KCOR4025.

01
 INDEX

INTRODUCTION ......................................................................................................................... 1
NECESSARY TOOLS ................................................................................................................. 2
HOSES CONNECTION SCHEME ............................................................................................... 3
HOW TO REMOVE BOOM TELESCOPING CYLINDER ............................................................ 4
KIT ASSEMBLY .......................................................................................................................... 5
 1 - INTRODUCTION

INDEX

SAFETY AND GENERAL INSTRUCTIONS..................................................................................................................................... 2

CONVERSION FACTORS ........................................................................................................................................................... 3

METRIC HARDWARE TORQUE SPECIFICATIONS ........................................................................................................................ 4

SCREW-LOCKING, SEALING AND LUBRICATING MATERIALS...................................................................................................... 5

1-1
 1 - INTRODUCTION

This manual provides the information necessary for a correct and safe way to carry out maintenance works not included in the
"INSTRUCTION HANDBOOK FOR OPERATING AND MAINTENANCE"; it is addressed to qualified fitters, who know enough about
mechanical components and the functioning of hydraulic and electrical systems for the machine on which it is operating. The action
necessary to implement and enforce the policies related to the Environment and Health and Safety procedures are left to the
responsability of the workshop manager.

SAFETY AND GENERAL INSTRUCTIONS

CAUTION !!!
This machine is designed and manufactured according to Merlo S.p.A. specifications. To avoid accidents and to ensure
optimum performance, the machine must not be modified or altered unless approved by Merlo, nor should it be used in
conditions or for purposes which it is not designed for. All information, illustrations and specifications in this manual are
based on the latest product information available at the time of publication. The right is reserved to make changes at any
time without notice.

CAUTION !!!
Always ensure any work carried out on the vehicle is carried out on level ground. If this is not possible the ground should be
as level as possible and the vehicle should be chocked to prevent any possibility of the vehicle rolling.

CAUTION !!!
Servicing of the machine shall only be carried out by skilled and competent personnel. For repair of parts that are not part of
the normal scheduling, refer MERLO S.p.A. technical service.

CAUTION !!!
Always wear suitable protective clothing and safety equipment when using lubricants (gloves, masks, goggles, overalls,
etc.). Extra care should be taken to avoid burns when working with hot fluids or elements.

CAUTION !!!
Always dispose of oils, filters or other mediums in an environmentally friendly manner. Use official organisations for the
disposal of such fluids.

1-2
 1 - INTRODUCTION

CONVERSION FACTORS

Units of Pressure Atm bar Pa Psi Nmm²

5
1 Atm 1 1 10 14,4 0,1
1 bar 1 1 105 14,4 0,1
1 Pa 0,00001 0,00001 1 0,000144 0,000001
1 Psi 0,069444 0,069444 6944,4 1 14,4
6
1 Nmm² 10 10 10 144 1

Units of Weight N daN kN Kg lbs

1N 1 0,1 0,001 0,102 0,225
1 daN 10 1 0,01 1,02 2,25
1 kN 1000 100 1 102 225
1 Kg 9,81 0,981 0,00981 1 2,205
1 lbs 4,448 0,448 0,00448 0,4536 1

Units of Torque Nm daNm kNm kgm lb-in

1 Nm 1 0,1 0,001 0,102 8,854
1 daNm 10 1 0,01 1,02 88,54
1 kNm 1000 100 1 102 8854
1 kgm 9,81 0,981 0,00981 1 86,8
1 lb-in 0,1129 0,01129 0,0001129 0,01152 1

Units of Length m cm yds inch ft

1m 1 100 1,094 39,37 3,280
1 cm 0,01 1 0,01094 0,3937 0,03280
1 yd 0,9144 91,44 1 36 3
1 inch 0,0254 2,54 0,0277 1 0,0833
1 ft 0,3048 30,48 0,333 12 1

Units of Power CV Hp Kw Watts

1 Cv 1 0,9863 0,7355 735,5
1 Hp 1,0139 1 0,7457 745,7
1 Kw 1,359 1,341 1 1000
1 Watt 0,00136 0,00134 0,001 1

Ohm's Law
I = Current intensity I=V/R
V = Electromotive force R=V/I
R = Resistance V=I*R

1-3
 1 - INTRODUCTION

METRIC HARDWARE TORQUE SPECIFICATIONS

Tightening torque Ma of a given bolt or nut is the necessary torque to put the bolt under a given preloading. Tightening torque valve
should be used to adjust dynemometric wrenches to avoid fatigue failures.
The following table contains tightening torque specifications relative to external diameter of metric thread. Figure are approximate.

Unit = Nm

TYPE OF BOLT

SIZE OF BOLT 8.8 10.9 12.9

Standards - Standards - Standards - Standards - Standards - Standards -
Loctite 242 Loctite 270 Loctite 242 Loctite 270 Loctite 242 Loctite 270
M6 x 1 9,5 – 10,5 10,5 – 11,5 14,3 – 15,7 15,2 – 16,8 16,2 – 17,8 18,1 – 20,0
M8 x 1,25 23,8 – 26,2 25,6 – 28,4 34,2 – 37,8 36,7 – 40,5 39,0 – 43,0 43,7 – 48,3
M10 x 1,5 48 – 53 52 – 58 68 – 75 73 – 81 80 – 88 88 – 97
M12 x 1,75 82 – 91 90 – 100 116 – 128 126 – 139 139 – 153 152 – 168
M14 x 2 129 – 143 143 – 158 182 – 202 200 – 221 221 - 244 238 – 263

COARSE M16 x 2 200 – 221 219 – 242 283 – 312 309 – 341 337 – 373 371 – 410
PITCH M18 x 2,5 276 – 305 299 – 331 390 – 431 428 – 473 466 – 515 509 – 562
M20 x 2,5 390 – 431 428 – 473 553 – 611 603 – 667 660 – 730 722 – 798
M22 x 2,5 523 – 578 575 – 635 746 – 824 817 – 903 893 – 987 974 – 1076
M24 x 3 675 – 746 732 – 809 950 – 1050 1040 – 1150 1140 – 1260 1240 – 1370
M27 x 3 998 – 1103 1088 – 1202 1411 – 1559 1539 – 1701 1710 – 1890 1838 – 2032
M30 x 3,5 1378 – 1523 1473 – 1628 1914 – 2115 2085 – 2305 2280 – 2520 2494 – 2757

M8 x 1 25,7 – 28,3 27,5 – 30,5 36,2 – 39,8 40,0 – 44,0 42,8 – 47,2 47,5 – 52,5
M10 x 1,25 49,4 – 54,6 55,2 – 61,0 71,5 – 78,5 78,0 – 86,0 86,0 – 94,0 93,0 – 103,0
M12 x 1,25 90 – 100 98 – 109 128 – 142 139 – 154 152 – 168 166 – 184
M12 x 1,5 86 – 95 94 – 104 120 – 132 133 – 147 143 – 158 159 – 175
M14 x 1,5 143 – 158 157 – 173 200 – 222 219 – 242 238 – 263 261 – 289

FINE M16 x 1,5 214 – 236 233 – 257 302 – 334 333 – 368 361 – 399 394 – 436
PITCH M18 x 1,5 312 – 345 342 – 378 442 – 489 485 – 536 527 – 583 580 – 641
M20 x 1,5 437 – 483 475 – 525 613 – 677 674 – 745 736 – 814 808 – 893
M22 x 1,5 581 – 642 637 – 704 822 – 908 903 – 998 998 – 1103 1078 – 1191
M24 x 2 741 – 819 808 – 893 1045 – 1155 1140 – 1260 1235 – 1365 1363 – 1507
M27 x 2 1083 – 1197 1178 – 1302 1520 – 1680 1672 – 1848 1834 – 2027 2000 – 2210
M30 x 2 1511 - 1670 1648 - 1822 2138 – 2363 2332 - 2577 2565 - 2835 2788 - 3082

1-4
 1 - INTRODUCTION

SCREW-LOCKING, SEALING AND LUBRICATING MATERIALS

Locking, sealing and lubricating materials referred to in this manual are the same used in the shop floor.
The table below gives an account of the typical applications of each single material, in order to facilitate
replacement with similar products marketed by different brand names with different trademarks.

DENOMINATION APPLICATION
Anaerobic product apt to prevent the loosening of screws, nuts and plugs. Used for
Loctite 242 medium-strength locking. Before using it, completely remove any lubricant by using the
specific activator.
The oleo compatible alternative to “242”. Does not require the activation of lubricated
Loctite 243
surfaces.
Anaerobic product for very-high strength locking of screw and nuts. Before using it,
Loctite 270 completely remove any lubricant by using the specific activator. To remove parts, it may
be necessary to heat them at 80°C approx.
Anaerobic product suitable for high-strength locking and sealing of large threaded parts,
Loctite 275 bolts and stud bolts, for pipe sealing and for protecting parts against tampering; suitable
for sealing coupling surfaces with a maximum diametrical clearance of 0,25 mm.
Anaerobic product for the hermetic sealing of flanged units and screw holes
Loctite 510
communicating with fluids. Can seal clearances between flanges up to 0,2 mm.
Quick anaerobic sealant for sealing threaded portions of conical or cylindrical unions up to
M80. Before using it, completely remove any lubricant by using the specific activator. After
Loctite 577
polymerisation, disassembly may result rather difficult, so heating may be necessary for
larger diameters.
Anaerobic adhesive for fast and high-strength gluing of cylindrical metal joints. Can glue
Loctite 638
together parts with clearance ranging between 0,1 e 0,25 mm.
Anaerobic adhesive for fast and medium-strength gluing of cylindrical metal joints. Can
Loctite 648
glue together parts with radial clearance below 0,1 mm.
Lithium-based Applied to bearing, sliding parts and used to lubricate seals or parts during assembly.
grease
Highly adhesive synthetic grease, with silicone compounds added. Applied to adjustment
Silicone-based
screws with hole communicating with oil-type fluids. Used when frequent adjusting is
grease
required.

1-5
 2 - NECESSARY TOOLS

INDEX

STANDARD TOOLS .................................................................................................................................................................. 2

SPECIAL TOOLS AND ATTACHMENTS ....................................................................................................................................... 3

2-1
 2 - NECESSARY TOOLS

STANDARD TOOLS

Fissa combinata - Spanner - Clé fixe Esagonale - Hexagon head driver - Hexagonal
Größe - Llave fija Imbusschlüssel - Exagonal

10 - 13 - 17
19 - 22 - 24 6
27 - 36

Leva a cricco - Click lever Leva scorrevole - Sliding lever - Levier coulissant
Levier à cliquet - Knarre – Caraca Knebel - Palanca corrediza

Bussole esagono esterno

Bussole esagono interno - Bush inner exagone
Bush external exagone
Douilles hexagone intèrne - Nüsse Imbusnüsse
Douilles hexagone extèrne - Nüsse
Llave de tubo exágono interior
Llave de tubo exágono exterior

8 - 12 - 17 - 30 13 - 19 - 30

Chiave a “T” snodata

Prolunga – Extension - Rallonge
“T” universal socket wrench - Clé en “T” articulée
Verlängerungen - Alargadera
Llave en “T” articulada - “T”-Gelenkschlüssel

L = 100 mm
L = 200 mm

2-2
 2 - NECESSARY TOOLS

SPECIAL TOOLS AND ATTACHMENTS

Tools for the securing of the ducts on the pulleys

False chamber extraction device
of the false chamber

055200 055195

Nipple M22x1,5 Plug DIN F22x1,5 Nipple M30x2 Plug DIN F30x2
(quantity 25) (quantity 45) (quantity 1) (quantity 1)

035123 035737
038026 043697

2-3
 3 - HOSES CONNECTION SCHEME

A) Lower hoses
B) Upper hoses
C) Lower metal pipes
D) Upper metal pipes
E) False chamber

3-1
 4 - HOW TO REMOVE BOOM TELESCOPING CYLINDER

WARNING !!! Except where otherwise stated, carry out the following instructions with diesel engine switched off.

1) Start the engine and then lift the machine arm.

Remove the 2 fixture screws of the iron pipe, positioned
in the vicinity of the lifting jack attachment..

2) Lower the telescopic arm and switch off the thermal

engine; unscrew the four iron pipe fixture screws, located
beneath the final section of the first arm..

3) Dismantle the fixture plate of the fork and relay ducts on

the rear part of the arm..

4-1
 4 - HOW TO REMOVE BOOM TELESCOPING CYLINDER

4) To facilitate re-assembly, mark the positions of the four ducts; then disconnect them from the iron pipes.

NOTE !!! To avoid excessive leakage of hydrostatic

oil, always remember to cap the ducts after having
disconnected them; also cap the iron pipes.

5) Dismantle the fixture plate of the iron pipes.

4-2
 4 - HOW TO REMOVE BOOM TELESCOPING CYLINDER

6) Disconnect all the connectors present on the electric

cables that escape from the iron pipes..

7) Remove the two holding brackets of the ducts and the electric cables, present above the pulleys.

8) Switch on the engine and extract the telescopic boom by about 20 cm, after which, switch off the engine.

NOTE !!! This operation is necessary in order to facilitate the dismantling opf the two lower screws that secure the
stem on the first boom..

4-3
 4 - HOW TO REMOVE BOOM TELESCOPING CYLINDER

9) Remove the two upper screws that secure the stem.

10) Whilst keeping the screws secured from the inside,

remove the fixture nut and then repeat the operation for
the other nut.

11) Pull the iron pipes outwards by about half a metre, so as

to eliminate the tension of the ducts on the pulleys; then
proceed to loosen the fixture screw of the jack pulley
support.

4-4
 4 - HOW TO REMOVE BOOM TELESCOPING CYLINDER

12) Switch on the engine and carefully extract the telescopic boom by a further 20-30 cm (to prevent damage to the ducts); switch
off the engine and extract the support complete with pulleys.

13) Using a bridge crane or other suitable equipment, fully extract the iron pipes and the ducts connected to the same.

IMPORTANT !!! During this operation take care not to bend the iron pipes and not to damage the ducts.

14) Place the whole set on the ground or on a work bench; remove the two blocks (B);

4-5
 4 - HOW TO REMOVE BOOM TELESCOPING CYLINDER

15) Disconnect the ducts from the lower iron pipes and those positioned on the false chamber.

WARNING !!! IN VIEW OF THE HIGH SPRING CHARGE, ALWAYS FOLLOW THESE INSTRUCTIONS CAREFULLY BEFORE
PROCEEDING WITH DISMANTLING OPERATIONS.

16) Slowly loosen the nuts (A) untile releasing the spring
compression.

17) Remove the two tie-rod regulation nuts, loosening them

alternatively by the same amount.

4-6
 4 - HOW TO REMOVE BOOM TELESCOPING CYLINDER

18) Extract any excessive cable and loosen the clamp.

19) Using a copper hammer, beat the tie-rod locking wedge from behind making it come out from the front part, thereby releasing the
cable.

20) Fully extract the cable from the wedge and the tie rod so
that it is completely released.

4-7
 4 - HOW TO REMOVE BOOM TELESCOPING CYLINDER

21) Tie an elastic cord of about 3 metres in length to the end of the cable, securing it with tape; attach the other end of the elastic
cord to the telescopic boom.

22) Remove the support of the boom retraction micro (E),

located on the jack breech.

23) Remove the upper slide carrier plate (F) on the rear side of the machine, between the first and second boom.

4-8
 4 - HOW TO REMOVE BOOM TELESCOPING CYLINDER

24) Grabbing and pulling it, extract the rope from the pulley
located between the first and the second boom.

25) From the front part of the boom (in the upper area, where
the tail and springs are located), pull the rope until about
50 cm are extracted.

26) On the back of the boom, grab and pull the rope
extracting it from the pulley located inside the second
boom.

4-9
 4 - HOW TO REMOVE BOOM TELESCOPING CYLINDER

27) Remove the 4 fixture screws of the ram on the second boom.

28) Remove lid (A) on the top part of the boom (A).

29) Manually rotate the upper pulley (B), until the hole present on the same matches up with the two fixture Allen screws on the lower
pulley.

4 - 10
 4 - HOW TO REMOVE BOOM TELESCOPING CYLINDER

30) Disconnect the return and delivery ducts on the breech.

31) Extract the lower pulley.

32) Using a bridge crane or other suitable equipment, harness

the stem and extract it by about 2 m.

4 - 11
 4 - HOW TO REMOVE BOOM TELESCOPING CYLINDER

33) To facilitate the subsequent extraction of the false

chamber, remove the two slide rollers (A) of the steel
cable, removing the respective fixture split pins (B) and
removing the pins.

34) Loosen the fixture bolts (C) joining the false chamber to the third section of the boom, the those (D) securing the internal pulley
support to the fourth section of the boom.

4 - 12
 4 - HOW TO REMOVE BOOM TELESCOPING CYLINDER

35) Grip the chamber and pull outwards until it advances from
the boom by about 20 cm.

36) Remove the two casings (E) which secure the ducts, fixed to the pulley support.

37) Replace the two casings that have just been removed, with the two special tools (F), serial number 055200 (see chapter entitled
"REQUIRED SPANNERS / ENVISAGED TIMES", under the paragraph entitled "SPANNERS AND SPECIAL TOOLS ").

4 - 13
 4 - HOW TO REMOVE BOOM TELESCOPING CYLINDER

38) Using a bridge crane or other suitable tool, begin extracting the ram and the false chamber from the telescopic boom; during this
operation take care not to damage the ducts and pipes present on the false chamber.

39) Use the special tool (G), serial number 055195 (see
chapter entitled "REQUIRED SPANNERS / ENVISAGED
TIMES", Paragraph entitled "SPECIAL SPANNERS AND
TOOLS"), to facilitate the its projection from the boom of
the of the internal pulley support. The tool must be
screwed into one of the threaded holes present on the
pulley support.

40) Once the boom has been made to come out of the pulley
support, remove the two special tools from the same (F)
previously inserted (see point "37") and expose the ducts
from the pulleys.

41) Shift the harnessing in order to balance the weight, then,

once the whole thing has been extracted, place on the
ground or on a work bench.

4 - 14
 4 - HOW TO REMOVE BOOM TELESCOPING CYLINDER

42) On the boom face, disconnect the two ducts of the fork ram and/or the tool ducts.

43) Connect a steel cable to each of the ducts, to faciliate

their recovery during the re-assembly stage.

44) Disconnect the electric socket box, and then loosen the electric cable stop.

4 - 15
 4 - HOW TO REMOVE BOOM TELESCOPING CYLINDER

45) Extract the socket from the support and disconnect all the wires present (for re-connection, see the table A).

"A" TABLE

Pin Colour Wire number Position on connector

5 8
1 7
Black 2 2
4 4
3 3

4 5
6 6
Red 2 9
3 10
1 1

Yellow / Green On socket mass

46) Make the electric cables project from the box; connect a steel cable of length of approx. 40 metres to the ends of the same.

4 - 16
 4 - HOW TO REMOVE BOOM TELESCOPING CYLINDER

47) To facilitate the following operations we recommend the

removal of the socket support; then extract the electrical
cables from the inside of the boom facing.

48) On the back area, inside the boom, disconnect the two
duct supports (A), fastened to the fifth section.
Pull the ducts until the clamps (B) of the back ducts come
out of the boom.

4 - 17
 5 - KIT ASSEMBLY

COMPOSITION OF THE KIT

PART No. DESCRIPTION QUANTITY

045768 GALVANIZED FASTENING BLOCK FOR 2 PIPES, Ø 15 mm 2

045769 WELDED FASTENING BLOCK FOR 2 PIPES, Ø 15 mm 2

045770 GALVANIZED FASTENING BLOCK FOR 6 PIPESØ 15 mm 1

045771 WELDED FASTENING BLOCK FOR 6 PIPES Ø 15 mm 1

060836 RIGHT DUCT GUIDE 1

060837 LEFT DUCT GUIDE 1

060838 SELF-LUBRICATED ROLL=58,5 mm 2

060839 DUCT SPACER 8

060842 DIN DUCT, ARRANGED IN THREES, 22X1,5 FD+FD 4

060843 ROLL SUPPORT AND CYLINDRICAL DUCT GUIDE 1

060849 SHEAVE, Ø 152 mm, 1 GROOVE 2

060850 SHEAVE, Ø 190 mm, 1 GROOVE 2

060865 SHEATH FOR ELECTRICAL SYSTEM Ø 11 TA L0,5 4

802110 ELECTRICAL CABLE 7X1 mm² L=31mt. 2

5-1
 5 - KIT ASSEMBLY

1) Separate the front ducts from the supports (A) extracted

in point "47" of the previous chapter, then remove the
clamps (B).

2) On the lower pipe pack, remove the clips and the clamps.

3) Disconnect the ducts from the pipes. In order to avoid any further hydraulic oil leakage, plug the pipes.

5-2
 5 - KIT ASSEMBLY

4) Cut the electrical cable and extract it from the pipes.

5) On the chamber, remove the front and back blocks fastening the electrical cable.

6) Cut the electrical cable - and the RILSAN pipe around it -

coming out of the inside of the boom at about 30 cm from
the end of the back ducts support (A). On the front of the
boom, extract completely the electrical cable from the
RILSAN pipe.

5-3
 5 - KIT ASSEMBLY

7) Extract the cable from the passages on the head of the ram.

8) Cut the electrical cable near to where it enters the upper pipe. On the opposite side, extract the cable from the pipe.

9) Remove and discard the ducts connected to the metal pipes on the ram (these ducts will be replaced by new ones, code
060842, included in the kit).

5-4
 5 - KIT ASSEMBLY

10) Remove the first two upper blocks fastening the metal pipes on the chamber.

11) Disconnect the metal pipes from the support on the head of the ram. Loosen the bolts fastening the pipe support to the ram, as
illustrated in the picture, then extract the support from the fake chamber.

5-5
 5 - KIT ASSEMBLY

12) Remove the sheave support from the fake chamber.

13) Using a grinding stone, eliminate the pipe fastening plate, welded to the end of the fake chamber.

14) Measure 60 cm from the end of the fake chamber and

place the new pipe fastening plate incluced in the kit
(code 045771) at the measured disntance.

5-6
 5 - KIT ASSEMBLY

15) Weld the new plate on the fake chamber. In order to

prevent the unintended displacement of the plate while
being welded, place the metal pipes on the appropriate
guides found on the plate itself.

16) Remove the bush and the bush end stop from the old pulley support (see point 12).

17) Mount again the bush and the bush end stop (removed during the previous step) on the new pulley support (code 060843)
included in the kit.

5-7
 5 - KIT ASSEMBLY

18) Insert the new pulley support on the chamber, then mount
again the duct and metal pipe support (see point 11).

19) Remove the guide skids from the duct and pipe support.

20) Place the skid on a clamp, as illustrated in the picture below. Using a grinding stone, round off the edge of the skid indicated by
the arrows.

5-8
 5 - KIT ASSEMBLY

21) Connect again the metal pipes to the support.

22) After rounding off both guide skids (see point 20), mount them back on the duct and pipe support.

23) Mount back the pipe fastening plates (apply some thread locking paste on the screws).

5-9
 5 - KIT ASSEMBLY

24) On the ram breech, mount the the pipe stopping blocks (one on each side) and remove the existing faileader.

25) On the new pulley support, insert the sheaves (A), fit the new ducts and mount the duct supports/guides (B) with their rolls (C).

5 - 10
 5 - KIT ASSEMBLY

26) Fasten the ducts support carter.

27) At one end of the new electrical cable, insert one of the
black spacers provided.

NOTE !!! When inserting the spacers, please check that the hole with the largest diameter (X) always faces the duct to
which it will be connected. The smallest hole (Y) shall face the RISLAN pipe or, according to the situation, the plastic
sheaths.

5 - 11
 5 - KIT ASSEMBLY

28) Connect a probe (or a small steel cable) to the electrical

cable (A). Please use some insulating tape to fasten
them, so that they do not come apart. Insert the probe (or
the small steel cable) inside the RISLAN pipe (B) until it
comes out of the back side of the boom.
From the back of the boom, keep on pulling the probe
until about 1 meter of electrical cable (A) comes out.

29) Proceeding in the same way as before, connect the other end of the electrical cable (A) to the probe, apply the insulating tape
and insert the probe into the central pipe (C) between the two ducts.

5 - 12
 5 - KIT ASSEMBLY

30) From the opposite end of the ducts, pull the probe so that the electrical cable (A) comes out. Keep on pulling and, at the same
time, on the front side, bring the ducts and the pipe (C) containing the electrical cable (C) closer to the RISLAN pipe (B), until the
spacer (D) is connected both to the RISLAN pipe and to the pipe (C).

31) Connect the pipes coming from the ram to the fixed ducts inside the boom.

32) Fasten the RISLAN to the ducts with a clip. Pull the ducts from the front part of the boom, so that the duct support (S) moves
closer into position. This can then be accomodated into its housing inside the boom.

5 - 13
 5 - KIT ASSEMBLY

33) Fasten the support bracket (S) in its housing.

34) Insert a second spacer (D) on the electrical cable, following the instructions provided in the note to point "27". Insert an
approximately 30 cm long piece of black sheath.

35) Insert the electrical cable through the hole located on the metal pipe support, then insert it into the metal pipe.

5 - 14
 5 - KIT ASSEMBLY

36) On the back of the ram. pull the electrical cable so that it
comes out of the metal pipe.

37) On the front of the ram, connect the ducts to the pipe
support. Without tightening it completely, mount the plate
(E) of the fastening block of the electrical cable sheath.

38) Pull the electrical cable making sure it is not too

stretched. Place the sheath (F) inside the black spacer
(D), tighten completely the screw fastening the plate to
the block (E).

5 - 15
 5 - KIT ASSEMBLY

39) On the fron side of the ram, insert a 30 cm long piece of sheath on the electrical cable coming out of the metal pipe. Then, have
the sheath go through the block (G); fasten the closing plate of the block (G) without tightening it completely.

40) Insert a black spacer (keep in mind what point "27" specifies) on the electrical cable, move it until it is connected to the sheath.
Insert the electrical cable inside the gum pipe included in the second set of new ducts of the kit.

41) Insert the gum pipe inside the black spacer (D); connect the two ducts to the corresponding metal pipes.

42) Pull the electrical cable from the other end of the gum pipe, so that it is not excessive (if needed, insert the sheath further inside
the metal pipe, see point "39"). Tighten completely the closing plate of the block (G), see point "39", thus blocking the sheath and
the electrical cable.

5 - 16
 5 - KIT ASSEMBLY

43) Insert the black spacer (D) and a piece of plastic sheath abuut 30 cm long, on the electrical cable coming out of the gum pipe.
Insert the electrical cable through the hole on the fixing block located on the metal pipe pack.

44) Insert the electrical cable through the second hole on the pipe fixing block and, consequently, through the metal pipe, until it
completely comes out of the opposite pipe end.

45) Connect the ducts to the pipe pack.

5 - 17
 5 - KIT ASSEMBLY

46) Pull again the electrical cable from the end of the metal pipe, so as to reduce its curve on the pipe pack. Fasten the cable and the
plastic sheath to the ducts with a clip.

47) With the help of a grinding stone, round off the edges indicated by the arrows inside the telescopic boom.

48) Using a bridge crane or other suitable equipment, balance

and lift the ram to the correct height for insertion inside
the boom itself.

5 - 18
 5 - KIT ASSEMBLY

RE-ASSEMBLY

For re-assembly undertake all the operations described from point (41) to point (1) of Chapter "4 - HOW TO REMOVE BOOM
TELESCOPING CYLINDER" in reverse order, bearing in mind the following:
[a] Before replacing the chamber inside the boom, check to ensure the correct passage of the ducts and the electrical cables on the
pulleys.

[b] Inserting the chamber inside the boom, pull the pulley support at the same time, so as to tighten the ducts and the electrical
cables, making sure that they do not become entangled; use the special tool indicated at point "39" for this purpose.

[c] Before re-assemblying the pulley support (see point "12" of Chapter "4 - HOW TO REMOVE BOOM TELESCOPING CYLINDER"),
replace the pulleys with the new ones included in the kit (code 060850).

[d] Mount bach the lower fastening bolts of the ram body (see point "10" of Chapter "4 - HOW TO REMOVE BOOM TELESCOPING
CYLINDER") with the head facing the inside of the boom, that is with the nut on the outside.

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