SECTION 2 - SERVICE PROCEDURES
31215808
2-33
NOTE:
Mast section-1 is fixed to the base and mast section-2 is
attached to the lift cylinder, these sections require no
adjustment.
3. Adjust one mast section at a time starting from the back
(section-3, section-4, etc.)
of the mast and work forward.
(i.e. if three is OK, then jump to four, etc.)
4. To adjust, elevate the platform until the chain/cable
anchor adjust nuts are accessible at the front and bottom
of each mast section.
NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL PLATFORM HAS BEEN
SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD
SLING.
5. Start with the mast section which needs adjustment and
loosen the bottom
(jam)
nut on each chain/cable.
6.
Tighten
(to raise mast section),
or loosen
(to lower mast
section)
the adjusting nut
against the anchor plate
on
each
chain/cable. Adjust the nut the amount required to
raise or lower the top of the mast section to match the
side profile shown in Figure 2-7. when the mast is
retracted. Be certain each chain/cable pair is adjusted to
equal tension.
(The threaded end of the chain/cable will
need to be restrained while tightening the adjust nut to keep
the chain/cable from twisting.)
7. Retract the mast all the way and check if the top of the
mast sections appear as shown in Figure 2-7.
8. Repeat steps (1) through (7) for remaining mast sections.
ENSURE THAT ALL CHAIN/CABLE PAIRS HAVE EQUAL TEN-
SION.
9. Once mast section adjustment is completed, apply
Medium Strength Threadlocking Compound to the
threads under the
(jam)
nuts that were loosened. Then
re-tighten the loosened
(jam)
nuts until tight against the
top
(adjust)
nut. Chain/cable should have slight tension
but should not be taut. Run mast through several cycles
to verify cable/chain adjustments and ensure no interfer-
ence exists between chain anchor brackets and mast.
Sequencing Cable Adjustment
1. Retract mast completely, and check each sequencing
cable on outside of masts for excessive slack. Adjust only
to remove slack from cable.
2. Tighten nylock-nut just enough to remove excessive
slack from sequencing cable. The springs should not be
compressed more than 25% after adjusting.
2.13 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 fac-
tory cable. Also included is a clamp
(drum/socket type)
to
secure the bottom end of the cable. Use the following proce-
dure 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 com-
pletely 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 2-7., 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 washers, spring, spring cap
and lock nut previously disassembled. 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.
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)
THE MANUFACTURER OF THE DRUM/SOCKET CLAMP RECOMMENDS THE USE
OF THEIR CABLE CLAMP ASSEMBLY KIT (JLG PN - 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.
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to
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to
order
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