JLG 534D-10 - Manual (Page 39)

3.11 534D-9, 534D-10 & 544D
Boom
10. Loosen and remove the bolts holding the strong
back to the rear of the first boom section. Remove
the strong back.
11. Remove the wear pads from the front of the first
boom section. Note the location of the wear pads,
mounting bolts and number of shims from each
location.
12. Remove the wear pads from the top rear and one
side of the second boom section. Note the location
of the wear pads, mounting bolts and number of
shims from each location.
Note: It may be necessary to pull the boom section(s)
out far enough to access the wear pads.
13. Slowly pull the two boom sections out of the first
boom section. The extend cables, retract cable and
the tilt/aux hoses will come out along with the boom
sections.
Pay close attention to the retract cable and tilt/aux
hoses during the boom section removal as not to
allow the cable or hoses to become jammed
between the second and first boom sections.
14. Lift the two boom sections free of the machine and
place on the ground or suitable supports.
3.4.4 Second Boom Section Installation
1. Grease the inside wear pad paths of the first boom
section and the outside wear paths of the second
boom section.
2. Position the second boom section into the front of
the first boom section. Leave room at the bottom
front to install the retract cable adjustment block.
3. Install the retract cable adjustment block to the
inside front of the first boom section.
4. Install the wear pads and shims in the front of the
first boom section.
5. Install the wear pads and shims at the top rear and
one side of the second boom section.
6. Feed the tilt hoses (and auxiliary hoses if equipped)
through the bottom of the hose sheaves at the rear
of the second boom section.
Note: Make sure the tilt/aux hoses do not cross each
other between the first and second boom sections.
7. Install the hose take-up brackets and install the tilt/
aux hoses to the correct fittings on the take-up
brackets.
3.4.5 Third Boom Section Installation
1. Grease the inside wear pad paths of the second
boom section and the outside wear paths of the third
boom section.
2. With the retract cable fed through the front of the
second boom section, position the third boom
section into the front of the second boom section.
3. Feed the retract cable over the cable sheave at the
rear of the second boom section and out the rear of
the first boom section.
4. Install the wear pads and shims in the front of the
second boom section.
5. Install the wear pads and shims at the top rear and
one side of the third boom section.
6. Install the back of the push beam into the head of
the third boom section. With the push beam installed
50% into the third boom section, feed the extend
cables through the bottom and over the cable
sheaves.
7. Install the push beam into position and pin into place
at the rear of the second boom section. Pull the third
and second boom section out of the first section
together approximately 12 in.to allow slack in the tilt/
aux hoses.
8. Install the bulkhead brackets at the front of the third
boom section.
9. Feed the tilt/aux hoses through the trays at the
bottom corners of the third boom sections.
10. Uncap and reconnect the previously labeled tilt/aux
hoses to the fittings on the bulkhead brackets.
11. Push the third and second boom section back
against the first boom section.
12. Install the strong back and pin the extend/retract to
the strong back.
13. Uncap and reconnect the previously labeled extend/
retract hoses to the fittings on the extend/retract
cylinder.
14. Feed the extend cables through the strong back and
install the jam nuts on each cable.
15. Install the guide and cable cover on the front of the
push beam.
16. Install the tilt cylinder and hoses in the third boom
section boom head.
17. Install the hose and cable cover at the rear of the
second boom section.
18. Adjust the boom sections, cables and hoses to the
proper dimensions.