SERVICE 800D
5-34
Published 5-27-2018 Control # 039-06
12. Install a jumper across the terminals of one of the
connectors and check for continuity at the opposite
connector. If the new wire does not have continuity,
check the terminals to ensure they have been attached
correctly.
13. Do not proceed until this wire shows continuity.
14. Visually inspect interior routing of anti-two-block wire for
excess slack in wire, inaccurate routing of wire, etc.
Correct any problems before boom operation.
15. Make all wire connections, reattach the wire to the
cushion clamp on the bottom of the boom and check
system for correct operation.
16. Slowly cycle the boom while checking for proper wire
operation.
Alternative No. 2
This procedure is used for anti-two-block wire replacement in
the event of a complete separation of the wire or the inability
to access one or both ends of the damaged wire outside of
the boom assembly.
Specials tools or equipment
•Electrical tape
•Installation tools
1. Retract boom completely.
2. Measure the lengths of the two ends of the anti-two-
block wires that are outside of the clamps on the first and
second boom sections. Record these dimensions.
3. Remove capscrews and retaining plates from the top
plates of the first and second sections. Remove both
ends of the damaged anti-two-block cord from the boom.
4. Extend the boom until the reinforcing plate on the top of
the second section is outside of the first section by about
24 in (61 cm).
5. At the sheave case end of the boom, remove the two
capscrews and washer from the spacer bar under the
bottom of the first section top plate.
6. Using the anchor button on the steel cable, which drives
the anti-two-block wire, remove the spacer bar and pull
the traveling blocks out of the boom.
7. Inspect the steel cable for damage or defects.
8. Extend the boom to maximum extension. This provides
the least amount of overlap between the two sections
and makes it easier to hook an installation tool at the
back of the second section.
9. Using No. 9 wire or another stiff yet bendable material,
make two tools which are about 72 in (183 cm) in length
with a hook at one end which has an opening of 0.5 in
(1,3 cm).
10. Insert the hooked end of the two “tools” into the space
between the tops of the first and second sections and
run them back until the tools hook over the top plate of
the second section.
11. Run the replacement wire through the open sheave (one
sheave will have the steel cable routed through it
already) of the traveling block and temporarily attach
each end of the new wire to the two tools. You have now
made a big loop with the two tools and the new wire
routed through the sheave.
12. Slowly retract the boom maintaining tension on the new
wire, both sides of the loop, and the steel proportioning
cable. At the time when the reinforcing plate is about 24
in (61 cm) outside of the first section, you need to allow
the traveling block to pass back into the first section.
13. While still maintaining tension on both sides of the loop
of the new wire and a little tension on the steel
proportioning cable, retract the boom to full retraction.
Do not allow the retention button on the steel cable to go
inside of the boom.
14. At the hoist end of the boom, reach inside of the boom
and draw out the two tools hooked over the top plate of
the second section.
15. At the sheave case end of the boom, reinstall the spacer
plate between the top front of the first and second
sections. Make sure that the steel cable is still running
through the slot in the spacer bar.
16. At the hoist end of the boom, draw the two ends of the
new wire out of the boom until the retention button on the
steel cable is drawn against the spacer bar.
17. Run the new wire back and forth through the traveling
block sheave to make sure it runs freely. Do this by
alternately pulling on one end or the other of the new
wire while maintaining slight tension on the other end of
the wire.
18. Loosely replace the retention clamps on the wire after
measuring out one end to ensure the correct wire length
for the connector.
19. Tighten the clamp on the measured end of the wire and
replace the connector. The connectors on this cable are
two separate styles. Make sure the Weather-Pack
connector is on the end that will attach to the 2/3/4 wire.
20. While pulling on the new wire with a tension of about 15-
25 lb (7-11 kg), tighten the capscrews on the second
retaining plate.
21. Using the length recorded earlier, measure the cord and
attach the connector. The connectors on this cable are
two separate styles. Make sure the Weather-Pack
connector is on the end that will attach to the 2/3/4 wire.
Fo
r
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