JLG 450A_AJ Series II Service Manual - Manual (Page 269)

SECTION 4 - BOOM & PLATFORM
3121180 – JLG Lift – 4-3
Assembly of Main Boom
1. Install power track to the attach point on the base
boom section. Secure power track with the attaching
hardware.
2. Install hydraulic lines and electrical cables into
power track.
3. Install wear pads to the aft end of the fly section.
4. Using suitable lifting equipment, slide fly section into
the base section until power track attach point aligns
with holes in side of base section.
5. Attach power track to aft end of fly boom section.
Secure power track with attaching hardware.
6. Using suitable lifting equipment, slide fly boom sec-
tion out to gain access to telescope cylinder attach
pin hole.
7. Measure distance between telescope cylinder port
block attach point on base boom section and attach
point on fly boom section.
8. Connect a suitable auxiliary hydraulic power source
to telescope cylinder port block.
9. Extend telescope cylinder the distance of the two
attach points.
10. Secure sling and lifting device at telescope cylin-
der’s approximate center of gravity. Lift cylinder to
aft end of boom assembly.
WHEN INSERTING TELESCOPE CYLINDER INTO BOOM, CARE
MUST BE TAKEN NOT TO DAMAGE POWER TRACK ASSEMBLY.
11. Slowly slide telescope cylinder into boom assembly
Align rod end with attach point in fly section. Insert
pin and secure with retaining ring.
12. Align bolt holes at aft end of base boom section with
telescope cylinder port block. Secure telescope cyl-
inder with hardware.
13. Install wear pads at end of base boom section.
Using shims, adjust adjustable wear pads to zero
clearance. Adjust pads alternately side to side, so fly
boom section is centered in base boom section.
14. Retract boom section fully. Using shims, adjust wear
pads at aft end of boom section to zero clearance.
Adjust pads alternately side to side, so fly boom sec-
tion is centered in base boom section.
15. Disconnect auxiliary power source from telescope
cylinder.
Installation of Boom Assembly
1. Using suitable lifting equipment, position boom
assembly on turntable so boom pivot holes in boom
and turntable are aligned.
2. Install boom pivot pin, ensuring location of hole in
pivot pin aligns with attach point on upright.
3. Using all applicable safety precautions, operate lift-
ing equipment to position boom lift cylinder and
level link so holes in cylinder rod end and level link
are aligned with one in turntable. Insert cylinder
pins.
4. If necessary, gently tap pins into position with a soft
headed mallet, ensuring attach holes in pins are
aligned with attach holes in boom structure. Secure
with hardware.
5. Connect all hosing and wiring.
6. Install platform to boom assembly.
7. Connect all hosing and wiring at platform control
station.
8. Using all safety precautions, operate machine sys-
tems and extend and retract boom for four or five
cycles.
9. Shut down machine systems and check for leaks.