JLG 510AJ Service Manual - Manual (Page 201)

SECTION 4 - BOOM AND PLATFORM
3121181 – JLG Lift – 4-3
Assemble Main Boom
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 into the
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 the power track to the aft end of fly boom sec-
tion. Secure power track with the attaching hardware.
6. Using suitable lifting equipment, slide fly boom section
out to gain access to telescope cylinder attach pin hole.
7. Measure the distance between the telescope cylinder
port block attach point on base boom section and the
attach point on fly boom section.
8. Connect a suitable auxiliary hydraulic power source to
the telescope cylinder port block.
9. Extend the telescope cylinder the distance of the two
attach points.
10. Secure the sling and lifting device at the telescope cylin-
der’s approximate center of gravity, and lift the cylinder
to the aft end of the boom assembly.
WHEN INSERTING THE TELESCOPE CYLINDER INTO THE
B O O M, C A RE MUS T B E TAK E N N OT TO DAMAG E T H E
POWER TRACK ASSEMBLY.
11. Slowly slide the 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 the adjustable wear pads to zero clear-
ance. Adjust pads alternately side to side, so that 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 that fly boom sec-
tion 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 that boom pivot holes in both boom
and turntable are aligned.
2. Install boom pivot pin, ensuring that location of the hole
in pivot pin aligns with attach point on upright.
3. Using all applicable safety precautions, operate lifting
equipment in order to position boom lift cylinder and
level link so that holes in cylinder rod end and level link
are aligned with the one in the turntable. Insert cylinder
pins.
4. If necessary, gently tap pins into position with a soft
headed mallet, ensuring that attach holes in pins are
aligned with attach holes in boom structure. Secure with
hardware.
5. Connect all hosing and wiring.
6. Install the platform to the boom assembly.
7. Connect all hosing and wiring at platform control sta-
tion.
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 leakage.