BOOM MAINTENANCE SERVICE MANUAL 1400A
4-4 1-21-2019 Control # 104-07
Boom Disassembly Alternative #2
The extend cylinder can be removed from the rear of the
boom without disassembly of the boom sections. This allows
quick access to the cylinder, retract cables, and various
internal boom components for service or replacement. If this
procedure is used for disassembly, reverse procedure for
reassembly, or locate the appropriate step in the assembly
procedure in this manual to start reassembly from.
1. Remove the hoist and anti-two block components.
2. From the rear of boom, remove capscrews securing the
extend cable anchor in the rear of the 4
TH
section.
Remove two capscrews securing lock bar to extend
cylinder and remove the lock bar
3. Remove the nuts which secure the extend cables to the
extend cable anchor in the back of the 2
ND
section.
• Remove the capscrews from keeper plates holding
extend anchor in place.
• Remove the keepers.
• Remove the anchor.
4. Place extend cables inside the boom and slide the cable
anchor plate out of the side of the hoist mount.
5. Remove the two capscrews, lockwashers, and spacers
which anchor the extend cylinder rod butt plate to the
rear of the 1
ST
section.
6. Using an appropriate lifting device, lift the extend
cylinder up and out of retaining slots on rear of 2
ND
and
3
RD
sections. Retracting the cylinder with an external
hydraulic power source during this step may be
necessary.
7. Pull the cylinder out through the rear of boom assembly
approximately one-half the length of the cylinder.
Turning of the butt plate and rod 90 degrees may aid in
sliding cylinder through the hoist mount area. Keep the
extend cables tight to minimize the possibility of
damage.
Additional Maintenance, Disassembled
Boom
1. Clean all boom sections and inspect for wear, dents,
bent or crooked boom sections, gouged metal, broken
welds or any abnormal conditions. Repair or replace as
required.
2. Inspect all sheaves for excessive groove wear or
abnormal rim wear. Replace as required.
3. Inspect all sheave bearings for excessive wear or cut
inner liner material. If installed bearing diameter is 0.38
mm (0.015 inch) larger than pin diameter, bearing must
be replaced. Any cut or gouge which causes the bearing
liner to lose strands is cause for bearing replacement.
4. Clean and inspect all cable assemblies according to wire
rope inspection procedures in section one. Pay
particular attention to any wire breakage at the end
connections. Replace cable assemblies as required.
Lubricate all cable assemblies before reinstalling them
in boom.
5. Inspect all sheave pins for nicks, gouges or pitting due to
rust in the bearing surface area. Replace if any damage
is evident.
6. Inspect all grease fittings and grease paths in pins to
ensure proper grease flow. Clean and replace as
required.
7. Replace all lubricating plugs in all wear pads.
FOUR SECTION BOOM ASSEMBLY
NOTE: Note: Do not use Loctite on any cable threaded
ends. Always use the locknut and nut provided.
When initially assembling threaded ends of cables, thread
the first nut on past the flat in the cables so adjustment can
be made later.
1. Assemble the sheaves into 4
TH
section sheave case.
Install the top sheave to the left side of the boom with the
spacer to the right side.
2. Attach the rear wear pads on bottom of 4
TH
section.
Using Loctite 243, on all wear pad mounting capscrews.
3. Install 4
TH
section boom into 3
RD
section. Slide together
approximately 152 cm (5 feet).
4. Assemble bottom front wear pads for 3
RD
section and
Teflon wear plugs. Attach pads to pad plate.
5. Lift the 4th section with a lifting device to allow for wear
pad/pad plate installation in front of the 3
RD
section.
Install the wear pad/pad plate assembly. Slide the
sections together within 30 cm (12 inches) of full
retraction.
6. Install the cable guide and upper spacer to front of 3
RD
section.
7. Install the front side wear pads with appropriate shims
between 4
TH
and 3
RD
sections. If the boom has been
disassembled, and no sections have been replaced,
reinstall the shims as removal tags.
DANGER
Do not, under any circumstances, work at an elevated
height without using proper fall protection as required by
local, state or federal regulations.
Fo
r
Reference
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