JLG 41EL Service Manual - Manual (Page 42)

SECTION 2 - SERVICE PROCEDURES
2-24 – JLG Lift – 3120782
30. Locate mast section-4, carefully slide section-4
closed rail into section-3 open rail. Slide sections
together until ends are even.
31. Locate one (1) of the chain/cable anchor plates (one
with two threaded holes vertically aligned in center of
bracket). Attach through inner (vertical) set of holes
at bottom of mast section-4 using two (2) 1/4"-
20UNC x 3/4" long bolts, place a flatwashers under
head of each bolt.
32. Slide mast section-4 out the top of mast section-3 so
the chain/cable anchor plate on bottom of mast sec-
tion-4 is easily accessible at top end of mast section-
3. Rest the top end of mast section-4 on a support
while performing next step.
33. Insert threaded ends of chain assembly (attached to
anchor block on top mast section-2) through the
chain/cable anchor plate located on bottom of
extended mast section-4. Loosely thread two (2) 3/
8"-16UNC nuts onto stud threads on each chain.
Chains will be adjusted later in assembly.
NOTE: Step 34 applies to 25 and 36 ft., six (6) section masts
and 30 & 41 ft., seven (7) section masts only. For five
(5) section 20 ft. masts skip to step 35.
34. While mast section-4 is still extended from section-3;
locate two cable assemblies. Attach the eyelet
anchor end of each cable to the inside set of holes
near top of mast section-4 using 3/8"-16UNC x 1-1/4"
long hex head bolts, nuts and flatwashers. Place a
flatwasher under bolt head and nut.
35. While mast section-4 is still extended from section-3,
assemble cable sheaves to top of mast section-4 as
follows;
a. Locate the wide tube spacer and slide onto
sheave pin.
b. Slide two (2) cable sheave wheels onto sheave
pin, one each end of sheave pin to outside of
tube spacer.
c. Place two (2) large flat washers, one each end of
sheave pin to outside of cable sheave wheels.
d. Place two (2) sheave pin attach bars, one each
end of sheave pin to outside of large flatwash-
ers.
e. Holding complete cable sheave wheel assem-
bly, slide assembly into top of mast section-4
and align threaded holes in sheave pin attach
bars with holes in mast rails.
f. Attach to top of mast section-4 using two (2) 3/
8"-16UNC x 1/2" long socket head-countersunk-
flathead cap screws, each side. Coat threads
with Loctite #171 and tighten.
NOTE: When sliding mast sections together, be careful not
to scratch or score the anodized finish in the slide
pad channels.
36. Carefully slide mast section-4 back into section-3
until ends are even. Check to make sure chain
assembly (narrow chains) are seating properly in
chain sheave wheels attached to top of mast sec-
tion-3.
37. Insert slide pads into the top end mast rails between
section-3 and -4, (one on each side of the mast),
with beveled surface facing inward towards section-
4.
NOTE: Before fastening and shimming the slide pad on the
top left side of the mast, install a sequence cable
bracket against the mast under the flatwasher.
38. Thread slide pad attaching bolts, (two (2) 1/4"-
20UNC x 3/8" long hex head bolts, place a flat
washer under head of each bolt), through holes in
outside rail, on top of mast section-3 and into the
slide pad inserts. Thread in enough to hold pad in
place.
39. Shim per instructions in step 7, Mast Section 2 -
Assembly.
40. Insert slide pads into the bottom end mast rails
between section-3 and -4, (one on each side of the
mast), with beveled surface facing out towards sec-
tion-3.
41. Thread slide pad attaching bolts, (two (2) 1/4"-
20UNC x 3/8" long hex head bolts, place a flat
washer under head of each bolt), through holes on
inside rail, on bottom end of mast section-4 and into
the slide pad inserts. Thread in enough to hold pad
in place.
42. Shim per instructions in step 7, Mast Section 2 -
Assembly.
Mast Section 5 - Assembly (25/30/36/41 ft. Masts)
NOTE: Steps 43 thru 56 apply to six (6) section 25 and 36 ft.
and seven (7) section 30 and 41 ft. masts only. For
five (5) section 20 ft. masts continue to step 70.
NOTE: When sliding mast sections together, be careful not
to scratch or score the anodized finish in the slide
pad channels.
43. Locate mast section-5, carefully slide section-5
closed rail into section-4 open rail. Slide sections
together until ends are even.
44. Locate one (1) of the chain/cable anchor plates (one
with threaded holes horizontally aligned to outside
edges of bracket). Attach through outer set of holes
in bottom of mast section-5 with two (2) 1/4"-20UNC