JLG 800A_AJ ANSI Service Manual - Manual (Page 223)

SECTION 4 - BOOM & PLATFORM
3120740 – JLG Lift – 4-9
Installation
NOTE: Steps 1 thru 4 are only necessary if the upright level
cylinder is to be removed.
1. Using a suitable lifting device, carefully install the
upright lift cylinder into place in the tower boom.
2. Install the pin and mounting hardware at the barrel
end of the upright lift cylinder.
3. Connect the hydraulic lines to the upright lift cylinder
as tagged during removal.
4. Override the tower telescope limit switch and retract
the tower boom.
5. Using an adequate lifting device, install the upright
into position. Install pin # 4 into the tower boom
assembly and secure it in place with the mounting
hardware.
6. Connect the Upright Level Cylinder as follows:
a. Align the holes in the cylinder and upright for pin
#3, and install the pin into the upright and con-
nect the upright level cylinder to the upright.
Install the mounting hardware securing the pin.
b. Install the hose bracket and secure in place with
the mounting hardware.
7. Connect the wiring harness to horizontal limit switch.
8. Align the holes in the upper lift cylinder and upright
for pin #1 and install the pin. Secure the pin in place
with the mounting hardware.
9. Connect the hydraulic lines to the upper lift cylinder
as tagged during removal.
10. Install the upper boom. Refer to Section 4.4, Upper
Boom.
4.6 TOWER BOOM ASSEMBLY
Removal
HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDI-
ATELY AFTER DISCONNECTING LINES TO AVOID ENTRY OF CON-
TAMINANTS INTO SYSTEM.
1. Using an overhead crane or suitable lifting device,
support the entire Tower Boom Assembly and sepa-
rately support the tower lift cylinder.
2. Remove mounting hardware from tower lift cylinder
rod end. with a brass drift and hammer, remove the
tower Lift cylinder Pin disconnecting the tower lift
cylinder.
3. Remove mounting hardware from the upright level-
ing cylinder rod end. with a brass drift and hammer,
remove the pin, disconnecting the upright cylinder.
Remove with suitable lifting device.
4. Remove mounting hardware from the tower boom
pivot pin. Using a suitable brass drift and hammer,
remove pin #2 from turntable assembly.
5. Using all applicable safety precautions, carefully lift
the Tower Boom Assembly clear of turntable and
lower to ground or a suitable supported work sur-
face.
6. Remove the Tower Fly as follows:
a. Mark all hoses and wiring harnesses at bracket
on rear end of tower base boom for future
assembly.Remove hoses and wiring from tower
boom powertrack.