JLG 680S, Service And Maintenance Manual

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SECTION 4 - BOOM & PLATFORM
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5. Connect the hydraulic lines to the cylinder as tagged
during removal.
6. Remove the supporting device and function check the
boom to make sure the lift cylinder operates properly
and there are no leaks.
4.8 WIRE ROPE
Each day before using the machine:
1. Raise the main boom to approximately horizontal.
2. Extend and retract the boom sections.
3. Check for delayed movement of the fly section, which
indicates loose wire ropes.
Inspection
NOTE: The pictures in this paragraph are just samples to show the
replacement criteria of the rope.
1. Inspect ropes for broken wires, particularly valley wire
breaks and breaks at end terminations.
2. Inspect ropes for corrosion.
3. Inspect ropes for kinks or abuse.
4. Inspect sheaves for condition of bearings/pins. (See
Dimension Of Sheaves for proper dimension.)
5. Inspect sheaves for condition of flanges. (See Dimension
Of Sheaves for proper dimension.)
6. Inspect sheaves with a groove wearout gauge for exces-
sive 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 rope tension by deflecting the ropes by hand.
Properly tensioned ropes should have little or no move-
ment.
12 Year or 7000 Hour Replacement
Mandatory wire rope and sheave replacement.
Additional inspection required if:
1. Machine is exposed to hostile environment or condi-
tions.
2. Erratic boom operation or unusual noise exists.
3. Machine is idle for an extended period.
4. Boom is overloaded or sustained a shock load.
5. Boom exposed to electrical arc. Wires may be fused
internally.
Replacement Criteria
1. Sheaves and wire rope must be replaced as sets.
2. Rusted or corroded wire ropes.
3. Kinked, “bird caged”, or crushed ropes.
4. Ropes at end of adjustment range.
5. Sheaves failing wearout gage inspection.
6. 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.
Flexing a wire rope can often expose broken wires hidden in
valleys between strands.
A kink is caused by pulling down a loop
in a slack line during improper handling,
installation, or operation.
Observe the groove so that it may be clearly seen whether the
contour of the gauge matches the
contour of the bottom of the groove.