My boom lift nearly went KaBOOM! How does a 3 section boom telescope mechanism work? I build a model and explain the mechanism in detail. Then we move on to inspecting and fixing the fire damage. Lots of wire repair, several hydraulic hoses, a grease hose, and some cleanup and...does it work?

Yes the wire I shortened was a FUSIBLE LINK. It did it's job and protected the rest of the harness. I will replace it with a fuse.

Part 1 here:    • JLG Boom Lift Tear Down, Ended In Dis...  
Complete boom lift series here:    • JLG Boom Lift  

My parts supplier:
Bennett Equipment and Supply
864-277-7272

HEY ENGINEERS! - Regarding the chain tension, the tensioners are torqued to 50 ft-lbs, and it's a 3/4" 10 TPI thread. What would the max tension on the extend chains be assuming the lift is pointing straight up, the fly boom and basket weigh 1200 pounds, and there's 1000 pounds in the basket, for a total of 2200 pounds being lifted?

So far I've gotten several answers. One said that in worst case scenario there is a safety factor of 11.5, meaning the chain can hold 11.5 times as much as would ever be put on it. Another said that the maximum force the chain would ever see is 7000 pounds, while a single chain has a breaking strength of 23000, for a safety factor of 3+ even with only 1 chain.

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00:00 Intro
1:13 Start building model
5:45 Model demonstrated
15:35 Troubleshoot fire damage
17:15 Soldering wires
22:15 Meanwhile
24:00 Holding valves
26:24 How to raise the boom
31:20 Assess fire damage
34:35 Problem found and fixed
36:00 Assess hydraulic lines
40:40 New parts
41:32 Install new hydraulic lines and clean up
48:32 Getting it to work finally.