11-11
5540F/YB5515 SERVICE MANUAL STRUCTURALS
Assembly
NOTE: During assembly, use Loctite 242 (blue) on all
fastener threads. Apply lubricant (bronze anti-
seize) to all wear pads. Apply grease to the inside
bottom, top, and sides of all boom sections.
NOTE: Refer to Figure 11-11 For steps 1 thru 11.
Steps 1 thru 11 pertain to assembly (as necessary)
of the telescope cylinder assembly.
1. Install the elbow fittings in the ports of both telescope
cylinders. Do no tighten at this time.
2. Position the bracket on the barrel end of the lower
cylinder and secure the four bolts and lockwashers.
3. Install the upper cylinder on the lower cylinder by
installing the four bolts and lockwasher at the barrel end
of the upper cylinder and installing the four bolts,
washer, lockwashers and nuts at the piston end of the
upper cylinder.
4. Connect the longer tube between the elbow fittings on
the upper and lower cylinder piston ends.
5. Connect one end of the shorter tube to the elbow fitting
on the barrel end of the upper cylinder.
6. Connect the hose assembly to the other end of the
shorter tube.
7. Install a connector fitting in each port of the check valve
manifold and connect the manifold to the hose
assembly.
8. Connect the manifold to the elbow fitting on the barrel
end of the lower cylinder.
9. Tighten all fittings.
10. Position the wear pad on the bracket on the lower
cylinder barrel and secure with the bolts and nuts.
11. On the four section boom, install the guide pad and pad
support bar to the piston end of the lower telescope
cylinder and secure with the bolts, washers,
lockwashers and
NOTE: Refer to Figure 11-10 For steps 12 thru 15.
Steps 12 thru 15 pertain to the disassembly of
boom section 4 of the four section boom and
section 3 of the three section boom.
12. As necessary, install the following items on the boom
section:
a. On the three section boom only, install the rear
bottom wear pad and secure with the bolts and
lockwashers.
b. On the boom nose, install the three clevis pins and
cotter pins.
c. On the four section boom, install the retract adjuster
using two nuts.
d. Replace the bearings in the sheaves as necessary.
e. Install the upper sheave and two nylatron washers.
Install the upper sheave pin and secure with a bolt.
f. Install the lower sheave and three nylatron washers.
Install the lower sheave pin and secure with a bolt.
13. Install the top rear wear pads on the boom section.
14. Slide the telescope cylinder assembly into the boom
section.
15. Install the pin securing the telescope cylinder to the
boom section. Install the snapper pin in the pin. (refer to
Figure 11-11)
NOTE: Refer to Figure 11-9 For steps 16 thru 19.
Steps 16 thru 19 pertain only to the disassembly of
boom section 3 of the four section boom.
16. As necessary, Install the following items on the boom
section 3:
a. Install the lower rear wear pad and secure with the
bolts and lockwashers.
b. Install the wire rope guide two bolts, washers(4),
lockwashers, and nuts.
c. Install the two long wear bars in the bottom of the
section and secure with the bolts and lockwashers.
d. Install the bumper and shim(s) to the bracket in the
front of the section and secure with the bolts and
lockwashers.
e. Install the holding bracket on the side of the boom
section and secure with the bolt, lockwasher and
washer
.
17. Slide the
assembly into the boom section 3.
18. Raise up on the boom section 4 assembly and install the
front bottom wear pads in the boom section 3. Install the
bolts and lockwashers securing the wear pads.
19. Install the top rear wear pads on the boom section 3.
NOTE: Refer to Figure 11-8 for steps 20 thru 26.
20. As necessary, install the following items on the boom
section 2:
a. Install the lower rear wear pads and secure with the
bolts and lockwashers.
b. Install the front top and bottom side wear pads,
plugs and set screws. Do not tighten the set screw
at this time.
21. Slide the assembly into the boom section 2.
Reference Only
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