How To Replace The Boom Extend/Retract Cables - Terex Genie SX-105 XC Service And Repair Manual

May 2020
How to Replace the Boom
Extend/ Retract Cables
Note: The cable pulley must also be replaced
when replacing the cables.
1
Remove the primary boom extension cylinder.
Refer to Repair Procedure, How to Remove
the Primary Boom Extension Cylinder.
Boom extend cables:
2
Remove the retaining fasteners that secure
the extension cable retainer to the pulley
mount. Remove the retainer.
3
Remove the cables from the lower boom
extend cable bracket that attaches to the
number 3 boom tube.
4
Remove the front and rear fasteners from the
anchor bracket that supports the cable
anchors. Remove the bracket.
5
Remove the pulley and boom extend cables
from the extension cylinder assembly. Discard
the old cables and pulleys.
6
Route the new boom extend cables through
the boom extend pulley bracket.
Note: Be sure before installing the extend cables
through the boom adjustment coupling that the tall
end of the cable anchors are facing down.
7
Install the new boom extend cable pulley,
pivot pin and snap rings.
Note: Be sure the boom extend cables are routed
through the grooves of the pulley and the upper
wear pad on the extension cylinder.
8
Install the boom extend cables to the lower
extend cable bracket that mounts to the
number 3 boom tube.
Part No. 1271700GT
Boom retract cables:
9
10
11
12
13
14
15
16
17
18
19
SX™-105 XC™ • SX™-125 XC™
Service and Repair Manual
Boom Components
Remove the fastener from the boom retract
cable at the platform end of the #1 boom.
Attach a rope to one of the boom retract
cables at the pivot end of the boom.
At the platform end of the boom, pull on the
boom retract cable that has the rope attached
to it.
Pull the old cable completely out of the boom
tube. Discard the old boom retract cable.
Remove the rope from the old cable and
securely attach the rope to the same end of
the new boom retract cable.
At the pivot end of the boom, carefully pull the
rope with the new retract cable attached.
Pull the new cable towards the pivot end of
the boom until the end of the cables is at the
end of the boom tube. Remove the rope.
Repeat steps 11 through 16 for the other
boom retract cable.
At the platform end of the boom, install the
retract cables and fasteners to the adjustment
plate.
Remove and discard the old boom retract
pulleys from the pivot end of the boom
extension cylinder.
Install the new boom retract pulleys to the
pivot end of the boom extension cylinder.
67