iii - parts raptor bt4000 boom trucks parts manual introduction this terex cranes parts manual is...

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 manufacturer’s 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 driver’s 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

v

USING 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 Operator’s 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 ROOFER’S PACKAGE51.24 ROOFER’S PACKAGE51.25 ROOFER’S 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................................................. 10’12 222-00006 Washer - Flat 1/4....................................... 2


13 221-90001 Nut, HH Top Lock 1/4UNC.........................314 400-01375 Wire - 16Ga Green.....................................8’15 400-01411 Loom - Wire 1/4 I.D....................................35”16 400-02202 Connector - Terminal Butt..........................117 400-01248 Harness - Electrical ID Lights.....................118 400-01389 Wire - 16Ga Blue .......................................26’19 400-01412 Wire - Loom 3/8 I.D....................................8’20 400-01377 Wire - 16Ga Yellow....................................8’21 400-01378 Wire - 16Ga Black......................................8’22 400-01374 Wire - 16Ga Brown ....................................11’23 400-02226 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-Frame

RM4792 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

Operator’s 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

161213,14,15

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 1/2”ong...........................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 1/4”4 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 ......... 147 801-00104 Console, Sub-Assembly ............................ 148* 802-01390 Cover, Console Front ................................ 249** 802-01489 Cover, Console End, C.S. ......................... 1


50** 802-01490 Cover, Console End, S.S. ..........................151 709-01119 Block, Bearing............................................252 222-00006 Flat washer, 1/4 PLTD ...............................1853 221-90001 Nut, Hex LK, 1/4-20UNC PLTD .................1854 220-00007 Bolt, Hex Head, 1/4-20UNC x 2PL.............1855** 400-15086 Cable Tie, Nylon ........................................556 209-00444 Handle, C/H #2399D..................................257 220-02004 Bolt, Hex Head3/8UNC x 1 GR5 PL ..........458 222-12001 Washer, Lock, 3/8 PLTD............................1059 221-02001 Nut, 3/8-16UNC PLTD ...............................660 220-02005 Bolt Hex Head 3/8-16UN x 2 1/2 GR5 .......461 220-02011 Bolt Hex Head, 3/8-16UNC x 2 GR5..........262 220-04048 Bolt, Hex Head, 1/2-13UN x 2 GR5 ...........463 222-14001 Washer, Lock 1/2 PLTD.............................464 222-04001 Washer, Flat 1/2 PLTD ..............................265 221-04001 Nut, Hex, 1/2-13UNC PLTD.......................466 222-01001 Washer, Flat, 5/16 PLTD ...........................30

*ITEM REMOVED FOR CLARITY**ITEMS NOT SHOWN

Control Console

9

34

513340,42

33

3637

38 39 40

41 42,43

40,42

46

46

47

52,53,54

62,62,64,6562,63,65

58,59,60,6658,59,60



GROUP



Page 28.4


67 223-00102 FHMS, #8-32 x 3/4" Long.......................... 668 221--0008 Nut, Hex, #8-32 Nylock ............................. 669 263-00044 Gasket, Level Mounting............................. 270 209-00831 Level Base, Circular Level......................... 271 209-00832 Level Indicator, Circular............................. 272 NOT USED73 NOT USED76 651-00269 Placard, Control......................................... 2


77 650-00654 Placard, Control, 2 Speed Winch...............278 209-00791 Hole, Plug, 1/2 Dia Push-In........................279 220-01004 Bolt, Hex Head, 5/16-18NC x 3/4 PLTD ....2280 NOT USED81 222-11002 Washer, Lock, 5/16 PLTD..........................2282 221-01001 Nut, 5/16-18NC PLTD................................683 400-04122 Switch, DPDT Moment...............................484 400-04036 Switch, Guard ............................................4

Control Console Assembly

7170

68

67

69

83,84

79,66,81,8278

76

77

56

57,58,66



GROUP



Page 28.5


1 809-00407 Throttle Weldment ..................................... 12 809-00389 Throttle Shaft, Casting............................... 13 709-01612 Bearing, Block Acceleration Pedal ............ 24 806-00198 Control Pedal, Main Link ........................... 15 220-00007 Bolt, Hex Head1/4 NC x 2" Long............... 46 222-00006 Washer, Flat, 1/4 PLTD............................. 47 221-90001 Nut, Hex Head, 1/4 NC Toplock ................ 4


8 870-00002 Pin, Clevis, 1/4 x 3/4 ..................................29 224-01001 Pin, Cotter, 3/32 x 1/2" Long......................210 100-30029 Throttle Pedal, Casting ..............................111 08074200 Nylon Spacer .............................................212 224-12001 Pin, Roll, 1/8 x 1 1/8" Long ........................113 870-00132 Pin, 3/8 x 4 Long........................................1

Throttle Assembly

12 13

10 811

48

21

57

36

9

THROTTLE ASSEMBLY


GROUP



Page 28.6


1 600-40347 Throttle Sub-assembly .............................. 22 809-00390 Clevis Assembly ........................................ 23 600-40329 Cable, Throttle........................................... 24 201-00141 Tube, clamp 1/4......................................... 25 220-00003 Bolt, Hex head 1/4NC x 3/4" Long ............ 46 222-00006 Washer, Flat, 1/4 PLTD............................. 107 221-90001 Nut, Hex, 1/4 NC Top Lock ....................... 9


8 201-00143 Cable, clamp..............................................29 220-00004 Bolt, Hex Head 1/4 NC x 1 1/4" Long ........110 202-10062 Spring, Throttle Pedal Return ....................211 209-00046 Swivel Stop ................................................212 220-00007 Bolt, Hex Head 1/4NC x 2" Long ...............413 036-10040 Spacer Tube, 1/2 Dia. Long.......................4

Throttle Installation

THROTTLE INSTALLATION


GROUP




Page 29.1

29 TOOLS, PAINT, LUBRICANTS


706A8760 Tool Kit ...................................................... Opt(Includes Items 1 Through 19)

1 1226-54 Wrench, Adjustable, Hydraulic Fitting ....... 12 1226-55 Wrench Set, Combination (17 Pc)............. 13 1226-56 Socket Set, 3/4” Drive (12 Pc)................... 14 1226-57 Flex Handle, 3/4” Drive, 18” Long ............. 15 1226-58 Extension Bar, 3/4” Drive, 16” Long .......... 16 1226-59 Socket, 3/4” 12 Point ................................. 17 1226-60 Universal Joint, 3/4” Drive ......................... 18 1226-61 Spanner< Adjustable Hook (2”-4 3/4”) ...... 1


9 1226-62 Punch, Long Taper (1/4 x 12” ....................110 1226-32 Hammer, Ball Peen (32 Oz.)......................111 1226-63 Tool Box.....................................................112 12019-556 Disconnect, Female ...................................113 1226-11 Wrench, Wheel ..........................................114 32179 Handle, Wrench .........................................115 A29372 Kit, Hose ....................................................Opt16 204260 Gauge, Pressure (0-6000 Psi) ...................Opt17 706-8758 Tool, Brake Adjust......................................Opt18 12019-557 Disconnect, Male .......................................319 12019-558 Cap, Dust ...................................................3


1 218536 Paint, Terex White..................................... AR2 218538 Aerosol Paint, Terex White........................ AR


3 218535 Paint, Terex Grey.......................................AR4 218539 Aerosol Paint, Terex Grey..........................AR5 216537 Primer ........................................................AR

Pressure Gauge

Paints

TOOLS/PAINTS


GROUP



Page 29.2

O-RING SAE SIZE (-) FORPART NO. 16ths Inch TUBE OD

1218-282, 460 0080 -4 1/41218-283 -5 5/161218-284, 460 0885 -6 3/81218-285, 460 0886 -8 1/21218-286, 460 0079 -10 5/81218-290, 460 0887 -12 3/4

O-RING SAE SIZE (-) FORPART NO. 16ths Inch TUBE OD

1218-292, 460 0888 -14 7/81218-287, 460 0163 -16 11218-288, 460 0133 -20 1-1/41218-289, 460 0889 -24 1-1/21218-293, 460 0890 -32 2

TUBE OD PART NO. DESCRIPTION QTY.

3/4” 12019-279 Split Flange Clamp ......................... 21218-26 O-Ring ............................................ 11200-61 Capscrew, 3/8C x 1-1/4 .................. 41210-20 Lock Washer................................... 4

1” 1219-665 Split Flange Clamp ......................... 21218-103 O-Ring ............................................ 11200-61 Capscrew, 3/8C x 1-1/4 .................. 41210-20 Lock washer ................................... 4

1-1/4” 1219-392 Split Flange Clamp ......................... 21218-63 O-Ring ............................................ 11200-307 Capscrew, 7/16C x 1-1/2 ................ 41210-23 Lock Washer................................... 4

TUBE OD PART NO. DESCRIPTION QTY.

1-1/2” 1219-390 Split Flange Clamp..........................21218-72 O-Ring.............................................11200-100 Capscrew, 1/2C x 1-1/2 ...................41210-26 Lock Washer ...................................4

2” 1219-885 Split Flange Clamp..........................21218-126 O-Ring.............................................11200-100 Capscrew, 1/2C x 1-1/2 ...................41210-26 Lock Washer ...................................4

3” 1219-393 Split Flange Clamp..........................21218-61 O-Ring.............................................11200-146 Capscrew, 5/8C x 1-3/4 ...................41210-32 Lock Washer ...................................4

O-Ring Adapters

Split Flange Clamps

SPLIT FLANGE CLAMPS


GROUP



Page 29.3

Clamps

1/4” 5/16” 3/8” 1/2” 5/8” 3/4” 7/8” 1” 1 1/4” 1 1/2”

CLAMP SET 1240-172 1240-163 1240-160 1240-168 1240-146 1240-132

COVER PLATE 1240-174 1240-162 1240-162 1240-170 1240-148 1240-148

NUT 1240-173 1240-161 1240-161 1240-169 1240-157 1240-156*

CAPSCREW 1200-31/4C x1

1200-51/4Cx1 1/4

1200-51/4Cx1 1/4

1200-71/4Cx1 1/2

1200-131/4Cx2 1/4

1200-131/4Cx2 1/4

WHERE USED Hyd Brakes Air Brakes Air Brakes Outriggers Upper & Lower Hyd.

Upper Hydraulics

Dual Clamps

1/4” 5/16” 3/8” 1/2” 5/8” 3/4” 7/8” 1” 1 1/4” 1 1/2”

CLAMP SET 1240-172 1240-163 1240-160 1240-168 1240-146 1240-132

COVER PLATE 1240-174 1240-162 1240-162 1240-170 1240-148 1240-148

NUT 1240-173 1240-161 1240-161 1240-169 1240-157 1240-156*

CAPSCREW 1200-31/4C x1

1200-51/4Cx1 1/4

1200-51/4Cx1 1/4

1200-71/4Cx1 1/2

1200-131/4Cx2 1/4

1200-131/4Cx2 1/4

WHERE USED Hyd Brakes Air Brakes Air Brakes Outriggers Upper & Lower Hyd.

Upper Hydraulics

CLAMPS


GROUP



Page 30.1

30 DECALS & PLACARDS


* 656-00002 Outrigger Decal Kit .................................... 1

1 12400-955 Decal, DANGER Outrigger Extension ....... 22 652-00469 Decal, Outrigger Beam Pin........................ 23 651-00186 Decal, DANGER Outrigger........................ 4

1

11

2

3

OUTRIGGER DECALS - BT 4000


GROUP



Page 30.2


* 565-00003 JIB Decal Kit.............................................. 1

1 651-00196 Decal, Lanyard Anchor Point..................... 22 651-00203 Decal, DANGER-Remove SFJ.................. 23 651-00327 Decal, Offset JIB Warning ......................... 24 651-00332 Decal, DANGER, Falling JIB ..................... 2


5 651-00366 Decal, RH Boom Angle Indicator ...............16 651-00367 Decal, LH Boom Angle Indicator................17 651-00371 Decal, Crush Hazard..................................28 652-00131 Decal, SFJ Installation ...............................29 652-00132 Decal, 2 Stage SFG Operation ..................210 653-00394 Decal, TEREX LOGO ................................2

10

35

1

2

2

8 947

JIB DECALS - BT 4000


GROUP



Page 30.3


1 652-00111 Decal, Operating Instructions .................... 22 652-00525 Decal, Master Lube Chart ......................... 23 652-00114 Decal, Crane hand Signals........................ 24 651-00253 Decal, WARNING Replacement................ 25 651-00270 Decal, DANGER 2-BLOCKING................. 2

6 12400-303 Decal, Crane VIN.......................................17 654-00704 Quality Control Certification .......................n/a8 651-00376 Decal, Personnel Attachment ....................19 653-00229 Decal, Stability Certification .......................110 651-00269 Decal, Switch Control.................................2

Pedestal Decals

4

1

36

9

5

2

7

8

CONSOLE & PEDESTAL DECALS - BT 4000


GROUP



Page 30.4


10 650-00329 Decal, Swing-horz. Knob ...........................211 650-00411 Decal, Telescope-Horz Knob.....................212 650-00330 Decal, Boom-Horz Knob ............................213 650-00431 Decal, Front CS Outrigger Horz Knob .......214 650-00432 Decal, Front SS Outrigger Horz Knob........215 650-00433 Decal, Rear CS Outrigger Horz Knob........216 650-00434 Decal, Rear SS Outrigger Horz Knob ........217 650-00654 Decal, 2Speed Winch Control Knob ..........218 651-00270 Decal, DANGER, 2 Blocking......................219 653-00332 Decal, MADE IN USA ................................1

12171110

151413

18

16

19

CONSOLE & TURRET DECALS - BT4000


GROUP



Page 30.5


1 12400-1003 Decal, Fire Extinguisher ............................ 12 651-00184 Decal, Electocution Hazard ....................... 63 651-00185 Decal, DANGER Ride ............................... 2


4 651-00187 Decal, Electrocution Hazard ......................25 651-00195 Decal, DANGER Driveline .........................26 652-00073 Decal, HYDRAULIC OIL ONLY .................1

Flatbed/Platform Decals

Flatbed/Platform Decals

1

2

6

5

4

3

FLATBED/PLATFORM DECALS - BT 4000


GROUP



Page 33.1

33 ELECTRICAL SYSTEM


1 400-02445 Harness Assembly, Main Electrical ........... 12 400-25155 Harness Assembly, Console Electrical

(Continuos Rotation) ................................. 1400-25153 Harness Assembly, Crane Console

(370 Deg. Rotation) ................................... 13 400-25163 Harness, Tail Lights Electrical ................... 1


4 400-25084 Harness, Auxiliary Outriggers, (H-frame Aux. O/R Only)............................1

400-25137 Harness Assembly Outriggers,(A-frame Aux. O/R Only)............................1

5 400-02435 Harness, Front Bumper OutriggerElectrical (Optional)....................................1

Electrical Harnesses

1

2

3

4

5

Optional Out & Down Auxiliary Outriggers Optional Front Bumper Outriggers

ELECTRICAL HARNESSES


GROUP



Page 39.1


* 721-00242-2 Boom Assembly, 92’.................................. Ref

1 722-01309 Boom, Base Weldment.............................. 12 729-02235 Wear Pad, 1 3/4 x 6 3/4’ Long................... 183 787-00238 Shim, 0.040 x 1 3/4 x 6 3/4 As Needed4 787-00239 Shim, 0.063 x 1 3/4 x 6 3/4..........As Needed5 787-00240 Shim, 0.100 x 1 3/4 x 6 3/4..........As Needed6 780-00279 Support Block, Retract Cable 3rd ............. 27 221-06001 Nut, Hex Head, 5/8 NC GRC-PLTD .......... 28 221-06002 Nut, Hex Head Jam 5/8 - 11 NC - 2B........ 29 861-13009 Retract Cable, 3rd .................................... 410 220-02004 Bolt, Hex Head 3/8 x 1’.............................. 2611 222-12001 Washer, Lock 5/16 .................................... 3612 220-02048 Capscrew, Hex Head 3/8 x 1 1/4 GR8 ...... 8 13 220-02011 Capscrew, Hex Head 3/8 x 2 GR5 ............ 814 870-90031 Pin, 2.75 x 16.625 ..................................... 115 224-26005 Rod End 5/8 x 4’........................................ 116 220-06037 Hex Head Cap Screw ............................... 217 222-16003 Washer, lock 5/8........................................ 3


18 220-36010 Socket Head Cap Screw ...........................119 223-01202 RHMS, 1/4-20NC x 1/2 ..............................420 222-10005 Washer, Lock 1/2.......................................421 802-01572 Cover Base Boom Access .........................122 220-03004 Cap Screw, Hex Head 7/16 x 1 1/4” ..........223 729-02578 Pointer, Boom Angle Assembly .................224 222-03002 Washer, flat 7/16........................................225 221-03001 Nut, Hex 7/16.............................................226 271-18002 Bushing, Hinge Pin ....................................227 515-06004 Elbow 3/4 x 45 Deg....................................228 514-66004 Elbow Swivel 3/4 x 90 Deg. .......................229 221-18003 Nut, Hex Jam 1 1/4-7.................................230 221-18001 Nut, Hex 1 1/4-7.........................................231 729-02345 Cover Plate, Base Boom............................132 222-11002 Washer, Lock 5/16.....................................433 223-15210 Screw, 5/16 x 3/4” Self Tap........................434 729-02348 Wear Pad, 2 Hole.......................................135 223-00425 FSHM 3/8...................................................236 222-02011 Flatwasher 3/8 Hardened...........................8

BOOM ASSEMBLY92’ Base

1

2

3,4,5 2

6

7

89

1011

36 13

12

14

15

1617

1718192021

2223

24

25

2627

28

29

30

31

32

33

34

35

11


GROUP



Page 39.2


1 722-01257 2nd Stage Weldment................................. 12 780-00280 Support Block, Retract Cable, 4th ............. 13 861-13010 Retract Cable 4th ...................................... 24 729-02236 Wear Pad .................................................. 105 223-00409 FSHMS 3/8NC X 1 1/4 .............................. 286 220-07009 Hex Head Capscrew ................................. 127 222-07003 Washer, Flat .............................................. 128 220-01003 Hex Head Capscrew ................................. 89 222-01001 Washer, flat ............................................... 810 221-91002 Nut, Toplock, Hex Head ............................ 811 729-02310 Cable Guide (2nd Retract) ........................ 212 501-03001 Zerk, Grease ............................................. 513 200-10013 Retaining Ring TRUARC........................... 414 870-30208 Pin, Retract Sheave, 2nd .......................... 215 861-13009 Retract Cable 3rd ...................................... 416 860-10009 Sheave Assembly, 5/16 rope .................... 617 274-20004 Roller Bearing, Inner race ......................... 618 729-02405 Cable retainer, 3rd retract ......................... 219 222-29004 Machine Bushing, 1.25 ID x 1.875 OD ...... 1020 781-00188 Support Boss, Extension Cylinder ............. 2


21 548-00017 Extension Cylinder Assembly, 92’............. 122 031-40229 Spacer, retaining Sheave 2nd................... 223 729-02335 Anti-Shift Wear Pad .................................. 224 787-00308 Wear Pad Shim 0.040............................... 425 787-00309 Wear Pad Shim 0.063............................... 426 787-00310 Wear Pad Shim 0.100............................... 427 783-03524 Anti Shift Wear Pad Mounting Bar ............ 228 729-02235 Wear Pad, 1 3/4 x 6 3/4’ Long ................ Ref29 787-00238 Shim, 0.040 x 1 3/4 x 6 3/4 ..................... Ref30 787-00239 Shim, 0.063 x 1 3/4 x 6 3/4 ..................... Ref31 787-00240 Shim, 0.100 x 1 3/4 x 6 3/4 ..................... Ref32 221-06001 Nut, Hex Head, 5/8 NC GRC-PLTD........ Ref33 221-06002 Nut, Hex Head Jam 5/8 - 11 NC - 2B...... Ref34 220-02004 Bolt, Hex Head 3/8 x 1’ ........................... Ref35 222-12001 Washer, Lock 3/8 .................................... Ref36 220-02048 Capscrew, Hex Head 3/8 x 1 1/4 GR8.... Ref37 220-02011 Capscrew, Hex Head 3/8 x 2 GR5.......... Ref38 222-02011 Washer, Flat 3/8...................................... Ref39 221-18001 Hex Nut 7/8-14 .......................................... 640 221-18003 Hex Jam Nut 7/8-14 .................................. 6

BOOM ASSEMBLY92’ 2ND Stage

1

2

3

4

5

6

5

5

7

8

9

10

9

11

12

13

14

15

16

17

18

19

20 21

20

22

23

24,25

26

27

28

29,30,31

32

33

3435

37

36

38

29,30,31

35

39

40


GROUP



Page 39.3

BOOM ASSEMBLY92’ 3RD Stage


1 722-01145 3rd Stage Weldment, 92’ .......................... 12 729-02235 Wear Pad, 1 3/4 x 6 3/4’ Long .................Ref3 787-00238 Shim, 0.040 x 1 3/4 x 6 3/4 ......................Ref4 787-00239 Shim, 0.063 x 1 3/4 x 6 3/4 ......................Ref5 787-00240 Shim, 0.100 x 1 3/4 x 6 3/4 ......................Ref6 220-02004 Bolt, Hex Head 3/8 x 1’ ............................Ref7 222-12001 Washer, Lock 5/16 ...................................Ref8 721-00139 Extend Tube Assembly ............................. 19 222-04009 Washer Flat, Hardened............................. 1910 729-02311 Cable Guide 3rd........................................ 211 220-04038 Hex Head Capscrew ................................. 312 100-10075 Extend /Retract Cable Anchor .................. 113 870-30210 Pin, Retract Sheave 3rd............................ 214 224-23008 Rod End 3/8 ............................................. 2


15 781-00193 Boss Extension Cable Anchor 3rd.............116 220-04035 Hex Head Capscrew..................................417 861-13010 Retract Cable 4th.................................... Ref18 729-02236 Wear Pad................................................ Ref19 223-00409 FSHMS 3/8NC X 1 1/4 ........................... Ref20 861-13009 Retract Cable 3rd ................................... Ref21 860-10009 Sheave Assembly, 5/16 rope.................. Ref22 274-20004 Roller Bearing, Inner race....................... Ref23 222-01001 Washer, flat ............................................ Ref24 221-91002 Nut, Toplock, Hex Head ......................... Ref25 729-02405 Cable retainer, 3rd retract....................... Ref26 222-29004 Machine Bushing, 1.25 ID x 1.875 OD ... Ref27 548-00017 Extension Cylinder Assembly, 92’ .......... Ref

12

3,4,5

6

7

8

3,4,5

3,4,5

99

101112

13

14

1516

17

18

18

19

19

20

21

2223

23

2425

26

7

7

6

6

12

12

27


GROUP



Page 39.4


1 722-01359 4th Stage Weldment 92’ ............................ 12 787-00238 Shim, 0.040 x 1 3/4 x 6 3/4......................Ref3 787-00239 Shim, 0.063 x 1 3/4 x 6 3/4......................Ref4 787-00240 Shim, 0.100 x 1 3/4 x 6 3/4......................Ref5 729-02236 Wear Pad ................................................Ref6 224-02006 Hairpin 0.120 Dia....................................... 27 870-10199 Pin, 3/4 x 5 ................................................ 28 729-02579 Pointer Angle............................................. 29 221-92008 Nut, Lock, 3/8 Nylon Insert ........................ 210 651-00160 Decal, Jib Angle ........................................ 111 729-02663 Spacer Weld, Boom Tip sheave................ 112 860-40082 Sheave Assembly 9/16 Rope .................... 313 274-30006 Bearing, Inner Race .................................. 3


14 870-60214 Pin, Sheave Tip......................................... 215 870P30200 Pin, 1 1/4 x 5 1/4 ....................................... 116 224-04002 Hairpin 3/16............................................... 117 224-04001 Cotter Pin .................................................. 118 220-04040 Hex Head Capscrew ................................. 819 729-02323 Boom Support Bar .................................... 120 781-00271 Extend Cable Anchor 4th .......................... 121 781-00191 Boss Retract Cable Anchor 4th................. 222 223-00409 FSHMS 3/8NC X 1 1/4.............................Ref23 222-04009 Washer. Flat, Hardened.......................... Ref24 501-03001 Zerk, Grease ........................................... Ref25 200-30006 Retaining Ring .......................................... 426 222-01001 Washer, Flat............................................ Ref27 861-13010 Retract Cable 4th .................................... Ref

BOOM ASSEMBLY92’ 4TH Stage

1

2,3,4

5

6

7

8

910

1112

12

13

13

14

141516

17

18

19

20

21

22

23

23

18

24

25

25

24

2424

22

5

2,3,4

27

26

26


GROUP



Page 39.5


* 548-00017 Extension Cylinder Assembly.................... Ref

1 Pg 39.6 Extend Cylinder ......................................... 12 222-09003 Washer, Flat 1”.......................................... 23 222-19001 Washer, Lock 1” ........................................ 24 220-09011 Bolt, Hex Head 1” x 2” ............................... 25 777-00094 Bracket, Extension Sheave Weldment ...... 16 860-40081 Sheave, Extension, 5/8 Rope.................... 17 274-40009 Bearing, Inner............................................ 28 870-80006 Pin, Sheave ............................................... 19 501-03001 Zerk, Grease 1/4 - 28 ................................ 210 200-50004 Ring, Snap................................................. 211 782-01397 Spacer, Boom Ext. Sheave Bracket .......... 312 220-01029 Bolt, Hex Head 5/16” x 7 1/2” .................... 313 222-01001 Washer, Flat 5/16” ..................................... 614 729-02341 Wear Pad .................................................. 415 220-01005 Bolt, Hex Head 5/16 x 1” ........................... 816 222-11002 Washer, Lock 5/16 ................................... 817 861-17029 Cable Assembly ........................................ 218 221-91001 Nut, Hex Head, Toplock 3/8 ...................... 3

EXTENSION CYLINDER ASSEMBLY92’ Boom


* 540-80078 Extension Cylinder .................................... Ref

268-72021 Cylinder Seal Kit (Items 1 through 10)

1 Wear Ring ................................................. 22 Piston Seal ................................................ 13 Back Up Ring ............................................ 24 O-Ring ....................................................... 15 O-Ring ....................................................... 16 Back Up Ring ............................................ 17 Wear Ring ................................................. 38 U-Cup ........................................................ 19 Wiper ......................................................... 110 O-Ring ....................................................... 211 898-00173 Screw - SHS 1/4 x 3/8” .............................. 412 898-00174 Nut Ring .................................................... 113 898-00175 Piston ........................................................ 114 898-00176 Spacer Weldment...................................... 115 898-00177 Rod Weldment........................................... 116 898-00178 Case Weldment......................................... 117 898-00180 Head Gland ............................................... 118 898-00152 Valve Block................................................ 119 898-00179 Screw- SHC 1/2 x 3”.................................. 420 552-00132 Counterbalance Valve ............................... 1

059-00015 Seal Kit for Item 20

1

11

132

314

15 165,6

17

8

118

19

209

7

3,4

12

10

EXTENSION CYLINDER92’ Boom


GROUP



Page 39.#


GROUP



Page 39.7


* 721-00139 Extend Tube Assembly..............................Ref

1 422-01149 Extended Tube Weldment 92’ ...................12 860-40065 Extended Sheave Assembly......................23 274-30006 Race, Inner ................................................24 870-60201 Pin, Extended Sheave ...............................15 501-03001 Zerk, Grease..............................................26 200-30006 Ring, Snap .................................................27 782-01310 Spacer .......................................................38 220-02049 Bolt, Hex Head 3/8” x 5 1/2” ......................39 222-02005 Washer, Flat3/8 .........................................610 729-02174 Pad Spacer................................................411 220-01013 Bolt Hex Head 5/16” x 5/8” ........................812 222-11002 Washer, Lock 5/16”....................................813 861-17030 Wire Rope Assembly 5/8” ..........................214 221-92001 Nut, Toplock 3/8” .......................................3

EXTENSION TUBE ASSEMBLY92’ Boom


GROUP



Page 39.8

1


1 729-02687 Rope Guide - Rear Base Boom................. 12 729-02349 Rope Guide - 3rd Stage ............................ 13 729-02352 mid base boom rope guide........................ 14 729-02354 Bracket, Boom Tip Cable Anchor .............. 15 729-02696 2nd stage rope guide................................ 16 729-02351 rope guide, base boom - front ................... 17 222-01001 Washer, Flat 5/16 ...................................... 148 222-11002 Washer Lock 5/16 ..................................... 149 220-01013 Bolt, Hex Head, 5/16 x 5/8 ........................ 14

5 2

4

3

CABLE GUIDE INSTALLATION92’ Boom

67,8,9


GROUP



Page 39.9


1 Page 39.9 Assembly, Topping Cylinder .....................12 224-26005 Rod End, 5/8Dia x 4 Long..........................33 222-16003 Washer, Lock, 5/8 Med. LTD .....................34 220-36010 Bolt, SH, 5/8-11NC x 3/4-A574, PLTD.......65 220-06037 Bolt, Hex Head, 5/8NC x 1 1/2GR5 PLT....36 870-70068 Pin, 2 1/4 Dia. x 20 ...................................27 870-70069 Pin, 2 1/4 Dia. x 9 3/4 ................................1

1

4

62,3,5

7

2,3,4

4

2,3,4

6

4

BOOM INSTALLATION


GROUP



Page 39.10


548-00054-3 Topping Cylinder Assembly

1 Page 39.10 Topping Cylinder ....................................... 12 514-56005 Elbow, 90 Deg Long #10........................... 2*3 514-52005 Elbow, 90 Deg #4...................................... 1

* Item Hidden from View

TOPPING CYLINDER ASSEMBLY

1

3

2


GROUP



Page 39.11

540-90087


* 540-90087 Topping Cylinder, Boom ............................Ref

* 268-90159 Seal Kit, Topping Cylinder .........................1(Includes Items 16 Through 27)

1 346-00742 Case, Weldment ........................................12 346-00740 Rod, Weldment ..........................................13 346-00739 Ring, Thread ..............................................14 346-00738 Gland, Head...............................................15 346-00737 Piston.........................................................16 346-00732 Spacer, Bushing ........................................17 346-00743 Nut, ring .....................................................18 552-00102 Counterbalance Valve ...............................19 346-00699 Valve..........................................................110 271-18002 Bushing......................................................411 346-00735 Screw, Cap ................................................112 346-00736 Washer, Lock.............................................213 346-00703 Plug, Port ...................................................114 346-00704 Plug, Port ...................................................115* O-Ring .......................................................116* O-Ring .......................................................217* Plug, Nylon ................................................118* Ring, Back-Up............................................119* O-Ring .......................................................120* Seal, Teflon................................................121* Ring, Wear.................................................222* O-Ring .......................................................123* Ring, Wear.................................................124* U-Cup ........................................................125* Ring, Back-Up............................................126* Wiper, D Type............................................1

**SEAL KIT #059-00012 (For CB Valve)

TOPPING CYLINDER

8

9

15

14

21

2021

2

1

16

13

12

11

6

26

3174

1819

22

5

7

10

23 24 25


GROUP


39ADATE: Revised 03-2006


Page 39A.1

39A 2 STAGE SIDE FOLDING JIB 26/44FT

SFJ ASSEMBLY, 2 STAGE, 26/44Ft. BT4792


730-50185 SFJ Assembly, 2 Stage............................. 1

1 730-51273 Weldment, Base Jib .................................. 12 730-51269 Weldment, 2nd Stage Jib .......................... 13 770-01987 Weldment, Jib Tip...................................... 14 860-70005 Sheave, 9/16 Rope Assembly ................... 15 274-30004 Bearing, Inner Race .................................. 16 870-50058 Pin, sheave................................................ 11


7 501-03001 Zerk, Grease, 1/4-28UNF ..........................18 200-30001 Ring, Retaining ..........................................29 220-02048 Screw, Hex Head C 3/8NC x 1 1/4" Long ..-10 221-92001 Nut, Hex, 3/8 Toplock PLTD ......................611 222-02011 Washer, flat, 3/8.........................................1212 729-02170 Wear Pad...................................................213 729-02341 Wear Pad 1 1/2 x 3 1/2 ..............................914 787-00241 Shim, .040..................................................1015 787-00242 Shim, .063..................................................1016 787-00243 Shim, .100..................................................2

2 Stage JIB Assembly

SFJ JIB ASSEMBLY 2 STAGE


GROUP



Page 39A.2


17 783-02908 Support Bar, Jib......................................... 118 870-00136 Pin 2 ......................................................... 119 870-20236 Pin 1 .......................................................... 120 200-10002 Ring, Snap................................................. 221 870-20237 Pin 3 .......................................................... 122 224-19006 Pin, Roll 1/4 x 2 1/4 ................................... 123 224-16003 Pin, Roll 1/2 x 4 ......................................... 124 224-04002 Pin, Cotter 3/16 ......................................... 1


25 223-00304 FSHMS 5/16NC x 5/8 PLTD ......................126 222-11002 Washer, Lock 5/16 PLTD...........................1827 220-01013 Screw, Hex Head 5/16NC x 5/8 ................1028 220-01003 Screw, Hex Head 5/16NC x 1 1/4 .............829 224-02006 Hairpin, .120...............................................230 870-10174 Pin, Clevis ..................................................131 224-04006 Pin, Cotter ..................................................232 - 39 NOT USED40 220-02051 Capscrew...................................................6

2 Stage JIB Assembly 92’

SFJ JIB ASSEMBLY 2 STAGE


GROUP



Page 39A.3


730-50272 JIB INSTALLATION Kit, ........................... 1(Includes Items 1 Through 58)

1 770-01738 Bracket, Cable Guide ................................ 22 870-40186 Pin, 1 1/2Dia.............................................. 43 220-06038 Screw, Hex Head Cap 5/8NC x 1 1/4" ..... 124 222-16003 Washer, Lock 5/8 PLTD ............................ 125 222-06006 Washer, Flat 5/8 PLTD.............................. 126 770-01736 Bracket, Jib Stow Boom Tip ...................... 17 770-02321 Bracket, Jib Stow....................................... 18 770-02322 Bracket, Jib Stow Ramp............................ 19 224-04002 Hairpin, .178 .............................................. 410 770-01822 Bracket, Jib Stop ....................................... 111 222-12001 Washer, Lock 3/8 PLTD ............................ 812 220-02004 Screw, Hex Head Cap 3/8NC x 1" Long ... 413 400-23339 Receptacle, 6-Pin Panel Mount................. 114 774-00054 Bracket, ATB Switch Adapter .................... 1


15 222-11002 Washer, Lock 5/16 PLTD...........................816 220-31004 Screw, SH Cap, 5/16NC x 1 1/4" Long ......217 787-00226 Shim, .040..................................................218 787-00227 Shim, .063..................................................219 787-00228 Shim, .100..................................................220 870-00152 Pin Assembly, Hitch, 7/8" Dia. x 8" Long ...121 220-02045 Screw, Hex Head Cap 3/8NC x 7/8" Long .422 659-00354 Placard, Striping.........................................18’23* Placard, TEREX STINGER Logo...............224 990-50024 Side Folding Jib, Erect & Store Procedure 125 651-00280 Placard, Person Lift Attach ........................226 651-00196 Placard, DANGER LANYARD ANCHOR...227 652-00131 Placard, SFJ Installation ............................228 870-20256 Pin, Jib Ramp 1 Dia. ..................................1

Side Folding JIB Installation

SFJ JIB INSTALLATION


GROUP



Page 39A.4


29 200-10011 Snap Ring.................................................. 230 400-23244 Female Insert, 6-Pin .................................. 131 652-00132 Placard, 2nd Stage Operation ................... 232 400-25085 Cable Assembly, ATB Jib.......................... 133 222-00006 Washer, Flat 1/4 PLTD.............................. 934 223-01121 Screw, RHM Slotted #10NC x 3/4" Long... 835 222-10006 Washer, Lock #10 PLTD ........................... 836 201-00171 Clamp, 1/8 Dia. x .281 Hole ...................... 937 223-15219 Screw, ST 1/4 x 1/2 Long .......................... 938 808-00047 Knob, Hand ............................................... 239 220-31007 Screw, SH Cap, 5/16NC x 5/8" Long ........ 240 202-10066 Spring, Cable Tensioning .......................... 141 NOT USED42 NOT USED43 NOT USED


44 729-02611 Bracket, Jib Stow Wear Pad ......................145 221-01001 Nut, Hex, 5/16............................................446 223-00308 Screw, FSHM5/16NC x 1 1/2" Long ..........447* Placard, TEREX, Logo...............................248 651-00327 Placard, Jib Warning..................................249 651-00332 Placard, Danger, Falling Jib.......................150 220-04005 Screw, Hex Head Cap 1/2NC x 1 1/2" Long251 221-04001 Nut, Hex 1/2NC..........................................252 651-00203 Placard, Danger Side Folding Jib ..............153 651-00159 Placard Jib Angle L/H ................................154 651-00160 Placard, Jib Angle R/H...............................155 NOT USED56 222-01001 Washer, Flat 3/8 PLTD ..............................457 221-92008 Nut, Lock 3/8NC Nylon Insert ....................458 729-02579 Pointer, Angle ............................................2

JIB Installation

SFJ JIB INSTALLATION


GROUP


39BDATE: Revised 03-2006


Page 39B.5

39B 1 STAGE SIDE FOLDING JIB 26FT

SFJ ASSEMBLY, 1 STAGE, 26Ft. BT4792


730-50184 SFJ Assembly, 1 Stage............................. 1See “SFJ JIB INSTALLATION” on page39A.3.

1 730-51273 Weldment, Base Jib .................................. 12 770-01987 Weldment, Jib Tip...................................... 13 860-70005 Sheave, 9/16 Rope Assembly ................... 14 274-30004 Bearing, Inner Race .................................. 15 870-50058 Pin, sheave................................................ 11


6 501-03001 Zerk, Grease, 1/4-28UNF ..........................17 200-30001 Ring, Retaining ..........................................28 220-02048 Screw, Hex Head C 3/8NC x 1 1/4" Long ..-9 222-02011 Washer, flat, 3/8.........................................610 224-02006 Hairpin,.120................................................111 870-10174 Pin, Clevis ..................................................112 221-92001 Nut, Hex, 3/8 Toplock PLTD ......................-13 NOT USED14 220-02060 Capscrew, 3/8NC x 1 1/8 ...........................14

Single Stage JIB Assembly

SINGLE STAGE JIB ASSEMBLY


GROUP



Page 40.1

40 HYDRAULIC WINCH


1 293-00037 Assembly, Winch - Braden ........................ 12 514-59021 Elbow, 90 Deg. .......................................... 13 513-90032 Connector.................................................. 14 NOT USED5 NOT USED6 220-07051 Bolt, 3/4NC x 2 3/4" Long.......................... 4


7 221-97002 Nut, 3/4UNC...............................................48 222-07003 Washer, Flat 3/4.........................................89 519-70032 Cap, 3/4”, #12FNL-S..................................210 502-40908 Hose Assembly, Winch..............................211 518-60007 Bulk Head Union, FF2700-LN-12...............212 058-00581 Cable Drum................................................1

Winch Installation

WINCH INSTALLATION


GROUP




Page 40.2

See page 40.3.

WINCH ASSEMBLY


GROUP



Page 40.3


293-00037 Winch

1 1058-00632 Brake Cylinder........................................... 12 058-00429 Seal ........................................................... 13 058-00430 Pressure Plate........................................... 14 058-00432 Backup Ring .............................................. 15 058-00431 Spring ........................................................ 126 058-00634 Disc, Friction.............................................. 77 058-00629 Disc, Steel ................................................. 810 058-00584 Primary Planet Carrier............................... 111 058-00585 Primary Planet Gear.................................. 312 058-00396 Primary Planet Gear Shift.......................... 313 058-00397 Bearing, Roller........................................... 314 058-00398 Washer, Thrust.......................................... 615 058-00399 Spirol Pin, Primary Planet Carrier ............. 315 085-00627 Spirol Pin Output Planet Carrier ................ 316 058-00402 Output Planet Carrier ................................ 117 058-00403 Output Planet Gear ................................... 318 058-00404 Output Planet Gear Shift ........................... 319 058-00405 Bearing, Roller........................................... 620 058-00406 Bearing, Spacer......................................... 321 058-00407 Washer, Thrust.......................................... 122 058-00579 Base .......................................................... 123 058-00636 Bearing Support ........................................ 124 058-00581 Cable Drum ............................................... 125 058-00582 Cable Drum Closure.................................. 126 058-00413 Bearing, Ball .............................................. 227 058-00420 Seal ........................................................... 128 058-00421 O-Ring Flush Plug ..................................... 129 058-00487 Seal ........................................................... 130 058-00423 Retaining ring ............................................ 131 058-00610 Washer, thrust ........................................... 1


32 058-00637 Motor Support ............................................133 058-00540 O-Ring........................................................134 058-00415 Output Sun Gear........................................135 058-00416 Primary Sun Gear ......................................136 058-00433 Spacer .................................................137 058-00400 Primary Thrust Plate ..................................138 058-00408 Output Thrust Plate....................................139 058-00444 Spacer, Bar ................................................240 058-00568 Capscrew..............................................1441 058-00034 Washer, Lock.............................................2242 058-00565 Capscrew...................................................443 058-00611 Washer, Lock.............................................144 058-00595 O-Ring Flush Plug......................................145 058-00426 O-Ring, Flush Plug.....................................146 058-00608 Plug, Vent ..................................................147 058-00434 O-Ring........................................................148 058-00435 Backup Ring...............................................1

058-00597 Brake Clutch Assembly (Items 49 thru 55).......................................1

49 Outer Brake Race ......................................150 Inner Brake Race.......................................151 058-00609 Sprag Bearing............................................252 058-00389 Washer, Thrust ..........................................253 058-00390 Retaining Ring ...........................................254 Sprag, Clutch .............................................155 058-00391 Retaining Ring ...........................................157 058-00639 Cable, Wedge ............................................179 058-00598 Side Plate, Support End.............................180 058-00599 Side Plate, Motor End................................182 058-00440 Capscrew...................................................899 058-00643 Spring, Cover .............................................1

See page 40.2.

WINCH ASSEMBLY


GROUP



Page 40.4


24 058-00581 Cable Drum ............................................... 125 058-00582 Cable Drum Closure.................................. 126 058-00413 Bearing, Ball .............................................. 227 058-00420 Seal ........................................................... 128 058-00421 O-Ring Flush Plug ..................................... 129 058-00487 Seal ........................................................... 130 058-00423 Retaining ring ............................................ 131 058-00610 Washer, thrust ........................................... 132 058-00637 Motor Support............................................ 133 058-00540 O-Ring ....................................................... 134 058-00415 Output Sun Gear ....................................... 135 058-00416 Primary Sun Gear...................................... 136 058-00433 Spacer ....................................................... 137 058-00400 Primary Thrust Plate.................................. 138 058-00408 Output Thrust Plate ................................... 139 058-00444 Spacer, Bar ............................................... 240 058-00568 Capscrew .................................................. 1441 058-00034 Washer, Lock ............................................ 2242 058-00565 Capscrew .................................................. 443 058-00611 Washer, Lock ............................................ 144 058-00595 O-Ring Flush Plug ..................................... 145 058-00426 O-Ring, Flush Plug .................................... 146 058-00608 Plug, Vent.................................................. 147 058-00434 O-Ring ....................................................... 148 058-00435 Backup Ring .............................................. 1

058-00597 Brake Clutch Assembly (Items 49 thru 55) ...................................... 1

49 Outer Brake Race...................................... 1


50 Inner Brake Race.......................................151 058-00609 Sprag Bearing............................................252 058-00389 Washer, Thrust ..........................................253 058-00390 Retaining Ring ...........................................254 Sprag, Clutch .............................................155 058-00391 Retaining Ring ...........................................156 NOT USED57 058-00639 Cable, Wedge ............................................158 058-00586 Manifold .....................................................159-62 NOT USED63 058-00644 Tube (Brake Valve To Manifold) ................165 058-00085 Brake Valve Assembly ...............................166 058-00646 Tee.............................................................167 058-00591 Adapter, 90 Deg.........................................168 058-00593 Adapter, 90 Deg.........................................170 058-00647 Capscrew...................................................471 058-00589 Tube, (Manifold to Brake Release) ............172 058-00109 Hydraulic Motor..........................................173 058-00590 Adapter, Straight ........................................174 058-00586 O-Ring........................................................175 058-00547 Capscrew...................................................479 058-00598 Side Plate, Support End.............................180 058-00599 Side Plate, Motor End................................182 058-00440 Capscrew...................................................883 058-00546 O-Ring........................................................284 058-00607 Washer, Lock.............................................885* 058-00712 Back Cover ................................................199 058-00643 Spring, Cover .............................................1100 Housing......................................................1

Brake Valve Assembly

WINCH ASSEMBLY


GROUP



Page 40.5


1 Housing ................................................. 12 058-00660 Valve Spring Shim................................. AR3 058-00649 Spring, Retainer .................................... 14 058-00655 O-Ring ................................................... 15 058-00654 Spool, Spring......................................... 16 Damper Piston....................................... 17 058-00657 O-Ring ................................................... 18 058-00659 Backup Ring .......................................... 19 058-00656 O-Ring ................................................... 110 058-00658 Backup Ring .......................................... 111 Spool ..................................................... 112 058-00650 Plug, (With O-Ring ................................ 113 058-00651 O-Ring ................................................... 114 058-00653 Check Valve Spring............................... 115 058-00648 Spring, Retainer .................................... 1


16 Check Valve Poppet ..............................117 058-00586 O-Ring....................................................118 058-00085 Brake Valve Assembly ...........................119 058-00647 Capscrew...............................................420 058-00593 Adapter, 90 Deg.....................................121 058-00644 Tube (Brake Valve To Manifold) ............122 058-00576 Capscrew...............................................4

058-00034 Washer, Lock.........................................423 058-00590 Adapter, Straight ....................................124 058-00591 Adapter, 90 Deg.....................................125 058-00589 Tube, (Manifold to Brake Release) ........126 058-00646 Tee.........................................................127 058-00586 Manifold .................................................128 058-00547 Capscrew...............................................429 058-00546 O-Ring....................................................230 Page 40.1 Hydraulic Motor......................................1

Brake Valve Assembly

123

4

5

67

8

91011

12 13 14 15 16

1718

19

20

21 22 23 24

25

26

27

28

29

30

WINCH ASSEMBLY


GROUP



Page 40.6


717-00021 Tensioner, WInch

1 802-01562 Cover, Winch........................................ 12 901-00189 Tensioner, Cable Asm .......................... 13 Bearing, Sleeve.................................... 24 Arm - Cable Packer.............................. 1


5 Roller, Cable Packer - Outer.................26 Roller, Cable Packer .............................17 Capscrew..............................................28 Flange, Ball Bearing .............................29 Spring, Cable Packer............................110 Spring, Cable Packer - LH....................1

Winch Tensioner

WINCH TENSIONER


GROUP




Page 45.1

45 Wire Rope, Pendants, Reeving


1 861-60090 Ball and Hook, Swivel, 7 Ton .................... 1* 861-90367 Ball and Hook, Non-Swivel 7 Ton.............. 12 861-60024 Load Block, 17 Ton 3 Part Line ................. 1

861-60025 Load Block, 22 Ton 3, 4, and 5 Part Line .. 1861-60033 Load Block, 17.5 Ton 4 Part Line .............. 1861-60029 Load Block, 17.5 Ton 2, 3 Part Line .......... 1861-60028 Load Block, 22.5 Ton 4 and 5 Part Line .... 1

3 861-90296 Wedge and Socket 9/16 ............................ 1


4 861-90059 Clamp.........................................................15 205-00033 Weight and Chain Anti-2Block ...................16 870-30200 Pin, 1 1/4 x 5 1/4" Long..............................17 224-04002 Hairpin........................................................18 224-04001 Pin, Cotter ..................................................19 861-16085 Wire rope, Spin Resistant, 9/16 x 315’.......1

861-16089 Wire Rope, 6 x 25 IWRC, 9/16 x 315’ ........110 735-00001 Sheave, Auxiliary .......................................1

*USE WITH 861-16089

Wire, Rope, Reeving

WIRE, ROPE, REEVING


GROUP



Page 51.1

51 OPTIONAL EQUIPMENT


1 600-32312 Tool Box, 36 x 18 x 19............................... 12 221-02001 Nut Hex Head 3/8NC................................. 83 222-02008 Washer, Flat 3/8 PLTD.............................. 8


4 222-12001 Washer, Lock 3/8 PLTD.............................85 770-02206 Utility Box Stud Bar ....................................26 783-03386 Utility Box, Back-Up ...................................27 220-02048 Bolt, HH 3/8 NC 1 1/2 ................................8

Tool Box Installation

2

43

1

6

7

5

5

6

TOOL BOX INSTALLATION


GROUP



Page 51.2


1 400-05505 Cooler, Oil ..................................................12 400-05506 Switch, Thermal, 160 Deg..........................13 400-05203 Switch, Boot ...............................................14 502-50316 Hose Assembly, Cooler Supply .................15 502-50317 Hose Assembly ..........................................16 782-01269 Support, Oil Cooler ....................................27 785-01481 Angle, Cooler Support................................18 517-90006 Adapter, 16 FOR x 1 MPT .........................29 514-59021 Elbow, 90 Deg. 16 OFS .............................110 516-89013 Tee, special run .........................................111 517-00045 Adapter, 6 FP x 10 ORB ............................112 220-01005 Screw, Cap, 5/16-18 x 1" Long ..................113 222-11002 Washer, Lock 5/16 .....................................414 221-01001 Nut, Hex 5/16-18........................................415 220-02004 Screw, Cap, 3/8-16 x 1" Long ....................416 222-12001 Washer, Lock 3/8 .......................................617 221-02001 Nut, Hex 3/8-16..........................................618 400-10011 Circuit Breaker 20 Amp..............................1

Oil Cooler Installation

Main Electrical Box

OIL COOLER INSTALLATION


GROUP



Page 51.3


19 400-15086 Wrap Tie, 7 7/16........................................ 1020 400-02337 Ring, Terminal 10-15/14 GA...................... 421 400-01569 Wire, Flame Retardant, White 14 Ga. ....... 10’22 400-01537 Wire, Flame Retardant, Red 14 Ga........... 10’23 400-01477 Buss Bar, 2 Gang...................................... 1


24 400-01411 Loom, 1/4 Split ...........................................35’25 400-05508 Strain Relief, 1/2" Hub ...............................126 400-02343 Connector, Butt 14/16 HS..........................227 400-15054 Nut, Hub, 1/2" ............................................1

Oil Cooler Installation

OIL COOLER INSTALLATION


GROUP



Page 51.4


* 730-20413 1 Person Steel Platform Assembly............ Ref

1 730-20413 Platform, 1 Person Steel Weldment .......... 12 730-20114 Brake, Disc Sub-Assembly........................ 13 770-00995 Brake Bracket............................................ 14 730-20009 Brake, Gravity Handle ............................... 15 222-01003 Washer, Flat .............................................. 16 730-20013 Brake, Disc ................................................ 17 730-20064 Brake, Disc Weldment............................... 18 870-60206 Pin, 2 x 1/2X x 21 1/16" Long.................... 19 870-00131 Pin, Hitch Assembly .................................. 110 224-19004 Pin, Roll, 1/2 x 3" Long.............................. 211 220-02004 Bolt, Hex Head3/8 x 1" Long ..................... 212 222-12001 Washer, Lock 3/8 ...................................... 2


* 651-00355 Placard Kit..................................................113* 651-00202 Placard, Attachment Instructions ...............114* 651-00060 Operating ...................................................115* 651-00191 Placard, Operator Training.........................116* 651-00187 Placard, Electrocution Hazard ...................117* 651-00203 Placard, Side Folding Jib Work Platform ...118* 651-00335 Placard, Falling From Platform ..................119* 652-00496 Placard, Crane Hand Signals.....................120* 654-00594 Placard, Basket Identification.....................121** 209-00434 Lanyard, Aerial Shock Absorber ................122** 209-00809 Harness, Safety .........................................123** 666-10001 Flag, ATB Bypass ......................................1

*ITEM NOT SHOWN**ITEM INCLUDED IN 731-20001

1 Person Steel Platform Assembly

1 PERSON STEEL PLATFORM ASSEMBLY


GROUP



Page 51.5


* 730-20408 2 Person Steel Assembly .......................... Ref

1 730-20410 2 Person Steel Platform Weldment ........... 12 559-00055 Brake, Hydraulic ........................................ 13 559-00056 Pump, Hand .............................................. 14 771-00128 Bracket, Hand Pump ................................. 25 600-40280 Gauge........................................................ 16 730-20338 Disc, Weldment ......................................... 17 222-29011 Bushing, 3 x 2 - 14 Ga............................... 48 870-60222 Pin, Pivot RH............................................. 19 870-00149 Pin, Disc Locking Assembly ...................... 110 870-60220 Pin, Pivot LH.............................................. 111 870-00131 Pin, Bucket Assembly................................ 312 513-20002 Connector, Straight ................................... 2


13 510-20447 Tube Assembly, Brake Pump ....................114 510-20448 Tube Assembly, Brake Pump ....................115 514-62001 Elbow, 90 Deg............................................116 513-20001 Connector, Straight ....................................117 513-20006 Connector, Straight ....................................118 730-20409 Door, Swing Away Weldment ....................119 870-80013 Pin, Latch...................................................220 224-19017 Pin, Roll 1/2 x 1 1/4" Long .........................221 501-03001 Grease Fitting, Straight ..............................222 220-04011 Bolt, 1/2 x 4" Long......................................223 220-00005 Bolt, 1/4 x 2 1/2" Long................................4





GROUP



Page 51.6

RREF PART NO. DESCRIPTION QTY

24 222-10005 Washer, Lock 1/4 ...................................... 425 222-14003 Washer, Lock 1/2 ...................................... 226 221-04001 Nut, Hex, 1/2 ............................................. 227 221-00001 Nut, Hex, 1/4 ............................................. 228 224-12009 Pin, Roll, 1/8 x 1" Long.............................. 229 222-04011 Washer, Flat, 1/2ID x 1/16OD ................... 130 202-10077 Spring, Compression................................. 131 220-04025 Screw, Hex Head, 1/2NC x 3 1/2" Long .... 232 221-94002 Nut, 1/2NC PLT......................................... 233 808-00031 Knob, Push-Pull......................................... 1* 651-00355 Placard Kit ................................................. 1


34* 651-00202 Placard, Attachment Instructions ...............135* 651-00060 Operating ...................................................136* 651-00191 Placard, Operator Training.........................137* 651-00187 Placard, Electrocution Hazard ...................138* 651-00203 Placard, Side Folding Jib Work Platform ...139* 651-00335 Placard, Falling From Platform ..................140* 652-00496 Placard, Crane Hand Signals.....................141* 654-00594 Placard, Basket Identification.....................142** 209-00434 Lanyard, Aerial Shock Absorber ................143** 209-00809 Harness, Safety .........................................144** 666-10001 Flag, ATB Bypass ......................................1





GROUP



Page 51.7


* 730-20299 Self-Leveling Platform Assembly............... Ref

1 730-20222 Platform, 36 x 72 Weldment ...................... 12 730-20205 Pylon Weldment ........................................ 13 770-01541 Mount, Lower Weldment ........................... 14 271-14016 Bushing ..................................................... 15 222-50066 Washer, Retainer ...................................... 26 773-00014 Mount, Rotation Weldment, SLP............... 17 730-20407 Spacer, Rotation........................................ 18 280-00513 Gearbox, Rotator....................................... 19 271-13006 Bushing ..................................................... 210 204-00030 Key, Square 3/8 x 2 1/2............................. 111 031-00034 Tube, 7/16 x 1 1/2" Long ........................... 212 222-12001 Washer, Lock Med. 3/8 ............................. 613 220-02004 Bolt, Hex Head, 3/8 x 1" Long ................... 1414 222-02011 Washer, Flat, 3/8 Hardened ...................... 815 220-04007 Bolt, Hex Head 1/2 x 1 3/4" Long PLTD.... 1016 221-90001 Nut, Toplock, 1/4 PLTD............................. 2117 221-94006 Nut, Toplock, 1/2 PLTD............................. 1318 222-04001 Washer, Flat Med. 1/2 ............................... 1419 807-00035 Crank, Rotator Assembly .......................... 120 225-00011 Setscrew, 1/4 x 3/8" Long ......................... 1


21 730-20233 Gate, Gravity Weldment.............................122 220-00011 Bolt, Hex Head 1/4 x 2 1/4" Long...............223 201-00141 Clamp, tube................................................124 773-00019 Bracket, Lifting ...........................................125 730-20297 Bracket, Mounting SLP Weldment .............126 501-04150 Quick Disconnect, Nipple...........................227 501-04151 Quick disconnect, Dust Cap.......................228 222-00006 Washer, Flat, Med. 1/4...............................1729 400-00449 Leveler, PQ Modification............................130 770-01680 Cover, Leveler Weldment ..........................131 770-01681 Bracket, Auto Leveler.................................132 221-00001 Nut, Hex 1/4 PLTD.....................................233 540-30135 Cylinder, SLP.............................................134 400-15169 Heat Shrink Tube, 1"...................................5’35 870-30204 Pin, 1 1/4 x 10" Long..................................236 870-20217 Pin, 1 x 5 3/16" Long..................................137 224-18003 Pin, Roll, 3/8 x 2" Long ..............................238 224-25005 Pin, Rod End..............................................239 870-40186 Pin. Jib 1 1/2 Dia........................................440 224-04002 Pin, Cotter 3/16..........................................4

Self Leveling Platform Installation

SELF LEVELING PLATFORM INSTALLATION


GROUP



Page 51.8


41 220-00001 Bolt, Hex Head 1/4 x 1’ Long PLTD .......... 1142 729-02579 Pointer, Angle Assembly ........................... 243 220-03004 Bolt, 7/16 x 1 1/4" Long PLTD................... 244 221-03001 Nut, Hex, 7/16 PLTD ................................. 245 502-11016 Hose Assembly, SLP Tilt........................... 246 513-20002 Connector 1/4............................................ 247 514-52001 Elbow, 90 Deg. .......................................... 248 514-62001 Elbow, 90 Deg. .......................................... 149 510-20356 Tube Assembly, 10 3/4.............................. 150* 653-00273 Placard, Indicator, Boom angle, LH........... 151* 653-00272 Placard, Indicator, Boom Angle, RH.......... 152* 651-00060 Placard, Caution........................................ 153* 651-00196 Placard, Danger, Lanyard Anchor ............. 154* 651-00191 Placard, Danger Operator Trunnion .......... 155* 651-00242 Placard, Electrocution Hazard................... 156* 650-00663 Placard, Operating Instructions ................. 157* 651-00234 Placard, Caution, Center Platform............. 1


58* 651-00235 Placard, 2 Person SLP...............................159* 651-00203 Placard, Danger, Remove SFJ ..................260* 651-00335 Placard, Falling From Platform ..................161* 652-00496 Placard, Crane Hand Signals.....................162 110-85200 Manual Storage box...................................163 789-04931 Manual Storage Box, Mounting Plate ........164 223-04004 Screw, Machine, RND HD, 10-32 x 3/4 .....465 221-90003 Nut, Locking 10-32.....................................466 220-00007 Bolt, Hex Head 1/4 x 2 ...............................867* 653-00320 Placard, Platform Certification ...................168 222-09040 Washer, Flat 1 1/2 ID x 2 3/4 OD...............169 220-01003 Bolt, Hex Head 5/16NC x 1 1/4" Long .......270 222-01001 Washer, Flat 5/16.......................................471 221-91001 Nut, Lock 5/16NC.......................................272 783-03609 Bar, Tilt Stop ..............................................173 787-00300 Shim, .040..................................................AR74* 209-00434 Lanyard, Aerial Harness ............................275* 209-00809 Harness, Safety Body ................................2

*ITEM NOT SHOWN

SELF LEVELING PLATFORM INSTALLATION


GROUP



Page 51.9


* 400-05503 NBB Remote Relay Box ............................ Ref

1 400-05509 Enclosure, 10 x 8 x 4................................. 12 400-05510 Base, Relay ............................................... 83 400-05511 Relay, SPDT.............................................. 84 400-10092 Circuit Breaker, 30Amp. ............................ 15 400-02446 Terminal 1/4 Spade Locking...................... 346 400-03072 Terminal Block........................................... 187 400-05512 Partion Plate.............................................. 18 400-03073 Ground Block............................................. 39 400-05513 End Cover ................................................. 110 400-05514 End Bracket............................................... 211 400-03074 Din Rail 35mm........................................... 0.312 400-05515 Jumper, 2 Position..................................... 513 400-23461 Connector, 6 Position Tower ..................... 114 400-23460 Connector, 6 Position Shroud ................... 115 400-23529 Connector, 4 Position Tower ..................... 116 400-23530 Connector, 3 Position Tower ..................... 117 400-23406 Connector, 3 Position Shroud ................... 3


18 400-23336 Connector, 2 Position Tower......................119 400-23531 Seal............................................................3020 400-23407 Sockets ......................................................1321 400-23408 Pins, Male ..................................................1522 400-23308 Cavity Plug.................................................223 400-15572 Cord, Grip ..................................................124 400-15573 Cord Grip ...................................................125 400-15574 Cord, Grip ..................................................626 NOT USED27 NOT USED28 400-02447 Cable, 14/3.................................................20’29 400-02448 Cable, 14/5.................................................6’30 400-02449 Cable, 14/9.................................................8’31 400-02450 Cable, 12/4.................................................3’32 400-02451 Cable,10/3..................................................20’33 Wire, 14 AWG Black GXL..........................334 400-02452 Ring, Terminal #10.....................................235 400-05516 Jumper, 5 Position .....................................136 400-05517 End cover...................................................1

NBB REMOTE RELAY BOX


GROUP



Page 51.10


1 403-00008 Kit, NBB Radio Remotes With SLP........... 1(Includes Items 1A through 1K)

1A Hose Kit, Pressure and Return.................. 11B 402-00036 Box, Receiver With SLP............................ 11C 403-00001 Antenna Assembly With Cable.................. 11D 403-00009 Transmitter, With SLP ............................... 11E 520-90026 Powerpak Assembly Pump/Motor/Tank .... 11F 559-00243 Actuator, Servo 4 Function........................ 11G 775-00189 Bracket, Receiver Mounting ...................... 11H 806-00255 Kit, Clevis/Linkage Rod ............................. 11I 400-25134 Harness Assembly, Receiver Power in ..... 11J 403-00004 Battery, 7.2 Vdc Rechargeable ................. 21K 403-00007 Battery, 12-24 Vdc Charger....................... 1


2 210-00080 Kit, Electrical, NBB Remote .......................1(Includes Items 3 Through 9)

3 400-05503 Electric Box Assembly, Relay ....................14 400-25156 Harness, SW NBB Remote........................15 400-25157 Harness, SLP Solenoid..............................16 400-25131 Harness, Throttle Motor/Relays .................17 400-23460 Connector ..................................................18 400-23408 Male terminal .............................................69 400-23462 Cable Seal .................................................610 NOT USED11 400-23378 Dust Cap....................................................112 400-23463 Dust Cap Plug............................................113 205-00005 Chain, #16 Jack Type ................................514 400-23412 Receptacle .................................................1

Radio Remote Control Installation

RADIO REMOTE CONTROL INSTALLATION


GROUP



Page 51.11


15 400-23349 Plug, Deutsche ......................................... 116 400-23343 Pin, ............................................................ 617 400-23295 Socket ....................................................... 418 400-23355 Sealing Plug .............................................. 219 400-23351 Strain Relief............................................... 220 NOT USED21 NOT USED22 NOT USED23 400-05496 Reel Assembly Conductor cable ............... 124 400-00449 Switch, Lever PQ W/Pigtail ....................... 125 400-10045 Remote Throttle Install Group ................... 125a 400-11027 Motor, Remote Throttle ............................. 126 551-10065 Solenoid Valve, SLP Tilt............................ 127 NOT USED28 400-15086 Tyrap 3/16 x 7” Long ................................. 229 400-02221 Ring Eyelet, ............................................... 430 NOT USED31 NOT USED


32 NOT USED33 NOT USED34 NOT USED35 222-00006 Washer, Flat...............................................1636 222-10005 Washer, Lock.............................................637 221-00001 Nut, Hex 1/4-20NC PLT.............................638 559-00130 Valve, Flow Control, SLP...........................139 220-02005 HHCS 3/8-16NC x 2 1/2” Long ..................240 222-05005 Washer, Flat 3/8 PLT.................................1041 222-12001 Washer, Flat 3/8 Med PLT.........................3442 221-02001 Nut, Hex 3/8-16NC PLT.............................443 220-00004 HHCS 1/4-20NC x 1 1/4” Long ..................444 220-01006 HHCS 5/16 x 1 1/2” Long...........................245 222-01001 Washer, flat 5/16 PLT ................................3246 222-11002 Washer, Lock 5/16 .....................................2647 221-01001 Nut, Hex 5/1648 220-50603 HHCS.........................................................649 775-00191 Angle, LH Servo Mounting.........................150 775-00190 Angle, RH Servo mounting ........................1

Radio Remote Control Installation



GROUP



Page 51.12


51 220-01005 HHCS 5/16-18 x 1” Long ........................... 652 789-05245 Mounting Bracket, Powerpak .................... 153 223-01101 Screw, Rd. Head, #10-24 x 3/4 PLTD....... 154 222-00007 Washer, Flat .............................................. 255 222-10006 Washer, Lock #10 ..................................... 256 221-00002 Nut, Hex #10 ............................................. 257 514-52005 Elbow, 90 Deg. .......................................... 358 502-11017 Hose, SLP Solenoid Valve/Boom Reel ..... 259 502-11000 Hose, 1/4 x 72” Long................................. 260 516-82003 SW Nut Run Tee ....................................... 261 502-11158 Hose, /A Flaw Valve .................................. 162 513-20019 Connector, Straight ................................... 363 517-30010 Plug, Hex................................................... 164 514-57010 Elbow, 90 Deg. 12ORB/12OFS................. 165 514-56004 Elbow, 90Deg. 12 ORB x 10 OFS............. 166 502-40828 Hose Assembly Press SLP ...................... 167 730-20299 SLP Platform Assembly 4700.................... 168 518-30001 Bulkhead ................................................... 269 511-41001 Bulkhead Locknut...................................... 270 511-40001 Tube, Nut................................................... 471 519-40002 Tube Reducer............................................ 472 501-04150 Q/Disc Nipple #12 ..................................... 273 501-04149 Q/Disc Nipple CPLG.................................. 274 280-00001 O-Ring, #6 ................................................. 275 209-00658 Bump Ball 7/16 .......................................... 1


76 770-02353 Support Bracket, Quick Disconnect ...........177 501-04151 Q/Disc Dust Cap Dust cap .........................279 502-00177 Twin Hose, 3/16 x 82FT.............................180 666-10001 ATB Switch, Lock Out, Greer.....................181 770-02606 Bracket, Cable Reel ...................................182 220-02002 HHCS 3/8-16 x 1 1/4” Long........................283 785-01483 Angle, SLP Cable/Hose Reel Support .......284 220-02003 Bolt, Hex Head 3/8-16 x 3/4” Long.............3085 220-04007 Bolt, Hex Head, 1/2-13 x 1 3/4” Long.........486 783-01640 Square Washer Plate 1/2” Dia ...................487 222-04001 Washer, Flat 1/2 PLT.................................1688 221-94006 Locknut, 1/2-13NC PLT .............................689 223-00304 FLT 50CHD Machine 5/16 .........................490 729-02369 Rub Pad Twin Boom Hose.........................291 501-07066 Hose, Reel MOD SLP................................191a 501-07056 Hose Reel, No Modification .......................192 770-01853 Support Bracket, SLP Hose Reel...............193 220-04002 Bolt, Hex Head1/2-13 x 1 1/4” Long...........494 787-00263 Shim, 1 3/4 x 12, 10 CL 0.04Thk ...............195 787-00265 Shim, 1 3/4 x 12, 10 CL 0.10Thk ...............196 201-00050 P-Clamp Aeroquip......................................2697 220-01004 Bolt, Hex Head 5/16...................................498 220-01010 Bolt, Hex Head 5/16...................................699 031-10011 Spacer, Cable Clamp.................................5100 650-00683 Placard, Switch Operating Instructions ......2



GROUP



Page 51.13


101 651-00234 Placard, Switch Operating Instruction ....... 2102 651-00276 Placard, Platform Center, Instruction ........ 2103 651-00326 Placard, SLP Capacity, 4700 .................... 4104 665-00007 Placard, Elect Remote Box Electrocution.. 1105 865-00015 Roller Guide, Cable/Hose.......................... 3106 785-02082 Roller Guide Assembly, ATB..................... 1107 220-02004 Bar, Cable Guide Mounting ....................... 1108 209-00809 Bolt, Hex Head 3/16 .................................. 2109 209-00434 Harness, Body, Safety .............................. 2110 221-92001 Lanyard, Aerial .......................................... 2111 770-02625 Locknut, 3/8............................................... 2


112 220-30012 Holder Box, NBB Transmitter.....................5113 221-90001 Bolt, Button, Socket Head 1/4....................5114 209-00585 Snap 19mm Fixed Eye...............................1115 209-00359 S-Hook.......................................................2116 205-00007 Chain..........................................................6”117 770-01721 Support Bracket, Control Box Mounting.....1118 NOT USED119 NOT USED120 514-52004 Elbow, 90 Deg. SW Nut 4 OFS..................2



GROUP



Page 51.14

RADIO REMOTE HYDRAULIC PIPING

See “RADIO REMOTE CONTROL INSTALLATION” on page 51.13.


GROUP



Page 51.15


* 730-91005 Roofer’s Package...................................... Ref

1 553-00002 Valve Selector ........................................... 12 502-40722 Hose Assembly, Main Valve Select........... 23 502-30597 Hose Assembly, Select Valve/Reel ........... 24 513-70023 Connector, Straight ................................... 6


5 220-02001 Screw 3/8 x 3” Long...................................26 222-12001 Washer, Lock 3/8 .......................................227 221-02001 Nut 3/8 .......................................................88 501-07064 Reel Hose ..................................................19 502-20809 Hose, Dual 3/8 x 122’ Assembly ................110 501-04131 Nose, Q’Coupler ........................................1

Roofer’s Package Installation

5,6,7

3

2

VIEW H-H

2

34

1

5,6,7

ROOFER’S PACKAGE INSTALLATION


GROUP



Page 51.16


11 501-04018 Cap, Dust .................................................. 112 501-04130 Body, Q’Coupler ........................................ 113 501-04028 Plug, Dust.................................................. 114 513-50002 Connector, Straight ................................... 415 770-01850 Bracket, Hose Reel Weldment .................. 1


16 780-00248 Plate, Support ............................................117 209-00586 Lock Pin, Hose Reel ..................................118 223-15210 Screw, 5/16 x 3/4” Long.............................1219 222-01001 Washer, Flat 5/16.......................................820 223-15209 Screw, 3/8 x 3/4” Long...............................14


8

15 6,20

3015

6,20

18,19

22

22

18,19

22



GROUP



Page 51.17


21 222-08001 Washer, Flat 7/8 ........................................ 222 201-00050 Clamp, Hose.............................................. 1323 220-02009 Bolt, 3/8 x 4” Long ..................................... 624 222-02005 Washer, flat 3/8 ......................................... 425 785-01503 Angle, Roller Support LH........................... 1


26 785-01504 Angle, Roller Support RH...........................127 870-00135 Pin, Roller Guide........................................128 865-00008 Guide, Roller Hose.....................................129 224-12001 Pin, Roller 1/8 x 1 1/8” Long ......................230 785-01483 Angle Support ............................................1




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Page 51.18


* 975-00592 Turret Lock Assembly................................ Ref

1 220-39006 SHCH, 1NC x 5" Long............................... 32 222-09004 Washer, Flat, 1 PLTD..............................REF3 221-99002 Nut, Toplock 1NC...................................... 34 789-04679 Plate, Turret Lock Mounting ...................... 15 870-20189 Pin, Turret Lock Retain.............................. 1


6 782-01554 Collar, Turret Lock .....................................17 224-18004 Pin, roll 3/8 Dia x 4" Long ..........................18 784-01030 Gusset, Turret Lock Collar

Support ......................................................19 784-01132 Gusset, Turret Lock Collar

Support ......................................................1

Turret Lock Installation

TURRET LOCK INSTALLATION


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52DATE: Issued 03-2006


Page 52.1

52 RATED CAPACITY INDICATOR


508-00083 MG 586 Assembly

400-16135 RCI KIT (Greer MG586) ............................ 1(Includes Items 1 Through 5)

1 717 0882 Cwt w/ Chain ............................................. 1 2 774-00054 Bracket, ATB Switch (Plated) .................... 1

729-02729 Bracket LMI/ATB Switch (Painted) ............ 1861-90467 ATB Switch Assembly ............................... 1 213830 Bolt ............................................................ 2 213844 Switch, Contact ......................................... 1 213845 Magnet ...................................................... 1


3 Page 52.3 Reeling Drum.............................................1 4 Page 52.4 Display .......................................................1 5 Page 52.2 Computer Assembly...................................1 6 865-00019 Roller Guide Assembly, ATB .....................1

400-16132 Bracket, Extend..........................................Opt220-00021 Capscrew, 1/4-20 UNC x .63 Lg ................Opt221-90001 Locknut, 1/4-20 UNC .................................Opt

7 865-00019 Roller Guide Assembly, ATB .....................1 8 201-00141 Clamp, ø1/4 x .40.......................................3

222-00006 Flatwasher, 1/4 Zinc...................................3226-00021 Rivet, .50 HD .25D x .63 Lg .......................A/R

GREER RCI

1

2

3

4

5

67

8

GREER MG 586 RCI ASSEMBLY


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Page 52.2

REF. PART.NO. DESCRIPTION QTY

400-16122 Computer, MG586

1 717 0776 System Chip [Generic - Not Programmed] 12 514-62002 Elbow, 90° ................................................. 13 502-11225 Hose.......................................................... 14 502-10916 Hose.......................................................... 1


5 400-02444 Harness, Elec - Cab/Box............................16 400-25155 Harness, Console ......................................17 400-01530 Cable, Ground............................................18 666-10002 Cable, Computer To Display......................19 220-00003 Capscrew, 1/4 NC x 3/4” Lg.......................4

222-10005 Washer, Lock, 1/4 Plated...........................4

Computer Control Box, MG586

1

BREAKERSCIRCUIT CIRCUIT

RELAYS

TO EXTERNALREEL CABLE

85

PRESSURETRANSDUCERS

9 1

7

6

4

2

3

GREER MG 586 COMPUTER


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Page 52.3


861-90466 Reeling Drum, MG586

1 666-10008 Base Plate Assembly ................................ 1 1A 216652 Potentiometer, Extension .......................... 1 2 216653 Slip Ring .................................................... 1


3 216654 O-Ring........................................................1 4 216655 Cover Assembly.........................................1 5 216656 Screw.........................................................12 6 861-90406 Cable, Tail..................................................1 7 861-90392 Ext. Cable Assembly..................................1

RCI 510 Reel Assembly

7

3

1 2

1A

4

5

6

GREER MG586 REEL


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Page 52.4


1 400-16119 Display, MG586......................................... 1 2 786-01826 Bracket, Display Mount ............................. 1 3 785-01826 Angle, Display Mount ................................ 1

220-02004 Capscrew, 3/8-16 UNC x 1.00 Lg.............. 2222-02005 Flatwasher, 3/8.......................................... 2221-02001 Hexnut, 3/8-16 UNC.................................. 2


4 220-00021 Capscrew, 1/4-20 UNC x .63 Lg ................2222-00006 Flatwasher, 1/4 Zinc...................................2221-90001 Locknut, 1/4-20 UNC .................................2

GREER MG586 Display

1

243

GREER MG 586 DISPLAY

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