Service and Repair Manual October 2019Boom Components44 S® -80 XC ™ • S® -85 XC ™ • S®-80 HF • S®-85 HF Part No. 1280490GT9 Locate and remove the counterweightretaining fastener at the center of thecounterweight. Carefully lift the counterweightupwards and remove the counterweight fromthe machine. Set the counterweight on theground. Do not leave the counterweightsuspended above the ground.Crushing hazard. The turntablecounterweight will fall if notproperly supported by theoverhead crane resulting indeath or serious injury. Keeppersonnel away from the areawhen removing thecounterweight.10 Remove the end cover from the pivot end ofthe primary boom.11 Remove the limit switch mounting fastenersfrom the limit switch on the ground controlsside of the primary boom. Do not disconnectthe wiring. Remove the limit switch.12 Disconnect the electrical connector from thestring potentiometer.13 Disconnect the electrical connector from theprimary boom angle sensor.Note: The primary boom angle sensor is located onthe pivot pin on the engine side of the boom.14 Remove the primary boom angle sensorbracket mounting fasteners and remove theprimary boom angle sensor from the primaryboom. Do not remove the angle sensor fromthe bracket.Note: When the primary boom is installed, theprimary boom angle sensor will need to becalibrated. Refer to Repair Procedure, How toCalibrate the Primary Boom Angle Sensor.15 Remove the hose and cable guide fasteners atthe primary boom pivot pin. Remove the hoseand cable guide.16 Attach lifting straps from a 5 ton / 5000 kgoverhead crane to each end of the boom.Support the boom. Do not apply any liftingpressure.17 Support and secure the rod end of the boomlift cylinder to a second overhead crane orsimilar lifting device.18 Remove the lift cylinder rod-end pivot pinretaining fasteners. Use a soft metal drift toremove the pin.Crushing hazard. The boomcould fall if not properlysupported when the lift cylinderrod-end pivot pin is removed.19 Using auxiliary power, activate the boom downfunction so the cylinder will retract. Retract thecylinder just enough until the rod end of thecylinder will clear the mounting bracket on theboom. Turn the machine off.Crushing hazard. The boom liftcylinder could fall if not properlysupported and secured to thelifting device.20 Using the overhead crane, carefully lower theboom lift cylinder and allow it to rest on theboom rest pad. Protect the cylinder rod fromdamage.21 Remove the boom end cover retainingfasteners and remove the cover.
