Maintenance Manual April 2018
Annual Maintenance Procedures
120 S
®
Booms • Z
®
Booms Part No. 1268489GT
6 Measure the distance between boom tubes #2
and #3 using points (9) and (10) in the
illustration. The gap should be
1 in / 2.6 cm to 1.5 in /3.9 cm greater than
dimension "A"
Note: As an example, if the dimension "A" is 1.25 in
/ 3.2 cm, then the gap between boom tubes #2 and
#3 should be between 2.25 in / 5.7 cm and 2.75 in /
7.1 cm.
Result: The distance between boom tubes #2
and #3 is 1 in / 2.6 cm to 1.5 in /3.9 cm greater
than dimension A. The boom tube is in
tolerance. Proceed to step 7.
Result: The distance between boom tubes #2
and #3 is less then 1 in / 2.6 cm or more than
1.5 in / 3.8 cm greater than dimension "A". The
boom tubes need to be adjusted. Refer to
Repair Procedure in the appropriate Service
and Repair Manual for your machine, How to
Adjust the Boom Extend/Retract Cables.
7 Measure the distance between boom tubes #3
and #4 using points 7 and 8 as shown in the
illustration.
Result: The distance between boom tubes #3
and #4 is 1 in / 2.6 cm to 1.5 in / 3.9 cm
greater than dimension A. The boom tube is in
tolerance.
Result: The distance between boom tubes #3
and #4 is less then 1 in / 2.6 cm or more than
1.5 in / 3.8 cm greater than dimension "A".
The boom tubes need to be adjusted. Refer to
Repair Procedure in the appropriate Service
and Repair Manual for your machine, How to
Adjust the Boom Extend/Retract Cables.
All models:
Note: This procedure will require the use of an
aerial work platform.
1 Remove the cover from the pivot end of the
boom.
2 From the ground controls, raise the boom to
the horizontal position and fully extend the
boom.
3 Raise and extend the boom until all the
inspection holes are visible.
Note: The inspection holes are covered with a
black oval decal.
4 Remove the black oval decal from the
inspection holes and discard.
5 Visually inspect the cables and components
through the inspection holes for the following:
• Frayed or broken wire strands
• Kinks or crushed cables
• Corrosion
• Paint or foreign materials on the cable
• Split or cracked cable ends
• Cables are on all sheaves
• Cables at end of adjustment range
• Broken or damaged sheaves
• Unusual or excessive wear
• All fasteners in place and secure
Note: A flashlight and inspection mirror may be
necessary to thoroughly inspect the above items,
or an endoscope inspection camera.
Note: Refer to Maintenance Procedure P12-3,
Cable Replacement Criteria.
Note: If required, the extend or retract cables must
be replaced as a set.
Note: If the boom extend or retract cables are
replaced, quarterly maintenance inspections must
be performed for the first year.
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