JLG 601S ANSI Service Manual - Manual (Page 136)

SECTION 4 - BOOM & PLATFORM
4-8 – JLG Lift – 3120746
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.
18. Secure the sling and lifting device at the telescope
cylinder’s approximate center of gravity, and lift the
cylinder to the aft end of the boom assembly.
WHEN INSERTING THE TELESCOPE CYLINDER INTO THE BOOM,
IT MAY BE NECESSARY AT SOME POINT TO TURN THE CYLIN-
DER SLIGHTLY IN ORDER TO CLEAR ASSEMBLIES MOUNTED
WITHIN THE BOOM. CARE MUST BE TAKEN TO MOVE THE CYL-
INDER SLOWLY INTO POSITION. DAMAGE TO COMPONENTS
MAY RESULT FROM FORCIBLE IMPACT WITH THESE ASSEM-
BLIES.
19. Align the cylinder with the slots at aft end of mid
boom section, then secure cylinder with mounting
hardware.
20. Align holes in aft end of the fly boom section with
holes in wire rope mounting block, then secure with
mounting hardware.
21. Align holes in aft end of the mid boom section with
holes in wire rope mounting block, then secure with
mounting hardware.
NOTE: Boom wire ropes must be torqued after installation of
the boom assembly.
22. Align holes in rod end of the telescope cylinder with
holes in push bar. Install push bar pin and secure
with mounting hardware.
23. Install the hydraulic lines and electrical cables, and
the harnessing powertrack components as follows:
a. Align holes in powertrack rail with attachment
holes in side of the base boom section. Secure
the rail with mounting hardware.
b. Install powertrack to rail with mounting hard-
ware.
c. Attach push tube bracket to the side of the mid
boom section with mounting hardware.
NOTE: Do not over tighten attach bolt on push tube bracket.
It should pivot freely.
d. Install slide block and wear pads to the pow-
ertrack rail with mounting hardware.
e. Install powertrack to push tube with mounting
hardware.
f. Carefully feed the hoses and electrical cables
through the aft end of the powertrack rail, pow-
ertrack and push tube.
g. Ensure all hoses and cables are properly routed
through the powertrack rail, powertrack and
push tube. Tighten or install all clamping or
securing apparatus to the hoses or cables, as
necessary.
h. Install powertrack cover and push tube rods with
mounting hardware.