JLG 450A_AJ Series II Service Manual - Manual (Page 215)

SECTION 4 - BOOM & PLATFORM
3121290 – JLG Lift – 4-3
Main Boom Assembly
1. Install power track to the attach point on the base boom
section. Secure power track with the attaching hard-
ware.
2. Install hydraulic lines and electrical cables in 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 section
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 cylinder’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 cylinder
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 section
is centered in base boom section.
15. Disconnect auxiliary power source from telescope cylin-
der.
Install Boom Assembly
1. Using suitable lifting equipment, position boom assem-
bly on turntable so boom pivot holes in boom and turn-
table 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 lifting
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. Ensure attach holes in pins are aligned
with attach holes in boom structure. Secure with hard-
ware.
5. Connect all hoses and wiring.
6. Install platform to boom assembly.
7. Connect hoses and wiring at platform control station.
8. Using all safety precautions, operate machine systems
and extend and retract boom for four or five cycles.
9. Shut down machine systems and check for leaks.