components, 6X4
Figure 5-18 Front Axle – Service Brakes, 6X4
Figure 5-19 Front Axle – Disc Wheel & Rims, 6X4
Figure 5-20 Front Axle – Spring Assembly
Figure 5-21 Rear Axle – Axle Assembly, 6X4
Figure 5-22 Rear Axle – Forward Housing
Figure 5-23 Rear Axle – Rear Housing
Figure 5-24 Rear Axle – Forward Differential Assembly
Figure 5-25 Rear Axle – Rear Differential Assembly
Figure 5-26 Rear Axle – Service Brake
Figure 5-27 Rear Axle – Disc Wheel & Rim
Figure 5-28 Equalizer Beams
Section 6 Cab
Figure 6-1 Cab Assembly, Upperstructure
Figure 6-2 Cab Assembly, Upperstructure
Figure 6-3 Cab Door Assembly, Upperstructure
Figure 6-4 Cab Interior Components, Upperstructure
Figure 6-5 Cab Console, Upperstructure
Figure 6-6 Seat Assembly, Upperstructure
Figure 6-7 Cab Heater & Installation, Upperstructure
Figure 6-8 Cab Assembly, Undercarriage
Figure 6-9 Cab Assembly, Undercarriage
Figure 6-10 Cab Door Assembly, Undercarriage
Figure 6-11 Seat Assembly, Undercarriage
Figure 6-12 Seat Suspension, Undercarriage
Figure 6-13 Heater & Defroster, Undercarriage
Figure 6-14 Pilot Cutoff Assembly
Section 7 Controls
Figure 7-1 Joystick Assembly
Figure 7-2 Steering Column Assembly
Figure 7-3 Steering Drive Shaft Assembly
Figure 7-4 Steering Drag Link Assembly
Figure 7-5 Foot Operated Pedal Valve Assembly
Figure 7-6 Foot Operated Pedal Plate Assembly
Section 8 Hydraulic Circuits
Figure 8-1 Hydraulic Oil Supply to Main Pump
Figure 8-2 Main Hydraulic Pump to Center Pin
Figure 8-3 Hydraulic Pressure from Center Pin to Control Valve
Figure 8-4 Main Valve to Pilot Manifold
Figure 8-5 Hydraulic Hosing To Joysticks & Foot Operated Pedal Valve
Figure 8-6 Upper Dump
Figure 8-7 Chassis Dump
Figure 8-8 Hoist Pilot
Figure 8-9 Boom Pilot
Figure 8-10 Tool Pilot
Figure 8-11 Tilt Pilot
Figure 8-12 Heater & Auxiliary Pilot
Figure 8-13 Hoist Cylinder
Figure 8-14 Boom Cylinder
Figure 8-15 Tool Cylinder
Figure 8-16 Swing & Swing Brake Pilot
Figure 8-17 Tool Pilot
Figure 8-18 Swing Motor
Figure 8-19 Tilt Motor
Figure 8-20 Steering Gear
Figure 8-21 Remote Propelling
Figure 8-22 Remote Steering
Figure 8-23 Stabilizer Cylinder
Section 9 Hydraulic Components
Figure 9-1 Hoist Cylinder Assembly
Figure 9-2 Boom Cylinder Assembly
Figure 9-3 Tool Cylinder Assembly
Figure 9-4 Stabilizer Cylinder Assembly
Figure 9-5 Stabilizer Valve Assembly
Figure 9-6 Remote Steering Hydraulic Cylinder Assembly
Figure 9-7 Front Main Pump
Figure 9-8 Rear Main Pump
Figure 9-9 Main Hydraulic Control Valve Assembly
Figure 9-10 Main Hydraulic Control Valve Assembly
Figure 9-11 Main Hydraulic Control Valve Assembly
Figure 9-12 Main Hydraulic Control Valve Kits
Figure 9-13 Pilot Manifold Valve Tray Hydraulic Components
Figure 9-14 Pilot Manifold Assembly
Figure 9-15 Reservoir Assembly
Figure 9-16 Swing Transmission Installation
Figure 9-17 Swing Transmission Assembly
Figure 9-18 Swing Motor Assembly
Figure 9-19 Swing Brake Assembly
Figure 9-20 Tilt Transmission
Figure 9-21 Tilt Transmission Assembly
Figure 9-22 Tilt Motor Assembly
Figure 9-23 Tilt Brake Assembly
Figure 9-24 Travel Motor
Figure 9-25 Center Pin Assembly
Figure 9-26 Power Take-Off Assembly
Figure 9-27 Power Take-Off Counter Shaft
Figure 9-28 Oil Cooler Assembly
Figure 9-29 Hydraulic Heater Pump Assembly
Figure 9-30 Hydraulic Heater Manifold Assembly
Figure 9-31 Steering Gear Assembly
Figure 9-32 Counterbalance Valve Assembly
Figure 9-33 Counterbalance Valve
Figure 9-34 Cooling Fan Valve Assembly
Figure 9-35 Steering Valve Assembly
Figure 9-36 Dual Solenoid Valve Assembly
Figure 9-37 Hoist Limit Valve
Section 10 Electrical
Figure 10-1 Miscellaneous Electrical Components, Upperstructure
Figure 10-2 Battery Box, Batteries & Cables
Figure 10-3 Tail & Marker Lights
Figure 10-4 Head & Marker Lights
Figure 10-5 Horn & Miscellaneous, Undercarriage
Figure 10-6 Cab Console Circuit Board, Upperstructure
Figure 10-7 Cab Console Circuit Board, Undercarriage
Figure 10-8 Instrument Panel
Figure 10-9 Accessory Panel
Section 11 Decals
Figure 11-1 Decals, Upperstructure
Figure 11-2 Decals, Undercarriage
Section 12 Options
Figure 12-1 Air Conditioner Installation Components, Upperstructure
Figure 12-2 ‘04 EPA Air Conditioner Installation (Undercarriage)
Figure 12-3 Air Conditioner Evaporator Kit
Figure 12-4 Block Heater Installation Components
Figure 12-5 Additional Battery Installation & Master Disconnect Switch Installation
Figure 12-6 Floodlight Installation Components
Figure 12-7 Grid Heater Installation Components
Figure 12-8 Locking Fuel Cap
Figure 12-9 Strobe Light Installation Components
Figure 12-10 Dual Air Horn Installation
Figure 12-11 Lube Chart Installation, (Upperstructure)
Figure 12-12 Drain Valve Installation
Figure 12-13 Fire Extinguisher Installation
Figure 12-14 Rail Gear Installation
Figure 12-15 Lube Chart Installation, (Chassis)
Figure 12-16 GVW Tag Installation (Chassis)
Figure 12-17 Strobe Light Installation
Figure 12-18 Brake Activated Lights Installation
Figure 12-19 Auxiliary Hydraulics
Recommended Spare Parts
Part Number Index
XL4100II Illustrated Parts Manual 31200197 2005.pdf (444 Pages)
Contents:
Service Kit
Section 1 Frame & Attaching Parts
Figure 1-1 Frame Assembly
Figure 1-2 Mirror & Grab Rails
Figure 1-3 Engine Cover
Figure 1-4 R.H. Fender & Mirrors
Figure 1-5 L.H. Fender
Figure 1-6 Rear Fender Assembly
Figure 1-7 Deck & Cover
Figure 1-8 Left Side Cover Assembly
Figure 1-9 Rotating Platform
Figure 1-10 Swing Bearing, Cradle & Hoist Cylinder Mounting & Lube System
Figure 1-11 Valve Cover
Section 2 Boom
Figure 2-1 Boom Cradle
Figure 2-2 Main Boom Assembly
Figure 2-3 Telescope Boom Assembly
Figure 2-4 Boom Roller Assemblies
Figure 2-5 Bucket Linkage
Section 3 Attachments
Figure 3-1 Fixed Thumb Grapple Assembly
Figure 3-2 24” Ditching Bucket
Figure 3-3 48” Ditching Bucket
Figure 3-4 60” Ditching Bucket
Section 4 Engine & Attaching Parts
Figure 4-1 Engine Assembly, L.H. View
Figure 4-2 Engine Assembly, R.H. View
Figure 4-3 Air Cleaner Assembly
Figure 4-4 Power Steering Reservoir Assembly
Figure 4-5 Exhaust System
Figure 4-6 Fuel Tank & Lines
Figure 4-7 Radiator & Cooler Assemblies
Figure 4-8 Oil Cooler & Hoses
Figure 4-9 Air Brake System
Figure 4-10 Spring Brake Control Valve & Parking Brake Valve Assemblies
Figure 4-11 Lockout Air Valve, Air Dryer & Adapter Assemblies
Figure 4-12 Air Valve Assemblies
Figure 4-13 Air Valve & Double Check Valve Assemblies
Figure 4-14 Air Reservoir Assemblies
Figure 4-15 Relay Valve Assemblies
Figure 4-16 Foot Pedal Valve & Air Fitting Assembly
Figure 4-17 Air Valve Assemblies
Figure 4-18 Air Valve & Air Fitting Assemblies
Section 5 Drive Train
Figure 5-1 Clutch Assembly
Figure 5-2 Clutch Release Bearing
Figure 5-3 Slave Valve Assembly
Figure 5-4 Transmission – Slave Control Assembly
Figure 5-5 Transmission – Slave Valve w/Hoses
Figure 5-6 Transmission – Clutch Housing
Figure 5-7 Transmission – Shift Bar Housing
Figure 5-8 Transmission – Reverse Idler, Input Shaft & Drive Gear
Figure 5-9 Transmission – Mainshaft & Countershaft Gears
Figure 5-10 Transmission – Auxiliary Mainshaft
Figure 5-11 Transmission – Auxiliary Case Assembly
Figure 5-12 Transmission – Range Cylinder
Figure 5-13 Transmission – Auxiliary Countershaft & Auxiliary Drive Gear
Figure 5-14 Transmission – Master Shift Valve Assembly
Figure 5-15 Propeller Shaft
Figure 5-16 Front Axle – Axle Assembly, 6X4
Figure 5-17 Front Axle – Steering Components, 6X4
Figure 5-18 Front Axle – Service Brakes, 6X4
Figure 5-19 Front Axle – Disc Wheel & Rims, 6X4
Figure 5-20 Front Axle – Spring Assembly
Figure 5-21 Rear Axle – Axle Assembly, 6X4
Figure 5-22 Rear Axle – Forward Housing
Figure 5-23 Rear Axle – Rear Housing
Figure 5-24 Rear Axle – Forward Differential Assembly
Figure 5-25 Rear Axle – Rear Differential Assembly
Figure 5-26 Rear Axle – Service Brake
Figure 5-27 Rear Axle – Disc Wheel & Rim
Figure 5-28 Equalizer Beams
Section 6 Cab
Figure 6-1 Cab Assembly, Upperstructure
Figure 6-2 Cab Assembly, Upperstructure
Figure 6-3 Cab Door Assembly, Upperstructure
Figure 6-4 Cab Interior Components, Upperstructure
Figure 6-5 Cab Console, Upperstructure
Figure 6-6 Seat Assembly, Upperstructure
Figure 6-7 Cab Heater & Installation, Upperstructure
Figure 6-8 Cab Assembly, Undercarriage
Figure 6-9 Cab Assembly, Undercarriage
Figure 6-10 Cab Door Assembly, Undercarriage
Figure 6-11 Seat Assembly, Undercarriage
Figure 6-12 Seat Suspension, Undercarriage
Figure 6-13 Heater & Defroster, Undercarriage
Figure 6-14 Pilot Cutoff Assembly
Section 7 Controls
Figure 7-1 Joystick Assembly
Figure 7-2 Steering Column Assembly
Figure 7-3 Steering Drive Shaft Assembly
Figure 7-4 Steering Drag Link Assembly
Figure 7-5 Foot Operated Pedal Valve Assembly
Figure 7-6 Foot Operated Pedal Plate Assembly
Section 8 Hydraulic Circuits
Figure 8-1 Hydraulic Oil Supply to Main Pump
Figure 8-2 Main Hydraulic Pump to Center Pin
Figure 8-3 Hydraulic Pressure from Center Pin to Control Valve
Figure 8-4 Main Valve to Pilot Manifold
Figure 8-5 Hydraulic Hosing To Joysticks & Foot Operated Pedal Valve
Figure 8-6 Upper Dump
Figure 8-7 Chassis Dump
Figure 8-8 Hoist Pilot
Figure 8-9 Boom Pilot
Figure 8-10 Tool Pilot
Figure 8-11 Tilt Pilot
Figure 8-12 Heater & Auxiliary Pilot
Figure 8-13 Hoist Cylinder
Figure 8-14 Boom Cylinder
Figure 8-15 Tool Cylinder
Figure 8-16 Swing & Swing Brake Pilot
Figure 8-17 Tool Pilot
Figure 8-18 Swing Motor
Figure 8-19 Tilt Motor
Figure 8-20 Steering Gear
Figure 8-21 Remote Propelling
Figure 8-22 Remote Steering
Figure 8-23 Stabilizer Cylinder
Section 9 Hydraulic Components
Figure 9-1 Hoist Cylinder Assembly
Figure 9-2 Boom Cylinder Assembly
Figure 9-3 Tool Cylinder Assembly
Figure 9-4 Stabilizer Cylinder Assembly
Figure 9-5 Stabilizer Valve Assembly
Figure 9-6 Remote Steering Hydraulic Cylinder Assembly
Figure 9-7 Front Main Pump
Figure 9-8 Rear Main Pump
Figure 9-9 Main Hydraulic Control Valve Assembly
Figure 9-10 Main Hydraulic Control Valve Assembly
Figure 9-11 Main Hydraulic Control Valve Assembly
Figure 9-12 Main Hydraulic Control Valve Kits
Figure 9-13 Pilot Manifold Valve Tray Hydraulic Components
Figure 9-14 Pilot Manifold Assembly
Figure 9-15 Reservoir Assembly
Figure 9-16 Swing Transmission Installation
Figure 9-17 Swing Transmission Assembly
Figure 9-18 Swing Motor Assembly
Figure 9-19 Swing Brake Assembly
Figure 9-20 Tilt Transmission
Figure 9-21 Tilt Transmission Assembly
Figure 9-22 Tilt Motor Assembly
Figure 9-23 Tilt Brake Assembly
Figure 9-24 Travel Motor
Figure 9-25 Center Pin Assembly
Figure 9-26 Power Take-Off Assembly
Figure 9-27 Power Take-Off Counter Shaft
Figure 9-28 Oil Cooler Assembly
Figure 9-29 Hydraulic Heater Pump Assembly
Figure 9-30 Hydraulic Heater Manifold Assembly
Figure 9-31 Steering Gear Assembly
Figure 9-32 Counterbalance Valve Assembly
Figure 9-33 Counterbalance Valve
Figure 9-34 Cooling Fan Valve Assembly
Figure 9-35 Steering Valve Assembly
Figure 9-36 Dual Solenoid Valve Assembly
Figure 9-37 Hoist Limit Valve
Section 10 Electrical
Figure 10-1 Miscellaneous Electrical Components, Upperstructure
Figure 10-2 Battery Box, Batteries & Cables
Figure 10-3 Tail & Marker Lights
Figure 10-4 Head & Marker Lights
Figure 10-5 Horn & Miscellaneous, Undercarriage
Figure 10-6 Cab Console Circuit Board, Upperstructure
Figure 10-7 Cab Console Circuit Board, Undercarriage
Figure 10-8 Instrument Panel
Figure 10-9 Accessory Panel
Section 11 Decals
Figure 11-1 Decals, Upperstructure
Figure 11-2 Decals, Undercarriage
Section 12 Options
Figure 12-1 Air Conditioner Installation Components, Upperstructure
Figure 12-2 ‘04 EPA Air Conditioner Installation (Undercarriage)
Figure 12-3 Air Conditioner Evaporator Kit
Figure 12-4 Block Heater Installation Components
Figure 12-5 Additional Battery Installation & Master Disconnect Switch Installation
Figure 12-6 Floodlight Installation Components
Figure 12-7 Grid Heater Installation Components
Figure 12-8 Locking Fuel Cap
Figure 12-9 Strobe Light Installation Components
Figure 12-10 Dual Air Horn Installation
Figure 12-11 Lube Chart Installation, (Upperstructure)
Figure 12-12 Drain Valve Installation
Figure 12-13 Fire Extinguisher Installation
Figure 12-14 Rail Gear Installation
Figure 12-15 Lube Chart Installation, (Chassis)
Figure 12-16 GVW Tag Installation (Chassis)
Figure 12-17 Strobe Light Installation
Figure 12-18 Brake Activated Lights Installation
Figure 12-19 Auxiliary Hydraulics
Recommended Spare Parts
Part Number Index
XL4100II Illustrated Parts Manual 31200199 2005.pdf (436 Pages)
Contents:
Service Kits
Section 1 Frame & Attaching Parts
Figure 1-1 Frame Assembly
Figure 1-2 Mirror & Grab Rails
Figure 1-3 Engine Cover
Figure 1-4 R.H. Fender & Mirrors
Figure 1-5 L.H. Fender
Figure 1-6 Rear Fender Assembly
Figure 1-7 Deck & Cover
Figure 1-8 Left Side Cover Assembly
Figure 1-9 Rotating Platform
Figure 1-10 Swing Bearing, Cradle & Hoist Cylinder Mounting & Lube System
Figure 1-11 Valve Cover
Section 2 Boom
Figure 2-1 Boom Cradle
Figure 2-2 Main Boom Assembly
Figure 2-3 Telescope Boom Assembly
Figure 2-4 Boom Roller Assemblies
Figure 2-5 Bucket Linkage
Section 3 Attachments
Figure 3-1 60” Ditching Bucket
Figure 3-2 Fixed Thumb Grapple Assembly
Section 4 Engine & Attaching Parts
Figure 4-1 Engine Assembly, L.H. View
Figure 4-2 Engine Assembly, R.H. View
Figure 4-3 Air Cleaner Assembly
Figure 4-4 Power Steering Reservoir Assembly
Figure 4-5 Exhaust System
Figure 4-6 Fuel Tank & Lines
Figure 4-7 Radiator & Cooler Assemblies
Figure 4-8 Oil Cooler & Hoses
Figure 4-9 Air Brake System
Figure 4-10 Spring Brake Control Valve & Parking Brake Valve Assemblies
Figure 4-11 Lockout Air Valve, Air Dryer & Adapter Assemblies
Figure 4-12 Air Valve Assemblies
Figure 4-13 Air Valve & Double Check Valve Assemblies
Figure 4-14 Air Reservoir Assemblies
Figure 4-15 Relay Valve Assemblies
Figure 4-16 Foot Pedal Valve & Air Fitting Assembly
Figure 4-17 Air Valve Assemblies
Figure 4-18 Air Valve & Air Fitting Assemblies
Section 5 Drive Train
Figure 5-1 Clutch Assembly
Figure 5-2 Clutch Release Bearing
Figure 5-3 Slave Valve Assembly
Figure 5-4 Transmission – Slave Control Assembly
Figure 5-5 Transmission – Slave Valve w/Hoses
Figure 5-6 Transmission – Clutch Housing
Figure 5-7 Transmission – Shift Bar Housing
Figure 5-8 Transmission – Reverse Idler, Input Shaft & Drive Gear
Figure 5-9 Transmission – Mainshaft & Countershaft Gears
Figure 5-10 Transmission – Auxiliary Mainshaft
Figure 5-11 Transmission – Auxiliary Case Assembly
Figure 5-12 Transmission – Range Cylinder
Figure 5-13 Transmission – Auxiliary Countershaft & Auxiliary Drive Gear
Figure 5-14 Transmission – Master Shift Valve Assembly
Figure 5-15 Propeller Shaft
Figure 5-16 Front Axle – Axle Assembly, 6X4
Figure 5-17 Front Axle – Steering Components, 6X4
Figure 5-18 Front Axle – Service Brakes, 6X4
Figure 5-19 Front Axle – Disc Wheel & Rims, 6X4
Figure 5-20 Front Axle – Spring Assembly
Figure 5-21 Rear Axle – Axle Assembly, 6X4
Figure 5-22 Rear Axle – Forward Housing
Figure 5-23 Rear Axle – Rear Housing
Figure 5-24 Rear Axle – Forward Differential Assembly
Figure 5-25 Rear Axle – Rear Differential Assembly
Figure 5-26 Rear Axle – Service Brake
Figure 5-27 Rear Axle – Disc Wheel & Rim
Figure 5-28 Equalizer Beams
Section 6 Cab
Figure 6-1 Cab Assembly, Upperstructure
Figure 6-2 Cab Assembly, Upperstructure
Figure 6-3 Cab Door Assembly, Upperstructure
Figure 6-4 Cab Interior Components, Upperstructure
Figure 6-5 Cab Console, Upperstructure
Figure 6-6 Seat Assembly, Upperstructure
Figure 6-7 Cab Heater & Installation, Upperstructure
Figure 6-8 Cab Assembly, Undercarriage
Figure 6-9 Cab Assembly, Undercarriage
Figure 6-10 Cab Door Assembly, Undercarriage
Figure 6-11 Seat Assembly, Undercarriage
Figure 6-12 Seat Suspension, Undercarriage
Figure 6-13 Heater & Defroster, Undercarriage
Figure 6-14 Pilot Cutoff Assembly
Section 7 Controls
Figure 7-1 Joystick Assembly
Figure 7-2 Steering Column Assembly
Figure 7-3 Steering Drive Shaft Assembly
Figure 7-4 Steering Drag Link Assembly
Figure 7-5 Foot Operated Pedal Valve Assembly
Figure 7-6 Foot Operated Pedal Plate Assembly
Section 8 Hydraulic Circuits
Figure 8-1 Hydraulic Oil Supply to Main Pump
Figure 8-2 Main Hydraulic Pump to Center Pin
Figure 8-3 Hydraulic Pressure from Center Pin to Control Valve
Figure 8-4 Main Valve to Pilot Manifold
Figure 8-5 Hydraulic Hosing To Joysticks & Foot Operated Pedal Valve
Figure 8-6 Upper Dump
Figure 8-7 Chassis Dump
Figure 8-8 Hoist Pilot
Figure 8-9 Boom Pilot
Figure 8-10 Tool Pilot
Figure 8-11 Tilt Pilot
Figure 8-12 Heater & Auxiliary Pilot
Figure 8-13 Hoist Cylinder
Figure 8-14 Boom Cylinder
Figure 8-15 Tool Cylinder
Figure 8-16 Swing & Swing Brake Pilot
Figure 8-17 Tool Pilot
Figure 8-18 Swing Motor
Figure 8-19 Tilt Motor
Figure 8-20 Steering Gear
Figure 8-21 Remote Propelling
Figure 8-22 Remote Steering
Figure 8-23 Stabilizer Cylinder
Section 9 Hydraulic Components
Figure 9-1 Hoist Cylinder Assembly
Figure 9-2 Boom Cylinder Assembly
Figure 9-3 Tool Cylinder Assembly
Figure 9-4 Stabilizer Cylinder Assembly
Figure 9-5 Stabilizer Valve Assembly
Figure 9-6 Remote Steering Hydraulic Cylinder Assembly
Figure 9-7 Front Main Pump
Figure 9-8 Rear Main Pump
Figure 9-9 Main Hydraulic Control Valve Assembly
Figure 9-10 Main Hydraulic Control Valve Assembly
Figure 9-11 Main Hydraulic Control Valve Assembly
Figure 9-12 Main Hydraulic Control Valve Kits
Figure 9-13 Pilot Manifold Valve Tray Hydraulic Components
Figure 9-14 Pilot Manifold Assembly
Figure 9-15 Reservoir Assembly
Figure 9-16 Swing Transmission Installation
Figure 9-17 Swing Transmission Assembly
Figure 9-18 Swing Motor Assembly
Figure 9-19 Swing Brake Assembly
Figure 9-20 Tilt Transmission
Figure 9-21 Tilt Transmission Assembly
Figure 9-22 Tilt Motor Assembly
Figure 9-23 Tilt Brake Assembly
Figure 9-24 Travel Motor
Figure 9-25 Center Pin Assembly
Figure 9-26 Power Take-Off Assembly
Figure 9-27 Power Take-Off Counter Shaft
Figure 9-28 Oil Cooler Assembly
Figure 9-29 Hydraulic Heater Pump Assembly
Figure 9-30 Hydraulic Heater Manifold Assembly
Figure 9-31 Steering Gear Assembly
Figure 9-32 Counterbalance Valve Assembly
Figure 9-33 Counterbalance Valve
Figure 9-34 Cooling Fan Valve Assembly
Figure 9-35 Steering Valve Assembly
Figure 9-36 Dual Solenoid Valve Assembly
Figure 9-37 Hoist Limit Valve
Section 10 Electrical
Figure 10-1 Miscellaneous Electrical Components, Upperstructure
Figure 10-2 Battery Box, Batteries & Cables
Figure 10-3 Tail & Marker Lights
Figure 10-4 Head & Marker Lights
Figure 10-5 Horn & Miscellaneous, Undercarriage
Figure 10-6 Cab Console Circuit Board, Upperstructure
Figure 10-7 Cab Console Circuit Board, Undercarriage
Figure 10-8 Instrument Panel
Figure 10-9 Accessory Panel
Section 11 Decals
Figure 11-1 Decals, Upperstructure
Figure 11-2 Decals, Undercarriage
Section 12 Options
Figure 12-1 Air Conditioner Installation Components, Upperstructure
Figure 12-2 ‘04 EPA Air Conditioner Installation (Undercarriage)
Figure 12-3 Air Conditioner Evaporator Kit
Figure 12-4 Additional Battery Installation Components
Figure 12-5 Floodlight Installation Components
Figure 12-6 Strobe Light Installation Components
Figure 12-7 Ansul Fire Extinguisher
Figure 12-8 Spark Arrestor Installation
Figure 12-9 Auxiliary Hydraulics
Figure 12-10 Chassis Lights Installation
Figure 12-11 Radio & Antenna Installation (Upperstructure)
Figure 12-12 Rail Gear Installation
Figure 12-13 Flare & Triangle Kit
Figure 12-14 Dual Air Horn Installation
Figure 12-15 AM/FM Cassette Stereo Installation
Figure 12-16 Strobe Light Installation
Figure 12-17 Tilt Steering Column Installation
Recommended Spare Parts
Part Number Index
XL4100II Illustrated Parts Manual 31200200 2005.pdf (444 Pages)
Contents:
Service Kits
Section 1 Frame & Attaching Parts
Figure 1-1 Frame Assembly
Figure 1-2 Mirror & Grab Rails
Figure 1-3 Engine Cover
Figure 1-4 R.H. Fender & Mirrors
Figure 1-5 L.H. Fender
Figure 1-6 Rear Fender Assembly
Figure 1-7 Deck & Cover
Figure 1-8 Left Side Cover Assembly
Figure 1-9 Rotating Platform
Figure 1-10 Swing Bearing, Cradle & Hoist Cylinder Mounting & Lube System
Figure 1-11 Valve Cover
Section 2 Boom
Figure 2-1 Boom Cradle
Figure 2-2 Main Boom Assembly
Figure 2-3 Telescope Boom Assembly
Figure 2-4 Boom Roller Assemblies
Figure 2-5 Bucket Linkage
Section 3 Attachments
Figure 3-1 72” Ditching Bucket
Figure 3-2 Fixed Thumb Grapple Assembly
Section 4 Engine & Attaching Parts
Figure 4-1 Engine Assembly, L.H. View
Figure 4-2 Engine Assembly, R.H. View
Figure 4-3 Air Cleaner Assembly
Figure 4-4 Power Steering Reservoir Assembly
Figure 4-5 Exhaust System
Figure 4-6 Fuel Tank & Lines
Figure 4-7 Radiator & Cooler Assemblies
Figure 4-8 Oil Cooler & Hoses
Figure 4-9 Air Brake System
Figure 4-10 Spring Brake Control Valve & Parking Brake Valve Assemblies
Figure 4-11 Lockout Air Valve, Air Dryer & Adapter Assemblies
Figure 4-12 Air Valve Assemblies
Figure 4-13 Air Valve & Double Check Valve Assemblies
Figure 4-14 Air Reservoir Assemblies
Figure 4-15 Relay Valve Assemblies
Figure 4-16 Foot Pedal Valve & Air Fitting Assembly
Figure 4-17 Air Valve Assemblies
Figure 4-18 Air Valve & Air Fitting Assemblies
Section 5 Drive Train
Figure 5-1 Clutch Assembly
Figure 5-2 Clutch Release Bearing
Figure 5-3 Slave Valve Assembly
Figure 5-4 Transmission – Slave Control Assembly
Figure 5-5 Transmission – Slave Valve w/Hoses
Figure 5-6 Transmission – Clutch Housing
Figure 5-7 Transmission – Shift Bar Housing
Figure 5-8 Transmission – Reverse Idler, Input Shaft & Drive Gear
Figure 5-9 Transmission – Mainshaft & Countershaft Gears
Figure 5-10 Transmission – Auxiliary Mainshaft
Figure 5-11 Transmission – Auxiliary Case Assembly
Figure 5-12 Transmission – Range Cylinder
Figure 5-13 Transmission – Auxiliary Countershaft & Auxiliary Drive Gear
Figure 5-14 Transmission – Master Shift Valve Assembly
Figure 5-15 Propeller Shaft
Figure 5-16 Transfer Case Assembly, 6X6
Figure 5-17 Front Axle – Axle Assembly, 6X4
Figure 5-18 Front Axle – Steering Components, 6X4
Figure 5-19 Front Axle – Service Brakes, 6X4
Figure 5-20 Front Axle – Disc Wheel & Rims, 6X4
Figure 5-21 Front Axle – Axle Assembly, 6X6
Figure 5-22 Front Axle – Housing Assembly, 6X6
Figure 5-23 Front Axle – Differential Assembly, 6X6
Figure 5-24 Front Axle – Steering Components, 6X6
Figure 5-25 Front Axle – Service Brake, 6X6
Figure 5-26 Front Axle – Disc Wheels & Rims, 6X6
Figure 5-27 Front Axle – Spring Assembly
Figure 5-28 Rear Axle – Axle Assembly, 6X4
Figure 5-29 Rear Axle – Axle Assembly, 6X6
Figure 5-30 Rear Axle – Forward Housing
Figure 5-31 Rear Axle – Rear Housing
Figure 5-32 Rear Axle – Forward Differential Assembly
Figure 5-33 Rear Axle – Rear Differential Assembly
Figure 5-34 Rear Axle – Service Brake
Figure 5-35 Rear Axle – Disc Wheel & Rim
Figure 5-36 Equalizer Beams
Section 6 Cab
Figure 6-1 Cab Assembly, Upperstructure
Figure 6-2 Cab Assembly, Upperstructure
Figure 6-3 Cab Door Assembly, Upperstructure
Figure 6-4 Cab Interior Components, Upperstructure
Figure 6-5 Cab Console, Upperstructure
Figure 6-6 Seat Assembly, Upperstructure
Figure 6-7 Cab Heater & Installation, Upperstructure
Figure 6-8 Cab Assembly, Undercarriage
Figure 6-9 Cab Assembly, Undercarriage
Figure 6-10 Cab Door Assembly, Undercarriage
Figure 6-11 Seat Assembly, Undercarriage
Figure 6-12 Seat Suspension, Undercarriage
Figure 6-13 Heater & Defroster, Undercarriage
Figure 6-14 Pilot Cutoff Assembly
Section 7 Controls
Figure 7-1 Joystick Assembly
Figure 7-2 Steering Column Assembly
Figure 7-3 Steering Drive Shaft Assembly
Figure 7-4 Steering Drag Link Assembly
Figure 7-5 Foot Operated Pedal Valve Assembly
Figure 7-6 Foot Operated Pedal Plate Assembly
Section 8 Hydraulic Circuits
Figure 8-1 Hydraulic Oil Supply to Main Pump
Figure 8-2 Main Hydraulic Pump to Center Pin
Figure 8-3 Hydraulic Pressure from Center Pin to Control Valve
Figure 8-4 Main Valve to Pilot Manifold
Figure 8-5 Hydraulic Hosing To Joysticks & Foot Operated Pedal Valve
Figure 8-6 Upper Dump
Figure 8-7 Chassis Dump
Figure 8-8 Hoist Pilot
Figure 8-9 Boom Pilot
Figure 8-10 Tool Pilot
Figure 8-11 Tilt Pilot
Figure 8-12 Heater & Auxiliary Pilot
Figure 8-13 Hoist Cylinder
Figure 8-14 Boom Cylinder
Figure 8-15 Tool Cylinder
Figure 8-16 Swing & Swing Brake Pilot
Figure 8-17 Tool Pilot
Figure 8-18 Swing Motor
Figure 8-19 Tilt Motor
Figure 8-20 Steering Gear
Figure 8-21 Remote Propelling
Figure 8-22 Remote Steering
Figure 8-23 Stabilizer Cylinder
Section 9 Hydraulic Components
Figure 9-1 Hoist Cylinder Assembly
Figure 9-2 Boom Cylinder Assembly
Figure 9-3 Tool Cylinder Assembly
Figure 9-4 Stabilizer Cylinder Assembly
Figure 9-5 Stabilizer Valve Assembly
Figure 9-6 Remote Steering Hydraulic Cylinder Assembly
Figure 9-7 Front Main Pump
Figure 9-8 Rear Main Pump
Figure 9-9 Main Hydraulic Control Valve Assembly
Figure 9-10 Main Hydraulic Control Valve Assembly
Figure 9-11 Main Hydraulic Control Valve Assembly
Figure 9-12 Main Hydraulic Control Valve Kits
Figure 9-13 Pilot Manifold Valve Tray Hydraulic Components
Figure 9-14 Pilot Manifold Assembly
Figure 9-15 Reservoir Assembly
Figure 9-16 Swing Transmission Installation
Figure 9-17 Swing Transmission Assembly
Figure 9-18 Swing Motor Assembly
Figure 9-19 Swing Brake Assembly
Figure 9-20 Tilt Transmission
Figure 9-21 Tilt Transmission Assembly
Figure 9-22 Tilt Motor Assembly
Figure 9-23 Tilt Brake Assembly
Figure 9-24 Travel Motor
Figure 9-25 Center Pin Assembly
Figure 9-26 Power Take-Off Assembly
Figure 9-27 Power Take-Off Counter Shaft
Figure 9-28 Oil Cooler Assembly
Figure 9-29 Hydraulic Heater Pump Assembly
Figure 9-30 Hydraulic Heater Manifold Assembly
Figure 9-31 Steering Gear Assembly
Figure 9-32 Counterbalance Valve Assembly
Figure 9-33 Counterbalance Valve
Figure 9-34 Cooling Fan Valve Assembly
Figure 9-35 Steering Valve Assembly
Figure 9-36 Dual Solenoid Valve Assembly
Figure 9-37 Hoist Limit Valve
Section 10 Electrical
Figure 10-1 Miscellaneous Electrical Components, Upperstructure
Figure 10-2 Battery Box, Batteries & Cables
Figure 10-3 Tail & Marker Lights
Figure 10-4 Head & Marker Lights
Figure 10-5 Horn & Miscellaneous, Undercarriage
Figure 10-6 Cab Console Circuit Board, Upperstructure
Figure 10-7 Cab Console Circuit Board, Undercarriage
Figure 10-8 Instrument Panel
Figure 10-9 Accessory Panel
Section 11 Decals
Figure 11-1 Decals, Upperstructure
Figure 11-2 Decals, Undercarriage
Section 12 Options
Figure 12-1 Air Conditioner Installation Components, Upperstructure
Figure 12-2 ‘04 EPA Air Conditioner Installation
Figure 12-3 Air Conditioner Evaporator Kit
Figure 12-4 Locking Fuel Cap
Figure 12-5 Seat Belt Installation Components
Figure 12-6 Back-Up Alarm Installation
Figure 12-7 Fire Extinguisher Installation
Figure 12-8 Chassis Lights Installation
Figure 12-9 Mudflap Installation
Figure 12-10 Strobe Light Installation
Figure 12-11 Locking Toolbox
Figure 12-12 Fire Extinguisher Installation
Recommended Spare Parts
Part Number Index
XL4100II Illustrated Parts Manual 31200210 2005.pdf (442 Pages)
Contents:
Service Kits
Section 1 Frame & Attaching Parts
Figure 1-1 Frame Assembly
Figure 1-2 Mirror & Grab Rails
Figure 1-3 Engine Cover
Figure 1-4 R.H. Fender & Mirrors
Figure 1-5 L.H. Fender
Figure 1-6 Rear Fender Assembly
Figure 1-7 Deck & Cover
Figure 1-8 Left Side Cover Assembly
Figure 1-9 Rotating Platform
Figure 1-10 Swing Bearing, Cradle & Hoist Cylinder Mounting & Lube System
Figure 1-11 Valve Cover
Section 2 Boom
Figure 2-1 Boom Cradle
Figure 2-2 Main Boom Assembly
Figure 2-3 Telescope Boom Assembly
Figure 2-4 Boom Roller Assemblies
Figure 2-5 Bucket Linkage
Section 3 Attachments
Figure 3-1 60” Ditching Bucket
Figure 3-2 Fixed Thumb Grapple Assembly
Section 4 Engine & Attaching Parts
Figure 4-1 Engine Assembly, L.H. View
Figure 4-2 Engine Assembly, R.H. View
Figure 4-3 Air Cleaner Assembly
Figure 4-4 Power Steering Reservoir Assembly
Figure 4-5 Exhaust System
Figure 4-6 Fuel Tank & Lines
Figure 4-7 Radiator & Cooler Assemblies
Figure 4-8 Oil Cooler & Hoses
Figure 4-9 Air Brake System
Figure 4-10 Spring Brake Control Valve & Parking Brake Valve Assemblies
Figure 4-11 Lockout Air Valve, Air Dryer & Adapter Assemblies
Figure 4-12 Air Valve Assemblies
Figure 4-13 Air Valve & Double Check Valve Assemblies
Figure 4-14 Air Reservoir Assemblies
Figure 4-15 Relay Valve Assemblies
Figure 4-16 Foot Pedal Valve & Air Fitting Assembly
Figure 4-17 Air Valve Assemblies
Figure 4-18 Air Valve & Air Fitting Assemblies
Section 5 Drive Train
Figure 5-1 Clutch Assembly
Figure 5-2 Clutch Release Bearing
Figure 5-3 Slave Valve Assembly
Figure 5-4 Transmission – Slave Control Assembly
Figure 5-5 Transmission – Slave Valve w/Hoses
Figure 5-6 Transmission – Clutch Housing
Figure 5-7 Transmission – Shift Bar Housing
Figure 5-8 Transmission – Reverse Idler, Input Shaft & Drive Gear
Figure 5-9 Transmission – Mainshaft & Countershaft Gears
Figure 5-10 Transmission – Auxiliary Mainshaft
Figure 5-11 Transmission – Auxiliary Case Assembly
Figure 5-12 Transmission – Range Cylinder
Figure 5-13 Transmission – Auxiliary Countershaft & Auxiliary Drive Gear
Figure 5-14 Transmission – Master Shift Valve Assembly
Figure 5-15 Propeller Shaft
Figure 5-16 Transfer Case Assembly, 6X6
Figure 5-17 Front Axle – Axle Assembly, 6X6
Figure 5-18 Front Axle – Housing Assembly, 6X6
Figure 5-19 Front Axle – Differential Assembly, 6X6
Figure 5-20 Front Axle – Steering Components, 6X6
Figure 5-21 Front Axle – Service Brake, 6X6
Figure 5-22 Front Axle – Disc Wheels & Rims, 6X6
Figure 5-23 Front Axle – Spring Assembly
Figure 5-24 Rear Axle – Axle Assembly, 6X6
Figure 5-25 Rear Axle – Forward Housing
Figure 5-26 Rear Axle – Rear Housing
Figure 5-27 Rear Axle – Forward Differential Assembly
Figure 5-28 Rear Axle – Rear Differential Assembly
Figure 5-29 Rear Axle – Service Brake
Figure 5-30 Rear Axle – Disc Wheel & Rim
Figure 5-31 Equalizer Beams
Section 6 Cab
Figure 6-1 Cab Assembly, Upperstructure
Figure 6-2 Cab Assembly, Upperstructure
Figure 6-3 Cab Door Assembly, Upperstructure
Figure 6-4 Cab Interior Components, Upperstructure
Figure 6-5 Cab Console, Upperstructure
Figure 6-6 Seat Assembly, Upperstructure
Figure 6-7 Cab Heater & Installation, Upperstructure
Figure 6-8 Cab Assembly, Undercarriage
Figure 6-9 Cab Assembly, Undercarriage
Figure 6-10 Cab Door Assembly, Undercarriage
Figure 6-11 Seat Assembly, Undercarriage
Figure 6-12 Seat Suspension, Undercarriage
Figure 6-13 Heater & Defroster, Undercarriage
Figure 6-14 Pilot Cutoff Assembly
Section 7 Controls
Figure 7-1 Joystick Assembly
Figure 7-2 Steering Column Assembly
Figure 7-3 Steering Drive Shaft Assembly
Figure 7-4 Steering Drag Link Assembly
Figure 7-5 Foot Operated Pedal Valve Assembly
Figure 7-6 Foot Operated Pedal Plate Assembly
Section 8 Hydraulic Circuits
Figure 8-1 Hydraulic Oil Supply to Main Pump
Figure 8-2 Main Hydraulic Pump to Center Pin
Figure 8-3 Hydraulic Pressure from Center Pin to Control Valve
Figure 8-4 Main Valve to Pilot Manifold
Figure 8-5 Hydraulic Hosing To Joysticks & Foot Operated Pedal Valve
Figure 8-6 Upper Dump
Figure 8-7 Chassis Dump
Figure 8-8 Hoist Pilot
Figure 8-9 Boom Pilot
Figure 8-10 Tool Pilot
Figure 8-11 Tilt Pilot
Figure 8-12 Heater & Auxiliary Pilot
Figure 8-13 Hoist Cylinder
Figure 8-14 Boom Cylinder
Figure 8-15 Tool Cylinder
Figure 8-16 Swing & Swing Brake Pilot
Figure 8-17 Tool Pilot
Figure 8-18 Swing Motor
Figure 8-19 Tilt Motor
Figure 8-20 Steering Gear
Figure 8-21 Remote Propelling
Figure 8-22 Remote Steering
Figure 8-23 Stabilizer Cylinder
Section 9 Hydraulic Components
Figure 9-1 Hoist Cylinder Assembly
Figure 9-2 Boom Cylinder Assembly
Figure 9-3 Tool Cylinder Assembly
Figure 9-4 Stabilizer Cylinder Assembly
Figure 9-5 Stabilizer Valve Assembly
Figure 9-6 Remote Steering Hydraulic Cylinder Assembly
Figure 9-7 Front Main Pump
Figure 9-8 Rear Main Pump
Figure 9-9 Main Hydraulic Control Valve Assembly
Figure 9-10 Main Hydraulic Control Valve Assembly
Figure 9-11 Main Hydraulic Control Valve Assembly
Figure 9-12 Main Hydraulic Control Valve Kits
Figure 9-13 Pilot Manifold Valve Tray Hydraulic Components
Figure 9-14 Pilot Manifold Assembly
Figure 9-15 Reservoir Assembly
Figure 9-16 Swing Transmission Installation
Figure 9-17 Swing Transmission Assembly
Figure 9-18 Swing Motor Assembly
Figure 9-19 Swing Brake Assembly
Figure 9-20 Tilt Transmission
Figure 9-21 Tilt Transmission Assembly
Figure 9-22 Tilt Motor Assembly
Figure 9-23 Tilt Brake Assembly
Figure 9-24 Travel Motor
Figure 9-25 Center Pin Assembly
Figure 9-26 Power Take-Off Assembly
Figure 9-27 Power Take-Off Counter Shaft
Figure 9-28 Oil Cooler Assembly
Figure 9-29 Hydraulic Heater Pump Assembly
Figure 9-30 Hydraulic Heater Manifold Assembly
Figure 9-31 Steering Gear Assembly
Figure 9-32 Counterbalance Valve Assembly
Figure 9-33 Counterbalance Valve
Figure 9-34 Cooling Fan Valve Assembly
Figure 9-35 Steering Valve Assembly
Figure 9-36 Dual Solenoid Valve Assembly
Figure 9-37 Hoist Limit Valve
Section 10 Electrical
Figure 10-1 Miscellaneous Electrical Components, Upperstructure
Figure 10-2 Battery Box, Batteries & Cables
Figure 10-3 Tail & Marker Lights
Figure 10-4 Head & Marker Lights
Figure 10-5 Horn & Miscellaneous, Undercarriage
Figure 10-6 Cab Console Circuit Board, Upperstructure
Figure 10-7 Cab Console Circuit Board, Undercarriage
Figure 10-8 Instrument Panel
Figure 10-9 Accessory Panel
Section 11 Decals
Figure 11-1 Decals, Upperstructure
Figure 11-2 Decals, Undercarriage
Section 12 Options
Figure 12-1 Air Conditioner Installation Components, Upperstructure
Figure 12-2 ‘04 EPA Air Conditioner Installation
Figure 12-3 Air Conditioner Evaporator Kit
Figure 12-4 Locking Fuel Cap
Figure 12-5 Fire Extinguisher Installation
Figure 12-6 Seat Belt Installation Components
Figure 12-7 Strobe Light Installation Components
Figure 12-8 Worklight Package
Figure 12-9 Fire Extinguisher Installation
Figure 12-10 Strobe Light Installation
Figure 12-11 Back-Up Alarm Installation
Figure 12-12 Mudflap Installation
Figure 12-13 Locking Toolbox
Figure 12-14 Radio & Antenna Installation (Upperstructure)
Figure 12-15 Auxiliary Hydraulics
Recommended Spare Parts
Part Number Index
XL4100II Illustrated Parts Manual 31200211 2016.pdf (452 Pages)
Contents:
Service Kits
Section 1 Frame & Attaching Parts
Figure 1-1 Frame Assembly
Figure 1-2 Mirror & Grab Rails
Figure 1-3 Engine Cover
Figure 1-4 R.H. Fender & Mirrors
Figure 1-5 L.H. Fender
Figure 1-6 Rear Fender Assembly
Figure 1-7 Deck & Cover
Figure 1-8 Left Side Cover Assembly
Figure 1-9 Rotating Platform
Figure 1-10 Swing Bearing, Cradle & Hoist Cylinder Mounting & Lube System
Figure 1-11 Valve Cover
Section 2 Boom
Figure 2-1 Boom Cradle
Figure 2-2 Main Boom Assembly
Figure 2-3 Telescope Boom Assembly
Figure 2-4 Boom Roller Assemblies
Figure 2-5 Bucket Linkage
Section 3 Attachments
Figure 3-1 24” Excavating Buckets
Figure 3-2 36” Excavating Buckets
Figure 3-3 60” Ditching Bucket
Section 4 Engine & Attaching Parts
Figure 4-1 Engine Assembly, L.H. View
Figure 4-2 Engine Assembly, R.H. View
Figure 4-3 Air Cleaner Assembly
Figure 4-4 Power Steering Reservoir Assembly
Figure 4-5 Exhaust System
Figure 4-6 Fuel Tank & Lines
Figure 4-7 Radiator & Cooler Assemblies
Figure 4-8 Oil Cooler & Hoses
Figure 4-9 Air Brake System
Figure 4-10 Spring Brake Control Valve & Parking Brake Valve Assemblies
Figure 4-11 Lockout Air Valve, Air Dryer & Adapter Assemblies
Figure 4-12 Air Valve Assemblies
Figure 4-13 Air Valve & Double Check Valve Assemblies
Figure 4-14 Air Reservoir Assemblies
Figure 4-15 Relay Valve Assemblies
Figure 4-16 Foot Pedal Valve & Air Fitting Assembly
Figure 4-17 Air Valve Assemblies
Figure 4-18 Air Valve & Air Fitting Assemblies
Section 5 Drive Train
Figure 5-1 Clutch Assembly
Figure 5-2 Clutch Release Bearing
Figure 5-3 Slave Valve Assembly
Figure 5-4 Transmission – Slave Control Assembly
Figure 5-5 Transmission – Slave Valve w/Hoses
Figure 5-6 Transmission – Clutch Housing
Figure 5-7 Transmission – Shift Bar Housing
Figure 5-8 Transmission – Reverse Idler, Input Shaft & Drive Gear
Figure 5-9 Transmission – Mainshaft & Countershaft Gears
Figure 5-10 Transmission – Auxiliary Mainshaft
Figure 5-11 Transmission – Auxiliary Case Assembly
Figure 5-12 Transmission – Range Cylinder
Figure 5-13 Transmission – Auxiliary Countershaft & Auxiliary Drive Gear
Figure 5-14 Transmission – Master Shift Valve Assembly
Figure 5-15 Propeller Shaft
Figure 5-16 Front Axle – Axle Assembly, 6X4
Figure 5-17 Front Axle – Steering Components, 6X4
Figure 5-18 Front Axle – Service Brakes, 6X4
Figure 5-19 Front Axle – Disc Wheel & Rims, 6X4
Figure 5-20 Front Axle – Spring Assembly
Figure 5-21 Rear Axle – Axle Assembly, 6X4
Figure 5-22 Rear Axle – Forward Housing
Figure 5-23 Rear Axle – Rear Housing
Figure 5-24 Rear Axle – Forward Differential Assembly
Figure 5-25 Rear Axle – Rear Differential Assembly
Figure 5-26 Rear Axle – Service Brake
Figure 5-27 Rear Axle – Disc Wheel & Rim
Figure 5-28 Equalizer Beams
Section 6 Cab
Figure 6-1 Cab Assembly, Upperstructure
Figure 6-2 Cab Assembly, Upperstructure
Figure 6-3 Cab Door Assembly, Upperstructure
Figure 6-4 Cab Interior Components, Upperstructure
Figure 6-5 Cab Console, Upperstructure
Figure 6-6 Seat Assembly, Upperstructure
Figure 6-7 Cab Heater & Installation, Upperstructure
Figure 6-8 Cab Assembly, Undercarriage
Figure 6-9 Cab Assembly, Undercarriage
Figure 6-10 Cab Door Assembly, Undercarriage
Figure 6-11 Seat Assembly, Undercarriage
Figure 6-12 Seat Suspension, Undercarriage
Figure 6-13 Heater & Defroster, Undercarriage
Figure 6-14 Pilot Cutoff Assembly
Section 7 Controls
Figure 7-1 Joystick Assembly
Figure 7-2 Steering Column Assembly
Figure 7-3 Steering Drive Shaft Assembly
Figure 7-4 Steering Drag Link Assembly
Figure 7-5 Foot Operated Pedal Valve Assembly
Figure 7-6 Foot Operated Pedal Plate Assembly
Section 8 Hydraulic Circuits
Figure 8-1 Hydraulic Oil Supply to Main Pump
Figure 8-2 Main Hydraulic Pump to Center Pin
Figure 8-3 Hydraulic Pressure from Center Pin to Control Valve
Figure 8-4 Main Valve to Pilot Manifold
Figure 8-5 Hydraulic Hosing To Joysticks & Foot Operated Pedal Valve
Figure 8-6 Upper Dump
Figure 8-7 Chassis Dump
Figure 8-8 Hoist Pilot
Figure 8-9 Boom Pilot
Figure 8-10 Tool Pilot
Figure 8-11 Tilt Pilot
Figure 8-12 Heater & Auxiliary Pilot
Figure 8-13 Hoist Cylinder
Figure 8-14 Boom Cylinder
Figure 8-15 Tool Cylinder
Figure 8-16 Swing & Swing Brake Pilot
Figure 8-17 Tool Pilot
Figure 8-18 Swing Motor
Figure 8-19 Tilt Motor
Figure 8-20 Steering Gear
Figure 8-21 Remote Propelling
Figure 8-22 Remote Steering
Figure 8-23 Stabilizer Cylinder
Section 9 Hydraulic Components
Figure 9-1 Hoist Cylinder Assembly
Figure 9-2 Boom Cylinder Assembly
Figure 9-3 Tool Cylinder Assembly
Figure 9-4 Stabilizer Cylinder Assembly
Figure 9-5 Stabilizer Valve Assembly
Figure 9-6 Remote Steering Hydraulic Cylinder Assembly
Figure 9-7 Front Main Pump
Figure 9-8 Rear Main Pump
Figure 9-9 Main Hydraulic Control Valve Assembly
Figure 9-10 Main Hydraulic Control Valve Assembly
Figure 9-11 Main Hydraulic Control Valve Assembly
Figure 9-12 Main Hydraulic Control Valve Kits
Figure 9-13 Pilot Manifold Valve Tray Hydraulic Components
Figure 9-14 Pilot Manifold Assembly
Figure 9-15 Reservoir Assembly
Figure 9-16 Swing Transmission Installation
Figure 9-17 Swing Transmission Assembly
Figure 9-18 Swing Motor Assembly
Figure 9-19 Swing Brake Assembly
Figure 9-20 Tilt Transmission
Figure 9-21 Tilt Transmission Assembly
Figure 9-22 Tilt Motor Assembly
Figure 9-23 Tilt Brake Assembly
Figure 9-24 Travel Motor
Figure 9-25 Center Pin Assembly
Figure 9-26 Power Take-Off Assembly
Figure 9-27 Power Take-Off Counter Shaft
Figure 9-28 Oil Cooler Assembly
Figure 9-29 Hydraulic Heater Pump Assembly
Figure 9-30 Hydraulic Heater Manifold Assembly
Figure 9-31 Steering Gear Assembly
Figure 9-32 Counterbalance Valve Assembly
Figure 9-33 Counterbalance Valve
Figure 9-34 Cooling Fan Valve Assembly
Figure 9-35 Steering Valve Assembly
Figure 9-36 Dual Solenoid Valve Assembly
Figure 9-37 Hoist Limit Valve
Section 10 Electrical
Figure 10-1 Miscellaneous Electrical Components, Upperstructure
Figure 10-2 Battery Box, Batteries & Cables
Figure 10-3 Tail & Marker Lights
Figure 10-4 Head & Marker Lights
Figure 10-5 Horn & Miscellaneous, Undercarriage
Figure 10-6 Cab Console Circuit Board, Upperstructure
Figure 10-7 Cab Console Circuit Board, Undercarriage
Figure 10-8 Instrument Panel
Figure 10-9 Accessory Panel
Section 11 Decals
Figure 11-1 Decals, Upperstructure
Figure 11-2 Decals, Undercarriage
Section 12 Options
Figure 12-1 Air Conditioner Installation Components, Upperstructure
Figure 12-2 ‘04 EPA Air Conditioner Installation, (Undercarriage)
Figure 12-3 Air Conditioner Evaporator Kit
Figure 12-4 Additional Battery Installation Components
Figure 12-5 Block Heater Installation Components
Figure 12-6 Strobe Light Installation Components
Figure 12-7 Step Tread Installation
Figure 12-8 Stemco Seal Installation, Rear Axle
Figure 12-9 Stemco Seal Installation, Front Axle
Figure 12-10 Floodlight Installation Components
Figure 12-11 Fire Extinguisher Installation, (Upperstructure)
Figure 12-12 Lube Chart Installation, (Upperstructure)
Figure 12-13 Air Restriction Gauge Installation
Figure 12-14 Strobe Light Installation, (Undercarriage)
Figure 12-15 Drain Valve Installation
Figure 12-16 Two-Way Radio Power Installation
Figure 12-17 Cigarette Lighter
Figure 12-18 Fuel Warmer & Coolant Filter Installation
Figure 12-19 Fire Extinguisher Installation, (Undercarriage)
Figure 12-20 Lube Chart Installation, (Undercarriage)
Figure 12-21 Rear Window Cover Installation, (Undercarriage)
Figure 12-22 Rubber Battery Pad Installation
Figure 12-23 GVWR Plate Installation
Figure 12-24 Flare & Triangle Kit
Figure 12-25 Synthetic Fluid Installation
Recommended Spare Parts
Part Number Index
XL4100II Illustrated Parts Manual 31200224 2006.pdf (438 Pages)
Contents:
Service Kits
Section 1 Frame & Attaching Parts
Figure 1-1 Frame Assembly
Figure 1-2 Mirror & Grab Rails
Figure 1-3 Engine Cover
Figure 1-4 R.H. Fender & Mirrors
Figure 1-5 L.H. Fender
Figure 1-6 Rear Fender Assembly
Figure 1-7 Deck & Cover
Figure 1-8 Left Side Cover Assembly
Figure 1-9 Rotating Platform
Figure 1-10 Swing Bearing, Cradle & Hoist Cylinder Mounting & Lube System
Figure 1-11 Valve Cover
Section 2 Boom
Figure 2-1 Boom Cradle
Figure 2-2 Main Boom Assembly
Figure 2-3 Telescope Boom Assembly
Figure 2-4 Boom Roller Assemblies
Figure 2-5 Bucket Linkage
Section 3 Attachments
Figure 3-1 60” Ditching Bucket
Figure 3-2 72” Dredging Bucket
Figure 3-3 Fixed Thumb Grapple Assembly
Figure 3-4 Telestick
Section 4 Engine & Attaching Parts
Figure 4-1 Engine Assembly, L.H. View
Figure 4-2 Engine Assembly, R.H. View
Figure 4-3 Air Cleaner Assembly
Figure 4-4 Power Steering Reservoir Assembly
Figure 4-5 Exhaust System
Figure 4-6 Fuel Tank & Lines
Figure 4-7 Radiator & Cooler Assemblies
Figure 4-8 Oil Cooler & Hoses
Figure 4-9 Air Brake System
Figure 4-10 Spring Brake Control Valve & Parking Brake Valve Assemblies
Figure 4-11 Lockout Air Valve, Air Dryer & Adapter Assemblies
Figure 4-12 Air Valve Assemblies
Figure 4-13 Air Valve & Double Check Valve Assemblies
Figure 4-14 Air Reservoir Assemblies
Figure 4-15 Relay Valve Assemblies
Figure 4-16 Foot Pedal Valve & Air Fitting Assembly
Figure 4-17 Air Valve Assemblies
Figure 4-18 Air Valve & Air Fitting Assemblies
Section 5 Drive Train
Figure 5-1 Clutch Assembly
Figure 5-2 Clutch Release Bearing
Figure 5-3 Slave Valve Assembly
Figure 5-4 Transmission – Slave Control Assembly
Figure 5-5 Transmission – Slave Valve w/Hoses
Figure 5-6 Transmission – Clutch Housing
Figure 5-7 Transmission – Shift Bar Housing
Figure 5-8 Transmission – Reverse Idler, Input Shaft & Drive Gear
Figure 5-9 Transmission – Mainshaft & Countershaft Gears
Figure 5-10 Transmission – Auxiliary Mainshaft
Figure 5-11 Transmission – Auxiliary Case Assembly
Figure 5-12 Transmission – Range Cylinder
Figure 5-13 Transmission – Auxiliary Countershaft & Auxiliary Drive Gear
Figure 5-14 Transmission – Master Shift Valve Assembly
Figure 5-15 Propeller Shaft
Figure 5-16 Transfer Case Assembly, 6X6
Figure 5-17 Front Axle – Axle Assembly, 6X6
Figure 5-18 Front Axle – Housing Assembly, 6X6
Figure 5-19 Front Axle – Differential Assembly, 6X6
Figure 5-20 Front Axle – Steering Components, 6X6
Figure 5-21 Front Axle – Service Brake, 6X6
Figure 5-22 Front Axle – Disc Wheels & Rims, 6X6
Figure 5-23 Front Axle – Spring Assembly
Figure 5-24 Rear Axle – Axle Assembly, 6X6
Figure 5-25 Rear Axle – Forward Housing
Figure 5-26 Rear Axle – Rear Housing
Figure 5-27 Rear Axle – Forward Differential Assembly
Figure 5-28 Rear Axle – Rear Differential Assembly
Figure 5-29 Rear Axle – Service Brake
Figure 5-30 Rear Axle – Disc Wheel & Rim
Figure 5-31 Equalizer Beams
Section 6 Cab
Figure 6-1 Cab Assembly, Upperstructure
Figure 6-2 Cab Assembly, Upperstructure
Figure 6-3 Cab Door Assembly, Upperstructure
Figure 6-4 Cab Interior Components, Upperstructure
Figure 6-5 Cab Console, Upperstructure
Figure 6-6 Seat Assembly, Upperstructure
Figure 6-7 Cab Heater & Installation, Upperstructure
Figure 6-8 Cab Assembly, Undercarriage
Figure 6-9 Cab Assembly, Undercarriage
Figure 6-10 Cab Door Assembly, Undercarriage
Figure 6-11 Seat Assembly, Undercarriage
Figure 6-12 Seat Suspension, Undercarriage
Figure 6-13 Heater & Defroster, Undercarriage
Figure 6-14 Pilot Cutoff Assembly
Section 7 Controls
Figure 7-1 Joystick Assembly
Figure 7-2 Steering Column Assembly
Figure 7-3 Steering Drive Shaft Assembly
Figure 7-4 Steering Drag Link Assembly
Figure 7-5 Foot Operated Pedal Valve Assembly
Figure 7-6 Foot Operated Pedal Plate Assembly
Section 8 Hydraulic Circuits
Figure 8-1 Hydraulic Oil Supply to Main Pump
Figure 8-2 Main Hydraulic Pump to Center Pin
Figure 8-3 Hydraulic Pressure from Center Pin to Control Valve
Figure 8-4 Main Valve to Pilot Manifold
Figure 8-5 Hydraulic Hosing To Joysticks & Foot Operated Pedal Valve
Figure 8-6 Upper Dump
Figure 8-7 Chassis Dump
Figure 8-8 Hoist Pilot
Figure 8-9 Boom Pilot
Figure 8-10 Tool Pilot
Figure 8-11 Tilt Pilot
Figure 8-12 Heater & Auxiliary Pilot
Figure 8-13 Hoist Cylinder
Figure 8-14 Boom Cylinder
Figure 8-15 Tool Cylinder
Figure 8-16 Swing & Swing Brake Pilot
Figure 8-17 Tool Pilot
Figure 8-18 Swing Motor
Figure 8-19 Tilt Motor
Figure 8-20 Steering Gear
Figure 8-21 Remote Propelling
Figure 8-22 Remote Steering
Figure 8-23 Stabilizer Cylinder
Section 9 Hydraulic Components
Figure 9-1 Hoist Cylinder Assembly
Figure 9-2 Boom Cylinder Assembly
Figure 9-3 Tool Cylinder Assembly
Figure 9-4 Stabilizer Cylinder Assembly
Figure 9-5 Stabilizer Valve Assembly
Figure 9-6 Remote Steering Hydraulic Cylinder Assembly
Figure 9-7 Front Main Pump
Figure 9-8 Rear Main Pump
Figure 9-9 Main Hydraulic Control Valve Assembly
Figure 9-10 Main Hydraulic Control Valve Assembly
Figure 9-11 Main Hydraulic Control Valve Assembly
Figure 9-12 Main Hydraulic Control Valve Kits
Figure 9-13 Pilot Manifold Valve Tray Hydraulic Components
Figure 9-14 Pilot Manifold Assembly
Figure 9-15 Reservoir Assembly
Figure 9-16 Swing Transmission Installation
Figure 9-17 Swing Transmission Assembly
Figure 9-18 Swing Motor Assembly
Figure 9-19 Swing Brake Assembly
Figure 9-20 Tilt Transmission
Figure 9-21 Tilt Transmission Assembly
Figure 9-22 Tilt Motor Assembly
Figure 9-23 Tilt Brake Assembly
Figure 9-24 Travel Motor
Figure 9-25 Center Pin Assembly
Figure 9-26 Power Take-Off Assembly
Figure 9-27 Power Take-Off Counter Shaft
Figure 9-28 Oil Cooler Assembly
Figure 9-29 Hydraulic Heater Pump Assembly
Figure 9-30 Hydraulic Heater Manifold Assembly
Figure 9-31 Steering Gear Assembly
Figure 9-32 Counterbalance Valve Assembly
Figure 9-33 Counterbalance Valve
Figure 9-34 Cooling Fan Valve Assembly
Figure 9-35 Steering Valve Assembly
Figure 9-36 Dual Solenoid Valve Assembly
Figure 9-37 Hoist Limit Valve
Section 10 Electrical
Figure 10-1 Miscellaneous Electrical Components, Upperstructure
Figure 10-2 Battery Box, Batteries & Cables
Figure 10-3 Tail & Marker Lights
Figure 10-4 Head & Marker Lights
Figure 10-5 Horn & Miscellaneous, Undercarriage
Figure 10-6 Cab Console Circuit Board, Upperstructure
Figure 10-7 Cab Console Circuit Board, Undercarriage
Figure 10-8 Instrument Panel
Figure 10-9 Accessory Panel
Section 11 Decals
Figure 11-1 Decals, Upperstructure
Figure 11-2 Decals, Undercarriage
Section 12 Options
Figure 12-1 Air Conditioner Installation Components, Upperstructure
Figure 12-2 ‘04 EPA Air Conditioner Installation
Figure 12-3 Air Conditioner Evaporator Kit
Figure 12-4 Locking Fuel Cap
Figure 12-5 Fire Extinguisher Installation
Figure 12-6 Seat Belt Installation Components
Figure 12-7 Fire Extinguisher Installation
Figure 12-8 Back-Up Alarm Installation
Figure 12-9 Mudflap Installation
Figure 12-10 Locking Toolbox
Figure 12-11 Radio & Antenna Installation (Upperstructure)
Recommended Spare Parts
Part Number Index
XL4100II Illustrated Parts Manual 31200235 2006.pdf (440 Pages)
Contents:
Service Kits
Section 1 Frame & Attaching Parts
Figure 1-1 Frame Assembly
Figure 1-2 Mirror & Grab Rails
Figure 1-3 Engine Cover
Figure 1-4 R.H. Fender & Mirrors
Figure 1-5 L.H. Fender
Figure 1-6 Rear Fender Assembly
Figure 1-7 Deck & Cover
Figure 1-8 Left Side Cover Assembly
Figure 1-9 Rotating Platform
Figure 1-10 Swing Bearing, Cradle & Hoist Cylinder Mounting & Lube System
Figure 1-11 Valve Cover
Section 2 Boom
Figure 2-1 Boom Cradle
Figure 2-2 Main Boom Assembly
Figure 2-3 Telescope Boom Assembly
Figure 2-4 Boom Roller Assemblies
Figure 2-5 Bucket Linkage
Section 3 Attachments
Figure 3-1 48” Excavating Bucket
Figure 3-2 60” Ditching Bucket
Figure 3-3 Hydraulic Thumb Installation
Figure 3-4 Hydraulic Thumb Weldment
Section 4 Engine & Attaching Parts
Figure 4-1 Engine Assembly, L.H. View
Figure 4-2 Engine Assembly, R.H. View
Figure 4-3 Air Cleaner Assembly
Figure 4-4 Power Steering Reservoir Assembly
Figure 4-5 Exhaust System
Figure 4-6 Fuel Tank & Lines
Figure 4-7 Radiator & Cooler Assembly
Figure 4-8 Oil Cooler & Hoses
Figure 4-9 Air Brake System
Figure 4-10 Spring Brake Control Valve & Parking Brake Valve Assemblies
Figure 4-11 Lockout Air Valve, Air Dryer & Adapter Assemblies
Figure 4-12 Air Valve Assemblies
Figure 4-13 Air Valve & Double Check Valve Assemblies
Figure 4-14 Air Reservoir Assemblies
Figure 4-15 Relay Valve Assemblies
Figure 4-16 Foot Pedal Valve & Air Fitting Assembly
Figure 4-17 Air Valve Assemblies
Figure 4-18 Air Valve & Air Fitting Assemblies
Section 5 Drive Train
Figure 5-1 Clutch Assembly
Figure 5-2 Clutch Release Bearing
Figure 5-3 Slave Valve Assembly
Figure 5-4 Transmission – Slave Control Assembly
Figure 5-5 Transmission – Slave Valve w/Hoses
Figure 5-6 Transmission – Clutch Housing
Figure 5-7 Transmission – Shift Bar Housing
Figure 5-8 Transmission – Reverse Idler, Input Shaft & Drive Gear
Figure 5-9 Transmission – Mainshaft & Countershaft Gears
Figure 5-10 Transmission – Auxiliary Mainshaft
Figure 5-11 Transmission – Auxiliary Case Assembly
Figure 5-12 Transmission – Range Cylinder
Figure 5-13 Transmission – Auxiliary Countershaft & Auxiliary Drive Gear
Figure 5-14 Transmission – Master Shift Valve Assembly
Figure 5-15 Propeller Shaft
Figure 5-16 Transfer Case Assembly, 6X6
Figure 5-17 Front Axle – Axle Assembly, 6X4
Figure 5-18 Front Axle – Steering Components, 6X4
Figure 5-19 Front Axle – Service Brakes, 6X4
Figure 5-20 Front Axle – Disc Wheel & Rims, 6X4
Figure 5-21 Front Axle – Axle Assembly, 6X6
Figure 5-22 Front Axle – Housing Assembly, 6X6
Figure 5-23 Front Axle – Differential Assembly, 6X6
Figure 5-24 Front Axle – Steering Components, 6X6
Figure 5-25 Front Axle – Service Brake, 6X6
Figure 5-26 Front Axle – Disc Wheels & Rims, 6X6
Figure 5-27 Front Axle – Spring Assembly
Figure 5-28 Rear Axle – Axle Assembly, 6X4
Figure 5-29 Rear Axle – Axle Assembly, 6X6
Figure 5-30 Rear Axle – Forward Housing
Figure 5-31 Rear Axle – Rear Housing
Figure 5-32 Rear Axle – Forward Differential Assembly
Figure 5-33 Rear Axle – Rear Differential Assembly
Figure 5-34 Rear Axle – Service Brake
Figure 5-35 Rear Axle – Disc Wheel & Rim
Figure 5-36 Equalizer Beams
Section 6 Cab
Figure 6-1 Operators Cab, Upperstructure
Figure 6-2 Operators Cab, Upperstructure
Figure 6-3 Cab Door, Upperstructure
Figure 6-4 Cab Interior Components, Upperstructure
Figure 6-5 Cab Console, Upperstructure
Figure 6-6 Cab Seat, Upperstructure
Figure 6-7 Cab Heater & Installation, Upperstructure
Figure 6-8 Operators Cab, Undercarriage
Figure 6-9 Operators Cab, Undercarriage
Figure 6-10 Cab Door, Undercarriage
Figure 6-11 Cab Seat, Undercarriage
Figure 6-12 Seat Suspension, Undercarriage
Figure 6-13 Heater & Defroster, Undercarriage
Figure 6-14 Pilot Cut-off Assembly
Section 7 Controls
Figure 7-1 Joystick Assembly
Figure 7-2 Steering Column Assembly
Figure 7-3 Steering Drive Shaft Assembly
Figure 7-4 Steering Drag Link Assembly
Figure 7-5 Foot Operated Pedal Valve Assembly
Figure 7-6 Foot Operated Pedal Plate Assembly
Section 8 Hydraulic Circuits
Figure 8-1 Hydraulic Oil Supply to Main Pump
Figure 8-2 Main Hydraulic Pump to Center Pin
Figure 8-3 Hydraulic Pressure from Center Pin to Control Valve
Figure 8-4 Main Valve to Pilot Manifold
Figure 8-5 Hydraulic Hosing To Joysticks & Foot Operated Pedal Valve
Figure 8-6 Upper Dump
Figure 8-7 Chassis Dump
Figure 8-8 Hoist Pilot
Figure 8-9 Boom Pilot
Figure 8-10 Tool Pilot
Figure 8-11 Tilt Pilot
Figure 8-12 Heater & Auxiliary Pilot
Figure 8-13 Hoist Cylinder
Figure 8-14 Boom Cylinder
Figure 8-15 Tool Cylinder
Figure 8-16 Swing & Swing Brake Pilot
Figure 8-17 Tool Pilot
Figure 8-18 Swing Motor
Figure 8-19 Tilt Motor
Figure 8-20 Steering Gear
Figure 8-21 Remote Propelling
Figure 8-22 Remote Steering
Figure 8-23 Stabilizer Cylinder
Section 9 Hydraulic Components
Figure 9-1 Hoist Cylinder Assembly
Figure 9-2 Boom Cylinder Assembly
Figure 9-3 Tool Cylinder Assembly
Figure 9-4 Stabilizer Cylinder Assembly
Figure 9-5 Stabilizer Valve Assembly
Figure 9-6 Remote Steering Hydraulic Cylinder Assembly
Figure 9-7 Main Pump – Front
Figure 9-8 Main Pump – Rear
Figure 9-9 Main Hydraulic Control Valve
Figure 9-10 Main Hydraulic Control Valve – Spools & End Caps
Figure 9-11 Main Hydraulic Control Valve – Swing Section
Figure 9-12 Main Hydraulic Control Valve – Seal Kits
Figure 9-13 Pilot Manifold Valve Tray Hydraulic Components
Figure 9-14 Pilot Manifold Assembly
Figure 9-15 Reservoir Assembly
Figure 9-16 Swing Transmission Installation
Figure 9-17 Swing Transmission Assembly
Figure 9-18 Swing Motor Assembly
Figure 9-19 Swing Brake Assembly
Figure 9-20 Tilt Transmission
Figure 9-21 Tilt Transmission Assembly
Figure 9-22 Tilt Motor Assembly
Figure 9-23 Tilt Brake Assembly
Figure 9-24 Travel Motor
Figure 9-25 Center Pin Assembly
Figure 9-26 Power Take-Off Assembly
Figure 9-27 Power Take-Off Counter Shaft
Figure 9-28 Oil Cooler Assembly
Figure 9-29 Hydraulic Heater Pump Assembly
Figure 9-30 Hydraulic Heater Manifold Assembly
Figure 9-31 Steering Gear Assembly
Figure 9-32 Counterbalance Valve Assembly
Figure 9-33 Counterbalance Valve
Figure 9-34 Cooling Fan Valve Assembly
Figure 9-35 Steering Valve Assembly
Figure 9-36 Dual Solenoid Valve Assembly
Figure 9-37 Hoist Limit Valve
Section 10 Electrical
Figure 10-1 Miscellaneous Electrical Components, Upperstructure
Figure 10-2 Battery Box, Batteries & Cables
Figure 10-3 Tail & Marker Lights
Figure 10-4 Head & Marker Lights
Figure 10-5 Horn & Miscellaneous, Undercarriage
Figure 10-6 Cab Console Circuit Board, Upperstructure
Figure 10-7 Cab Console Circuit Board, Undercarriage
Figure 10-8 Instrument Panel
Figure 10-9 Accessory Panel
Section 11 Decals
Figure 11-1 Decals, Upperstructure
Figure 11-2 Decals, Undercarriage
Section 12 Options
Figure 12-1 Air Conditioner Installation Components, Upperstructure
Figure 12-2 ‘04 EPA Air Conditioner Installation, Undercarriage
Figure 12-3 Air Conditioner General Kit
Figure 12-4 Floodlight Installation Components
Figure 12-5 AM/FM Cassette Stereo Installation Components
Figure 12-6 Auxiliary Hydraulics
Recommended Spare Parts
Part Number Index
XL4100II Illustrated Parts Manual 31200238 2006.pdf (450 Pages)
Contents:
Service Kits
Section 1 Frame & Attaching Parts
Figure 1-1 Frame Assembly
Figure 1-2 Mirror & Grab Rails
Figure 1-3 Engine Cover
Figure 1-4 R.H. Fender & Mirrors
Figure 1-5 L.H. Fender
Figure 1-6 Rear Fender Assembly
Figure 1-7 Deck & Cover
Figure 1-8 Left Side Cover Assembly
Figure 1-9 Rotating Platform
Figure 1-10 Swing Bearing, Cradle & Hoist Cylinder Mounting & Lube System
Figure 1-11 Valve Cover
Section 2 Boom
Figure 2-1 Boom Cradle
Figure 2-2 Main Boom Assembly
Figure 2-3 Telescope Boom Assembly
Figure 2-4 Boom Roller Assemblies
Figure 2-5 Bucket Linkage
Section 3 Attachments
Figure 3-1 24” Excavating Buckets
Figure 3-2 66” Ditching Bucket
Figure 3-3 Guardrail Back Scraper
Figure 3-4 Fixed Thumb Grapple Assembly
Section 4 Engine & Attaching Parts
Figure 4-1 Engine Assembly, L.H. View
Figure 4-2 Engine Assembly, R.H. View
Figure 4-3 Air Cleaner Assembly
Figure 4-4 Power Steering Reservoir Assembly
Figure 4-5 Exhaust System
Figure 4-6 Fuel Tank & Lines
Figure 4-7 Radiator & Cooler Assembly
Figure 4-8 Oil Cooler & Hoses
Figure 4-9 Air Brake System
Figure 4-10 Spring Brake Control Valve & Parking Brake Valve Assemblies
Figure 4-11 Lockout Air Valve, Air Dryer & Adapter Assemblies
Figure 4-12 Air Valve Assemblies
Figure 4-13 Air Valve & Double Check Valve Assemblies
Figure 4-14 Air Reservoir Assemblies
Figure 4-15 Relay Valve Assemblies
Figure 4-16 Foot Pedal Valve & Air Fitting Assembly
Figure 4-17 Air Valve Assemblies
Figure 4-18 Air Valve & Air Fitting Assemblies
Section 5 Drive Train
Figure 5-1 Clutch Assembly
Figure 5-2 Clutch Release Bearing
Figure 5-3 Slave Valve Assembly
Figure 5-4 Transmission – Slave Control Assembly
Figure 5-5 Transmission – Slave Valve w/Hoses
Figure 5-6 Transmission – Clutch Housing
Figure 5-7 Transmission – Shift Bar Housing
Figure 5-8 Transmission – Reverse Idler, Input Shaft & Drive Gear
Figure 5-9 Transmission – Mainshaft & Countershaft Gears
Figure 5-10 Transmission – Auxiliary Mainshaft
Figure 5-11 Transmission – Auxiliary Case Assembly
Figure 5-12 Transmission – Range Cylinder
Figure 5-13 Transmission – Auxiliary Countershaft & Auxiliary Drive Gear
Figure 5-14 Transmission – Master Shift Valve Assembly
Figure 5-15 Propeller Shaft
Figure 5-16 Transfer Case Assembly, 6X6
Figure 5-17 Front Axle – Axle Assembly, 6X4
Figure 5-18 Front Axle – Steering Components, 6X4
Figure 5-19 Front Axle – Service Brakes, 6X4
Figure 5-20 Front Axle – Disc Wheel & Rims, 6X4
Figure 5-21 Front Axle – Axle Assembly, 6X6
Figure 5-22 Front Axle – Housing Assembly, 6X6
Figure 5-23 Front Axle – Differential Assembly, 6X6
Figure 5-24 Front Axle – Steering Components, 6X6
Figure 5-25 Front Axle – Service Brake, 6X6
Figure 5-26 Front Axle – Disc Wheels & Rims, 6X6
Figure 5-27 Front Axle – Spring Assembly
Figure 5-28 Rear Axle – Axle Assembly, 6X4
Figure 5-29 Rear Axle – Axle Assembly, 6X6
Figure 5-30 Rear Axle – Forward Housing
Figure 5-31 Rear Axle – Rear Housing
Figure 5-32 Rear Axle – Forward Differential Assembly
Figure 5-33 Rear Axle – Rear Differential Assembly
Figure 5-34 Rear Axle – Service Brake
Figure 5-35 Rear Axle – Disc Wheel & Rim
Figure 5-36 Equalizer Beams
Section 6 Cab
Figure 6-1 Operators Cab, Upperstructure
Figure 6-2 Operators Cab, Upperstructure
Figure 6-3 Cab Door, Upperstructure
Figure 6-4 Cab Interior Components, Upperstructure
Figure 6-5 Cab Console, Upperstructure
Figure 6-6 Cab Seat, Upperstructure
Figure 6-7 Cab Heater & Installation, Upperstructure
Figure 6-8 Operators Cab, Undercarriage
Figure 6-9 Operators Cab, Undercarriage
Figure 6-10 Cab Door, Undercarriage
Figure 6-11 Cab Seat, Undercarriage
Figure 6-12 Seat Suspension, Undercarriage
Figure 6-13 Heater & Defroster, Undercarriage
Figure 6-14 Pilot Cut-off Assembly
Section 7 Controls
Figure 7-1 Joystick Assembly
Figure 7-2 Steering Column Assembly
Figure 7-3 Steering Drive Shaft Assembly
Figure 7-4 Steering Drag Link Assembly
Figure 7-5 Foot Operated Pedal Valve Assembly
Figure 7-6 Foot Operated Pedal Plate Assembly
Section 8 Hydraulic Circuits
Figure 8-1 Hydraulic Oil Supply to Main Pump
Figure 8-2 Main Hydraulic Pump to Center Pin
Figure 8-3 Hydraulic Pressure from Center Pin to Control Valve
Figure 8-4 Main Valve to Pilot Manifold
Figure 8-5 Hydraulic Hosing To Joysticks & Foot Operated Pedal Valve
Figure 8-6 Upper Dump
Figure 8-7 Chassis Dump
Figure 8-8 Hoist Pilot
Figure 8-9 Boom Pilot
Figure 8-10 Tool Pilot
Figure 8-11 Tilt Pilot
Figure 8-12 Heater & Auxiliary Pilot
Figure 8-13 Hoist Cylinder
Figure 8-14 Boom Cylinder
Figure 8-15 Tool Cylinder
Figure 8-16 Swing & Swing Brake Pilot
Figure 8-17 Tool Pilot
Figure 8-18 Swing Motor
Figure 8-19 Tilt Motor
Figure 8-20 Steering Gear
Figure 8-21 Remote Propelling
Figure 8-22 Remote Steering
Figure 8-23 Stabilizer Cylinder
Section 9 Hydraulic Components
Figure 9-1 Hoist Cylinder Assembly
Figure 9-2 Boom Cylinder Assembly
Figure 9-3 Tool Cylinder Assembly
Figure 9-4 Stabilizer Cylinder Assembly
Figure 9-5 Stabilizer Valve Assembly
Figure 9-6 Remote Steering Hydraulic Cylinder Assembly
Figure 9-7 Main Pump – Front
Figure 9-8 Main Pump – Rear
Figure 9-9 Main Hydraulic Control Valve
Figure 9-10 Main Hydraulic Control Valve – Spools & End Caps
Figure 9-11 Main Hydraulic Control Valve – Swing Section
Figure 9-12 Main Hydraulic Control Valve – Seal Kits
Figure 9-13 Pilot Manifold Valve Tray Hydraulic Components
Figure 9-14 Pilot Manifold Assembly
Figure 9-15 Reservoir Assembly
Figure 9-16 Swing Transmission Installation
Figure 9-17 Swing Transmission Assembly
Figure 9-18 Swing Motor Assembly
Figure 9-19 Swing Brake Assembly
Figure 9-20 Tilt Transmission
Figure 9-21 Tilt Transmission Assembly
Figure 9-22 Tilt Motor Assembly
Figure 9-23 Tilt Brake Assembly
Figure 9-24 Travel Motor
Figure 9-25 Center Pin Assembly
Figure 9-26 Power Take-Off Assembly
Figure 9-27 Power Take-Off Counter Shaft
Figure 9-28 Oil Cooler Assembly
Figure 9-29 Hydraulic Heater Pump Assembly
Figure 9-30 Hydraulic Heater Manifold Assembly
Figure 9-31 Steering Gear Assembly
Figure 9-32 Counterbalance Valve Assembly
Figure 9-33 Counterbalance Valve
Figure 9-34 Cooling Fan Valve Assembly
Figure 9-35 Steering Valve Assembly
Figure 9-36 Dual Solenoid Valve Assembly
Figure 9-37 Hoist Limit Valve
Section 10 Electrical
Figure 10-1 Miscellaneous Electrical Components, Upperstructure
Figure 10-2 Battery Box, Batteries & Cables
Figure 10-3 Tail & Marker Lights
Figure 10-4 Head & Marker Lights
Figure 10-5 Horn & Miscellaneous, Undercarriage
Figure 10-6 Cab Console Circuit Board, Upperstructure
Figure 10-7 Cab Console Circuit Board, Undercarriage
Figure 10-8 Instrument Panel
Figure 10-9 Accessory Panel
Section 11 Decals
Figure 11-1 Decals, Upperstructure
Figure 11-2 Decals, Undercarriage
Section 12 Options
Figure 12-1 Air Conditioner Installation Components, Upperstructure
Figure 12-2 Air Conditioner General Kit
Figure 12-3 Block Heater Installation Components
Figure 12-4 Floodlight Installation Components
Figure 12-5 AM/FM Cassette Stereo Installation Components
Figure 12-6 Vandal Covers w/o Worklight Installation
Figure 12-7 Vandal Covers Installation Components
Figure 12-8 Auxiliary Hydraulics
Figure 12-9 Window Screen Installation
Figure 12-10 AM/FM Cassette Stereo Installation
Figure 12-11 Tilt Steering Column Installation
Recommended Spare Parts
Part Number Index
XL4100II Illustrated Parts Manual 31200240 2006.pdf (462 Pages)
Contents:
Service Kits
Section 1 Frame & Attaching Parts
Figure 1-1 Frame Assembly
Figure 1-2 Mirror & Grab Rails
Figure 1-3 Engine Cover
Figure 1-4 R.H. Fender & Mirrors
Figure 1-5 L.H. Fender
Figure 1-6 Rear Fender Assembly
Figure 1-7 Deck & Cover
Figure 1-8 Left Side Cover Assembly
Figure 1-9 Rotating Platform
Figure 1-10 Swing Bearing, Cradle & Hoist Cylinder Mounting & Lube System
Figure 1-11 Valve Cover
Section 2 Boom
Figure 2-1 Boom Cradle
Figure 2-2 Main Boom Assembly
Figure 2-3 Telescope Boom Assembly
Figure 2-4 Boom Roller Assemblies
Figure 2-5 Bucket Linkage
Section 3 Attachments
Figure 3-1 24” Excavating Buckets
Figure 3-2 36” Excavating Buckets
Figure 3-3 40” Pavement Removal Bucket
Figure 3-4 60” Ditching Bucket
Figure 3-5 6’ Boom Extension
Figure 3-6 72” Dredging Bucket
Figure 3-7 Bucket Carrier Assembly
Figure 3-8 21” Trenching Bucket
Section 4 Engine & Attaching Parts
Figure 4-1 Engine Assembly, L.H. View
Figure 4-2 Engine Assembly, R.H. View
Figure 4-3 Air Cleaner Assembly
Figure 4-4 Power Steering Reservoir Assembly
Figure 4-5 Exhaust System
Figure 4-6 Fuel Tank & Lines
Figure 4-7 Radiator & Cooler Assembly
Figure 4-8 Oil Cooler & Hoses
Figure 4-9 Air Brake System
Figure 4-10 Spring Brake Control Valve & Parking Brake Valve Assemblies
Figure 4-11 Lockout Air Valve, Air Dryer & Adapter Assemblies
Figure 4-12 Air Valve Assemblies
Figure 4-13 Air Valve & Double Check Valve Assemblies
Figure 4-14 Air Reservoir Assemblies
Figure 4-15 Relay Valve Assemblies
Figure 4-16 Foot Pedal Valve & Air Fitting Assembly
Figure 4-17 Air Valve Assemblies
Figure 4-18 Air Valve & Air Fitting Assemblies
Section 5 Drive Train
Figure 5-1 Clutch Assembly
Figure 5-2 Clutch Release Bearing
Figure 5-3 Slave Valve Assembly
Figure 5-4 Transmission – Slave Control Assembly
Figure 5-5 Transmission – Slave Valve w/Hoses
Figure 5-6 Transmission – Clutch Housing
Figure 5-7 Transmission – Shift Bar Housing
Figure 5-8 Transmission – Reverse Idler, Input Shaft & Drive Gear
Figure 5-9 Transmission – Mainshaft & Countershaft Gears
Figure 5-10 Transmission – Auxiliary Mainshaft
Figure 5-11 Transmission – Auxiliary Case Assembly
Figure 5-12 Transmission – Range Cylinder
Figure 5-13 Transmission – Auxiliary Countershaft & Auxiliary Drive Gear
Figure 5-14 Transmission – Master Shift Valve Assembly
Figure 5-15 Propeller Shaft
Figure 5-16 Transfer Case Assembly, 6X6
Figure 5-17 Front Axle – Axle Assembly, 6X4
Figure 5-18 Front Axle – Steering Components, 6X4
Figure 5-19 Front Axle – Service Brakes, 6X4
Figure 5-20 Front Axle – Disc Wheel & Rims, 6X4
Figure 5-21 Front Axle – Axle Assembly, 6X6
Figure 5-22 Front Axle – Housing Assembly, 6X6
Figure 5-23 Front Axle – Differential Assembly, 6X6
Figure 5-24 Front Axle – Steering Components, 6X6
Figure 5-25 Front Axle – Service Brake, 6X6
Figure 5-26 Front Axle – Disc Wheels & Rims, 6X6
Figure 5-27 Front Axle – Spring Assembly
Figure 5-28 Rear Axle – Axle Assembly, 6X4
Figure 5-29 Rear Axle – Axle Assembly, 6X6
Figure 5-30 Rear Axle – Forward Housing
Figure 5-31 Rear Axle – Rear Housing
Figure 5-32 Rear Axle – Forward Differential Assembly
Figure 5-33 Rear Axle – Rear Differential Assembly
Figure 5-34 Rear Axle – Service Brake
Figure 5-35 Rear Axle – Disc Wheel & Rim
Figure 5-36 Equalizer Beams
Section 6 Cab
Figure 6-1 Operators Cab, Upperstructure
Figure 6-2 Operators Cab, Upperstructure
Figure 6-3 Cab Door, Upperstructure
Figure 6-4 Cab Interior Components, Upperstructure
Figure 6-5 Cab Console, Upperstructure
Figure 6-6 Cab Seat, Upperstructure
Figure 6-7 Cab Heater & Installation, Upperstructure
Figure 6-8 Operators Cab, Undercarriage
Figure 6-9 Operators Cab, Undercarriage
Figure 6-10 Cab Door, Undercarriage
Figure 6-11 Cab Seat, Undercarriage
Figure 6-12 Seat Suspension, Undercarriage
Figure 6-13 Heater & Defroster, Undercarriage
Figure 6-14 Pilot Cut-off Assembly
Section 7 Controls
Figure 7-1 Joystick Assembly
Figure 7-2 Steering Column Assembly
Figure 7-3 Steering Drive Shaft Assembly
Figure 7-4 Steering Drag Link Assembly
Figure 7-5 Foot Operated Pedal Valve Assembly
Figure 7-6 Foot Operated Pedal Plate Assembly
Section 8 Hydraulic Circuits
Figure 8-1 Hydraulic Oil Supply to Main Pump
Figure 8-2 Main Hydraulic Pump to Center Pin
Figure 8-3 Hydraulic Pressure from Center Pin to Control Valve
Figure 8-4 Main Valve to Pilot Manifold
Figure 8-5 Hydraulic Hosing To Joysticks & Foot Operated Pedal Valve
Figure 8-6 Upper Dump
Figure 8-7 Chassis Dump
Figure 8-8 Hoist Pilot
Figure 8-9 Boom Pilot
Figure 8-10 Tool Pilot
Figure 8-11 Tilt Pilot
Figure 8-12 Heater & Auxiliary Pilot
Figure 8-13 Hoist Cylinder
Figure 8-14 Boom Cylinder
Figure 8-15 Tool Cylinder
Figure 8-16 Swing & Swing Brake Pilot
Figure 8-17 Tool Pilot
Figure 8-18 Swing Motor
Figure 8-19 Tilt Motor
Figure 8-20 Steering Gear
Figure 8-21 Remote Propelling
Figure 8-22 Remote Steering
Figure 8-23 Stabilizer Cylinder
Section 9 Hydraulic Components
Figure 9-1 Hoist Cylinder Assembly
Figure 9-2 Boom Cylinder Assembly
Figure 9-3 Tool Cylinder Assembly
Figure 9-4 Stabilizer Cylinder Assembly
Figure 9-5 Stabilizer Valve Assembly
Figure 9-6 Remote Steering Hydraulic Cylinder Assembly
Figure 9-7 Main Pump – Front
Figure 9-8 Main Pump – Rear
Figure 9-9 Main Hydraulic Control Valve
Figure 9-10 Main Hydraulic Control Valve – Spools & End Caps
Figure 9-11 Main Hydraulic Control Valve – Swing Section
Figure 9-12 Main Hydraulic Control Valve – Seal Kits
Figure 9-13 Pilot Manifold Valve Tray Hydraulic Components
Figure 9-14 Pilot Manifold Assembly
Figure 9-15 Reservoir Assembly
Figure 9-16 Swing Transmission Installation
Figure 9-17 Swing Transmission Assembly
Figure 9-18 Swing Motor Assembly
Figure 9-19 Swing Brake Assembly
Figure 9-20 Tilt Transmission
Figure 9-21 Tilt Transmission Assembly
Figure 9-22 Tilt Motor Assembly
Figure 9-23 Tilt Brake Assembly
Figure 9-24 Travel Motor
Figure 9-25 Center Pin Assembly
Figure 9-26 Power Take-Off Assembly
Figure 9-27 Power Take-Off Counter Shaft
Figure 9-28 Oil Cooler Assembly
Figure 9-29 Hydraulic Heater Pump Assembly
Figure 9-30 Hydraulic Heater Manifold Assembly
Figure 9-31 Steering Gear Assembly
Figure 9-32 Counterbalance Valve Assembly
Figure 9-33 Counterbalance Valve
Figure 9-34 Cooling Fan Valve Assembly
Figure 9-35 Steering Valve Assembly
Figure 9-36 Dual Solenoid Valve Assembly
Figure 9-37 Hoist Limit Valve
Section 10 Electrical
Figure 10-1 Miscellaneous Electrical Components, Upperstructure
Figure 10-2 Battery Box, Batteries & Cables
Figure 10-3 Tail & Marker Lights
Figure 10-4 Head & Marker Lights
Figure 10-5 Horn & Miscellaneous, Undercarriage
Figure 10-6 Cab Console Circuit Board, Upperstructure
Figure 10-7 Cab Console Circuit Board, Undercarriage
Figure 10-8 Instrument Panel
Figure 10-9 Accessory Panel
Section 11 Decals
Figure 11-1 Decals, Upperstructure
Figure 11-2 Decals, Undercarriage
Section 12 Options
Figure 12-1 Air Conditioner Installation Components, Upperstructure
Figure 12-2 Air Conditioner General Kit
Figure 12-3 Additional Battery Installation & Master Disconnect Switch Installation
Figure 12-4 Floodlight Installation Components
Figure 12-5 Seat Belt Installation Components
Figure 12-6 AM/FM Cassette Stereo Installation Components
Figure 12-7 Auxiliary Hydraulics
Figure 12-8 AM/FM Cassette Stereo Installation
Figure 12-9 Tilt Steering Column Installation
Figure 12-10 Coolant Filter Install
Figure 12-11 Silicone Hose Installation
Figure 12-12 Fuel Filter Installation
Recommended Spare Parts
Part Number Index
XL4100II Illustrated Parts Manual 31200242 2006.pdf (450 Pages)
Contents:
Service Kits
Section 1 Frame & Attaching Parts
Figure 1-1 Frame Assembly
Figure 1-2 Mirror & Grab Rails
Figure 1-3 Engine Cover
Figure 1-4 R.H. Fender & Mirrors
Figure 1-5 L.H. Fender
Figure 1-6 Rear Fender Assembly
Figure 1-7 Deck & Cover
Figure 1-8 Left Side Cover Assembly
Figure 1-9 Rotating Platform
Figure 1-10 Swing Bearing, Cradle & Hoist Cylinder Mounting & Lube System
Figure 1-11 Valve Cover
Section 2 Boom
Figure 2-1 Boom Cradle
Figure 2-2 Main Boom Assembly
Figure 2-3 Telescope Boom Assembly
Figure 2-4 Boom Roller Assemblies
Figure 2-5 Bucket Linkage
Section 3 Attachments
Figure 3-1 42” Excavating Buckets
Figure 3-2 40” Pavement Removal Bucket
Figure 3-3 66” Ditching Bucket
Figure 3-4 6’ Boom Extension
Figure 3-5 Fixed Thumb Grapple Assembly
Figure 3-6 Bucket Carrier Assembly
Section 4 Engine & Attaching Parts
Figure 4-1 Engine Assembly, L.H. View
Figure 4-2 Engine Assembly, R.H. View
Figure 4-3 Air Cleaner Assembly
Figure 4-4 Power Steering Reservoir Assembly
Figure 4-5 Exhaust System
Figure 4-6 Fuel Tank & Lines
Figure 4-7 Radiator & Cooler Assembly
Figure 4-8 Oil Cooler & Hoses
Figure 4-9 Air Brake System
Figure 4-10 Spring Brake Control Valve & Parking Brake Valve Assemblies
Figure 4-11 Lockout Air Valve, Air Dryer & Adapter Assemblies
Figure 4-12 Air Valve Assemblies
Figure 4-13 Air Valve & Double Check Valve Assemblies
Figure 4-14 Air Reservoir Assemblies
Figure 4-15 Relay Valve Assemblies
Figure 4-16 Foot Pedal Valve & Air Fitting Assembly
Figure 4-17 Air Valve Assemblies
Figure 4-18 Air Valve & Air Fitting Assemblies
Section 5 Drive Train
Figure 5-1 Clutch Assembly
Figure 5-2 Clutch Release Bearing
Figure 5-3 Slave Valve Assembly
Figure 5-4 Transmission – Slave Control Assembly
Figure 5-5 Transmission – Slave Valve w/Hoses
Figure 5-6 Transmission – Clutch Housing
Figure 5-7 Transmission – Shift Bar Housing
Figure 5-8 Transmission – Reverse Idler, Input Shaft & Drive Gear
Figure 5-9 Transmission – Mainshaft & Countershaft Gears
Figure 5-10 Transmission – Auxiliary Mainshaft
Figure 5-11 Transmission – Auxiliary Case Assembly
Figure 5-12 Transmission – Range Cylinder
Figure 5-13 Transmission – Auxiliary Countershaft & Auxiliary Drive Gear
Figure 5-14 Transmission – Master Shift Valve Assembly
Figure 5-15 Propeller Shaft
Figure 5-16 Transfer Case Assembly, 6X6
Figure 5-17 Front Axle – Axle Assembly, 6X4
Figure 5-18 Front Axle – Steering Components, 6X4
Figure 5-19 Front Axle – Service Brakes, 6X4
Figure 5-20 Front Axle – Disc Wheel & Rims, 6X4
Figure 5-21 Front Axle – Axle Assembly, 6X6
Figure 5-22 Front Axle – Housing Assembly, 6X6
Figure 5-23 Front Axle – Differential Assembly, 6X6
Figure 5-24 Front Axle – Steering Components, 6X6
Figure 5-25 Front Axle – Service Brake, 6X6
Figure 5-26 Front Axle – Disc Wheels & Rims, 6X6
Figure 5-27 Front Axle – Spring Assembly
Figure 5-28 Rear Axle – Axle Assembly, 6X4
Figure 5-29 Rear Axle – Axle Assembly, 6X6
Figure 5-30 Rear Axle – Forward Housing
Figure 5-31 Rear Axle – Rear Housing
Figure 5-32 Rear Axle – Forward Differential Assembly
Figure 5-33 Rear Axle – Rear Differential Assembly
Figure 5-34 Rear Axle – Service Brake
Figure 5-35 Rear Axle – Disc Wheel & Rim
Figure 5-36 Equalizer Beams
Section 6 Cab
Figure 6-1 Operators Cab, Upperstructure
Figure 6-2 Operators Cab, Upperstructure
Figure 6-3 Cab Door, Upperstructure
Figure 6-4 Cab Interior Components, Upperstructure
Figure 6-5 Cab Console, Upperstructure
Figure 6-6 Cab Seat, Upperstructure
Figure 6-7 Cab Heater & Installation, Upperstructure
Figure 6-8 Operators Cab, Undercarriage
Figure 6-9 Operators Cab, Undercarriage
Figure 6-10 Cab Door, Undercarriage
Figure 6-11 Cab Seat, Undercarriage
Figure 6-12 Seat Suspension, Undercarriage
Figure 6-13 Heater & Defroster, Undercarriage
Figure 6-14 Pilot Cut-off Assembly
Section 7 Controls
Figure 7-1 Joystick Assembly
Figure 7-2 Steering Column Assembly
Figure 7-3 Steering Drive Shaft Assembly
Figure 7-4 Steering Drag Link Assembly
Figure 7-5 Foot Operated Pedal Valve Assembly
Figure 7-6 Foot Operated Pedal Plate Assembly
Section 8 Hydraulic Circuits
Figure 8-1 Hydraulic Oil Supply to Main Pump
Figure 8-2 Main Hydraulic Pump to Center Pin
Figure 8-3 Hydraulic Pressure from Center Pin to Control Valve
Figure 8-4 Main Valve to Pilot Manifold
Figure 8-5 Hydraulic Hosing To Joysticks & Foot Operated Pedal Valve
Figure 8-6 Upper Dump
Figure 8-7 Chassis Dump
Figure 8-8 Hoist Pilot
Figure 8-9 Boom Pilot
Figure 8-10 Tool Pilot
Figure 8-11 Tilt Pilot
Figure 8-12 Heater & Auxiliary Pilot
Figure 8-13 Hoist Cylinder
Figure 8-14 Boom Cylinder
Figure 8-15 Tool Cylinder
Figure 8-16 Swing & Swing Brake Pilot
Figure 8-17 Tool Pilot
Figure 8-18 Swing Motor
Figure 8-19 Tilt Motor
Figure 8-20 Steering Gear
Figure 8-21 Remote Propelling
Figure 8-22 Remote Steering
Figure 8-23 Stabilizer Cylinder
Section 9 Hydraulic Components
Figure 9-1 Hoist Cylinder Assembly
Figure 9-2 Boom Cylinder Assembly
Figure 9-3 Tool Cylinder Assembly
Figure 9-4 Stabilizer Cylinder Assembly
Figure 9-5 Stabilizer Valve Assembly
Figure 9-6 Remote Steering Hydraulic Cylinder Assembly
Figure 9-7 Main Pump – Front
Figure 9-8 Main Pump – Rear
Figure 9-9 Main Hydraulic Control Valve
Figure 9-10 Main Hydraulic Control Valve – Spools & End Caps
Figure 9-11 Main Hydraulic Control Valve – Swing Section
Figure 9-12 Main Hydraulic Control Valve – Seal Kits
Figure 9-13 Pilot Manifold Valve Tray Hydraulic Components
Figure 9-14 Pilot Manifold Assembly
Figure 9-15 Reservoir Assembly
Figure 9-16 Swing Transmission Installation
Figure 9-17 Swing Transmission Assembly
Figure 9-18 Swing Motor Assembly
Figure 9-19 Swing Brake Assembly
Figure 9-20 Tilt Transmission
Figure 9-21 Tilt Transmission Assembly
Figure 9-22 Tilt Motor Assembly
Figure 9-23 Tilt Brake Assembly
Figure 9-24 Travel Motor
Figure 9-25 Center Pin Assembly
Figure 9-26 Power Take-Off Assembly
Figure 9-27 Power Take-Off Counter Shaft
Figure 9-28 Oil Cooler Assembly
Figure 9-29 Hydraulic Heater Pump Assembly
Figure 9-30 Hydraulic Heater Manifold Assembly
Figure 9-31 Steering Gear Assembly
Figure 9-32 Counterbalance Valve Assembly
Figure 9-33 Counterbalance Valve
Figure 9-34 Cooling Fan Valve Assembly
Figure 9-35 Steering Valve Assembly
Figure 9-36 Dual Solenoid Valve Assembly
Figure 9-37 Hoist Limit Valve
Section 10 Electrical
Figure 10-1 Miscellaneous Electrical Components, Upperstructure
Figure 10-2 Battery Box, Batteries & Cables
Figure 10-3 Tail & Marker Lights
Figure 10-4 Head & Marker Lights
Figure 10-5 Horn & Miscellaneous, Undercarriage
Figure 10-6 Cab Console Circuit Board, Upperstructure
Figure 10-7 Cab Console Circuit Board, Undercarriage
Figure 10-8 Instrument Panel
Figure 10-9 Accessory Panel
Section 11 Decals
Figure 11-1 Decals, Upperstructure
Figure 11-2 Decals, Undercarriage
Section 12 Options
Figure 12-1 Air Conditioner Installation Components, Upperstructure
Figure 12-2 ‘04 EPA Air Conditioner Installation, Undercarriage
Figure 12-3 Air Conditioner General Kit
Figure 12-4 Block Heater Installation Components
Figure 12-5 Floodlight Installation Components
Figure 12-6 Seat Belt Installation Components
Figure 12-7 AM/FM Cassette Stereo Installation
Figure 12-8 Chassis Lights Installation
Figure 12-9 Strobe Light Installation
Recommended Spare Parts
Part Number Index
XL4100II Illustrated Parts Manual 31200243 2006.pdf (478 Pages)
Contents:
Service Kits
Section 1 Frame & Attaching Parts
Figure 1-1 Frame Assembly
Figure 1-2 Mirror & Grab Rails
Figure 1-3 Engine Cover
Figure 1-4 R.H. Fender & Mirrors
Figure 1-5 L.H. Fender
Figure 1-6 Rear Fender Assembly
Figure 1-7 Deck & Cover
Figure 1-8 Left Side Cover Assembly
Figure 1-9 Rotating Platform
Figure 1-10 Swing Bearing, Cradle & Hoist Cylinder Mounting & Lube System
Figure 1-11 Valve Cover
Section 2 Boom
Figure 2-1 Boom Cradle
Figure 2-2 Main Boom Assembly
Figure 2-3 Telescope Boom Assembly
Figure 2-4 Boom Roller Assemblies
Figure 2-5 Bucket Linkage
Section 3 Attachments
Figure 3-1 24” Excavating Buckets
Figure 3-2 36” Excavating Buckets
Figure 3-3 60” Ditching Bucket
Section 4 Engine & Attaching Parts
Figure 4-1 Engine Assembly, L.H. View
Figure 4-2 Engine Assembly, R.H. View
Figure 4-3 Air Cleaner Assembly
Figure 4-4 Power Steering Reservoir Assembly
Figure 4-5 Exhaust System
Figure 4-6 Fuel Tank & Lines
Figure 4-7 Radiator & Cooler Assembly
Figure 4-8 Oil Cooler & Hoses
Figure 4-9 Air Brake System
Figure 4-10 Spring Brake Control Valve & Parking Brake Valve Assemblies
Figure 4-11 Lockout Air Valve, Air Dryer & Adapter Assemblies
Figure 4-12 Air Valve Assemblies
Figure 4-13 Air Valve & Double Check Valve Assemblies
Figure 4-14 Air Reservoir Assemblies
Figure 4-15 Relay Valve Assemblies
Figure 4-16 Foot Pedal Valve & Air Fitting Assembly
Figure 4-17 Air Valve Assemblies
Figure 4-18 Air Valve & Air Fitting Assemblies
Section 5 Drive Train
Figure 5-1 Clutch Assembly
Figure 5-2 Clutch Release Bearing
Figure 5-3 Slave Valve Assembly
Figure 5-4 Transmission – Slave Control Assembly
Figure 5-5 Transmission – Slave Valve w/Hoses
Figure 5-6 Transmission – Clutch Housing
Figure 5-7 Transmission – Shift Bar Housing
Figure 5-8 Transmission – Reverse Idler, Input Shaft & Drive Gear
Figure 5-9 Transmission – Mainshaft & Countershaft Gears
Figure 5-10 Transmission – Auxiliary Mainshaft
Figure 5-11 Transmission – Auxiliary Case Assembly
Figure 5-12 Transmission – Range Cylinder
Figure 5-13 Transmission – Auxiliary Countershaft & Auxiliary Drive Gear
Figure 5-14 Transmission – Master Shift Valve Assembly
Figure 5-15 Propeller Shaft
Figure 5-16 Transfer Case Assembly, 6X6
Figure 5-17 Front Axle – Axle Assembly, 6X4
Figure 5-18 Front Axle – Steering Components, 6X4
Figure 5-19 Front Axle – Service Brakes, 6X4
Figure 5-20 Front Axle – Disc Wheel & Rims, 6X4
Figure 5-21 Front Axle – Axle Assembly, 6X6
Figure 5-22 Front Axle – Housing Assembly, 6X6
Figure 5-23 Front Axle – Differential Assembly, 6X6
Figure 5-24 Front Axle – Steering Components, 6X6
Figure 5-25 Front Axle – Service Brake, 6X6
Figure 5-26 Front Axle – Disc Wheels & Rims, 6X6
Figure 5-27 Front Axle – Spring Assembly
Figure 5-28 Rear Axle – Axle Assembly, 6X4
Figure 5-29 Rear Axle – Axle Assembly, 6X6
Figure 5-30 Rear Axle – Forward Housing
Figure 5-31 Rear Axle – Rear Housing
Figure 5-32 Rear Axle – Forward Differential Assembly
Figure 5-33 Rear Axle – Rear Differential Assembly
Figure 5-34 Rear Axle – Service Brake
Figure 5-35 Rear Axle – Disc Wheel & Rim
Figure 5-36 Equalizer Beams
Section 6 Cab
Figure 6-1 Operators Cab, Upperstructure
Figure 6-2 Operators Cab, Upperstructure
Figure 6-3 Cab Door, Upperstructure
Figure 6-4 Cab Interior Components, Upperstructure
Figure 6-5 Cab Console, Upperstructure
Figure 6-6 Cab Seat, Upperstructure
Figure 6-7 Cab Heater & Installation, Upperstructure
Figure 6-8 Operators Cab, Undercarriage
Figure 6-9 Operators Cab, Undercarriage
Figure 6-10 Cab Door, Undercarriage
Figure 6-11 Cab Seat, Undercarriage
Figure 6-12 Seat Suspension, Undercarriage
Figure 6-13 Heater & Defroster, Undercarriage
Figure 6-14 Pilot Cut-off Assembly
Section 7 Controls
Figure 7-1 Joystick Assembly
Figure 7-2 Steering Column Assembly
Figure 7-3 Steering Drive Shaft Assembly
Figure 7-4 Steering Drag Link Assembly
Figure 7-5 Foot Operated Pedal Valve Assembly
Figure 7-6 Foot Operated Pedal Plate Assembly
Section 8 Hydraulic Circuits
Figure 8-1 Hydraulic Oil Supply to Main Pump
Figure 8-2 Main Hydraulic Pump to Center Pin
Figure 8-3 Hydraulic Pressure from Center Pin to Control Valve
Figure 8-4 Main Valve to Pilot Manifold
Figure 8-5 Hydraulic Hosing To Joysticks & Foot Operated Pedal Valve
Figure 8-6 Upper Dump
Figure 8-7 Chassis Dump
Figure 8-8 Hoist Pilot
Figure 8-9 Boom Pilot
Figure 8-10 Tool Pilot
Figure 8-11 Tilt Pilot
Figure 8-12 Heater & Auxiliary Pilot
Figure 8-13 Hoist Cylinder
Figure 8-14 Boom Cylinder
Figure 8-15 Tool Cylinder
Figure 8-16 Swing & Swing Brake Pilot
Figure 8-17 Tool Pilot
Figure 8-18 Swing Motor
Figure 8-19 Tilt Motor
Figure 8-20 Steering Gear
Figure 8-21 Remote Propelling
Figure 8-22 Remote Steering
Figure 8-23 Stabilizer Cylinder
Section 9 Hydraulic Components
Figure 9-1 Hoist Cylinder Assembly
Figure 9-2 Boom Cylinder Assembly
Figure 9-3 Tool Cylinder Assembly
Figure 9-4 Stabilizer Cylinder Assembly
Figure 9-5 Stabilizer Valve Assembly
Figure 9-6 Remote Steering Hydraulic Cylinder Assembly
Figure 9-7 Main Pump – Front
Figure 9-8 Main Pump – Rear
Figure 9-9 Main Hydraulic Control Valve
Figure 9-10 Main Hydraulic Control Valve – Spools & End Caps
Figure 9-11 Main Hydraulic Control Valve – Swing Section
Figure 9-12 Main Hydraulic Control Valve – Seal Kits
Figure 9-13 Pilot Manifold Valve Tray Hydraulic Components
Figure 9-14 Pilot Manifold Assembly
Figure 9-15 Reservoir Assembly
Figure 9-16 Swing Transmission Installation
Figure 9-17 Swing Transmission Assembly
Figure 9-18 Swing Motor Assembly
Figure 9-19 Swing Brake Assembly
Figure 9-20 Tilt Transmission
Figure 9-21 Tilt Transmission Assembly
Figure 9-22 Tilt Motor Assembly
Figure 9-23 Tilt Brake Assembly
Figure 9-24 Travel Motor
Figure 9-25 Center Pin Assembly
Figure 9-26 Power Take-Off Assembly
Figure 9-27 Power Take-Off Counter Shaft
Figure 9-28 Oil Cooler Assembly
Figure 9-29 Hydraulic Heater Pump Assembly
Figure 9-30 Hydraulic Heater Manifold Assembly
Figure 9-31 Steering Gear Assembly
Figure 9-32 Counterbalance Valve Assembly
Figure 9-33 Counterbalance Valve
Figure 9-34 Cooling Fan Valve Assembly
Figure 9-35 Steering Valve Assembly
Figure 9-36 Dual Solenoid Valve Assembly
Figure 9-37 Hoist Limit Valve
Section 10 Electrical
Figure 10-1 Miscellaneous Electrical Components, Upperstructure
Figure 10-2 Battery Box, Batteries & Cables
Figure 10-3 Tail & Marker Lights
Figure 10-4 Head & Marker Lights
Figure 10-5 Horn & Miscellaneous, Undercarriage
Figure 10-6 Cab Console Circuit Board, Upperstructure
Figure 10-7 Cab Console Circuit Board, Undercarriage
Figure 10-8 Instrument Panel
Figure 10-9 Accessory Panel
Section 11 Decals
Figure 11-1 Decals, Upperstructure
Figure 11-2 Decals, Undercarriage
Section 12 Options
Figure 12-1 Air Conditioner Installation Components, Upperstructure
Figure 12-2 ‘04 EPA Air Conditioner Installation, Undercarriage
Figure 12-3 Air Conditioner General Kit
Figure 12-4 Additional Battery Installation Components
Figure 12-5 Block Heater Installation Components
Figure 12-6 Floodlight Installation Components
Figure 12-7 Locking Fuel Cap
Figure 12-8 Fire Extinguisher Installation, (Upperstructure)
Figure 12-9 Lube Chart Installation, (Upperstructure)
Figure 12-10 Strobe Light Installation, (Upperstructure)
Figure 12-11 Air Restriction Gauge Installation
Figure 12-12 Strobe Light Installation, (Undercarriage)
Figure 12-13 Drain Valve Installation
Figure 12-14 Two-Way Radio Power Installation
Figure 12-15 Cigarette Lighter
Figure 12-16 Fuel Warmer & Coolant Filter Installation
Figure 12-17 Fire Extinguisher Installation, (Undercarriage)
Figure 12-18 Lube Chart Installation, (Undercarriage)
Figure 12-19 Rear Window Cover Installation, (Undercarriage)
Figure 12-20 Rubber Battery Pad Installation
Figure 12-21 GVWR Plate Installation
Figure 12-22 Flare & Triangle Kit
Figure 12-23 Step Tread Installation
Figure 12-24 Stemco Seal Installation, Rear Axle
Figure 12-25 Stemco Seal Installation, Front Axle
Figure 12-26 Synthetic Fluid Installation
Recommended Spare Parts
Part Number Index
XL4100II Illustrated Parts Manual 31200247 2006.pdf (448 Pages)
Contents:
Service Kits
Section 1 Frame & Attaching Parts
Figure 1-1 Frame Assembly
Figure 1-2 Mirror & Grab Rails
Figure 1-3 Engine Cover
Figure 1-4 R.H. Fender & Mirrors
Figure 1-5 L.H. Fender
Figure 1-6 Rear Fender Assembly
Figure 1-7 Deck & Cover
Figure 1-8 Left Side Cover Assembly
Figure 1-9 Rotating Platform
Figure 1-10 Swing Bearing, Cradle & Hoist Cylinder Mounting & Lube System
Figure 1-11 Valve Cover
Section 2 Boom
Figure 2-1 Boom Cradle
Figure 2-2 Main Boom Assembly
Figure 2-3 Telescope Boom Assembly
Figure 2-4 Boom Roller Assemblies
Figure 2-5 Bucket Linkage
Section 3 Attachments
Figure 3-1 60” Ditching Bucket
Section 4 Engine & Attaching Parts
Figure 4-1 Engine Assembly, L.H. View
Figure 4-2 Engine Assembly, R.H. View
Figure 4-3 Air Cleaner Assembly
Figure 4-4 Power Steering Reservoir Assembly
Figure 4-5 Exhaust System
Figure 4-6 Fuel Tank & Lines
Figure 4-7 Radiator & Cooler Assembly
Figure 4-8 Oil Cooler & Hoses
Figure 4-9 Air Brake System
Figure 4-10 Spring Brake Control Valve & Parking Brake Valve Assemblies
Figure 4-11 Lockout Air Valve, Air Dryer & Adapter Assemblies
Figure 4-12 Air Valve Assemblies
Figure 4-13 Air Valve & Double Check Valve Assemblies
Figure 4-14 Air Reservoir Assemblies
Figure 4-15 Relay Valve Assemblies
Figure 4-16 Foot Pedal Valve & Air Fitting Assembly
Figure 4-17 Air Valve Assemblies
Figure 4-18 Air Valve & Air Fitting Assemblies
Section 5 Drive Train
Figure 5-1 Clutch Assembly
Figure 5-2 Clutch Release Bearing
Figure 5-3 Slave Valve Assembly
Figure 5-4 Transmission – Slave Control Assembly
Figure 5-5 Transmission – Slave Valve w/Hoses
Figure 5-6 Transmission – Clutch Housing
Figure 5-7 Transmission – Shift Bar Housing
Figure 5-8 Transmission – Reverse Idler, Input Shaft & Drive Gear
Figure 5-9 Transmission – Mainshaft & Countershaft Gears
Figure 5-10 Transmission – Auxiliary Mainshaft
Figure 5-11 Transmission – Auxiliary Case Assembly
Figure 5-12 Transmission – Range Cylinder
Figure 5-13 Transmission – Auxiliary Countershaft & Auxiliary Drive Gear
Figure 5-14 Transmission – Master Shift Valve Assembly
Figure 5-15 Propeller Shaft
Figure 5-16 Transfer Case Assembly, 6X6
Figure 5-17 Front Axle – Axle Assembly, 6X4
Figure 5-18 Front Axle – Steering Components, 6X4
Figure 5-19 Front Axle – Service Brakes, 6X4
Figure 5-20 Front Axle – Disc Wheel & Rims, 6X4
Figure 5-21 Front Axle – Axle Assembly, 6X6
Figure 5-22 Front Axle – Housing Assembly, 6X6
Figure 5-23 Front Axle – Differential Assembly, 6X6
Figure 5-24 Front Axle – Steering Components, 6X6
Figure 5-25 Front Axle – Service Brake, 6X6
Figure 5-26 Front Axle – Disc Wheels & Rims, 6X6
Figure 5-27 Front Axle – Spring Assembly
Figure 5-28 Rear Axle – Axle Assembly, 6X4
Figure 5-29 Rear Axle – Axle Assembly, 6X6
Figure 5-30 Rear Axle – Forward Housing
Figure 5-31 Rear Axle – Rear Housing
Figure 5-32 Rear Axle – Forward Differential Assembly
Figure 5-33 Rear Axle – Rear Differential Assembly
Figure 5-34 Rear Axle – Service Brake
Figure 5-35 Rear Axle – Disc Wheel & Rim
Figure 5-36 Equalizer Beams
Section 6 Cab
Figure 6-1 Operators Cab, Upperstructure
Figure 6-2 Operators Cab, Upperstructure
Figure 6-3 Cab Door, Upperstructure
Figure 6-4 Cab Interior Components, Upperstructure
Figure 6-5 Cab Console, Upperstructure
Figure 6-6 Cab Seat, Upperstructure
Figure 6-7 Cab Heater & Installation, Upperstructure
Figure 6-8 Operators Cab, Undercarriage
Figure 6-9 Operators Cab, Undercarriage
Figure 6-10 Cab Door, Undercarriage
Figure 6-11 Cab Seat, Undercarriage
Figure 6-12 Seat Suspension, Undercarriage
Figure 6-13 Heater & Defroster, Undercarriage
Figure 6-14 Pilot Cut-off Assembly
Section 7 Controls
Figure 7-1 Joystick Assembly
Figure 7-2 Steering Column Assembly
Figure 7-3 Steering Drive Shaft Assembly
Figure 7-4 Steering Drag Link Assembly
Figure 7-5 Foot Operated Pedal Valve Assembly
Figure 7-6 Foot Operated Pedal Plate Assembly
Section 8 Hydraulic Circuits
Figure 8-1 Hydraulic Oil Supply to Main Pump
Figure 8-2 Main Hydraulic Pump to Center Pin
Figure 8-3 Hydraulic Pressure from Center Pin to Control Valve
Figure 8-4 Main Valve to Pilot Manifold
Figure 8-5 Hydraulic Hosing To Joysticks & Foot Operated Pedal Valve
Figure 8-6 Upper Dump
Figure 8-7 Chassis Dump
Figure 8-8 Hoist Pilot
Figure 8-9 Boom Pilot
Figure 8-10 Tool Pilot
Figure 8-11 Tilt Pilot
Figure 8-12 Heater & Auxiliary Pilot
Figure 8-13 Hoist Cylinder
Figure 8-14 Boom Cylinder
Figure 8-15 Tool Cylinder
Figure 8-16 Swing & Swing Brake Pilot
Figure 8-17 Tool Pilot
Figure 8-18 Swing Motor
Figure 8-19 Tilt Motor
Figure 8-20 Steering Gear
Figure 8-21 Remote Propelling
Figure 8-22 Remote Steering
Figure 8-23 Stabilizer Cylinder
Section 9 Hydraulic Components
Figure 9-1 Hoist Cylinder Assembly
Figure 9-2 Boom Cylinder Assembly
Figure 9-3 Tool Cylinder Assembly
Figure 9-4 Stabilizer Cylinder Assembly
Figure 9-5 Stabilizer Valve Assembly
Figure 9-6 Remote Steering Hydraulic Cylinder Assembly
Figure 9-7 Main Pump – Front
Figure 9-8 Main Pump – Rear
Figure 9-9 Main Hydraulic Control Valve
Figure 9-10 Main Hydraulic Control Valve – Spools & End Caps
Figure 9-11 Main Hydraulic Control Valve – Swing Section
Figure 9-12 Main Hydraulic Control Valve – Seal Kits
Figure 9-13 Pilot Manifold Valve Tray Hydraulic Components
Figure 9-14 Pilot Manifold Assembly
Figure 9-15 Reservoir Assembly
Figure 9-16 Swing Transmission Installation
Figure 9-17 Swing Transmission Assembly
Figure 9-18 Swing Motor Assembly
Figure 9-19 Swing Brake Assembly
Figure 9-20 Tilt Transmission
Figure 9-21 Tilt Transmission Assembly
Figure 9-22 Tilt Motor Assembly
Figure 9-23 Tilt Brake Assembly
Figure 9-24 Travel Motor
Figure 9-25 Center Pin Assembly
Figure 9-26 Power Take-Off Assembly
Figure 9-27 Power Take-Off Counter Shaft
Figure 9-28 Oil Cooler Assembly
Figure 9-29 Hydraulic Heater Pump Assembly
Figure 9-30 Hydraulic Heater Manifold Assembly
Figure 9-31 Steering Gear Assembly
Figure 9-32 Counterbalance Valve Assembly
Figure 9-33 Counterbalance Valve
Figure 9-34 Cooling Fan Valve Assembly
Figure 9-35 Steering Valve Assembly
Figure 9-36 Dual Solenoid Valve Assembly
Figure 9-37 Hoist Limit Valve
Section 10 Electrical
Figure 10-1 Miscellaneous Electrical Components, Upperstructure
Figure 10-2 Battery Box, Batteries & Cables
Figure 10-3 Tail & Marker Lights
Figure 10-4 Head & Marker Lights
Figure 10-5 Horn & Miscellaneous, Undercarriage
Figure 10-6 Cab Console Circuit Board, Upperstructure
Figure 10-7 Cab Console Circuit Board, Undercarriage
Figure 10-8 Instrument Panel
Figure 10-9 Accessory Panel
Section 11 Decals
Figure 11-1 Decals, Upperstructure
Figure 11-2 Decals, Undercarriage
Section 12 Options
Figure 12-1 Air Conditioner Installation Components, Upperstructure
Figure 12-2 ‘04 EPA Air Conditioner Installation, Undercarriage
Figure 12-3 Air Conditioner General Kit
Figure 12-4 Floodlight Installation Components
Figure 12-5 Locking Fuel Cap
Figure 12-6 Seat Belt Installation Components
Figure 12-7 Strobe Light Installation Components
Figure 12-8 Fire Extinguisher Installation
Figure 12-9 Back-Up Alarm Installation
Figure 12-10 Fire Extinguisher Installation
Figure 12-11 Locking Toolbox
Figure 12-12 Mudflap Installation
Figure 12-13 Strobe Light Installation
Figure 12-14 Synthetic Fluid Installation
Recommended Spare Parts
Part Number Index
XL4100II Illustrated Parts Manual 31200248 2006.pdf (462 Pages)
Contents:
XL4100II Parts Manual T#220254, 227825
Effectivity Page
Table of Contents
Service Kits
Section 1 Frame & Attaching Parts
Figure 1-1 Frame Assembly
Figure 1-2 Mirror & Grab Rails
Figure 1-3 Engine Cover
Figure 1-4 R.H. Fender & Mirrors
Figure 1-5 L.H. Fender
Figure 1-6 Rear Fender Assembly
Figure 1-7 Deck & Cover
Figure 1-8 Left Side Cover Assembly
Figure 1-9 Rotating Platform
Figure 1-10 Swing Bearing, Cradle & Hoist Cylinder Mounting & Lube System
Figure 1-11 Valve Cover
Section 2 Boom
Figure 2-1 Boom Cradle
Figure 2-2 Main Boom Assembly
Figure 2-3 Telescope Boom Assembly
Figure 2-4 Boom Roller Assemblies
Figure 2-5 Bucket Linkage
Section 3 Attachments
Figure 3-1 60” Ditching Bucket
Figure 3-2 Hydraulic Thumb Installation
Figure 3-3 Hydraulic Thumb Weldment
Figure 3-4 72” Ditching Bucket
Figure 3-5 48” Excavating Bucket
Section 4 Engine & Attaching Parts
Figure 4-1 Engine Assembly, L.H. View
Figure 4-2 Engine Assembly, R.H. View
Figure 4-3 Air Cleaner Assembly
Figure 4-4 Power Steering Reservoir Assembly
Figure 4-5 Exhaust System
Figure 4-6 Fuel Tank & Lines
Figure 4-7 Radiator & Cooler Assemblies
Figure 4-8 Oil Cooler & Hoses
Figure 4-9 Air Brake System
Figure 4-10 Spring Brake Control Valve & Parking Brake Valve Assemblies
Figure 4-11 Lockout Air Valve, Air Dryer & Adapter Assemblies
Figure 4-12 Air Valve Assemblies
Figure 4-13 Air Valve & Double Check Valve Assemblies
Figure 4-14 Air Reservoir Assemblies
Figure 4-15 Relay Valve Assemblies
Figure 4-16 Foot Pedal Valve & Air Fitting Assembly
Figure 4-17 Air Valve Assemblies
Figure 4-18 Air Valve & Air Fitting Assemblies
Section 5 Drive Train
Figure 5-1 Clutch Assembly
Figure 5-2 Clutch Release Bearing
Figure 5-3 Slave Valve Assembly
Figure 5-4 Transmission – Slave Control Assembly
Figure 5-5 Transmission – Slave Valve w/Hoses
Figure 5-6 Transmission – Clutch Housing
Figure 5-7 Transmission – Shift Bar Housing
Figure 5-8 Transmission – Reverse Idler, Input Shaft & Drive Gear
Figure 5-9 Transmission – Mainshaft & Countershaft Gears
Figure 5-10 Transmission – Auxiliary Mainshaft
Figure 5-11 Transmission – Auxiliary Case Assembly
Figure 5-12 Transmission – Range Cylinder
Figure 5-13 Transmission – Auxiliary Countershaft & Auxiliary Drive Gear
Figure 5-14 Transmission – Master Shift Valve Assembly
Figure 5-15 Propeller Shaft
Figure 5-16 Transfer Case Assembly, 6X6
Figure 5-17 Front Axle – Axle Assembly, 6X4
Figure 5-18 Front Axle – Steering Components, 6X4
Figure 5-19 Front Axle – Service Brakes, 6X4
Figure 5-20 Front Axle – Disc Wheel & Rims, 6X4
Figure 5-21 Front Axle – Axle Assembly, 6X6
Figure 5-22 Front Axle – Housing Assembly, 6X6
Figure 5-23 Front Axle – Differential Assembly, 6X6
Figure 5-24 Front Axle – Steering Components, 6X6
Figure 5-25 Front Axle – Service Brake, 6X6
Figure 5-26 Front Axle – Disc Wheels & Rims, 6X6
Figure 5-27 Front Axle – Spring Assembly
Figure 5-28 Rear Axle – Axle Assembly, 6X4
Figure 5-29 Rear Axle – Axle Assembly, 6X6
Figure 5-30 Rear Axle – Forward Housing
Figure 5-31 Rear Axle – Rear Housing
Figure 5-32 Rear Axle – Forward Differential Assembly
Figure 5-33 Rear Axle – Rear Differential Assembly
Figure 5-34 Rear Axle – Service Brake
Figure 5-35 Rear Axle – Disc Wheel & Rim
Figure 5-36 Equalizer Beams
Section 6 Cab
Figure 6-1 Operators Cab, Upperstructure
Figure 6-2 Operators Cab, Upperstructure
Figure 6-3 Cab Door, Upperstructure
Figure 6-4 Cab Interior Components, Upperstructure
Figure 6-5 Cab Console, Upperstructure
Figure 6-6 Cab Seat, Upperstructure
Figure 6-7 Cab Heater & Installation, Upperstructure
Figure 6-8 Operators Cab, Undercarriage
Figure 6-9 Operators Cab, Undercarriage
Figure 6-10 Cab Door, Undercarriage
Figure 6-11 Cab Seat, Undercarriage
Figure 6-12 Seat Suspension, Undercarriage
Figure 6-13 Heater & Defroster, Undercarriage
Figure 6-14 Pilot Cut-off Assembly
Section 7 Controls
Figure 7-1 Joystick Assembly
Figure 7-2 Steering Column Assembly
Figure 7-3 Steering Drive Shaft Assembly
Figure 7-4 Steering Drag Link Assembly
Figure 7-5 Foot Operated Pedal Valve Assembly
Figure 7-6 Foot Operated Pedal Plate Assembly
Section 8 Hydraulic Circuits
Figure 8-1 Hydraulic Oil Supply to Main Pump
Figure 8-2 Main Hydraulic Pump to Center Pin
Figure 8-3 Hydraulic Pressure from Center Pin to Control Valve
Figure 8-4 Main Valve to Pilot Manifold
Figure 8-5 Hydraulic Hosing To Joysticks & Foot Operated Pedal Valve
Figure 8-6 Upper Dump
Figure 8-7 Chassis Dump
Figure 8-8 Hoist Pilot
Figure 8-9 Boom Pilot
Figure 8-10 Tool Pilot
Figure 8-11 Tilt Pilot
Figure 8-12 Heater & Auxiliary Pilot
Figure 8-13 Hoist Cylinder
Figure 8-14 Boom Cylinder
Figure 8-15 Tool Cylinder
Figure 8-16 Swing & Swing Brake Pilot
Figure 8-17 Tool Pilot
Figure 8-18 Swing Motor
Figure 8-19 Tilt Motor
Figure 8-20 Steering Gear
Figure 8-21 Remote Propelling
Figure 8-22 Remote Steering
Figure 8-23 Stabilizer Cylinder
Section 9 Hydraulic Components
Figure 9-1 Hoist Cylinder Assembly
Figure 9-2 Boom Cylinder Assembly
Figure 9-3 Tool Cylinder Assembly
Figure 9-4 Stabilizer Cylinder Assembly
Figure 9-5 Stabilizer Valve Assembly
Figure 9-6 Remote Steering Hydraulic Cylinder Assembly
Figure 9-7 Main Pump – Front
Figure 9-8 Main Pump – Rear
Figure 9-9 Main Hydraulic Control Valve
Figure 9-10 Main Hydraulic Control Valve – Spools & End Caps
Figure 9-11 Main Hydraulic Control Valve – Swing Section
Figure 9-12 Main Hydraulic Control Valve – Seal Kits
Figure 9-13 Pilot Manifold Valve Tray Hydraulic Components
Figure 9-14 Pilot Manifold Assembly
Figure 9-15 Reservoir Assembly
Figure 9-16 Swing Transmission Installation
Figure 9-17 Swing Transmission Assembly
Figure 9-18 Swing Motor Assembly
Figure 9-19 Swing Brake Assembly
Figure 9-20 Tilt Transmission
Figure 9-21 Tilt Transmission Assembly
Figure 9-22 Tilt Motor Assembly
Figure 9-23 Tilt Brake Assembly
Figure 9-24 Travel Motor
Figure 9-25 Center Pin Assembly
Figure 9-26 Power Take-Off Assembly
Figure 9-27 Power Take-Off Counter Shaft
Figure 9-28 Oil Cooler Assembly
Figure 9-29 Hydraulic Heater Pump Assembly
Figure 9-30 Hydraulic Heater Manifold Assembly
Figure 9-31 Steering Gear Assembly
Figure 9-32 Counterbalance Valve Assembly
Figure 9-33 Counterbalance Valve
Figure 9-34 Cooling Fan Valve Assembly
Figure 9-35 Steering Valve Assembly
Figure 9-36 Dual Solenoid Valve Assembly
Figure 9-37 Hoist Limit Valve
Section 10 Electrical
Figure 10-1 Miscellaneous Electrical Components, Upperstructure
Figure 10-2 Battery Box, Batteries & Cables
Figure 10-3 Tail & Marker Lights
Figure 10-4 Head & Marker Lights
Figure 10-5 Horn & Miscellaneous, Undercarriage
Figure 10-6 Cab Console Circuit Board, Upperstructure
Figure 10-7 Cab Console Circuit Board, Undercarriage
Figure 10-8 Instrument Panel
Figure 10-9 Accessory Panel
Section 11 Decals
Figure 11-1 Decals, Upperstructure
Figure 11-2 Decals, Undercarriage
Section 12 Options
Figure 12-1 Air Conditioner Installation Components, Upperstructure
Figure 12-2 ‘04 EPA Air Conditioner Installation, Undercarriage
Figure 12-3 Air Conditioner General Kit
Figure 12-4 Block Heater Installation Components
Figure 12-5 Floodlight Installation Components
Figure 12-6 Grid Heater Installation Components
Figure 12-7 Seat Belt Installation Components, Upperstructure
Figure 12-8 Strobe Light Installation Components
Figure 12-9 Radio & Antenna Installation (Upperstructure)
Figure 12-10 Auxiliary Hydraulics
Figure 12-11 Air Restriction Gauge Installation
Figure 12-12 AM/FM Cassette Stereo Installation
Figure 12-13 Strobe Light Installation
Figure 12-14 Dual Air Horn Installation
Figure 12-15 Additional Battery Installation & Master Disconnect Switch Installation
Recommended Spare Parts
Part Number Index
XL4100II Illustrated Parts Manual 31200254 2006.pdf (474 Pages)
Contents:
Service Kits
Section 1 Frame & Attaching Parts
Figure 1-1 Frame Assembly
Figure 1-2 Mirror & Grab Rails
Figure 1-3 Engine Cover
Figure 1-4 R.H. Fender & Mirrors
Figure 1-5 L.H. Fender
Figure 1-6 Rear Fender Assembly
Figure 1-7 Deck & Cover
Figure 1-8 Left Side Cover Assembly
Figure 1-9 Rotating Platform
Figure 1-10 Swing Bearing, Cradle & Hoist Cylinder Mounting & Lube System
Figure 1-11 Valve Cover
Section 2 Boom
Figure 2-1 Boom Cradle
Figure 2-2 Main Boom Assembly
Figure 2-3 Telescope Boom Assembly
Figure 2-4 Boom Roller Assemblies
Figure 2-5 Bucket Linkage
Section 3 Attachments
Figure 3-1 60” Ditching Bucket
Section 4 Engine & Attaching Parts
Figure 4-1 Engine Assembly, L.H. View
Figure 4-2 Engine Assembly, R.H. View
Figure 4-3 Air Cleaner Assembly
Figure 4-4 Power Steering Reservoir Assembly
Figure 4-5 Exhaust System
Figure 4-6 Fuel Tank & Lines
Figure 4-7 Radiator & Cooler Assemblies
Figure 4-8 Oil Cooler & Hoses
Figure 4-9 Air Brake System
Figure 4-10 Spring Brake Control Valve & Parking Brake Valve Assemblies
Figure 4-11 Lockout Air Valve, Air Dryer & Adapter Assemblies
Figure 4-12 Air Valve Assemblies
Figure 4-13 Air Valve & Double Check Valve Assemblies
Figure 4-14 Air Reservoir Assemblies
Figure 4-15 Relay Valve Assemblies
Figure 4-16 Foot Pedal Valve & Air Fitting Assembly
Figure 4-17 Air Valve Assemblies
Figure 4-18 Air Valve & Air Fitting Assemblies
Section 5 Drive Train
Figure 5-1 Clutch Assembly
Figure 5-2 Clutch Release Bearing
Figure 5-3 Slave Valve Assembly
Figure 5-4 Transmission – Slave Control Assembly
Figure 5-5 Transmission – Slave Valve w/Hoses
Figure 5-6 Transmission – Clutch Housing
Figure 5-7 Transmission – Shift Bar Housing
Figure 5-8 Transmission – Reverse Idler, Input Shaft & Drive Gear
Figure 5-9 Transmission – Mainshaft & Countershaft Gears
Figure 5-10 Transmission – Auxiliary Mainshaft
Figure 5-11 Transmission – Auxiliary Case Assembly
Figure 5-12 Transmission – Range Cylinder
Figure 5-13 Transmission – Auxiliary Countershaft & Auxiliary Drive Gear
Figure 5-14 Transmission – Master Shift Valve Assembly
Figure 5-15 Propeller Shaft
Figure 5-16 Transfer Case Assembly, 6X6
Figure 5-17 Front Axle – Axle Assembly, 6X4
Figure 5-18 Front Axle – Steering Components, 6X4
Figure 5-19 Front Axle – Service Brakes, 6X4
Figure 5-20 Front Axle – Disc Wheel & Rims, 6X4
Figure 5-21 Front Axle – Axle Assembly, 6X6
Figure 5-22 Front Axle – Housing Assembly, 6X6
Figure 5-23 Front Axle – Differential Assembly, 6X6
Figure 5-24 Front Axle – Steering Components, 6X6
Figure 5-25 Front Axle – Service Brake, 6X6
Figure 5-26 Front Axle – Disc Wheels & Rims, 6X6
Figure 5-27 Front Axle – Spring Assembly
Figure 5-28 Rear Axle – Axle Assembly, 6X4
Figure 5-29 Rear Axle – Axle Assembly, 6X6
Figure 5-30 Rear Axle – Forward Housing
Figure 5-31 Rear Axle – Rear Housing
Figure 5-32 Rear Axle – Forward Differential Assembly
Figure 5-33 Rear Axle – Rear Differential Assembly
Figure 5-34 Rear Axle – Service Brake
Figure 5-35 Rear Axle – Disc Wheel & Rim
Figure 5-36 Equalizer Beams
Section 6 Cab
Figure 6-1 Operators Cab, Upperstructure
Figure 6-2 Operators Cab, Upperstructure
Figure 6-3 Cab Door, Upperstructure
Figure 6-4 Cab Interior Components, Upperstructure
Figure 6-5 Cab Console, Upperstructure
Figure 6-6 Cab Seat, Upperstructure
Figure 6-7 Cab Heater & Installation, Upperstructure
Figure 6-8 Operators Cab, Undercarriage
Figure 6-9 Operators Cab, Undercarriage
Figure 6-10 Cab Door, Undercarriage
Figure 6-11 Cab Seat, Undercarriage
Figure 6-12 Seat Suspension, Undercarriage
Figure 6-13 Heater & Defroster, Undercarriage
Figure 6-14 Pilot Cut-off Assembly
Section 7 Controls
Figure 7-1 Joystick Assembly
Figure 7-2 Steering Column Assembly
Figure 7-3 Steering Drive Shaft Assembly
Figure 7-4 Steering Drag Link Assembly
Figure 7-5 Foot Operated Pedal Valve Assembly
Figure 7-6 Foot Operated Pedal Plate Assembly
Section 8 Hydraulic Circuits
Figure 8-1 Hydraulic Oil Supply to Main Pump
Figure 8-2 Main Hydraulic Pump to Center Pin
Figure 8-3 Hydraulic Pressure from Center Pin to Control Valve
Figure 8-4 Main Valve to Pilot Manifold
Figure 8-5 Hydraulic Hosing To Joysticks & Foot Operated Pedal Valve
Figure 8-6 Upper Dump
Figure 8-7 Chassis Dump
Figure 8-8 Hoist Pilot
Figure 8-9 Boom Pilot
Figure 8-10 Tool Pilot
Figure 8-11 Tilt Pilot
Figure 8-12 Heater & Auxiliary Pilot
Figure 8-13 Hoist Cylinder
Figure 8-14 Boom Cylinder
Figure 8-15 Tool Cylinder
Figure 8-16 Swing & Swing Brake Pilot
Figure 8-17 Tool Pilot
Figure 8-18 Swing Motor
Figure 8-19 Tilt Motor
Figure 8-20 Steering Gear
Figure 8-21 Remote Propelling
Figure 8-22 Remote Steering
Figure 8-23 Stabilizer Cylinder
Section 9 Hydraulic Components
Figure 9-1 Hoist Cylinder Assembly
Figure 9-2 Boom Cylinder Assembly
Figure 9-3 Tool Cylinder Assembly
Figure 9-4 Stabilizer Cylinder Assembly
Figure 9-5 Stabilizer Valve Assembly
Figure 9-6 Remote Steering Hydraulic Cylinder Assembly
Figure 9-7 Main Pump – Front
Figure 9-8 Main Pump – Rear
Figure 9-9 Main Hydraulic Control Valve
Figure 9-10 Main Hydraulic Control Valve – Spools & End Caps
Figure 9-11 Main Hydraulic Control Valve – Swing Section
Figure 9-12 Main Hydraulic Control Valve – Seal Kits
Figure 9-13 Pilot Manifold Valve Tray Hydraulic Components
Figure 9-14 Pilot Manifold Assembly
Figure 9-15 Reservoir Assembly
Figure 9-16 Swing Transmission Installation
Figure 9-17 Swing Transmission Assembly
Figure 9-18 Swing Motor Assembly
Figure 9-19 Swing Brake Assembly
Figure 9-20 Tilt Transmission
Figure 9-21 Tilt Transmission Assembly
Figure 9-22 Tilt Motor Assembly
Figure 9-23 Tilt Brake Assembly
Figure 9-24 Travel Motor
Figure 9-25 Center Pin Assembly
Figure 9-26 Power Take-Off Assembly
Figure 9-27 Power Take-Off Counter Shaft
Figure 9-28 Oil Cooler Assembly
Figure 9-29 Hydraulic Heater Pump Assembly
Figure 9-30 Hydraulic Heater Manifold Assembly
Figure 9-31 Steering Gear Assembly
Figure 9-32 Counterbalance Valve Assembly
Figure 9-33 Counterbalance Valve
Figure 9-34 Cooling Fan Valve Assembly
Figure 9-35 Steering Valve Assembly
Figure 9-36 Dual Solenoid Valve Assembly
Figure 9-37 Hoist Limit Valve
Section 10 Electrical
Figure 10-1 Miscellaneous Electrical Components, Upperstructure
Figure 10-2 Battery Box, Batteries & Cables
Figure 10-3 Tail & Marker Lights
Figure 10-4 Head & Marker Lights
Figure 10-5 Horn & Miscellaneous, Undercarriage
Figure 10-6 Cab Console Circuit Board, Upperstructure
Figure 10-7 Cab Console Circuit Board, Undercarriage
Figure 10-8 Instrument Panel
Figure 10-9 Accessory Panel
Section 11 Decals
Figure 11-1 Decals, Upperstructure
Figure 11-2 Decals, Undercarriage
Section 12 Options
Figure 12-1 Air Conditioner Installation Components, Upperstructure
Figure 12-2 ‘04 EPA Air Conditioner Installation, Undercarriage
Figure 12-3 Air Conditioner General Kit
Figure 12-4 Floodlight Installation Components
Figure 12-5 Grid Heater Installation Components
Figure 12-6 Radio & Antenna Installation (Upperstructure)
Figure 12-7 Air Restriction Gauge Installation
Figure 12-8 AM/FM Cassette Stereo Installation
Figure 12-9 Seat Belt Installation, Upperstructure
Figure 12-10 Chassis Cab Vandal Covers Installation Components
Figure 12-11 Additional Battery Installation Components
Figure 12-12 Upper Cab Vandal Kit
Figure 12-13 Three Point Seat Belt Installation
Figure 12-14 Coolant Filter Install
Figure 12-15 Fuel Filter Installation
Figure 12-16 Stemco Seal Installation, Rear Axle
Figure 12-17 Stemco Seal Installation, Front Axle
Figure 12-18 Synthetic Fluid Installation
Figure 12-19 Tilt Steering Column Installation
Figure 12-20 Wheel Chock Tray Installation
Figure 12-21 Sun Visor Installation, Upper Cab
Figure 12-22 Air Accessory Outlet w/Pressure Protection Installation
Figure 12-23 Low Engine Coolant Warning Installation
Figure 12-24 Transmission Oil Temperature Gauge Installation
Figure 12-25 Low Engine Coolant Warning Installation
Figure 12-26 Side Mounted Strobe Light Installation
Recommended Spare Parts
Part Number Index
XL4100II Illustrated Parts Manual 31200255 2006.pdf (472 Pages)
Contents:
Service Kits
Section 1 – Frame & Attaching Parts
Section 2 – Boom
Section 3 – Attachments
Section 4 – Engine & Attaching Parts
Section 5 – Drive Train
Section 6 – Cab
Section 7 – Controls
Section 8 – Hydraulic Circuits
Section 9 – Hydraulic Components
Section 10 – Electrical
Section 11 – Decals
Section 12 – Options
Recommended Spare Parts
Part Number Index
XL4100II Illustrated Parts Manual 31200257 2006.pdf (438 Pages)
Contents:
Service Kits
Section 1 – Frame & Attaching Parts
Section 2 – Boom
Section 3 – Attachments
Section 4 – Engine & Attaching Parts
Section 5 – Drive Train
Section 6 – Cab
Section 7 – Controls
Section 8 – Hydraulic Circuits
Section 9 – Hydraulic Components
Section 10 – Electrical
Section 11 – Decals
Section 12 – Options
Recommended Spare Parts
Part Number Index
XL4100II Illustrated Parts Manual 31200258 2006.pdf (452 Pages)
Contents:
Service Kits
Section 1 Frame & Attaching Parts
Figure 1-1 Frame Assembly
Figure 1-2 Mirror & Grab Rails
Figure 1-3 Engine Cover
Figure 1-4 R.H. Fender & Mirrors
Figure 1-5 L.H. Fender
Figure 1-6 Rear Fender Assembly
Figure 1-7 Deck & Cover
Figure 1-8 Left Side Cover Assembly
Figure 1-9 Rotating Platform
Figure 1-10 Swing Bearing, Cradle & Hoist Cylinder Mounting & Lube System
Figure 1-11 Valve Cover
Section 2 Boom
Figure 2-1 Boom Cradle
Figure 2-2 Main Boom Assembly
Figure 2-3 Telescope Boom Assembly
Figure 2-4 Boom Roller Assemblies
Figure 2-5 Bucket Linkage
Section 3 Attachments
Figure 3-1 24” Ditching Bucket
Figure 3-2 48” Ditching Bucket
Figure 3-3 24” Excavating Buckets
Figure 3-4 48” Excavating Bucket
Figure 3-5 Fixed Thumb Grapple Assembly
Figure 3-6 60” Ditching Bucket
Figure 3-7 60” Excavating Buckets
Section 4 Engine & Attaching Parts
Figure 4-1 Engine Assembly, L.H. View
Figure 4-2 Engine Assembly, R.H. View
Figure 4-3 Air Cleaner Assembly
Figure 4-4 Power Steering Reservoir Assembly
Figure 4-5 Exhaust System
Figure 4-6 Fuel Tank & Lines
Figure 4-7 Radiator & Cooler Assemblies
Figure 4-8 Oil Cooler & Hoses
Figure 4-9 Air Brake System
Figure 4-10 Spring Brake Control Valve & Parking Brake Valve Assemblies
Figure 4-11 Lockout Air Valve, Air Dryer & Adapter Assemblies
Figure 4-12 Air Valve Assemblies
Figure 4-13 Air Valve & Double Check Valve Assemblies
Figure 4-14 Air Reservoir Assemblies
Figure 4-15 Relay Valve Assemblies
Figure 4-16 Foot Pedal Valve & Air Fitting Assembly
Figure 4-17 Air Valve Assemblies
Figure 4-18 Air Valve & Air Fitting Assemblies
Section 5 Drive Train
Figure 5-1 Clutch Assembly
Figure 5-2 Clutch Release Bearing
Figure 5-3 Slave Valve Assembly
Figure 5-4 Transmission – Slave Control Assembly
Figure 5-5 Transmission – Slave Valve w/Hoses
Figure 5-6 Transmission – Clutch Housing
Figure 5-7 Transmission – Shift Bar Housing
Figure 5-8 Transmission – Reverse Idler, Input Shaft & Drive Gear
Figure 5-9 Transmission – Mainshaft & Countershaft Gears
Figure 5-10 Transmission – Auxiliary Mainshaft
Figure 5-11 Transmission – Auxiliary Case Assembly
Figure 5-12 Transmission – Range Cylinder
Figure 5-13 Transmission – Auxiliary Countershaft & Auxiliary Drive Gear
Figure 5-14 Transmission – Master Shift Valve Assembly
Figure 5-15 Propeller Shaft
Figure 5-16 Front Axle – Axle Assembly, 6X4
Figure 5-17 Front Axle – Steering Components, 6X4
Figure 5-18 Front Axle – Service Brakes, 6X4
Figure 5-19 Front Axle – Disc Wheel & Rims, 6X4
Figure 5-20 Front Axle – Spring Assembly
Figure 5-21 Rear Axle – Axle Assembly, 6X4
Figure 5-22 Rear Axle – Forward Housing
Figure 5-23 Rear Axle – Rear Housing
Figure 5-24 Rear Axle – Forward Differential Assembly
Figure 5-25 Rear Axle – Rear Differential Assembly
Figure 5-26 Rear Axle – Service Brake
Figure 5-27 Rear Axle – Disc Wheel & Rim
Figure 5-28 Equalizer Beams
Section 6 Cab
Figure 6-1 Cab Assembly, Upperstructure
Figure 6-2 Cab Assembly, Upperstructure
Figure 6-3 Cab Door Assembly, Upperstructure
Figure 6-4 Cab Interior Components, Upperstructure
Figure 6-5 Cab Console, Upperstructure
Figure 6-6 Seat Assembly, Upperstructure
Figure 6-7 Cab Heater & Installation, Upperstructure
Figure 6-8 Cab Assembly, Undercarriage
Figure 6-9 Cab Assembly, Undercarriage
Figure 6-10 Cab Door Assembly, Undercarriage
Figure 6-11 Seat Assembly, Undercarriage
Figure 6-12 Seat Suspension, Undercarriage
Figure 6-13 Heater & Defroster, Undercarriage
Figure 6-14 Pilot Cutoff Assembly
Section 7 Controls
Figure 7-1 Joystick Assembly
Figure 7-2 Steering Column Assembly
Figure 7-3 Steering Drive Shaft Assembly
Figure 7-4 Steering Drag Link Assembly
Figure 7-5 Foot Operated Pedal Valve Assembly
Figure 7-6 Foot Operated Pedal Plate Assembly
Section 8 Hydraulic Circuits
Figure 8-1 Hydraulic Oil Supply to Main Pump
Figure 8-2 Main Hydraulic Pump to Center Pin
Figure 8-3 Hydraulic Pressure from Center Pin to Control Valve
Figure 8-4 Main Valve to Pilot Manifold
Figure 8-5 Hydraulic Hosing To Joysticks & Foot Operated Pedal Valve
Figure 8-6 Upper Dump
Figure 8-7 Chassis Dump
Figure 8-8 Hoist Pilot
Figure 8-9 Boom Pilot
Figure 8-10 Tool Pilot
Figure 8-11 Tilt Pilot
Figure 8-12 Heater & Auxiliary Pilot
Figure 8-13 Hoist Cylinder
Figure 8-14 Boom Cylinder
Figure 8-15 Tool Cylinder
Figure 8-16 Swing & Swing Brake Pilot
Figure 8-17 Tool Pilot
Figure 8-18 Swing Motor
Figure 8-19 Tilt Motor
Figure 8-20 Steering Gear
Figure 8-21 Remote Propelling
Figure 8-22 Remote Steering
Figure 8-23 Stabilizer Cylinder
Section 9 Hydraulic Components
Figure 9-1 Hoist Cylinder Assembly
Figure 9-2 Boom Cylinder Assembly
Figure 9-3 Tool Cylinder Assembly
Figure 9-4 Stabilizer Cylinder Assembly
Figure 9-5 Stabilizer Valve Assembly
Figure 9-6 Remote Steering Hydraulic Cylinder Assembly
Figure 9-7 Front Main Pump
Figure 9-8 Rear Main Pump
Figure 9-9 Main Hydraulic Control Valve Assembly
Figure 9-10 Main Hydraulic Control Valve Assembly
Figure 9-11 Main Hydraulic Control Valve Assembly
Figure 9-12 Main Hydraulic Control Valve Kits
Figure 9-13 Pilot Manifold Valve Tray Hydraulic Components
Figure 9-14 Pilot Manifold Assembly
Figure 9-15 Reservoir Assembly
Figure 9-16 Swing Transmission Installation
Figure 9-17 Swing Transmission Assembly
Figure 9-18 Swing Motor Assembly
Figure 9-19 Swing Brake Assembly
Figure 9-20 Tilt Transmission
Figure 9-21 Tilt Transmission Assembly
Figure 9-22 Tilt Motor Assembly
Figure 9-23 Tilt Brake Assembly
Figure 9-24 Travel Motor
Figure 9-25 Center Pin Assembly
Figure 9-26 Power Take-Off Assembly
Figure 9-27 Power Take-Off Counter Shaft
Figure 9-28 Oil Cooler Assembly
Figure 9-29 Hydraulic Heater Pump Assembly
Figure 9-30 Hydraulic Heater Manifold Assembly
Figure 9-31 Steering Gear Assembly
Figure 9-32 Counterbalance Valve Assembly
Figure 9-33 Counterbalance Valve
Figure 9-34 Cooling Fan Valve Assembly
Figure 9-35 Steering Valve Assembly
Figure 9-36 Dual Solenoid Valve Assembly
Figure 9-37 Hoist Limit Valve
Section 10 Electrical
Figure 10-1 Miscellaneous Electrical Components, Upperstructure
Figure 10-2 Battery Box, Batteries & Cables
Figure 10-3 Tail & Marker Lights
Figure 10-4 Head & Marker Lights
Figure 10-5 Horn & Miscellaneous, Undercarriage
Figure 10-6 Cab Console Circuit Board, Upperstructure
Figure 10-7 Cab Console Circuit Board, Undercarriage
Figure 10-8 Instrument Panel
Figure 10-9 Accessory Panel
Section 11 Decals
Figure 11-1 Decals, Upperstructure
Figure 11-2 Decals, Undercarriage
Section 12 Options
Figure 12-1 Air Conditioner Installation Components, Upperstructure
Figure 12-2 ‘04 EPA Air Conditioner Installation (Undercarriage)
Figure 12-3 Air Conditioner Evaporator Kit
Figure 12-4 Additional Battery Installation & Master Disconnect Switch Installation
Figure 12-5 Floodlight Installation Components
Figure 12-6 Grid Heater Installation Components
Figure 12-7 Locking Fuel Cap
Figure 12-8 Strobe Light Installation Components
Figure 12-9 Dual Air Horn Installation
Figure 12-10 Lube Chart Installation, (Upperstructure)
Figure 12-11 Drain Valve Installation
Figure 12-12 Fire Extinguisher Installation
Figure 12-13 Rail Gear Installation
Figure 12-14 Lube Chart Installation, (Chassis)
Figure 12-15 GVW Tag Installation (Chassis)
Figure 12-16 Strobe Light Installation
Figure 12-17 Brake Activated Lights Installation
Figure 12-18 Auxiliary Hydraulics
Figure 12-19 Engine Block Heater Installation
Recommended Spare Parts
Part Number Index
XL4100II Illustrated Parts Manual 31200259 2006.pdf (480 Pages)
Contents:
Service Kits
Section 1 Frame & Attaching Parts
Figure 1-1 Frame Assembly
Figure 1-2 Mirror & Grab Rails
Figure 1-3 Engine Cover
Figure 1-4 R.H. Fender & Mirrors
Figure 1-5 L.H. Fender
Figure 1-6 Rear Fender Assembly
Figure 1-7 Deck & Cover
Figure 1-8 Left Side Cover Assembly
Figure 1-9 Rotating Platform
Figure 1-10 Swing Bearing, Cradle & Hoist Cylinder Mounting & Lube System
Figure 1-11 Valve Cover
Section 2 Boom
Figure 2-1 Boom Cradle
Figure 2-2 Main Boom Assembly
Figure 2-3 Telescope Boom Assembly
Figure 2-4 Boom Roller Assemblies
Figure 2-5 Bucket Linkage
Section 3 Attachments
Figure 3-1 24” Excavating Buckets
Figure 3-2 36” Excavating Buckets
Figure 3-3 60” Ditching Bucket
Section 4 Engine & Attaching Parts
Figure 4-1 Engine Assembly, L.H. View
Figure 4-2 Engine Assembly, R.H. View
Figure 4-3 Air Cleaner Assembly
Figure 4-4 Power Steering Reservoir Assembly
Figure 4-5 Exhaust System
Figure 4-6 Fuel Tank & Lines
Figure 4-7 Radiator & Cooler Assemblies
Figure 4-8 Oil Cooler & Hoses
Figure 4-9 Air Brake System
Figure 4-10 Spring Brake Control Valve & Parking Brake Valve Assemblies
Figure 4-11 Lockout Air Valve, Air Dryer & Adapter Assemblies
Figure 4-12 Air Valve Assemblies
Figure 4-13 Air Valve & Double Check Valve Assemblies
Figure 4-14 Air Reservoir Assemblies
Figure 4-15 Relay Valve Assemblies
Figure 4-16 Foot Pedal Valve & Air Fitting Assembly
Figure 4-17 Air Valve Assemblies
Figure 4-18 Air Valve & Air Fitting Assemblies
Section 5 Drive Train
Figure 5-1 Clutch Assembly
Figure 5-2 Clutch Release Bearing
Figure 5-3 Slave Valve Assembly
Figure 5-4 Transmission – Slave Control Assembly
Figure 5-5 Transmission – Slave Valve w/Hoses
Figure 5-6 Transmission – Clutch Housing
Figure 5-7 Transmission – Shift Bar Housing
Figure 5-8 Transmission – Reverse Idler, Input Shaft & Drive Gear
Figure 5-9 Transmission – Mainshaft & Countershaft Gears
Figure 5-10 Transmission – Auxiliary Mainshaft
Figure 5-11 Transmission – Auxiliary Case Assembly
Figure 5-12 Transmission – Range Cylinder
Figure 5-13 Transmission – Auxiliary Countershaft & Auxiliary Drive Gear
Figure 5-14 Transmission – Master Shift Valve Assembly
Figure 5-15 Propeller Shaft
Figure 5-16 Transfer Case Assembly, 6X6
Figure 5-17 Front Axle – Axle Assembly, 6X4
Figure 5-18 Front Axle – Steering Components, 6X4
Figure 5-19 Front Axle – Service Brakes, 6X4
Figure 5-20 Front Axle – Disc Wheel & Rims, 6X4
Figure 5-21 Front Axle – Axle Assembly, 6X6
Figure 5-22 Front Axle – Housing Assembly, 6X6
Figure 5-23 Front Axle – Differential Assembly, 6X6
Figure 5-24 Front Axle – Steering Components, 6X6
Figure 5-25 Front Axle – Service Brake, 6X6
Figure 5-26 Front Axle – Disc Wheels & Rims, 6X6
Figure 5-27 Front Axle – Spring Assembly
Figure 5-28 Rear Axle – Axle Assembly, 6X4
Figure 5-29 Rear Axle – Axle Assembly, 6X6
Figure 5-30 Rear Axle – Forward Housing
Figure 5-31 Rear Axle – Rear Housing
Figure 5-32 Rear Axle – Forward Differential Assembly
Figure 5-33 Rear Axle – Rear Differential Assembly
Figure 5-34 Rear Axle – Service Brake
Figure 5-35 Rear Axle – Disc Wheel & Rim
Figure 5-36 Equalizer Beams
Section 6 Cab
Figure 6-1 Operators Cab, Upperstructure
Figure 6-2 Operators Cab, Upperstructure
Figure 6-3 Cab Door, Upperstructure
Figure 6-4 Cab Interior Components, Upperstructure
Figure 6-5 Cab Console, Upperstructure
Figure 6-6 Cab Seat, Upperstructure
Figure 6-7 Cab Heater & Installation, Upperstructure
Figure 6-8 Operators Cab, Undercarriage
Figure 6-9 Operators Cab, Undercarriage
Figure 6-10 Cab Door, Undercarriage
Figure 6-11 Cab Seat, Undercarriage
Figure 6-12 Seat Suspension, Undercarriage
Figure 6-13 Heater & Defroster, Undercarriage
Figure 6-14 Pilot Cut-off Assembly
Section 7 Controls
Figure 7-1 Joystick Assembly
Figure 7-2 Steering Column Assembly
Figure 7-3 Steering Drive Shaft Assembly
Figure 7-4 Steering Drag Link Assembly
Figure 7-5 Foot Operated Pedal Valve Assembly
Figure 7-6 Foot Operated Pedal Plate Assembly
Section 8 Hydraulic Circuits
Figure 8-1 Hydraulic Oil Supply to Main Pump
Figure 8-2 Main Hydraulic Pump to Center Pin
Figure 8-3 Hydraulic Pressure from Center Pin to Control Valve
Figure 8-4 Main Valve to Pilot Manifold
Figure 8-5 Hydraulic Hosing To Joysticks & Foot Operated Pedal Valve
Figure 8-6 Upper Dump
Figure 8-7 Chassis Dump
Figure 8-8 Hoist Pilot
Figure 8-9 Boom Pilot
Figure 8-10 Tool Pilot
Figure 8-11 Tilt Pilot
Figure 8-12 Heater & Auxiliary Pilot
Figure 8-13 Hoist Cylinder
Figure 8-14 Boom Cylinder
Figure 8-15 Tool Cylinder
Figure 8-16 Swing & Swing Brake Pilot
Figure 8-17 Tool Pilot
Figure 8-18 Swing Motor
Figure 8-19 Tilt Motor
Figure 8-20 Steering Gear
Figure 8-21 Remote Propelling
Figure 8-22 Remote Steering
Figure 8-23 Stabilizer Cylinder
Section 9 Hydraulic Components
Figure 9-1 Hoist Cylinder Assembly
Figure 9-2 Boom Cylinder Assembly
Figure 9-3 Tool Cylinder Assembly
Figure 9-4 Stabilizer Cylinder Assembly
Figure 9-5 Stabilizer Valve Assembly
Figure 9-6 Remote Steering Hydraulic Cylinder Assembly
Figure 9-7 Main Pump – Front
Figure 9-8 Main Pump – Rear
Figure 9-9 Main Hydraulic Control Valve
Figure 9-10 Main Hydraulic Control Valve – Spools & End Caps
Figure 9-11 Main Hydraulic Control Valve – Swing Section
Figure 9-12 Main Hydraulic Control Valve – Seal Kits
Figure 9-13 Pilot Manifold Valve Tray Hydraulic Components
Figure 9-14 Pilot Manifold Assembly
Figure 9-15 Reservoir Assembly
Figure 9-16 Swing Transmission Installation
Figure 9-17 Swing Transmission Assembly
Figure 9-18 Swing Motor Assembly
Figure 9-19 Swing Brake Assembly
Figure 9-20 Tilt Transmission
Figure 9-21 Tilt Transmission Assembly
Figure 9-22 Tilt Motor Assembly
Figure 9-23 Tilt Brake Assembly
Figure 9-24 Travel Motor
Figure 9-25 Center Pin Assembly
Figure 9-26 Power Take-Off Assembly
Figure 9-27 Power Take-Off Counter Shaft
Figure 9-28 Oil Cooler Assembly
Figure 9-29 Hydraulic Heater Pump Assembly
Figure 9-30 Hydraulic Heater Manifold Assembly
Figure 9-31 Steering Gear Assembly
Figure 9-32 Counterbalance Valve Assembly
Figure 9-33 Counterbalance Valve
Figure 9-34 Cooling Fan Valve Assembly
Figure 9-35 Steering Valve Assembly
Figure 9-36 Dual Solenoid Valve Assembly
Figure 9-37 Hoist Limit Valve
Section 10 Electrical
Figure 10-1 Miscellaneous Electrical Components, Upperstructure
Figure 10-2 Battery Box, Batteries & Cables
Figure 10-3 Tail & Marker Lights
Figure 10-4 Head & Marker Lights
Figure 10-5 Horn & Miscellaneous, Undercarriage
Figure 10-6 Cab Console Circuit Board, Upperstructure
Figure 10-7 Cab Console Circuit Board, Undercarriage
Figure 10-8 Instrument Panel
Figure 10-9 Accessory Panel
Section 11 Decals
Figure 11-1 Decals, Upperstructure
Figure 11-2 Decals, Undercarriage
Section 12 Options
Figure 12-1 Air Conditioner Installation Components, Upperstructure
Figure 12-2 ‘04 EPA Air Conditioner Installation, Undercarriage
Figure 12-3 Air Conditioner General Kit
Figure 12-4 Additional Battery Installation Components
Figure 12-5 Block Heater Installation Components
Figure 12-6 Floodlight Installation Components
Figure 12-7 Step Tread Installation
Figure 12-8 Stemco Seal Installation, Rear Axle
Figure 12-9 Stemco Seal Installation, Front Axle
Figure 12-10 Fire Extinguisher Installation, (Upperstructure)
Figure 12-11 Lube Chart Installation, (Upperstructure)
Figure 12-12 Air Restriction Gauge Installation
Figure 12-13 Strobe Light Installation, (Undercarriage)
Figure 12-14 Drain Valve Installation
Figure 12-15 Two-Way Radio Power Installation
Figure 12-16 Cigarette Lighter
Figure 12-17 Fuel Warmer & Coolant Filter Installation
Figure 12-18 Fire Extinguisher Installation, (Undercarriage)
Figure 12-19 Lube Chart Installation, (Undercarriage)
Figure 12-20 Rear Window Cover Installation, (Undercarriage)
Figure 12-21 Rubber Battery Pad Installation
Figure 12-22 GVWR Plate Installation
Figure 12-23 Flare & Triangle Kit
Figure 12-24 Synthetic Fluid Installation
Figure 12-25 Auxiliary Hydraulics
Figure 12-26 Strobe Light Installation, (Upperstructure)
Recommended Spare Parts
Part Number Index
XL4100II Illustrated Parts Manual 31200264 2006.pdf (454 Pages)
Contents:
Service Kits
Section 1 Frame & Attaching Parts
Figure 1-1 Frame Assembly
Figure 1-2 Mirror & Grab Rails
Figure 1-3 Engine Cover
Figure 1-4 R.H. Fender & Mirrors
Figure 1-5 L.H. Fender
Figure 1-6 Rear Fender Assembly
Figure 1-7 Deck & Cover
Figure 1-8 Left Side Cover Assembly
Figure 1-9 Rotating Platform
Figure 1-10 Swing Bearing, Cradle & Hoist Cylinder Mounting & Lube System
Figure 1-11 Valve Cover
Section 2 Boom
Figure 2-1 Boom Cradle
Figure 2-2 Main Boom Assembly
Figure 2-3 Telescope Boom Assembly
Figure 2-4 Boom Roller Assemblies
Figure 2-5 Bucket Linkage
Section 3 Attachments
Figure 3-1 60” Ditching Bucket
Figure 3-2 Telestick Installation
Section 4 Engine & Attaching Parts
Figure 4-1 Engine Assembly, L.H. View
Figure 4-2 Engine Assembly, R.H. View
Figure 4-3 Air Cleaner Assembly
Figure 4-4 Power Steering Reservoir Assembly
Figure 4-5 Exhaust System
Figure 4-6 Fuel Tank & Lines
Figure 4-7 Radiator & Cooler Assemblies
Figure 4-8 Oil Cooler & Hoses
Figure 4-9 Air Brake System
Figure 4-10 Spring Brake Control Valve & Parking Brake Valve Assemblies
Figure 4-11 Lockout Air Valve, Air Dryer & Adapter Assemblies
Figure 4-12 Air Valve Assemblies
Figure 4-13 Air Valve & Double Check Valve Assemblies
Figure 4-14 Air Reservoir Assemblies
Figure 4-15 Relay Valve Assemblies
Figure 4-16 Foot Pedal Valve & Air Fitting Assembly
Figure 4-17 Air Valve Assemblies
Figure 4-18 Air Valve & Air Fitting Assemblies
Section 5 Drive Train
Figure 5-1 Clutch Assembly
Figure 5-2 Clutch Release Bearing
Figure 5-3 Slave Valve Assembly
Figure 5-4 Transmission – Slave Control Assembly
Figure 5-5 Transmission – Slave Valve w/Hoses
Figure 5-6 Transmission – Clutch Housing
Figure 5-7 Transmission – Shift Bar Housing
Figure 5-8 Transmission – Reverse Idler, Input Shaft & Drive Gear
Figure 5-9 Transmission – Mainshaft & Countershaft Gears
Figure 5-10 Transmission – Auxiliary Mainshaft
Figure 5-11 Transmission – Auxiliary Case Assembly
Figure 5-12 Transmission – Range Cylinder
Figure 5-13 Transmission – Auxiliary Countershaft & Auxiliary Drive Gear
Figure 5-14 Transmission – Master Shift Valve Assembly
Figure 5-15 Propeller Shaft
Figure 5-16 Transfer Case Assembly, 6X6
Figure 5-17 Front Axle – Axle Assembly, 6X4
Figure 5-18 Front Axle – Steering Components, 6X4
Figure 5-19 Front Axle – Service Brakes, 6X4
Figure 5-20 Front Axle – Disc Wheel & Rims, 6X4
Figure 5-21 Front Axle – Axle Assembly, 6X6
Figure 5-22 Front Axle – Housing Assembly, 6X6
Figure 5-23 Front Axle – Differential Assembly, 6X6
Figure 5-24 Front Axle – Steering Components, 6X6
Figure 5-25 Front Axle – Service Brake, 6X6
Figure 5-26 Front Axle – Disc Wheels & Rims, 6X6
Figure 5-27 Front Axle – Spring Assembly
Figure 5-28 Rear Axle – Axle Assembly, 6X4
Figure 5-29 Rear Axle – Axle Assembly, 6X6
Figure 5-30 Rear Axle – Forward Housing
Figure 5-31 Rear Axle – Rear Housing
Figure 5-32 Rear Axle – Forward Differential Assembly
Figure 5-33 Rear Axle – Rear Differential Assembly
Figure 5-34 Rear Axle – Service Brake
Figure 5-35 Rear Axle – Disc Wheel & Rim
Figure 5-36 Equalizer Beams
Section 6 Cab
Figure 6-1 Operators Cab, Upperstructure
Figure 6-2 Operators Cab, Upperstructure
Figure 6-3 Cab Door, Upperstructure
Figure 6-4 Cab Interior Components, Upperstructure
Figure 6-5 Cab Console, Upperstructure
Figure 6-6 Cab Seat, Upperstructure
Figure 6-7 Cab Heater & Installation, Upperstructure
Figure 6-8 Operators Cab, Undercarriage
Figure 6-9 Operators Cab, Undercarriage
Figure 6-10 Cab Door, Undercarriage
Figure 6-11 Cab Seat, Undercarriage
Figure 6-12 Seat Suspension, Undercarriage
Figure 6-13 Heater & Defroster, Undercarriage
Figure 6-14 Pilot Cut-off Assembly
Section 7 Controls
Figure 7-1 Joystick Assembly
Figure 7-2 Steering Column Assembly
Figure 7-3 Steering Drive Shaft Assembly
Figure 7-4 Steering Drag Link Assembly
Figure 7-5 Foot Operated Pedal Valve Assembly
Figure 7-6 Foot Operated Pedal Plate Assembly
Section 8 Hydraulic Circuits
Figure 8-1 Hydraulic Oil Supply to Main Pump
Figure 8-2 Main Hydraulic Pump to Center Pin
Figure 8-3 Hydraulic Pressure from Center Pin to Control Valve
Figure 8-4 Main Valve to Pilot Manifold
Figure 8-5 Hydraulic Hosing To Joysticks & Foot Operated Pedal Valve
Figure 8-6 Upper Dump
Figure 8-7 Chassis Dump
Figure 8-8 Hoist Pilot
Figure 8-9 Boom Pilot
Figure 8-10 Tool Pilot
Figure 8-11 Tilt Pilot
Figure 8-12 Heater & Auxiliary Pilot
Figure 8-13 Hoist Cylinder
Figure 8-14 Boom Cylinder
Figure 8-15 Tool Cylinder
Figure 8-16 Swing & Swing Brake Pilot
Figure 8-17 Tool Pilot
Figure 8-18 Swing Motor
Figure 8-19 Tilt Motor
Figure 8-20 Steering Gear
Figure 8-21 Remote Propelling
Figure 8-22 Remote Steering
Figure 8-23 Stabilizer Cylinder
Section 9 Hydraulic Components
Figure 9-1 Hoist Cylinder Assembly
Figure 9-2 Boom Cylinder Assembly
Figure 9-3 Tool Cylinder Assembly
Figure 9-4 Stabilizer Cylinder Assembly
Figure 9-5 Stabilizer Valve Assembly
Figure 9-6 Remote Steering Hydraulic Cylinder Assembly
Figure 9-7 Main Pump – Front
Figure 9-8 Main Pump – Rear
Figure 9-9 Main Hydraulic Control Valve
Figure 9-10 Main Hydraulic Control Valve – Spools & End Caps
Figure 9-11 Main Hydraulic Control Valve – Swing Section
Figure 9-12 Main Hydraulic Control Valve – Seal Kits
Figure 9-13 Pilot Manifold Valve Tray Hydraulic Components
Figure 9-14 Pilot Manifold Assembly
Figure 9-15 Reservoir Assembly
Figure 9-16 Swing Transmission Installation
Figure 9-17 Swing Transmission Assembly
Figure 9-18 Swing Motor Assembly
Figure 9-19 Swing Brake Assembly
Figure 9-20 Tilt Transmission
Figure 9-21 Tilt Transmission Assembly
Figure 9-22 Tilt Motor Assembly
Figure 9-23 Tilt Brake Assembly
Figure 9-24 Travel Motor
Figure 9-25 Center Pin Assembly
Figure 9-26 Power Take-Off Assembly
Figure 9-27 Power Take-Off Counter Shaft
Figure 9-28 Oil Cooler Assembly
Figure 9-29 Hydraulic Heater Pump Assembly
Figure 9-30 Hydraulic Heater Manifold Assembly
Figure 9-31 Steering Gear Assembly
Figure 9-32 Counterbalance Valve Assembly
Figure 9-33 Counterbalance Valve
Figure 9-34 Cooling Fan Valve Assembly
Figure 9-35 Steering Valve Assembly
Figure 9-36 Dual Solenoid Valve Assembly
Figure 9-37 Hoist Limit Valve
Section 10 Electrical
Figure 10-1 Miscellaneous Electrical Components, Upperstructure
Figure 10-2 Battery Box, Batteries & Cables
Figure 10-3 Tail & Marker Lights
Figure 10-4 Head & Marker Lights
Figure 10-5 Horn & Miscellaneous, Undercarriage
Figure 10-6 Cab Console Circuit Board, Upperstructure
Figure 10-7 Cab Console Circuit Board, Undercarriage
Figure 10-8 Instrument Panel
Figure 10-9 Accessory Panel
Section 11 Decals
Figure 11-1 Decals, Upperstructure
Figure 11-2 Decals, Undercarriage
Section 12 Options
Figure 12-1 Air Conditioner Installation Components, Upperstructure
Figure 12-2 ‘04 EPA Air Conditioner Installation, Undercarriage
Figure 12-3 Air Conditioner General Kit
Figure 12-4 Locking Fuel Cap
Figure 12-5 Seat Belt Installation Components
Figure 12-6 Strobe Light Installation Components
Figure 12-7 Fire Extinguisher Installation
Figure 12-8 Fire Extinguisher Installation
Figure 12-9 Back-Up Alarm Installation
Figure 12-10 Mudflap Installation
Figure 12-11 Locking Toolbox
Figure 12-12 Auxiliary Hydraulics
Figure 12-13 Floodlight Installation Components
Recommended Spare Parts
Part Number Index
XL4100II Illustrated Parts Manual 31200265 2006.pdf (460 Pages)
Contents:
XL4100II Parts Manual SO#851302
Effectivity Page
Table of Contents
Service Kits
Section 1 Frame & Attaching Parts
Figure 1-1 Frame Assembly
Figure 1-2 Mirror & Grab Rails
Figure 1-3 Engine Cover
Figure 1-4 R.H. Fender & Mirrors
Figure 1-5 L.H. Fender
Figure 1-6 Rear Fender Assembly
Figure 1-7 Deck & Cover
Figure 1-8 Left Side Cover Assembly
Figure 1-9 Rotating Platform
Figure 1-10 Swing Bearing, Cradle & Hoist Cylinder Mounting & Lube System
Figure 1-11 Valve Cover
Section 2 Boom
Figure 2-1 Boom Cradle
Figure 2-2 Main Boom Assembly
Figure 2-3 Telescope Boom Assembly
Figure 2-4 Boom Roller Assemblies
Figure 2-5 Bucket Linkage
Section 3 Attachments
Figure 3-1 30” Excavating Buckets
Figure 3-2 66” Ditching Bucket
Figure 3-3 6’ Boom Extension
Figure 3-4 Fixed Thumb Grapple Assembly
Figure 3-5 Telestick Installation
Section 4 Engine & Attaching Parts
Figure 4-1 Engine Assembly, L.H. View
Figure 4-2 Engine Assembly, R.H. View
Figure 4-3 Air Cleaner Assembly
Figure 4-4 Power Steering Reservoir Assembly
Figure 4-5 Exhaust System
Figure 4-6 Fuel Tank & Lines
Figure 4-7 Radiator & Cooler Assemblies
Figure 4-8 Oil Cooler & Hoses
Figure 4-9 Air Brake System
Figure 4-10 Spring Brake Control Valve & Parking Brake Valve Assemblies
Figure 4-11 Lockout Air Valve, Air Dryer & Adapter Assemblies
Figure 4-12 Air Valve Assemblies
Figure 4-13 Air Valve & Double Check Valve Assemblies
Figure 4-14 Air Reservoir Assemblies
Figure 4-15 Relay Valve Assemblies
Figure 4-16 Foot Pedal Valve & Air Fitting Assembly
Figure 4-17 Air Valve Assemblies
Figure 4-18 Air Valve & Air Fitting Assemblies
Section 5 Drive Train
Figure 5-1 Clutch Assembly
Figure 5-2 Clutch Release Bearing
Figure 5-3 Slave Valve Assembly
Figure 5-4 Transmission – Slave Control Assembly
Figure 5-5 Transmission – Slave Valve w/Hoses
Figure 5-6 Transmission – Clutch Housing
Figure 5-7 Transmission – Shift Bar Housing
Figure 5-8 Transmission – Reverse Idler, Input Shaft & Drive Gear
Figure 5-9 Transmission – Mainshaft & Countershaft Gears
Figure 5-10 Transmission – Auxiliary Mainshaft
Figure 5-11 Transmission – Auxiliary Case Assembly
Figure 5-12 Transmission – Range Cylinder
Figure 5-13 Transmission – Auxiliary Countershaft & Auxiliary Drive Gear
Figure 5-14 Transmission – Master Shift Valve Assembly
Figure 5-15 Propeller Shaft
Figure 5-16 Transfer Case Assembly, 6X6
Figure 5-17 Front Axle – Axle Assembly, 6X4
Figure 5-18 Front Axle – Steering Components, 6X4
Figure 5-19 Front Axle – Service Brakes, 6X4
Figure 5-20 Front Axle – Disc Wheel & Rims, 6X4
Figure 5-21 Front Axle – Axle Assembly, 6X6
Figure 5-22 Front Axle – Housing Assembly, 6X6
Figure 5-23 Front Axle – Differential Assembly, 6X6
Figure 5-24 Front Axle – Steering Components, 6X6
Figure 5-25 Front Axle – Service Brake, 6X6
Figure 5-26 Front Axle – Disc Wheels & Rims, 6X6
Figure 5-27 Front Axle – Spring Assembly
Figure 5-28 Rear Axle – Axle Assembly, 6X4
Figure 5-29 Rear Axle – Axle Assembly, 6X6
Figure 5-30 Rear Axle – Forward Housing
Figure 5-31 Rear Axle – Rear Housing
Figure 5-32 Rear Axle – Forward Differential Assembly
Figure 5-33 Rear Axle – Rear Differential Assembly
Figure 5-34 Rear Axle – Service Brake
Figure 5-35 Rear Axle – Disc Wheel & Rim
Figure 5-36 Equalizer Beams
Section 6 Cab
Figure 6-1 Operators Cab, Upperstructure
Figure 6-2 Operators Cab, Upperstructure
Figure 6-3 Cab Door, Upperstructure
Figure 6-4 Cab Interior Components, Upperstructure
Figure 6-5 Cab Console, Upperstructure
Figure 6-6 Cab Seat, Upperstructure
Figure 6-7 Cab Heater & Installation, Upperstructure
Figure 6-8 Operators Cab, Undercarriage
Figure 6-9 Operators Cab, Undercarriage
Figure 6-10 Cab Door, Undercarriage
Figure 6-11 Cab Seat, Undercarriage
Figure 6-12 Seat Suspension, Undercarriage
Figure 6-13 Heater & Defroster, Undercarriage
Figure 6-14 Pilot Cut-off Assembly
Section 7 Controls
Figure 7-1 Joystick Assembly
Figure 7-2 Steering Column Assembly
Figure 7-3 Steering Drive Shaft Assembly
Figure 7-4 Steering Drag Link Assembly
Figure 7-5 Foot Operated Pedal Valve Assembly
Figure 7-6 Foot Operated Pedal Plate Assembly
Section 8 Hydraulic Circuits
Figure 8-1 Hydraulic Oil Supply to Main Pump
Figure 8-2 Main Hydraulic Pump to Center Pin
Figure 8-3 Hydraulic Pressure from Center Pin to Control Valve
Figure 8-4 Main Valve to Pilot Manifold
Figure 8-5 Hydraulic Hosing To Joysticks & Foot Operated Pedal Valve
Figure 8-6 Upper Dump
Figure 8-7 Chassis Dump
Figure 8-8 Hoist Pilot
Figure 8-9 Boom Pilot
Figure 8-10 Tool Pilot
Figure 8-11 Tilt Pilot
Figure 8-12 Heater & Auxiliary Pilot
Figure 8-13 Hoist Cylinder
Figure 8-14 Boom Cylinder
Figure 8-15 Tool Cylinder
Figure 8-16 Swing & Swing Brake Pilot
Figure 8-17 Tool Pilot
Figure 8-18 Swing Motor
Figure 8-19 Tilt Motor
Figure 8-20 Steering Gear
Figure 8-21 Remote Propelling
Figure 8-22 Remote Steering
Figure 8-23 Stabilizer Cylinder
Section 9 Hydraulic Components
Figure 9-1 Hoist Cylinder Assembly
Figure 9-2 Boom Cylinder Assembly
Figure 9-3 Tool Cylinder Assembly
Figure 9-4 Stabilizer Cylinder Assembly
Figure 9-5 Stabilizer Valve Assembly
Figure 9-6 Remote Steering Hydraulic Cylinder Assembly
Figure 9-7 Main Pump – Front
Figure 9-8 Main Pump – Rear
Figure 9-9 Main Hydraulic Control Valve
Figure 9-10 Main Hydraulic Control Valve – Spools & End Caps
Figure 9-11 Main Hydraulic Control Valve – Swing Section
Figure 9-12 Main Hydraulic Control Valve – Seal Kits
Figure 9-13 Pilot Manifold Valve Tray Hydraulic Components
Figure 9-14 Pilot Manifold Assembly
Figure 9-15 Reservoir Assembly
Figure 9-16 Swing Transmission Installation
Figure 9-17 Swing Transmission Assembly
Figure 9-18 Swing Motor Assembly
Figure 9-19 Swing Brake Assembly
Figure 9-20 Tilt Transmission
Figure 9-21 Tilt Transmission Assembly
Figure 9-22 Tilt Motor Assembly
Figure 9-23 Tilt Brake Assembly
Figure 9-24 Travel Motor
Figure 9-25 Center Pin Assembly
Figure 9-26 Power Take-Off Assembly
Figure 9-27 Power Take-Off Counter Shaft
Figure 9-28 Oil Cooler Assembly
Figure 9-29 Hydraulic Heater Pump Assembly
Figure 9-30 Hydraulic Heater Manifold Assembly
Figure 9-31 Steering Gear Assembly
Figure 9-32 Counterbalance Valve Assembly
Figure 9-33 Counterbalance Valve
Figure 9-34 Cooling Fan Valve Assembly
Figure 9-35 Steering Valve Assembly
Figure 9-36 Dual Solenoid Valve Assembly
Figure 9-37 Hoist Limit Valve
Section 10 Electrical
Figure 10-1 Miscellaneous Electrical Components, Upperstructure
Figure 10-2 Battery Box, Batteries & Cables
Figure 10-3 Tail & Marker Lights
Figure 10-4 Head & Marker Lights
Figure 10-5 Horn & Miscellaneous, Undercarriage
Figure 10-6 Cab Console Circuit Board, Upperstructure
Figure 10-7 Cab Console Circuit Board, Undercarriage
Figure 10-8 Instrument Panel
Figure 10-9 Accessory Panel
Section 11 Decals
Figure 11-1 Decals, Upperstructure
Figure 11-2 Decals, Undercarriage
Section 12 Options
Figure 12-1 Air Conditioner Installation Components, Upperstructure
Figure 12-2 ‘04 EPA Air Conditioner Installation, Undercarriage
Figure 12-3 Air Conditioner General Kit
Figure 12-4 Locking Fuel Cap
Figure 12-5 L.H. Rear Step Assembly
Figure 12-6 Seat Belt Installation Components
Figure 12-7 Hourmeter Installation
Figure 12-8 License Plate Bracket Installation
Figure 12-9 Dual Air Horn Installation
Figure 12-10 TXDOT Light Package
Figure 12-11 Floodlight Installation Components
Figure 12-12 Lube Chart Installation, (Upperstructure)
Figure 12-13 Lube Chart Installation, (Chassis)
Figure 12-14 Fire Extinguisher Installation
Recommended Spare Parts
Part Number Index
XL4100II Illustrated Parts Manual 31200266 2006.pdf (436 Pages)
Contents:
Service Kits
Section 1 Frame & Attaching Parts
Figure 1-1 Frame Assembly
Figure 1-2 Mirror & Grab Rails
Figure 1-3 Engine Cover
Figure 1-4 R.H. Fender & Mirrors
Figure 1-5 L.H. Fender
Figure 1-6 Rear Fender Assembly
Figure 1-7 Deck & Cover
Figure 1-8 Left Side Cover Assembly
Figure 1-9 Rotating Platform
Figure 1-10 Swing Bearing, Cradle & Hoist Cylinder Mounting & Lube System
Figure 1-11 Valve Cover
Section 2 Boom
Figure 2-1 Boom Cradle
Figure 2-2 Main Boom Assembly
Figure 2-3 Telescope Boom Assembly
Figure 2-4 Boom Roller Assemblies
Figure 2-5 Bucket Linkage
Section 3 Attachments
Figure 3-1 48” Excavating Bucket
Section 4 Engine & Attaching Parts
Figure 4-1 Engine Assembly, L.H. View
Figure 4-2 Engine Assembly, R.H. View
Figure 4-3 Air Cleaner Assembly
Figure 4-4 Power Steering Reservoir Assembly
Figure 4-5 Exhaust System
Figure 4-6 Fuel Tank & Lines
Figure 4-7 Radiator & Cooler Assemblies
Figure 4-8 Oil Cooler & Hoses
Figure 4-9 Air Brake System
Figure 4-10 Spring Brake Control Valve & Parking Brake Valve Assemblies
Figure 4-11 Lockout Air Valve, Air Dryer & Adapter Assemblies
Figure 4-12 Air Valve Assemblies
Figure 4-13 Air Valve & Double Check Valve Assemblies
Figure 4-14 Air Reservoir Assemblies
Figure 4-15 Relay Valve Assemblies
Figure 4-16 Foot Pedal Valve & Air Fitting Assembly
Figure 4-17 Air Valve Assemblies
Figure 4-18 Air Valve & Air Fitting Assemblies
Section 5 Drive Train
Figure 5-1 Clutch Assembly
Figure 5-2 Clutch Release Bearing
Figure 5-3 Slave Valve Assembly
Figure 5-4 Transmission – Slave Control Assembly
Figure 5-5 Transmission – Slave Valve w/Hoses
Figure 5-6 Transmission – Clutch Housing
Figure 5-7 Transmission – Shift Bar Housing
Figure 5-8 Transmission – Reverse Idler, Input Shaft & Drive Gear
Figure 5-9 Transmission – Mainshaft & Countershaft Gears
Figure 5-10 Transmission – Auxiliary Mainshaft
Figure 5-11 Transmission – Auxiliary Case Assembly
Figure 5-12 Transmission – Range Cylinder
Figure 5-13 Transmission – Auxiliary Countershaft & Auxiliary Drive Gear
Figure 5-14 Transmission – Master Shift Valve Assembly
Figure 5-15 Propeller Shaft
Figure 5-16 Transfer Case Assembly, 6X6
Figure 5-17 Front Axle – Axle Assembly, 6X4
Figure 5-18 Front Axle – Steering Components, 6X4
Figure 5-19 Front Axle – Service Brakes, 6X4
Figure 5-20 Front Axle – Disc Wheel & Rims, 6X4
Figure 5-21 Front Axle – Axle Assembly, 6X6
Figure 5-22 Front Axle – Housing Assembly, 6X6
Figure 5-23 Front Axle – Differential Assembly, 6X6
Figure 5-24 Front Axle – Steering Components, 6X6
Figure 5-25 Front Axle – Service Brake, 6X6
Figure 5-26 Front Axle – Disc Wheels & Rims, 6X6
Figure 5-27 Front Axle – Spring Assembly
Figure 5-28 Rear Axle – Axle Assembly, 6X4
Figure 5-29 Rear Axle – Axle Assembly, 6X6
Figure 5-30 Rear Axle – Forward Housing
Figure 5-31 Rear Axle – Rear Housing
Figure 5-32 Rear Axle – Forward Differential Assembly
Figure 5-33 Rear Axle – Rear Differential Assembly
Figure 5-34 Rear Axle – Service Brake
Figure 5-35 Rear Axle – Disc Wheel & Rim
Figure 5-36 Equalizer Beams
Section 6 Cab
Figure 6-1 Operators Cab, Upperstructure
Figure 6-2 Operators Cab, Upperstructure
Figure 6-3 Cab Door, Upperstructure
Figure 6-4 Cab Interior Components, Upperstructure
Figure 6-5 Cab Console, Upperstructure
Figure 6-6 Cab Seat, Upperstructure
Figure 6-7 Cab Heater & Installation, Upperstructure
Figure 6-8 Operators Cab, Undercarriage
Figure 6-9 Operators Cab, Undercarriage
Figure 6-10 Cab Door, Undercarriage
Figure 6-11 Cab Seat, Undercarriage
Figure 6-12 Seat Suspension, Undercarriage
Figure 6-13 Heater & Defroster, Undercarriage
Figure 6-14 Pilot Cut-off Assembly
Section 7 Controls
Figure 7-1 Joystick Assembly
Figure 7-2 Steering Column Assembly
Figure 7-3 Steering Drive Shaft Assembly
Figure 7-4 Steering Drag Link Assembly
Figure 7-5 Foot Operated Pedal Valve Assembly
Figure 7-6 Foot Operated Pedal Plate Assembly
Section 8 Hydraulic Circuits
Figure 8-1 Hydraulic Oil Supply to Main Pump
Figure 8-2 Main Hydraulic Pump to Center Pin
Figure 8-3 Hydraulic Pressure from Center Pin to Control Valve
Figure 8-4 Main Valve to Pilot Manifold
Figure 8-5 Hydraulic Hosing To Joysticks & Foot Operated Pedal Valve
Figure 8-6 Upper Dump
Figure 8-7 Chassis Dump
Figure 8-8 Hoist Pilot
Figure 8-9 Boom Pilot
Figure 8-10 Tool Pilot
Figure 8-11 Tilt Pilot
Figure 8-12 Heater & Auxiliary Pilot
Figure 8-13 Hoist Cylinder
Figure 8-14 Boom Cylinder
Figure 8-15 Tool Cylinder
Figure 8-16 Swing & Swing Brake Pilot
Figure 8-17 Tool Pilot
Figure 8-18 Swing Motor
Figure 8-19 Tilt Motor
Figure 8-20 Steering Gear
Figure 8-21 Remote Propelling
Figure 8-22 Remote Steering
Figure 8-23 Stabilizer Cylinder
Section 9 Hydraulic Components
Figure 9-1 Hoist Cylinder Assembly
Figure 9-2 Boom Cylinder Assembly
Figure 9-3 Tool Cylinder Assembly
Figure 9-4 Stabilizer Cylinder Assembly
Figure 9-5 Stabilizer Valve Assembly
Figure 9-6 Remote Steering Hydraulic Cylinder Assembly
Figure 9-7 Main Pump – Front
Figure 9-8 Main Pump – Rear
Figure 9-9 Main Hydraulic Control Valve
Figure 9-10 Main Hydraulic Control Valve – Spools & End Caps
Figure 9-11 Main Hydraulic Control Valve – Swing Section
Figure 9-12 Main Hydraulic Control Valve – Seal Kits
Figure 9-13 Pilot Manifold Valve Tray Hydraulic Components
Figure 9-14 Pilot Manifold Assembly
Figure 9-15 Reservoir Assembly
Figure 9-16 Swing Transmission Installation
Figure 9-17 Swing Transmission Assembly
Figure 9-18 Swing Motor Assembly
Figure 9-19 Swing Brake Assembly
Figure 9-20 Tilt Transmission
Figure 9-21 Tilt Transmission Assembly
Figure 9-22 Tilt Motor Assembly
Figure 9-23 Tilt Brake Assembly
Figure 9-24 Travel Motor
Figure 9-25 Center Pin Assembly
Figure 9-26 Power Take-Off Assembly
Figure 9-27 Power Take-Off Counter Shaft
Figure 9-28 Oil Cooler Assembly
Figure 9-29 Hydraulic Heater Pump Assembly
Figure 9-30 Hydraulic Heater Manifold Assembly
Figure 9-31 Steering Gear Assembly
Figure 9-32 Counterbalance Valve Assembly
Figure 9-33 Counterbalance Valve
Figure 9-34 Cooling Fan Valve Assembly
Figure 9-35 Steering Valve Assembly
Figure 9-36 Dual Solenoid Valve Assembly
Figure 9-37 Hoist Limit Valve
Section 10 Electrical
Figure 10-1 Miscellaneous Electrical Components, Upperstructure
Figure 10-2 Battery Box, Batteries & Cables
Figure 10-3 Tail & Marker Lights
Figure 10-4 Head & Marker Lights
Figure 10-5 Horn & Miscellaneous, Undercarriage
Figure 10-6 Cab Console Circuit Board, Upperstructure
Figure 10-7 Cab Console Circuit Board, Undercarriage
Figure 10-8 Instrument Panel
Figure 10-9 Accessory Panel
Section 11 Decals
Figure 11-1 Decals, Upperstructure
Figure 11-2 Decals, Undercarriage
Section 12 Options
Figure 12-1 Additional Battery Installation Components
Figure 12-2 Block Heater Installation Components
Figure 12-3 Grid Heater Installation Components
Figure 12-4 Floodlight Installation Components
Figure 12-5 Auxiliary Hydraulics
Figure 12-6 Strobe Light Installation
Figure 12-7 Battery and Hydraulic Tank Heater Components
Recommended Spare Parts
Part Number Index
XL4100II Illustrated Parts Manual 31200267 2006.pdf (448 Pages)
Contents:
Service Kits
Section 1 Frame & Attaching Parts
Figure 1-1 Frame Assembly
Figure 1-2 Mirror & Grab Rails
Figure 1-3 Engine Cover
Figure 1-4 R.H. Fender & Mirrors
Figure 1-5 L.H. Fender
Figure 1-6 Rear Fender Assembly
Figure 1-7 Deck & Cover
Figure 1-8 Left Side Cover Assembly
Figure 1-9 Rotating Platform
Figure 1-10 Swing Bearing, Cradle & Hoist Cylinder Mounting & Lube System
Figure 1-11 Valve Cover
Section 2 Boom
Figure 2-1 Boom Cradle
Figure 2-2 Main Boom Assembly
Figure 2-3 Telescope Boom Assembly
Figure 2-4 Boom Roller Assemblies
Figure 2-5 Bucket Linkage
Section 3 Attachments
Figure 3-1 24” Excavating Buckets
Figure 3-2 36” Excavating Buckets
Figure 3-3 8’ Grading Blade
Figure 3-4 Fixed Thumb Grapple Assembly
Figure 3-5 60” Ditching Bucket w/Bolt-on Cutting Edge
Section 4 Engine & Attaching Parts
Figure 4-1 Engine Assembly, L.H. View
Figure 4-2 Engine Assembly, R.H. View
Figure 4-3 Air Cleaner Assembly
Figure 4-4 Power Steering Reservoir Assembly
Figure 4-5 Exhaust System
Figure 4-6 Fuel Tank & Lines
Figure 4-7 Radiator & Cooler Assemblies
Figure 4-8 Oil Cooler & Hoses
Figure 4-9 Air Brake System
Figure 4-10 Spring Brake Control Valve & Parking Brake Valve Assemblies
Figure 4-11 Lockout Air Valve, Air Dryer & Adapter Assemblies
Figure 4-12 Air Valve Assemblies
Figure 4-13 Air Valve & Double Check Valve Assemblies
Figure 4-14 Air Reservoir Assemblies
Figure 4-15 Relay Valve Assemblies
Figure 4-16 Foot Pedal Valve & Air Fitting Assembly
Figure 4-17 Air Valve Assemblies
Figure 4-18 Air Valve & Air Fitting Assemblies
Section 5 Drive Train
Figure 5-1 Clutch Assembly
Figure 5-2 Clutch Release Bearing
Figure 5-3 Slave Valve Assembly
Figure 5-4 Transmission – Slave Control Assembly
Figure 5-5 Transmission – Slave Valve w/Hoses
Figure 5-6 Transmission – Clutch Housing
Figure 5-7 Transmission – Shift Bar Housing
Figure 5-8 Transmission – Reverse Idler, Input Shaft & Drive Gear
Figure 5-9 Transmission – Mainshaft & Countershaft Gears
Figure 5-10 Transmission – Auxiliary Mainshaft
Figure 5-11 Transmission – Auxiliary Case Assembly
Figure 5-12 Transmission – Range Cylinder
Figure 5-13 Transmission – Auxiliary Countershaft & Auxiliary Drive Gear
Figure 5-14 Transmission – Master Shift Valve Assembly
Figure 5-15 Propeller Shaft
Figure 5-16 Transfer Case Assembly, 6X6
Figure 5-17 Front Axle – Axle Assembly, 6X4
Figure 5-18 Front Axle – Steering Components, 6X4
Figure 5-19 Front Axle – Service Brakes, 6X4
Figure 5-20 Front Axle – Disc Wheel & Rims, 6X4
Figure 5-21 Front Axle – Axle Assembly, 6X6
Figure 5-22 Front Axle – Housing Assembly, 6X6
Figure 5-23 Front Axle – Differential Assembly, 6X6
Figure 5-24 Front Axle – Steering Components, 6X6
Figure 5-25 Front Axle – Service Brake, 6X6
Figure 5-26 Front Axle – Disc Wheels & Rims, 6X6
Figure 5-27 Front Axle – Spring Assembly
Figure 5-28 Rear Axle – Axle Assembly, 6X4
Figure 5-29 Rear Axle – Axle Assembly, 6X6
Figure 5-30 Rear Axle – Forward Housing
Figure 5-31 Rear Axle – Rear Housing
Figure 5-32 Rear Axle – Forward Differential Assembly
Figure 5-33 Rear Axle – Rear Differential Assembly
Figure 5-34 Rear Axle – Service Brake
Figure 5-35 Rear Axle – Disc Wheel & Rim
Figure 5-36 Equalizer Beams
Section 6 Cab
Figure 6-1 Operators Cab, Upperstructure
Figure 6-2 Operators Cab, Upperstructure
Figure 6-3 Cab Door, Upperstructure
Figure 6-4 Cab Interior Components, Upperstructure
Figure 6-5 Cab Console, Upperstructure
Figure 6-6 Cab Seat, Upperstructure
Figure 6-7 Cab Heater & Installation, Upperstructure
Figure 6-8 Operators Cab, Undercarriage
Figure 6-9 Operators Cab, Undercarriage
Figure 6-10 Cab Door, Undercarriage
Figure 6-11 Cab Seat, Undercarriage
Figure 6-12 Seat Suspension, Undercarriage
Figure 6-13 Heater & Defroster, Undercarriage
Figure 6-14 Pilot Cut-off Assembly
Section 7 Controls
Figure 7-1 Joystick Assembly
Figure 7-2 Steering Column Assembly
Figure 7-3 Steering Drive Shaft Assembly
Figure 7-4 Steering Drag Link Assembly
Figure 7-5 Foot Operated Pedal Valve Assembly
Figure 7-6 Foot Operated Pedal Plate Assembly
Section 8 Hydraulic Circuits
Figure 8-1 Hydraulic Oil Supply to Main Pump
Figure 8-2 Main Hydraulic Pump to Center Pin
Figure 8-3 Hydraulic Pressure from Center Pin to Control Valve
Figure 8-4 Main Valve to Pilot Manifold
Figure 8-5 Hydraulic Hosing To Joysticks & Foot Operated Pedal Valve
Figure 8-6 Upper Dump
Figure 8-7 Chassis Dump
Figure 8-8 Hoist Pilot
Figure 8-9 Boom Pilot
Figure 8-10 Tool Pilot
Figure 8-11 Tilt Pilot
Figure 8-12 Heater & Auxiliary Pilot
Figure 8-13 Hoist Cylinder
Figure 8-14 Boom Cylinder
Figure 8-15 Tool Cylinder
Figure 8-16 Swing & Swing Brake Pilot
Figure 8-17 Tool Pilot
Figure 8-18 Swing Motor
Figure 8-19 Tilt Motor
Figure 8-20 Steering Gear
Figure 8-21 Remote Propelling
Figure 8-22 Remote Steering
Figure 8-23 Stabilizer Cylinder
Section 9 Hydraulic Components
Figure 9-1 Hoist Cylinder Assembly
Figure 9-2 Boom Cylinder Assembly
Figure 9-3 Tool Cylinder Assembly
Figure 9-4 Stabilizer Cylinder Assembly
Figure 9-5 Stabilizer Valve Assembly
Figure 9-6 Remote Steering Hydraulic Cylinder Assembly
Figure 9-7 Main Pump – Front
Figure 9-8 Main Pump – Rear
Figure 9-9 Main Hydraulic Control Valve
Figure 9-10 Main Hydraulic Control Valve – Spools & End Caps
Figure 9-11 Main Hydraulic Control Valve – Swing Section
Figure 9-12 Main Hydraulic Control Valve – Seal Kits
Figure 9-13 Pilot Manifold Valve Tray Hydraulic Components
Figure 9-14 Pilot Manifold Assembly
Figure 9-15 Reservoir Assembly
Figure 9-16 Swing Transmission Installation
Figure 9-17 Swing Transmission Assembly
Figure 9-18 Swing Motor Assembly
Figure 9-19 Swing Brake Assembly
Figure 9-20 Tilt Transmission
Figure 9-21 Tilt Transmission Assembly
Figure 9-22 Tilt Motor Assembly
Figure 9-23 Tilt Brake Assembly
Figure 9-24 Travel Motor
Figure 9-25 Center Pin Assembly
Figure 9-26 Power Take-Off Assembly
Figure 9-27 Power Take-Off Counter Shaft
Figure 9-28 Oil Cooler Assembly
Figure 9-29 Hydraulic Heater Pump Assembly
Figure 9-30 Hydraulic Heater Manifold Assembly
Figure 9-31 Steering Gear Assembly
Figure 9-32 Counterbalance Valve Assembly
Figure 9-33 Counterbalance Valve
Figure 9-34 Cooling Fan Valve Assembly
Figure 9-35 Steering Valve Assembly
Figure 9-36 Dual Solenoid Valve Assembly
Figure 9-37 Hoist Limit Valve
Section 10 Electrical
Figure 10-1 Miscellaneous Electrical Components, Upperstructure
Figure 10-2 Battery Box, Batteries & Cables
Figure 10-3 Tail & Marker Lights
Figure 10-4 Head & Marker Lights
Figure 10-5 Horn & Miscellaneous, Undercarriage
Figure 10-6 Cab Console Circuit Board, Upperstructure
Figure 10-7 Cab Console Circuit Board, Undercarriage
Figure 10-8 Instrument Panel
Figure 10-9 Accessory Panel
Section 11 Decals
Figure 11-1 Decals, Upperstructure
Figure 11-2 Decals, Undercarriage
Section 12 Options
Figure 12-1 Air Conditioner Installation Components, Upperstructure
Figure 12-2 ‘04 EPA Air Conditioner Installation, Undercarriage
Figure 12-3 Air Conditioner General Kit
Figure 12-4 Block Heater Installation Components
Figure 12-5 Grid Heater Installation Components
Figure 12-6 Floodlight Installation Components
Figure 12-7 Fuel Filter Installation
Figure 12-8 Auxiliary Hydraulics
Recommended Spare Parts
Part Number Index
XL4100II Illustrated Parts Manual 31200270 2006.pdf (432 Pages)
Contents:
Service Kits
Section 1 Frame & Attaching Parts
Figure 1-1 Frame Assembly
Figure 1-2 Mirror & Grab Rails
Figure 1-3 Engine Cover
Figure 1-4 R.H. Fender & Mirrors
Figure 1-5 L.H. Fender
Figure 1-6 Rear Fender Assembly
Figure 1-7 Deck & Cover
Figure 1-8 Left Side Cover Assembly
Figure 1-9 Rotating Platform
Figure 1-10 Swing Bearing, Cradle & Hoist Cylinder Mounting & Lube System
Figure 1-11 Valve Cover
Section 2 Boom
Figure 2-1 Boom Cradle
Figure 2-2 Main Boom Assembly
Figure 2-3 Telescope Boom Assembly
Figure 2-4 Boom Roller Assemblies
Figure 2-5 Bucket Linkage
Section 3 Attachments
Figure 3-1 36” Excavating Bucket
Figure 3-2 41” Ditching Bucket
Section 4 Engine & Attaching Parts
Figure 4-1 Engine Assembly, L.H. View
Figure 4-2 Engine Assembly, R.H. View
Figure 4-3 Air Cleaner Assembly
Figure 4-4 Power Steering Reservoir Assembly
Figure 4-5 Exhaust System
Figure 4-6 Fuel Tank & Lines
Figure 4-7 Radiator & Cooler Assemblies
Figure 4-8 Oil Cooler & Hoses
Figure 4-9 Air Brake System
Figure 4-10 Spring Brake Control Valve & Parking Brake Valve Assemblies
Figure 4-11 Lockout Air Valve, Air Dryer & Adapter Assemblies
Figure 4-12 Air Valve Assemblies
Figure 4-13 Air Valve & Double Check Valve Assemblies
Figure 4-14 Air Reservoir Assemblies
Figure 4-15 Relay Valve Assemblies
Figure 4-16 Foot Pedal Valve & Air Fitting Assembly
Figure 4-17 Air Valve Assemblies
Figure 4-18 Air Valve & Air Fitting Assemblies
Section 5 Drive Train
Figure 5-1 Clutch Assembly
Figure 5-2 Clutch Release Bearing
Figure 5-3 Slave Valve Assembly
Figure 5-4 Transmission – Slave Control Assembly
Figure 5-5 Transmission – Slave Valve w/Hoses
Figure 5-6 Transmission – Clutch Housing
Figure 5-7 Transmission – Shift Bar Housing
Figure 5-8 Transmission – Reverse Idler, Input Shaft & Drive Gear
Figure 5-9 Transmission – Mainshaft & Countershaft Gears
Figure 5-10 Transmission – Auxiliary Mainshaft
Figure 5-11 Transmission – Auxiliary Case Assembly
Figure 5-12 Transmission – Range Cylinder
Figure 5-13 Transmission – Auxiliary Countershaft & Auxiliary Drive Gear
Figure 5-14 Transmission – Master Shift Valve Assembly
Figure 5-15 Propeller Shaft
Figure 5-16 Transfer Case Assembly, 6X6
Figure 5-17 Front Axle – Axle Assembly, 6X4
Figure 5-18 Front Axle – Steering Components, 6X4
Figure 5-19 Front Axle – Service Brakes, 6X4
Figure 5-20 Front Axle – Disc Wheel & Rims, 6X4
Figure 5-21 Front Axle – Axle Assembly, 6X6
Figure 5-22 Front Axle – Housing Assembly, 6X6
Figure 5-23 Front Axle – Differential Assembly, 6X6
Figure 5-24 Front Axle – Steering Components, 6X6
Figure 5-25 Front Axle – Service Brake, 6X6
Figure 5-26 Front Axle – Disc Wheels & Rims, 6X6
Figure 5-27 Front Axle – Spring Assembly
Figure 5-28 Rear Axle – Axle Assembly, 6X4
Figure 5-29 Rear Axle – Axle Assembly, 6X6
Figure 5-30 Rear Axle – Forward Housing
Figure 5-31 Rear Axle – Rear Housing
Figure 5-32 Rear Axle – Forward Differential Assembly
Figure 5-33 Rear Axle – Rear Differential Assembly
Figure 5-34 Rear Axle – Service Brake
Figure 5-35 Rear Axle – Disc Wheel & Rim
Figure 5-36 Equalizer Beams
Section 6 Cab
Figure 6-1 Operators Cab, Upperstructure
Figure 6-2 Operators Cab, Upperstructure
Figure 6-3 Cab Door, Upperstructure
Figure 6-4 Cab Interior Components, Upperstructure
Figure 6-5 Cab Console, Upperstructure
Figure 6-6 Cab Seat, Upperstructure
Figure 6-7 Cab Heater & Installation, Upperstructure
Figure 6-8 Operators Cab, Undercarriage
Figure 6-9 Operators Cab, Undercarriage
Figure 6-10 Cab Door, Undercarriage
Figure 6-11 Cab Seat, Undercarriage
Figure 6-12 Seat Suspension, Undercarriage
Figure 6-13 Heater & Defroster, Undercarriage
Figure 6-14 Pilot Cut-off Assembly
Section 7 Controls
Figure 7-1 Joystick Assembly
Figure 7-2 Steering Column Assembly
Figure 7-3 Steering Drive Shaft Assembly
Figure 7-4 Steering Drag Link Assembly
Figure 7-5 Foot Operated Pedal Valve Assembly
Figure 7-6 Foot Operated Pedal Plate Assembly
Section 8 Hydraulic Circuits
Figure 8-1 Hydraulic Oil Supply to Main Pump
Figure 8-2 Main Hydraulic Pump to Center Pin
Figure 8-3 Hydraulic Pressure from Center Pin to Control Valve
Figure 8-4 Main Valve to Pilot Manifold
Figure 8-5 Hydraulic Hosing To Joysticks & Foot Operated Pedal Valve
Figure 8-6 Upper Dump
Figure 8-7 Chassis Dump
Figure 8-8 Hoist Pilot
Figure 8-9 Boom Pilot
Figure 8-10 Tool Pilot
Figure 8-11 Tilt Pilot
Figure 8-12 Heater & Auxiliary Pilot
Figure 8-13 Hoist Cylinder
Figure 8-14 Boom Cylinder
Figure 8-15 Tool Cylinder
Figure 8-16 Swing & Swing Brake Pilot
Figure 8-17 Tool Pilot
Figure 8-18 Swing Motor
Figure 8-19 Tilt Motor
Figure 8-20 Steering Gear
Figure 8-21 Remote Propelling
Figure 8-22 Remote Steering
Figure 8-23 Stabilizer Cylinder
Section 9 Hydraulic Components
Figure 9-1 Hoist Cylinder Assembly
Figure 9-2 Boom Cylinder Assembly
Figure 9-3 Tool Cylinder Assembly
Figure 9-4 Stabilizer Cylinder Assembly
Figure 9-5 Stabilizer Valve Assembly
Figure 9-6 Remote Steering Hydraulic Cylinder Assembly
Figure 9-7 Main Pump – Front
Figure 9-8 Main Pump – Rear
Figure 9-9 Main Hydraulic Control Valve
Figure 9-10 Main Hydraulic Control Valve – Spools & End Caps
Figure 9-11 Main Hydraulic Control Valve – Swing Section
Figure 9-12 Main Hydraulic Control Valve – Seal Kits
Figure 9-13 Pilot Manifold Valve Tray Hydraulic Components
Figure 9-14 Pilot Manifold Assembly
Figure 9-15 Reservoir Assembly
Figure 9-16 Swing Transmission Installation
Figure 9-17 Swing Transmission Assembly
Figure 9-18 Swing Motor Assembly
Figure 9-19 Swing Brake Assembly
Figure 9-20 Tilt Transmission
Figure 9-21 Tilt Transmission Assembly
Figure 9-22 Tilt Motor Assembly
Figure 9-23 Tilt Brake Assembly
Figure 9-24 Travel Motor
Figure 9-25 Center Pin Assembly
Figure 9-26 Power Take-Off Assembly
Figure 9-27 Power Take-Off Counter Shaft
Figure 9-28 Oil Cooler Assembly
Figure 9-29 Hydraulic Heater Pump Assembly
Figure 9-30 Hydraulic Heater Manifold Assembly
Figure 9-31 Steering Gear Assembly
Figure 9-32 Counterbalance Valve Assembly
Figure 9-33 Counterbalance Valve
Figure 9-34 Cooling Fan Valve Assembly
Figure 9-35 Steering Valve Assembly
Figure 9-36 Dual Solenoid Valve Assembly
Figure 9-37 Hoist Limit Valve
Section 10 Electrical
Figure 10-1 Miscellaneous Electrical Components, Upperstructure
Figure 10-2 Battery Box, Batteries & Cables
Figure 10-3 Tail & Marker Lights
Figure 10-4 Head & Marker Lights
Figure 10-5 Horn & Miscellaneous, Undercarriage
Figure 10-6 Cab Console Circuit Board, Upperstructure
Figure 10-7 Cab Console Circuit Board, Undercarriage
Figure 10-8 Instrument Panel
Figure 10-9 Accessory Panel
Section 11 Decals
Figure 11-1 Decals, Upperstructure
Figure 11-2 Decals, Undercarriage
Section 12 Options
Figure 12-1 Air Conditioner Installation Components, Upperstructure
Figure 12-2 Air Conditioner General Kit
Figure 12-3 Floodlight Installation Components
Figure 12-4 Seat Belt Installation Components
Figure 12-5 Strobe Light Installation Components
Recommended Spare Parts
Part Number Index
XL4100II Illustrated Parts Manual 31200274 2006.pdf (428 Pages)
Contents:
XL4100II Parts Manual SO899206
Effectivity Page
Table of Contents
Service Kits
Section 1 Frame & Attaching Parts
Figure 1-1 Frame Assembly
Figure 1-2 Mirror & Grab Rails
Figure 1-3 Engine Cover
Figure 1-4 R.H. Fender & Mirrors
Figure 1-5 L.H. Fender
Figure 1-6 Rear Fender Assembly
Figure 1-7 Deck & Cover
Figure 1-8 Left Side Cover Assembly
Figure 1-9 Rotating Platform
Figure 1-10 Swing Bearing, Cradle & Hoist Cylinder Mounting & Lube System
Figure 1-11 Valve Cover
Section 2 Boom
Figure 2-1 Boom Cradle
Figure 2-2 Main Boom Assembly
Figure 2-3 Telescope Boom Assembly
Figure 2-4 Boom Roller Assemblies
Figure 2-5 Bucket Linkage
Section 3 Attachments
Figure 3-1 60” Ditching Bucket
Section 4 Engine & Attaching Parts
Figure 4-1 Engine Assembly, L.H. View
Figure 4-2 Engine Assembly, R.H. View
Figure 4-3 Air Cleaner Assembly
Figure 4-4 Power Steering Reservoir Assembly
Figure 4-5 Exhaust System
Figure 4-6 Fuel Tank & Lines
Figure 4-7 Radiator & Cooler Assemblies
Figure 4-8 Oil Cooler & Hoses
Figure 4-9 Air Brake System
Figure 4-10 Spring Brake Control Valve & Parking Brake Valve Assemblies
Figure 4-11 Lockout Air Valve, Air Dryer & Adapter Assemblies
Figure 4-12 Air Valve Assemblies
Figure 4-13 Air Valve & Double Check Valve Assemblies
Figure 4-14 Air Reservoir Assemblies
Figure 4-15 Relay Valve Assemblies
Figure 4-16 Foot Pedal Valve & Air Fitting Assembly
Figure 4-17 Air Valve Assemblies
Figure 4-18 Air Valve & Air Fitting Assemblies
Section 5 Drive Train
Figure 5-1 Clutch Assembly
Figure 5-2 Clutch Release Bearing
Figure 5-3 Slave Valve Assembly
Figure 5-4 Transmission – Slave Control Assembly
Figure 5-5 Transmission – Slave Valve w/Hoses
Figure 5-6 Transmission – Clutch Housing
Figure 5-7 Transmission – Shift Bar Housing
Figure 5-8 Transmission – Reverse Idler, Input Shaft & Drive Gear
Figure 5-9 Transmission – Mainshaft & Countershaft Gears
Figure 5-10 Transmission – Auxiliary Mainshaft
Figure 5-11 Transmission – Auxiliary Case Assembly
Figure 5-12 Transmission – Range Cylinder
Figure 5-13 Transmission – Auxiliary Countershaft & Auxiliary Drive Gear
Figure 5-14 Transmission – Master Shift Valve Assembly
Figure 5-15 Propeller Shaft
Figure 5-16 Transfer Case Assembly, 6X6
Figure 5-17 Front Axle – Axle Assembly, 6X4
Figure 5-18 Front Axle – Steering Components, 6X4
Figure 5-19 Front Axle – Service Brakes, 6X4
Figure 5-20 Front Axle – Disc Wheel & Rims, 6X4
Figure 5-21 Front Axle – Axle Assembly, 6X6
Figure 5-22 Front Axle – Housing Assembly, 6X6
Figure 5-23 Front Axle – Differential Assembly, 6X6
Figure 5-24 Front Axle – Steering Components, 6X6
Figure 5-25 Front Axle – Service Brake, 6X6
Figure 5-26 Front Axle – Disc Wheels & Rims, 6X6
Figure 5-27 Front Axle – Spring Assembly
Figure 5-28 Rear Axle – Axle Assembly, 6X4
Figure 5-29 Rear Axle – Axle Assembly, 6X6
Figure 5-30 Rear Axle – Forward Housing
Figure 5-31 Rear Axle – Rear Housing
Figure 5-32 Rear Axle – Forward Differential Assembly
Figure 5-33 Rear Axle – Rear Differential Assembly
Figure 5-34 Rear Axle – Service Brake
Figure 5-35 Rear Axle – Disc Wheel & Rim
Figure 5-36 Equalizer Beams
Section 6 Cab
Figure 6-1 Operators Cab, Upperstructure
Figure 6-2 Operators Cab, Upperstructure
Figure 6-3 Cab Door, Upperstructure
Figure 6-4 Cab Interior Components, Upperstructure
Figure 6-5 Cab Console, Upperstructure
Figure 6-6 Cab Seat, Upperstructure
Figure 6-7 Cab Heater & Installation, Upperstructure
Figure 6-8 Operators Cab, Undercarriage
Figure 6-9 Operators Cab, Undercarriage
Figure 6-10 Cab Door, Undercarriage
Figure 6-11 Cab Seat, Undercarriage
Figure 6-12 Seat Suspension, Undercarriage
Figure 6-13 Heater & Defroster, Undercarriage
Figure 6-14 Pilot Cut-off Assembly
Section 7 Controls
Figure 7-1 Joystick Assembly
Figure 7-2 Steering Column Assembly
Figure 7-3 Steering Drive Shaft Assembly
Figure 7-4 Steering Drag Link Assembly
Figure 7-5 Foot Operated Pedal Valve Assembly
Figure 7-6 Foot Operated Pedal Plate Assembly
Section 8 Hydraulic Circuits
Figure 8-1 Hydraulic Oil Supply to Main Pump
Figure 8-2 Main Hydraulic Pump to Center Pin
Figure 8-3 Hydraulic Pressure from Center Pin to Control Valve
Figure 8-4 Main Valve to Pilot Manifold
Figure 8-5 Hydraulic Hosing To Joysticks & Foot Operated Pedal Valve
Figure 8-6 Upper Dump
Figure 8-7 Chassis Dump
Figure 8-8 Hoist Pilot
Figure 8-9 Boom Pilot
Figure 8-10 Tool Pilot
Figure 8-11 Tilt Pilot
Figure 8-12 Heater & Auxiliary Pilot
Figure 8-13 Hoist Cylinder
Figure 8-14 Boom Cylinder
Figure 8-15 Tool Cylinder
Figure 8-16 Swing & Swing Brake Pilot
Figure 8-17 Tool Pilot
Figure 8-18 Swing Motor
Figure 8-19 Tilt Motor
Figure 8-20 Steering Gear
Figure 8-21 Remote Propelling
Figure 8-22 Remote Steering
Figure 8-23 Stabilizer Cylinder
Section 9 Hydraulic Components
Figure 9-1 Hoist Cylinder Assembly
Figure 9-2 Boom Cylinder Assembly
Figure 9-3 Tool Cylinder Assembly
Figure 9-4 Stabilizer Cylinder Assembly
Figure 9-5 Stabilizer Valve Assembly
Figure 9-6 Remote Steering Hydraulic Cylinder Assembly
Figure 9-7 Main Pump – Front
Figure 9-8 Main Pump – Rear
Figure 9-9 Main Hydraulic Control Valve
Figure 9-10 Main Hydraulic Control Valve – Spools & End Caps
Figure 9-11 Main Hydraulic Control Valve – Swing Section
Figure 9-12 Main Hydraulic Control Valve – Seal Kits
Figure 9-13 Pilot Manifold Valve Tray Hydraulic Components
Figure 9-14 Pilot Manifold Assembly
Figure 9-15 Reservoir Assembly
Figure 9-16 Swing Transmission Installation
Figure 9-17 Swing Transmission Assembly
Figure 9-18 Swing Motor Assembly
Figure 9-19 Swing Brake Assembly
Figure 9-20 Tilt Transmission
Figure 9-21 Tilt Transmission Assembly
Figure 9-22 Tilt Motor Assembly
Figure 9-23 Tilt Brake Assembly
Figure 9-24 Travel Motor
Figure 9-25 Center Pin Assembly
Figure 9-26 Power Take-Off Assembly
Figure 9-27 Power Take-Off Counter Shaft
Figure 9-28 Oil Cooler Assembly
Figure 9-29 Hydraulic Heater Pump Assembly
Figure 9-30 Hydraulic Heater Manifold Assembly
Figure 9-31 Steering Gear Assembly
Figure 9-32 Counterbalance Valve Assembly
Figure 9-33 Counterbalance Valve
Figure 9-34 Cooling Fan Valve Assembly
Figure 9-35 Steering Valve Assembly
Figure 9-36 Dual Solenoid Valve Assembly
Figure 9-37 Hoist Limit Valve
Section 10 Electrical
Figure 10-1 Miscellaneous Electrical Components, Upperstructure
Figure 10-2 Battery Box, Batteries & Cables
Figure 10-3 Tail & Marker Lights
Figure 10-4 Head & Marker Lights
Figure 10-5 Horn & Miscellaneous, Undercarriage
Figure 10-6 Cab Console Circuit Board, Upperstructure
Figure 10-7 Cab Console Circuit Board, Undercarriage
Figure 10-8 Instrument Panel
Figure 10-9 Accessory Panel
Section 11 Decals
Figure 11-1 Decals, Upperstructure
Figure 11-2 Decals, Undercarriage
Section 12 Options
Figure 12-1 Air Conditioner Installation Components, Upperstructure
Figure 12-2 Air Conditioner General Kit
Figure 12-3 AM/FM Cassette Stereo Installation Components
Recommended Spare Parts
Part Number Index
XL4100II Illustrated Parts Manual 31200277 2006.pdf (450 Pages)
Contents:
Service Kits
Section 1 Frame & Attaching Parts
Figure 1-1 Frame Assembly
Figure 1-2 Mirror & Grab Rails
Figure 1-3 Engine Cover
Figure 1-4 R.H. Fender & Mirrors
Figure 1-5 L.H. Fender
Figure 1-6 Rear Fender Assembly
Figure 1-7 Deck & Cover
Figure 1-8 Left Side Cover Assembly
Figure 1-9 Rotating Platform
Figure 1-10 Swing Bearing, Cradle & Hoist Cylinder Mounting & Lube System
Figure 1-11 Valve Cover
Section 2 Boom
Figure 2-1 Boom Cradle
Figure 2-2 Main Boom Assembly
Figure 2-3 Telescope Boom Assembly
Figure 2-4 Boom Roller Assemblies
Figure 2-5 Bucket Linkage
Section 3 Attachments
Figure 3-1 42” Excavating Buckets
Figure 3-2 66” Ditching Bucket
Figure 3-3 6’ Boom Extension
Figure 3-4 Bucket Carrier Assembly
Section 4 Engine & Attaching Parts
Figure 4-1 Engine Assembly, L.H. View
Figure 4-2 Engine Assembly, R.H. View
Figure 4-3 Air Cleaner Assembly
Figure 4-4 Power Steering Reservoir Assembly
Figure 4-5 Exhaust System
Figure 4-6 Fuel Tank & Lines
Figure 4-7 Radiator & Cooler Assemblies
Figure 4-8 Oil Cooler & Hoses
Figure 4-9 Air Brake System
Figure 4-10 Spring Brake Control Valve & Parking Brake Valve Assemblies
Figure 4-11 Lockout Air Valve, Air Dryer & Adapter Assemblies
Figure 4-12 Air Valve Assemblies
Figure 4-13 Air Valve & Double Check Valve Assemblies
Figure 4-14 Air Reservoir Assemblies
Figure 4-15 Relay Valve Assemblies
Figure 4-16 Foot Pedal Valve & Air Fitting Assembly
Figure 4-17 Air Valve Assemblies
Figure 4-18 Air Valve & Air Fitting Assemblies
Section 5 Drive Train
Figure 5-1 Clutch Assembly
Figure 5-2 Clutch Release Bearing
Figure 5-3 Slave Valve Assembly
Figure 5-4 Transmission – Slave Control Assembly
Figure 5-5 Transmission – Slave Valve w/Hoses
Figure 5-6 Transmission – Clutch Housing
Figure 5-7 Transmission – Shift Bar Housing
Figure 5-8 Transmission – Reverse Idler, Input Shaft & Drive Gear
Figure 5-9 Transmission – Mainshaft & Countershaft Gears
Figure 5-10 Transmission – Auxiliary Mainshaft
Figure 5-11 Transmission – Auxiliary Case Assembly
Figure 5-12 Transmission – Range Cylinder
Figure 5-13 Transmission – Auxiliary Countershaft & Auxiliary Drive Gear
Figure 5-14 Transmission – Master Shift Valve Assembly
Figure 5-15 Propeller Shaft
Figure 5-16 Transfer Case Assembly, 6X6
Figure 5-17 Front Axle – Axle Assembly, 6X4
Figure 5-18 Front Axle – Steering Components, 6X4
Figure 5-19 Front Axle – Service Brakes, 6X4
Figure 5-20 Front Axle – Disc Wheel & Rims, 6X4
Figure 5-21 Front Axle – Axle Assembly, 6X6
Figure 5-22 Front Axle – Housing Assembly, 6X6
Figure 5-23 Front Axle – Differential Assembly, 6X6
Figure 5-24 Front Axle – Steering Components, 6X6
Figure 5-25 Front Axle – Service Brake, 6X6
Figure 5-26 Front Axle – Disc Wheels & Rims, 6X6
Figure 5-27 Front Axle – Spring Assembly
Figure 5-28 Rear Axle – Axle Assembly, 6X4
Figure 5-29 Rear Axle – Axle Assembly, 6X6
Figure 5-30 Rear Axle – Forward Housing
Figure 5-31 Rear Axle – Rear Housing
Figure 5-32 Rear Axle – Forward Differential Assembly
Figure 5-33 Rear Axle – Rear Differential Assembly
Figure 5-34 Rear Axle – Service Brake
Figure 5-35 Rear Axle – Disc Wheel & Rim
Figure 5-36 Equalizer Beams
Section 6 Cab
Figure 6-1 Operators Cab, Upperstructure
Figure 6-2 Operators Cab, Upperstructure
Figure 6-3 Cab Door, Upperstructure
Figure 6-4 Cab Interior Components, Upperstructure
Figure 6-5 Cab Console, Upperstructure
Figure 6-6 Cab Seat, Upperstructure
Figure 6-7 Cab Heater & Installation, Upperstructure
Figure 6-8 Operators Cab, Undercarriage
Figure 6-9 Operators Cab, Undercarriage
Figure 6-10 Cab Door, Undercarriage
Figure 6-11 Cab Seat, Undercarriage
Figure 6-12 Seat Suspension, Undercarriage
Figure 6-13 Heater & Defroster, Undercarriage
Figure 6-14 Pilot Cut-off Assembly
Section 7 Controls
Figure 7-1 Joystick Assembly
Figure 7-2 Steering Column Assembly
Figure 7-3 Steering Drive Shaft Assembly
Figure 7-4 Steering Drag Link Assembly
Figure 7-5 Foot Operated Pedal Valve Assembly
Figure 7-6 Foot Operated Pedal Plate Assembly
Section 8 Hydraulic Circuits
Figure 8-1 Hydraulic Oil Supply to Main Pump
Figure 8-2 Main Hydraulic Pump to Center Pin
Figure 8-3 Hydraulic Pressure from Center Pin to Control Valve
Figure 8-4 Main Valve to Pilot Manifold
Figure 8-5 Hydraulic Hosing To Joysticks & Foot Operated Pedal Valve
Figure 8-6 Upper Dump
Figure 8-7 Chassis Dump
Figure 8-8 Hoist Pilot
Figure 8-9 Boom Pilot
Figure 8-10 Tool Pilot
Figure 8-11 Tilt Pilot
Figure 8-12 Heater & Auxiliary Pilot
Figure 8-13 Hoist Cylinder
Figure 8-14 Boom Cylinder
Figure 8-15 Tool Cylinder
Figure 8-16 Swing & Swing Brake Pilot
Figure 8-17 Tool Pilot
Figure 8-18 Swing Motor
Figure 8-19 Tilt Motor
Figure 8-20 Steering Gear
Figure 8-21 Remote Propelling
Figure 8-22 Remote Steering
Figure 8-23 Stabilizer Cylinder
Section 9 Hydraulic Components
Figure 9-1 Hoist Cylinder Assembly
Figure 9-2 Boom Cylinder Assembly
Figure 9-3 Tool Cylinder Assembly
Figure 9-4 Stabilizer Cylinder Assembly
Figure 9-5 Stabilizer Valve Assembly
Figure 9-6 Remote Steering Hydraulic Cylinder Assembly
Figure 9-7 Main Pump – Front
Figure 9-8 Main Pump – Rear
Figure 9-9 Main Hydraulic Control Valve
Figure 9-10 Main Hydraulic Control Valve – Spools & End Caps
Figure 9-11 Main Hydraulic Control Valve – Swing Section
Figure 9-12 Main Hydraulic Control Valve – Seal Kits
Figure 9-13 Pilot Manifold Valve Tray Hydraulic Components
Figure 9-14 Pilot Manifold Assembly
Figure 9-15 Reservoir Assembly
Figure 9-16 Swing Transmission Installation
Figure 9-17 Swing Transmission Assembly
Figure 9-18 Swing Motor Assembly
Figure 9-19 Swing Brake Assembly
Figure 9-20 Tilt Transmission
Figure 9-21 Tilt Transmission Assembly
Figure 9-22 Tilt Motor Assembly
Figure 9-23 Tilt Brake Assembly
Figure 9-24 Travel Motor
Figure 9-25 Center Pin Assembly
Figure 9-26 Power Take-Off Assembly
Figure 9-27 Power Take-Off Counter Shaft
Figure 9-28 Oil Cooler Assembly
Figure 9-29 Hydraulic Heater Pump Assembly
Figure 9-30 Hydraulic Heater Manifold Assembly
Figure 9-31 Steering Gear Assembly
Figure 9-32 Counterbalance Valve Assembly
Figure 9-33 Counterbalance Valve
Figure 9-34 Cooling Fan Valve Assembly
Figure 9-35 Steering Valve Assembly
Figure 9-36 Dual Solenoid Valve Assembly
Figure 9-37 Hoist Limit Valve
Section 10 Electrical
Figure 10-1 Miscellaneous Electrical Components, Upperstructure
Figure 10-2 Battery Box, Batteries & Cables
Figure 10-3 Tail & Marker Lights
Figure 10-4 Head & Marker Lights
Figure 10-5 Horn & Miscellaneous, Undercarriage
Figure 10-6 Cab Console Circuit Board, Upperstructure
Figure 10-7 Cab Console Circuit Board, Undercarriage
Figure 10-8 Instrument Panel
Figure 10-9 Accessory Panel
Section 11 Decals
Figure 11-1 Decals, Upperstructure
Figure 11-2 Decals, Undercarriage
Section 12 Options
Figure 12-1 Air Conditioner Installation Components, Upperstructure
Figure 12-2 ‘04 EPA Air Conditioner Installation, Undercarriage
Figure 12-3 Air Conditioner General Kit
Figure 12-4 Seat Belt Installation Components
Figure 12-5 AM/FM Cassette Stereo Installation
Figure 12-6 Chassis Lights Installation
Figure 12-7 Strobe Light Installation
Figure 12-8 Block Heater Installation Components
Figure 12-9 Floodlight Installation Components
Figure 12-10 Auxiliary Hydraulics
Recommended Spare Parts
Part Number Index
XL4100II Illustrated Parts Manual 31200282 2007.pdf (446 Pages)
Contents:
Service Kits
Section 1 Frame & Attaching Parts
Figure 1-1 Frame Assembly
Figure 1-2 Mirror & Grab Rails
Figure 1-3 Engine Cover
Figure 1-4 R.H. Fender & Mirrors
Figure 1-5 L.H. Fender
Figure 1-6 Rear Fender Assembly
Figure 1-7 Deck & Cover
Figure 1-8 Left Side Cover Assembly
Figure 1-9 Rotating Platform
Figure 1-10 Swing Bearing, Cradle & Hoist Cylinder Mounting & Lube System
Figure 1-11 Valve Cover
Section 2 Boom
Figure 2-1 Boom Cradle
Figure 2-2 Main Boom Assembly
Figure 2-3 Telescope Boom Assembly
Figure 2-4 Boom Roller Assemblies
Figure 2-5 Bucket Linkage
Section 3 Attachments
Figure 3-1 36” Excavating Buckets
Figure 3-2 60” Ditching Bucket
Figure 3-3 Fixed Thumb Grapple Assembly
Section 4 Engine & Attaching Parts
Figure 4-1 Engine Assembly, L.H. View
Figure 4-2 Engine Assembly, R.H. View
Figure 4-3 Air Cleaner Assembly
Figure 4-4 Power Steering Reservoir Assembly
Figure 4-5 Exhaust System
Figure 4-6 Fuel Tank & Lines
Figure 4-7 Radiator & Cooler Assemblies
Figure 4-8 Oil Cooler & Hoses
Figure 4-9 Air Brake System
Figure 4-10 Spring Brake Control Valve & Parking Brake Valve Assemblies
Figure 4-11 Lockout Air Valve, Air Dryer & Adapter Assemblies
Figure 4-12 Air Valve Assemblies
Figure 4-13 Air Valve & Double Check Valve Assemblies
Figure 4-14 Air Reservoir Assemblies
Figure 4-15 Relay Valve Assemblies
Figure 4-16 Foot Pedal Valve & Air Fitting Assembly
Figure 4-17 Air Valve Assemblies
Figure 4-18 Air Valve & Air Fitting Assemblies
Section 5 Drive Train
Figure 5-1 Clutch Assembly
Figure 5-2 Clutch Release Bearing
Figure 5-3 Slave Valve Assembly
Figure 5-4 Transmission – Slave Control Assembly
Figure 5-5 Transmission – Slave Valve w/Hoses
Figure 5-6 Transmission – Clutch Housing
Figure 5-7 Transmission – Shift Bar Housing
Figure 5-8 Transmission – Reverse Idler, Input Shaft & Drive Gear
Figure 5-9 Transmission – Mainshaft & Countershaft Gears
Figure 5-10 Transmission – Auxiliary Mainshaft
Figure 5-11 Transmission – Auxiliary Case Assembly
Figure 5-12 Transmission – Range Cylinder
Figure 5-13 Transmission – Auxiliary Countershaft & Auxiliary Drive Gear
Figure 5-14 Transmission – Master Shift Valve Assembly
Figure 5-15 Propeller Shaft
Figure 5-16 Transfer Case Assembly, 6X6
Figure 5-17 Front Axle – Axle Assembly, 6X4
Figure 5-18 Front Axle – Steering Components, 6X4
Figure 5-19 Front Axle – Service Brakes, 6X4
Figure 5-20 Front Axle – Disc Wheel & Rims, 6X4
Figure 5-21 Front Axle – Axle Assembly, 6X6
Figure 5-22 Front Axle – Housing Assembly, 6X6
Figure 5-23 Front Axle – Differential Assembly, 6X6
Figure 5-24 Front Axle – Steering Components, 6X6
Figure 5-25 Front Axle – Service Brake, 6X6
Figure 5-26 Front Axle – Disc Wheels & Rims, 6X6
Figure 5-27 Front Axle – Spring Assembly
Figure 5-28 Rear Axle – Axle Assembly, 6X4
Figure 5-29 Rear Axle – Axle Assembly, 6X6
Figure 5-30 Rear Axle – Forward Housing
Figure 5-31 Rear Axle – Rear Housing
Figure 5-32 Rear Axle – Forward Differential Assembly
Figure 5-33 Rear Axle – Rear Differential Assembly
Figure 5-34 Rear Axle – Service Brake
Figure 5-35 Rear Axle – Disc Wheel & Rim
Figure 5-36 Equalizer Beams
Section 6 Cab
Figure 6-1 Operators Cab, Upperstructure
Figure 6-2 Operators Cab, Upperstructure
Figure 6-3 Cab Door, Upperstructure
Figure 6-4 Cab Interior Components, Upperstructure
Figure 6-5 Cab Console, Upperstructure
Figure 6-6 Cab Seat, Upperstructure
Figure 6-7 Cab Heater & Installation, Upperstructure
Figure 6-8 Operators Cab, Undercarriage
Figure 6-9 Operators Cab, Undercarriage
Figure 6-10 Cab Door, Undercarriage
Figure 6-11 Cab Seat, Undercarriage
Figure 6-12 Seat Suspension, Undercarriage
Figure 6-13 Heater & Defroster, Undercarriage
Figure 6-14 Pilot Cut-off Assembly
Section 7 Controls
Figure 7-1 Joystick Assembly
Figure 7-2 Steering Column Assembly
Figure 7-3 Steering Drive Shaft Assembly
Figure 7-4 Steering Drag Link Assembly
Figure 7-5 Foot Operated Pedal Valve Assembly
Figure 7-6 Foot Operated Pedal Plate Assembly
Section 8 Hydraulic Circuits
Figure 8-1 Hydraulic Oil Supply to Main Pump
Figure 8-2 Main Hydraulic Pump to Center Pin
Figure 8-3 Hydraulic Pressure from Center Pin to Control Valve
Figure 8-4 Main Valve to Pilot Manifold
Figure 8-5 Hydraulic Hosing To Joysticks & Foot Operated Pedal Valve
Figure 8-6 Upper Dump
Figure 8-7 Chassis Dump
Figure 8-8 Hoist Pilot
Figure 8-9 Boom Pilot
Figure 8-10 Tool Pilot
Figure 8-11 Tilt Pilot
Figure 8-12 Heater & Auxiliary Pilot
Figure 8-13 Hoist Cylinder
Figure 8-14 Boom Cylinder
Figure 8-15 Tool Cylinder
Figure 8-16 Swing & Swing Brake Pilot
Figure 8-17 Tool Pilot
Figure 8-18 Swing Motor
Figure 8-19 Tilt Motor
Figure 8-20 Steering Gear
Figure 8-21 Remote Propelling
Figure 8-22 Remote Steering
Figure 8-23 Stabilizer Cylinder
Section 9 Hydraulic Components
Figure 9-1 Hoist Cylinder Assembly
Figure 9-2 Boom Cylinder Assembly
Figure 9-3 Tool Cylinder Assembly
Figure 9-4 Stabilizer Cylinder Assembly
Figure 9-5 Stabilizer Valve Assembly
Figure 9-6 Remote Steering Hydraulic Cylinder Assembly
Figure 9-7 Main Pump – Front
Figure 9-8 Main Pump – Rear
Figure 9-9 Main Hydraulic Control Valve
Figure 9-10 Main Hydraulic Control Valve – Spools & End Caps
Figure 9-11 Main Hydraulic Control Valve – Swing Section
Figure 9-12 Main Hydraulic Control Valve – Seal Kits
Figure 9-13 Pilot Manifold Valve Tray Hydraulic Components
Figure 9-14 Pilot Manifold Assembly
Figure 9-15 Reservoir Assembly
Figure 9-16 Swing Transmission Installation
Figure 9-17 Swing Transmission Assembly
Figure 9-18 Swing Motor Assembly
Figure 9-19 Swing Brake Assembly
Figure 9-20 Tilt Transmission
Figure 9-21 Tilt Transmission Assembly
Figure 9-22 Tilt Motor Assembly
Figure 9-23 Tilt Brake Assembly
Figure 9-24 Travel Motor
Figure 9-25 Center Pin Assembly
Figure 9-26 Power Take-Off Assembly
Figure 9-27 Power Take-Off Counter Shaft
Figure 9-28 Oil Cooler Assembly
Figure 9-29 Hydraulic Heater Pump Assembly
Figure 9-30 Hydraulic Heater Manifold Assembly
Figure 9-31 Steering Gear Assembly
Figure 9-32 Counterbalance Valve Assembly
Figure 9-33 Counterbalance Valve
Figure 9-34 Cooling Fan Valve Assembly
Figure 9-35 Steering Valve Assembly
Figure 9-36 Dual Solenoid Valve Assembly
Figure 9-37 Hoist Limit Valve
Section 10 Electrical
Figure 10-1 Miscellaneous Electrical Components, Upperstructure
Figure 10-2 Battery Box, Batteries & Cables
Figure 10-3 Tail & Marker Lights
Figure 10-4 Head & Marker Lights
Figure 10-5 Horn & Miscellaneous, Undercarriage
Figure 10-6 Cab Console Circuit Board, Upperstructure
Figure 10-7 Cab Console Circuit Board, Undercarriage
Figure 10-8 Instrument Panel
Figure 10-9 Accessory Panel
Section 11 Decals
Figure 11-1 Decals, Upperstructure
Figure 11-2 Decals, Undercarriage
Section 12 Options
Figure 12-1 Air Conditioner Installation Components, Upperstructure
Figure 12-2 ‘04 EPA Air Conditioner Installation, Undercarriage
Figure 12-3 Air Conditioner General Kit
Figure 12-4 Block Heater Installation Components
Figure 12-5 Locking Fuel Cap
Figure 12-6 Seat Belt Installation Components
Figure 12-7 Auxiliary Hydraulics
Figure 12-8 Dual Air Horn Installation
Figure 12-9 Tilt Steering Column Installation
Figure 12-10 Air Accessory Outlet w/Pressure Protection Installation
Recommended Spare Parts
Part Number Index
XL4100II Illustrated Parts Manual 31200286 2007.pdf (436 Pages)
Contents:
Service Kits
Section 1 Frame & Attaching Parts
Figure 1-1 Frame Assembly
Figure 1-2 Mirror & Grab Rails
Figure 1-3 Engine Cover
Figure 1-4 R.H. Fender & Mirrors
Figure 1-5 L.H. Fender
Figure 1-6 Rear Fender Assembly
Figure 1-7 Deck & Cover
Figure 1-8 Left Side Cover Assembly
Figure 1-9 Rotating Platform
Figure 1-10 Swing Bearing, Cradle & Hoist Cylinder Mounting & Lube System
Figure 1-11 Valve Cover
Section 2 Boom
Figure 2-1 Boom Cradle
Figure 2-2 Main Boom Assembly
Figure 2-3 Telescope Boom Assembly
Figure 2-4 Boom Roller Assemblies
Figure 2-5 Bucket Linkage
Section 3 Attachments
Figure 3-1 66” Ditching Bucket
Figure 3-2 Fixed Thumb Grapple Assembly
Section 4 Engine & Attaching Parts
Figure 4-1 Engine Assembly, L.H. View
Figure 4-2 Engine Assembly, R.H. View
Figure 4-3 Air Cleaner Assembly
Figure 4-4 Power Steering Reservoir Assembly
Figure 4-5 Exhaust System
Figure 4-6 Fuel Tank & Lines
Figure 4-7 Radiator & Cooler Assemblies
Figure 4-8 Oil Cooler & Hoses
Figure 4-9 Air Brake System
Figure 4-10 Spring Brake Control Valve & Parking Brake Valve Assemblies
Figure 4-11 Lockout Air Valve, Air Dryer & Adapter Assemblies
Figure 4-12 Air Valve Assemblies
Figure 4-13 Air Valve & Double Check Valve Assemblies
Figure 4-14 Air Reservoir Assemblies
Figure 4-15 Relay Valve Assemblies
Figure 4-16 Foot Pedal Valve & Air Fitting Assembly
Figure 4-17 Air Valve Assemblies
Figure 4-18 Air Valve & Air Fitting Assemblies
Section 5 Drive Train
Figure 5-1 Clutch Assembly
Figure 5-2 Clutch Release Bearing
Figure 5-3 Slave Valve Assembly
Figure 5-4 Transmission – Slave Control Assembly
Figure 5-5 Transmission – Slave Valve w/Hoses
Figure 5-6 Transmission – Clutch Housing
Figure 5-7 Transmission – Shift Bar Housing
Figure 5-8 Transmission – Reverse Idler, Input Shaft & Drive Gear
Figure 5-9 Transmission – Mainshaft & Countershaft Gears
Figure 5-10 Transmission – Auxiliary Mainshaft
Figure 5-11 Transmission – Auxiliary Case Assembly
Figure 5-12 Transmission – Range Cylinder
Figure 5-13 Transmission – Auxiliary Countershaft & Auxiliary Drive Gear
Figure 5-14 Transmission – Master Shift Valve Assembly
Figure 5-15 Propeller Shaft
Figure 5-16 Transfer Case Assembly, 6X6
Figure 5-17 Front Axle – Axle Assembly, 6X4
Figure 5-18 Front Axle – Steering Components, 6X4
Figure 5-19 Front Axle – Service Brakes, 6X4
Figure 5-20 Front Axle – Disc Wheel & Rims, 6X4
Figure 5-21 Front Axle – Axle Assembly, 6X6
Figure 5-22 Front Axle – Housing Assembly, 6X6
Figure 5-23 Front Axle – Differential Assembly, 6X6
Figure 5-24 Front Axle – Steering Components, 6X6
Figure 5-25 Front Axle – Service Brake, 6X6
Figure 5-26 Front Axle – Disc Wheels & Rims, 6X6
Figure 5-27 Front Axle – Spring Assembly
Figure 5-28 Rear Axle – Axle Assembly, 6X4
Figure 5-29 Rear Axle – Axle Assembly, 6X6
Figure 5-30 Rear Axle – Forward Housing
Figure 5-31 Rear Axle – Rear Housing
Figure 5-32 Rear Axle – Forward Differential Assembly
Figure 5-33 Rear Axle – Rear Differential Assembly
Figure 5-34 Rear Axle – Service Brake
Figure 5-35 Rear Axle – Disc Wheel & Rim
Figure 5-36 Equalizer Beams
Section 6 Cab
Figure 6-1 Operators Cab, Upperstructure
Figure 6-2 Operators Cab, Upperstructure
Figure 6-3 Cab Door, Upperstructure
Figure 6-4 Cab Interior Components, Upperstructure
Figure 6-5 Cab Console, Upperstructure
Figure 6-6 Cab Seat, Upperstructure
Figure 6-7 Cab Heater & Installation, Upperstructure
Figure 6-8 Operators Cab, Undercarriage
Figure 6-9 Operators Cab, Undercarriage
Figure 6-10 Cab Door, Undercarriage
Figure 6-11 Cab Seat, Undercarriage
Figure 6-12 Seat Suspension, Undercarriage
Figure 6-13 Heater & Defroster, Undercarriage
Figure 6-14 Pilot Cut-off Assembly
Section 7 Controls
Figure 7-1 Joystick Assembly
Figure 7-2 Steering Column Assembly
Figure 7-3 Steering Drive Shaft Assembly
Figure 7-4 Steering Drag Link Assembly
Figure 7-5 Foot Operated Pedal Valve Assembly
Figure 7-6 Foot Operated Pedal Plate Assembly
Section 8 Hydraulic Circuits
Figure 8-1 Hydraulic Oil Supply to Main Pump
Figure 8-2 Main Hydraulic Pump to Center Pin
Figure 8-3 Hydraulic Pressure from Center Pin to Control Valve
Figure 8-4 Main Valve to Pilot Manifold
Figure 8-5 Hydraulic Hosing To Joysticks & Foot Operated Pedal Valve
Figure 8-6 Upper Dump
Figure 8-7 Chassis Dump
Figure 8-8 Hoist Pilot
Figure 8-9 Boom Pilot
Figure 8-10 Tool Pilot
Figure 8-11 Tilt Pilot
Figure 8-12 Heater & Auxiliary Pilot
Figure 8-13 Hoist Cylinder
Figure 8-14 Boom Cylinder
Figure 8-15 Tool Cylinder
Figure 8-16 Swing & Swing Brake Pilot
Figure 8-17 Tool Pilot
Figure 8-18 Swing Motor
Figure 8-19 Tilt Motor
Figure 8-20 Steering Gear
Figure 8-21 Remote Propelling
Figure 8-22 Remote Steering
Figure 8-23 Stabilizer Cylinder
Section 9 Hydraulic Components
Figure 9-1 Hoist Cylinder Assembly
Figure 9-2 Boom Cylinder Assembly
Figure 9-3 Tool Cylinder Assembly
Figure 9-4 Stabilizer Cylinder Assembly
Figure 9-5 Stabilizer Valve Assembly
Figure 9-6 Remote Steering Hydraulic Cylinder Assembly
Figure 9-7 Main Pump – Front
Figure 9-8 Main Pump – Rear
Figure 9-9 Main Hydraulic Control Valve
Figure 9-10 Main Hydraulic Control Valve – Spools & End Caps
Figure 9-11 Main Hydraulic Control Valve – Swing Section
Figure 9-12 Main Hydraulic Control Valve – Seal Kits
Figure 9-13 Pilot Manifold Valve Tray Hydraulic Components
Figure 9-14 Pilot Manifold Assembly
Figure 9-15 Reservoir Assembly
Figure 9-16 Swing Transmission Installation
Figure 9-17 Swing Transmission Assembly
Figure 9-18 Swing Motor Assembly
Figure 9-19 Swing Brake Assembly
Figure 9-20 Tilt Transmission
Figure 9-21 Tilt Transmission Assembly
Figure 9-22 Tilt Motor Assembly
Figure 9-23 Tilt Brake Assembly
Figure 9-24 Travel Motor
Figure 9-25 Center Pin Assembly
Figure 9-26 Power Take-Off Assembly
Figure 9-27 Power Take-Off Counter Shaft
Figure 9-28 Oil Cooler Assembly
Figure 9-29 Hydraulic Heater Pump Assembly
Figure 9-30 Hydraulic Heater Manifold Assembly
Figure 9-31 Steering Gear Assembly
Figure 9-32 Counterbalance Valve Assembly
Figure 9-33 Counterbalance Valve
Figure 9-34 Cooling Fan Valve Assembly
Figure 9-35 Steering Valve Assembly
Figure 9-36 Dual Solenoid Valve Assembly
Figure 9-37 Hoist Limit Valve
Section 10 Electrical
Figure 10-1 Miscellaneous Electrical Components, Upperstructure
Figure 10-2 Battery Box, Batteries & Cables
Figure 10-3 Tail & Marker Lights
Figure 10-4 Head & Marker Lights
Figure 10-5 Horn & Miscellaneous, Undercarriage
Figure 10-6 Cab Console Circuit Board, Upperstructure
Figure 10-7 Cab Console Circuit Board, Undercarriage
Figure 10-8 Instrument Panel
Figure 10-9 Accessory Panel
Section 11 Decals
Figure 11-1 Decals, Upperstructure
Figure 11-2 Decals, Undercarriage
Section 12 Options
Figure 12-1 Air Conditioner Installation Components, Upperstructure
Figure 12-2 ‘04 EPA Air Conditioner Installation, Undercarriage
Figure 12-3 Air Conditioner General Kit
Figure 12-4 Floodlight Installation Components
Figure 12-5 AM/FM Cassette Stereo Installation Components
Figure 12-6 Fire Extinguisher Installation
Figure 12-7 Strobe Light Installation
Recommended Spare Parts
Part Number Index
XL4100II Illustrated Parts Manual 31200294 2007.pdf (444 Pages)
Contents:
Service Kits
Section 1 Frame & Attaching Parts
Figure 1-1 Frame Assembly
Figure 1-2 Mirror & Grab Rails
Figure 1-3 Engine Cover
Figure 1-4 R.H. Fender & Mirrors
Figure 1-5 L.H. Fender
Figure 1-6 Rear Fender Assembly
Figure 1-7 Deck & Cover
Figure 1-8 Left Side Cover Assembly
Figure 1-9 Rotating Platform
Figure 1-10 Swing Bearing, Cradle & Hoist Cylinder Mounting & Lube System
Figure 1-11 Valve Cover
Section 2 Boom
Figure 2-1 Boom Cradle
Figure 2-2 Main Boom Assembly
Figure 2-3 Telescope Boom Assembly
Figure 2-4 Boom Roller Assemblies
Figure 2-5 Bucket Linkage
Section 3 Attachments
Figure 3-1 36” Excavating Buckets
Figure 3-2 60” Ditching Bucket
Figure 3-3 66” Ditching Bucket
Section 4 Engine & Attaching Parts
Figure 4-1 Engine Assembly, L.H. View
Figure 4-2 Engine Assembly, R.H. View
Figure 4-3 Air Cleaner Assembly
Figure 4-4 Power Steering Reservoir Assembly
Figure 4-5 Exhaust System
Figure 4-6 Fuel Tank & Lines
Figure 4-7 Radiator & Cooler Assemblies
Figure 4-8 Oil Cooler & Hoses
Figure 4-9 Air Brake System
Figure 4-10 Spring Brake Control Valve & Parking Brake Valve Assemblies
Figure 4-11 Lockout Air Valve, Air Dryer & Adapter Assemblies
Figure 4-12 Air Valve Assemblies
Figure 4-13 Air Valve & Double Check Valve Assemblies
Figure 4-14 Air Reservoir Assemblies
Figure 4-15 Relay Valve Assemblies
Figure 4-16 Foot Pedal Valve & Air Fitting Assembly
Figure 4-17 Air Valve Assemblies
Figure 4-18 Air Valve & Air Fitting Assemblies
Section 5 Drive Train
Figure 5-1 Clutch Assembly
Figure 5-2 Clutch Release Bearing
Figure 5-3 Slave Valve Assembly
Figure 5-4 Transmission – Slave Control Assembly
Figure 5-5 Transmission – Slave Valve w/Hoses
Figure 5-6 Transmission – Clutch Housing
Figure 5-7 Transmission – Shift Bar Housing
Figure 5-8 Transmission – Reverse Idler, Input Shaft & Drive Gear
Figure 5-9 Transmission – Mainshaft & Countershaft Gears
Figure 5-10 Transmission – Auxiliary Mainshaft
Figure 5-11 Transmission – Auxiliary Case Assembly
Figure 5-12 Transmission – Range Cylinder
Figure 5-13 Transmission – Auxiliary Countershaft & Auxiliary Drive Gear
Figure 5-14 Transmission – Master Shift Valve Assembly
Figure 5-15 Propeller Shaft
Figure 5-16 Transfer Case Assembly, 6X6
Figure 5-17 Front Axle – Axle Assembly, 6X4
Figure 5-18 Front Axle – Steering Components, 6X4
Figure 5-19 Front Axle – Service Brakes, 6X4
Figure 5-20 Front Axle – Disc Wheel & Rims, 6X4
Figure 5-21 Front Axle – Axle Assembly, 6X6
Figure 5-22 Front Axle – Housing Assembly, 6X6
Figure 5-23 Front Axle – Differential Assembly, 6X6
Figure 5-24 Front Axle – Steering Components, 6X6
Figure 5-25 Front Axle – Service Brake, 6X6
Figure 5-26 Front Axle – Disc Wheels & Rims, 6X6
Figure 5-27 Front Axle – Spring Assembly
Figure 5-28 Rear Axle – Axle Assembly, 6X4
Figure 5-29 Rear Axle – Axle Assembly, 6X6
Figure 5-30 Rear Axle – Forward Housing
Figure 5-31 Rear Axle – Rear Housing
Figure 5-32 Rear Axle – Forward Differential Assembly
Figure 5-33 Rear Axle – Rear Differential Assembly
Figure 5-34 Rear Axle – Service Brake
Figure 5-35 Rear Axle – Disc Wheel & Rim
Figure 5-36 Equalizer Beams
Section 6 Cab
Figure 6-1 Operators Cab, Upperstructure
Figure 6-2 Operators Cab, Upperstructure
Figure 6-3 Cab Door, Upperstructure
Figure 6-4 Cab Interior Components, Upperstructure
Figure 6-5 Cab Console, Upperstructure
Figure 6-6 Cab Seat, Upperstructure
Figure 6-7 Cab Heater & Installation, Upperstructure
Figure 6-8 Operators Cab, Undercarriage
Figure 6-9 Operators Cab, Undercarriage
Figure 6-10 Cab Door, Undercarriage
Figure 6-11 Cab Seat, Undercarriage
Figure 6-12 Seat Suspension, Undercarriage
Figure 6-13 Heater & Defroster, Undercarriage
Figure 6-14 Pilot Cut-off Assembly
Section 7 Controls
Figure 7-1 Joystick Assembly
Figure 7-2 Steering Column Assembly
Figure 7-3 Steering Drive Shaft Assembly
Figure 7-4 Steering Drag Link Assembly
Figure 7-5 Foot Operated Pedal Valve Assembly
Figure 7-6 Foot Operated Pedal Plate Assembly
Section 8 Hydraulic Circuits
Figure 8-1 Hydraulic Oil Supply to Main Pump
Figure 8-2 Main Hydraulic Pump to Center Pin
Figure 8-3 Hydraulic Pressure from Center Pin to Control Valve
Figure 8-4 Main Valve to Pilot Manifold
Figure 8-5 Hydraulic Hosing To Joysticks & Foot Operated Pedal Valve
Figure 8-6 Upper Dump
Figure 8-7 Chassis Dump
Figure 8-8 Hoist Pilot
Figure 8-9 Boom Pilot
Figure 8-10 Tool Pilot
Figure 8-11 Tilt Pilot
Figure 8-12 Heater & Auxiliary Pilot
Figure 8-13 Hoist Cylinder
Figure 8-14 Boom Cylinder
Figure 8-15 Tool Cylinder
Figure 8-16 Swing & Swing Brake Pilot
Figure 8-17 Tool Pilot
Figure 8-18 Swing Motor
Figure 8-19 Tilt Motor
Figure 8-20 Steering Gear
Figure 8-21 Remote Propelling
Figure 8-22 Remote Steering
Figure 8-23 Stabilizer Cylinder
Section 9 Hydraulic Components
Figure 9-1 Hoist Cylinder Assembly
Figure 9-2 Boom Cylinder Assembly
Figure 9-3 Tool Cylinder Assembly
Figure 9-4 Stabilizer Cylinder Assembly
Figure 9-5 Stabilizer Valve Assembly
Figure 9-6 Remote Steering Hydraulic Cylinder Assembly
Figure 9-7 Main Pump – Front
Figure 9-8 Main Pump – Rear
Figure 9-9 Main Hydraulic Control Valve
Figure 9-10 Main Hydraulic Control Valve – Spools & End Caps
Figure 9-11 Main Hydraulic Control Valve – Swing Section
Figure 9-12 Main Hydraulic Control Valve – Seal Kits
Figure 9-13 Pilot Manifold Valve Tray Hydraulic Components
Figure 9-14 Pilot Manifold Assembly
Figure 9-15 Reservoir Assembly
Figure 9-16 Swing Transmission Installation
Figure 9-17 Swing Transmission Assembly
Figure 9-18 Swing Motor Assembly
Figure 9-19 Swing Brake Assembly
Figure 9-20 Tilt Transmission
Figure 9-21 Tilt Transmission Assembly
Figure 9-22 Tilt Motor Assembly
Figure 9-23 Tilt Brake Assembly
Figure 9-24 Travel Motor
Figure 9-25 Center Pin Assembly
Figure 9-26 Power Take-Off Assembly
Figure 9-27 Power Take-Off Counter Shaft
Figure 9-28 Oil Cooler Assembly
Figure 9-29 Hydraulic Heater Pump Assembly
Figure 9-30 Hydraulic Heater Manifold Assembly
Figure 9-31 Steering Gear Assembly
Figure 9-32 Counterbalance Valve Assembly
Figure 9-33 Counterbalance Valve
Figure 9-34 Cooling Fan Valve Assembly
Figure 9-35 Steering Valve Assembly
Figure 9-36 Dual Solenoid Valve Assembly
Figure 9-37 Hoist Limit Valve
Section 10 Electrical
Figure 10-1 Miscellaneous Electrical Components, Upperstructure
Figure 10-2 Battery Box, Batteries & Cables
Figure 10-3 Tail & Marker Lights
Figure 10-4 Head & Marker Lights
Figure 10-5 Horn & Miscellaneous, Undercarriage
Figure 10-6 Cab Console Circuit Board, Upperstructure
Figure 10-7 Cab Console Circuit Board, Undercarriage
Figure 10-8 Instrument Panel
Figure 10-9 Accessory Panel
Section 11 Decals
Figure 11-1 Decals, Upperstructure
Figure 11-2 Decals, Undercarriage
Section 12 Options
Figure 12-1 Air Conditioner Installation Components, Upperstructure
Figure 12-2 ‘04 EPA Air Conditioner Installation, Undercarriage
Figure 12-3 Air Conditioner General Kit
Figure 12-4 Block Heater Installation Components
Figure 12-5 Floodlight Installation Components
Figure 12-6 Stemco Seal Installation, Rear Axle
Figure 12-7 Stemco Seal Installation, Front Axle
Figure 12-8 Cigarette Lighter, Chassis Cab
Figure 12-9 Fire Extinguisher Installation
Figure 12-10 Dual Air Horn Installation
Recommended Spare Parts
Part Number Index
XL4100II Illustrated Parts Manual 31200299 2007.pdf (446 Pages)
Contents:
Service Kits
Section 1 Frame & Attaching Parts
Figure 1-1 Frame Assembly
Figure 1-2 Mirror & Grab Rails
Figure 1-3 Engine Cover
Figure 1-4 R.H. Fender & Mirrors
Figure 1-5 L.H. Fender
Figure 1-6 Rear Fender Assembly
Figure 1-7 Deck & Cover
Figure 1-8 Left Side Cover Assembly
Figure 1-9 Rotating Platform
Figure 1-10 Swing Bearing, Cradle & Hoist Cylinder Mounting & Lube System
Figure 1-11 Valve Cover
Section 2 Boom
Figure 2-1 Boom Cradle
Figure 2-2 Main Boom Assembly
Figure 2-3 Telescope Boom Assembly
Figure 2-4 Boom Roller Assemblies
Figure 2-5 Bucket Linkage
Section 3 Attachments
Figure 3-1 66” Ditching Bucket
Figure 3-2 Fixed Thumb Grapple Assembly
Figure 3-3 Telestick Installation
Section 4 Engine & Attaching Parts
Figure 4-1 Engine Assembly, L.H. View
Figure 4-2 Engine Assembly, R.H. View
Figure 4-3 Air Cleaner Assembly
Figure 4-4 Power Steering Reservoir Assembly
Figure 4-5 Exhaust System
Figure 4-6 Fuel Tank & Lines
Figure 4-7 Radiator & Cooler Assemblies
Figure 4-8 Oil Cooler & Hoses
Figure 4-9 Air Brake System
Figure 4-10 Spring Brake Control Valve & Parking Brake Valve Assemblies
Figure 4-11 Lockout Air Valve, Air Dryer & Adapter Assemblies
Figure 4-12 Air Valve Assemblies
Figure 4-13 Air Valve & Double Check Valve Assemblies
Figure 4-14 Air Reservoir Assemblies
Figure 4-15 Relay Valve Assemblies
Figure 4-16 Foot Pedal Valve & Air Fitting Assembly
Figure 4-17 Air Valve Assemblies
Figure 4-18 Air Valve & Air Fitting Assemblies
Section 5 Drive Train
Figure 5-1 Clutch Assembly
Figure 5-2 Clutch Release Bearing
Figure 5-3 Slave Valve Assembly
Figure 5-4 Transmission – Slave Control Assembly
Figure 5-5 Transmission – Slave Valve w/Hoses
Figure 5-6 Transmission – Clutch Housing
Figure 5-7 Transmission – Shift Bar Housing
Figure 5-8 Transmission – Reverse Idler, Input Shaft & Drive Gear
Figure 5-9 Transmission – Mainshaft & Countershaft Gears
Figure 5-10 Transmission – Auxiliary Mainshaft
Figure 5-11 Transmission – Auxiliary Case Assembly
Figure 5-12 Transmission – Range Cylinder
Figure 5-13 Transmission – Auxiliary Countershaft & Auxiliary Drive Gear
Figure 5-14 Transmission – Master Shift Valve Assembly
Figure 5-15 Propeller Shaft
Figure 5-16 Transfer Case Assembly, 6X6
Figure 5-17 Front Axle – Axle Assembly, 6X4
Figure 5-18 Front Axle – Steering Components, 6X4
Figure 5-19 Front Axle – Service Brakes, 6X4
Figure 5-20 Front Axle – Disc Wheel & Rims, 6X4
Figure 5-21 Front Axle – Axle Assembly, 6X6
Figure 5-22 Front Axle – Housing Assembly, 6X6
Figure 5-23 Front Axle – Differential Assembly, 6X6
Figure 5-24 Front Axle – Steering Components, 6X6
Figure 5-25 Front Axle – Service Brake, 6X6
Figure 5-26 Front Axle – Disc Wheels & Rims, 6X6
Figure 5-27 Front Axle – Spring Assembly
Figure 5-28 Rear Axle – Axle Assembly, 6X4
Figure 5-29 Rear Axle – Axle Assembly, 6X6
Figure 5-30 Rear Axle – Forward Housing
Figure 5-31 Rear Axle – Rear Housing
Figure 5-32 Rear Axle – Forward Differential Assembly
Figure 5-33 Rear Axle – Rear Differential Assembly
Figure 5-34 Rear Axle – Service Brake
Figure 5-35 Rear Axle – Disc Wheel & Rim
Figure 5-36 Equalizer Beams
Section 6 Cab
Figure 6-1 Operators Cab, Upperstructure
Figure 6-2 Operators Cab, Upperstructure
Figure 6-3 Cab Door, Upperstructure
Figure 6-4 Cab Interior Components, Upperstructure
Figure 6-5 Cab Console, Upperstructure
Figure 6-6 Cab Seat, Upperstructure
Figure 6-7 Cab Heater & Installation, Upperstructure
Figure 6-8 Operators Cab, Undercarriage
Figure 6-9 Operators Cab, Undercarriage
Figure 6-10 Cab Door, Undercarriage
Figure 6-11 Cab Seat, Undercarriage
Figure 6-12 Seat Suspension, Undercarriage
Figure 6-13 Heater & Defroster, Undercarriage
Figure 6-14 Pilot Cut-off Assembly
Section 7 Controls
Figure 7-1 Joystick Assembly
Figure 7-2 Steering Column Assembly
Figure 7-3 Steering Drive Shaft Assembly
Figure 7-4 Steering Drag Link Assembly
Figure 7-5 Foot Operated Pedal Valve Assembly
Figure 7-6 Foot Operated Pedal Plate Assembly
Section 8 Hydraulic Circuits
Figure 8-1 Hydraulic Oil Supply to Main Pump
Figure 8-2 Main Hydraulic Pump to Center Pin
Figure 8-3 Hydraulic Pressure from Center Pin to Control Valve
Figure 8-4 Main Valve to Pilot Manifold
Figure 8-5 Hydraulic Hosing To Joysticks & Foot Operated Pedal Valve
Figure 8-6 Upper Dump
Figure 8-7 Chassis Dump
Figure 8-8 Hoist Pilot
Figure 8-9 Boom Pilot
Figure 8-10 Tool Pilot
Figure 8-11 Tilt Pilot
Figure 8-12 Heater & Auxiliary Pilot
Figure 8-13 Hoist Cylinder
Figure 8-14 Boom Cylinder
Figure 8-15 Tool Cylinder
Figure 8-16 Swing & Swing Brake Pilot
Figure 8-17 Tool Pilot
Figure 8-18 Swing Motor
Figure 8-19 Tilt Motor
Figure 8-20 Steering Gear
Figure 8-21 Remote Propelling
Figure 8-22 Remote Steering
Figure 8-23 Stabilizer Cylinder
Section 9 Hydraulic Components
Figure 9-1 Hoist Cylinder Assembly
Figure 9-2 Boom Cylinder Assembly
Figure 9-3 Tool Cylinder Assembly
Figure 9-4 Stabilizer Cylinder Assembly
Figure 9-5 Stabilizer Valve Assembly
Figure 9-6 Remote Steering Hydraulic Cylinder Assembly
Figure 9-7 Main Pump – Front
Figure 9-8 Main Pump – Rear
Figure 9-9 Main Hydraulic Control Valve
Figure 9-10 Main Hydraulic Control Valve – Spools & End Caps
Figure 9-11 Main Hydraulic Control Valve – Swing Section
Figure 9-12 Main Hydraulic Control Valve – Seal Kits
Figure 9-13 Pilot Manifold Valve Tray Hydraulic Components
Figure 9-14 Pilot Manifold Assembly
Figure 9-15 Reservoir Assembly
Figure 9-16 Swing Transmission Installation
Figure 9-17 Swing Transmission Assembly
Figure 9-18 Swing Motor Assembly
Figure 9-19 Swing Brake Assembly
Figure 9-20 Tilt Transmission
Figure 9-21 Tilt Transmission Assembly
Figure 9-22 Tilt Motor Assembly
Figure 9-23 Tilt Brake Assembly
Figure 9-24 Travel Motor
Figure 9-25 Center Pin Assembly
Figure 9-26 Power Take-Off Assembly
Figure 9-27 Power Take-Off Counter Shaft
Figure 9-28 Oil Cooler Assembly
Figure 9-29 Hydraulic Heater Pump Assembly
Figure 9-30 Hydraulic Heater Manifold Assembly
Figure 9-31 Steering Gear Assembly
Figure 9-32 Counterbalance Valve Assembly
Figure 9-33 Counterbalance Valve
Figure 9-34 Cooling Fan Valve Assembly
Figure 9-35 Steering Valve Assembly
Figure 9-36 Dual Solenoid Valve Assembly
Figure 9-37 Hoist Limit Valve
Section 10 Electrical
Figure 10-1 Miscellaneous Electrical Components, Upperstructure
Figure 10-2 Battery Box, Batteries & Cables
Figure 10-3 Tail & Marker Lights
Figure 10-4 Head & Marker Lights
Figure 10-5 Horn & Miscellaneous, Undercarriage
Figure 10-6 Cab Console Circuit Board, Upperstructure
Figure 10-7 Cab Console Circuit Board, Undercarriage
Figure 10-8 Instrument Panel
Figure 10-9 Accessory Panel
Section 11 Decals
Figure 11-1 Decals, Upperstructure
Figure 11-2 Decals, Undercarriage
Section 12 Options
Figure 12-1 Air Conditioner Installation Components, Upperstructure
Figure 12-2 ‘04 EPA Air Conditioner Installation, Undercarriage
Figure 12-3 Air Conditioner General Kit
Figure 12-4 Floodlight Installation Components
Figure 12-5 Seat Belt Installation Components
Figure 12-6 Strobe Light Installation, Upperstructure
Figure 12-7 Hourmeter Installation
Figure 12-8 Fire Extinguisher Installation
Figure 12-9 Strobe Light Installation, Undercarriage
Recommended Spare Parts
Part Number Index
XL4100II Illustrated Parts Manual 31200300 2007.pdf (434 Pages)
Contents:
Service Kits
Section 1 Frame & Attaching Parts
Figure 1-1 Frame Assembly
Figure 1-2 Mirror & Grab Rails
Figure 1-3 Engine Cover
Figure 1-4 R.H. Fender & Mirrors
Figure 1-5 L.H. Fender
Figure 1-6 Rear Fender Assembly
Figure 1-7 Deck & Cover
Figure 1-8 Left Side Cover Assembly
Figure 1-9 Rotating Platform
Figure 1-10 Swing Bearing, Cradle & Hoist Cylinder Mounting & Lube System
Figure 1-11 Valve Cover
Section 2 Boom
Figure 2-1 Boom Cradle
Figure 2-2 Main Boom Assembly
Figure 2-3 Telescope Boom Assembly
Figure 2-4 Boom Roller Assemblies
Figure 2-5 Bucket Linkage
Section 3 Attachments
Figure 3-1 Bucket Carrier Assembly
Section 4 Engine & Attaching Parts
Figure 4-1 Engine Assembly, L.H. View
Figure 4-2 Engine Assembly, R.H. View
Figure 4-3 Air Cleaner Assembly
Figure 4-4 Power Steering Reservoir Assembly
Figure 4-5 Exhaust System
Figure 4-6 Fuel Tank & Lines
Figure 4-7 Radiator & Cooler Assemblies
Figure 4-8 Oil Cooler & Hoses
Figure 4-9 Air Brake System
Figure 4-10 Spring Brake Control Valve & Parking Brake Valve Assemblies
Figure 4-11 Lockout Air Valve, Air Dryer & Adapter Assemblies
Figure 4-12 Air Valve Assemblies
Figure 4-13 Air Valve & Double Check Valve Assemblies
Figure 4-14 Air Reservoir Assemblies
Figure 4-15 Relay Valve Assemblies
Figure 4-16 Foot Pedal Valve & Air Fitting Assembly
Figure 4-17 Air Valve Assemblies
Figure 4-18 Air Valve & Air Fitting Assemblies
Section 5 Drive Train
Figure 5-1 Clutch Assembly
Figure 5-2 Clutch Release Bearing
Figure 5-3 Slave Valve Assembly
Figure 5-4 Transmission – Slave Control Assembly
Figure 5-5 Transmission – Slave Valve w/Hoses
Figure 5-6 Transmission – Clutch Housing
Figure 5-7 Transmission – Shift Bar Housing
Figure 5-8 Transmission – Reverse Idler, Input Shaft & Drive Gear
Figure 5-9 Transmission – Mainshaft & Countershaft Gears
Figure 5-10 Transmission – Auxiliary Mainshaft
Figure 5-11 Transmission – Auxiliary Case Assembly
Figure 5-12 Transmission – Range Cylinder
Figure 5-13 Transmission – Auxiliary Countershaft & Auxiliary Drive Gear
Figure 5-14 Transmission – Master Shift Valve Assembly
Figure 5-15 Propeller Shaft
Figure 5-16 Transfer Case Assembly, 6X6
Figure 5-17 Front Axle – Axle Assembly, 6X4
Figure 5-18 Front Axle – Steering Components, 6X4
Figure 5-19 Front Axle – Service Brakes, 6X4
Figure 5-20 Front Axle – Disc Wheel & Rims, 6X4
Figure 5-21 Front Axle – Axle Assembly, 6X6
Figure 5-22 Front Axle – Housing Assembly, 6X6
Figure 5-23 Front Axle – Differential Assembly, 6X6
Figure 5-24 Front Axle – Steering Components, 6X6
Figure 5-25 Front Axle – Service Brake, 6X6
Figure 5-26 Front Axle – Disc Wheels & Rims, 6X6
Figure 5-27 Front Axle – Spring Assembly
Figure 5-28 Rear Axle – Axle Assembly, 6X4
Figure 5-29 Rear Axle – Axle Assembly, 6X6
Figure 5-30 Rear Axle – Forward Housing
Figure 5-31 Rear Axle – Rear Housing
Figure 5-32 Rear Axle – Forward Differential Assembly
Figure 5-33 Rear Axle – Rear Differential Assembly
Figure 5-34 Rear Axle – Service Brake
Figure 5-35 Rear Axle – Disc Wheel & Rim
Figure 5-36 Equalizer Beams
Section 6 Cab
Figure 6-1 Operators Cab, Upperstructure
Figure 6-2 Operators Cab, Upperstructure
Figure 6-3 Cab Door, Upperstructure
Figure 6-4 Cab Interior Components, Upperstructure
Figure 6-5 Cab Console, Upperstructure
Figure 6-6 Cab Seat, Upperstructure
Figure 6-7 Cab Heater & Installation, Upperstructure
Figure 6-8 Operators Cab, Undercarriage
Figure 6-9 Operators Cab, Undercarriage
Figure 6-10 Cab Door, Undercarriage
Figure 6-11 Cab Seat, Undercarriage
Figure 6-12 Seat Suspension, Undercarriage
Figure 6-13 Heater & Defroster, Undercarriage
Figure 6-14 Pilot Cut-off Assembly
Section 7 Controls
Figure 7-1 Joystick Assembly
Figure 7-2 Steering Column Assembly
Figure 7-3 Steering Drive Shaft Assembly
Figure 7-4 Steering Drag Link Assembly
Figure 7-5 Foot Operated Pedal Valve Assembly
Figure 7-6 Foot Operated Pedal Plate Assembly
Section 8 Hydraulic Circuits
Figure 8-1 Hydraulic Oil Supply to Main Pump
Figure 8-2 Main Hydraulic Pump to Center Pin
Figure 8-3 Hydraulic Pressure from Center Pin to Control Valve
Figure 8-4 Main Valve to Pilot Manifold
Figure 8-5 Hydraulic Hosing To Joysticks & Foot Operated Pedal Valve
Figure 8-6 Upper Dump
Figure 8-7 Chassis Dump
Figure 8-8 Hoist Pilot
Figure 8-9 Boom Pilot
Figure 8-10 Tool Pilot
Figure 8-11 Tilt Pilot
Figure 8-12 Heater & Auxiliary Pilot
Figure 8-13 Hoist Cylinder
Figure 8-14 Boom Cylinder
Figure 8-15 Tool Cylinder
Figure 8-16 Swing & Swing Brake Pilot
Figure 8-17 Tool Pilot
Figure 8-18 Swing Motor
Figure 8-19 Tilt Motor
Figure 8-20 Steering Gear
Figure 8-21 Remote Propelling
Figure 8-22 Remote Steering
Figure 8-23 Stabilizer Cylinder
Section 9 Hydraulic Components
Figure 9-1 Hoist Cylinder Assembly
Figure 9-2 Boom Cylinder Assembly
Figure 9-3 Tool Cylinder Assembly
Figure 9-4 Stabilizer Cylinder Assembly
Figure 9-5 Stabilizer Valve Assembly
Figure 9-6 Remote Steering Hydraulic Cylinder Assembly
Figure 9-7 Main Pump – Front
Figure 9-8 Main Pump – Rear
Figure 9-9 Main Hydraulic Control Valve
Figure 9-10 Main Hydraulic Control Valve – Spools & End Caps
Figure 9-11 Main Hydraulic Control Valve – Swing Section
Figure 9-12 Main Hydraulic Control Valve – Seal Kits
Figure 9-13 Pilot Manifold Valve Tray Hydraulic Components
Figure 9-14 Pilot Manifold Assembly
Figure 9-15 Reservoir Assembly
Figure 9-16 Swing Transmission Installation
Figure 9-17 Swing Transmission Assembly
Figure 9-18 Swing Motor Assembly
Figure 9-19 Swing Brake Assembly
Figure 9-20 Tilt Transmission
Figure 9-21 Tilt Transmission Assembly
Figure 9-22 Tilt Motor Assembly
Figure 9-23 Tilt Brake Assembly
Figure 9-24 Travel Motor
Figure 9-25 Center Pin Assembly
Figure 9-26 Power Take-Off Assembly
Figure 9-27 Power Take-Off Counter Shaft
Figure 9-28 Oil Cooler Assembly
Figure 9-29 Hydraulic Heater Pump Assembly
Figure 9-30 Hydraulic Heater Manifold Assembly
Figure 9-31 Steering Gear Assembly
Figure 9-32 Counterbalance Valve Assembly
Figure 9-33 Counterbalance Valve
Figure 9-34 Cooling Fan Valve Assembly
Figure 9-35 Steering Valve Assembly
Figure 9-36 Dual Solenoid Valve Assembly
Figure 9-37 Hoist Limit Valve
Section 10 Electrical
Figure 10-1 Miscellaneous Electrical Components, Upperstructure
Figure 10-2 Battery Box, Batteries & Cables
Figure 10-3 Tail & Marker Lights
Figure 10-4 Head & Marker Lights
Figure 10-5 Horn & Miscellaneous, Undercarriage
Figure 10-6 Cab Console Circuit Board, Upperstructure
Figure 10-7 Cab Console Circuit Board, Undercarriage
Figure 10-8 Instrument Panel
Figure 10-9 Accessory Panel
Section 11 Decals
Figure 11-1 Decals, Upperstructure
Figure 11-2 Decals, Undercarriage
Section 12 Options
Figure 12-1 Floodlight Installation Components
Figure 12-2 Strobe Light Installation Components
Figure 12-3 Air Conditioner Installation
Figure 12-4 Air Conditioner General Kit
Figure 12-5 Dual Auxiliary Installation
Recommended Spare Parts
Part Number Index
XL4100II Illustrated Parts Manual 31200302 2007.pdf (466 Pages)
Contents:
Service Kits
Section 1 Frame & Attaching Parts
Figure 1-1 Frame Assembly
Figure 1-2 Mirror & Grab Rails
Figure 1-3 Engine Cover
Figure 1-4 R.H. Fender & Mirrors
Figure 1-5 L.H. Fender
Figure 1-6 Rear Fender Assembly
Figure 1-7 Deck & Cover
Figure 1-8 Left Side Cover Assembly
Figure 1-9 Rotating Platform
Figure 1-10 Swing Bearing, Cradle & Hoist Cylinder Mounting & Lube System
Figure 1-11 Valve Cover
Section 2 Boom
Figure 2-1 Boom Cradle
Figure 2-2 Main Boom Assembly
Figure 2-3 Telescope Boom Assembly
Figure 2-4 Boom Roller Assemblies
Figure 2-5 Bucket Linkage
Section 3 Attachments
Figure 3-1 30” Excavating Buckets
Figure 3-2 66” Ditching Bucket
Figure 3-3 6’ Boom Extension
Figure 3-4 Fixed Thumb Grapple Assembly
Figure 3-5 Telestick Installation
Section 4 Engine & Attaching Parts
Figure 4-1 Engine Assembly, L.H. View
Figure 4-2 Engine Assembly, R.H. View
Figure 4-3 Air Cleaner Assembly
Figure 4-4 Power Steering Reservoir Assembly
Figure 4-5 Exhaust System
Figure 4-6 Fuel Tank & Lines
Figure 4-7 Radiator & Cooler Assemblies
Figure 4-8 Oil Cooler & Hoses
Figure 4-9 Air Brake System
Figure 4-10 Spring Brake Control Valve & Parking Brake Valve Assemblies
Figure 4-11 Lockout Air Valve, Air Dryer & Adapter Assemblies
Figure 4-12 Air Valve Assemblies
Figure 4-13 Air Valve & Double Check Valve Assemblies
Figure 4-14 Air Reservoir Assemblies
Figure 4-15 Relay Valve Assemblies
Figure 4-16 Foot Pedal Valve & Air Fitting Assembly
Figure 4-17 Air Valve Assemblies
Figure 4-18 Air Valve & Air Fitting Assemblies
Section 5 Drive Train
Figure 5-1 Clutch Assembly
Figure 5-2 Clutch Release Bearing
Figure 5-3 Slave Valve Assembly
Figure 5-4 Transmission – Slave Control Assembly
Figure 5-5 Transmission – Slave Valve w/Hoses
Figure 5-6 Transmission – Clutch Housing
Figure 5-7 Transmission – Shift Bar Housing
Figure 5-8 Transmission – Reverse Idler, Input Shaft & Drive Gear
Figure 5-9 Transmission – Mainshaft & Countershaft Gears
Figure 5-10 Transmission – Auxiliary Mainshaft
Figure 5-11 Transmission – Auxiliary Case Assembly
Figure 5-12 Transmission – Range Cylinder
Figure 5-13 Transmission – Auxiliary Countershaft & Auxiliary Drive Gear
Figure 5-14 Transmission – Master Shift Valve Assembly
Figure 5-15 Propeller Shaft
Figure 5-16 Transfer Case Assembly, 6X6
Figure 5-17 Front Axle – Axle Assembly, 6X4
Figure 5-18 Front Axle – Steering Components, 6X4
Figure 5-19 Front Axle – Service Brakes, 6X4
Figure 5-20 Front Axle – Disc Wheel & Rims, 6X4
Figure 5-21 Front Axle – Axle Assembly, 6X6
Figure 5-22 Front Axle – Housing Assembly, 6X6
Figure 5-23 Front Axle – Differential Assembly, 6X6
Figure 5-24 Front Axle – Steering Components, 6X6
Figure 5-25 Front Axle – Service Brake, 6X6
Figure 5-26 Front Axle – Disc Wheels & Rims, 6X6
Figure 5-27 Front Axle – Spring Assembly
Figure 5-28 Rear Axle – Axle Assembly, 6X4
Figure 5-29 Rear Axle – Axle Assembly, 6X6
Figure 5-30 Rear Axle – Forward Housing
Figure 5-31 Rear Axle – Rear Housing
Figure 5-32 Rear Axle – Forward Differential Assembly
Figure 5-33 Rear Axle – Rear Differential Assembly
Figure 5-34 Rear Axle – Service Brake
Figure 5-35 Rear Axle – Disc Wheel & Rim
Figure 5-36 Equalizer Beams
Section 6 Cab
Figure 6-1 Operators Cab, Upperstructure
Figure 6-2 Operators Cab, Upperstructure
Figure 6-3 Cab Door, Upperstructure
Figure 6-4 Cab Interior Components, Upperstructure
Figure 6-5 Cab Console, Upperstructure
Figure 6-6 Cab Seat, Upperstructure
Figure 6-7 Cab Heater & Installation, Upperstructure
Figure 6-8 Operators Cab, Undercarriage
Figure 6-9 Operators Cab, Undercarriage
Figure 6-10 Cab Door, Undercarriage
Figure 6-11 Cab Seat, Undercarriage
Figure 6-12 Seat Suspension, Undercarriage
Figure 6-13 Heater & Defroster, Undercarriage
Figure 6-14 Pilot Cut-off Assembly
Section 7 Controls
Figure 7-1 Joystick Assembly
Figure 7-2 Steering Column Assembly
Figure 7-3 Steering Drive Shaft Assembly
Figure 7-4 Steering Drag Link Assembly
Figure 7-5 Foot Operated Pedal Valve Assembly
Figure 7-6 Foot Operated Pedal Plate Assembly
Section 8 Hydraulic Circuits
Figure 8-1 Hydraulic Oil Supply to Main Pump
Figure 8-2 Main Hydraulic Pump to Center Pin
Figure 8-3 Hydraulic Pressure from Center Pin to Control Valve
Figure 8-4 Main Valve to Pilot Manifold
Figure 8-5 Hydraulic Hosing To Joysticks & Foot Operated Pedal Valve
Figure 8-6 Upper Dump
Figure 8-7 Chassis Dump
Figure 8-8 Hoist Pilot
Figure 8-9 Boom Pilot
Figure 8-10 Tool Pilot
Figure 8-11 Tilt Pilot
Figure 8-12 Heater & Auxiliary Pilot
Figure 8-13 Hoist Cylinder
Figure 8-14 Boom Cylinder
Figure 8-15 Tool Cylinder
Figure 8-16 Swing & Swing Brake Pilot
Figure 8-17 Tool Pilot
Figure 8-18 Swing Motor
Figure 8-19 Tilt Motor
Figure 8-20 Steering Gear
Figure 8-21 Remote Propelling
Figure 8-22 Remote Steering
Figure 8-23 Stabilizer Cylinder
Section 9 Hydraulic Components
Figure 9-1 Hoist Cylinder Assembly
Figure 9-2 Boom Cylinder Assembly
Figure 9-3 Tool Cylinder Assembly
Figure 9-4 Stabilizer Cylinder Assembly
Figure 9-5 Stabilizer Valve Assembly
Figure 9-6 Remote Steering Hydraulic Cylinder Assembly
Figure 9-7 Main Pump – Front
Figure 9-8 Main Pump – Rear
Figure 9-9 Main Hydraulic Control Valve
Figure 9-10 Main Hydraulic Control Valve – Spools & End Caps
Figure 9-11 Main Hydraulic Control Valve – Swing Section
Figure 9-12 Main Hydraulic Control Valve – Seal Kits
Figure 9-13 Pilot Manifold Valve Tray Hydraulic Components
Figure 9-14 Pilot Manifold Assembly
Figure 9-15 Reservoir Assembly
Figure 9-16 Swing Transmission Installation
Figure 9-17 Swing Transmission Assembly
Figure 9-18 Swing Motor Assembly
Figure 9-19 Swing Brake Assembly
Figure 9-20 Tilt Transmission
Figure 9-21 Tilt Transmission Assembly
Figure 9-22 Tilt Motor Assembly
Figure 9-23 Tilt Brake Assembly
Figure 9-24 Travel Motor
Figure 9-25 Center Pin Assembly
Figure 9-26 Power Take-Off Assembly
Figure 9-27 Power Take-Off Counter Shaft
Figure 9-28 Oil Cooler Assembly
Figure 9-29 Hydraulic Heater Pump Assembly
Figure 9-30 Hydraulic Heater Manifold Assembly
Figure 9-31 Steering Gear Assembly
Figure 9-32 Counterbalance Valve Assembly
Figure 9-33 Counterbalance Valve
Figure 9-34 Cooling Fan Valve Assembly
Figure 9-35 Steering Valve Assembly
Figure 9-36 Dual Solenoid Valve Assembly
Figure 9-37 Hoist Limit Valve
Section 10 Electrical
Figure 10-1 Miscellaneous Electrical Components, Upperstructure
Figure 10-2 Battery Box, Batteries & Cables
Figure 10-3 Tail & Marker Lights
Figure 10-4 Head & Marker Lights
Figure 10-5 Horn & Miscellaneous, Undercarriage
Figure 10-6 Cab Console Circuit Board, Upperstructure
Figure 10-7 Cab Console Circuit Board, Undercarriage
Figure 10-8 Instrument Panel
Figure 10-9 Accessory Panel
Section 11 Decals
Figure 11-1 Decals, Upperstructure
Figure 11-2 Decals, Undercarriage
Section 12 Options
Figure 12-1 Air Conditioner Installation Components, Upperstructure
Figure 12-2 ‘04 EPA Air Conditioner Installation, Undercarriage
Figure 12-3 Air Conditioner General Kit
Figure 12-4 Floodlight Installation Components
Figure 12-5 Locking Fuel Cap
Figure 12-6 L.H. Rear Step Assembly
Figure 12-7 Seat Belt Installation Components
Figure 12-8 Fire Extinguisher Installation, (Undercarriage)
Figure 12-9 License Plate Bracket Installation
Figure 12-10 Dual Air Horn Installation
Figure 12-11 TXDOT Light Package
Figure 12-12 Air Restriction Indicator Installation
Figure 12-13 Hourmeter Installation
Figure 12-14 Lube Chart Installation, (Upperstructure)
Figure 12-15 Lube Chart Installation, (Chassis)
Recommended Spare Parts
Part Number Index
XL4100II Illustrated Parts Manual 31200306 2007.pdf (454 Pages)
Contents:
Service Kits
Section 1 Frame & Attaching Parts
Figure 1-1 Frame Assembly
Figure 1-2 Mirror & Grab Rails
Figure 1-3 Engine Cover
Figure 1-4 R.H. Fender & Mirrors
Figure 1-5 L.H. Fender
Figure 1-6 Rear Fender Assembly
Figure 1-7 Deck & Cover
Figure 1-8 Left Side Cover Assembly
Figure 1-9 Rotating Platform
Figure 1-10 Swing Bearing, Cradle & Hoist Cylinder Mounting & Lube System
Figure 1-11 Valve Cover
Section 2 Boom
Figure 2-1 Boom Cradle
Figure 2-2 Main Boom Assembly
Figure 2-3 Telescope Boom Assembly
Figure 2-4 Boom Roller Assemblies
Figure 2-5 Bucket Linkage
Section 3 Attachments
Figure 3-1 36” Excavating Bucket
Figure 3-2 Fixed Thumb Grapple Assembly
Figure 3-3 60” Ditching Bucket w/Bolt-on Cutting Edge
Section 4 Engine & Attaching Parts
Figure 4-1 Engine Assembly, L.H. View
Figure 4-2 Engine Assembly, R.H. View
Figure 4-3 Air Cleaner Assembly
Figure 4-4 Power Steering Reservoir Assembly
Figure 4-5 Exhaust System
Figure 4-6 Fuel Tank & Lines
Figure 4-7 Radiator & Cooler Assemblies
Figure 4-8 Oil Cooler & Hoses
Figure 4-9 Air Brake System
Figure 4-10 Spring Brake Control Valve & Parking Brake Valve Assemblies
Figure 4-11 Lockout Air Valve, Air Dryer & Adapter Assemblies
Figure 4-12 Air Valve Assemblies
Figure 4-13 Air Valve & Double Check Valve Assemblies
Figure 4-14 Air Reservoir Assemblies
Figure 4-15 Relay Valve Assemblies
Figure 4-16 Foot Pedal Valve & Air Fitting Assembly
Figure 4-17 Air Valve Assemblies
Figure 4-18 Air Valve & Air Fitting Assemblies
Section 5 Drive Train
Figure 5-1 Clutch Assembly
Figure 5-2 Clutch Release Bearing
Figure 5-3 Slave Valve Assembly
Figure 5-4 Transmission – Slave Control Assembly
Figure 5-5 Transmission – Slave Valve w/Hoses
Figure 5-6 Transmission – Clutch Housing
Figure 5-7 Transmission – Shift Bar Housing
Figure 5-8 Transmission – Reverse Idler, Input Shaft & Drive Gear
Figure 5-9 Transmission – Mainshaft & Countershaft Gears
Figure 5-10 Transmission – Auxiliary Mainshaft
Figure 5-11 Transmission – Auxiliary Case Assembly
Figure 5-12 Transmission – Range Cylinder
Figure 5-13 Transmission – Auxiliary Countershaft & Auxiliary Drive Gear
Figure 5-14 Transmission – Master Shift Valve Assembly
Figure 5-15 Propeller Shaft
Figure 5-16 Transfer Case Assembly, 6X6
Figure 5-17 Front Axle – Axle Assembly, 6X4
Figure 5-18 Front Axle – Steering Components, 6X4
Figure 5-19 Front Axle – Service Brakes, 6X4
Figure 5-20 Front Axle – Disc Wheel & Rims, 6X4
Figure 5-21 Front Axle – Axle Assembly, 6X6
Figure 5-22 Front Axle – Housing Assembly, 6X6
Figure 5-23 Front Axle – Differential Assembly, 6X6
Figure 5-24 Front Axle – Steering Components, 6X6
Figure 5-25 Front Axle – Service Brake, 6X6
Figure 5-26 Front Axle – Disc Wheels & Rims, 6X6
Figure 5-27 Front Axle – Spring Assembly
Figure 5-28 Rear Axle – Axle Assembly, 6X4
Figure 5-29 Rear Axle – Axle Assembly, 6X6
Figure 5-30 Rear Axle – Forward Housing
Figure 5-31 Rear Axle – Rear Housing
Figure 5-32 Rear Axle – Forward Differential Assembly
Figure 5-33 Rear Axle – Rear Differential Assembly
Figure 5-34 Rear Axle – Service Brake
Figure 5-35 Rear Axle – Disc Wheel & Rim
Figure 5-36 Equalizer Beams
Section 6 Cab
Figure 6-1 Operators Cab, Upperstructure
Figure 6-2 Operators Cab, Upperstructure
Figure 6-3 Cab Door, Upperstructure
Figure 6-4 Cab Interior Components, Upperstructure
Figure 6-5 Cab Console, Upperstructure
Figure 6-6 Cab Seat, Upperstructure
Figure 6-7 Cab Heater & Installation, Upperstructure
Figure 6-8 Operators Cab, Undercarriage
Figure 6-9 Operators Cab, Undercarriage
Figure 6-10 Cab Door, Undercarriage
Figure 6-11 Cab Seat, Undercarriage
Figure 6-12 Seat Suspension, Undercarriage
Figure 6-13 Heater & Defroster, Undercarriage
Figure 6-14 Pilot Cut-off Assembly
Section 7 Controls
Figure 7-1 Joystick Assembly
Figure 7-2 Steering Column Assembly
Figure 7-3 Steering Drive Shaft Assembly
Figure 7-4 Steering Drag Link Assembly
Figure 7-5 Foot Operated Pedal Valve Assembly
Figure 7-6 Foot Operated Pedal Plate Assembly
Section 8 Hydraulic Circuits
Figure 8-1 Hydraulic Oil Supply to Main Pump
Figure 8-2 Main Hydraulic Pump to Center Pin
Figure 8-3 Hydraulic Pressure from Center Pin to Control Valve
Figure 8-4 Main Valve to Pilot Manifold
Figure 8-5 Hydraulic Hosing To Joysticks & Foot Operated Pedal Valve
Figure 8-6 Upper Dump
Figure 8-7 Chassis Dump
Figure 8-8 Hoist Pilot
Figure 8-9 Boom Pilot
Figure 8-10 Tool Pilot
Figure 8-11 Tilt Pilot
Figure 8-12 Heater & Auxiliary Pilot
Figure 8-13 Hoist Cylinder
Figure 8-14 Boom Cylinder
Figure 8-15 Tool Cylinder
Figure 8-16 Swing & Swing Brake Pilot
Figure 8-17 Tool Pilot
Figure 8-18 Swing Motor
Figure 8-19 Tilt Motor
Figure 8-20 Steering Gear
Figure 8-21 Remote Propelling
Figure 8-22 Remote Steering
Figure 8-23 Stabilizer Cylinder
Section 9 Hydraulic Components
Figure 9-1 Hoist Cylinder Assembly
Figure 9-2 Boom Cylinder Assembly
Figure 9-3 Tool Cylinder Assembly
Figure 9-4 Stabilizer Cylinder Assembly
Figure 9-5 Stabilizer Valve Assembly
Figure 9-6 Remote Steering Hydraulic Cylinder Assembly
Figure 9-7 Main Pump – Front
Figure 9-8 Main Pump – Rear
Figure 9-9 Main Hydraulic Control Valve
Figure 9-10 Main Hydraulic Control Valve – Spools & End Caps
Figure 9-11 Main Hydraulic Control Valve – Swing Section
Figure 9-12 Main Hydraulic Control Valve – Seal Kits
Figure 9-13 Pilot Manifold Valve Tray Hydraulic Components
Figure 9-14 Pilot Manifold Assembly
Figure 9-15 Reservoir Assembly
Figure 9-16 Swing Transmission Installation
Figure 9-17 Swing Transmission Assembly
Figure 9-18 Swing Motor Assembly
Figure 9-19 Swing Brake Assembly
Figure 9-20 Tilt Transmission
Figure 9-21 Tilt Transmission Assembly
Figure 9-22 Tilt Motor Assembly
Figure 9-23 Tilt Brake Assembly
Figure 9-24 Travel Motor
Figure 9-25 Center Pin Assembly
Figure 9-26 Power Take-Off Assembly
Figure 9-27 Power Take-Off Counter Shaft
Figure 9-28 Oil Cooler Assembly
Figure 9-29 Hydraulic Heater Pump Assembly
Figure 9-30 Hydraulic Heater Manifold Assembly
Figure 9-31 Steering Gear Assembly
Figure 9-32 Counterbalance Valve Assembly
Figure 9-33 Counterbalance Valve
Figure 9-34 Cooling Fan Valve Assembly
Figure 9-35 Steering Valve Assembly
Figure 9-36 Dual Solenoid Valve Assembly
Figure 9-37 Hoist Limit Valve
Section 10 Electrical
Figure 10-1 Miscellaneous Electrical Components, Upperstructure
Figure 10-2 Battery Box, Batteries & Cables
Figure 10-3 Tail & Marker Lights
Figure 10-4 Head & Marker Lights
Figure 10-5 Horn & Miscellaneous, Undercarriage
Figure 10-6 Cab Console Circuit Board, Upperstructure
Figure 10-7 Cab Console Circuit Board, Undercarriage
Figure 10-8 Instrument Panel
Figure 10-9 Accessory Panel
Section 11 Decals
Figure 11-1 Decals, Upperstructure
Figure 11-2 Decals, Undercarriage
Section 12 Options
Figure 12-1 Air Conditioner Installation Components, Upperstructure
Figure 12-2 ‘04 EPA Air Conditioner Installation, Undercarriage
Figure 12-3 Air Conditioner General Kit
Figure 12-4 Floodlight Installation Components
Figure 12-5 Seat Belt Installation Components
Figure 12-6 Strobe Light Installation Components
Figure 12-7 Strobe Light Installation
Figure 12-8 Fire Extinguisher Installation
Figure 12-9 Fire Extinguisher Installation
Figure 12-10 Vandal Covers w/o Worklight Installation
Figure 12-11 Coolant Filter Installation
Figure 12-12 Air Greaser Installation
Recommended Spare Parts
Part Number Index
XL4100II Illustrated Parts Manual 31200312 2007.pdf (456 Pages)
Contents:
Service Kits
Section 1 Frame & Attaching Parts
Figure 1-1 Frame Assembly
Figure 1-2 Mirror & Grab Rails
Figure 1-3 Engine Cover
Figure 1-4 R.H. Fender & Mirrors
Figure 1-5 L.H. Fender
Figure 1-6 Rear Fender Assembly
Figure 1-7 Deck & Cover
Figure 1-8 Left Side Cover Assembly
Figure 1-9 Rotating Platform
Figure 1-10 Swing Bearing, Cradle & Hoist Cylinder Mounting & Lube System
Figure 1-11 Valve Cover
Section 2 Boom
Figure 2-1 Boom Cradle
Figure 2-2 Main Boom Assembly
Figure 2-3 Telescope Boom Assembly
Figure 2-4 Boom Roller Assemblies
Figure 2-5 Bucket Linkage
Section 3 Attachments
Figure 3-1 60” Ditching Buckets
Section 4 Engine & Attaching Parts
Figure 4-1 Engine Assembly, L.H. View
Figure 4-2 Engine Assembly, R.H. View
Figure 4-3 Air Cleaner Assembly
Figure 4-4 Power Steering Reservoir Assembly
Figure 4-5 Exhaust System
Figure 4-6 Fuel Tank & Lines
Figure 4-7 Radiator & Cooler Assemblies
Figure 4-8 Oil Cooler & Hoses
Figure 4-9 Air Brake System
Figure 4-10 Spring Brake Control Valve & Parking Brake Valve Assemblies
Figure 4-11 Lockout Air Valve, Air Dryer & Adapter Assemblies
Figure 4-12 Air Valve Assemblies
Figure 4-13 Air Valve & Double Check Valve Assemblies
Figure 4-14 Air Reservoir Assemblies
Figure 4-15 Relay Valve Assemblies
Figure 4-16 Foot Pedal Valve & Air Fitting Assembly
Figure 4-17 Air Valve Assemblies
Figure 4-18 Air Valve & Air Fitting Assemblies
Section 5 Drive Train
Figure 5-1 Clutch Assembly
Figure 5-2 Clutch Release Bearing
Figure 5-3 Slave Valve Assembly
Figure 5-4 Transmission – Slave Control Assembly
Figure 5-5 Transmission – Slave Valve w/Hoses
Figure 5-6 Transmission – Clutch Housing
Figure 5-7 Transmission – Shift Bar Housing
Figure 5-8 Transmission – Reverse Idler, Input Shaft & Drive Gear
Figure 5-9 Transmission – Mainshaft & Countershaft Gears
Figure 5-10 Transmission – Auxiliary Mainshaft
Figure 5-11 Transmission – Auxiliary Case Assembly
Figure 5-12 Transmission – Range Cylinder
Figure 5-13 Transmission – Auxiliary Countershaft & Auxiliary Drive Gear
Figure 5-14 Transmission – Master Shift Valve Assembly
Figure 5-15 Propeller Shaft
Figure 5-16 Transfer Case Assembly, 6X6
Figure 5-17 Front Axle – Axle Assembly, 6X4
Figure 5-18 Front Axle – Steering Components, 6X4
Figure 5-19 Front Axle – Service Brakes, 6X4
Figure 5-20 Front Axle – Disc Wheel & Rims, 6X4
Figure 5-21 Front Axle – Axle Assembly, 6X6
Figure 5-22 Front Axle – Housing Assembly, 6X6
Figure 5-23 Front Axle – Differential Assembly, 6X6
Figure 5-24 Front Axle – Steering Components, 6X6
Figure 5-25 Front Axle – Service Brake, 6X6
Figure 5-26 Front Axle – Disc Wheels & Rims, 6X6
Figure 5-27 Front Axle – Spring Assembly
Figure 5-28 Rear Axle – Axle Assembly, 6X4
Figure 5-29 Rear Axle – Axle Assembly, 6X6
Figure 5-30 Rear Axle – Forward Housing
Figure 5-31 Rear Axle – Rear Housing
Figure 5-32 Rear Axle – Forward Differential Assembly
Figure 5-33 Rear Axle – Rear Differential Assembly
Figure 5-34 Rear Axle – Service Brake
Figure 5-35 Rear Axle – Disc Wheel & Rim
Figure 5-36 Equalizer Beams
Section 6 Cab
Figure 6-1 Operators Cab, Upperstructure
Figure 6-2 Operators Cab, Upperstructure
Figure 6-3 Cab Door, Upperstructure
Figure 6-4 Cab Interior Components, Upperstructure
Figure 6-5 Cab Console, Upperstructure
Figure 6-6 Cab Seat, Upperstructure
Figure 6-7 Cab Heater & Installation, Upperstructure
Figure 6-8 Operators Cab, Undercarriage
Figure 6-9 Operators Cab, Undercarriage
Figure 6-10 Cab Door, Undercarriage
Figure 6-11 Cab Seat, Undercarriage
Figure 6-12 Seat Suspension, Undercarriage
Figure 6-13 Heater & Defroster, Undercarriage
Figure 6-14 Pilot Cut-off Assembly
Section 7 Controls
Figure 7-1 Joystick Assembly
Figure 7-2 Steering Column Assembly
Figure 7-3 Steering Drive Shaft Assembly
Figure 7-4 Steering Drag Link Assembly
Figure 7-5 Foot Operated Pedal Valve Assembly
Figure 7-6 Foot Operated Pedal Plate Assembly
Section 8 Hydraulic Circuits
Figure 8-1 Hydraulic Oil Supply to Main Pump
Figure 8-2 Main Hydraulic Pump to Center Pin
Figure 8-3 Hydraulic Pressure from Center Pin to Control Valve
Figure 8-4 Main Valve to Pilot Manifold
Figure 8-5 Hydraulic Hosing To Joysticks & Foot Operated Pedal Valve
Figure 8-6 Upper Dump
Figure 8-7 Chassis Dump
Figure 8-8 Hoist Pilot
Figure 8-9 Boom Pilot
Figure 8-10 Tool Pilot
Figure 8-11 Tilt Pilot
Figure 8-12 Heater & Auxiliary Pilot
Figure 8-13 Hoist Cylinder
Figure 8-14 Boom Cylinder
Figure 8-15 Tool Cylinder
Figure 8-16 Swing & Swing Brake Pilot
Figure 8-17 Tool Pilot
Figure 8-18 Swing Motor
Figure 8-19 Tilt Motor
Figure 8-20 Steering Gear
Figure 8-21 Remote Propelling
Figure 8-22 Remote Steering
Figure 8-23 Stabilizer Cylinder
Section 9 Hydraulic Components
Figure 9-1 Hoist Cylinder Assembly
Figure 9-2 Boom Cylinder Assembly
Figure 9-3 Tool Cylinder Assembly
Figure 9-4 Stabilizer Cylinder Assembly
Figure 9-5 Stabilizer Valve Assembly
Figure 9-6 Remote Steering Hydraulic Cylinder Assembly
Figure 9-7 Main Pump – Front
Figure 9-8 Main Pump – Rear
Figure 9-9 Main Hydraulic Control Valve
Figure 9-10 Main Hydraulic Control Valve – Spools & End Caps
Figure 9-11 Main Hydraulic Control Valve – Swing Section
Figure 9-12 Main Hydraulic Control Valve – Seal Kits
Figure 9-13 Pilot Manifold Valve Tray Hydraulic Components
Figure 9-14 Pilot Manifold Assembly
Figure 9-15 Reservoir Assembly
Figure 9-16 Swing Transmission Installation
Figure 9-17 Swing Transmission Assembly
Figure 9-18 Swing Motor Assembly
Figure 9-19 Swing Brake Assembly
Figure 9-20 Tilt Transmission
Figure 9-21 Tilt Transmission Assembly
Figure 9-22 Tilt Motor Assembly
Figure 9-23 Tilt Brake Assembly
Figure 9-24 Travel Motor
Figure 9-25 Center Pin Assembly
Figure 9-26 Power Take-Off Assembly
Figure 9-27 Power Take-Off Counter Shaft
Figure 9-28 Oil Cooler Assembly
Figure 9-29 Hydraulic Heater Pump Assembly
Figure 9-30 Hydraulic Heater Manifold Assembly
Figure 9-31 Steering Gear Assembly
Figure 9-32 Counterbalance Valve Assembly
Figure 9-33 Counterbalance Valve
Figure 9-34 Cooling Fan Valve Assembly
Figure 9-35 Steering Valve Assembly
Figure 9-36 Dual Solenoid Valve Assembly
Figure 9-37 Hoist Limit Valve
Section 10 Electrical
Figure 10-1 Miscellaneous Electrical Components, Upperstructure
Figure 10-2 Battery Box, Batteries & Cables
Figure 10-3 Tail & Marker Lights
Figure 10-4 Head & Marker Lights
Figure 10-5 Horn & Miscellaneous, Undercarriage
Figure 10-6 Cab Console Circuit Board, Upperstructure
Figure 10-7 Cab Console Circuit Board, Undercarriage
Figure 10-8 Instrument Panel
Figure 10-9 Accessory Panel
Section 11 Decals
Figure 11-1 Decals, Upperstructure
Figure 11-2 Decals, Undercarriage
Section 12 Options
Figure 12-1 Air Conditioner Installation Components, Upperstructure
Figure 12-2 ‘04 EPA Air Conditioner Installation, Undercarriage
Figure 12-3 Air Conditioner General Kit
Figure 12-4 Block Heater Installation Components
Figure 12-5 Floodlight Installation Components
Figure 12-6 Grid Heater Installation Components
Figure 12-7 Upper Cab Seat Belt Installation Components
Figure 12-8 AM/FM Cassette Stereo Installation Components, Upper Cab
Figure 12-9 Dual Air Horn Installation
Figure 12-10 Back-Up Alarm Installation
Figure 12-11 Auxiliary Hydraulics
Figure 12-12 AM/FM Cassette Stereo Installation, Chassis Cab
Figure 12-13 Strobe Light Installation Components, Upper Cab
Figure 12-14 Strobe Light Installation Components, Chassis Cab
Recommended Spare Parts
Part Number Index
XL4100II Illustrated Parts Manual 31200314 2007.pdf (452 Pages)
Contents:
Service Kits
Section 1 Frame & Attaching Parts
Figure 1-1 Frame Assembly
Figure 1-2 Mirror & Grab Rails
Figure 1-3 Engine Cover
Figure 1-4 R.H. Fender & Mirrors
Figure 1-5 L.H. Fender
Figure 1-6 Rear Fender Assembly
Figure 1-7 Deck & Cover
Figure 1-8 Left Side Cover Assembly
Figure 1-9 Rotating Platform
Figure 1-10 Swing Bearing, Cradle & Hoist Cylinder Mounting & Lube System
Figure 1-11 Valve Cover
Section 2 Boom
Figure 2-1 Boom Cradle
Figure 2-2 Main Boom Assembly
Figure 2-3 Telescope Boom Assembly
Figure 2-4 Boom Roller Assemblies
Figure 2-5 Bucket Linkage
Section 3 Attachments
Figure 3-1 36” Excavating Buckets
Figure 3-2 66” Ditching Bucket
Section 4 Engine & Attaching Parts
Figure 4-1 Engine Assembly, L.H. View
Figure 4-2 Engine Assembly, R.H. View
Figure 4-3 Air Cleaner Assembly
Figure 4-4 Power Steering Reservoir Assembly
Figure 4-5 Exhaust System
Figure 4-6 Fuel Tank & Lines
Figure 4-7 Radiator & Cooler Assemblies
Figure 4-8 Oil Cooler & Hoses
Figure 4-9 Air Brake System
Figure 4-10 Spring Brake Control Valve & Parking Brake Valve Assemblies
Figure 4-11 Lockout Air Valve, Air Dryer & Adapter Assemblies
Figure 4-12 Air Valve Assemblies
Figure 4-13 Air Valve & Double Check Valve Assemblies
Figure 4-14 Air Reservoir Assemblies
Figure 4-15 Relay Valve Assemblies
Figure 4-16 Foot Pedal Valve & Air Fitting Assembly
Figure 4-17 Air Valve Assemblies
Figure 4-18 Air Valve & Air Fitting Assemblies
Section 5 Drive Train
Figure 5-1 Clutch Assembly
Figure 5-2 Clutch Release Bearing
Figure 5-3 Slave Valve Assembly
Figure 5-4 Transmission – Slave Control Assembly
Figure 5-5 Transmission – Slave Valve w/Hoses
Figure 5-6 Transmission – Clutch Housing
Figure 5-7 Transmission – Shift Bar Housing
Figure 5-8 Transmission – Reverse Idler, Input Shaft & Drive Gear
Figure 5-9 Transmission – Mainshaft & Countershaft Gears
Figure 5-10 Transmission – Auxiliary Mainshaft
Figure 5-11 Transmission – Auxiliary Case Assembly
Figure 5-12 Transmission – Range Cylinder
Figure 5-13 Transmission – Auxiliary Countershaft & Auxiliary Drive Gear
Figure 5-14 Transmission – Master Shift Valve Assembly
Figure 5-15 Propeller Shaft
Figure 5-16 Transfer Case Assembly, 6X6
Figure 5-17 Front Axle – Axle Assembly, 6X4
Figure 5-18 Front Axle – Steering Components, 6X4
Figure 5-19 Front Axle – Service Brakes, 6X4
Figure 5-20 Front Axle – Disc Wheel & Rims, 6X4
Figure 5-21 Front Axle – Axle Assembly, 6X6
Figure 5-22 Front Axle – Housing Assembly, 6X6
Figure 5-23 Front Axle – Differential Assembly, 6X6
Figure 5-24 Front Axle – Steering Components, 6X6
Figure 5-25 Front Axle – Service Brake, 6X6
Figure 5-26 Front Axle – Disc Wheels & Rims, 6X6
Figure 5-27 Front Axle – Spring Assembly
Figure 5-28 Rear Axle – Axle Assembly, 6X4
Figure 5-29 Rear Axle – Axle Assembly, 6X6
Figure 5-30 Rear Axle – Forward Housing
Figure 5-31 Rear Axle – Rear Housing
Figure 5-32 Rear Axle – Forward Differential Assembly
Figure 5-33 Rear Axle – Rear Differential Assembly
Figure 5-34 Rear Axle – Service Brake
Figure 5-35 Rear Axle – Disc Wheel & Rim
Figure 5-36 Equalizer Beams
Section 6 Cab
Figure 6-1 Operators Cab, Upperstructure
Figure 6-2 Operators Cab, Upperstructure
Figure 6-3 Cab Door, Upperstructure
Figure 6-4 Cab Interior Components, Upperstructure
Figure 6-5 Cab Console, Upperstructure
Figure 6-6 Cab Seat, Upperstructure
Figure 6-7 Cab Heater & Installation, Upperstructure
Figure 6-8 Operators Cab, Undercarriage
Figure 6-9 Operators Cab, Undercarriage
Figure 6-10 Cab Door, Undercarriage
Figure 6-11 Cab Seat, Undercarriage
Figure 6-12 Seat Suspension, Undercarriage
Figure 6-13 Heater & Defroster, Undercarriage
Figure 6-14 Pilot Cut-off Assembly
Section 7 Controls
Figure 7-1 Joystick Assembly
Figure 7-2 Steering Column Assembly
Figure 7-3 Steering Drive Shaft Assembly
Figure 7-4 Steering Drag Link Assembly
Figure 7-5 Foot Operated Pedal Valve Assembly
Figure 7-6 Foot Operated Pedal Plate Assembly
Section 8 Hydraulic Circuits
Figure 8-1 Hydraulic Oil Supply to Main Pump
Figure 8-2 Main Hydraulic Pump to Center Pin
Figure 8-3 Hydraulic Pressure from Center Pin to Control Valve
Figure 8-4 Main Valve to Pilot Manifold
Figure 8-5 Hydraulic Hosing To Joysticks & Foot Operated Pedal Valve
Figure 8-6 Upper Dump
Figure 8-7 Chassis Dump
Figure 8-8 Hoist Pilot
Figure 8-9 Boom Pilot
Figure 8-10 Tool Pilot
Figure 8-11 Tilt Pilot
Figure 8-12 Heater & Auxiliary Pilot
Figure 8-13 Hoist Cylinder
Figure 8-14 Boom Cylinder
Figure 8-15 Tool Cylinder
Figure 8-16 Swing & Swing Brake Pilot
Figure 8-17 Tool Pilot
Figure 8-18 Swing Motor
Figure 8-19 Tilt Motor
Figure 8-20 Steering Gear
Figure 8-21 Remote Propelling
Figure 8-22 Remote Steering
Figure 8-23 Stabilizer Cylinder
Section 9 Hydraulic Components
Figure 9-1 Hoist Cylinder Assembly
Figure 9-2 Boom Cylinder Assembly
Figure 9-3 Tool Cylinder Assembly
Figure 9-4 Stabilizer Cylinder Assembly
Figure 9-5 Stabilizer Valve Assembly
Figure 9-6 Remote Steering Hydraulic Cylinder Assembly
Figure 9-7 Main Pump – Front
Figure 9-8 Main Pump – Rear
Figure 9-9 Main Hydraulic Control Valve
Figure 9-10 Main Hydraulic Control Valve – Spools & End Caps
Figure 9-11 Main Hydraulic Control Valve – Swing Section
Figure 9-12 Main Hydraulic Control Valve – Seal Kits
Figure 9-13 Pilot Manifold Valve Tray Hydraulic Components
Figure 9-14 Pilot Manifold Assembly
Figure 9-15 Reservoir Assembly
Figure 9-16 Swing Transmission Installation
Figure 9-17 Swing Transmission Assembly
Figure 9-18 Swing Motor Assembly
Figure 9-19 Swing Brake Assembly
Figure 9-20 Tilt Transmission
Figure 9-21 Tilt Transmission Assembly
Figure 9-22 Tilt Motor Assembly
Figure 9-23 Tilt Brake Assembly
Figure 9-24 Travel Motor
Figure 9-25 Center Pin Assembly
Figure 9-26 Power Take-Off Assembly
Figure 9-27 Power Take-Off Counter Shaft
Figure 9-28 Oil Cooler Assembly
Figure 9-29 Hydraulic Heater Pump Assembly
Figure 9-30 Hydraulic Heater Manifold Assembly
Figure 9-31 Steering Gear Assembly
Figure 9-32 Counterbalance Valve Assembly
Figure 9-33 Counterbalance Valve
Figure 9-34 Cooling Fan Valve Assembly
Figure 9-35 Steering Valve Assembly
Figure 9-36 Dual Solenoid Valve Assembly
Figure 9-37 Hoist Limit Valve
Section 10 Electrical
Figure 10-1 Miscellaneous Electrical Components, Upperstructure
Figure 10-2 Battery Box, Batteries & Cables
Figure 10-3 Tail & Marker Lights
Figure 10-4 Head & Marker Lights
Figure 10-5 Horn & Miscellaneous, Undercarriage
Figure 10-6 Cab Console Circuit Board, Upperstructure
Figure 10-7 Cab Console Circuit Board, Undercarriage
Figure 10-8 Instrument Panel
Figure 10-9 Accessory Panel
Section 11 Decals
Figure 11-1 Decals, Upperstructure
Figure 11-2 Decals, Undercarriage
Section 12 Options
Figure 12-1 Air Conditioner Installation Components, Upperstructure
Figure 12-2 ‘04 EPA Air Conditioner Installation, Undercarriage
Figure 12-3 Air Conditioner General Kit
Figure 12-4 Block Heater Installation Components
Figure 12-5 Floodlight Installation Components
Figure 12-6 Locking Fuel Cap
Figure 12-7 Seat Belt Installation Components
Figure 12-8 Strobe Light Installation Components
Figure 12-9 Auxiliary Hydraulics
Figure 12-10 Fire Extinguisher Installation
Figure 12-11 Fire Extinguisher Installation
Figure 12-12 Mudflap Installation
Figure 12-13 Back-Up Alarm Installation
Recommended Spare Parts
Part Number Index
XL4100II Combined Service Manual 8040-4002 2007.pdf (1238 Pages)
Contents:
8040-4002 XL4100II COMBINED SERVICE MANUAL
VOLUME I
OPERATOR INSTRUCTION
HYDRAULIC TEST & ADJUSTMENT
MECHANICAL ADJUSTMENT
MISCELLANEOUS
STEERING
CLUTCH
MAIN TRANSMISSION
VOLUME II
FRONT AXLE
REAR AXLE
DRIVE LINES
BRAKE SYSTEMS
WHEEL & RIM
MISCELLANEOUS
XL4100II Operators Manual 8040-4003 2004.pdf (74 Pages)
XL4100II 04EPA Operators & Safety Manual 8040-4122 2004.pdf (72 Pages)
XL4100II 04EPA Combined Service Manual 8040-4123 2007.pdf (1242 Pages)
Contents:
8040-4123 XL4100II_04EPA COMBINED SERVICE MANUAL
VOLUME I
OPERATOR INSTRUCTION
HYDRAULIC TEST & ADJUSTMENT
MECHANICAL ADJUSTMENT
MISCELLANEOUS
STEERING
CLUTCH
MAIN TRANSMISSION
VOLUME II
FRONT AXLE
REAR AXLE
DRIVE LINES
BRAKE SYSTEMS
WHEEL & RIM
MISCELLANEOUS
XL4100II Illustrated Parts Manual 80404001 2025.pdf (600 Pages)
Contents:
Service Kits
Section 1 Frame & Attaching Parts
Figure 1-1 Frame Assembly
Figure 1-2 Mirror & Grab Rails
Figure 1-3 Engine Cover
Figure 1-4 R.H. Fender & Mirrors
Figure 1-5 L.H. Fender
Figure 1-6 Rear Fender Assembly
Figure 1-7 Deck & Cover
Figure 1-8 Left Side Cover Assembly
Figure 1-9 Rotating Platform
Figure 1-10 Swing Bearing, Cradle & Hoist Cylinder Mounting & Lube System
Figure 1-11 Valve Cover
Section 2 Boom
Figure 2-1 Boom Cradle
Figure 2-2 Main Boom Assembly
Figure 2-3 Telescope Boom Assembly
Figure 2-4 Boom Roller Assemblies
Figure 2-5 Bucket Linkage
Section 3 Attachments
Figure 3-1 24” & 30” Excavating Buckets
Figure 3-2 36” & 42” Excavating Buckets
Figure 3-3 48” Excavating Bucket & 15” Trenching Bucket
Figure 3-4 18” & 28” Pavement Removal Buckets
Figure 3-5 40” Pavement Removal Bucket & 60” Ditching Bucket
Figure 3-6 28” Pavement Removal Bucket & 30” Ditching Bucket
Figure 3-7 60” Ditching Bucket
Figure 3-8 66” Ditching Bucket
Figure 3-9 72” Ditching Bucket
Figure 3-10 Guardrail Back Scraper & 66” Ditching Bucket
Figure 3-11 8’ Grading Blade & Single Tooth Ripper
Figure 3-12 4’ Boom Extension
Figure 3-13 6’ Boom Extension
Figure 3-14 8’ Boom Extension
Figure 3-15 12’ Boom Extension
Figure 3-16 Fixed Thumb Grapple Assembly
Figure 3-17 72” Dredging Bucket
Figure 3-18 108” Dredging Bucket
Figure 3-19 Bucket Carrier Assembly
Figure 3-20 66”& 72” Ditching Bucket w/Bolt-on Cutting Edge
Figure 3-21 60” Ditching Bucket w/Bolt-on Cutting Edge
Figure 3-22 Limb Lopper
Figure 3-23 Telestick Assembly
Figure 3-24 6’ Live Boom Extension
Section 4 Engine & Attaching Parts
Figure 4-1 Engine Assembly, L.H. View
Figure 4-2 Engine Assembly, R.H. View
Figure 4-3 Air Cleaner Assembly
Figure 4-4 Power Steering Reservoir Assembly
Figure 4-5 Exhaust System
Figure 4-6 Fuel Tank & Lines
Figure 4-7 Radiator & Cooler Assemblies
Figure 4-8 Oil Cooler & Hoses
Figure 4-9 Air Brake System
Figure 4-10 Spring Brake Control Valve & Parking Brake Valve Assemblies
Figure 4-11 Lockout Air Valve, Air Dryer & Adapter Assemblies
Figure 4-12 Air Valve Assemblies
Figure 4-13 Air Valve & Double Check Valve Assemblies
Figure 4-14 Air Reservoir Assemblies
Figure 4-15 Relay Valve Assemblies
Figure 4-16 Foot Pedal Valve & Air Fitting Assembly
Figure 4-17 Air Valve Assemblies
Figure 4-18 Air Valve & Air Fitting Assemblies
Section 5 Drive Train
Figure 5-1 Clutch Assembly
Figure 5-2 Clutch Release Bearing
Figure 5-3 Slave Valve Assembly
Figure 5-4 Transmission – Transmission Control Unit
Figure 5-5 Transmission – Slave Valve w/Hoses
Figure 5-6 Transmission – Clutch Housing
Figure 5-7 Transmission – Shift Bar Housing
Figure 5-8 Transmission – Reverse Idler, Input Shaft & Drive Gear
Figure 5-9 Transmission – Mainshaft & Countershaft Gears
Figure 5-10 Transmission – Auxiliary Mainshaft
Figure 5-11 Transmission – Auxiliary Case Assembly
Figure 5-12 Transmission – Range Cylinder
Figure 5-13 Transmission – Auxiliary Countershaft & Auxiliary Drive Gear
Figure 5-14 Transmission – Master Shift Valve Assembly
Figure 5-15 Propeller Shaft
Figure 5-16 Transfer Case Assembly, 6X6
Figure 5-17 Front Axle – Axle Assembly, 6X4
Figure 5-18 Front Axle – Steering Components, 6X4
Figure 5-19 Front Axle – Service Brakes, 6X4
Figure 5-20 Front Axle – Disc Wheel & Rims, 6X4
Figure 5-21 Front Drive Axle – Axle Assembly, (6X6)
Figure 5-22 Front Drive Axle – Housing Assembly, (6X6)
Figure 5-23 Front Drive Axle – Differential Assembly, (6X6)
Figure 5-24 Front Drive Axle – Steering Components, (6X6)
Figure 5-25 Front Drive Axle – Service Brake, (6X6)
Figure 5-26 Front Drive Axle – Disc Wheels & Rims, (6X6)
Figure 5-27 Front Axle – Spring Assembly
Figure 5-28 Rear Axle – Axle Assembly, 6X4
Figure 5-29 Rear Axle – Axle Assembly, 6X6
Figure 5-30 Rear Axle – Forward Housing
Figure 5-31 Rear Axle – Rear Housing
Figure 5-32 Rear Axle – Forward Differential Assembly
Figure 5-33 Rear Axle – Rear Differential Assembly
Figure 5-34 Rear Axle – Service Brake
Figure 5-35 Rear Axle – Disc Wheel & Rim
Figure 5-36 Equalizer Beams
Section 6 Cab
Figure 6-1 Operators Cab, Upperstructure
Figure 6-2 Operators Cab, Upperstructure
Figure 6-3 Cab Door, Upperstructure
Figure 6-4 Cab Interior Components, Upperstructure
Figure 6-5 Cab Console, Upperstructure
Figure 6-6 Cab Seat, Upperstructure
Figure 6-7 Cab Heater & Installation, Upperstructure
Figure 6-8 Operators Cab, Undercarriage
Figure 6-9 Operators Cab, Undercarriage
Figure 6-10 Cab Door, Undercarriage
Figure 6-11 Cab Seat, Undercarriage
Figure 6-12 Heater & Defroster, Undercarriage
Figure 6-13 Pilot Cut-off Assembly
Figure 6-14 Wiper-Washer Installation Components
Figure 6-15 Heater Card Replacement Kit
Section 7 Controls
Figure 7-1 Joystick Assembly
Figure 7-2 Steering Column Assembly
Figure 7-3 Steering Drive Shaft Assembly
Figure 7-4 Foot Operated Pedal Valve Assembly
Figure 7-5 Foot Operated Pedal Plate Assembly
Section 8 Hydraulic Circuits
Figure 8-1 Hydraulic Oil Supply to Main Pump
Figure 8-2 Main Hydraulic Pump to Center Pin
Figure 8-3 Hydraulic Pressure from Center Pin to Control Valve
Figure 8-4 Supply Tube Replacement Kit
Figure 8-5 Main Valve to Pilot Manifold
Figure 8-6 Hydraulic Hosing To Joysticks & Foot Operated Pedal Valve
Figure 8-7 Upper Dump
Figure 8-8 Chassis Dump
Figure 8-9 Hoist Pilot
Figure 8-10 Boom Pilot
Figure 8-11 Tool Pilot
Figure 8-12 Tilt Pilot
Figure 8-13 Heater & Auxiliary Pilot
Figure 8-14 Hoist Cylinder
Figure 8-15 Hoist Tubes Replacement Kit
Figure 8-16 Boom Cylinder
Figure 8-17 Tool Cylinder
Figure 8-18 Swing & Swing Brake Pilot
Figure 8-19 Tool Pilot
Figure 8-20 Swing Motor
Figure 8-21 Swing Tubes Replacement Kit
Figure 8-22 Tilt Motor
Figure 8-23 Steering Gear
Figure 8-24 Remote Propelling
Figure 8-25 Remote Steering
Figure 8-26 Stabilizer Cylinder
Section 9 Hydraulic Components
Figure 9-1 Hoist Cylinder Assembly
Figure 9-2 Boom Cylinder Assembly
Figure 9-3 Tool Cylinder Assembly
Figure 9-4 Stabilizer Valve Assembly
Figure 9-5 Main Pump – Front
Figure 9-6 Main Pump – Rear
Figure 9-7 Main Hydraulic Control Valve
Figure 9-8 Main Hydraulic Control Valve – Spools & End Caps
Figure 9-9 Main Hydraulic Control Valve – Swing Section
Figure 9-10 Main Hydraulic Control Valve – Seal Kits
Figure 9-11 Pilot Manifold Valve Tray Hydraulic Components
Figure 9-12 Pilot Manifold Assembly
Figure 9-13 Reservoir Assembly
Figure 9-14 Swing Transmission Assembly
Figure 9-15 Swing Drive Assembly
Figure 9-16 Swing Motor Assembly
Figure 9-17 Swing Brake Assembly
Figure 9-18 Tilt Transmission
Figure 9-19 Tilt Drive Assembly
Figure 9-20 Tilt Motor Assembly
Figure 9-21 Tilt Brake Assembly
Figure 9-22 Travel Motor
Figure 9-23 Center Pin Assembly
Figure 9-24 Power Take-Off Assembly
Figure 9-25 Power Take-Off Counter Shaft
Figure 9-26 Oil Cooler Assembly
Figure 9-27 Hydraulic Heater Pump Assembly
Figure 9-28 Hydraulic Heater Manifold Assembly
Figure 9-29 Steering Gear Assembly
Figure 9-30 Counterbalance Valve Assembly
Figure 9-31 Counterbalance Valve
Figure 9-32 Cooling Fan Valve Assembly
Figure 9-33 Steering Valve Assembly
Figure 9-34 Dual Solenoid Valve Assembly
Figure 9-35 Hydraulic Heater Replacement Kit
Section 10 Electrical
Figure 10-1 Miscellaneous Electrical Components, Upperstructure
Figure 10-2 Battery Box, Batteries & Cables
Figure 10-3 Tail & Marker Lights
Figure 10-4 Head & Marker Lights
Figure 10-5 Horn & Miscellaneous, Undercarriage
Figure 10-6 Cab Console Circuit Board, Upperstructure
Figure 10-7 Cab Console Circuit Board, Undercarriage
Figure 10-8 Instrument Panel
Figure 10-9 Accessory Panel
Section 11 Decals
Figure 11-1 Decals, Upperstructure
Figure 11-2 Decals, Undercarriage
Section 12 Options
Figure 12-1 Air Conditioner Installation Components, Upperstructure
Figure 12-2 Air Conditioner Installation Components, Undercarriage
Figure 12-3 Air Conditioner General Kit
Figure 12-4 Air Conditioning Evaporator Kit
Figure 12-5 Auxiliary Hydraulic Field Conversion Kit
Figure 12-6 Auxiliary Return-to-Tank Field Installation Kit
Figure 12-7 Additional Battery Installation Components
Figure 12-8 Block Heater Installation Components
Figure 12-9 Bucket Hold-Open Kit
Figure 12-10 Floodlight Installation Components
Figure 12-11 Grid Heater Installation Components
Figure 12-12 Locking Fuel Cap
Figure 12-13 L.H. Rear Step Assembly
Figure 12-14 Seat Belt Installation Components
Figure 12-15 AM/FM Cassette Stereo Installation Components
Figure 12-16 Strobe Light Installation Components
Figure 12-17 Vandal Covers w/o Worklight Installation
Figure 12-18 Vandal Covers Installation Components
Figure 12-19 Accumulator Installation
Figure 12-20 Heated Fuel Filter Installation
Figure 12-21 Battery Disconnect Switch Installation
Figure 12-22 Air Operated Onboard Greaser
Figure 12-23 Floodlight Installation
Figure 12-24 Strobe Light Installation, Undercarriage
Recommended Spare Parts
XL4100II Technical Manual 80404137 2011.pdf (424 Pages)
Contents:
80404137_XL4100II Technical Manual_5-11
ELECTRICAL
XL4100II Electrical System Manual
HYDRAULIC
XL4100II Hydraulic System Operation
XL4100II Hydraulic Pressure Setting Manual
XL4100II Final Test Report
MECHANICAL
Remote Drive PTO Removal & Replacement
XL4100II Maintenance Manual
Product Support Information – Clutch Adjustment Procedure
Climate Control Systems
Product Support Information – Engine Oil Pan Drain Plugs
Product Support Information – A/C System Reciever Dryers
Product Support Information – A/C Systems & Compressed Air
Product Support Information – A/C System Moisture Contamination
Product Support Information – Swing Transmission Lube Check & Refill Requirements
Product Support Information – Rear Axle Walking Beam Clearance
Transmission Service Manual (Eaton/Fuller)
Hydraulic Heater Circuit & A/C Circuit Operation
SCHEMATICS
XL4100II Hydraulic Schematic (80409001)
XL4100II Electrical Schematic (80489007)
XL4100II Air Schematic (80489004)
XL4100 XL4100II Hydraulic Schematic 80409001.pdf (1 Pages)
XL4100II Air Diagram 80489003.pdf (1 Pages)
XL4100 XL4100II Air Schematic 80489004.pdf (1 Pages)
XL3100EPA XL4100II Chassis Dash Panels Electrical Schematic 80489007.pdf (9 Pages)
XL3100EPA XL4100 XL4100II Electrical Schematic 80489008.pdf (9 Pages)
X410-5185 XL4100II Additional Center Pin Wiring Diagram.pdf (1 Pages)