A Practical Guide to Replacing Wear Pads on Your Terex Telescopic Boom

Maintaining a Terex telescopic boom involves paying close attention to various components, but the wear pads are among the most critical. These pads endure constant friction as the boom extends and retracts, and when they wear down, the effects are immediate and noticeable. Sections may start binding, the extension becomes rough, and metal surfaces can show signs of scoring. Replacing these pads is a task that requires patience, a safe setup, and, most importantly, genuine, quality Terex parts.

Safety First: Setting Up for Success

Any maintenance work on a telescopic boom should begin with stabilizing the machine. This means pulling the key, isolating the battery, and releasing any hydraulic pressure. Ensuring the boom is fully supported with slings or blocking is crucial before loosening any components. Trusting hydraulics to hold a section in place is a recipe for disaster; one small drift or hose failure can turn a routine job into a hazardous situation.

Most technicians find it helpful to lay out all the necessary tools, pads, fasteners, and the service manual beforehand. Having everything within reach not only keeps the job steady but also prevents rushing once the boom is opened up.

Inspection Before Disassembly

Before removing any bolts, it’s essential to extend the boom slowly and observe how each section behaves. Note any hesitation or sideways shifts. Taking photos of the pad layout, shim positions, and bolt patterns can be incredibly useful during reassembly, especially if you haven’t worked on this exact model recently.

Measuring the pad thickness and comparing it to the service limits is also a good practice. If the pads are at or below the recommended minimum thickness, replacement is the best course of action.

Removing the Old Pads

Once the boom is securely supported and documented, start loosening the pad fasteners. Applying penetrating oil to the bolts, especially on machines that operate in harsh environments, can make the process smoother. Back the bolts out evenly to prevent the pads from binding as they come off.

If a pad is particularly stubborn, a soft mallet and a small pry bar can help break it free. Avoid using metal-on-metal strikes or sharp tools, as any gouges on the boom surface can cause problems down the line.

After removing the pad, thoroughly clean the area. Old adhesive, rust flakes, and packed-in dirt are common culprits that can affect how well the new pad seats.

Preparing the Seating Surface

This step is often rushed but is crucial for the longevity of the new pads. Wipe down the surface with solvent and inspect the metal for any signs of corrosion. Light corrosion can be removed with a wire brush, but deep pitting, warping, or cracks need to be addressed before proceeding.

Ensure the surface is completely dry before installing the new pads. Any moisture or debris trapped under the pad can lead to uneven wear and potential misalignment.

Installing the New Wear Pads

The new pads should sit flush without any rocking. Position each pad exactly as the original, including orientation and any shims. Hand-start the bolts to ensure clean thread engagement. If the service manual specifies the use of anti-seize or threadlocker, follow these instructions precisely to avoid future complications.

Tighten the bolts gradually in the recommended pattern, adhering strictly to Terex torque specifications. Proper torque ensures the pads remain in place under load and prevents fasteners from stretching or backing out.

If a pad doesn’t sit flat after torquing, reevaluate the situation. Clean the surface again or check for debris under a shim. Forcing a pad into place is never a good idea.

Testing the Boom After Installation

Once all the pads are installed and torqued, retract the boom fully and cycle it a few times at low speed. Listen for any scraping, clicking, or unusual resistance. The boom should move smoothly without hesitation. Many technicians recheck the torque after a few cycles, as the pads may settle slightly.

Inspect the hydraulic lines, hoses, and wiring around the boom to ensure nothing is rubbing or out of place. Document the date, hours, pad part numbers, and torque values for future reference.

Troubleshooting Common Issues

While most wear pad replacements go smoothly, a few issues can arise. Unevenly seated pads usually indicate debris or damage on the mating surface. Fasteners that won’t torque properly may signal stretched bolts or damaged threads. Binding during extension is often due to alignment or support issues, so double-check your setup.

If pads wear out prematurely, consider misalignment between boom sections or using pads that don’t meet Terex requirements. Choosing verified quality Terex parts ensures the correct tolerances and materials, making a significant difference in the longevity and performance of your boom.

Conclusion

Replacing wear pads may not be the most glamorous task, but it’s essential for maintaining the health of a telescopic boom. Taking a slow and careful approach, supporting the sections safely, cleaning the mating surfaces, and following the service manual’s specifications are key to preventing binding, protecting the boom sections, and ensuring smooth machine operation. Trust your hands, your eyes, and the service manual to get the job done right.