Grua Barrick BT4000_parts

iii

BT4000 BOOM TRUCKS

Parts ManualINTRODUCTION

This TEREX CRANES Parts manual is supplied to aid you in the location andcorrect identification of component parts replacement and is based upon TEREXCRANES assembly standards at the time of manufacture.

The TEREX CRANES parts manual will enable you to maintain your unitaccording to manufacturers recommendations. This unit is not to be altered ormodified in any way without prior factory approval.

NOTICE

If this boom truck becomes involved in an accident resulting in property damageor personal injury, please contact your local TEREX CRANES dealer or theTEREX CRANES service department at (319) 352-3920 IMMEDIATELY.

All illustrations and specifications contained in this manual are based on the latestproduct information available at the time of publication. Right is reserved to makechanges at any time, without notice, in specifications, material and descriptions.

MADE IN THE U.S.A.

This manual is delivered for the sole purpose of operating and maintaining specificequipment for its intended use and shall not be copied or information contained

herein delivered to third parties without prior written approval of TEREX CRANES.

iv

INSTRUCTIONS FOR ORDERING PARTS

When ordering parts, contact your nearest Terex Cranes distributor and give the following information to assure prompt service:

MACHINE IDENTIFICATION:

State the model and serial number, located on a plate on the turret on the drivers side.

REF. PART.NO. DESCRIPTION QTY.

1 707 6594 Gear ..................................................... 1

PART IDENTIFICATION:

State the part number, description andquantity required. Do not use the item number.Avoid using the words Pairs or Sets.

SHIPPING INSTRUCTIONS:

State the invoicing address. Unless otherwisespecified, invoices will be mailed to theshipping address.

State the correct shipping address and themeans of shipment: parcel post, air mail,air freight, UPS, bus, etc.

INVOICE TO:Mid State EquipmentMilwaukee, WI

SHIP TO:Ace Construction Co.Madison, WI

vUSING THIS PARTS BOOK

This Parts Manual has been designed for optimumease of reading and is the key to Customer-Distributor-Factory communication. Genuine replacement parts, along with interchangeable product improvements as they become available, will keep your machine in a reliable and productive condition.

The following instructions describe the features of the manual and how to use it effectively.

Use this manual also as a supplement to the Operators Manual and Maintenance Manual when performing service procedures on the machine.

The PARTS GROUP INDEX shows the functional arrangement of associated parts for the machine. A group number identifies the same group of parts regardless of model (Group 25 is always the hydraulic system). The groups which apply to the machine are listed in numerical order. A letter suffix to a group number, 25A, is used for variable or optional parts groups.

PAGE NUMBERS are in numerical sequence within each parts group. The first number is the group number and the second number is the numerical sequence number. Letter suffixes are used to maintain continuity to the manual as revisions are incorporated (1.1, 1.2, 1.2A, 1.2B, 1.3, etc.).

EXPLODED VIEW ILLUSTRATIONS show the relationship of assembled parts. The illustrations are keyed to an accompanying parts list on the same page or on the facing page and are positioned for ease in reading the manual.

This manual lists serviceable parts for EVERY machine built of this model designation. Serial numbers are used to identify parts when a product improvement is made or an alternate component is used. KNOW THE SERIAL NUMBER OF YOUR MACHINE before searching for replacement parts.

IMPORTANT

25 HYDRAULIC SYSTEM

25.1 HYDRAULIC RESERVOIR ASSEMBLY

25.2 HYDRAULIC RESERVOIR INSTALLATION

25.3 HYDRAULIC RESERVOIR FILTER INSTALLATION

25.4 HYDRAULIC RESERVOIR PIPING

25.5 MAIN VALVE BREAKDOWN25.6 MAIN VALVE ASSEMBLY

STANDARD WINCH 25.7 MAIN VALVE PIPING

NON-CONTINUOUS ROTATION

25.8 WINCH VALVE ASSEMBLY25.9 HYDRAULIC PIPING

NON-CONTINUOUS ROTATION

25.10 HYDRAULIC PIPING - SWING25.11 UNLOADER VALVE ASSEMBLY25.12 PRIORITY VALVE

CONTROLS

28 OPERATOR CONTROLS

28.1 CONTROL CONSOLE ASSEMBLY



28.4 THROTTLE ASSEMBLY28.5 THROTTLE INSTALLATION

MISCELLANEOUS

29 TOOLS, PAINT, LUBRICANTS

29.1 TOOLS / PAINTS29.2 SPLIT FLANGE CLAMPS29.3 CLAMPS

30 DECALS & PLACARDS

30.1 MARKING DECAL PLACEMENT30.2 MARKING DECAL PLACEMENT30.3 MARKING DECAL PLACEMENT

ELECTRICAL

33 ELECTRICAL SYSTEM

33.1 ELECTRICAL SYSTEM HARNESSES

33.2 ELECTRICAL SYSTEM CONSOLE CONTROLS

33.3 ELECTRICAL SYSTEMOUTRIGGER ALARM SWITCH

BT4000PARTS GROUPS

II

WINCH, BOOM, & ATTACHMENTS

39 HYDRAULIC TELESCOPING BOOMS

39.1 BOOM ASSEMBLY - 92 BASE39.2 BOOM ASSEMBLY - 92

2ND STAGE39.3 BOOM ASSEMBLY - 92

3RD STAGE39.4 BOOM ASSEMBLY - 92

4TH STAGE39.5 EXTENSION CYLINDER

ASSEMBLY - 92 BOOM 39.6 EXTENSION CYLINDER39.7 EXTENSION TUBE ASSEMBLY

92 BOOM39.8 CABLE GUIDE INSTALLATION

92 BOOM 39.9 BOOM INSTALLATION 39.10 TOPPING CYLINDER

ASSEMBLY39.11 TOPPING CYLINDER

39A JIB

39A.1 JIB ASSEMBLY - SINGLE STAGE

39A.2 JIB ASSEMBLY - TWO STAGE39A.3 JIB STOWAGE

40 HYDRAULIC WINCH

40.1 WINCH MOTOR40.2 WINCH ASSEMBLY40.3 WINCH ASSEMBLY40.4 WINCH BRAKE VALVE

44 HOOK BLOCKS, BALLS

44.1 HOOK BLOCK - 1 SHEAVE / 17.5 TON

44.2 HOOK BLOCK - 2 SHEAVE / 22.5 TON

44.3 HOOK BALLS

45 WIRE ROPE AND REEVING45.1 WIRE ROPE AND REEVING

BT4000PARTS GROUPS

III

ACCESSORIES

51 OPTIONAL EQUIPMENT

51.1 TOOL BOX - INSTALLATION51.2 OIL COOLER INSTALLATION51.3 FRONT BUMPER OUTRIGGER -

INSTALLATION51.4 FRONT BUMPER OUTRIGGER

ASSEMBLY51.5 FRONT BUMPER OUTRIGGER

ASSEMBLY51.6 FRONT BUMPER OUTRIGGER

VALVE51.7 HYDRAULIC PIPING / WIRING -

CONTINOUS ROTATION OPTION

51.8 HYDRAULIC SWIVEL / COLLECTOR RING CONTINUOUS ROTATION OPTION

51.9 MAIN VALVE PIPING - CONTINUOUS ROTATION OPTION

51.10 WINCH VALVE PIPING - CONTINUOUS ROTATION OPTION

51.11 MOTOR SHIFT 2 SPEED WINCH OPTION

51.12 MOTOR SHIFT 2 SPEED WINCH OPTION

51.13 1 PERSON STEEL PLATFORM - ASSEMBLY

51.14 SELF LEVELING PLATFORM - ASSEMBLY

51.15 SELF LEVELING PLATFORM - ASSEMBLY



51.18 RADIO REMOTE CONTROL51.19 RADIO REMOTE CONTROL51.20 RADIO REMOTE CONTROL -

THROTTLE INSTALLATION51.21 RADIO REMOTE CONTROL -

RELAY BOX ASSEMBLY51.22 WINCH CABLE TENSIONER -

ASSEMBLY51.23 ROOFERS PACKAGE51.24 ROOFERS PACKAGE51.25 ROOFERS PACKAGE -

INSTALLATION51.26 HYD GROUND TOOL CIRCUIT51.27 AUXILIARY SHEAVE

52 RATED CAPACITY INDICATOR

52.1 GREER MG586 RCI/ATB ASSEMBLY

52.2 GREER MG586 COMPUTER52.3 GREER MG586 REEL52.4 GREER MG586 DISPLAY52.5 ANGLE DISPLAY (OPTION)

BT4000PARTS GROUPS

IV

WHEN ORDERING PARTS, SPECIFY MODEL NUMBER, SERIAL NUMBER AND DESCRIPTION OF PARTS REQUIRED

GROUP


02DATE: Revised 03-2006

MODEL: BT4000

Page 02.1

02 CARRIER FRAME

Refer to Truck Chassis manufacturer (Ford, Freightliner, Sterling, etc.) for truck repair/replacement parts.

RECORD VEHICLE/MACHINE INFORMATION BELOW FOR USE WHEN ORDERING PARTS

Truck Chassis

TRUCK CHASSIS

Truck ChassisManufacturer______________________________ Model

Boom TruckModel No. Serial No.

Optional Equipment

Comments

Comments

Comments


GROUP


MODEL: BT4000

Page 02.2

REF PART NO DESCRIPTION QTY

1* Refer to SUB-FRAME/FLATBED OPTIONS on page 2.3.Sub-Frame - Weldment ............................. 1

2 201-00142 Clamp - Tube 1/4 x 1/2.............................. 83 223-15213 Bolt 1/4UNC x 3/4 Long ........................... 94 222-10005 Washer - Lock 1/4 ..................................... 95 400-05130 Horn - Outrigger & Backup ........................ 16 400-09094 Light........................................................... 37 400-09291 Grommet ................................................... 38 400-02298 Ring - Terminal 1/4.................................... 29 220-00003 Bolt 1/4UNC x 3/4 Long ........................... 310 201-00141 Clamp 1/4 x 5/16 ....................................... 211 209-00174 Trim - Seal................................................. 1012 222-00006 Washer - Flat 1/4....................................... 2


13 221-90001 Nut, HH Top Lock 1/4UNC.........................314 400-01375 Wire - 16Ga Green.....................................815 400-01411 Loom - Wire 1/4 I.D....................................3516 400-02202 Connector - Terminal Butt..........................117 400-01248 Harness - Electrical ID Lights.....................118 400-01389 Wire - 16Ga Blue .......................................2619 400-01412 Wire - Loom 3/8 I.D....................................820 400-01377 Wire - 16Ga Yellow....................................821 400-01378 Wire - 16Ga Black......................................822 400-01374 Wire - 16Ga Brown ....................................1123 400-02226 Connector, Terminal Butt ...........................1

Refer to SUB-FRAME/FLATBED OPTIONS on page 2.3, or consult dealer for various sub-frames.

Sub-Frame Installation, Boom Truck (BT)s

SUBFRAME INSTALLATION BOOM TRUCKS (BT)


GROUP



MODEL: BT4000

Page 02.3

NOTE* Not all options are listed above. Contact dealer for complete list of options available.

Sub Frame/Flatbed Options

Sub-Frame

Flatbed

Model Bed Length Standard Steel Flatbed Sub-FrameRM4792 16 Feet 600-38023 701-00554

BT4485 20 Feet 600-38021 701-00486

BT4792 21 Feet 600-38143 701-00511

SUB-FRAME/FLATBED OPTIONS


GROUP


MODEL: BT4000

Page 02.4

REF PART NO. DESCRIPTION QTY

1 709-01251 Plate - Shear ............................................. 12 220-06032 Bolt 5/8UNC x1/2 Long ............................ 6


3 222-06010 Washer - Flat 5/8 .......................................124 221-96005 Nut - Lock 5/8UNC.....................................6

2

3

3,4

1

SHEAR PLATE INSTALLATION

WHEN ORDERING PARTS, SPECIFY MODEL NUMBER, SERIAL NUMBER AND DESCRIPTION OF PARTS REQUIREDWHEN ORDERING PARTS, SPECIFY MODEL NUMBER, SERIAL NUMBER AND DESCRIPTION OF PARTS REQUIRED

GROUP


MODEL: BT4000 Series

Page 02.5


1 Refer to SUB-FRAME/FLATBED OPTIONS on page 2.3.

* 209-00596 Install Group, Super Duty Flatbed(Includes Items 2 Through 17)

2 709-01221 Bolt Weld, Flatbed Tie Down..................... 103 222-32005 Washer, Beveled-1/2"Bolt ......................... 104 221-94002 Nut, Toplock, 1/2 GR C ............................. 105 1200-104 HHCS 1/2-13 X 2, GR.5 ............................ 26 400-02202 Terminal, Butt Connector, 16-14 Ga. ........ 16


7 400-09096 Light, Clearance, Amber ............................28 400-09003 Light, Clearance, Red ................................49 400-09097 Grommet Kit, Truck Light ...........................810 220-00001 Bolt, 20 x 1 HCS ........................................1211 220-00019 Washer, Flat 1/4 x 1 1/2 Z..........................612 220-04001 Nut, Hex Head 1/2 ....................................1213 209-00461 Mud Flap-1/2x24x36 Logo Wht .................214 785-00561 Support Angle Mud Flap(Ey2)....................215 201-00141 Clamp, 1/4 x 5/16 Dia. ..............................216* 210-00002 Fastener Kit-FB Install-BT..........................117* 990-50023 Instruction Sheet, Decal Install ..................1

* -Consists of items: (3, 4, 9, 10, & 11)

Flatbed Installation

1 1

7

1211

312

10

10

15

2

3

4

15

9

8

5

17

516

17 18

5

8

6

13

FLATBED INSTALLATION BOOM TRUCKS (BT)


GROUP


MODEL: BT4000

Page 02.6


698-00018 Install Group, Boom rest

* 210-00057 Kit, Boom Rest assembly 4700

1 709-01212 Boom Rest Weldment ............................... 12 729-02175 Pad, Wear, 2 x 6 PLYSERT ...................... 23 220-01005 Bolt, Hex Head

5/16-18NC x 1 Long, GR5........................ 44 222-01001 Washer, Flat, 5/16, PLTD.......................... 20


5 222-11002 Washer, Lock, 5/16 Med., PLTD................126 22001010 Bolt, Hex Head

5/16-18NC x 1 3/4 Long, GR5 ..................87 221-01001 Nut, Hex Head, 5/16-18 NC.......................88 709-01318 Support Plate, Boom Rest .........................1

Boom Rest Assembly

8

1

8

73,4,5

2

6

BOOM REST ASSEMBLY


GROUP



Page 02.7

REF PART NO. DESCRIPTIION QTY

700-00719 Install Group Pedestal 38/47 .................... 1

210-00048 Kit Main Frame Install, 10FT ..................... 1(Consists of Items 1 through 6)

1 701-00527 Mainframe Sub-Assembly Weldment ........ 1

REF PART NO. DESCRIPTIION QTY

2 783-02895 Bar, clamp..................................................43 220-09078 Bolt, 1 1/4NF x 30" Long............................164 221-99014 Nut, Lock 1 1/4NF......................................325 221-29006 Nut, Jam 1 1/4NF.......................................166 222-09005 Washer, Flat 1 1/4PLTD ............................32

Mainframe Sub-Assembly Installation

1

45

6

45

6

3

3

2

6

42

MAINFRAME SUB-ASSEMBLY INSTALLATION


GROUP


MODEL: BT4000

Page 02.8


706-00022 Platform Installation Group

1 709-01301 Platform, LH Weldment ............................. 12* 709-01300 Platform, RH Weldment............................. 13 222-12001 Washer, Lock 3/8 PLTD ............................ 124 222-02005 Washer, flat 3/8 PLTD............................... 85 221-02001 Nut, Hex 3/8NC ......................................... 8


6 220-02011 Bolt, Hex Head, 3/8NC x 2" Long ..............47 220-02007 Bolt, Hex Head 3/8 NC x 3/4 Long............48 209-00444 Handle, grab ..............................................29 220-02008 Bolt, Hex Head 3/8NC x 3 1/2 Long..........410 783-03022 Bar, spacer.................................................2

* ITEM NOT SHOWN

Operators Platform Installation

93

4

10

1,2

6

8

7

4

35

35

OPERATOR PLATFORM INSTALLATION


GROUP



Page 02.9


* 700-00981 Mainframe Sub-Assembly, ....................... Ref

1 701-00527 Mainframe Machining, BT 4000 ................ 12 209-00470 Seal, Trim.................................................. 4Ft3 400-02438 Computer Control Installation.................... 14 710-00275 Turret Installation, Continuous Rotating .... 15 706-00022 Platform Installation................................... 26 800-50054 Control Console Assembly ........................ 2


7 705-00041 Swing Group Installation, ...........................18 500-01708 Center Post Installation..............................19 292-00037 Rotation Gearbox Assembly ......................110 500-01794 Hydraulic Piping, Mainframe

(Continuous Rotation) ................................111 550-00392 Main Control Valve Assembly ....................112 760-00292 Main Outrigger Assembly...........................113 559-00146 Priority Valve, Auxiliary Outrigger ..............1

Mainframe Assembly, Continuous Rotation

1

2 3

4

5

6

7

8

9

10

10

11

12

13

MAINFRAME ASSEMBLY, CONTINUOUS ROTATION


GROUP


MODEL: BT4000

Page 02.10


* 700-00981 Mainframe Sub-assembly 4000 Series ..... Ref

1 701-00527 Main Frame Machining, BT 4700 .............. 12 209-00470 Seal, Trim.................................................. 4Ft3 400-16122 Computer Control Box, (Greer 586) .......... 14 710-00226 Turret & Rotation Bearing

Installation, 370 Deg.................................. 15 706-00007 Platform Installation................................... Ref6 800-50038 Control Console Assembly, Triple-4700... 27 705-00013 Swing Group Installation, BT 4700............ 1


8 809-00410 Rotation Stop Installation, 370 Deg. ..........19 292-00037 Rotation Gearbox Assembly ......................110 500-30001 Hydraulic Piping, Swing .............................111 500-10017 Hydraulic Piping, Topping & Extension......112 500-20003 Hydraulic Piping, Winch.............................113 550-00392 Main Control Valve Assembly ....................114 765-00011 Main Outrigger Assembly...........................115 559-00146 Priority Valve, Auxiliary Outrigger ..............1

Mainframe Assembly - 370 Deg rotation

12 11

4

1

9

7

10

6

13

5

8

14

15

2

3

MAINFRAME ASSEMBLY, 370 Deg. ROTATION


GROUP



MODEL: BT4000

Page 03.1

03 OUTRIGGERS


1 760-00378 Aux. Outrigger Assembly (BT4485/4792).. 1760-00315 Aux. Outrigger Assembly (RM4792)

2 760-00306 Main Outrigger Assembly .......................... 13* 760-00436 Front Bumper Outrigger

(Optional)................................................... 1

* See Group 51 (Optional Equipment)

Outtiggers

1

2

Front Bumper Outrigger

3*

BT OUTRIGGERS


GROUP



MODEL: BT4000

Page 03.2

42

36,7

9,10

25

7,8

19,2012

1

21,22,2346

123

10,11

1218,20

2

43

5 334

26

22,23,32 27

22,23,32 2643

33

2727

29 3520,28,38

3631

30

25 21

1

4141 34 34

1717

1612

13,14,15

12

13,14,15

12

4

10

29

10

9

19,20

57

2

7

8 5

2

7763

13,14,15124

18,2011

1012

129

10

AUXILLIARY OUTRIGGER ASSEMBLY - BT

See page 3.3


GROUP



Page 03.3


* 760-00378 Auxiliary Outrigger Assembly (BT4485/4792)(Includes Items 1 through 46).................... 1

1 760-20436 Auxiliary Outrigger, Horizontal Outer Weld ............................... 1

2 760-10336 Auxiliary Outrigger, Horizontal inner Weld ................................ 2

3 760-10335 Auxiliary Outrigger, Vertical inner Weld .................................... 2

4 540-00061 Auxiliary Outrigger, Horizontal Cylinder .................................... 2

5 540-30177 Auxiliary Outrigger, Vertical Cylinder......... 26 870-30211 Pin, Cylinder Vertical, Rod end ................. 27 200-10013 Ring, Retaining, 1 1/4................................ 88 70-30212 Pin. Cylinder Vertical, Barrel End .............. 29 870-10184 Pin, Cylinder Horizontal Rod end .............. 210 200-00006 Ring, retaining 3/4 ..................................... 811 870-10185 Pin, Cylinder Horizontal Barrel End........... 212 729-02238 Pad, Wear ................................................. 613 787-00255 Shim, Wear Pad -.040............................... 414 787-00256 Shim, Wear Pad -.063............................... 415 787-00257 Shim, Wear Pad -.100............................... 416 870-10186 Lock Pin, Horizontal Auxiliary Outrigger.... 217 224-16014 Pin, Roll - 1/4 x 1 1/2 - PLTD..................... 218 220-01004 Bolt, Hex Head 5/16-18UNC x 1" .............. 419 220-01005 Bolt, Hex Head 5/16-18UNC x 3/4 ........... 4


20 222-11002 Washer, Lock 5/16 .....................................1421 802-01594 Cover, Control Valve Auxiliary Outrigger ...122 220-00002 Bolt, hex Head 1/4-20UNC x 1/2 ..............623 222-10005 Washer, Lock 1/4......................................624 220-01003 Bolt, Hex Head 5/16-18UNC x 1 1/4.........425 394-00003 Nut, Normally Closed.................................226 201-00170 Clamp, Double 5/8 x.406H.........................227 502-20971 Hose Assembly, Auxiliary OR Horizontal...428 222-01001 Washer, Flat 5/16 STD - PLD ....................229 513-40014 Connector, #6 x #6 ORB............................430 394-00002 Coil, Molded 12 VDC Dual Spade..............431 394-00008 Spacer, Coil ...............................................232 222-00006 Washer, flat 1/4..........................................233 513-40015 Connector, Long - #6 OFS x #6 ORB ........434 653-00276 Placard, Arrow - Outrigger Beam...............435 513-50026 Connector, #8 OFS x #5 ORB ...................436 551-10122 Solenoid Valve Sub Assembly ...................237 559-00157 Valve, Control Auxiliary Outrigger..............138 220-01008 Bolt, Hex Head 5/16-18NC x 3 -PLT GR5 .239 NOT USED40 NOT USED41 651-00275 Placard, CAUTION- OUTRIGGER BEAM .442 651-00186 Placard, CAUTION- OUTRIGGER EXTEND243 652-00469 Placard, OUTRIGGER BEAM PIN.............244 NOT USED45 NOT USED46 783-03010 Bar, Auxiliary Outrigger Support ................2

See page 3.2

AUXILLIARY OUTRIGGER ASSEMBLY - BT


GROUP


MODEL: BT4000

Page 03.4


1 760-00378 Auxiliary Outrigger Assembly .................... 12 783-03010 Bar Support, Auxiliary. Outrigger............... 23 220-09089 Stud, Tie Down.......................................... 44 221-99013 Nut, Lock 1 1/4UNF................................... 85 222-09003 Washer, Flat .............................................. 8


6 221-29005 Nut, Jam 1 1/4UNC....................................47* 021-40042 Frame, Stiffener (Not shown).................. REF8 400-25084 Harness Assembly, Electrical, O/R Valve ..

(Not Shown) ...............................................19 559-00187 Valve, Control, Aux. Outrigger ...................1

*REF - The number of Frame Stiffeners depends on Flatbed size

Auxiliary Outrigger Installation

1

2

3

5,4

5,4

6

94

5

3

9

1

56

4

AUXILIARY OUTRIGGER INSTALLATION-BT


GROUP



Page 03.5


1 760-00306 Main Outrigger Assembly .......................... 22 760-90034 Link Bar ..................................................... 43 870-60202 Pin, Link Bar .............................................. 4


4 870-70066 Pin, Outrigger.............................................25 200-30006 Snap, Ring .................................................86 200-30009 Snap, Ring .................................................4

Main Outrigger Installation-BT

6

4

2

2

5

5

3

1

MAIN OUTRIGGER INSTALLATION


GROUP


MODEL: BT4000

Page 03.6


540-50043 Main Outrigger Cylinder Assembly............ 2(Includes Items 1 Through 19)

268-90179 Seal Kit, (For P/N 540-50043) .................. 1(Includes Items 12 Through 19)

1 346-00749 Case, Weldment........................................ 12 346-00748 Rod, Weldment.......................................... 13 346-00747 Ring, thread............................................... 1


4 346-00746 Gland, Head...............................................15 346-00745 Piston .........................................................16 346-00744 Spacer........................................................17 346-00698 Nut, ring .....................................................18 552-00088 CB Cartridge ..............................................2

059-00013 Seal Kit for CB Cartridge............................1

9 346-00701 Screw, Cap ................................................110 346-00702 Washer, Lock.............................................111 346-00715 Plug, Port ...................................................2

ALTERNATE CYLINDER MANUFACTURERS


* 540-50034 Main Outrigger Cylinder Assembly............ 2(Great Bend)

* 269-90079 Kit, Seal, (For P/N 540-50034) .................. 1


* 540-50018 Main Outrigger Cylinder Assembly ............2(Green)

* 268-91012 Kit, Seal, (For P/N 540-50018)...................1

SEAL KITS CONTENTS12 O-Ring ....................................................... 213 Plug, Nylon ................................................ 114 Ring, Back-Up ........................................... 115 O-Ring ....................................................... 1

16 U-Cup.........................................................217 O-ring .........................................................118 U-Cup.........................................................119 Wiper- AN ..................................................1

Main Outrigger Cylinders

540-50043

8

125

7

16

17 6

1 215 14 13 3

19

9

10

4 18

MAIN OUTRIGGER CYLINDER (Goldstar)


GROUP



Page 03.7


540-30177 Auxiliary Outrigger Vertical Cylinder.......... 2(Goldstar) (Includes Items 1 Through 15)

268-90170 Seal Kit (For P/N 540-30177) .................... 1(Includes Items 1 Through 9)

059-0013 Seal Kit for Counterbalance Valve ............ 1


10 346-00722 Lock Nut.....................................................111 346-00723 Piston .........................................................112 346-00724 Barrel Assembly.........................................113 346-00725 Rod Assembly............................................114 346-00726 Internal Head .............................................115 552-00088 Counterbalance Valve................................2

ALTERNATE CYLINDER MANUFACTURERS


* 540-30175 Auxiliary Outrigger Vertical Cylinder.......... 2(Great Bend)

* 269-90079 Kit, Seal, (For P/N 540-30175) .................. 1(Includes Items 1 Through 9)


* 540-30157 Auxiliary Outrigger Vertical Cylinder ..........2(Green)

* 268-91012 Kit, Seal, (For P/N 540-30157)...................1(Includes Items 1 Through 9)

SEAL KITS CONTENTS

1 N/A Wear, Ring ................................................ 12 N/A PSP Seal ................................................... 13 N/A Back-Up Ring ............................................ 24 N/A O-Ring ....................................................... 15 N/A O-Ring ....................................................... 1

6 N/A Back-Up ring ..............................................17 N/A Wear ring ...................................................18 N/A Loaded U-Cup............................................19 N/A Rod Wiper ..................................................1

Auxiliary Outrigger Vertical Cylinders

9

14

7 8

651312

3 43

112

110

15

AUXILIARY OUTRIGGER VERTICAL CYLINDER


GROUP


MODEL: BT4000

Page 03.8


* 540-00061 Auxiliary Outrigger Horizontal Cylinder ..... 2(Includes Items 1 Through 16)

* 268-91011 Seal Kit (For P/N 540-00061) .................... 1(Includes items 2, 4, & 10 Through 13)

1 341-00169 Nut, Hex, Jam,........................................... 13 341-00171 Piston ........................................................ 15 341-00172 Rod Assembly ........................................... 1


6 341-00173 Barrel Assembly.........................................17 341-00174 Stop Tube ..................................................18 341-00175 Stop Tube ..................................................19 341-00008 Sleeve........................................................114 341-00011 Washer.......................................................115 341-00012 Machine, Screw .........................................116 341-00010 Lock, Wire ..................................................1

SEAL KITS CONTENTS

2 Piston Seal ................................................ 24 O-Ring ....................................................... 110 O-Ring ....................................................... 1

11 Back-Up .....................................................112 Rod, Seal ...................................................113 Rod, Wiper .................................................1

Auxiliary Outrigger Horizontal Cylinder-(Green)

15

14

1611

1087

6

4

2

31

5

1213

540-00061

AUXILIARY OUTRIGGER HORIZONTAL CYL. - Green


GROUP



MODEL: BT4000

Page 03.8A


540-00061 Aux. Outrigger, Horizontal Cyl. (Goldstar). 2(Includes Items 1 Through 16)

268-90169 Seal Kit (For P/N 540-00061) .................... 1(Includes Items 1 Through 9)

SEAL KITS CONTENTS1 N/A Wear, Ring ................................................ 12 N/A PSP Seal ................................................... 13 N/A Back-Up ring.............................................. 24 N/A O-Ring ....................................................... 15 N/A O-ring ........................................................ 16 N/A Back-Up Ring ............................................ 1


7 N/A Wear Ring..................................................18 N/A U-Cup, Loaded...........................................19 N/A Rod, Wiper .................................................1

10 812-00001 Lock Nut.....................................................111 812-00002 Piston .........................................................112 812-00003 Barrel Assembly.........................................113 812-00004 Rod Assembly............................................114 812-00005 Set Screw, Cup Point.................................115 812-00007 Cap, Threaded...........................................116 812-00008 Cap Head, Threaded .................................1

Auxiliary Outrigger Horizontal Cylinder-(Goldstar)

540-0006110 1

2

3 4 3

1112 13 14

5 6 15 1617

987

AUX. OUTRIGGER HORIZ. CYLINDER - Goldstar


GROUP




Page 12.1

12 SUPERSTRUCTURE


1 712-00180 Turret Assembly, Standard........................ 1711-00008 (BT4700 Standard Install Group)

712-00239 Turret Assembly, Tall ................................ 1711-00034 (BT4700 Tall Install Group)

2 716-00032 Bearing, Rotation....................................... 13 220-39003 Screw, SH Cap 1NC x 4 1/2" Long ........... 464 222-09004 Washer, Flat 1 PLTD................................. 22


5 221-99002 Nut, Top Lock, 1NC ...................................226 224-26005 Rod End, 5/8 x 4 1/4" Long........................27 220-06037 Bolt, Hex Head 5/8NC x 1 1/2" Long .........28 222-16003 Washer, Lock 5/8 PLTD.............................69 220-36010 Bolt, SH 5/8NC x 3/4" Long .......................410 870-90030 Pin, 2 3/4 x 26 1/16" Long..........................211* 220-32001 Bolt, SH 3/8NC x1" Long ...........................112* 011-20014 Spacer, Pipe 3/8 x 7/16" Long ...................113 209-00802 Edging, Jumbo Trim...................................2ft

*Item 11 & 12 not seen (engages Swing Stop)

Turret Assembly

1

10

8,9

78 6

3

5

4

2

13

11,12

TURRET ASSEMBLY


GROUP



Page 12.2


1 712-00180 Turret Assembly, Standard........................ 1711-00008 (BT4700 Standard Install Group)

712-00239 Turret Assembly, Tall ................................ 1711-00034 (BT4700 Tall Install Group)

2 222-09004 Washer, Flat 1 PLTD................................. 243 221-99002 Nut, Top Lock ............................................ 24


6 518-20001 Connector, Bulkhead 1/8FPT.....................27 511-21001 Nut, Lock....................................................28 501-03002 Zerk, 1/8NPT..............................................29 514-02002 Elbow, 90 Deg. 1/4 Tube x 1/8NPT ...........210 719-00323 Rod, Swing Stop Weldment .......................111 785-01678 Angle, Swing Stop Support ........................112 220-01003 Screw, HHC 5/16NC x 1 1/4" Long............213 222-01001 Washer, Flat 5/16 PLTD ............................4


14 222-11002 Washer, Lock 5/16 PLTD...........................2

Turret /Rotation Gear Installation

1SECTION A - A

SECTION B - B

2

2

3

34

4

8

6

5,7

9

16

11

12,13

13,14,15

25,26

27

23

24,25

17

18,19

21

10

22

29

31

30

TURRET /ROTATION GEAR INSTALLATION


GROUP



Page 12.3

15 221-01001 Nut, Hex 5/16NC ....................................... 216 502-00180 Hose Assembly, Swing Bearing Lube ....... 217 100-30028 Collar Casting, Swing stop ........................ 118 870-00129 Clevis Pin, 5/16 ........................................ 219 224-02001 Cotter Pin .................................................. 220 224-14004 Roll Pin ...................................................... 121 806-00245 Swing K/O Link Assembly ......................... 122 716-00030 Rotation Bearing........................................ 123 224-26005 Rod End .................................................... 2


24 220-06037 Bolt, Hex Head 5/8-11................................225 222-16003 Washer, Lock 5/8......................................826 220-36010 Bolt, Socket Head 5/8 ................................427 870-70068 Pin..............................................................228 220-32001 Bolt socket Head 3/8-16.............................129 011-20013 Spacer........................................................130 209-00802 Trim Edging 5/8 .........................................2ft31 209-00470 Trim Edging 1/2..........................................3ft

TURRET /ROTATION GEAR INSTALLATION


GROUP



Page 12.4


809-00410 Rotation Stop............................................. 11 100-30028 Collar, Swing stop Casting ....................... 12 806-00245 Link, Swing Knockout Assembly ............... 1* 809-00265 Yoke, 5/16 ................................................. 2


* 221-11001 Nut, Hex Jam 5/16UNC .............................2* 229-01008 Stud, Swing Kick Out .................................13 870-00129 Pin, Clevis, 5/16 .........................................24 224-02001 Pin, Cotter ..................................................25 224-14004 Pin, Roll 3/16 x 1 1/2ong...........................1

*INCLUDED WITH iTEM #2

ROTATION STOP INSTALL (370 Deg. ROTATION)


GROUP



Page 22.1

22 SWING SYSTEM


210-00047 Kit, Swing Install ........................................ Ref(Includes Items 2,3, & 17 through 19)

1 292-00037 Gearbox, Rotation Assembly..................... 1530-20130 Motor, Swing (W/Valve, Swing Assembly . 1

2 220-37020 Bolt, Socket Head, 3/4-10UNRC-3 x 2 1/44 3 222-07003 Washer, Flat 3/4 PLT Hard........................ 44 058-00668 Output Pinion Gear.................................... 15* 280-00523 Ring, Eccentric .......................................... 16 514-52003 Elbow, 90 Deg. .......................................... 17 220-34007 Bolt, SOC HD, 1/2NC x 1 1/4" Long.......... 28 222-04009 Washer, Flat 1/2 Hardened ....................... 29 552-10202 Orifice Screw............................................. 1


10 552-10201 Adapter, Motor Control...............................111 513-20027 Connector, Straight ....................................112* 552-00101 Cartridge, Counterbalance.........................213 502-10974 Hose, Brake ...............................................114 ** Hose, Hydraulic Supply..............................115 ** Hose, Hydraulic Return..............................1

NOTE: The Following Items Are Removed For Clarity

15 802-01460 Cover, Pinion Gear ....................................116 802-01432 Cover, Front Plate......................................117 223-15210 Capscrew 5/16NC x 3/4 Self Thread .........618 222-11002 Washer, Lock 5/16 .....................................619 222-01001 Washer, Flat 5/16.......................................6

*SEAL KIT 059-00013** See HYDRAULIC PIPING- SWING Group 25 page 25.8

Rotation Gearbox Assembly Installation

5

1

7,8

1312

11

15,10

14,9

6

2,3

4

ROTATION GEARBOX ASSEMBLY


GROUP



Page 22.2


292-00037 Gearbox, Rotation ..................................... 12 058-00661 Ring, Gear ................................................. 13 058-00662 Primary Planet Gear Assembly ................. 14 058-00663 Output Planet Gear Assembly................... 15 058-00664 O-Ring ....................................................... 26 058-00665 Output Pinion Bearing Carrier ................... 17 058-00123 Grease Fitting............................................ 18 058-00047 Vent Plug................................................... 19 058-00666 ORB Flush Plug......................................... 210 058-00667 Capscrew, Socket Head,

(Metric 10mm 1.25 x 80mm G12.9)........... 1211 058-00668 Output Pinion Gear.................................... 112 058-00670 Seal ........................................................... 113 058-00671 Bearing Cone ............................................ 114 058-00672 Bearing Cup .............................................. 115 058-00673 Bearing Cone ............................................ 116 058-00674 Bearing Cup .............................................. 117 058-00675 Split Ring ................................................... 118 058-00676 Split Ring Retainer .................................... 119 058-00677 Thrust Washer........................................... 1


20 058-00678 Primary Sun Gear ......................................121 058-00679 Thrust Washer ...........................................122 058-00680 Capscrew, Socket Head,

(Metric 8mm 1.25 x 35mm G10.9) .............823 058-00681 Lock washer, Metric (8mm)........................1624 058-00682 Brake Housing ...........................................125 058-00683 Spring.........................................................626 058-00684 Spring Spacer ............................................127 058-00685 Brake Plate ................................................128 058-00686 Seal, U-Cup ...............................................129 058-00687 Brake Plate Spacer ....................................130 058-00688 Friction Disc ...............................................331 058-00689 Brake Disc..................................................832 058-00690 Brake Hub..................................................133 058-00691 Retaining Ring ...........................................134 058-00692 O-Ring........................................................135 058-00693 Pipe, Plug...................................................136 058-00694 O-Ring........................................................137 058-00696 Hydraulic Motor (5.9 cu. in.).......................138 058-00697 Motor Adapter ............................................1

Rotation Gearbox Assembly

ROTATION GEARBOX


GROUP



Page 22.3


39 058-00698 Capscrew, Hex Head (1/2NC x 1 1/4G5) .. 240 058-00034 Lock washer (1/2)...................................... 241 058-00699 Eccentric Ring ........................................... 142 058-00700 Brake Valve Block with CB Cartridges ...... 143 NOT USED44 058-00701 Capscrew, Hex Head (5/16NC x 2 1/2G5) 245 058-00702 O-Ring ....................................................... 2


46 058-00703 Elbow fitting, 90 Deg. .................................147 058-00704 Hose Assembly ..........................................148 NOT USED49 058-00705 Capscrew, Socket Head,

(Metric 8mm 1.25 x 25mm G10.9) .............850 058-00706 Adapter ......................................................151 058-00707 Swivel Nut 90 Deg. ....................................1

ROTATION GEARBOX


GROUP



Page 22.4


* 292-00033 Rotation Gearbox ...................................... Ref

1 342-00033 Output shaft............................................... 12 342-00005 Tapered Bearing Cone.............................. 13 342-00004 Tapered Bearing Cup................................ 14 342-00034 Housing ..................................................... 15 342-00014 Lip Seal ..................................................... 16 342-00006 Tapered bearing Cup ................................ 17 342-00007 Tapered Bearing Cone.............................. 18 342-00040 Internal gear .............................................. 19 342-00017 Carrier ....................................................... 110 342-00044 ID Plate...................................................... 111 342-00021 Planet Shaft............................................... 312 342-00045 Drive Screw............................................... 413 342-00020 Spacer ....................................................... 314 342-00019 Needle Bearing.......................................... 315 342-00018 Thrust Washer........................................... 11416 342-00030 Washer, Lock ............................................ 2017 342-00052 Bolt, Ferry.................................................. 2018 342-00032 Pipe, Plug Magnetic .................................. 119 342-00023 Pin, Roll ..................................................... 3


20 342-00049 Brake, Input................................................121 342-00039 Gear, Cluster..............................................322 342-00050 Ring, retaining............................................323 342-00047 Washer, Thrust ..........................................124 342-00046 Coupling.....................................................125 342-00028 Washer, thrust............................................226 342-00051 Bolt, Hex Head...........................................1227 342-00036 Seal, Lip .....................................................128 342-00013 Fitting, Grease ...........................................129 342-00037 Pipe, Magnetic Plug ...................................130 342-00009 Washer, flat................................................131 342-00010 Washer, flat................................................132 342-00011 Nut, bearing ...............................................133 342-00041 Gear, Ring..................................................134 342-00025 O-Ring........................................................235 342-00053 Pipe Plug....................................................336 342-00048 Brake, Hub.................................................137 342-00042 Spacer........................................................138 342-00035 Sun Gear....................................................139 342-00043 Ring, Retaining ..........................................140 342-00038 Coupling.....................................................1

Swing Gearbox

SWING GEARBOX


GROUP




Page 24.1

24 PUMP DRIVE CASE


1 520-10021 Hydraulic Pump Assembly (Salami) .......... 1520-10024 Hydraulic Pump Assembly (Vickers .......... 1

Hydraulic Pump

TRANSMISSION

POWER TAKE OFF (PTO)

1

TRIPLE VANE HYDRAULIC PUMP


GROUP



Page 24.2


* 520-10021 Hydraulic Pump Assembly (Salami) .......... Ref

1 943-00053 Tie Rod...................................................... 42 943-00054 Drive Gear ................................................. 13 943-00055 Idler Gear .................................................. 14 943-00056 Shaft Seal Kit............................................. 15 943-00057 Front Plate kit ............................................ 16 943-00058 Centering Pin............................................. 27 943-00059 Kit Washer for Tie Rod.............................. 18 943-00060 Kit Nut for Tie rod ...................................... 19 943-00061 Spacer ....................................................... 210 943-00062 Coupling Sleeve Kit ................................... 111 943-00062 Screw M10x55 INI 5931 ............................ 212 943-00063 Washer ...................................................... 2


13 943-00064 Assembly, plate kit .....................................114 943-00065 Double Pump Flange Kit ............................115 NOT USED16 943-00066 O-Ring........................................................117 943-00067 Pump Body ................................................118 943-00068 Idler Gear ...................................................119 943-00069 Seal Kit for Pump Body..............................120 943-00070 Seal Kit for Plate ........................................121 943-00071 Kit Plate......................................................122 943-00072 Pump Body ................................................123 943-00073 Idler Gear ...................................................124 943-00074 Coupling Sleeve.........................................1

Hydraulic Pump Assembly (Salami)

520-10021

HYDRAULIC PUMP ASSEMBLY (SALAMI)


GROUP



Page 24.3


* 520-10024 Hydraulic Pump Assembly (Vickers) ......... Ref

1 935-00119 Body Kit ..................................................... 12 935-00101 Primary Shaft Seal .................................... 13 935-00033 Washer ...................................................... 14 935-00097 Shaft (297 Type)........................................ 15 935-00020 Bearing ...................................................... 16 935-00025 Ring ........................................................... 17 935-00034 Lockring..................................................... 18 935-00119 Back Up Ring ............................................ 19 935-00026 O-Ring ....................................................... 110 935-00151 Seal Ring................................................... 111 935-00030 O-Ring ....................................................... 112 935-00150 Outlet Plate................................................ 113 935-00149 Seal Pac.................................................... 414 935-00120 Flex Side Plate .......................................... 215 935-00148 Ring ........................................................... 116 935-00044 Rotor.......................................................... 117 NOT USED18 935-00056 Vane Kit..................................................... 1


19 NOT USED20 935-00146 Inlet Plate ...................................................121 935-00147 Pin..............................................................222 935-00145 Hex Head Screw........................................223 935-00041 Inlet Cover..................................................124 935-00024 Bolt.............................................................425 935-00140 Screw.........................................................226 935-00141 Pin..............................................................227 935-00142 Inlet Plate ...................................................128 935-00143 Seal Pac.....................................................429 935-00121 Side Plate Kit .............................................130 935-00139 Ring............................................................131 935-00144 Vane Kit .....................................................132 935-00138 Rotor ..........................................................133 935-00143 Seal Pac.....................................................434 935-00117 Outlet Plate ................................................135 935-00028 O-Ring........................................................136 935-00136 Seal Ring ...................................................137 935-00060 O-Ring........................................................138 935-00122 Back-Up Ring.............................................1

Hydraulic Pump Assembly (Vickers)

HYDRAULIC PUMP ASSEMBLY (VICKERS)


GROUP



Page 24.4


39 935-00022 Bolt ............................................................ 440 935-00135 Rear Mounting Cover ................................ 141 935-00093 O-Ring ....................................................... 242 935-00111 Wear Plate................................................. 143 NOT USED44 935-00095 Pin ............................................................. 245 935-00110 Ring ........................................................... 1


46 935-00109 Vane Kit .....................................................147 935-00108 Rotor ..........................................................148 935-00107 Pressure Plate ..........................................149 935-00106 spring .........................................................150 935-00093 O-Ring........................................................151 935-00100 V10 Cover Option ......................................152 935-00088 Bolt.............................................................1

HYDRAULIC PUMP ASSEMBLY (VICKERS)


GROUP




Page 25.1

25 HYDRAULIC SYSTEM


1 875-90336 Reservoir, Hydraulic Oil, 90 Gal. ............... 12 503-03001 Hose 1 1/2 I.D ........................................... A/R3 201-00146 Clamp, Hose 1 1/2, T-Bolt ......................... 24 504-00706 Coupling Hose, 1 1/4 MPT ........................ 15 510-90279 Tube, Return Assembly............................. 16 509-02013 Filter Head................................................. 17 220-04001 Bolt, Hex Head, 1/2NC x 2" Long.............. 48 222-14003 Washer, Lock 1/2 PLTD ............................ 12


9 220-04005 Bolt, Hex Head 1/2NC x 1 1/2" Long .........810 221-96005 Nut, Hex Head 5/8NC PLTD......................811 222-06006 Washer, Flat 5/8 PLTD ..............................1612 505-03001 Flange, 1 1/2 ..............................................213* 260-30004 O-Ring........................................................314 875-90340 Gauge, Sight ..............................................115 504-03407 Hose, End, 90 Deg.....................................116 789-05507 Hydraulic Tank Frame Spacer ...................2

*NOT SEEN

Hydraulic Reservoir & Filter Installation

16

19

10,11,18

1424

32

3315

3130

3

2

14

25

1

HYDRAULIC RESERVOIR & FILTER INSTALLATION


GROUP



Page 25.2


17* 501-02014 Filter Element ............................................ 218 220-06032 Bolt, Hex Head 5/8 NC x 2" Long.............. 819 875-90350 Bracket, Steel Hydraulic Tank ................... 2

857-90325 Bracket, Aluminum Hydraulic Tank ........... 220 935-00113 Filter, By-Pass Gauge ............................... 121 770-02621 Bracket, Hydraulic Filter Mounting ........... 122 220-01004 Bolt, 5/16NC x 3/4" Long........................... 223 222-11002 Washer, Lock 5/16 PLTD .......................... 2


24 875-90326 Mounting Strap, Aluminum Tank................2875-90349 Mounting Strap, Steel Tank .......................2

25 875-90327 Rubber Strap, Aluminum Tank...................2875-90348 Rubber Strap, Steel Tank ..........................2

26 222-01001 Washer, Flat 5/16 PLTD ............................227 221-01001 Nut, Hex, 5/16NC PLTD.............................228 503-06008 Pump suction Hose....................................129** 505-03003 Flange, 1 1/2 ..............................................Ref

* ITEMS NOT SEEN**ITEM PART OF #12


2 8,913 6

3

5 22,23,26,27

21

20

28173536

34

12,2915



GROUP




Page 25.3


30 875-90329 Reducer, 2 1/2NPT x 2NPT....................... 131 875-90330 Diffuser, 2NPT x 1 1/4NPT........................ 132 875-90138 Cap, Breather Assembly ........................... 1


33 875-90332 Plug, Socket Head 3/4NPT........................134 570-90055 Valve, 2 1/2 Gate ......................................135 570-09005 Nipple, 2 1/2 Closed .................................136 504-00902 Coupling, 1 1/2 Hose ................................1


13

7,8

8,9

21

5



GROUP



Page 25.4


1 GROUP 24 Hydraulic Pump, Vickers ........................... 1

2* 503-06009 Hose, Suction Assembly ........................... 13* 502-40718 Hose, Main Valve Assembly...................... 14* 502-50312 Hose, Winch Supply assembly.................. 15** 505-06004 Flange Kit, 2 1/2" ....................................... 26*** 505-02002 Flange, 1" .................................................. 27**** 505-01002 Flange, 3/4" ............................................... 28** 260-50003 O-Ring ....................................................... 19*** 260-20003 O-Ring ....................................................... 110**** 260-10002 O-Ring ....................................................... 111** 220-04005 Bolt Hex Head1/2 NC x 1 1/2" Long GR5 . 6


12*** 220-02002 Bolt, Hex Head, 3/8NC x 1 1/4" Long GR5 813** 222-14003 Washer, Lock 1/2" Med. PLTD ..................614*** 222-12001 Washer, Lock 3/8" Med. PLTD ..................815 201-00248 Clamp, Hose, T Bolt, 2 1/2" Dia. ................216 201-00119 Clamp, Conduit, 2 1/2" Dia. .......................117 220-01010 Bolt, Hex Head, 5/16NC x 1 3/4" Long ......118 221-01001 Nut, Hex Head, 5/16NC, PLTD..................119 222-01001 Washer, Flat, 5/16 PLTD1 .........................120 222-11002 Washer, Flat, 5/16 PLTD ...........................121 50403509 Hose, End, Beaded, 90 Deg. .....................122 514-55011 Elbow, 90 Deg............................................123* 502-30532 Hose Assembly ..........................................1

*ITEMS LISTED IN HOSE KIT 503-93002**ITEMS LISTED I FLANGE KIT 505-06004

***ITEMS LISTED IN FLANGE KIT 505-02002****ITEMS LISTED IN FLANGE KIT 505-01002

Hydraulic Pump Assembly (Metaris)

PTO

HYDRAULIC RESERVOIR

2

15

1517,18,19,20

11

13

6

8

5

4

9 6 14 12

121473

10

1

22

21

11

13

HYDRAULIC PUMP ASSEMBLY (METARIS)


GROUP



Page 25.5


1 GROUP 24 Hydraulic Pump, Salami ............................ 1

2* 503-06009 Hose Assembly, Suction ........................... 13* 502-40718 Hose Assembly, Main Valve Supply.......... 14* 502-50502 Hose Assembly, Winch Supply ................. 15** 505-05002 Flange Kit, 2" ............................................. 27*** 505-01002 Flange, 3/4" ............................................... 48** 260-40005 O-Ring ....................................................... 110*** 260-10002 O-Ring ....................................................... 111** 220-04005 Bolt, Hex Head, 1/2NC x 1 1/2" Long........ 412 220-02002 Bolt, Hex Head, 3/8NC x 1 1/4" Long........ 813** 222-14003 Washer Lock 1/2 PLTD ............................. 414 222-12001 Washer, Lock 3/8 PLTD ............................ 815 201-00248 Clamp, Hose T-Bolt, 1/2" Dia. ................... 2


16 201-00119 Clamp, Conduit 2 1/2" Dia. ........................117 220-01010 Bolt, Hex Head, 5/16 NC x 1 3/4" Long .....118 221-01001 Nut, Hex Head 5/16NC ..............................119 222-01001 Washer, Flat, 5/16 PLTD ...........................120 222-11002 Washer, Lock 5/16 PLTD...........................121 504-03515 Hose, End, Beaded, 90 Deg. .....................122 514-55014 Elbow, 90 Deg............................................123* 502-30532 Hose Assembly ..........................................124 220-04005 Bolt, Hex Head 1/2NC x 1 1/2" Long .........225 222-14003 Washer, Lock, 1/2 PLTD...........................226**** 209-00804 Protector, Hose..........................................127 519-90067 Flange, Adapter 3/4 12 ORB......................128 514-59024 Elbow, 90 Deg............................................1

*ITEMS LISTED IN HOSE KIT #503-93006 ***ITEMS LISTED IN FLANGE KIT #505-01002**ITEMS LISTED IN FLANGE KIT #505-05002 ****ITEMS LISTED NOT SHOWN

Hydraulic Pump Installation (Salami)

1516

17,18,19,20

215 21

11

24 25

5

12

8

2728

43

2322

1

7

12,14

10

12

2728

HYDRAULIC PUMP ASSEMBLY (SALAMI)


GROUP



Page 25.6


1 502-35002 Hose Assembly, Boom Hoist..................... 22 502-40720 Hose Assembly, Telescope....................... 23 209-00174 Trim, Protective ......................................... Ref4 400-15088 Cable Tie ................................................... Ref


5 513-70030 Connector, #12 OFS X #8 orb ...................26 516-85004 Swivel Nut, Run Tee #8 OFS.....................17 519-50012 Reducer, #8 x #4 OFS ...............................18 511-50004 Nut, Tube #8 OFS......................................1

BOOM

IN

OUT

3 24

BOOM HOIST CYLINDER

TO GREARLOAD SENSE

1 BOOM EXTEND

BOOMRETRACT

RETURN MANIFOLDASSEMBLY

5

7,8

6

5

2

5(TO TELESCOPECYLINDER RETRACT PORT)

(TO BOOMEXTEND)

MAIN VALVE ASSEMBLY

HYDRAULIC PIPING - BOOM HOIST/EXTEND


GROUP



Page 25.7


1 502-40719 Hose assembly, Winch Raise/Lower......... 22 502-11045 Hose Assembly, Winch Drain/Return ........ 13 514-62002 Elbow, 90 Degree, Swivel Nut, 4 OFS ...... 14 400-15088 Tie Cable ................................................... *


5 513-20023 Connector, Straight 1/4 NPT x 4 OFS........16* 517-30010 Plug, Socket Head, 1/4 NPT......................Ref

2

1

WINCHASSEMBLY

4

6

WINCHUP

WINCHDOWN

3

2

RETURN MANIFOLDWINCH VALVE

ASSEMBLY

1

WINCHDOWN

WINCHUP

HYDRAULIC PIPING- WINCH


GROUP



Page 25.8


1 502-30557 Hose assembly, Swing .............................. 2


2 502-10974 Hose Assembly, Brake Release ................1

12

CLOCKWISESWING PORT

COUNTER-CLOCKWISESWING PORT

1

TO COUNTER-CLOCKWISESWING PORTTO CLOCKWISE

SWING PORT

HYDRAULIC PIPING- SWING


GROUP



Page 25.9


1 502-30534 Hose Assembly Main Outriggers............... 4

1

MAIN OUTRIGGERSTREET SIDE

RETRACTPORT

EXTENDPORT

1

MAIN OUTRIGGERCURBSIDE RETRACT PORT

EXTENDPORT

1

TO CSEXTEND PORT

RETRACT PORT

TO CS

4

TO STREET SIDEEXTEND

TO CURB SIDERETRACT

TO CURB SIDE EXTEND

TO STREET SIDERETRACT

HYDRAULIC PIPING- MAIN OUTRIGGERS


GROUP



Page 25.10

See page 25.11

NOTE:FLATBED REMOVED FOR CLARITY

10

107,8,9 7,8,9

3

411

8,9,14

15

12

44

33

HYDRAULIC PIPING AUXILIARY OUTRIGGERS


GROUP



Page 25.11


503-94003 Kit, Auxiliary Outrigger Hose ..................... 1(Includes Items 1 Through 4)

1 502-20798 Hose assembly, AuxiliaryOutrigger Valve, Supply ............................ 2

2 502-30586 Hose assembly, AuxiliaryOutrigger Valve, Return............................. 2

3 502-20973 Hose assembly, Vertical Outrigger ........... 24 502-20974 Hose assembly, Horizontal Outrigger ....... 25* 770-01820 Bracket, Support C/S Hose ....................... 16 201-00167 Clamp, Double Hose ................................. 3


7 220-01004 Bolt, Hex Head 5/16-18UNC x 3/4 Long...108 222-11002 Washer, Lock 5/16 .....................................149 221-01001 Nut, Hex Head 5/16-18 UNC .....................1410 770-01840 Support Bracket, Hose SS.........................111 201-00170 Clamp, Double Hose, 5/8...........................212* 774-00046 Trolley Track, Hose....................................213* 774-00047 Trolley, Hose..............................................214* 220-01005 Bolt, Hex Head 5/16-18NC x 1 Long ........415 400-15088 Cable, Tie 11 15/32....................................1516* 220-00004 Bolt, Hex Head 1/4-20 UNC x 1 1/4 Long.417* 221-90001 Nut, Toplock, 1/4-20 UNC..........................4

*ITEM NOT SHOWN

3

4MAIN VALVE ASSEMBLY

SUPPLY FROMHYDRAULIC PUMP

SUPPLY TOMAIN CONTROLVALVE

PRIORITY VALVE ASSEMBLY

1

SUPPLY FROMHYDRAULIC PUMP

DRAIN TO RETURN MANIFOLD

SUPPLY TOMAIN CONTROLVALVE

RETURN MANIFOLD ASSEMBLY

2

HYDRAULIC PIPING AUXILIARY OUTRIGGERS


GROUP



Page 25.12


1 559-00146 Priority Flow Control Valve.........................12 220-01011 Bolt, Hex Head5/16-18UNC x 3 1/2 ...........23 222-11002 Washer, Lock 5/16 .....................................24 221-01001 Nut, Hex Head 5/16-18 UNC .....................45 514-57011 Elbow, 90 Deg. #12 OFS x # 10 ORB........16 519-70032 Cap, #12 OFS............................................17 513-60008 Connector, #10 OFS x #10 ORB ...............18 502-40727 Hose Assembly, Valve Supply ...................A/R9 513-20019 Connector, #4 OFS x #6 ORB ...................110 502-11000 Hose Assembly, Drain-Priority Valve .........A/R11 513-40014 Connector, #6 OFS x #6 ORB ...................112 519-40007 Cap, #6 OFS..............................................113* 400-15086 Cable Tie....................................................2

*ITEM NOT SEEN

RELIEF ELECTRICAL FROMAUX OUTRIGGERS

1

2,3,4

PRIORITY FLOWTO AUX OUTRIGGERS

5

6

10

87

1112

9

10

8

HYDRAULIC PIPING PRIORITY VALVE


GROUP



Page 25.13


1* 551-10136 Valve, Unloader......................................... 12 514-52003 Elbow, 90 Deg., 4 OFS x 4 ORB............... 13 513-20017 Connector, 4 OFS x 4 ORB....................... 3


4A 394-00001 Solenoid Only Service................................24B 394-00002 Solenoid Coil, Service................................24C 394-00003 Solenoid Coil, Nut ......................................25 394-00004 Check Valve, Service.................................3

Unloader Valve Assembly

13

5

4C

4A,4B

2

UNLOADER VALVE ASSEMBLY


GROUP



Page 25.14


1 Page 25.16 Valve, Triple Assembly.............................. 1

2 514-52005 Elbow, 4 OFS x 4 ORB.............................. 53 514-55015 Elbow, 90 Deg. 8 OFS x 8 ORB................ 14 513-50027 Connector, 8 OFS x 10 ORB..................... 15 514-55011 Elbow, 90 - 8 OFS x 8 ORB ...................... 16 513-70038 Connector, 12 OFS x 10 ORB................... 17 513-50023 Connector, 8 OFS x 8 ORB....................... 68 513-70030 Connector,12 OFS x 8 ORB...................... 19 519-70032 Cap, #12 OFS ........................................... 110 519-40007 Cap #6 OFS .............................................. 4


11 513-40018 Connector, 6 OFS x 8 ORB .......................412 517-00014 Union, 12OFS ............................................113 552-00016 Valve, Check Spool....................................114 514-57010 Elbow, 90 12 OFS x 12 ORB .....................115 514-59024 Elbow, 90 16 OFS x 12 ORB .....................116 517-30004 Plug, 12 ORB.............................................117 943-00032 Boom Extend/Retract Adjuster...................118 943-00035 Swing Adjuster ...........................................119 516-85004 Tee Connector ...........................................120 519-50012 Reducer .....................................................121 511-50004 Nut, Hex Head ...........................................1

Main Valve Assembly-Salami

12,13,14WINCHVALVE

10,11

15

16

2

7

3

2

48

1920

21 7 5 186,9

MAIN VALVE ASSEMBLY (SALAMI)


GROUP



Page 25.17A


1 550-00392 Valve, Triple Assembly.............................. 12 514-52005 Elbow, 4 OFS x 4 ORB.............................. 53 514-55015 Elbow, 90 Deg. 8 OFS x 8 ORB................ 14 513-50027 Connector, 8 OFS x 10 ORB..................... 15 514-55011 Elbow, 90 - 8 OFS x 8 ORB ...................... 16 513-70038 Connector, 12 OFS x 10 ORB................... 17 513-50023 Connector, 8 OFS x 8 ORB....................... 68 513-70030 Connector,12 OFS x 8 ORB...................... 19 519-70032 Cap, #12 OFS ........................................... 110 519-40007 Cap #6 OFS .............................................. 4


11 513-40018 Connector, 6 OFS x 8 ORB .......................412 517-00014 Union, 12OFS ............................................113 552-00016 Valve, Check Spool....................................114 514-57010 Elbow, 90 12 OFS x 12 ORB .....................115 514-59024 Elbow, 90 16 OFS x 12 ORB .....................116 517-30004 Plug, 12 ORB.............................................117 943-00032 Boom Extend/Retract Adjuster...................118 943-00035 Swing Adjuster ...........................................119 516-85004 Tee Connector ...........................................120 519-50012 Reducer .....................................................121 511-50004 Nut, Hex Head ...........................................1

Main Valve Assembly-Husco

MAIN VALVE ASSEMBLY (HUSCO)


GROUP



Page 25.16


* 550-00392 Valve, Main Control Assembly .................. 11 943-00037 Inlet Section .............................................. 12 943-00036 Assembling................................................ 13 943-00035 Relief Valve, Swing ................................... 14 943-00034 SL Without Lever....................................... 75 943-00033 Spool Spring Return .................................. 76 943-00032 Main Relief Valve ...................................... 17 943-00031 Venting Valve EHU.................................... 38 943-00030 O-Ring Kit.................................................. 79 943-00029 Prearrangement Auxiliary Valves .............. 1210 943-00028 Load Check Valve ..................................... 711 943-00027 Plug ........................................................... 212 943-00026 Outlet Section............................................ 1


13 943-00025 Tandem Section withSecondary Relief Valve Port ......................1

14 943-00024 Parallel Section withSecondary Relief Valve Port ......................6

15 943-00023 Split Flow Mid Inlet Section........................116 943-00022 Plug............................................................117 943-00021 Plug............................................................118 943-00020 Double Acting Spool ..................................419 943-00019 Double Acting Motor Spool ........................120 943-00018 Double Acting Motor Spool B Port .............121 943-00017 Double Acting Motor Spool A Port .............122 943-00016 O-Ring Kit ..................................................923 943-00015 Plug............................................................2

Exploded View Main Valve Assembly-Salami

550-00392

MAIN VALVE ASSEMBLY (SALAMI)


GROUP



Page 25.17


1 550-00393 Valve Assembly, Winch 57 Gal. ................ 12* 514-52003 Connector, 90 Deg. Elbow ........................ 23 514-57010 Connector, 90 Deg. Elbow

#12OFS x #12ORB ................................... 1


4* 514-52005 Connector, 90 Deg. Elbow#4OFS x #6ORB........................................5

5 541-59021 Connector, 90 Deg. Elbow.........................16 513-70025 Connector, Straight ....................................1

Winch Valve Assembly-Husco

WINCH VALVE ASSEMBLY-HUSCO


GROUP



Page 25.17A


1 550-00393 Valve Assembly, Winch, 57 Gal. ............... 12 514-52003 Elbow, 90 Deg. #4 ..................................... 13 514-57010 Elbow, 90 Deg. #12................................... 1


4 514-52005 Elbow, 90 Deg. #4-6 ..................................15 514-59021 Elbow, 90 Deg. #16....................................16 513-70026 Connector, Straight, #12............................1

Winch Valve Assembly-Salami

WINCH VALVE ASSEMBLY-SALAMI


GROUP



Page 25.19


1 940-00000 Inlet section ............................................... 12 940-00001 Spool Section ............................................ 13 940-00002 Outlet Section............................................ 1

269-00094 Seal Kit, Control Valve .............................. 1(Includes Items 4 Through 8)

4 N/A O-Ring, Section ......................................... 15 N/A O-Ring, Spool............................................ 16 N/A Wiper, Spool.............................................. 27 N/A O-Ring, Plug.............................................. 18 N/A O-Ring, Gauge Port................................... 19 940-00003 Cartridge, Relief Valve .............................. 1

REF PART. NO. DESCRIPTION QTY

269-00095 Seal Kit, Relief valve ..................................1(Includes Items 10 Through 18)

10 N/A O-Ring, Adjusting Cap & Nut .....................211 N/A O-Ring, Pilot Section..................................112 N/A Spring, Pilot................................................113 N/A Back-up Ring, Pilot ....................................114 N/A O-Ring, Pilot...............................................115 N/A O-Ring, Housing ........................................116 N/A Spring, Piston.............................................117 N/A O-Ring, Main Poppet .................................118 N/A Back-Up ring, Main Poppet ........................119 940-00004 Cartridge, Anti-Void....................................1

(Includes Items 20 Through 23)

20 N/A O-Ring........................................................121 N/A Ring, Back-Up............................................122 N/A O-ring .........................................................123 N/A O-Ring........................................................1

Winch Valve (Salami)

WINCH VALVE (SALAMI)


GROUP



Page 28.1

28 OPERATOR CONTROLS


1 Pedestal Weldment ................................... Ref2* 800-50054 Console Assembly..................................... 13 220-02002 Bolt, Hex Head 3/8 UNC x 1 1/4" Long ..... 8


4 222-02005 Washer, Flat, 3/8 PLTD .............................245 222-12001 Washer, Lock 3/8 PLTD.............................126 221-02001 Nut, Hex Head 3/8 UNC, PLTD .................127 220-02004 Bolt, Hex Head, 3/8 UNC x 1" Long PLTD.4

Control Console Installation

1 3,4,5,6

3,4,5,6

4,5,6,7

4,5,6,7

3,4,5,6

3,4,5,6

4,5,6,7

2

CONTROL CONSOLE INSTALLATION


GROUP



Page 28.2


* 800-50054 Console Assembly..................................... Ref

1 500-01394 Valve Assembly, winch.............................. 1

2 550-00401 Valve Assembly, Main (Salami)................. 1 OR 550-00314 Valve Assembly, Main (Husco) ................. 13 519-90051 Manifold Return ......................................... 14 500-01397 Valve Assembly, Unload ........................... 15 500-01398 Gauge Assembly, Press............................ 16 502-10973 Hose Assembly, Shuttle Valve .................. 17 502-10999 Hose Assembly, Unload Valve Return ...... 18 502-50313 Hose Assembly, Valve Return................... 19 502-50314 Hose Assembly, Valve Return................... 110 510-20371 Tube Assembly, Unload Valve Supply ...... 111 510-20372 Tube Assembly, Telescope Unload........... 1

Tube assembly, Telescope Vent ............... 112 510-20370 Tube Assembly, Shuttle Supply ................ 113 510-70773 Tube Assembly, Power Beyond ................ 114 510-20373 Tube Assembly, Winch Unload ................. 1


15 400-05334 Horn, ATB, ECA.........................................116 400-04125 Switch, Momentary ....................................417 400-04123 Switch, Start/Stop ......................................218 804-00806 Control Handle, Swing ...............................119 804-00805 Control Handle, Boom Hoist ......................120 804-00807 Control Handle, Telescope ........................121 804-00829 Control Handle, Winch...............................122 804-00811 Control Handle, C.S. OR............................123 804-00812 Control Handle, S.S. O/R...........................124 804-00809 Control Handle, C.S. Aux. O/R ..................125 804-00810 Control Handle, S.S. Aux. O/R...................126 808-00048 Knob, Control, (Black)................................1427 808-00049 Knob, Control, Winch, (Black)....................228 809-00385 Rod, 2 Speed Winch..................................229 222-40007 Retainer, Rod.............................................230 221-06002 Nut, Jam, 5/8-11 UNC PLTD .....................1631 223-01101 RH MS Slot, #10-32 x 3/4 PL.....................232 221-90003 Nut Hex Nylon LK #10-32 PLTD................2

Control Console Assembly

12

4

4

5

67

9

10

11

12

14

14

7

162524232221201918

26

2627

29,28

26

30

13

15

31,32

356

57,58,66

CONTROL CONSOLE ASSEMBLY


GROUP



Page 28.3


33 783-02785 Bar, Valve Spacer ..................................... 234 806-00243 Control Link Assembly, Winch................... 135 806-00235 Control Link Assembly, Swing................... 136 806-00236 Control Link Assembly, Boom ................... 137 806-00237 Control Link Assembly, Telescope ............ 138 806-00238 Control link assembly, C.S. O/R................ 139 806-00239 Control Assembly. S.S. O/R ...................... 140 806-00240 Control Link Assembly, C.S. STB.............. 141 806-00241 Control Link Assembly, S.S. STB.............. 142 870-00129 Pin, Clevis 5/16 Dia. .................................. 943 870-00044 Pin, Clevis 3/16 Dia. .................................. 744 224-02001 Pin, Cotter 1/8 x 3/4................................... 945 224-01001 Pin, Cotter 3/32 x 1/2................................. 746 400-24062 Sub-Assembly, O/R Alarm Switches .

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