BOOM MAINTENANCE SERVICE MANUAL 1400A
4-8 1-21-2019 Control # 104-07
NOTE: The extend cable sheaves located at the top front
of the 2
ND
section can be accessed from any boom
length.
Five Section Boom Removal
1. Extend and set the outriggers and single front outrigger.
The boom must be completely retracted and stowed in
boom rest over the front of the truck.
2. If equipped, remove the swing around jib according to
procedures outlined in the Operator’s Manual.
3. Remove hook block or down haul weight, wind up rope
on hoist drum and stow wedge socket becket on pegs
provided on 1
ST
section. Shut down truck engine.
4. Attach a lifting device to rod end of lift cylinder, remove
boom lift cylinder pin keeper and pin from bottom of 1
ST
section boom. Lower lift cylinder rod end to the deck.
5. Tag and disconnect the extend cylinder and hoist
hydraulic and electric lines. Cap all openings. Unplug
anti-two-block/RCL from the receptacle in turret.
6. Attach a lifting device to provide even weight distribution
and raise the boom until weight is removed from the
boom pivot pin. Remove boom pivot pin keeper and
boom pivot pin. Lift boom free of turret.
Five Section Boom Disassembly
For reference, front is sheave case end, rear (base) is hoist
mount end, left and right are viewed from rear to front.
Steps 1 through 3 apply to a boom that is to be disassembled
with the 1st section and jib (if equipped) left on crane.
1. Extend and set all outriggers and SFO.
2. Fully retract boom and place it in a horizontal position.
3. Tag and disconnect the hydraulic lines to the telescope
cylinder. Cap all lines and fittings.
4. Loosen and remove the fasteners attaching the extend
cylinder butt plate to the base of the 1st section boom.
5. Mark the location of the hex nuts which secure the 3
RD
section extend cables to the hoist bar. Remove the nuts
and washers from 3
RD
section extend cables, and leave
the cable ends draped inside the boom.
6. Attach a sling or chain to the front of the 2
ND
section
boom, pull the 2
ND
-3
RD
-4
TH
-5
TH
assembly out of the 1
ST
section about 30 cm (12 inches).
• Remove the front upper spacer bar from 1
ST
section.
• Remove and tag the four side wear pads and shims
from the front of the 1
ST
section.
• Lift the 2
ND
-3
RD
-4
TH
-5
TH
assembly off of bottom pads.
7. Remove four capscrews which retain the lower front pad
plate to the 1
ST
section.
• Remove the pad plate.
• Remove upper back wear pads and cam plates from
2
ND
section.
• Pull the retract cables out and keep retract cables
taunt while pulling the 2
ND
-3
RD
-4
TH
-5
TH
assembly out
of the 1
ST
section. Support the base end of the 2
ND
as it exits the 1
ST
stage boom.
8. Place 2
ND
-3
RD
-4
TH
-5
H
assembly on a suitable horizontal
surface. Take care not to damage the retract cables
while lifting or supporting the 2
ND
-3
RD
-4
TH
-5
H
assembly.
9. Remove the lower L-pads, retract cables, and retract
cable retaining capscrews from rear of 2
ND
section.
• Remove retract cable retaining plates from the rear
of the 3
RD
section.
• Remove 3
RD
section retract cables from anchor
pocket in 3
RD
section.
10. Remove retaining capscrews from cylinder anchor
channels in the rear of the 2
ND
section. Remove upper
top wear pads and cam plates from upper rear of the 3
RD
section.
11. Remove the cable guide and upper spacer bar cable
retainers from the front top of the 2
ND
section.
• Attach a sling or chain to the tip of the 3
RD
section
boom and pull the 3
RD
-4
TH
-5
TH
assembly out of the
2
ND
section about 30 cm (12 inches).
• Keep the 3
RD
section off of the lower wear pads.
12. Remove the capscrews retaining the 3
RD
section extend
sheaves to the top plate of the 2
ND
section. This allows
the sheaves, pins, and extend cables to lay on the top
plate of the 3
RD
section.
13. Remove the four capscrews which retain the lower front
pad plate to the 2
ND
section.
• Remove the pad plate.
• Remove and tag the four side wear pads with shims
from front of the 2
ND
section.
• Pull the retract cables out and keep retract cables
taunt while pulling the 3
RD
-4
TH
-5
TH
assembly out of
the 2
ND
section.
• Support the base end of the 3
RD
section as it exits
the 2
ND
section boom.
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
Only
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