REPAIR 800D
6-12
Published 5-27-2018 Control # 039-06
conventional manner. Alternative #2 removes the telescope
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.
Do not, under any circumstances, work at an elevated
height without using proper fall protection as required
by local, state or federal regulations.
1. Extend and set the outriggers.
2. Fully retract the boom and place in a horizontal position.
3. Hoist removal optional.
Boom Disassembly Alternative #1
1. Gaining access through rear of boom, loosen capscrews
retaining the keeper plates holding the extend cable
anchor and retract cables in the rear of the 3rd section,
remove keeper plates.
2. Extend boom 24 in (60 cm). Loosen and remove the
nuts which secure the extend cables to the cable anchor
plate. Tag and disconnect hydraulic lines to the
telescope cylinder.
3. Drape extend cables 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 telescope cylinder rod butt
plate to the rear of the 1st section.
5. Loosen and remove two capscrews and lockwashers
securing spacer bar to the inside top of the front of the
1st section. Remove spacer bar.
6. Loosen and remove four capscrews securing wear pads
to the bottom of the 1st 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 2nd-3rd-4th assembly at the front with an
appropriate lifting method. Raise the 2nd-3rd-4th
assembly inside the 1st section to allow for front bottom
pad removal. Remove bottom wear pads.
8. With the 2nd-3rd-4th assembly supported, slide
assembly out of the 1st. Relocation of the sling point on
the 2nd-3rd-4th assembly will be necessary for proper
balancing of the assembly as it slides out of the 1st
section. Keep tension on retract cables as the assembly
is pulled out of the 1st to minimize the chance of retract
cable damage.
9. Place 2nd-3rd-4th 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 2nd section. They
will lift off the cam plates easily. Do not remove or loosen
the capscrews holding the cam plate to the section. This
will affect side clearance during re-assembly. Note
orientation of pad as it is removed. The hole in the
bottom is offset for adjustment purposes. Replacing the
wear pad in the same orientation is required to keep the
boom straight.
11. Loosen and remove four capscrews securing the rear
bottom wear pads on the 2nd 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
sheaves. Place retract cable ends in a location to
minimize the possibility of damage.
12. Loosen and remove six capscrews securing retract
sheave pins and sheaves to 2nd section. Remove
sheaves and pins.
13. Loosen and remove two capscrews functioning as upper
retract cable keepers. Remove retract cables.
14. Loosen and remove two capscrews securing lock bar to
the telescope cylinder collar. This bar constrains the
vertical movement of the telescope cylinder. Remove
bar.
15. Loosen capscrews retaining extend cable anchor to
back of the 4th section. Total removal of the capscrews
will allow the cable anchor to be completely
disassembled, backing capscrews out approximately
0.50 in (12 mm) will allow the anchor assembly to slide
rearward out of the section as the telescope cylinder is
removed.
16. Support telescope cylinder with an appropriate lifting
device and pull the cylinder out of the boom while
keeping the extend cables tensioned slightly by hand to
minimize the possibility of damage to the cables. Pull
cylinder to within 3 ft (91 cm) of complete removal from
the boom sections.
17. Pull the extend cable anchor out from its retaining pocket
on the bottom of the 4th section. A slight angle applied to
the anchor as it’s being pulled to the rear will permit
easier removal through the 2nd and 3rd sections.
18. Remove the telescope cylinder from the boom. Remove
extend cables. Place cylinder and cables in suitable
area to prevent possible damage.
19. Loosen and remove four capscrews, cable guide, wear
pad and spacer bars from the front top of the second
section.
Fo
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