JLG 4013PS Service Manual - Manual (Page 39)

3-7 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Boom
4. With the boom head still supported, install the top
wear pads, washers and bolts in the front of the first
boom section. Apply Loctite
® 243 TM and torque to
90 Nm (66 lb-ft). Remove the boom head from
supports and install the bottom wear pads, backing
plates, shims and bolts in the front of the first boom
section. Apply Loctite
® 243 TM and torque to 90 Nm
(66 lb-ft). Install both left and right side front wear
pads, backing plates, shims and bolts in the front of
the first boom section. Apply Loctite
® 243 TM and
torque to 50 Nm (37 lb-ft).
Note: Shim ALL side wear pads as needed to maintain
a minimum gap in the horizontal direction or a tight fit.
The number of shims can vary at each shim point except
on the bottom wear pads.
Note: Light lubrication of the boom wear surfaces with a
factory authorized grease is recommended to keep the
boom wear surfaces lubricated properly.
5. Tighten all wear pads after ensuring the minimum
gap requirements have been met. Refer to Section
3.10.1, “Wear Pad Inspection.”
3.3.6 Boom Installation
1. Insert the extend/retract cylinder through the rear of
the boom. Align the extend/retract rod end with the
cylinder pin mounting hole on the last boom section.
Install the extend/retract cylinder pin and retaining
clip.
Note: On 12 & 13M machines, install the two brackets
the secure the extend/retract cylinder to the second
boom section.
2. Align the extend/retract barrel end with the cylinder
pin mounting hole on the first boom section. Install
the extend/retract cylinder pin and retaining clip.
Note: Grease extend/retract cylinder barrel end bore
and pin before installing.
3. Attach a sling through the rod end of the tilt cylinder
and position the cylinder to its original mounting
location. Install the tilt cylinder pins and retaining
clips.
4. Insert the extend/retract, tilt and auxiliary hoses
through the boom.
5. Uncap and connect the previously labeled hydraulic
hoses to the appropriate locations on each cylinder.
6. Install the hose clamps inside the innermost boom
section.
7. Using suitable slings, turn the boom over to its
original orientation.
8. Rebalance the boom assembly with slings, lift and
carefully guide the boom into place. Align the frame
pivot bore with the boom pivot bore. Install the boom
pivot pin. Apply Loctite
® 243 TM and torque to 300 Nm
(221 lb-ft).
9. With the sling still in place, install both compensation
cylinders, pins and lock bolts. Apply Loctite ® 243 TM
and torque to 120 Nm (88 lb-ft).
10. With the sling still in place, raise the boom enough to
install the lift/lower pin and lock bolt. Apply Loctite ®
243 TM and torque to 300 Nm (221 lb-ft).
Note: Raising the boom up or down with the sling
maybe necessary so the boom, compensation and lift/
lower cylinder bores can be aligned for easier pin
installation.
Note: Grease the boom pivot bore, compensation
cylinder rod ends, lift/lower rod end and pins before
installing.
11. Uncap and connect the previously labeled hydraulic
hoses to the hose rack on the side of the first boom
section.
12. Connect the boom angle indicator rod from switch at
the inside left rear corner of the main boom section
and frame. Refer to Section 9.14.7, “Boom Angle
Sensor,” for adjustment information.
13. Properly connect the battery.
14. Start the engine and operate all boom functions
several times. Check for leaks, and check the
hydraulic oil level in the reservoir; add oil if required.
15. Install the access panel on the boom head.
16. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
17. Close and secure the engine cover.