JLG DVSP Series Service Manual - Manual (Page 92)

SECTION 5 - MAST COMPONENTS
5-4 – JLG Lift – 3121136
5.3 SEQUENCE CABLE REPLACEMENT KIT
A sequence cable replacement kit is available from the JLG
Parts Department to service broken or worn sequence
cables. This kit consists of a replacement sequence cable
with the threaded (top) end attached same as the top end of
the factory cable. Also included is a clamp (drum/socket
type) to secure the bottom end of the cable. Use the follow-
ing procedure to install the replacement cable and clamp kit.
Remove Old Cable
1. Remove the locking nut from the threaded end of
the cable at the top of the mast and then remove the
spring cap, spring, and spacer washers if installed.
2. Slide the threaded top end out of the upper anchor
bracket, then at the bottom end pull the cable out
though the sheave pulley/anchor bracket until it is
completely clear of the machine.
Replacement Cable Installation
1. Be certain the mast is completely retracted and at
the bottom of travel. Check the mast "Side Profile" at
the top of the mast as shown in Figure 5-2., adjust
mast sections to proper height if necessary.
2. To determine where the clamp will be installed at the
bottom of the replacement cable, temporarily
assemble the new replacement cable to the top
cable anchor bracket on the mast using the wash-
ers, spring, spring cap and lock nut previously dis-
assembled. Thread the lock nut on until
approximately 1/8 in. (3mm) of threads are exposed.
3. At the bottom of the mast, thread the loose end of
the replacement cable through the proper sheave
pulley and through the hole in the sheave pulley/
anchor bracket on the mast section ahead of the
sheave pulley.
4. Grasp the cable and pull on the cable until the
spring at the top of the cable is slightly compressed.
Use a black marker to mark the cable on the top
side of the sheave pulley/anchor bracket. This will
determine where the clamp (drum/socket) sleeve
will be positioned on the cable.
IMPORTANT
DO NOT CUT THE CABLE AT THE MARKED POINT ON THE CABLE
THIS IS ONLY USED AS A REFERENCE FOR POSITIONING THE
CABLE SLEEVE WHICH WILL REST AGAINST THE ANCHOR
BRACKET ONCE INSTALLED.
Clamp Installation (Drum/Socket Type)
IMPORTANT
THE MANUFACTURER OF THE DRUM/SOCKET CLAMP RECOM-
MENDS THE USE OF THEIR CABLE CLAMP ASSEMBLY KIT (JLG P/N
- 7023275) TO ASSEMBLE THE CLAMP TO THE WIRE ROPE. THE KIT
CONSISTS OF VISE JAWS TO HOLD THE WIRE ROPE IN A VISE
PROPERLY WITHOUT DAMAGING ANY ROPE STRANDS AND A PLUG
DRIVER TO DRIVE THE PLUG INTO THE CENTER OF THE WIRE ROPE
AND IS ALSO USED TO FORM THE STRANDS OF THE ROPE DURING
ASSEMBLY.
NOTE: The tools in the clamp assembly kit may be frabra-
cated if necessary. The vise clamp consists of vise
jaws with a hole drilled 1/32 in. smaller than the
diameter of the wire rope you are working with (i.e.
1/8 in. rope - 3/32 in. hole.)
The plug driver is a metal tube with a hole in the bot-
tom to allow the strands of the wire rope to be
shaped after the plug has been tapped into the cen-
ter of the wire rope.
1. Using the recommended vise jaws, clamp the wire
rope into a vise with the bottom edge of the black
mark made on the wire rope resting just above the
vise jaws.
1. Cable 3. Recommended Vise Jaws
2. Mark on Cable