SERVICE 800D
5-36
Published 5-27-2018 Control # 039-06
the bottom back end of the fourth section. If excessive
force is needed to pull the wire through, observe the
routing for obstructions and make adjustments to avoid
breaking the splice. If the splice fails Alternative No. 2
may need to be used.
7. Pull the wire through the boom until enough wire is left
on the sheave case end of the boom to attach the
connector and route and anchor the wire. Refer to
measurement taken earlier.
8. Tighten the clamp at the back bottom of the fourth
section.
9. Apply about 15-25 lb (7-11 kg) of tension to the wire at
the sheave case end of the boom. Tighten the clamp on
the wire in the sheave case.
10. Reattach the connector to the wire and make the
connection between the new wire and the anti-two-block
switch. The connectors on this cable are two separate
styles. Make sure the Weather-Pack connector is on the
end that will attach to the 1/2 wire.
11. Cut the splice from the new wire and slide the cord grip
to its approximate final position.
12. Reattach spring to cord grip and reassemble the parts at
the cable anchor on the back of the second boom
section. Slide cord grip up anti-two-block wire into boom
to increase spring tension on moving length of anti-two-
block wire. Approximately 2 in (51 mm) of spring
extension tension should be adequate for proper
operation.
13. Reattach the connector to the wire and make the
connection between the new wire and the anti-two-block
switch. The connectors on this cable are two separate
styles. Make sure the Weather-Pack connector is on the
end that will attach to the 1/2 wire.
14. Visually inspect interior routing of anti-two-block wire for
excess slack in wire, wrong routing of wire, etc. Correct
any problems before boom operation.
Alternative No. 2
This procedure is to be 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. This procedure routes a new anti- two-block
wire through the boom without having an existing wire to pull
it through (Alternative No. 1).
Special tools or equipment:
•Electrical tape
•Installation tool
To route the wire the entire length of the boom, a long tube,
to be used as an installation tool, must be utilized to transport
the end of the new anti-two-block wire from one end of the
boom assembly to the other. A telescopic grease applicator
for the boom, hydraulic tubing or electrical conduit are all
possibilities for use as an installation tool. The installation
tool should be at a minimum 2 ft (0,5 m) longer than the
retracted boom length.
1. Retract the boom completely.
2. 2.Loosen and remove the anti-two-block clamp from the
sheave case and fourth section extend cable anchor.
3. Remove the capscrew from extend cable anchor at the
back of the second boom section.
4. Remove the connector from the wire at the sheave case
end of the boom. Measure and record the length of the
pigtail from the cable clamp to the connector.
5. Remove all damaged wire from the boom. Visually
inspect the interior of the boom to make sure all of the
damaged wire is removed. Inspect sheave at the end of
the telescope cylinder to make sure it is not damaged.
6. Start installation of the replacement at the sheave case
end of the boom. Tape one end of the new wire to one
end of the installation tool.
7. Insert installation tool and wire into the sheave case in
the center open area between the sheave case side
plates. Visually guide the wire and installation tool over
the center sheave on the telescope cylinder sheave
case.
8. Push installation tool and wire until it can be pulled
through the hoist end of the boom. Detach wire from tool
and pull tool back out the sheave case end of the boom.
9. Attach the other end of the wire to the tool and again
insert the tool into the boom between the sheave case
side plates. This time guide the tool into the boom and
under the center sheave of the telescope cylinder.
10. Push tool and attached wire through the boom until it
can be grasped from hoist end. Do not detach wire at
this time.
11. Apply tension to both ends of the new wire. This will
draw the new wire into the groove of the center sheave
of the telescope cylinder sheave case.
12. From the sheave case end of the boom, verify that the
wire is in the groove of the center sheave. If the wire is
not properly aligned, a 5 ft (1,5 m) piece of stiff wire may
have to be used to guide the wire into the groove.
13. At the hoist mount end of the boom, assemble the clamp
attached to the extend anchor at the bottom back of the
fourth boom section.
14. Loop the wire that is still taped to the tool around the
clamp and slowly draw the tool back out of the sheave
case end of the boom.
Fo
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