SERVICE 1400H OPERATOR AND SERVICE MANUAL
5-30 Published 10-30-2014 Control # 040-09
FIVE SECTION BOOM DISASSEMBLY
For reference, front is sheave case end, rear (base) is
hoist mount end, left and right are viewed from rear to front.
Do not, under any circumstances, work at an
elevated height without using proper fall protection as
required by local, state or federal regulations.
Steps 1 thru 3 apply to a boom that is to be
disassembled with the 1st section and jib (if equipped) left on
crane. If the boom is to be unpinned from the turret of the
crane structure, refer to the Five Section Boom Removal
procedure section in this book.
1. Extend and set all outriggers.
2. Fully retract boom and place it in a horizontal position.
3. Tag and disconnect the hydraulic lines to the telescope
cylinder. Cap all lines and fittings.
4. Loosen and remove the fasteners attaching the extend
cylinder butt plate to the base of the 1st section boom.
5. Mark the location of the hex nuts which secure the 1/2/3
extend cables to the hoist bar. Remove hex nuts and
washers from 1/2/3 extend cables, Leave the cable ends
draped inside the boom.
6. Attach a sling or chain to the front of the 2nd section
boom, pull the 2nd-3rd-4th-5th assembly out of the 1st
section approx 12 in (30 cm). Remove front upper
spacer bar from 1st section. Remove and tag the four
side wear pads and shims from the front of the 1st
section. Suspend 2nd-3rd-4th-5th assembly off of
bottom pads.
7. Remove four capscrews which retain the lower front pad
plate to the 1st section. Remove pad plate. Remove
upper back wear pads and cam plates from 2nd section.
Pull the retract cables out and keep retract cables taunt
while pulling the 2nd-3rd-4th-5th assembly out of the 1st
section. Support the base end of the 2nd as it exits the
1st stage boom.
8. Place 2nd-3rd-4th-5th on a suitable horizontal surface.
Take care not to damage the retract cables while lifting
or supporting the 2nd-3rd-4th-5th assembly.
9. Remove lower L-pads , retract cables, and retract cable
retaining capscrews from rear of 2nd section. Remove
retract cable retaining plates from the rear of the 3rd
section, Remove 3/2/1 retract cables from anchor
pocket in 3rd section.
10. Remove retaining capscrews from cylinder anchor
channels in the rear of the 2nd section. Remove upper
top wear pads and cam plates from upper rear of the 3rd
section.
11. Remove cable guide and upper spacer bar/cable
retainers from the front top of the 2nd section. Attach a
sling or chain to the tip of the 3rd section boom and pull
the 3rd-4th-5th assembly out of the 2nd approximately
12 in (30 cm). Suspend the 3rd section off of the lower
wear pads.
12. Remove capscrews retaining 1/2/3 extend sheaves to
the top plate of the 2nd section, this will allow the
sheaves, pins, and extend cables to lay on the top plate
of the 3rd section.
13. Remove four capscrews which retain the lower front pad
plate to the 2nd section. Remove pad plate. Remove
and tag four side wear pads with shims from front of 2nd
section. Pull the retract cables out and keep retract
cables taunt while pulling the 3rd-4th-5th assembly out
of the 2nd section. Support the base end of the 3rd as it
exits the 2nd section boom.
14. Place 3rd-4th-5th assembly on a suitable horizontal
surface. Take care not to damage the retract cables
while lifting or supporting the 3rd-4th-5th assembly.
Remove 1/2/3 extend cables from the top of the 3rd
section by removing the anchor plates and capscrews at
the rear of the section, place cables in a area to avoid
damage.
15. Remove lower L-pads, retract cables, and retract cable
retaining capscrews from rear of 3rd section. Remove
retract cable retaining plates from the rear of the 4th
section, Remove 4/3/2 retract cables from the anchor
pocket in the 4th section.
16. Remove lock bar and hardware from extend cylinder
collar anchor pocket in the 3rd section. Lifting the butt
plate end of the cylinder up will disengage the cylinder
from its anchor pockets in the 3rd section. Slowly pull
cylinder out of the 3/4/5 assembly. Keep 2/3/4 extend
cables taunt and in position to avoid damage as cylinder
exits boom assembly. Remove 2/3/4 extend cable
anchor in the 4th section as the end of the cylinder nears
the anchor position.
17. Place cylinder assembly on suitable horizontal surface.
Take care not to damage the extend cables while lifting
or supporting the cylinder assembly. The cables can be
disassembled from the cylinder at this time by removing
the tapered wear pads on the front of the cylinder
assembly and routing the cables thru the access
opening made by removing the pad. After tapered pads
are removed use caution as the sheave pin and sheaves
can move forward from the lock position into the
assembly position.
18. Remove cable guide and upper spacer bar from the front
top of the 3rd section. Loosen and remove hex nuts from
threaded ends of 5/4/3 extend cables at rear of 3rd
section. Remove top rear wear pads and cam plates
from top of 4th section.
19. Attach a sling or chain to front of the 4th section boom
and pull the 4th-5th assembly out of the 3st approx. 12 in
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