Wire Rope Tensioning Procedure - JLG 1200SJP Service Maintenance Manual

4. If the Fly Boom needs extended:
a. Loosen the Fly Boom Retract Adjustment Nuts by an
amount equal to twice the distance the boom needs
to move to be in tolerance.
Fly Boom Retract Adjusting
Nuts and Lock Plates
b. Extend the boom 3-4 feet (1-1.5m).
c. To remove the slack caused by the previous step,
tighten the Fly Boom Retract Adjustment Nuts until
they just contact the plate.
d. Fully retract the boom sections.
5. Verify that the exposed boom section dimensions meet
the dimensions and tolerances of Figure 4-30., Wire
Rope Tensioning.
a. If the Fly Boom still does not fall within the dimen-
sion and tolerance of Figure 4-30., repeat the Fly
Boom Section Repositioning procedure.
b. If the Fly Boom falls within the dimension and toler-
ance of Figure 4-30., proceed to the Wire Rope Ten-
sioning Procedure.

Wire Rope Tensioning Procedure

NOTE: Verification of the rope tension should be determined by
proper function of the boom assembly and by the dimen-
sions and tolerances of Figure 4-30., Wire Rope Tensioning.
REPEAT WIRE ROPE TENSIONING PROCEDURE ONLY AS NECESSARY TO
ACHIEVE PROPER TENSION.
IF THE BOOMS HAVE BEEN PROPERLY POSITIONED AND THERE IS NOT
ENOUGH ADJUSTMENT REMAINING ON THE WIRE ROPES TO ACHIEVE TORQUE,
THE SERVICE LIFE OF THE WIRE ROPES HAS BEEN CONSUMED. DO NOT PRO-
CEED WITH THE REMAINDER OF THIS PROCEDURE. REPLACE THE WIRE ROPES
AND SHEAVES.
3121142
1. Remove any covers necessary to access the wire rope
adjustment nuts.
2. If not already done, remove the lock plates and nylon
collar locknuts from the wire rope adjustment nuts.
3. Position the boom so that it is horizontal within ±5°. If
the boom is below horizontal, ensure that the boom is
not on the boom rest.
4. Extend the boom so the platform moves 5 to 6 feet (1.5-
1.8 m) from the fully retracted position. This is done to
position the boom so the ropes to be tensioned are not
under load.
5. When extending the boom in the previous step, if the
boom reaches the end of travel and then automatically
retracts a small amount, the ropes may still be under
load. If so, perform the following steps:
a. Note where the boom hits the end of stroke.
b. Retract 3-4 feet (1-1.3 m).
c. Extend the boom and stop just before the boom
hits the end of stroke.
– JLG Lift –
SECTION 4 - BOOM & PLATFORM
4-67