JLG 680S Service Manual - Manual (Page 204)

SECTION 4 - BOOM & PLATFORM
4-10 – JLG Lift – 3121234
4. Install retract wire ropes into aft end of fly section,
route wire ropes thru holes in side of fly boom sec-
tion and pull into slot.
5. Install side, top and bottom wear pads to the aft end
of mid section; shim evenly to the measurements of
the inside of mid section.
WHEN ASSEMBLING BOOM SECTIONS, ENSURE THAT THE
BOOM SLIDING TRAJECTORIES HAVE BEEN CLEARED OF
CHAINS, TOOLS, AND OTHER OBSTRUCTIONS.
6. Shim the insides of the boom sections for a total of
1/16 inch (0.062) clearance (if the action is centered,
there will be 1/32 clearance on each side).
7. Slide fly boom section into the mid boom section.
Shim boom, if necessary, for a total of 1/16 inch
(0.062) clearance.
8. Install wear pads into the forward position of the mid
boom section. Shim boom, if necessary, for a total of
2/10 inch (0.20) clearance.
9. Properly position the retraction wire rope sheaves
assemblies at the aft end of the mid boom section;
ensure all sheave-to-mounting block attachment
holes align. Install the sheave pins and secure them
with mounting hardware. Position retract wire ropes
onto the sheaves.
10. Install sheave guards to aft end of mid boom section
and secure with mounting hardware.
11. Slide mid boom section into the base boom section.
Allow the retraction wire ropes to trail between the
bottom surfaces of boom sections. Shim boom, if
necessary, for a total of 1/16 inch (0.062) clearance.
12. Install wear pads into the forward position of the
base boom section. Shim boom, if necessary, for a
total of 2/10 inch (0.20) clearance.
13. Install sheave block to bottom of base boom section
and adjust block so that retract wire ropes do not
come into contact with boom surfaces.
14. Install wire rope threaded ends thru attachment
holes in the bottom of base boom section. Loosely
install nuts and jam nuts onto the threaded ends of
wire ropes.
15. Align the telescope cylinder barrel-to-sheave attach-
ment point. Install extend sheave pin through the
telescope cylinder barrel and sheave assembly;
secure pin with mounting hardware.
16. Route extend wire ropes around extend sheave and
secure wire ropes to the telescope cylinder.
17. Install extend wire rope mounting blocks to threaded
ends of wire ropes. Loosely install nuts and jam nuts
onto the threaded ends of wire ropes.
NOTE: When installing wire ropes, care must be taken not to
twist or cross the wire ropes.
Figure 4-10. Routing Installation of Retract Wire Ropes