4-4 Published 08/16/19 Control # 112-05
BOOM 500E2 SERVICE MANUAL
BOOM REMOVAL
1. Extend and set machine outriggers. Boom must be
completely retracted and stowed in the boom rest.
2. If equipped, remove swing around jib. See Section 4
Operator’s Handbook, Section 4.
3. Remove hook block or downhaul weight. Wind up rope
on hoist drum and stow wedge socket 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 the
1
st
section boom. Lower lift cylinder to a suitable
support.
5. Tag and disconnect extend cylinder lines and hoist
hydraulic lines. Cap all open lines and ports.
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.
Boom Disassembly
The 500E2 Service Manual boom can be disassembled by
using two different methods. Alternative #1 disassembles the
boom in the conventional manner. Alternative #2 removes
the extend cylinder from the rear of the boom, after removal
of the hoist. This feature facilitates cylinder service without
complete boom teardown.
For reference, the front of the boom refers to the sheave
case end, the rear of the boom is the hoist mount end. Left
and right are viewed from front to rear.
If the boom is to be unpinned from the turret of the crane
structure, please refer to the Boom Removal Procedure
section in this book. If the required service procedure is to be
performed on the boom while still pinned to the turret, please
follow these directions.
Boom Disassembly Alternative #1
1. Gaining access through rear of boom, loosen capscrews
retaining the extend cable anchor in the rear of the 3
rd
section as well as the capscrew on the anti-two-block
wire clamp on the anchor assembly.
2. Extend boom 24 inches (60 cm). Loosen and remove
the nuts which secure the extend cables to the cable
anchor plate. Remove nut from anti-two-block spade
bolt. Tag and disconnect hydraulic lines to the extend
cylinder.
3. Drape extend cables and anti-two-block cable inside
boom, and slide cable anchor plate out of the side of the
hoist mount if hoist has been removed from boom.
4. Loosen and remove two capscrews, lockwashers and
spacers which anchor the extend cylinder rod butt plate
to the rear of the 1
st
section.
5. Loosen and remove two capscrews and lockwashers
securing spacer bar to the inside top of the front of the
1
st
section. Remove spacer bar.
6. Loosen and remove four capscrews securing wear pads
to the bottom of the 1
st
section. Removal of side wear
pads is optional. Adequate clearance exists between
adjoining section side pads for boom disassembly. If
side pad removal is required, tag all pads, shims, and
corresponding locations for proper reassembly.
7. Support 2
nd
3
rd
assembly at the front with an appropriate
lifting method. Raise the 2
nd
3
rd
assembly inside the 1
st
section to allow for front bottom pad removal. Remove
bottom wear pads.
8. With the 2
nd
& 3
rd
assembly supported, slide assembly
out of the 1
st
. Relocation of the sling point on the 2
nd
&
3
rd
assembly will be necessary for proper balancing of
the assembly as it slides out of the 1
st
section. Keep
tension on retract cables as the assembly is pulled out of
the 1
st
, to minimize the chance of retract cable damage.
9. Place 2
nd
& 3
rd
assembly on a suitable horizontal
surface. Take care not to pinch or crush retract cables
while lifting or supporting assembly.
10. Remove top rear wear pads on the 2
nd
section. They will
lift off the cam plates easily. Do not remove or loosen the
capscrews holding the cam plates to the section. This
will affect side clearance during re-assembly.
11. Loosen and remove four capscrews securing the rear
bottom wear pads on the 2
nd
section. This pad serves as
a bottom and side pad as well as the retract cable
keeper under the retract sheaves. Removal of this pad
will allow the retract cables to uncoil off the retract
Boom Length Boom Weight
Cg From Pivot
Point
71 ft (21.6 m) 5145 lb (2334 kg) 140 in (3.56 m)
60 ft (18.2 m) 4660 lb (2113 kg) 118.8 in (3.02m)
DANGER
Do not, under any circumstances, work at an elevated
height without using proper fall protection as required by
local, state or federal regulations.
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