4-11
TMS800E SERVICE MANUAL BOOM
Published 01-29-2014, Control # 496-00
Ensure that top spacer and sheaves are in proper
orientation to lower sheaves.
NOTE: The lockwasher can be used more than once but
must be replaced if not in good condition.
NOTE: Install the lockwasher onto the sheave shaft with
the tabs facing out.
2. Install the locknut and shims (if necessary) onto the
boom nose sheave shaft with the chamfer side out.
Install the collar onto the opposite end of the sheave
shafts and secure in place with the capscrew and nut.
NOTE: If more than one shim is required, install an equal
amount on each side of the boom nose.
3. Tighten the locknut to eliminate all play in bearings.
4. Install the cable retainer hitch pin into the upper and
lower part of the boom nose and secure in place with the
hitch pin clip.
Assembly
NOTE: Apply medium strength threadlocking adhesive/
sealant to the threads of all attaching hardware
except cable ends and cable lock nuts.
NOTE: Apply multipurpose grease (MPG) to all wear
surfaces.
NOTE: Use standard Grade 5 and/or 8 torque values
specified in Section 1 of this Manual unless
otherwise specified.
1. Install wear pads on the sheave mount/support with the
capscrews. Torque capscrews.
2. Install the sheave mount to the front of the upper
telescope cylinder assembly with capscrews and
washers. Torque the capscrews.
3. Using the sheave shaft, install the sheave assembly in
the sheave mounting assembly. Secure the shaft with a
plate and two capscrews and washers on each side of
the sheave mounting assembly. Torque the capscrews.
4. Route the lug end of the extension cables up and around
the upper telescope cylinder sheaves about one foot on
to cylinder. To aid in assembly, secure the cables to the
end of the cylinder by wrapping tape around the cylinder.
5. Position the cable retainer plate on the front of the
sheave mounting assembly and secure with the
capscrews and lockwashers. Torque the capscrews.
6. Install the skid pad to the bottom of the lower telescope
cylinder mount with the capscrews. Torque the
capscrews.
7. Install the other ends of the extension cables into the
sled weld, making sure the extension cables are not
crossed and twisted.
8. Install the plate cover on the sled weld and secure with
capscrews and washers. Torque the capscrews.
9. Turn the lower telescope cylinder rod so the trunnion is
vertical.
10. At the rear of the tele 3 section, install the upper wear
pad grease line, connector and grease fitting on each
side.
NOTE: The grease lines are designed to be used only on
one side or the other (that is, RH - right hand or LH
- left hand).
11. Install the bottom rear wear pad on the tele 3 section
with the capscrews and washers. Torque the capscrews.
12. Route the two retract cables (threaded ends) through
the tele 3 section to the front. Insert the threaded ends
through the holes on the front of the tele 3 section and
install a washer and two nuts on each cable end.
DANGER
Boom assembly must be rotated 180° upside down before
performing any assembly or disassembly procedures.
DANGER
A rollover fixture with webbing is recommended to rotate
boom and sections. Chains are not recommended. If a
rollover fixture is not available, rotate sections using
adequate support with webbing very carefully
CAUTION
When adjusting cables, hold the cable end and turn the
nut. Do not turn cable. Turning cable while adjusting will
result in damage or failure of cable.
CAUTION
Install cables in their natural untwisted condition. Do not
twist cable. Twisting of cable will result in damage or
failure of cable.
Reference Only
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