Wire Rope; Inspection; Three Month Inspection; Year Or 7000 Hour Replacement - JLG 660SJ Service And Maintenance Manual

SECTION 4 - BOOM & PLATFORM

4.4 WIRE ROPE

WIRE ROPE CAN HAVE SHARP EDGES AND CAUSE SERIOUS INJURY. NEVER
HANDLE WIRE ROPE WITH BARE HANDS.
Each day before using machine:
1. Raise main boom approximately horizontal.
2. Extend and retract the boom sections.
3. Check for delayed movement of fly section which indi-
cates loose wire ropes.

Inspection

NOTE: Pictures in this paragraph are samples to show rope
replacement criteria.
1. Inspect ropes for broken wires, particularly valley wire
breaks and breaks at end terminations.
NOTE: Flexing a wire rope can often expose broken wires hidden
in valleys between strands.
Figure 4-7. Wire Rope Wire Breaks
2. Inspect ropes for corrosion.
3. Inspect ropes for kinks or abuse.
NOTE: A kink is caused by pulling down a loop in a slack line dur-
ing improper handling, installation, or operation.
Figure 4-8. Wire Rope Kink
4. Inspect sheaves for condition of bearings/pins. (See
Dimension Of Sheaves for proper dimension.)Inspect
sheaves for condition of flanges. (See Dimension Of
Sheaves for proper dimension.)
5. Inspect sheaves with a groove wearout gauge for exces-
sive wear.
4-4
NOTE: Check groove so that it may be clearly seen if gauge con-
tour matches sheave groove contour.
Figure 4-9. Sheave Groove Wear
7. Ropes passing inspection should be lubricated with wire
rope lubricant before reassembly.

Three Month Inspection

1. Remove boom covers and visually (with flashlight)
inspect the ropes for rust, broken wires, frays, abuse, or
any signs of abnormalities.
2. Check wire rope tension by deflecting wire ropes by
hand. Properly tensioned ropes should have little or no
movement.

12 Year or 7000 Hour Replacement

1. Mandatory wire rope and sheave replacement.
Additional inspection required if:
a. Machine is exposed to hostile environment or con-
ditions.
b. Erratic boom operation or unusual noise exists.
c. Machine is idle for an extended period.
d. Boom is overloaded or sustained a shock load.
e. Boom exposed to electrical arc. Wires may be fused
internally.

Additional Replacement Criteria

NOTE: Sheaves and wire rope must be replaced as sets.
1. Rusted or corroded wire ropes.
2. Kinked, "bird caged", or crushed ropes.
3. Ropes at end of adjustment range.
4. Sheaves failing wearout gage inspection.
5. Ropes with 6 total broken wires in one rope lay, 3 in one
strand in one rope lay, 1 valley break, or 1 break at any
end termination.
– JLG Lift – 3121298