BI005709

© Bucyrus
All Rights Reserved

BUCYRUS R

Technical Manual
I BI005709

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I MARION
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Manual
2009b
I SIN 23224

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081694

I Marion Division of INDRESCO Inc.

617 Wes Center Street • P.O. Box 505 • Marion, Ohio 43302 USA
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 I BI005709

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I Marion 8750 Walking Dragline
NTERMEDIATE BOOM SUSPENSION MANUAL

I [·········Thi·· ·~~~~~i . i·~·di~i·d·~d . i~t;·~·~j~·~ . ~~~ti~~~··~·~~~·rt·~~·th~ . ~·~ri;~·~··~~;~~·~·b·I·~ . ·······j

~ compo ents and systems of the Intermediate Boom Suspension. These sections ~
~ and their contents are organized as shown below. ~

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I ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1

- Table of Contents -

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1 GENERAL NFORMATION 1.1
I SAFETY
SAFETY
LERT SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.2
RECAUTIONS.............................................. 1.3

I FIRE PR
TRAININ
VENTION 1.5
1.6

I 21NTERMED ATE BOOM SUPPORT

ACCUM LATOR CHARGE
2.1
2.3
SYSTE CHARGE 2.7
I FILTER
RESER OIR
2.7
2.10
HYDRA L1C PUMP 2.12
I CYLIND R ASSEMBLY
REMOV L and INSTALLATION ofl.B.S. PENDANTS and CYLINDERS
2.13
2.13

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3 REPAIR P RTS

I TABLE
GENER
F CONTENTS 3.1
L INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3.2
INSTRU TIONS FOR ORDERING PARTS 3.4

I WARRA
PART S
TY
EETS
3.5
(Inserts)

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I BI005709

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I I termediate Boom Suspension

I 1 GENERA INFORMATION

This manual i designed to assist the owner in the maintenance of the Intermediate

I Boom Suspe
maintenance
sion System. Following easy to understand step-by-step procedures,
ersonnel can perform these tasks in a safe manner. When a systematic
and thorough maintenance/service procedure (a responsibility of the maintenance

I superintende
operation will
t) is used for this machine, minimum unplanned downtime and reliable
esult.

I Carefully read the instructions in Section 3 when ordering parts. All parts listed are for
THIS SPECIF C MACHINE. Order parts in exact quantity. Parts ordered by mistake and
returned, are ubject to a rehandling charge. RIGHT HAND and LEFT HAND parts on the
upper frame rrespond to the operator's hands at the controls; as seated when
I operating the achine. Please state the correct machine SERIAL NUMBER (located on a
plate in the 0 erator's cab) when corresponding or contacting factory service or parts
departments. ecords on each machine are filed by serial number and when given this
I number, your machine's specific design and original equipment is accessed quickly by
the Marion p s representative.

I Periodic addit ons or revisions may be made to this manual. These will be mailed direct to
you from the f ctory. Should you require additional information or factory service
assistance co tact your regional service representative or
I S rvice Department or
M ion Division of INDRESCO Inc.
I 61 West Center Street
P. .Box 505
Telephone 614/383-5211
Telex 24-5307
M ion, OH 43302 Telecopier 614/383-5211

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It is Marion's olicy to improve its products whenever possible and practical to do so. The

I company res rves the right to make changes or add improvements at any time without
incurring any bligation to install such changes on machines sold previously.

I Due to this co tinuous program of product research and development some procedures,
specifications and parts may be altered in a constant effort to improve machines.

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SAFETY ALERT SYMBOLS
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A This safety alert symbol is used here and throughout this manual to call
your attention to instructions concerning your personal safety. Carefully
read and follow these instructions and observe all SAFETY, DANGER, and
CAUTION graphics mounted on various areas of the machine.
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Be certain anyone servicing this machine is aware of these SAFETY SYMBOLS and their I
definition. In the event you question your ability to safely perform any of the enclosed
maintenance and operational procedures contact your regional Marion service
representative or the factory. I
The following defines distinctions between safety instructions. In all these definitions the
safety alert signal is used. I
AfANGER: Denotes extreme intrinsic hazard which exists and could result
in high probability of death or irreparable injury if proper
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precautions are ignored.

AfAUTION: Denotes a reminder of safety practices or directs attention to

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unsafe practices which could result in personal injury if proper
precautions are ignored. I
An example of a safety alert symbol and special instructions is shown below.
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ADANGER: Inherent danger exists in the operation of any high voltage
electrical equipment. A safe grounding system includes
ground conductors in the power cable, a neutral grounding I
resistor, and related relays and switch-gear. A ground
continuity check system is required by law in many parts of the
world. I
Operating, maintaining or servicing this machine is dangerous unless performed
properly. Each person must satisfy himself and his employer that he is alert, has the
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necessary skill, knowledge, proper tools and equipment, and that all the methods used
are safe and correct. Factory service representatives and specialists are available to
provide additional information or technical assistance.
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The operator must be alert, physically fit, and free from the influence of alcohol, drugs, or
medications that might effect his eyesight, hearing or reactions.
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Safety must always be the most important concern. Consult your supervisor when safety
is in doubt.
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SAFETY PRE

I - The owner d/or operator must replace any and all safety and warning product
graphics if t ey are defaced or removed from the machine.

I - Before doin any work on the machine, a qUalified electrician must lock out or remove
the electric ower supply from the machine and tag it so personnel are aware that

I someone is orking on the machine.

- Do not start an engine indoors unless adequate exhaust ventilators are provided. Once

I an engine i running, move the machine outdoors as soon as possible.

- Keep hand ,feet, and clothing away from rotating parts.

I - Do not mov or operate the machine without knowing the location and purpose of all
personnel, Ius test or support equipment, in or near the machine.

I you act. Carelessness is one lUXUry the service man cannot afford.

- Do not we rings, wrist watches or loose fitting clothing when working on machinery.
I They could atch on moving parts causing serious injury. Never adjust and/or service a
machine in are feet, sandals or sneakers.

I safety glasses when using a hammer, chisel or other tools that may cause

I - Excessive r repeated skin contact with sealants or solvents may cause skin irritation.
In case of s in contact, remove sealant or solvent promptly by washing with soap and
water.

I the machine air or hydraulic systems for support when working on the
activate and isolate the system prior to performing maintenance.

I - Equipment hould be parked on level ground at all times during machine servicing and
periods of i leness.

I - Cranes and hoists must be of sufficient capacity to lift the heavier components
(gearcases, dipper/bucket, boom, etc.) and have an ample safety margin.

I vy items are properly supported from cranes or hoists before removing

embers from machine.

I - Have suffici nt service personnel available when removing or installing large heavy
items to m ntain control at all times.

I - Always use safety stands in conjunction with hydraulic jacks or hoists. Do not rely on
the jack or oist to carry the load, they could fail.

I - Use safety atch on all hoist hooks. Do not take a chance, the load could slip off of the
hook.

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- If a heavy item begins to fall, let it fall, don't try to catch it.

- When disassembling machine, be sure to use safety stands and adequate cribbing to
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prevent tipping or rollover of components.

- Keep work area organized and clean. Wipe up oil or spills of any kind. Keep tools and I
parts off of the ground. Eliminate the possibility of a fall which could result in serious
injury.
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- Floors, walkways and stairways must be clean and dry. After draining operations be
sure all spillage is cleaned up. Electrical cords and wet metal floors make a dangerous
combination. I
- Check all wire ropes for telltale signs of early wear or failure. Look for and secure any
loose bolts or locking devices. I
- Use extreme caution while working near any electrical lines or equipment whether it be
high or low voltage. Never attempt electrical repairs unless qualified. Check limit
switches for proper operation.
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- When using an acetylene torch, always wear welding goggles and gloves. Keep a
·charged" fire extinguisher within reach. Be sure the acetylene and oxygen tanks are
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separated by a metal shield and are chained to the cart. Do not weld or heat areas near
transformers or electrical cabinets and utilize proper shielding around lubrication lines.
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- Use pullers to remove bearings, bushings, gears, cylinder sleeves, etc. when
applicable. Use hammers, punches and chisels only when absolutely necessary. Then,
be sure to wear safety glasses.
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- Be careful when using compressed air to dry parts. Use approved air blow guns, do
not exceed 30 PSI (207 kPa), wear safety glasses or goggles and use proper shielding I
to protect everyone in the work area

- Be sure to promptly reinstall safety devices, guards or shields after adjusting and/or
servicing the machine.
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- After servicing, be sure all tools, parts or servicing equipment are removed from the
machine, or secured in an appropriate storage area.
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- Protective eye goggles should be worn at all times when working on the air
conditioning system. Work on the air conditioning system only in a well ventilated area.
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- Wipe away excess lubricants around bearings and gears. Never lubricate parts in
motion.
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- Operate machine on level ground and be constantly aware of swing clearance. Never
hold a load longer than needed in the dump cycle. Use swing brakes only when
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machine is stopped.

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FIRE PREVEr TION

I - Always hav a "charged" fire extinguisher on hand and know how to use it. Inspect and
service the extinguisher as indicated on its instruction plate.

I - DO NOT SIT oke while handling flammables or when near batteries.

I - Inspect alii nes, tUbes, and hoses carefully. Tighten all connections to the
recommenc ed torque. See the Visual Inspection Schedule for the walk around
inspection I~rocedure.

I - Loose or dc~aged lines, tubes, and hoses, which leak, can cause a fire.

- Make certain that all clamps, guards, and shields are replaced correctly so as to
I prevent vib ation and the rubbing of one part against another which might result in
heat build-l p during operation.

I - DO NOT ca ry flammable fluids such as gasoline or solvents on board the machine.

- DO NOT ov~r-bend or strike pressurized hose lines. DO NOT install bent or damaged
I lines, tubes or hoses. Replace them with new immediately.

- DO NOT start the machine or move any of the controls if a warning tag is attached to

I the control or the start panel.

- Keep all c1e aning rags properly stored. DO NOT discard them into a pile on board.

I - Keep all str~ctural frame compartments, walkways, and work areas clean and free of
lubricant re~idue.

I - NEVER wel~, burn, or perform service on the machine alone.

I - If a motor cr other component is running hot, shutdown the machine until it has cooled
and/or the "'ause eliminated.

I ADANCER: FAILURE TO EXIT THE MACHINE COULD RESULT IN DEATH.

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TRAINING

Qualified maintenance personnel using a scheduled maintenance program are the best
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way to minimize machine downtime and maximize productivity of equipment.

Marion offers factory and mine site maintenance seminars and special familiarization
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programs for mechanics, oilers, electricians and operators on alee basis.

These programs are presented by qUalified factory specialists and service technicians. I
Special customized training programs can also be developed to meet specific mine
requirements.

Objectives of training and training materials are to provide the means for developing and
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maintaining on-site service repair capability.

For further information about Marion service training capabilities and programs contact:
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Customer Service Department
Marion Division of INDRESCO Inc.
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617 West Center St.
P.O.Box505
Marion, OH 43302
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I 2 INTERM DIATE 800M SUSPENSION SERVICE

I The mid-poi t of the boom structure is supported by 2 pre-loaded pendant assemblies.

These limit oom deflection during machine digging or dumping cycles to provide better
service life f r the boom. The intermediate boom support pendants are pin connected to
the head of he mast and to the boom near the mid-section through hydraulic cylinder
I assemblies. he connecting pins are lubricated by the front end auto lube system. Each
pendant is a 3.50 inch diameter bridge strand with zinced sockets on each end (the pin
holes of the ockets are perpendicular to each other).
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I INTERMEDIATE 800M SUPPORT
ibsJ2000.wpg

(Viewed from the Left Side of the Machine)

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~~ LEGEND:
;g
Socket Head Capscrew.
.5 Inch -llghten to 61 A.Lbs. B - Breather Air.
(4 per Connection) C - Equalizer.
P - Hydraulic Pressure.
T - Tank Return.
Intermediate Pendant Assembly

Mast

I\)

i\>

Anti-Rotation Rope
(WIre Rope, .5 Inch Dla.)

Front of
Machine

View-A
INTERMEDIATE BOOM SUPORT
(Left Side Shown, Right Side Opposite)
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Each pend t is pre-loaded by a hydraulic cylinder. Hydraulic pressure is supplied from
I a pump and eservoir assembly mounted on the deck of the rotating frame. The cylinder
tension is m 'ntained by an air-operated oil pump set to stall at a pre-determined
hydraulic pr ssure. Shock loads are absorbed by an accumulator mounted near each
I cylinder. Ref r to the schematic of this hydraulic system in this section.

Inspect the endants, the hydraulic pressure and the accumulator charge weekly.

I Replace a p ndant BEFORE it fails. Keep the oil pressure and nitrogen charge at their
specified lev Is. Refer to the following procedures.

I IMPORTANT. The boom must be in its operating position and the intermediate -
pendants connected before energizing the hydraulic system.

I ACCUMULA OR CHARGE

I Each accum lator is charged with dry nitrogen.

The charge ressure is determined ONLY when ~argeValVe
the hydraulic system is NOT PRESSURIZED.
I Charge the s stem with dry nitrogen to the values
indicated on he shematics.
Gas Chuck

Stem Valve t<§~§§~

I NOTES: To Hydraulic
Cylinder Accumulator

• The NIT GEN GAUGE on top of the \

I accumul
system I
tor is incapable of handling dynamic
ads. Therefore, the STEM VALVE
must be losed during machine operation. The
I STEM V
chuck 0
VE is CLOSED by screwing the gas
T. Accumulator
Support

I • The NITR GEN GAUGE will not handle bottle

pressure. Therefore, when precharging the
accumul tor, first open the STEM VALVE, then

I open the CHARGE VALVE slowly to obtain the

proper p ssure. Close the CHARGE, STEM Hydraulic
Gauge ---0-____.
and BO LE VALVES. Open the BLEEDER 0-5000 PSI

I VALVE d disconnect the hose. Close the

BLEEDE VALVE.
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I ACCUMULATOR ASSEMBLY

I ACAU ION: NEVER WORK ON THE BOOM WITHOUT USING A SAFETY

HARNESS.

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Right Pressure Gauge
I ~Cylinder Drain Valve
Cylinder
/' Accumulator I
1-/- Pressure
I Transducer
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Reliefl-

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Valve I

Pressure

__>Check
: Valve
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Gauge
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!I Hydraulic
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i Hydraulic Filter
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Filter

----~
(10 micron) __--1 (10 micron)

Air Return Line

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LEGEND:
T

Lines on the Boom.

B
C
P
Breather Air to Reservoir.
Connection Line Between Cylinders.
Oil Line to Cylinders.
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T Oil Return to Reservoir.
System Failure
Indicated in
the Operator's Cab SYSTEM PRESSURES:
+10
Nitrogen Charge: 290- PSI at 0 PSI Hyd.
Hyd. Relief Valve
Hyd. Charge Pressure:
3400±25PSI
525±15PSI
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'Air Pressure, Hyd. Charging: 18 PSI
'Air Pressure, Hyd. Operating:
Low Pressure Switch:
8 PSI
350 PSI Close
550 PSI Open
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Hydraulic Filter (OApprox. Values)

- - - -
(10 micron)

~ Hydraulic
Air Motor!
Pump Assembly
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Air Filter

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L..---rl-----i
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(40 micron)
Air Supply

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Air Shutoff Valve

1 Lube Reservoir
"-
Air Regulator
(Set as Required) I
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Schematic -INTERMEDIATE BOOM SUSPENSION
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To Check th Charge Pressure of the Nitrogen Gas in the Accumulators on each Cylinder
I Assembly:

1. Set the b cket and rigging on the ground and shut down the machine.

I 2. At the re ervoir close the valve in the air supply line to shut down the hydraulic pump.
Open the tinder drain valve located at the bottom of each accumulator in the system.

I 3. hydraulic system(s) to vent off pressure. The mid-section of the boom will
move an settle as the intermediate support ropes are relieved of tension. The low

I pressure warnings in the cab will come on. Each system's pressure is shown on the
gauge in he hydraulic manifold at the bottom end of each accumulator.

I 4. itrogen gas charge pressure in each accumulator at the gauge on top of the
accumul or. Refer to the Schematic on page 2.4. The oil pressure gauge on the bottom
of each a cumulator should be 0 PSI.

I NOTE: e accumulators are charged separately. Both gauges must be checked.

5. At each cumulator, if the gas charge is TOO HIGH:

I a. R fer to ACCUMULATOR CHARGE on page 4.10.4. Check that the bleeder and
c arge valves are closed. Screw the gas chuck IN to open the stem valve.
I b. S OWLY open the bleeder valve and monitor the nitrogen pressure gauge.
ose the valve when the gauge reads the proper pressure. Screw the gas chuck
I UT to close the stem valve.

c. se the same procedure on the other accumulator as required.

I 6. At each ccumulator, if the gas charge pressure is TOO LOW:

I a. efer to ACCUMULATOR CHARGE on page 4.10.4. Attach the charging hose

embly and nitrogen supply to the charge valve at the top of the accumulator.

I b. er attaching the nitrogen supply, purge the hose of air by opening the valve
o the nitrogen bottle. Open the bleeder and charge valves for 30 seconds to
rge air from the hose assembly. Close the charge and bleeder valves.

I c. rn the gas chuck IN to open the stem valve.

d. pen the charge valve and monitor the nitrogen pressure gage. When the
I g uge indicates the proper pressure, close the charge valve and screw the gas
c uck OUT to close the stem valve.

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e. Close the valve at the nitrogen bottle and open the bleeder valve. When the
nitrogen pressure is relieved, remove the hose assembly and close the bleeder
and charge valves.
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f. Repeat the above procedure for the other accumulator as required and continue with
Step 8. (If the nitrogen gas charge in either accumulator is acceptable, then proceed I
to Step NO.7 instead.)

7. Charge the hydraulic systems. Refer to the proper procedure. I

To charge a new or rebuilt accumulator assembly:

Follow the procedure given above for recharging. However, the accumulator can be charged
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before installing it in the hydraulic system by connecting it directly to a bottle of dry nitrogen,
using the charging assembly. Refer to the illustration of the charging system. One bottle of
dry nitrogen @ 2200 PSI and a capacity of 142 Cu.Ft. is required to precharge the
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accumulators to 100 PSI.

Nitrogen Charging Pressure Gauge

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Assembly (a . 1000 PSI )

-~~~~ ---- Bleeder

Valve
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Charging Hose,
10 Fl. "0IIII
_ ...------@~~~Gas
Chuck I
Stem Valve
Supply
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Accumulator
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Hydraulic Manifold

Pressure Gauge
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0·5000 PSI
System Relief Valve
Cylinder Drain Valve
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CHARGING SYSTEM for the Accumulators in the
INTERMEDIATE 800M SUPPORT System
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I 1. To chec the pressure relief valve settings in the Intermediate Support Rope system,
isolate th 2 cylinders by closing the needle valve in the common line "Co. Adjust the air
I pump re
valves at
ulator to obtain the hydraulic relief valve pressure. Adjust the pressure relief
ach accumulator. After adjusting the relief valves, open the needle valve one
complet turn in line "C".
I 2. For the r quired hyraulic charge pressure, refer to the schematic on page 2.4.

I 3. To set th operating pressure, set the pump air regulator at 5 PSI, close the air shutoff
valve, op n each cylinder drain valve to reduce the oil pressure in each cylinder to less
than the perating pressure and close the valve.
I 4. Open the pump air valve and allow the pump to stall. Slowly increase the air pressure by
adjusting the regulator to obtain the proper hydraulic pressure. When the pressure
I reaches e specified hydraulic charge pressure and the pump is stalled, lower the air
regulator pressure by 10 PSI. The hydraulic system is ready for operation. Refer to the
schemati on page 2.4.

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I FILTERS

The air sup Iy to the hydraulic pump on each reservoir assembly has a combination

I filter/regulat r unit in it. The filter is equipped with an automatic drain that dumps the
entrapped Iiq ids from the bowl at a pre-determined level. The 40 micron rated element in
the filter is pi ic and can be cleaned. The filter's transparent bowl can also be cleaned. Use

I mild soap an water for cleaning. Dry thoroughly before reinstallation. Check the filter daily
during visual oom inspection. Note the drain for proper operation. Clean the filter and bowl
at least quart rly, more frequently if needed. Shut off the air supply to the boom and vent off
the pressure before removing the bowl to service it and the element.
I The hydrauli oil line from each pump to each cylinder has a pressure line filter. This filter
has a 10m cron rated cellulose fiber element that is easily replaced. It has a visual
I mechanical i dicator that monitors the condition of the element and is equipped with a by-
pass circuit t at permits the oil to flow around the filter if it should become plugged. Note the
filter conditio daily during visual boom inspection and replace the element when indicated.
I The filter ele ents in each hydraulic system should be changed in sets.

I To replace t 10 micron element in the pressure line filters, use the following procedure.

1. cket and rigging on the ground and shut down the machine.

I 2. Close th globe valve in common line "Co. Close the valve in the air supply line to shut
down the pump. To remove the oil pressure at the filter, open the cylinder drain valve on
I the mani old at the bottom of each accumulator.

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ACAUTION: NEVER WORK ON THE BOOM WITHOUT USING A SAFETY
HARNESS. I
3. The mid-section of the boom may move and settle as the intermediate support ropes
loose tension. The low pressure warnings in the cab will come on.
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ACAUTION: Remove the filter bowl slOWly. Although the pump pressure has
been removed, there will be a small amount of pressure due to I
the check valve spring.

4. Carefully remove the bowl from the pressure line filters, take out the element, and I
thoroughly clean the bowl in an acceptable solvent. Discard the element in compliance
with local codes.

5. Install new filters and the clean bowl to the filter head. Pre-lube the O-rings with clean,
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filtered oil.

6. Open the air valve to start the pump.

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7. Purge the right hand cylinder piping of air and close the cylinder drain valve. I
8. Open the left hand cylinder drain valve and purge any air from the hydraulic lines and
close the valve. Repeat the above steps for the other hydraulic system as required. Open
the globe valve in line "C" one complete turn.
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9. With all cylinder drain valves closed, the intermediate boom support pendants will
retension. DO NOT adjust the air regulator higher than the setting at the start of this
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procedure until after the pump has stalled. Adjust the air regUlator upward in increments
as needed to obtain the proper hydraulic system pressure at stall. Refer to the
Operational Pressure Settings table on page 2.4. After the pump stalls, reduce the
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regulator setting by 10 PSI below this value. Adjust the tension in the anti-rotation ropes
if required. The machine is ready for operation.
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The hydraulic line from each cylinder to the tank has a return line filter. This filter is mounted
on top of the reservoir assembly and is a spin-on canister type with a paper element rated
at 10 microns. The filter has a by-pass circuit that permits the oil to flow around the filter if it I
is plugged. The canister should be replaced after the first 50 hours of use following the
replacement of an accumulator or cylinder assembly. Replace after every 1000 hours of
operation. I
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To replace tt. e 10 micron element in the return line filter, do the following.
I 1. Set the b ~cket on the ground and shut down the machine.

I 2. Loosen the hose fitting at the inlet port of the filter to be serviced to vent any residual
pressure ~d then, with a strap wrench, unscrew and remove the canister from the filter
head. Dispose of the canister element and its contents in compliance with local codes.
I 3. Apply at "lin film of clean, filtered oil to the new canister seal and install it onto the filter
head. Tif hten it in place by hand only, making sure it will not leak.

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4. Re-tighte 1 the hose end on the return line at the filter inlet. The machine can be returned
to operat on.

I The tank bn ather mounted on the reservoir assembly contains a 10 micron rated, dry,
polyester me jia element having a wrap-around prefilter. At the reservoir, remove the weather

I hood once er month and inspect the element. When its outside surface appears to be
evenly coatee ~ with dirt, remove it for cleaning. Plug the tank access port in the filter to guard
against con amination while cleaning element. Take the wrap-around prefilter off the

I element. Cle an the prefilter in warm water. Shake or blow off any dirt deposits from the
element. It c ~ be cleaned in a warm, mild detergent solution and then thoroughly rinsed
in warm wate r if needed. Allow the prefilter and element to dry before reassembly. If either
the prefilter ( r element is torn or ruptured or in an unacceptable condition, replace it.
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RESERVOIR

This machine is equipped with a reservoir (tank) which has sufficient capacity to receive the
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oil from both cylinders and accumulators in the system when vented. When the entire
system is pressurized and the all pendants tensioned, the oil level should be about 5 inches
above the tank bottom as shown by the level mark on the sight gauge on the side of the
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tank. DO NOT OVERFILL THE TANK.

Hydraulic fluid to specification HDF is used in this system. See Section 3, LUBRICATION, in
I
this manual, for more information. If it becomes necessary to add fluid, use only HDF oil with
the proper viscosity for the local ambient temperature range. Before adding oil to the tank,
filter the oil through a 10 micron or finer filtering unit that has no by-pass circuit. To add the I
oil, remove the .75 NPT plug in the tee next to the outlet port of the return line filter on top
of the tank.
I
If the oil must be replaced for any reason, it can be drained out through the drain port on the
side of the tank. This port is used to connect each tank together and is located just below
the level gauge. The tank cover is removable for parts access and cleaning. BE SURE TO
CONTAIN AND DISPOSE OF THE OIL AND/OR SOLVENTS IN COMPLIANCE WITH THE
I
LOCAL CODES.

A completely drained system will require 30 U.S. gallons of clean, filtered HDF oil in the
I
reservoir. Start the pump and let the oil circulate through the system to purge the air. Permit
the pump to stall after closing the cylinder drain valve. Start with the air regulator set at 5 PSI.
After the pump stalls, adjust the air regulator upwards in small increments until the proper
I
system hydraulic pressure is obtained with the pump stalled. Refer to the Schematic on
page 2.4. Reduce the air pressure by 10 PSI. The Intermediate Boom Support system is
ready for operation. Top off the oil level to the gauge mark as required.
I
ACAUTION: NEVER WORK ON THE BOOM WITHOUT USING A SAFETY
I
HARNESS.

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2.10
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I iate Support Rope Cylinders
·Low Pressure Switch
l~ -Supply Line Filter

I Tank Breather

I Connection for Return Line from

Cylinder *T. Port

dotL----!~---,,~ Tl"/""'-4- Return Li ne Fil ter (10 Micron)

I Pump Cycling Valve

Air Pilot Line

I 1-r-1t--YlY---:::<::---'l:Jl-riT1r-...-l

I
Connection for Air Supply

Return Line Filter (10 Micron)

Air Control Va ve

I I
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~S"PPIY
Pump'

I~~~
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Exhaust Muffl r Connection from
~===:!:~===~=ll Cylinder ·S· Port
U", Fill"

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: Oil Inlet Tube
I to Pump Reservoir

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L...£_
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I RESERVOIR ASSEMBLY for the

HY RAULIC INTERMEDIATE BOOM SUSPENSION System (I.B.S.)

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HYDRAULIC PUMP

The hydraulic pump for each pendant system is an air operated, double acting, reciprocating
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piston type that threads directly into the 1 NPT internally threaded suction pipe that extends
through the top of each hydraulic reservoir. It is rated at 1.5 HP (1.1 KW) with a maximum
air drive pressure of 150 PSI (1035 kPa). It has an actual output ratio of 29: 1. The outlet port
I
is threaded .5 NPT female and the air inlet port is threaded .5 NPSM female. The air exhaust
is fitted with a muffler.
I
In this system, each pump operates at a continuous stall condition. The air supply to each
pump is regulated by an adjustable regulator set to provide the hydraulic system pressure
specified. The pump is maintenance free and its rugged design should provide an excellent I
service life in this application.

When trouble-shooting a pump, isolate it from the rest of the system for testing to make sure
it is the problem. This can be accomplished by shutting off the air supply to the pump in
I
question, carefully venting off the pressure in the hose line connected to the outlet port, and
then connecting a test assembly to the pump outlet. This test assembly consists of: I
Manual Shutoff Valve. (5000 PSI (34.5 MPa)
- On one end, a size 6 JIC 37° Female Swivel Hose End fitting.
- On the other end, a length of SAE 100R9 grade or better size 6 hose.
I
(The Swivel Hose End connects to the fitting in the tee of the pump outlet line.)

A suitable container will be required for venting the oil from this test assembly after
I
pressurizing it. Shut down the machine to check the pump.

If a pump will not operate when air pressure is applied, shut off the air supply to the pump
I
in question and vent the line at the pump air inlet port. Remove the exhaust muffler and the
fitting in the port. Withdraw and clean the cycling valve spool. Reassemble the spool, fitting,
and muffler and see if the pump will operate. If not, replace it. I
If oil is seen coming out the air exhaust, the seal on the hydraulic piston has failed. Replace
the pump. I
If the pump operates but will not build pressure, the inlet or outlet check valves are probably
faulty. Replace the pump. I
To Replace a Pump:
I
1. Set the bucket on the ground and shut down the machine. I
2. Close the valve in the air supply to the pump. Carefully vent off the pressure in the pump
outlet line by loosening the hose fitting at the pressure line filter. Safely contain the oil
that will escape. The low pressure warning in the cab will come on.
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2.12
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I BI005709

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3. Disassem Ie the air line and components from the pump, including the pilot line for the
I cycling v ve.

4. Have an lectrician disconnect the wiring to the low pressure switch.

I 5. Remove he low pressure switch from the outlet line and then the outlet line from the
pump.
I IMPORTANT. Cap and plug all air and hydraulic lines and ports to guard against
contaminates entering either system. Contain any oil spills and dispose

I of the lost oil in compliance with local codes.

6. Unscrew the pump from the top of the reservoir and install a new or rebuilt pump.

I 7. Reverse his procedure to reassemble the air and hydraulic lines to the replacement
pump. sure to purge any air from the hydraulic line between the pump and the

I pressure line filter.

8. Adjust t e air regulator setting upwards in small increments as needed to obtain the

I hydrauli system operating pressure of 525 ±15 PSI, then reduce the air pressure
setting 1 PSI below this value for machine operation. These air operated pumps can be
rebuilt an reused. To order any seal kits and/or replacement parts needed, refer to the
parts bo k for this machine.
I
I
Their are 2 ydraulic cylinders used in the intermediate suspension on this machine. The
I cylinders co nect the intermediate boom support pendants and the top boom chords. Each
cylinder is a pedal JIC heavy duty series cylinder.

I Monitor the
Excessive I
ead end port on each cylinder for evidence of oil leaking past the piston seals.
akage indicates the seals need to be replaced. Remove the faulty cylinder
assembly fr m the boom for repair or rebuild and replace it with a spare. Have a qualified

I hydraulic sh
from our P
p do the work. Marion can perform the repair or rebuild for you. Obtain a quote
s Department. Our Customer Service Department will furnish the test data for
this assemb upon request.

I
I REMOVAL nd INSTALLATION of 1.8.S. PENDANTS and CYLINDERS

iate Suspension Pendants should be replaced in sets, the cylinders can be

I ividually.

ucket and rigging on the ground and shut down the machine.

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I 2.13
 BI005709
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2. At the reservoir, close the air supply valve to shut down the hydraulic pump. Open the
cylinder drain valve on the hydraulic manifold at the bottom of both accumulators in the
system.
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3. Permit the hydraulic system to vent off pressure. The mid-section of the boom may settle
as the two of the intermediate support ropes loose tension. The low pressure warning
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in the cab will come on.

IMPORTANT NOTE: It is best that both sides of the boom be relaxed (and/or I
tensioned) at the same time even though only one cylinder
assembly is to be replaced.
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4. Remove the anti-rotation ropes and support each cylinder to insure that the cylinders will
remain in position when the pendants are removed.

ALWAYS WEAR A SAFETY HARNESS WHEN WORKING ON THE

I
ACAUTION:
BOOM OR MAST TO AVOID FALLING.
I
5. Disconnect the auto lube lines from any pins to be removed. Cap and plug all the lines
and ports to guard against contamination. I
6. Choke the pendant near the socket at the cylinder end of the pendant with a sling and
attach it to lifting equipment. I
7. Carefully pull the pin from the pendant to cylinder joint, lifting it out of the way when free.

8. Lower the free end of the pendant down through the boom apex until it hangs vertically
I
from the head of the mast.

9. Choke the pendant near the socket at the mast end of the pendant with a sling and attach I
it to lifting equipment.

10. Carefully remove the pin from the pendant to link joint at the mast head, lifting it out of I
the way when free.

11. Lower the mast end of the pendant to the ground through the boom apex, using a tractor
or truck attached to the free end to control it.
I
If the cylinder assembly is to be removed, proceed through the following steps: I
12. Disconnect the pressure and breather lines from the cylinder assembly to be removed.
Cap the lines and plug the ports against contaminate entry. I
13. Connect the lifting equipment to the cylinder assembly. Remove the retainer pin and pull
the cylinder pin. Lift the cylinder from the boom and lower it to the ground. I
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2.14
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CL Boom

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I Anti-Rotation
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Front of
Machine
Wire Rope
Bracket

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I View for
Support Rope,
Left Lay
View for
Support Rope,
Right Lay

I
ibbb823e.wpg

I View B-B

I Capscrew,
.75 Inch Gr.5
!---.._-- G.. Pendant
and Cylinder
(2 per Pin)

I Pin

Pendant Socket

I
Bracket

Cylinder Rod Eye

I llI:----Anti-Rotation Rope,
Wire Rope, .5 Inch Dia.,
11 Ton Breaking Strength.

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I Section c-c
ibcc823e.wpg

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 BI005709
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14. The link can now be removed from the Tri-Structure if desired. Repeat steps 8 through
14 to remove the other pendant assembly. I
15. Clean and inspect all parts thoroughly for damage and wear prior to reassembly.
Replace or repair as needed.
I
16. Reverse the above procedure to install a new cylinder assembly and/or a new pendant.

a. After the cylinder has been installed, open the cylinder drain valve and extend
the cylinder rod.
I
b.
-
Pre-lube all bushings and pins with MPG. Purge the air from all auto lube lines
when reconnecting.
I
c. The stripe on each pendant must be a straight line from the Tri-Structure head
to the boom connection when installed. NO TWISTING IS ALLOWED.
I
d. The pendants will tend to twist when tensioned. Check the pendant wire lay and
install the socket/rod pin as noted in View B-B. DO NOT install the anti-rotation
ropes.
I
e. To tension the support pendants for machine operation: I
A. Check the nitrogen charge pressure.

B. Open the cylinder drain valve on the hydraulic manifolds at the end of each
I
accumulator.

C. Open the air valve to start each pump. Let the oil circulate thoroughly throughout
each system to purge the air.
I
O. Set the air regulator at 5 PSI. I
E. Close the cylinder drain valves to pressurize the system, letting the pump stall.
This will take 10 to 20 minutes. I
F. Check for leaks and eliminate any found.

G. Adjust the air regulator upward in small increments until the proper hydraulic I
pressure is obtained in each system with the pump stalled. Refer to the
Schematic on page 2.4. The system pressure is shown on the gauge mounted
on each hydraulic manifold. All pendants should be tensioned the same. Slowly
vent off excess pressure with the cylinder drain valve.
I
H. Reduce the air regulator value by 10 PSI below the value required to obtain the
pressure in step G. Install and adjust the anti-rotation ropes. The Hydraulic
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Suspension System is ready for machine operation.
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2.16
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-------------------
TABLE OF CONTENTS
8750 • SERIAL NUMBER 23224

INTERMEDIATE BOOM SUSPENSION

DESCRIPTION ASSEMBLY aUAN/ASSY

INTERMEDIATE BOOM SUSPENSION 210022-3 1

• HYDRAULIC RESERVOIR ASSEMBLY 361589-8 . . . . . . . . . . . .. 1
•• FILTER/REGULATOR 295880-5 1
•• PUMP 295882-1 . . . . . . . • .. 1
• CYLINDER ASSEMBLY 218444-3 . . . . . . . . . . . .. 2
•• CYLINDER HYDRAULIC 296078-8 1
• ACCUMULATOR ASSEMBLY 370498-0 . . . . . . . . . . . .. 2
•• MANIFOLD ASSEMBLY 299530-1 . . . . . . . . .. 1
• • ACCUMULATOR 370444-1 1
• PENDENT ASSEMBLY 218446-0 . . . . . . . . . . . .. 2
BI005709
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MARION
rJ¢W5j=f--i€- GENERAL INSTRUCTIONS

This parts book has been prepared for a specific machine as identified by the type and serial nllmber given on the cover page and included on a
serial number plate securely mounted Inside the operator's cab before the machine leaves the factory. ALL RECORDS PERTAINING TO THIS
MACHINE ARE KEPT BY SERIAL NUMBER AND YOU SHOULD USE IT WHEN ORDERING PARTS OR CONTACTING MARION FOR OTHER
ASSISTANCE.

The book has been organized to insure that the correct part can be easily identified and ordered. By reading and following the instructions on
identifying and ordering parts, you should be able to secure the proper. genuine Marion repair parts to keep your machine operating productively.

If you have any questions concerning parts or parts ordering procedures. contact Marion Division of INDRESCO Inc.; Repair Parts Department; 617
West Center S1.; Marion, Ohio 43302 (Telephone Number 614-383-5211).

If you have a question concerning the contents or organization of this book (or if you require replacement or additional copies), contact Marion
Division of INDRESCO Inc.; Engineering Technical Publications Department; 617 West Center S1.; Marion, Ohio 43302 (Telephone Number 614-383-
5211 ).

USING THIS BOOK TO IDENTIFY PARTS

This book has been prepared from the engineering drawings and the bills of material used to manufacture the machine which is identified by the serial
number in the front of the book. Mechanical and Electrical assemblies or individual parts requiring replacement over the life of the machine are
inclUded. Refer to the separate electrical parts book furnished for parts used In the major electrical components (Motors, M.G. Sets, Main Drive
Controls, Power Conversion Modules and etc.).

The table of contents is arranged to minimize the search for parts. Each section Is self-contained by including all the assemblies and subassemblies
required. The bullet (.) prefix Indicates a sub-assembly. For example:

Lubrication Systems, Hoist and Drag

• Oil Pump Assembly
•• Pump

In this case, the Pump will be Included in the all Pump Assembly, which in turn is Included In the Lubrication Systems. Holst and Drag Assembly.
BI005709

Marion DivisIon of INDRESCO Inc.

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MARION
%W5i=;LJ'-(- GENERAL INSTRUCTIONS (cont.)

ThA illl Ic:tr~tinn (~)

for p.;1r.h ;1~~p.mhlv Is arranaed In numerical order and Identifies the repair parts by visual representation in their approximate position
relative to other components in the assembly (views may be two or three dimensional and assembled or exploded-view). Each repaIr part Is assigned
an item number (circled number) which corresponds to the item number on the repair parts list. This visual representation may be sufficient to identify
the part you need to order, but it should be carefully checked against the part description on the repair parts list before ordering.

The repair parts list that corresponds to the assembly Illustration contains all the Information to Identify the part or parts. In addition to the item
number that corresponds to the Illustration, the repair parts list includes:

• Part Number which uniquely Identifies the item In Marion's parts ordering and inventory system.

• Description Includes the part name and, in many Instances, additional Information to define the part. Right and left hand designations on the
upper frame correspond to the operator's right and left hands when he is facing forward.

• auantity required identifies the number of the particular part that is used In this assembly.

• The caret (» in front of a part number indicates an assembly; refer to this part number for included parts.

The numerical and alphabetical Indices at the back of the book sort all parts contained in the repair parts lists, first numerically by Part Number and
second alphabetically by Part Description.
BI005709

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Marion DIvision of INDRESCO Inc.
BI005709
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MARION
i555i=;L-t-e- INSTRUCTIONS FOR ORDERING PARTS

REPLACEMENT PARTS SHOULD BE ORDERED FROM THE MARION DISTRIBUTOR, MARION FOREIGN ENTITY NEAREST YOUR MACHINE OR
FROM THE MARION DIVISION OF INDRESCO INC. REPAIR PARTS DEPARTMENT, TELEPHONE: 614-383-52't'r, fAX: 614-383-5035.

When ordering parts the following information must be included to insure proper selection and handling of your order:

1. Machine Type (from cover page)

2. Serial Number (from cover page or serial # plate inside cab)
3. Assembly Number (from top of parts list or illustration)
4. Item Number (from parts list)
5. Part Number (from parts list)
6. Description (complete description from parts list)

Be sure to provide specific instructions as to how (rail freight, air express, truck, parcel post, etc.) and where the part(s) Is to be delivered. PARTS
WHICH ARE RETURNED TO MARION (DUE TO MISTAKES IN ORDERING OR DELIVERY INSTRUCTIONS) ARE SUBJECT TO REHANDLING
CHARGES TO COVER OUR COSTS OF PACKING, UNPACKING, REHANDLING AND/OR RESTOCKING.

COMPATIBILITY WITH RECOMMENDED SPARE PARTS LIST

The machine referenced by this Repair Parts Catalog may have been provided with a preliminary Suggested Mechanical and Electrical Spare Parts
List. That list was generated prior to (or early in) the design/manufacturing cycle for the purpose of planning mine maintenance requirements. It
was Intended as a guideline for spare and/or repair parts and should not be used for ordering parts. Ordering should be done from this Parts Catalog
and the Electrical Parts Catalog which were prepared for this machine. In some instances, parts on the preliminary Suggested Mechanical and
Electrical Spare Parts List were superseded during the production of the actual unit. ALL such changes have been incorporated into this Repair Parts
Catalog. If you have any questions concerning the compatibility of your specific Spare Parts List, write

Marion Division of INDRESCO Inc., Repair Parts Department

617 West Center St., Marion, Ohio 43302
BI005709

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Marion Division of INDRESCO Inc.
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MARION
rb..T/ - TaI{-
REPAIR/SPARE PARTS WARRANTY

IVH:lllon Division of INDRESCO Inc. warrants that its products, when shipped, for a period of six (6) months from the date of delivArv F_O_B_ ooint
of shipment, will meet applicable, agreed specifications, if any with respect thereto, and will be free from defects in material and workmanship,
provided that the Marion products sold are properly stored, assembled, used and maintained. Products not manufactured by Marion shall be subject
only to such warranty as may be made by the manufacturer thereof. All claims under this warranty must be made In writing immediately upon
discovery. THE FOREGOING IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES WHATSOEVER, EXPRESS, IMPLIED AND STATUTORY,
INCLUDING, WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS.

Should any failure of the Marion products to conform to this warranty appear within the limited time period set forth above, Marion shall, upon Buyer's
submission of a claim as provided above, either 1) repair or replace, F.O.B. point of shipment, the nonconforming Marion part or parts which have
been returned for examination, transportation prepaid, or otherwise examined by Marion, and which examination discloses the nonconformity to
Marion's satisfaction; or 2) refund as equitable portion of the purchase price.

THE FOREGOING IS MARION'S ONLY OBLIGATION AND BUYER'S EXCLUSIVE REMEDY FOR BREACH OF WARRANTIES AND, EXCEPT FOR
GROSS NEGLIGENCE, WILLFUL MISCONDUCT, OR REMEDIES PERMITIED UNDER THE PERFORMANCE, INSPECTION, AND ACCEPTANCE
CLAUSE OF MARION'S TERMS AND CONDITIONS, THE FOREGOING IS BUYER'S EXCLUSIVE REMEDY AGAINST MARION FOR ALL CLAIMS
ARISING WITH RESPECT TO MARION PRODUCTS OR RELATING THERETO, WHETHER SUCH CLAIMS ARE BASED ON BREACH OF CONTRACT,
TORT (INCLUDING NEGLIGENCE AND STRICT LIABILITY) OR OTHER THEORIES. BUYER'S FAILURE TO SUBMIT A CLAIM AS PROVIDED ABOVE
SHALL SPECIFICALLY WAIVE ALL CLAIMS FOR DAMAGES OR OTHER RELIEF, INCLUDING, BUT NOT LIMITED TO, CLAIMS BASED ON LATENT
DEFECTS.

IN NO EVENT (INCLUDING, BUT NOT LIMITED TO, AVOIDANCE OF THE ABOVE LIMITED WARRANTIES AND REMEDIES) SHALL BUYER BE
ENTITLED TO ANY INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES, WHETHER ARISING FROM LATE PERFORMANCE OR A
FAILURE TO PERFORM, DEFICIENCIES OR NEGLIGENCE IN THE DESIGN, MANUFACTURE, SALE DELIVERY OR ASSEMBLY OF MARION
PRODUCTS OR FAILURE OF MARION PRODUCTS OR FROM ANY CAUSE WHATSOEVER AND WHETHER BASED ON BREACH OF CONTRACT,
TORT (INCLUDING NEGLIGENCE AND STRICT LIABILITY) OR OTHER THEORIES. ANY ACTION BY BUYER ARISING WITH RESPECT TO MARION
PRODUCTS OR RELATING THERETO MUST BE COMMENCED WITH ONE (1) YEAR AFTER THE CAUSE OF ACTION ACCRUES OR IT SHALL BE
BARRED.
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NAME: PART NO: 218444-3 REV:
MARION CYLINDER ASSEMBLY
DWG. NO:
_J~J==_r __

ROD PORT

PISTON PORT

APPLY A 1 INCH BAND

OF ITEM 25 AROUND
ROD THDS & TIGHTEN
SECURELY.

218444-3
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Marlon Division of INDRESCO Inc.
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MARION
rh~/. J.J==S-, 00(. J CYLINDER ASSEMBLY 218444-3
ITEM PART PART QUAN.
NO. NO. DESCRIPTION REQ.

5 > 296078-8 CYLINDER, HYDRAULIC 14 X 35 1

7 363350-1 KNUCKLE WITH BUSHING 1
7A 165214-1 BUSHING 1
11 109611-7 LOCKTITE #84 (10 CC BOTTLE) 1

I 218444-3
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Marlon Division of INDRESCO Inc. PAGE 2 OF 2 PAGES

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NAME: PPRT NO: 218446-0 REV:
MARION PENDANT ASSEMBLY DI..G. NO:

@)

-1---'- b 9 - I ( -+-

218446-0
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MARION
-{..-{. J
rr..~/. J,-)==J.-
PENDANT ASSEMBLY 218446-0
ITEM PART PART QUAN.
NO. NO. DESCRIPTION REQ.

5 190035-8 SOCKET, OPEN END 1

7 218445-1 ROPE, BRIDGE STRAND (3.5 DIAMETER) 2

I 218446-0
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- - ------------ - - - - -
NAME: PART NO: 210022-3 REV:
MARION INTERMEDIATE BOOM SUSPENSION DWG. NO: A
• - - LEGEND-

®. BREATHER·AIR

ROTATING FRAME -\ ®. HYD.PRESSURE

®. TANK·RETURN

®. AIR SUPPLY

©- EOUALIZER

OL. LEFT SIDE

OR. RIGHT SIDE

I
/

~~~
ct ROTATION

210022-3
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- - - - -- - - - - - - - - - - - - -
NAME: I PART NO: 210022-3 REV:
MARION INTERMEDIATE 800M SUSPENSION DWG. NO:

• "
"
iil/N" '
II ,I
209
""::1 ~
FRONT OF MACHINE

[.jI
13: l~
281111 ~

PIPING-AIR ~ ~
COMPRESSOR '-'J~
~. r

TOP OF DECK

1.25 INCH. STD. WT.•

SCHEDULE 40 PIPE
PICKLED & OILED

147
VIEW B-B
210022-3
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- - - - - - - - - - - -- - - - -- -
NAME: IPART NO: 210022-3 REV:
MARION INTERMEDIATE BOOM SUSPENSION DWG. NO:

- -
HEAT &
BEND AT
ASSY

57) HEAT & BEND MAST

AT ASSY
_--,--- -.=J
L P~TFORM OF
~ 188 BOOM LADDER-
INTMD SUSPENSION
' , BOTH ENDS
"':-~ ' ... AT ASfN
,
"'~-~,:,
NCH STD.
• ';',WT., :,
~ :' J 20 DS
.75 I U'LE 40 "-.
,~" PIPE~.
~ ~ v B O T H EN
~~~i~D OILE~D~'~ & ''-\,''

,
\ H , "~'"
"~.~, _'-',,-
1 INCH, STD. WT.,
SCHEDULE 40 PIPE ' ":~J")
PICKLED & OILED TYPICAL-2 PLCS
"~ TOP CHORD 204
3 PLCS N
BOOM CENTER
181) BOTH ENDS ~ SECTIO

VIEVV A
210022-3
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NAME: PART NO:
I 210022-3 REV:
MARION INTERMEDIATE BOOM SUSPENSION DWG. NO:

- -

3 PLCS

120~
" SYMMECTRICAL ABOUT ~ ~O::.:M::.:- _

HEAT &
BEND AT TO ACCUMULATOR
-::--:::_~-~ ASSY ASSEMBLY

FROM RESERVOIR
ASSEMBLY·HYD
VI'2N C
TYPICAL·2 PLCS

44

HEAT &
BEND AT
ASSY VI'2N E-E
210022-3
BI005709

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Marlon DIvision of INDRESCO Inc.
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NAME: PART NO:
I 210022-3 REV:
MARION INTERMEDIATE BOOM SUSPENSION DWG. NO:

CHARGE VALVE

~ IPLATFORM
~I HANDRAIL
I 53 )2 PLCS

,I I I·-TI--'---
...1 :==
:_3-

74
AT RIGHT ACCUMULATOR

HYDRAULIC GAGE-'/

VIEWD
VIEW F-F
RELIEF VALVE
AT LEFT ACCUMULATOR

210022-3
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Marlon Division of INDRESCO Inc.
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-------------------
NAME: PART NO:
I 210022-3 REV:
MARION INTERMEDIATE BOOM SUSPENSION DWG. NO:

_/~/==-r_.

WALf<MIAY TO UPPER BOOM CHORD

VIEW H-H

VIEWJ
---

~~~ LOWER BOOM CHORD WAUCWAY

HOSE ASSEMBLIES ALONG BOOM

WALf<MIAYS. TYPICAL 3 PLCS

210022-3
BI005709

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Marlon DivisIon of INDRESCO Inc.
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-------------------
MARION
r!t."-
INTERMEDIATE BOOM SUSPENSION 210022-3
- ITEM PART PART QUAN.
NO. NO. DESCRIPTION REQ.

2 > 361589-8 RESERVOIR ASSEMBLY, HYDRAULIC 1

5 138391-4 LINK WITH BUSHINGS 2
5A 115191-6 BUSHING 4
6 197372-0 LINK WITH BUSHINGS 2
6A 165214-1 BUSHING 4
36 > 370498-0 ACCUMULATOR ASSEMBLY 2
37 > 218444-3 CYLINDER ASSEMBLY 2
44 > 218446-0 PENDANT 2
50 094593-5 U-BOLT WITH NUTS 57
51 094594-3 U-BOLT WITH NUTS 114
52 094595-1 U-BOLT WITH NUTS 2
53 034907-1 U-BOLT WITH NUTS 4
57 035487-2 PIN T-HEAD 8
63 329526-5 PIN 2
64 217318-2 PIN 2
66 139220-4 PIN 2
67 139221-2 PIN 2
74 363348-9 HOSE ASSEMBLY 2
104 383358-5 PLATE, CONNECTOR 2
120 367085-6 TY-RAP 4
123 081852-6 CLAMP 1
124 088018-3 CLAMP 2
127 103205-4 CONNECTOR 6-8FTXS 2

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-------------------
MARION
rIJ.."- .J INTERMEDIATE BOOM SUSPENSION 210022-3
ITEM PART PART QUAN.
NO. NO. DESCRIPTION REQ.

128 188414-0 CONNECTOR 8F50XS 2

129 083722-9 CONNECTOR 8-8FTXS 2
130 098106-1 CONNECTOR 8-12FTXS 13
131 089684-5 CONNECTOR 12FTXS 1
132 089683-7 CONNECTOR 12-16FTXS 20
136 043618-6 COUPLING PFM .75 16
137 084473-0 COUPLING PFM 1 32
138 043620-8 COUPLING PFL 1.25 1
140 178354-8 ELBOW, STREET .25 2
141 179486-8 ELBOW6CTXS 1
143 051240-1 ELBOW 6-6CTXS 1
144 087631-3 ELBOW 12CTXS 2
145 043648-8 ELBOW PFM .75 1
146 079552-6 ELBOW PFM 1 3
147 043190-7 ELBOW PFL 1.25 1
149 273153-3 FILTER ASSEMBLY, HYDRAULIC 2
149A 280272-4 ELEMENT, FILTER 2
153 043986-0 FITTING, GREASE 6
154 039348-7 FITTING, GREASE 2
156 425798-7 FLANGE, SPLIT SFH-32 8
157 208101-6 GAUGE, HYDRAULIC (0-1000 PSI) 2
159 103462-6 HOSEAR12 3 FT
162 103393-0 HOSE R5-8 60FT

I 210022-3
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MARION
r!J..~/.]r-. • INTERMEDIATE BOOM SUSPENSION 210022-3
ITEM PART PART OUAN.
NO. NO. DESCRIPTION REO.

163 103314-0 HOSE R5-12 80 FT

167 103399-9 HOSE R2-6 50 FT
168 103282-8 HOSE R2-8 80 FT
174 037158-1 PLUG PFL 1 1
175 287199-8 * CHARGING ASSEMBLY, NITROGEN 2
178 383351-8 ** WIRE ROPE 2
181 072124-7 CLIP, WIRE ROPE 12
184 181682-9 O-RING 2
185 117825-3 O-RING 4
188 196580-8 SHACKLE WITH PIN 2
194 181719-1 TEE .25 MROS 1
195 082497-6 TEE PFM .25 1
199 038774-6 TEE PFL .75 1
201 043196-6 TEE PFL 1 2
202 038782-7 TEE PFL 1.25 1
204 305109-9 THIMBLE, WIRE ROPE 4
207 038808-4 UNION PFM .75 1
208 077571-1 UNION PFM 1 2

* INCLUDES 10 FT. HOSE ASSEMBLY, FITTINGS, ADAPTER WITH GAS VALVE,

BLEEDER VALVE AND GAS CHUCK.

** .5 DIA. X 8 FT., 6 X 37 CLASS, REGULAR LAY, IWRC

I 210022-3
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-------------------
MARION
rlJ,.'/- -J
INTERMEDIATE BOOM SUSPENSION 210022-3
ITEM PART PART OUAN.
NO. NO. DESCRIPTION REO.

209 043620-8 COUPLING PFL 1.25 3

211 296066-4 VALVE, CHECK 2
214 209666-8 VALVE, NEEDLE 1
217 139386-3 ADAPTER 6-1/4F50GS 2
218 103403-1 HOSE END FR2-6 2
219 103491-0 HOSE END F90R2-6 4
220 103315-8 HOSE END F90R2-8 3
221 103283-6 HOSE END FR2-8 11
222 103364-6 HOSE END F90R5-8 2
224 361590-1 ADAPTER 16-1/2F50GS 4
225 103325-5 HOSE END FR5-8 2
226 103396-4 HOSE END FAR12 2
228 103454-5 HOSE END FR5-12 24
233 084468-3 BUSHING, RED. PFH .38 X .25 1
237 084906-5 BUSHING, RED. PFL 1.25 X .75 1
238 048273-1 BUSHING, RED. PFL 2 X .75 2
239 041208-2 BUSHING, RED PFL 1 X .75 2
241 165822-1 NIPPLE, P1X PO .25 X 1.5 2
243 181548-2 NIPPLE, P1-PO 1 X 3 1
247 304986-8 CAPSCREW, HX .38 X .75 GR 5 6
248 145337-8 CAPSCREW, HX .38 X 1 GR 5 2
249 133608-8 CAPSCREW, HX .5 X 2.25 GR 5 4
250 046269-1 CAPSCREW, HX .75 X 2.5 GR 5 4

I 210022-3
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MARION
Jfj • rr-}=i---{~-) INTERMEDIATE BOOM SUSPENSION 210022-3
ITEM PART PART OUAN.
NO. NO. DESCRIPTION REO.

254 304996-5 CAPSCREW, HX .5 X 1.5 GR 8 8

255 363384-5 CAPSCREW, HX.5 X 10 GR 8 8
258 038255-8 NUT, HX .38 GR A 2
259 038253-1 NUT, HX .5 GR A 4
263 178789-6 NUT, HX .5 GR 2H 8
270 061792-0 WASHER, PLAIN ZP .5 GR A 8
277 037498-9 WASHER, LOCK 6MM 350
278 037506-3 WASHER, LOCK .38 14
279 037496-2 WASHER, LOCK .5 12
280 037494-6 WASHER, LOCK .75 4
281 036608-1 WASHER, LOCK .31 4
283 367459-2 VALVE EXTENSION 2
286 207942-9 TRANSDUCER, PRESSURE 2

I 210022-3
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PART NO. 295880-5 REV:
NAME:
MARION FILTER/REGULATOR DWG. NO. A
• Jr-J==-r _ _
BI005709

295880-5
DC46583 Marion Division of INDRESCO Inc. PAGE 1 OF 2 PAGES
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MARION
rh'/- J - J:::::l--;-t.- FILTER/REGULATOR 295880-5
ITEM PART PART OUAN.
NO. NO. DESCRIPTION REO.

1 387997-6 FILTER ELEMENT KIT 1

3 387844·9 BOWL & DRAIN KIT 1
4 289118·2 PISTON KIT 1
5 284475-3 POPPET KIT 1
6 289119-1 CONTROL SPRING 1
7 471118-2 GAUGE 0-160 PSI 1

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295880-5
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NAME: PART NO: 295882-1 REV:
MARION PUMP D\\G. NO: A
--t-., . . e
mf#"- --"i.o( !

UPPER CAP

PUMP BOOY

FiniNG
12

RETAINER RING
RETAINER---------j·

SPRING
e r-

RETAINER
SPRING .
9'
BALL-------

RING ~
SEAT Q:1

FITIING ~ f;;;:;:

~~ NUT ~ ',","
* USE TOOL (ITEM 13) TO ASSEMBLE
I tY EXTERNAL AIR PILOT LINE AND DISASSEMBLE PARTS
~
-L.Y[ ~ '---CONNECTS HERE
NIPPLE
I
10.-, SPRING GUIDE INLET
l SPRING FLUID
9 J-----.I:~ SPRING GUIDE
295882-1
BI005709

2~A
DC45130
082991
Marlon Division of INDRESCO Inc. PAGE 1 OF 2 PAGES
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-------------------
MARION
, fJ..'/. J,-1 ~--{ eII{. PUMP 295882-1
ITEM PART PART OUAN.
Nn NO. DESCRIPTION REO.

1 294502-9 SEAL KIT (AIR CONTROL VALVE) 1

2 294503-7 SEAL KIT (AIR MOTOR) 1
3 351272-0 ** SEAL KIT (PUMP BODY) 1
4 294403-1 CHECK VALVE ASSEMBLY (INLET) 1
5 294417-1 CHECK VALVE ASSEMBLY (OUTLET) 1
6 294234-8 O-RING 1
7 294252-6 BEARING 1
8 294247-0 BEARING 1
9 294075-2 SPRING 2
10 294097-3 STEM, PILOT 2
11 384285-1 KIT, LOW AIR PRESSURE CONTROL 1
12 384286-0 MUFFLER, EXHAUST 1
13 294258-5 TOOL 1

•• KIT INCLUDES INSTALLATION TOOL.

I 295882-1
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NAME: REV:
PJlRT NO: 296078-8
MARION CYLINDER, HYDRAULIC 14 X 35 D\fu. NO:
.Jr-J~ __

+ I I I

([OJ@
@O

296078-8
BI005709

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MARION
"",'/-Jr J =J,.:.~_. CYLINDER, HYDRAULIC 14 X 35 296078-8
ITEM PART PART OUAN.
NO. NO. DESCRIPTION REO.

1 385821-9 KIT, PISTON SEAL 1

2 385822-7 KIT, ROD SEAL 1
3 385823-5 KIT, TIE ROD 1

I 296078-8
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PART NO: 299530-1 REV:
NAME: MANIFOLD ASSEMBLY
MARION DW::;. NO: B
_Ir-I==-r _ _

299530-1
BI005709

DC46361 Marion Division of INDRESCO Inc. PAGE 1 OF 2 PAGES

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MARION
rh"-J,-J=1---;'.-(-J MANIFOLD ASSEMBLY 299530-1
ITEM PART PART OUAN.
NO. NO. DESCRIPTION REO.

1 299529-8 MANIFOLD 1
3 296077-0 VALVE, HYDRAULIC NEEDLE 1
6 323804-1 PLUG 6P50NS 2
7 399558-5 PLUG 8P50NS 2
8 201682-6 GAUGE 0-5000 PSI 1
9 285157-1 VALVE, RELIEF 1

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NAME: I PART NO: 361589-8 REV:
MARION RESERVOIR ASSEMBLY - HYDRAULIC D\-X;. NO: A

52.

@Y
VIEW A-A
2."1

4B~~

~
-$.
361589-8
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DC48154 Marion Division of INDRESCO Inc. PAGE 1 OF 3 PAGES

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MARION
rh~/.]-J=J._,~.
RESERVOIR ASSEMBLY - HYDRAULIC 361589-8
ITEM PART PART OUAN.
~
I'IV. I'\IV. REO.

4 084906-5 BUSHING, RED. PFL 1.25 X .75 1

5 041788-2 BUSHING, RED. PFL.5 X .12 1
6 084866-2 BUSHING, RED. PFH .5 X .38 1
16 103273-9 CONNECTOR 4FTXS 1
18 083722-9 CONNECTOR 8-8FTXS 4
22 334467-3 ELBOW 4CCCTXS 1
23 087631-3 ELBOW 12CTXS 1
24 103375-1 ELBOW 12-8CTXS 1
25 043629-1 ELBOW PFL.5 1
28 273153-3 FILTER, HYDRAULIC WITH ELEMENT 1
28A 280272-4 ELEMENT, FILTER 10 MICRON 1
29 > 295880-5 FILTER/REGULATOR 1
30 207821-0 FILTER/BREATHER 1
31 207819-8 ADAPTER KIT, BREATHER 1
32 103282-8 HOSE R2-8 2 FT
33 103283-6 HOSE END FR2-8 1
34 103315-8 HOSE END F90R2-8 1
35 103460-0 HOSEAR4 2 FT
36 103370-1 HOSE END FAR4 2
40 324027-4 NIPPLE, P1 X-PO .38 X 2 1
41 092121-1 NIPPLE, P1-PO .5 X 2 4
43 165869-7 NI PPLE, P1-PO .5 X 1.5 1
44 479361-7 NIPPLE, P1 1.25 X 6 1

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MARION
rtJ '/-]- • RESERVOIR ASSEMBLY - HYDRAULIC 361589-8
ITEM PART PART OUAN.
~
I'fV. .. ''''-. ;HII-' IN REO.

48 > 295882-1 PUMP 1

52 207818-0 RESERVOIR, HYDRAULIC 1
52A 276656-6 FILTER CARTRIDGE 1
56 295885-6 SWITCH, PRESSURE 1
60 038763-1 TEE PFL.5 1
61 095363-6 TEE PFH-3T .5 1
62 038782-7 TEE PFL 1.25 1
70 443922-8 VALVE, BALL 1
72 361590-1 ADAPTER 16-1/2F50GS 2
90 304986-8 CAPSCREW, HX .38 X .75 GR 5 3
95 037506-3 WASHER, LOCK .38 3

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NAME: PPRT 1\'0: 370444-1 REV,
MARION ACCUMULATOR Dl-c. NO:
_/r-J=-r _ _

• J

370444-1
BI005709

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MARION
rJ1J.~/. I,..
ACCUMULATOR 370444-1
- ITEM PART PART OUAN.
NV. ,-.v. ...,
.... ............. REO.

1 257383-1 KIT, REPAIR 1

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NAME: PART NO: 370498-0 REV:
MARION ACCUMULATOR ASSEMBLY
DWG. NO:
.}~J==-r .._

-----0

43 43

.. ~ I ~ I -----l-----\ 33

I I [28

370498-0
BI005709

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Marlon Division of INDRESCO Inc.
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-------------------
MARION
ACCUMULATOR ASSEMBLY 370498-0
W-a-; ITEM PART PART OUAN.
NO. NO. DESCRIPTION REO.

5 > 370444-1 ACCUMULATOR 1

14 425422-8 BAR, LOCK 1
25 425425-2 ANGLE, SUPPORT 1
26 425424-4 ANGLE, SPACER 1
28 > 299530-1 MANIFOLD ASSEMBLY 1
33 364380-8 PLATE, ADAPTER 1
38 117825-3 O-RING 1
43 362573-7 UNION 24-F50F50 1
57 430019-0 CAPSCREW, HX .62 X 7 GR 8 1
58 428124-1 CAPSCREW, HX .62 X 6.5 GR 8 2
59 038571-9 NUT, HX .75 GR A 2
60 324404-1 NUT, HX .62 GR 2H 3
63 430263-0 WASHER, PLAIN ZP .62 A 3
65 073432-2 CAPSCREW, HX .5 X 1.25 GR 5 2
67 139769-9 CAPSCREW, HX .38 X 1.25 GR 5 2
69 038253-1 NUT, HX .5 GR A 2
71 043435-3 NUT, HX LOCK .38 GR A 2
72 037494-6 WASHER, LOCK .75 2
73 037496-2 WASHER, LOCK.5 2

370498-0
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