SECTION 2 - BOOM

BOOM

Series IV Highway Speed Excavators 808040012-2

Boom Cradle, XL3100IV & XL4100IV

PAC2413

12 132

3

910

4

6

75

1

14 11

10 9

8

BOOM

80804001 Series IV Highway Speed Excavators 2-3

Boom Cradle, XL3100IV & XL4100IVItem Part Number Qty. Description Rev.

1 80826003 1 CRADLE WELDMENT, XL3100IV80726009 1 CRADLE WELDMENT, XL4100IV

2 88521206 2 HEX LOCKNUT, 3/8-163 80623016 2 BULKHEAD ADAPTER4 88671018 2 LUBE FITTING, 45 DEGREES, 1/85 80423001 1 TILT BEARING6 80323013 33 WHIZ-LOCK SCREW, 3/4-10X5, GR8, (loctite & torque to 320-345 lb-ft)7 83201058 29 HEX HD CAPSCREW, 3/4-10X3-3/4, GR8, (loctite & torque to 320-345 lb-ft)8 80923009 2 BUSHING9 88691302 2 BIJUR STRAIGHT CONNECTOR, 1-1/4

10 88661103 2 MALE ELBOW, 90 DEGREES, 1/8X1/4 TUBE11 84719793 2 HOSE ASSY12 80421094 1 LUBE BRACKET13 88201039 2 HEX HD CAPSCREW, 3/8-16X2, GR514 80423034 8 FLANGE HD CAPSCREW, 5/8-11X1-3/4, (loctite & torque to 200-215 lb-ft)

BOOM

Series IV Highway Speed Excavators 808040012-4

Boom Cradle, XL4100IV (360° Boom Tilt)

PAC4611

10

19

8

22

15

2215

16

17

23

18

2021

2

3

4

1

6

5

11

9

10

12

14

13

11

7

BOOM

80804001 Series IV Highway Speed Excavators 2-5

Boom Cradle, XL4100IV (360° Boom Tilt)Item Part Number Qty. Description Rev.

1 80726007 1 CRADLE WELDMENT2 80423001 1 TILT BEARING3 80323013 33 FLANGE HD CAPSCREW, 3/4-10X5, (loctite & torque to 320-345 lb-ft)4 83201058 29 HEX HD CAPSCREW, 3/4-10X3-3/4, GR8, (loctite & torque to 320-345 lb-ft)5 83201092 4 HEX HD CAPSCREW, 5/8-11X2, GR86 80993217 4 SPECIAL WASHER7 88521310 2 HEX LOCKNUT, 5/8-118 80923009 2 BUSHING9 80526011 1 HOOD WELDMENT

10 80973025 7 WHIZ-LOK SCREW, 3/8-16X111 88971004 7 HEX NUT, 3/8-1612 80421170 1 HOSE COVER13 80426036 1 STABILIZER WELDMENT14 83201115 4 HEX HD CAPSCREW, 3/8-16X1-1/4, GR815 88691302 2 BIJUR CONNECTOR16 84719793 2 HOSE ASSY17 80421094 1 LUBE BRACKET18 88201039 2 HEX HD CAPSCREW, 3/8-16X2, GR519 88521206 2 HEX LOCKNUT, 3/8-1620 80623016 2 BULKHEAD ADAPTER21 88671018 2 LUBE FITTING, 45 DEGREES, 1/822 88661103 2 MALE ELBOW, 90 DEGREES, 1/8X1/4 TUBE23 80423034 8 FLANGE HD CAPSCREW, 5/8-11X1-3/4, (loctite & torque to 200-215 lb-ft)

BOOM

Series IV Highway Speed Excavators 808040012-6

Boom Cradle, XL5100IV

PAC4841

6

75

8

1

910

11

12 132

3

910

4

1414

15

16

ITEM 15 BOTTOM 3 OF BOLT CIRCLE

BOOM

80804001 Series IV Highway Speed Excavators 2-7

Boom Cradle, XL5100IVItem Part Number Qty. Description Rev.

1 80526013 1 CRADLE WELDMENT, XL5100IV2 88521206 2 HEX LOCKNUT, 3/8-163 80623016 2 BULKHEAD ADAPTER4 88671018 2 LUBE FITTING, 45 DEGREES, 1/85 80523001 1 TILT BEARING6 80323013 33 WHIZ-LOCK SCREW, 3/4-10X5, GR8, (loctite & torque to 320-345 lb-ft)7 91403412 33 HEX HD CAPSCREW, 3/4-10X5, GR8, (loctite & torque to 320-345 lb-ft)8 80923009 2 BUSHING9 88712317 2 BRASS COUPLING, 1/8

10 88661103 2 MALE ELBOW, 90 DEGREES, 1/8X1/4 TUBE11 84719793 2 HOSE ASSY12 80421094 1 LUBE BRACKET13 88201039 2 HEX HD CAPSCREW, 3/8-16X2, GR514 80443014 2 BRASS PIPE NIPPLE, 1/8X315 83201058 3 HEX HD CAPSCREW, 3/4-10X3-3/4, GR8, (loctite & torque to 320-345 lb-ft)16 80423034 8 FLANGE HD CAPSCREW, 5/8-11X1-3/4, (loctite & torque to 200-215 lb-ft)

BOOM

Series IV Highway Speed Excavators 808040012-8

Boom Cradle, XL5100IV (360° Boom Tilt)

PAC4851

14

13

10

12

10

11

9

11

71

6

5

8

19

22

15

2

3

4

2215

16

1718

2021

2423

23

25

ITEM 24 BOTTOM 3 OF BOLT CIRCLE

BOOM

80804001 Series IV Highway Speed Excavators 2-9

Boom Cradle, XL5100IV (360° Boom Tilt)Item Part Number Qty. Description Rev.

1 80526013 1 CRADLE WELDMENT2 80523001 1 TILT BEARING3 80323013 33 FLANGE HD CAPSCREW, 3/4-10X5, (loctite & torque to 340-365 lb-ft)4 91403412 33 HEX HD CAPSCREW, 3/4-10X5, GR8, (loctite & torque to 340-365 lb-ft)5 83201092 4 HEX HD CAPSCREW, 5/8-11X2, GR86 80993217 4 SPECIAL WASHER7 88521310 2 HEX LOCKNUT, 5/8-118 80923009 2 BUSHING9 80526011 1 HOOD WELDMENT

10 80973025 7 WHIZ-LOK SCREW, 3/8-16X111 88971004 7 HEX NUT, 3/8-1612 80421170 1 HOSE COVER13 80426036 1 STABILIZER WELDMENT14 83201115 4 HEX HD CAPSCREW, 3/8-16X1-1/4, GR815 88712317 2 BRASS COUPLING, 1/816 84719793 2 HOSE ASSY17 80421094 1 LUBE BRACKET18 88201039 2 HEX HD CAPSCREW, 3/8-16X2, GR519 88521206 2 HEX LOCKNUT, 3/8-1620 80623016 2 BULKHEAD ADAPTER21 88671018 2 LUBE FITTING, 45 DEGREES, 1/822 88661103 2 MALE ELBOW, 90 DEGREES, 1/8X1/4 TUBE23 80443014 2 BRASS PIPE NIPPLE, 1/8X324 83201058 3 HEX HD CAPSCREW, 3/4-10X3-3/4, GR8, (loctite & torque to 340-365 lb-ft)25 80423034 8 FLANGE HD CAPSCREW, 5/8-11X1-3/4, (loctite & torque to 200-215 lb-ft)

BOOM

Series IV Highway Speed Excavators 808040012-10

Main Boom Assembly, XL3100IV & XL4100IV

PAC2421

1

2

3 4

24

56

7

6 7

8

10

9

BOOM

80804001 Series IV Highway Speed Excavators 2-11

Main Boom Assembly, XL3100IV & XL4100IVItem Part Number Qty. Description Rev.

1 80826002 1 MAIN BOOM WELDMENT, XL3100IV0801598 1 MAIN BOOM WELDMENT, XL4100IV80726006 1 MAIN BOOM WELDMENT, XL4100IV, (w/360° Boom Tilt option)

2 88671001 5 LUBE FITTING, STRAIGHT, 1/83 Ref BOOM ROLLER ASSY, CONCAVE, (see page 2-16 for details)4 80423005 5 ECCENTRIC SHAFT5 Ref BOOM ROLLER ASSY, FLAT, (see page 2-16 for details)6 80421109 5 ROLLER ADJUSTMENT PLATE7 80223035 10 FLANGE SCREW, 1/2-13X3/4, GR88 Consult Factory 1 ROLLER BRACKET WELDMENT9 80726011 1 BOOM REST PLATE

10 80973025 4 WHIZ-LOK SCREW, 3/8-16X1

BOOM

Series IV Highway Speed Excavators 808040012-12

Main Boom Assembly, XL5100IV

PAC0022

BOOM

80804001 Series IV Highway Speed Excavators 2-13

Main Boom Assembly, XL5100IVItem Part Number Qty. Description Rev.

1 0801505 1 MAIN BOOM WELDMENT, XL5100IV80526015 1 MAIN BOOM WELDMENT, XL5100IV, (w/360° Boom Tilt option)

2 Ref BOOM ROLLER ASSY, DOUBLE CONCAVE, (see page 2-18 for details)3 83201123 6 HEX HD CAPSCREW, 1/2-13X1, GR84 80921093 3 KEEPER5 80923036 6 HEX HD CAPSCREW, 1/2-13X3/4, GR86 85021683 3 CAP7 80921095 3 ECCENTRIC SHAFT8 Consult Factory 1 ROLLER BRACKET SUPPORT9 80223035 4 FLANGE SCREW, 1/2-13X3/4, GR8

10 80421109 2 ROLLER ADJUSTMENT PLATE11 80423005 2 ECCENTRIC SHAFT12 Ref BOOM ROLLER ASSY, FLAT, (see page 2-18 for details)13 Ref BOOM ROLLER ASSY, DOUBLE FLAT, (see page 2-18 for details)14 88671001 2 LUBE FITTING, STRAIGHT, 1/815 80726011 1 BOOM REST PLATE16 80973025 4 WHIZ-LOK SCREW, 3/8-16X117 88201093 3 HEX HD CAPSCREW, 5/8-11X1, GR5

BOOM

Series IV Highway Speed Excavators 808040012-14

Telescope Boom Assembly

PAC2431

11

1

10

12

2345

13

67

31

22

3233

14

24

34

15 16

11

17

35

8 9

1819

20

21

23 25

27

28 29

36

16

26

30

BOOM

80804001 Series IV Highway Speed Excavators 2-15

Telescope Boom AssemblyItem Part Number Qty. Description Rev.

1 80826001 1 TELESCOPE BOOM WELD, XL3100IV, (includes items 13, 31 & 35) D0801614Y 1 TELESCOPE BOOM WELD, XL4100IV, (includes items 13, 31 & 35) D0801542Y 1 TELESCOPE BOOM WELD, XL5100IV, (includes items 13, 31 & 35) D

2 80425010 3 BOOM ROLLER ASSY, (includes items 3 thru 5)3 83621145 3 INNER BUSHING4 83621262 6 THRUST WASHER5 83623005 6 FACE SEAL6 80423005 3 ECCENTRIC SHAFT7 80421109 3 ROLLER ADJUSTMENT PLATE8 80223035 6 FLANGE SCREW, 1/2-13X3/4, GR89 88691345 3 BIJUR 90 DEGREE CONNECTOR, 1-1/4

10 88743000 3 MALE ADAPTER, 1/8X1/4 TUBE11 84721171 1 HOSE ASSY, XL3100IV

84719787 1 HOSE ASSY, XL4100IV2754686 1 HOSE ASSY, XL5100IV

12 84721172 2 HOSE ASSY, XL3100IV84719786 2 HOSE ASSY, XL4100IV2754687 2 HOSE ASSY, XL5100IV

13 80426004 1 ROLLER BRACKET14 88201078 6 HEX HD CAPSCREW, 1/2-13X4-1/2, GR515 80421136 3 KEEPER16 80323039 6 SPIDER PAD17 80421139 3 SPIDER18 80221280 3 THREADED BAR19 88521308 6 HEX NUT, 1/2-1320 88671018 3 LUBE FITTING, 45 DEGREES, 1/821 80323020 6 HEX HD CAPSCREW, 5/8-11X1-1/2, GR822 80521023 6 CYLINDER RETAINER23 80423030 1 SPIDER RETAINER, (hand torque to 55-60 lb-ft)24 88212248 1 SOCKET HD CAPSCREW, 7/16-14X2-1/2, GR8, (never-seize & hand torque to

30-35 lb-ft)25 88681300 1 HEX LOCKNUT, 7/16-1426 84719790 1 HOSE ASSY27 84719789 1 HOSE ASSY28 80623016 5 BULKHEAD ADAPTER29 2160020 5 LUBE FITTING, 90 DEGREES, 1/830 88743021 1 MALE ELBOW, 45 DEGREES, 1/8X1/4 TUBE31 1 CYLINDER MOUNT WELDMENT, (not available for service)32 80926014 1 PIN WELDMENT33 83621283 1 SPECIAL WASHER34 83201129 1 HEX HD CAPSCREW, 1/2-13X1-1/4, GR8, (torque to 68-73 lb-ft)35 4341079 1 TOOL EYE WELDMENT36 88661103 1 ELBOW, 90 DEGREES, 1/8X3/16 TUBE

BOOM

Series IV Highway Speed Excavators 808040012-16

Boom Roller Assemblies, XL3100IV & XL4100IV

PAC2301

BOOM

80804001 Series IV Highway Speed Excavators 2-17

Boom Roller Assemblies, XL3100IV & XL4100IVItem Part Number Qty. Description Rev.

83625044 1 BOOM ROLLER ASSY, CONCAVE, (includes items 1 thru 4)1 83621215 1 CONCAVE ROLLER2 83621262 2 THRUST WASHER3 83623005 2 FACE SEAL4 83621145 1 INNER BUSHING

83625043 1 BOOM ROLLER ASSY, FLAT, (includes items 101 thru 104)101 83621214 1 FLAT ROLLER102 83621262 2 THRUST WASHER103 83623005 2 FACE SEAL104 83621145 1 INNER BUSHING

NOTE: QUANTITIES SHOWN FOR ONE ROLLER ASSY ONLY.

BOOM

Series IV Highway Speed Excavators 808040012-18

Boom Roller Assemblies, XL5100IV

PAC0041

201

202

203204

1

8

2

3

45

7

45

6

101

102103

104

105

106107

108

102103

203204

BOOM

80804001 Series IV Highway Speed Excavators 2-19

Boom Roller Assemblies, XL5100IVItem Part Number Qty. Description Rev.

80925003 1 BOOM ROLLER ASSY, DOUBLE FLAT, (includes items 1 thru 8) E1 80921002 1 BOOM ROLLER BRACKET2 88671001 2 LUBE FITTING, STRAIGHT, 1/83 85021704 2 ROLLER PIN4 83621262 4 THRUST WASHER5 83623005 4 FACE SEAL6 83621145 2 INNER BUSHING7 83621214 2 FLAT ROLLER8 88581140 2 RETAINING RING

80925002 1 BOOM ROLLER ASSY, DOUBLE CONCAVE, (includes items 101 thru 108) C

101 80921001 1 BOOM ROLLER BRACKET102 83621262 4 THRUST WASHER103 83623005 4 FACE SEAL104 83621145 2 INNER BUSHING105 83621215 2 CONCAVE ROLLER106 85021704 2 ROLLER PIN107 88671001 2 LUBE FITTING, STRAIGHT, 1/8108 88581140 2 RETAINING RING

83625043 1 BOOM ROLLER ASSY, FLAT, (includes items 201 thru 204)

201 83621214 1 FLAT ROLLER 202 83621145 1 INNER BUSHING203 83621262 2 THRUST WASHER204 83623005 2 FACE SEAL

NOTE: QUANTITIES SHOWN FOR ONE ROLLER ASSY ONLY.

BOOM

Series IV Highway Speed Excavators 808040012-20

Bucket Linkage

PAC2443

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�ITEM #14, USE SPECIAL WASHERS, AS NEEDED, TO KEEP ADAPTER SIDE CLEARANCE .040” OR LESS

BOOM

80804001 Series IV Highway Speed Excavators 2-21

Bucket LinkageItem Part Number Qty. Description Rev.

1 Ref TOOL CYLINDER ASSY, (see page 9-22 for details)2 Ref TELESCOPE BOOM ASSY, (see page 2-14 for details)3 80725006 1 BENT LINK ASSY, (includes qty 2 of items 5, 23, 27 & 31) B4 88671001 2 LUBE FITTING, STRAIGHT, 1/85 88671008 5 LUBE FITTING, STRAIGHT, 1/86 80725005 1 STRAIGHT LINK ASSY, (includes qty 3 of items 5 & 23) A7 0080275 1 BUCKET ADAPTER, (includes qty 2 of item 19 & qty 1 of item 27) I

80656037 1 XL4000 SERIES ATTACHMENT ADAPTER, (optional), (not illustrated)X4216010 1 HAMMER MOUNT ADAPTER, XL5100IV, (optional), (not illustrated)

8 80926014 2 PIN WELDMENT9 83201129 16 HEX HD CAPSCREW, 1/2-13X1-1/4, GR8, (torque to 68-73 lb-ft)

10 83621283 3 SPECIAL WASHER11 80526006 1 PIN WELDMENT12 3423229 1 BENT LINK PIN WELDMENT13 83623019 4 O-RING14 80721448 2 WASHER, (.274-.280 thick, no hump), (see illustration note)

80321134 A/R SPECIAL WASHER, (.266-.271 thick, 2 humps) 80321135 A/R SPECIAL WASHER, (.296-.301 thick, 3 humps)

15 90027471 1 HARDENED WASHER16 3423228 1 TOOL EYE PIN WELDMENT17 3575937 2 PIN RETAINER PLATE18 3575936 2 BUSHING RETAINER PLATE19 80323047 4 BUSHING20 88201043 2 HEX HD CAPSCREW, 3/8-16X3, GR521 88551011 2 LOCKWASHER, 3/822 3271601 2 HEX NUT, 3/8-1623 80723002 5 BUSHING24 91123029 4 O-RING25 83623018 2 O-RING26 3900383 2 WEDGE BOLT27 80421119 3 THREADED STUD, (loctite & torque to 175-185 lb-ft)28 80921174 2 HIGH NUT29 88551018 2 LOCKWASHER30 4740568 2 RECTANGLE WASHER31 88221183 2 HEX SOCKET SET SCREW, 1/4-28X1/4, (cup point)

80755041 A/R PIN & BUSHING KIT, (includes items 4, 11, 16 & qty. 2 of item 19) -

BOOM

Series IV Highway Speed Excavators 808040012-22

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