Amel Super Maramu 2000
Rebuilding Main Boom Car
Sock each of the 6 bold and nuts on the other side with ZEP 45 and wait
Remove the bold using 5.5 mm socket and screw driver
In reality it was not so easy and I broke 5 bolts.
The bold size was 6-32 x 1" - which surprises me - as it is an Italian product.
The nuts were not 6-32, I suspect they were 3 mm but was not able to confirm Confirm they are 3 mm
I suspect the original bold were 3 mm Confirm they are 3 mm.
If not available, the 6-32 x 1" with approriate nuts will work as well, just a little tighter to put in then remove
In order to remove the bold, I had to tap with a hammer on the back in order to pull them out, then use a wise grip
Then you can remove the top cover (left) and the 2 half bottom covers (right)
The round metal bar holding the shackle will slide out
Received from Amel the new shackle.
Put the shackle on the "shaft" and slide back
There was plastic or nylon washer which I don't have...
Slide the whole boom car on the extension rail
Prepared 1 set of balls, which I divided in 2 groups
With a small screw driver you push them all around the track.
Then the other side, still using a screw driver
Put the cover on top
Put upside down to access the bottom track and start to put the balls.
Then the other side
Put the 2 bottom overs
Put back screw (3 mm x 25) - in my case could not find the philips, the only available were allen head.
Buy spare bolt 3 mm x 25 mm and nuts for the next time it fails
On the bottom, I added Loctite to prevent problem
All 6 back in place
If you are buying the spare (Main or Mizzen) Boom Car, also purchase additional shackle, shipping won't be much more!