Part No. 88619 Z-80/60 4 - 43June 2011 Section 4 • Repair ProceduresREV D4-7Secondary BoomHow to Disassemble theSecondary BoomNote: Complete disassembly of the secondaryboom is only necessary if the outer or innersecondary boom tube must be replaced. Thesecondary extension boom tube can be removedwith the secondary boom tube on the machine.Note: The extension cylinder can be removedwithout completely disassembling the boom. See4-9,How to Remove the Secondary BoomExtension Cylinder.Bodily injury hazard. Theprocedures in this section requirespecific repair skills, liftingequipment and a suitableworkshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.Note: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2,Hydraulic Hose andFitting Torque Specifications.Follow the disassembly steps to the point requiredto complete the repair. Then re-assemble thesecondary boom by following the disassemblysteps in reverse order.1 Remove the primary boom. See 4-2,How toRemove the Primary Boom.3 Carefully remove the snap rings from each endof the damaged section of cable track.4 Remove the retaining fasteners from the upperblack rollers from the 4-link section of cabletrack to be replaced. Remove the rollers.5 Lift up the hoses and cables and carefullyremove the damaged 4-link section of cabletrack.Component damage hazard.Hoses and cables can bedamaged if they are kinked orpinched.6 Remove the upper rollers from the replacementsection of cable track.7 Lift up the hoses and cables and carefully insertthe new 4-link section of cable track.Component damage hazard.Hoses and cables can bedamaged if they are kinked orpinched.8 Connect the ends of the replacement cabletrack section to the existing cable track usingthe snap rings.9 Install the rollers onto the new section of cabletrack.10 Re-assemble and install the extension cylinderassembly into the secondary extension boom.11 Operate the boom extend/retract functionthrough a full cycle to ensure smooth operationof the cable track.BOOM COMPONENTS
