4-6 Published 08/16/19 Control # 112-05
BOOM 500E2 SERVICE MANUAL
anchor as it is being pulled to the rear will permit easier
removal.
9. Continue to pull extend cylinder and cables out of rear of
boom. Remove extend cables and store in an area to
minimize the possibility of damage.
Additional Maintenance, Disassembled
Boom
1. Clean all boom sections and inspect for wear, dents,
bent or bowed boom sections, gouged metal, broken
welds or any abnormal conditions. Repair or replace as
required.
2. Inspect all sheaves for excessive groove wear or
abnormal rim wear. Replace as required.
3. Inspect all sheave bearings for excessive wear or cut
liner material. If installed bearing diameter is 0.015 inch
(0.38 mm) larger than the pin diameter, bearing must be
replaced. Any cut or gouge which causes the bearing
liner to be distorted is cause for bearing replacement.
4. Clean and inspect all cable assemblies according to the
wire rope inspection procedures in this section. Pay
particular attention to any wire breakage within 6 feet
(180 cm) of the end connections. Replace cable
assemblies as required. Lubricate all cable assemblies
before reinstalling them in the boom.
5. Inspect all sheave pins for nicks, gouges or pitting due to
rust in the bearing surface area. Replace if any damage
is evident.
6. Inspect all grease fittings and grease paths in pins to
ensure proper grease flow. Clean and replace as
required.
7. Inspect all wear pads for excessive wear, gouges, or
abnormal conditions. Clean and replace as required.
THREE SECTION BOOM ASSEMBLY
NOTE: Do not use Loctite on any cable threaded ends.
Always use the locknut and nut provided.
When initially assembling threaded ends of cables,
thread the first nut on past the flat in the cables so
adjustment can be made later.
Refer to Inner Wear Pad Calibration on page 4-8 of
this section to determine Wear Pad shim thickness.
1. Assemble sheaves into 3
rd
section sheave case. Top
sheave is to be installed to the left hand side of the boom
with the spacer to the right hand side.
2. Attach rear wear pads on bottom of 3
rd
section. Using
Loctite 243 blue, Loctite all wear pad mounting
capscrews.
3. Install 3
rd
section boom into 2
nd
section. Slide together
approximately 5 feet (150 cm).
4. Assemble bottom front wear pads for 2
nd
section and
Teflon plugs. Attach pads to pad plate.
5. Using appropriate lifting device, lift 3
rd
section to allow
for wear pad/pad plate installation in front of 2
nd
. Install
wear pad/pad plate assembly. Slide sections together
within 12 inches (30 cm) of full retraction.
6. Install front side wear pads with appropriate shims,
between 3
rd
and 2
nd
sections. If boom has been
disassembled, and no sections have been replaced, use
same shim quantity and location as was previously
used.
7. Route anti-two-block wire through 3
rd
section, keeping
bulk of wire at the rear of the boom sections. Routing
can be accomplished using an installation tool, such as
a telescopic boom grease applicator, electrical conduit,
or hydraulic tubing. Route anti-two-block wire between
sheave case side plates. If locations are in question,
refer to Shim Calibration Section in this manual.
8. Uncoil retract cable assemblies, and insert button end
into anchors in back of the 3
rd
section. Place uncoiled
cable in area that will minimize the potential for damage.
9. Assemble retract sheaves and retract sheave pins in
rear of 2
nd
section. Coat surfaces of bearings with
grease before assembly.
10. Place retract cables over top of retract sheaves. Install
keeper capscrew above sheave to hold retract cables in
place.
11. Reeve cables over retract sheave and install keeper/
wear pad to bottom rear of 2
nd
section. This pad acts as
a side pad, bottom pad, and a cable retainer.
12. Assemble exterior extend cylinder components. Install
and center sheave pin into butt plate of extend cylinder.
Install bearings into extend cable sheaves. Coat surface
of bearings with grease and assemble extend sheaves
on sheave pin.
13. Wrap approximately 10 feet (300 cm) of each 5/8 inch
(15.88 mm) diameter extend cable around extend
sheaves and install extend cable anchor. Do not tighten
capscrews clamping anchor together completely. These
capscrews if tightened completely will not allow cable
anchor to install into 3
rd
section. Route anti-two-block
cable over center sheave on extend cylinder.
14. Install wear pad over extend cylinder sheave side plates.
This serves as a wear pad to keep the end of the extend
cylinder centered in the boom, as well as an extend
cable retainer.
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