JLG 1100S Service Manual - Manual (Page 169)

SECTION 4 - BOOM & PLATFORM
3121256 – JLG Lift – 4-21
2. Install the fly extend wire rope button ends into the
slots on the bottom of the fly boom section. Place
tape over the wire ends to keep them in place during
assembly.
3. Manufacture a special fixture as shown below to
keep four extend wire ropes from crossing over each
other.
4. Insert the fly into outer mid boom keep it out far
enough, about 2 feet (0.6 m, to enable access for
installation of the level cylinder pivot pin.
5. Install the front lower wear pads and shims to the
outer mid boom as marked during disassembly.
DO NOT ALLOW THE FLY BOOM TO REST ON THE FOUR EXTEND
WIRE ROPES WHILE INSERTING IT INTO THE OUTER MID BOOM.
6. Uncoil the fly retract wire ropes from the fly boom.
Route the threaded ends of the wire ropes through
the holes in the outer mid boom plates at the retract
sheave locations.
7. Apply a thin coat of moly paste lubricant to the
inside diameter of the sheave composite bearings.
Install the fly retract sheaves and bushing cups while
guiding the wire ropes from the previous step into
their respective sheave grooves. Apply moly paste
lubricant on the inside diameter of the sheave bush-
ing cup. Ensure the sheaves move freely. A 3/4” -
16UNF bolt may be used as a pulling tool to remove
the bushing cup if required.