SECTION 8 - HYDRAULIC CIRCUITS

HYDRAULIC CIRCUITS

Series IV Highway Speed Excavators 808040018-2

Hydraulic Oil Supply to Main Hydraulic Pump

PAC5570

1

2

2

3

4

2

57

6

89 TO BOTTOM OF MAIN

HYDRAULIC PUMPTO PILOT/POWERSTEERING PUMP

“INLET”

1011 TO MAIN HYDRAULIC

PUMP CASE DRAIN

HYDRAULIC CIRCUITS

80804001 Series IV Highway Speed Excavators 8-3

Hydraulic Oil Supply to Main Hydraulic PumpItem Part Number Qty. Description Rev.

1 Ref HYDRAULIC RESERVOIR ASSY, (see page 9-56 for details)2 91163129 3 HEAVY DUTY BAND CLAMP3 80783150 1 SUCTION HOSE4 80783139 1 SUCTION TUBE5 80483031 2 CUSHION CLAMP, 3”6 91053413 2 CUSHION CLAMP, 1”7 80783140 1 TUBE ASSY8 84721670 1 HOSE ASSY9 Ref HOSES & HARDWARE, (see page 4-8 for details)

10 80903011 1 CUSHION CLAMP, 1-1/8”11 84721672 1 HOSE ASSY

HYDRAULIC CIRCUITS


Main Hydraulic Pump to Center Pin

PAC6061

�

�

��

��

��

��

��

�

�

��

!��.��$��$��$��

$��$��.��$�.$

��

Before S/N’sXL3100IV - 3120000325 (4x2); 3140000360 (4x4)XL4100IV - 4100000645 (6x4); 4160000072 (6x6)

XL5100IV - 5100000606 (6x4 & 6x6)

HYDRAULIC CIRCUITS


Main Hydraulic Pump to Center PinItem Part Number Qty. Description Rev.

1 80783141 2 CUSHION CLAMP2 88662664 1 FLANGE KIT, (XL3100IV), (includes item 11)2 88662665 1 FLANGE KIT, (XL4100IV & XL5100IV), (includes item 11)3 1 HOSE ASSY, (XL3100IV),

(no longer available; order hose kit 84721684S, located on page 8-6 for hose replacement)

3 1 HOSE ASSY, (XL4100IV & XL5100IV),(no longer available; order hose kit 84721679S, located on page 8-6 for hose replacement)

4 84711333 2 FLANGE HALF5 88201036 4 HEX HD CAPSCREW, 3/8-16X1-1/4, GR56 88551011 4 LOCKWASHER, 3/87 88662485 1 FLANGE ELBOW8 91083106 1 O-RING9 Ref MAIN HYDRAULIC PUMP ASSY, (see page 9-26 for details)

10 Ref CENTER PIN INSTALLATION & ASSY, (see page 9-82 for details)11 88991221 1 O-RING, (XL3100IV)11 88991222 1 O-RING, (XL4100IV & XL5100IV)

Before S/N’sXL3100IV - 3120000325 (4x2); 3140000360 (4x4)XL4100IV - 4100000645 (6x4); 4160000072 (6x6)XL5100IV - 5100000606 (6x4 & 6x6)

HYDRAULIC CIRCUITS


Main Hydraulic Pump to Center Pin

PAC13960

5

6 PORT “P1” TO MAIN PUMP

139

14

1234

48

101115

12

6

7

FROM CENTER PINPORT “P1”

XL3100IV ONLY

XL4100IV & XL5100IV ONLY

After (& including) S/N’sXL3100IV - 3120000325 (4x2); 3140000360 (4x4)XL4100IV - 4100000645 (6x4); 4160000072 (6x6)

XL5100IV - 5100000606 (6x4 & 6x6)

HYDRAULIC CIRCUITS


Main Hydraulic Pump to Center PinItem Part Number Qty. Description Rev.

84721684S 1 HOSE KIT, (XL3100IV), (includes items 4, 6, 7, 8, 10 & 11 designated with ‘XL3100IV’ in the description)

84721679S 1 HOSE KIT, (XL4100IV & XL5100IV), (includes items 4, 6, 7, 8, 10, 11 & 15 designated with ‘XL4100IV & XL5100IV’ in the description)

1 84711333 2 FLANGE HALF2 88201036 4 HEX HD CAPSCREW, 3/8-16X1-1/4, GR53 88551011 4 LOCKWASHER, 3/84 91083106 2 O-RING, (XL3100IV)4 91083106 1 O-RING, (XL4100IV & XL5100IV)5 Ref CENTER PIN INSTALLATION & ASSY, (see page 9-82 for details)6 84718086 1 HOSE ASSY, (XL3100IV)6 84722508 1 HOSE ASSY, (XL4100IV & XL5100IV)7 88662831 1 ELBOW, 90 DEGREES, (XL3100IV)7 88662832 1 ELBOW, 90 DEGREES, (XL4100IV & XL5100IV)8 84712738 2 FLANGE HALF, (XL3100IV)8 84712739 2 FLANGE HALF, (XL4100IV & XL5100IV)9 90027187 2 TY-WRAP

10 88201053 4 HEX HD CAPSCREW, 7/16-14X1-3/4, GR5, (XL3100IV)10 88201069 4 HEX HD CAPSCREW, 1/2-13X2, GR5, (XL4100IV & XL5100IV)11 88551012 4 LOCKWASHER, 7/16, (XL3100IV)11 88551013 4 LOCKWASHER, 1/2, (XL4100IV & XL5100IV)12 Ref MAIN HYDRAULIC PUMP ASSY, (see page 9-26 for details)13 80783141 2 CUSHION CLAMP14 83953053 1 PROTECTIVE SLEEVE15 91083339 1 O-RING, (XL4100IV & XL5100IV)

After (& including) S/N’sXL3100IV - 3120000325 (4x2); 3140000360 (4x4)XL4100IV - 4100000645 (6x4); 4160000072 (6x6)XL5100IV - 5100000606 (6x4 & 6x6)

HYDRAULIC CIRCUITS


Hydraulic Pressure from Center Pin to Control Valve

PAC6072

�

�

�

��

�

�

�

��

��

��

��

��

��

�

��

��

� �

�

�

�

��

��

��

��


XL5100IV - 5100000606 (6x4 & 6x6)

HYDRAULIC CIRCUITS


Hydraulic Pressure from Center Pin to Control ValveItem Part Number Qty. Description Rev.

1 Ref CENTER PIN INSTALLATION & ASSY, (see page 9-82 for details)2 83783043 1 O-RING3 84712740 2 FLANGE HALF4 88551015 4 LOCKWASHER, 5/85 88201098 4 HEX HD CAPSCREW, 5/8-11X2-1/4, GR56 84719946 1 HOSE ASSY7 91083339 1 O-RING8 90205792 1 CUSHION CLAMP, 1-1/49 1 TUBE ASSY, (supply), (no longer available; order 80433193S Tube

Replacement Kit located on page 8-10 for tube replacement)10 91083106 2 O-RING11 84712738 2 FLANGE HALF12 88551012 6 LOCKWASHER, 7/1613 88201053 6 HEX HD CAPSCREW, 7/16-14X1-3/4, GR514 Ref TEMPERATURE SENSOR, (see page 10-2 for details)15 3460545 1 OIL COOLER TUBE16 84712739 2 FLANGE HALF17 84711333 2 FLANGE HALF18 88551011 4 LOCKWASHER, 3/819 88201036 4 HEX HD CAPSCREW, 3/8-16X1-1/4, GR520 Ref MAIN HYDRAULIC CONTROL VALVE ASSY, (see page 9-38 for details)21 88662330 1 ELBOW, 90 DEGREES, (includes item 22)22 88591205 1 O-RING23 88591510 1 O-RING24 88201069 4 HEX HD CAPSCREW, 1/2-13X2, GR525 88551013 4 LOCKWASHER, 1/226 88201046 2 HEX HD CAPSCREW, 3/8-16X3-3/4, GR527 88561109 2 FLAT WASHER, 3/828 80731014 1 TUBE SUPPORT BRACKET29 83251289 1 CLAMP SET30 83251291 1 COVER PLATE31 88521206 2 HEX LOCKNUT, 3/8-1632 88561110 2 FLAT WASHER, 7/1633 Ref CLAMP CHANNEL WELD, (see page 8-16 for details)


HYDRAULIC CIRCUITS


Hydraulic Pressure from Center Pin to Control Valve

PAC13971

1211

63

7

8

2

20

456

9

13

2210

14

1

1718

19

15

16

21

20

AT CENTER PIN


XL5100IV - 5100000606 (6x4 & 6x6)

HYDRAULIC CIRCUITS


Hydraulic Pressure from Center Pin to Control ValveItem Part Number Qty. Description Rev.

80433193S 1 TUBE REPLACEMENT KIT, (includes items 6 (qty.1), 9, 13, 14, 15 & 19)

1 Ref MAIN HYDRAULIC CONTROL VALVE ASSY, (see page 9-38 for details)2 3460545 1 TUBE ASSY3 84711333 2 FLANGE HALF4 88201036 4 HEX HD CAPSCREW, 3/8-16X1-1/4, GR55 88551011 4 LOCKWASHER, 3/86 91083106 2 O-RING7 88662330 1 ELBOW, 90 DEGREES, (includes item 8)8 88501205 1 O-RING9 84722280 1 HOSE ASSY, (includes item 22)

10 84712738 2 FLANGE HALF11 88201053 4 HEX HD CAPSCREW, 7/16-14X1-3/4, GR512 88551012 4 LOCKWASHER, 7/1613 84722281 1 HOSE ASSY14 80783141 1 CUSHION CLAMP, 1-3/8”15 88662535 1 FLANGE ELBOW, 90 DEGREES, (includes item 20)16 84712740 2 FLANGE HALF17 88201098 4 HEX HD CAPSCREW, 5/8-11X2-1/4, GR518 88551015 4 LOCKWASHER, 5/819 83783043 1 O-RING20 88591510 2 O-RING21 Ref CLAMP CHANNEL WELD, (see page 8-16 for details)22 88591509 1 O-RING


HYDRAULIC CIRCUITS


Main Valve to Pilot Manifold

PAC14030

��

��

�

�

�

��

��

�

�

�� %��

��$��

��$��.$�

��$��

��$��

��$��$�

��$��$��

��

��

�

��

��

��

��

��

��$��$�

��%�!��.��1��$$�� $��!��

PAC5641

HYDRAULIC CIRCUITS


Main Valve to Pilot Manifold

PAC5651

��

�

��

�

�

�

$��

$��

��$��$��

$��

$��

�� % ��+�

��$��

HYDRAULIC CIRCUITS


Main Valve to Pilot ManifoldItem Part Number Qty. Description Rev.

1 84719716 1 HOSE ASSY2 88591204 2 O-RING3 Ref PILOT MANIFOLD VALVE TRAY ASSY, (see page 9-48 for details)4 84721180 1 HOSE ASSY5 84721075 1 HOSE ASSY6 80973025 4 WHIZ-LOK SCREW, 3/8-16X17 80533008 1 TUBE ASSY8 80533009 1 TUBE ASSY9 84721398 1 HOSE ASSY9 84722593 1 HOSE ASSY, (use this hose only if item 18 tee is equipped on your machine)

10 84721399 1 HOSE ASSY11 3460523 1 TUBE ASSY12 84719270 2 HOSE ASSY13 Ref MAIN HYDRAULIC CONTROL VALVE ASSY, (see page 9-38 for details)14 80333184 1 CHECK VALVE, (includes item 2)15 84719295 1 HOSE ASSY16 Ref HOSE ASSY, (see page 8-16 for details)17 84718779 1 HOSE ASSY18 88662438 1 SWIVEL NUT RUN TEE, (see note)19 84721973 1 HOSE ASSY, (see note)20 88662329 1 ELBOW, 90 DEGREES, (includes item 2), (see note)

Note: Items 18, 19 & 20 are equipped on the following machines:XL3100IV (4X2) - S/N 3120000283 & AfterXL3100IV (4X4) - S/N 3140000335 & AfterXL4100IV (6X4) - S/N 4100000575 & AfterXL4100IV (6X6) - S/N 4160000061 & AfterXL5100IV - S/N 5100000599 & After

101 2120220 1 PILOT FILTER, (includes element, sight glass, indicator & o-ring)101.1 80533001 1 PILOT FILTER ELEMENT101.2 80514206 1 SIGHT GLASS101.3 80514207 1 INDICATOR101.4 80534053 1 O-RING, (between filter bowl and head of housing)102 88662448 2 CONNECTOR, (includes item 3)103 88591207 2 O-RING104 80303094 4 WHIZ-LOCK SCREW, 3/8-16X3/4105 84718992 2 HOSE ASSY

HYDRAULIC CIRCUITS


Main Valve to Pilot ManifoldItem Part Number Qty. Description Rev.

HYDRAULIC CIRCUITS


Upperstructure Dump Circuit

PAC6080

��

�

��

�

� �

��

�

��

�

�

�

��

��

��

�

��

�

��

�

�

��

��

��

��

��$��$��.��!��

��

��

��$��

HYDRAULIC CIRCUITS


Upperstructure Dump CircuitItem Part Number Qty. Description Rev.

1 Ref MAIN HYDRAULIC CONTROL VALVE ASSY, (see page 9-38 for details)2 84719395 1 HOSE ASSY3 91083106 1 O-RING4 84711333 2 FLANGE HALF5 88201036 4 HEX HD CAPSCREW, 3/8-16X1-1/4, GR56 88551011 4 LOCKWASHER, 3/87 88662333 1 ELBOW, 90 DEGREES, (includes item 8)8 88591209 1 O-RING9 90205793 1 CLAMP

10 80446012 1 CHANNEL11 88662330 1 ELBOW, 90 DEGREES, (includes item 30)12 88662175 1 HEX HD PLUG, (includes item 30)13 83251291 1 COVER PLATE14 88201034 2 HEX HD CAPSCREW, 3/8-16X7/8, GR515 88551011 2 LOCKWASHER, 3/816 Ref SWING TRANSMISSION ASSY, (see page 9-58 for details)17 84711342 2 FLANGE HALF18 83783043 1 O-RING19 88201067 4 HEX HD CAPSCREW, 1/2-13X1-1/2, GR520 88551013 2 LOCKWASHER, 1/221 84719567 1 HOSE ASSY22 84719502 1 HOSE ASSY, (return)23 88591511 1 O-RING24 Ref HOSE ASSY, (see page 6-32 for details)25 88591510 1 O-RING26 84721044 1 HOSE ASSY27 88662483 1 HEX NUT28 80333046 1 BULKHEAD ELBOW29 84718809 1 HOSE ASSY30 88591205 3 O-RING31 Ref CENTER PIN INSTALLATION & ASSY, (see page 9-82 for details)32 3460506 1 DUMP TUBE ASSY33 88662347 1 RUN TEE, (includes item 30)34 Ref HOSE ASSY, (see page 9-94 for details)

HYDRAULIC CIRCUITS


Undercarriage Dump Circuit

PAC6092

$��

$��

$��

��$��.��"��$�.$

$��$��

��.��

�

��

��

�

�

�

��

��

��

��

��

�

�

��

�

�

��

��

��

�

��

��

��

�

�

�

�

�

�

HYDRAULIC CIRCUITS


Undercarriage Dump CircuitItem Part Number Qty. Description Rev.

1 Ref HYDRAULIC RESERVOIR INSTALLATION & ASSY, (see page 9-56 for details)2 77363038 1 O-RING3 84711427 2 FLANGE HALF4 88551013 4 LOCKWASHER, 1/25 88201067 4 HEX HD CAPSCREW, 1/2-13X1-1/2, GR56 88662681 1 ELBOW, 90 DEGREES, (includes o-ring)7 83451129 1 MALE QUICK-DISCONNECT COUPLING7 83451128 1 FEMALE QUICK-DISCONNECT COUPLING, (supplied with tool kit)8 83623026 1 DUST CAP, (male)8 83623027 1 DUST CAP, (female), (supplied with tool kit)9 88681306 6 WHIZ-LOK SCREW, 3/8-16X1/2

10 80781167 1 DUMP TUBE GUARD11 84721682 1 HOSE ASSY12 84721689 1 HOSE ASSY, (XL3100IV)12 84721681 1 HOSE ASSY, (XL4100IV & XL5100IV)13 80783142 1 FRONT DUMP TUBE14 88591512 1 O-RING15 83863005 4 CLAMP, 2”16 90207463 1 CUSHION CLAMP, 3/4”17 84719528 2 HOSE ASSY18 88591509 2 O-RING19 88201036 8 HEX HD CAPSCREW, 3/8-16X1-1/4, GR520 88551011 8 LOCKWASHER, 3/821 84711133 4 FLANGE HALF22 91083106 2 O-RING23 80783143 1 REAR DUMP TUBE, (XL3100IV)23 80783164 1 REAR DUMP TUBE, (XL4100IV & XL5100IV)24 84721685 1 HOSE ASSY, (XL3100IV)24 84721683 1 HOSE ASSY, (XL4100IV & XL5100IV)25 Ref CENTER PIN INSTALLATION & ASSY, (see page 9-82 for details)26 91343012 4 CUSHION CLAMP, 27/32, (qty 3 for XL3100IV)27 91083217 1 CUSHION CLAMP, 5/8

HYDRAULIC CIRCUITS


Hoist Cylinder Hydraulic Circuit

PAC1352

��

��

��

��

��

��

��

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

��

��

�

�

�

�

�

�


XL5100IV - 5100000614 (6x4 & 6x6)

HYDRAULIC CIRCUITS


Hoist Cylinder Hydraulic CircuitItem Part Number Qty. Description Rev.

1 Ref MAIN HYDRAULIC CONTROL VALVE ASSY, (see page 9-38 for details)2 Ref HOIST CYLINDER ASSY, (See page 9-2 for details)3 77133089 2 MINI-CHECK COUPLING, (includes item 4)4 83763056 2 VITON O-RING, (lubricate lightly)5 88662332 4 ELBOW, 90 DEGREES. (includes item 6)6 88591207 4 O-RING7 84719882 4 HOSE ASSY8 88591508 8 O-RING9 80933066 2 O-RING

10 84712737 4 FLANGE HALF11 88201037 8 HEX HD CAPSCREW, 3/8-16X1-1/2, GR512 88551011 10 LOCKWASHER, 3/813 80433023 1 TUBE ASSY, (hoist up), (this item is no longer available; order Hoist Tube

Replacement Kit 80735055 located on page 8-22 for replacement)14 80433022 1 TUBE ASSY, (hoist down), (this item is no longer available; order Hoist Tube

Replacement Kit 80735055 located on page 8-22 for replacement)15 91053413 2 CUSHION CLAMP, 1”16 80446007 1 CLAMP & CHANNEL WELDMENT17 83251291 1 COVER PLATE18 88201034 2 HEX HD CAPSCREW, 3/8-16X7/8, GR5

Before S/N’sXL3100IV - 3120000368 (4x2); 3140000378 (4x4)XL4100IV - 4100000719(6x4); 4160000078 (6x6)XL5100IV - 5100000614 (6x4 & 6x6)

HYDRAULIC CIRCUITS


Hoist Cylinder Hydraulic Circuit

PAC14020

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

�

��

�

��

��

��

�

�

� ��

�

��

��

��

��

��

��

�

�


XL5100IV - 5100000614 (6x4 & 6x6)

HYDRAULIC CIRCUITS


Hoist Cylinder Hydraulic CircuitItem Part Number Qty. Description Rev.

80735055 1 HOIST TUBE REPLACEMENT KIT, (includes items 3, 5 (qty. 2), 6 (qty. 2), 7, 8, 11 (qty. 2), 16 (qty. 1), 18, 19, 20 & 22), (existing mounting hardware will be re-used for the installation of this kit. One kit contains enough components to replace both hoist tubes)

-

1 Ref MAIN HYDRAULIC CONTROL VALVE ASSY, (see page 9-38 for details)2 Ref HOIST CYLINDER ASSY, (See page 9-2 for details)3 80933066 2 O-RING4 84712737 4 FLANGE HALF5 88201037 8 HEX HD CAPSCREW, 3/8-16X1-1/2, GR56 88551011 12 LOCKWASHER, 3/87 80733120 1 TUBE ASSY, (hoist up)8 80733119 1 TUBE ASSY, (hoist down)9 88662332 4 ELBOW, 90 DEGREES, (includes item 10)

10 88591207 4 O-RING11 91053413 4 CUSHION CLAMP, 1”12 80446007 1 CLAMP & CHANNEL WELDMENT13 84719882 4 HOSE ASSY14 88591508 8 O-RING15 83763056 2 VITON O-RING, (lubricate lightly)16 83251291 2 COVER PLATE17 77133089 2 MINI-CHECK COUPLING, (includes item 15)18 84722489 1 HOSE ASSY19 84721992 1 HOSE ASSY20 88662866 1 ELBOW, 90 DEGREES21 88201034 4 HEX HD CAPSCREW, 3/8-16X7/8, GR522 80736004 1 CLAMP & CHANNEL WELDMENT


HYDRAULIC CIRCUITS


Boom Cylinder Hydraulic Circuit

PAC13990

��

�

��

�

��

�

��

�

��

�

�

��

�

�

��

�

�

��

�

�

��

�

�

�

�

�

�

�

�

�

��

��

��

��

��

��

��

�

�

��

��

��

�

�

��

��

��

�

��

��

��

��

��

��.��

��

��

��

��

��

�� .$��*�$

PAC14000

HYDRAULIC CIRCUITS


Boom Cylinder Hydraulic CircuitItem Part Number Qty. Description Rev.

80454036 A/R TUBE CLAMP KIT, (includes items 101 thru 105)

1 Ref MAIN HYDRAULIC CONTROL VALVE ASSY, (see page 9-38 for details)2 84712737 4 FLANGE HALF3 88201037 8 HEX HD CAPSCREW, 3/8-16X1-1/2, GR54 88551011 8 LOCKWASHER, 3/85 80933066 2 O-RING6 80433203 1 TUBE ASSY, (boom in)7 80433204 1 TUBE ASSY, (boom out)8 77133089 2 MINI-CHECK COUPLING, (includes item 9)9 83763056 2 VITON O-RING, (lubricate lightly)

10 88591509 5 O-RING11 84719452 2 HOSE ASSY12 80423020 1 TUBE ASSY, (boom out)13 80423019 1 TUBE ASSY, (boom in)14 80321083 2 TUBE CLAMP15 88201071 1 HEX HD CAPSCREW, 1/2-13X2-1/2, GR516 88551013 4 LOCKWASHER, 1/217 83251291 4 COVER PLATE18 83251289 4 CLAMP SET19 88201042 6 HEX HD CAPSCREW, 3/8-16X2-3/4, GR520 84719401 2 HOSE ASSY21 88591510 4 O-RING22 80423017 1 TUBE ASSY, (boom in)23 80423018 1 TUBE ASSY, (boom out)24 88662334 1 ELBOW, 90 DEGREES, (includes item 25)25 88591210 1 O-RING26 Ref BOOM CYLINDER ASSY, (see page 9-8 for details)27 88201046 2 HEX HD CAPSCREW, 3/8-16X3-3/4, GR528 88521206 2 HEX LOCKNUT, 3/8-1629 80421130 1 CLAMP BRACKET30 80973025 2 WHIZ-LOK SCREW, 3/8-16X131 80321085 2 CLAMP32 80221281 3 SPACER33 88211073 3 SOCKET HD CAPSCREW, 3/8-16X1-1/2, GR834 88521206 3 HEX LOCKNUT, 3/8-1635 80221277 8 CLAMP36 88561004 2 FLAT WASHER, 3/837 88201073 1 HEX HD CAPSCREW, 1/2-13X3, GR538 80323020 12 FLANGE HD CAPSCREW, 5/8-11X239 88211107 2 SOCKET HD CAPSCREW, 1/2-13X1-1/240 88991323 1 CLAMP CHANNEL41 88561006 4 FLAT WASHER, 1/242 88521208 2 HEX LOCKNUT, 1/2-1343 88201067 2 HEX HD CAPSCREW, 1/2-13X1-1/244 88561111 2 FLAT WASHER, 1/245 90205792 2 CLAMP46 80746074 1 TUBE SUPPORT BRACKET

HYDRAULIC CIRCUITS


101 80321085 2 CLAMP102 80221281 3 SPACER103 88211073 3 SOCKET HD CAPSCREW, 3/8-16X1-1/2, GR8104 88521206 3 HEX LOCKNUT, 3/8-16105 80221277 4 CLAMP


HYDRAULIC CIRCUITS



HYDRAULIC CIRCUITS


Boom Cylinder Hydraulic Circuit, (w/360° Boom Tilt)

PAC14000

� �

�

�

��

��

�

�

�

�

��

��

��

��

��

��

��

��

��

��

�

� �

�

��

�

�

�

��

��

��

��

��

�� %��%��.��%

��

��.��

��

��

��

��

��

�� .$��*�$PAC4592

HYDRAULIC CIRCUITS


Boom Cylinder Hydraulic Circuit, (w/360° Boom Tilt)Item Part Number Qty. Description Rev.

80424034 1 TILT GLAND SEAL KIT80454036 A/R TUBE CLAMP KIT, (includes items 101 thru 105)

1 Ref MAIN HYDRAULIC CONTROL VALVE ASSY, (see page 9-38 for details)2 84712737 4 FLANGE HALF3 88201037 8 HEX HD CAPSCREW, 3/8-16X1-1/2, GR54 88551011 8 LOCKWASHER, 3/85 80933066 2 O-RING6 80433203 1 TUBE ASSY, (boom in)7 80433204 1 TUBE ASSY, (boom out)8 77133089 2 MINI-CHECK COUPLING, (includes item 9)9 83763056 2 VITON O-RING, (lubricate lightly)

10 88591509 4 O-RING11 84719452 2 HOSE ASSY,12 80423020 1 TUBE ASSY, (boom out)13 80423019 1 TUBE ASSY, (boom in)14 80321083 2 TUBE CLAMP15 88201071 1 HEX HD CAPSCREW, 1/2-13X2-1/2, GR516 88551013 2 LOCKWASHER, 1/217 90205793 2 HYDRA-ZORB CLAMP, 1-1/218 80991124 4 INSERT19 84721362 2 HOSE ASSY20 88591510 2 O-RING21 88662336 1 ELBOW, 90 DEGREES, (includes item 22)22 88591207 1 O-RING23 80423033 1 TILT GLAND24 88591209 1 O-RING25 88662333 1 ELBOW, 90 DEGREES, (includes item 24)26 80321085 2 CLAMP27 80221281 3 SPACER28 88211073 3 SOCKET HD CAPSCREW, 3/8-16X1-1/2, GR829 88521206 3 HEX LOCKNUT, 3/8-1630 80221277 8 CLAMP31 88201073 1 HEX HD CAPSCREW, 1/2-13X3, GR532 88212257 6 SOCKET HD CAPSCREW, 5/8-11X1-3/433 80321201 2 GLAND CLAMP PLATE34 88591115 2 O-RING35 88212256 9 SOCKET HD CAPSCREW, 5/8-11X1-1/236 80321202 1 GLAND MOUNTING PLATE37 Ref TUBE SUPPORT BRACKET & HARDWARE, (see page 8-24 for details)


HYDRAULIC CIRCUITS


Tool Cylinder Hydraulic Circuit

�

��

�

�

�

� ��

��

�

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

�

�

��

��

�

�

�

�

�

�

�

��

��

��

�

��

��

��

��

��

�

��

��

��

��

��

��

��

��

��

��

��

�

��

��

�

��

��

PAC14000

��.��

��

��

��

��

��

�� .$��*�$

PAC14041

HYDRAULIC CIRCUITS


Tool Cylinder Hydraulic CircuitItem Part Number Qty. Description Rev.


1 Ref MAIN HYDRAULIC CONTROL VALVE ASSY, (see page 9-38 for details)2 80933066 2 O-RING3 84712737 4 FLANGE HALF4 88201037 8 HEX HD CAPSCREW, 3/8-16X1-1/2, GR55 88551011 8 LOCKWASHER, 3/86 80733124 1 TUBE ASSY, (tool open)6 80433027 1 TUBE ASSY, (tool open); (for machines not equipped with item 43)7 80433026 1 TUBE ASSY, (tool close)8 77133089 2 MINI-CHECK COUPLING, (includes item 9)9 83763056 2 VITON O-RING, (lubricate lightly)

10 88591508 10 O-RING11 84719337 1 HOSE ASSY12 80423022 1 TUBE ASSY, (tool open)13 80423021 1 TUBE ASSY, (tool close)14 3460463 1 TUBE ASSY15 3460464 1 TUBE ASSY16 83253009 6 CLAMP SET17 83253010 6 COVER PLATE18 88201042 4 HEX HD CAPSCREW, 3/8-16X2-3/4, GR519 80321137 1 CENTER CLAMP BOTTOM PLATE20 80321084 4 TUBE CLAMP21 88201073 2 HEX HD CAPSCREW, 1/2-13X3, GR522 88551013 4 LOCKWASHER, 1/223 84718116 2 HOSE ASSY24 2754405 2 HOSE ASSY25 80823001 2 STRAIGHT TUBE ASSY, (XL3100IV)25 3460577 2 STRAIGHT TUBE ASSY, (XL4100IV)25 80523002 2 STRAIGHT TUBE ASSY, (XL5100IV)26 88201068 6 HEX HD CAPSCREW, 1/2-13X1-3/4, GR527 80221278 3 KEEPER, (old-style)27 88561111 6 FLAT WASHER, 1/2, (new-style)28 2754396 1 HOSE ASSY29 84721544 1 HOSE ASSY30 88591509 4 O-RING31 80421121 3 KEEPER PLATE32 88201071 2 HEX HD CAPSCREW, 1/2-13X2-1/2, GR533 88521008 6 HEX LOCKNUT, 1/2-1334 88662332 2 ELBOW, 90 DEGREES, (includes item 35)35 88591207 3 O-RING36 Ref TOOL CYLINDER ASSY, (see page 9-20 for details)37 80321136 2 BOTTOM PLATE38 80423038 3 TUBE CLAMP CAST39 Ref TUBE SUPPORT BRACKET & HARDWARE, (see page 8-24 for details)40 90207463 1 CUSHION CLAMP, 3/441 91053413 1 CUSHION CLAMP, 1”42 80434318 1 ADAPTER, (includes o-ring)43 80434317 1 TOOL HOLD OPEN VALVE

HYDRAULIC CIRCUITS


44 88662304 1 STRAIGHT CONNECTOR, (includes item 35)45 84722762 1 HOSE ASSY



HYDRAULIC CIRCUITS



HYDRAULIC CIRCUITS


Tool Cylinder Hydraulic Circuit, (w/360° Boom Tilt)

��

�

�

�

��

��

��

��

��

��

��

��

��

��

��

�

�

��

��

��

�

��

��

�

��

�

�

��

��

��

��

��

��

�

��

�

��

��

�

��

��

��

��

��

��

�

��

��

�

��

��

��

��

��

��

�

�

�

�

�

��

��

��

PAC14000

SEE PAGE 8-28 FOR TILT GLAND MOUNTING COMPONENTS.

PAC4602

��.��

��

��

��

��

��

�� .$��*�$

HYDRAULIC CIRCUITS


Tool Cylinder Hydraulic Circuit, (w/360° Boom Tilt)Item Part Number Qty. Description Rev.


1 Ref MAIN HYDRAULIC CONTROL VALVE ASSY, (see page 9-38 for details)2 80933066 2 O-RING3 84712737 4 FLANGE HALF4 88201037 8 HEX HD CAPSCREW, 3/8-16X1-1/2, GR55 88551011 8 LOCKWASHER, 3/86 80733124 1 TUBE ASSY, (tool open)6 80433027 1 TUBE ASSY, (tool open); (for machines not equipped with item 52)7 80433026 1 TUBE ASSY, (tool close)8 77133089 2 MINI-CHECK COUPLING, (includes item 9)9 83763056 2 VITON O-RING, (lubricate lightly)

10 88591508 6 O-RING11 84719337 2 HOSE ASSY12 80423022 1 TUBE ASSY, (tool open)13 80423021 1 TUBE ASSY, (tool close)14 80523008 1 TUBE ASSY15 80523009 1 TUBE ASSY16 83253009 4 CLAMP SET17 83253010 4 COVER PLATE18 88201042 12 HEX HD CAPSCREW, 3/8-16X2-3/4, GR519 80321137 1 CENTER CLAMP PLATE20 80321084 4 TUBE CLAMP21 88201073 2 HEX HD CAPSCREW, 1/2-13X3, GR522 88551013 4 LOCKWASHER, 1/223 84721361 2 HOSE ASSY24 84721313 2 HOSE ASSY25 80823001 2 STRAIGHT TUBE ASSY, (XL3100IV)25 3460577 2 STRAIGHT TUBE ASSY, (XL4100IV)25 80523002 2 STRAIGHT TUBE ASSY, (XL5100IIV26 88201068 6 HEX HD CAPSCREW, 1/2-13X1-3/4, GR527 88591509 8 O-RING28 2754396 1 HOSE ASSY29 84721544 1 HOSE ASSY30 88201071 2 HEX HD CAPSCREW, 1/2-13X2-1/2, GR531 90027470 4 HARDENED WASHER32 88662566 2 CONNECTOR, (includes item 41)33 88521008 6 HEX NUT, 1/2-1334 88662332 2 ELBOW, 90 DEGREES, (includes item 35)35 88591207 3 O-RING36 Ref TOOL CYLINDER ASSY, (see page 9-20 for details)37 80423038 3 TOP CLAMP WELDMENT38 80321136 2 BOTTOM PLATE39 80523005 1 TUBE ASSY40 88662311 2 ADAPTER, (includes item 41)41 88591206 6 O-RING42 91053413 2 HYDRA-ZORB CLAMP, 1-1/443 80521042 4 INSERT44 80526012 2 CLAMP WELDMENT

HYDRAULIC CIRCUITS


45 80523006 1 TUBE ASSY46 88201035 4 HEX HD CAPSCREW, 3/8-16X1, GR547 Ref TILT GLAND, (see page 8-28 for details)48 80421121 3 KEEPER PLATE49 80221278 3 KEEPER, (old-style)49 88561111 6 FLAT WASHER, 1/2, (new-style)50 Ref TUBE SUPPORT BRACKET & HARDWARE, (see page 8-30 for details)51 80434318 1 ADAPTER, (includes o-ring)52 80434317 1 TOOL HOLD OPEN VALVE53 88662304 1 STRAIGHT CONNECTOR, (includes item 35)



HYDRAULIC CIRCUITS



HYDRAULIC CIRCUITS


Propel Hydraulic Circuit

1

12

2

3

4

5

6

7

892

3

3

3

4

5

89

10

11

10

22

22

20

21

16

17519 18

1315

14

11

8

8

PORT“P4”

PORT“P3”

20

PAC13980

��.$��*�$�!��.��'��

��

��

��

��

PAC1393

HYDRAULIC CIRCUITS


Propel Hydraulic CircuitItem Part Number Qty. Description Rev.

1 Ref MAIN HYDRAULIC CONTROL VALVE ASSY, (see page 9-38 for details)2 80933066 2 O-RING3 84712737 4 FLANGE HALF4 88201037 8 HEX HD CAPSCREW, 3/8-16X1-1/2, GR55 88551011 10 LOCKWASHER, 3/86 80433093 1 TUBE ASSY, (propel B)7 80433092 1 TUBE ASSY, (propel A)8 88591509 4 O-RING9 84719500 2 HOSE ASSY

10 77133089 2 MINI-CHECK COUPLING, (includes item 11)11 83763056 2 VITON O-RING, (lubricate lightly)12 Ref CENTER PIN INSTALLATION & ASSY, (see page 9-82 for details)13 80736005 1 MOUNT BRACKET14 88201034 2 HEX HD CAPSCREW, 3/8-16X7/8, GR515 83251291 1 COVER PLATE16 80731023 1 MOUNT BRACKET17 88201067 1 HEX HD CAPSCREW, 1/2-13X1-1/2, GR518 88521206 1 HEX LOCKNUT, 3/8-1619 88561006 1 FLAT WASHER, 1/220 80221277 2 CLAMP BRACKET21 88211076 1 HEX SOCKET HD CAPSCREW, 3/8-16X2-1/4, GR822 80221281 2 SPACER

101 88201026 1 HEX HD CAPSCREW, 5/16-18X2-1/2, GR5102 77133137 1 COVER PLATE103 77133279 1 CLAMP SET104 88521205 1 HEX LOCKNUT, 5/16-18

HYDRAULIC CIRCUITS


Swing Motor Hydraulic Circuit

1

2

34

5

8

6710

8

11

10

13

9

32

3

3

9

12

11

2

PAC1401

SEE PAGE 1-48 FOR HOSE INFORMATION


XL5100IV - 5100000606 (6x4 & 6x6)

HYDRAULIC CIRCUITS


Swing Motor Hydraulic CircuitItem Part Number Qty. Description Rev.

1 Ref MAIN HYDRAULIC CONTROL VALVE ASSY, (see page 9-38 for details)2 80933066 4 O-RING3 84712737 8 FLANGE HALF4 88551011 8 LOCKWASHER, 3/85 88201037 4 HEX HD CAPSCREW, 3/8-16X1-1/2, GR56 80433031 1 TUBE ASSY, (swing B), (this item is no longer available; order Swing Tube

Replacement Kit 84719758S located on page 8-42 for replacement)7 80433135 1 TUBE ASSY, (swing A), (this item is no longer available; order Swing Tube

Replacement Kit 84719758S located on page 8-42 for replacement)8 84719881 2 HOSE ASSY9 83191027 8 HEX HD CAPSCREW, M10-1.5x35, GR8.8

10 88591508 2 O-RING11 83191013 8 LOCKWASHER, M1012 3460513 1 TUBE ASSY13 Ref SWING TRANSMISSION ASSY, (see page 9-58 for details)


HYDRAULIC CIRCUITS


Swing Motor Hydraulic Circuit

3

2

4

5

13

9

8 8

9

3

11

10

2

6

6

7

7

12

12

101

ITEM 101 SHOULD BE USED IF REPLACINGTHE ELBOW AT THE LOCATION SHOWN.

PAC14011

SEE PAGE 1-48 FOR HOSE INFORMATION


XL5100IV - 5100000606 (6x4 & 6x6)

HYDRAULIC CIRCUITS


Swing Motor Hydraulic CircuitItem Part Number Qty. Description Rev.

84719758S 1 SWING TUBES REPLACEMENT KIT, (includes item 2, 6, 7 & 12), (existing mounting hardware will be re-used for the installation of this kit. One kit contains enough components to replace both swing tubes)

1 Ref MAIN HYDRAULIC CONTROL VALVE ASSY, (see page 9-38 for details)2 80933066 4 O-RING3 84712737 8 FLANGE HALF4 88551011 8 LOCKWASHER, 3/85 88201037 4 HEX HD CAPSCREW, 3/8-16X1-1/2, GR56 84719758 2 HOSE ASSY7 88662866 2 ELBOW, 90 DEGREES8 83191027 8 HEX HD CAPSCREW, M10-1.5x35, GR8.89 83191013 8 LOCKWASHER, M10

10 3460513 1 TUBE ASSY11 Ref SWING TRANSMISSION ASSY, (see page 9-58 for details)12 88591508 2 O-RING

101 80733118 1 TUBE ASSY


HYDRAULIC CIRCUITS


Tilt Motor Hydraulic Circuit

PAC1413

1

6

7

32

3 45 9

10

8

11 1516

14

12

13

17

18

19

2020

20

22

22

21

TO TILTTRANSMISSION

TILT DRAIN HOSEFROM DUMP CIRCUIT

HYDRAULIC CIRCUITS


Tilt Motor Hydraulic CircuitItem Part Number Qty. Description Rev.

1 Ref MAIN HYDRAULIC CONTROL VALVE ASSY, (see page 9-38 for details)2 80933066 2 O-RING3 84712737 4 FLANGE HALF4 88551011 8 LOCKWASHER, 3/85 88201037 8 HEX HD CAPSCREW, 3/8-16X1-1/2, GR56 80433091 1 TUBE ASSY, (tilt A)7 80433090 1 TUBE ASSY, (tilt B)8 88201024 1 HEX HD CAPSCREW, 5/16-18X2, GR59 77133139 1 CLAMP SET

10 77143140 2 COVER PLATE11 88521205 1 HEX LOCKNUT, 5/16-1812 80731001 1 BULKHEAD PLATE13 80303094 3 WHIZ-LOK SCREW, 3/8-16X3/414 88591506 2 O-RING15 88662503 2 BULKHEAD LOCKNUT16 88662372 2 ELBOW, 90 DEGREES, (swivel nut)17 88201067 2 HEX HD CAPSCREW, 1/2-13X1-1/2, GR518 80421120 1 PLATE19 88521208 2 HEX LOCKNUT, 1/2-1320 90207463 3 CUSHION CLAMP21 84721042 1 HOSE ASSY22 84719955 2 HOSE ASSY

HYDRAULIC CIRCUITS


Steering Gear Hydraulic Circuit

PAC14050

31314 46

47

25

409

39

20

3441238

2

7 151726

22

TO BOTTOMCOOLING TUBE

FROM “INLET”PORT ON PILOT

PUMP TO RESERVOIR

FROM “P” PORTON STEERING

VALVE TO “OUTLET” PORTON PILOT PUMP

TO TEE ON BOTTOMCOOLING TUBE

6

4244

43

24

45

36

23TO TOPCOOLING TUBE

FROM BOTTOM COOLINGTUBE TO “T1” PORT ON

STEERING VALVE

FROM TOP COOLING TUBETO “P1” PORT ONSTEERING VALVE

��!�� .

��%��

PAC5471

HOSE SHOWN APPLIES TO MACHINES EQUIPPED WITH POWER STEERING FILTER ONLY. THE POWER STEERING FILTER IS NO LONGER REQUIRED ON THESE MACHINES. CONTACT YOUR AUTHORIZED GRADALL DEALER FOR

INFORMATION ON REMOVAL OF POWER STEERING FILTER. REFERENCE SERVICE BULLETIN 41200105.

HYDRAULIC CIRCUITS


Steering Gear Hydraulic Circuit

PAC5481

�

�

�

� ��

��

��

�

�

��

��$��$��$��

��%�%��

��$��!��!��%�%��

��$� ��%��

��*�

��

� �� *

��

��

��

��

��

��

� !��.��$��%��

��

��

��

�!��.�� $��%��

��*�

��$�$-��

��$��$� ��

��%�$�.$

��%��%��*��$��%��!��%��*� ��.��%�

� ��$�� "��

� ��$��"��

�� .$-��

��$ ��%��

��

HYDRAULIC CIRCUITS


Steering Gear Hydraulic CircuitItem Part Number Qty. Description Rev.

1 14403364 A/R LOCTITE, (#242 blue)2 77133089 1 MINI-CHECK COUPLING, (includes item 48)3 77143015 4 WHIZ-LOK NUT, 3/8-164 77363082 1 ADAPTER5 77383118 6 HARDENED WASHER, 7/166 Ref STEERING GEAR ASSY, (see page 9-100 for details)7 77383746 1 POPPET ADJUSTING KIT, (4X4 & 6X4 only)8 Ref STEERING DRAG LINK ASSY, (see page 7-4 for details)9 80483051 2 TUBE ASSY

10 80483120 1 REMOTE STEERING HYDRAULIC CYLINDER ASSY11 Ref REMOTE STEERING VALVE ASSY, (see page 9-104 for details)12 80633113 1 SPECIAL RUN TEE13 Ref POWER STEERING RESERVOIR & DEAERATION TANK ASSY,

(see page 4-14 for details)14 80973096 4 WHIZ-LOK SCREW, 3/8-16X1-1/215 80983161 2 VERTICAL SOCKET ASSY16 83201001 1 HEX HD CAPSCREW, 3/4-10X4-1/4, GR8, (torque to 340-365 lb-ft)17 83201096 4 HEX HD CAPSCREW, 7/8-14X4, GR8, (loctite & torque to 490-510 lb-ft)18 83953053 1 SLEEVE19 83953231 1 PITMAN ARM20 84719932 1 HOSE ASSY21 84719941 2 HOSE ASSY22 84719942 1 HOSE ASSY23 84719943 1 HOSE ASSY24 84719950 1 HOSE ASSY25 84721019 1 HOSE ASSY26 88501314 4 HEX NUT, 7/8-1427 88521012 1 HEX LOCKNUT, 3/4-1028 88551009 2 LOCKWASHER, 1/429 88561002 2 FLAT WASHER, 1/430 88561115 1 FLAT WASHER, 3/431 88501506 4 O-RING32 88631321 4 COTTER PIN, 1/8X1-3/433 88662301 1 CONNECTOR, (includes item 49)34 88662302 1 CONNECTOR, (includes item 50)35 88662329 2 ELBOW, 90 DEGREES, (includes item 49)36 84719779 1 HOSE ASSY37 88662438 RUN TEE, (includes o-ring)38 88662440 1 CONNECTOR, (includes item 49)39 90027187 11 TY-RAP40 91083217 4 CUSHION CLAMP, 5/841 91143191 2 HEX HD CAPSCREW, 1/4-20X4-1/2, GR5, (torque to 11-14 lb-ft)42 80783141 1 CUSHION CLAMP, 1-3/843 84721716 1 HOSE ASSY44 90207463 1 CUSHION CLAMP, 3/445 85941017 2 SUPPORT CLAMP, 29/3246 77143003 1 WHIZ-LOK SCREW, 5/16-18X5/847 80973050 1 SUPPORT CLAMP, 2-5/848 83763056 1 VITON O-RING, (lubricate lightly)

HYDRAULIC CIRCUITS


49 88591204 4 O-RING50 88591205 1 O-RING

101 84721714 1 HOSE ASSY

Steering Gear Hydraulic CircuitItem Part Number Qty. Description Rev.

HYDRAULIC CIRCUITS


Remote Propelling Hydraulic Circuit

PAC6101

��

��

��

�$��- ��

�$��- ��

��

!��.��$��$��

��

��

�

�

�

�!��.��$��$��$��

�!��.��$��$��$��

� $��$��*��$��$��$��

�

�

�

��

$��

$��

HYDRAULIC CIRCUITS


Remote Propelling Hydraulic Circuit

PAC6111

��*� ��.��

��'��*� ��.��

� �

�

�

� � � �

HYDRAULIC CIRCUITS


Remote Propelling Hydraulic CircuitItem Part Number Qty. Description Rev.

1 84721688 1 HOSE ASSY, (XL3100IV)1 84721680 1 HOSE ASSY, (XL4100IV & XL5100IV)2 90207463 11 CUSHION CLAMP, 3/4, (qty 5 for XL3100IV)3 84721687 1 HOSE ASSY, (XL3100IV)3 84721678 1 HOSE ASSY, (XL4100IV & XL5100IV)4 84721686 1 HOSE ASSY, (XL3100IV)4 84721677 1 HOSE ASSY, (XL4100IV & XL5100IV)5 84721737 1 HOSE ASSY, (XL3100IV)5 84721736 1 HOSE ASSY, (XL4100IV & XL5100IV)6 80783141 4 CUSHION CLAMP, 1.375, (XL4100IV & XL5100IV only)7 Ref CENTER PIN INSTALLATION & ASSY, (see page 9-82 for details)8 Ref COUNTERBALANCE VALVE ASSY, (see page 9-108 for details)9 Ref PROPEL ANTI-CAVITATION VALVE, (see page 9-110 for details)

10 Ref STABILIZER VALVE ASSY, (see page 9-24 for details)

HYDRAULIC CIRCUITS


Remote Propelling Hydraulic CircuitItem Part Number Qty. Description Rev.

HYDRAULIC CIRCUITS


In-line Pilot Filter Hosing

PAC5931

�

�

�

��

�

�

�

��$��-$� ��%$�.$��

��$��!��

��$��!��

�� .�!�� (��

HYDRAULIC CIRCUITS


In-line Pilot Filter HosingItem Part Number Qty. Description Rev.

1 Ref HYDRAULIC RESERVOIR ASSY, (see page 9-56 for details)2 Ref IN-LINE PILOT FILTER, (see page 9-56 for details)3 84719597 1 HOSE ASSY4 84721671 1 HOSE ASSY5 77323029 3 CLAMP SET6 77133137 3 COVER PLATE7 88201023 3 HEX HD CAPSCREW, 5/16-18X1-3/4, GR58 Ref PILOT/POWER STEERING PUMP, (see page 4-2 for details)9 Ref STABILIZER VALVE ASSY, (see page 9-24 for details)

NOTE IF MACHINE IS EQUIPPED WITH RAILGEAR INSTALLATION LOCATED ON PAGE 12-88, ITEM(S) 3 WILL DIFFER FROM WHAT IS SHOWN.

HYDRAULIC CIRCUITS


This Page Intentionally Left Blank

SECTION 8 - HYDRAULIC CIRCUITS

Documents

Transcript of SECTION 8 - HYDRAULIC CIRCUITS