JLG 1100S Service Manual - Manual (Page 173)

SECTION 4 - BOOM & PLATFORM
3121256 – JLG Lift – 4-25
17. Route the threaded ends of the fly retract wire ropes
through the inner mid wire rope adjustment holes at
the forward end of the boom assembly. Engage the
threaded fitting pins into the adjuster tube slots.
18. Install the fly retract wire rope deflector sheaves,
retainer blocks and loosely install the adjuster nuts
onto the threaded fly retract wire rope fittings.
NOTE: The bolt heads of the deflector sheaves and retainer
blocks should face outward.
19. Route the threaded ends of the fly extend wire ropes
through the inner mid wire rope adjustment holes at
the forward end of the boom assembly. Engage the
threaded fitting pins into the adjuster tube slots.
20. Loosely install the adjuster nuts onto the threaded
fly extend wire rope fittings.
NOTE: Do not install the nylon collar lock nuts at this time.
21. Install the three section boom subassembly into the
base boom. Allow the boom subassembly to remain
about two feet (0.6 m) partially extended.
NOTE: Do not allow the three boom subassembly to rest on
the retract wire ropes while inserting it into the base
boom.
22. Route the threaded ends of the outer mid retract
wire ropes into their respective tubes located in the
adjuster box on the bottom of the base boom and
loosely install adjuster nuts into the threaded retract
wire rope fittings. Ensure that the threaded fitting
pins are engaged into the adjuster tube slots.
NOTE: The outer mid retract wire ropes adjuster nuts are
plated black to distinguish them from the fly retract
wire rope adjuster nuts, their thread sizes are similar
but not interchangeable.
23. Install the lower wear pads, spacer blocks, and
shims to the base boom at the forward end of the
boom assembly.
24. Install the deflector sheaves into the outer mid wire
rope adjuster box located on the bottom of the base
boom at the forward end. Using their respective
mounting slots, slide deflector sheaves into position
until sheaves are approximately 0.125” -0.156”
(3.175 - 3.962 mm) from the inner mid boom.
25. Apply a thin coat of moly paste lubricant to the
inside diameter of the sheave composite bearings.
Install the sheave and sheave pin to the end of the
telescope cylinder. Ensure that the sheave moves
freely.
26. Route the outer mid extend wire ropes around the
extend sheave on the telescope cylinder.
NOTE: The button ends of the wire ropes are to be posi-
tioned to the top of the assembly. The wire rope with
the 1-12UNF threaded fitting is to be placed into the
sheave groove on the side opposing the boom power
track, while the wire rope with the 1 3/8-6UNC
threaded fitting is to be placed into the sheave
groove on the power track side of the boom assem-
bly.