JLG 40H Service Manual - Manual (Page 33)

SECTION 2 - PROCEDURES
3120240 – JLG Lift –
2-13
NOTE: Steps 10 and 11 apply to 2 Section Boom Only.
10. Remove the capscrews and washers holding the
telescope cylinder rod pin to the fly boom.
11. Using a suitable brass drift, carefully drive the tele-
scope cylinder pin from the fly boom.
12. Attach a suitable sling to the telescope cylinder.
Support with an overhead crane or other suitable lift-
ing device.
NOTE: Steps 13, 14, 15 and 16 apply to 3 Section Boom
Only.
13. Remove the two (2) extension chain adjusting nuts
from the eyebolt through the chain adjust assembly.
14. Remove the four (4) bolts and lock washers attach-
ing the chain attach block to the base boom section
and remove block.
15. Attach a suitable lifting device to the extension chain
adjusting eyebolt above the cylinder rod.
NOTE: The extension chain will come out of the boom twice
as far as the telescope cylinder.
16. Using both lifting devices, carefully pull the cylinder
from the boom assembly.
NOTE: Step 17 applies to 2 Section Boom Only.
17. Using the lifting device, carefully pull the cylinder
from the boom assembly.
NOTE: Steps 18 and 19 apply to 3 Section Boom Only.
18. As the cylinder is removed from the boom, lay the
extension chain on top of the base boom.
19. Using another lifting device, support the sheave
wheel end of the cylinder and remove the cylinder
from the boom assembly.
NOTE: Step 20 applies to 2 Section Boom Only.
20. Using another lifting device, support the rod end of
the cylinder and remove the cylinder from the boom
assembly.
21. Carefully lift the cylinder clear of the boom assembly
and lower to the ground or suitably supported work
area.
Telescope Cylinder Installation.
1. Using suitable lifting equipment, carefully lower the
cylinder to the boom assembly.
2. Using another lifting device, support the sheave
wheel, or rod end, of the cylinder and install the cyl-
inder into the boom assembly.
3. Slide the cylinder into boom, sliding the extension
chain (3 Section Boom Only) in place as the cylinder
is moving in.
NOTE: Steps 4, 5 and 6 apply to 3 Section Boom Only.
4. Attach a suitable lifting device to the extension chain
adjusting eyebolt.
5. Install chain adjust block with four 4 lock washer and
bolts to base boom section.
6. Install the two (2) extension chain adjusting nuts that
attach the eyebolt to the chain adjust block.
7. Remove the lifting device from the telescope cylin-
der.
NOTE: Steps 8, 9 and 10 apply to 3 Section Boom Only.
8. Using a suitable brass drift install the trunnion pins
attaching the telescope cylinder to the mid boom
section.
9. Install the capscrews securing the trunnion pins to
each side of the boom. Note that loctite 242 is
required on the cap screw threads.
10. Install trunnion pin covers on each side of boom.
NOTE: Steps 11 and 12 apply to 2 Section Boom Only.
11. Carefully install the telescope cylinder rod pin
through the fly boom.
12. Install the capscrews and washers holding the tele-
scope cylinder rod pin to the fly boom. Note that loc-
tite 242 is required on the capscrew threads.
13. Carefully install the telescope cylinder barrel attach
pin into base boom.
14. Install the setscrews that retain the telescope cylin-
der pin to the base boom.
15. Remove applicable hydraulic line and port caps and
correctly connect the hydraulic lines to the tele-
scope cylinder. Ensure all hoses are correctly
routed.
16. Install boom end cover.
17. Activate hydraulic system.
18. Using all applicable safety precautions, operate the
boom functions. Check for correct operation and
hydraulic leaks. Secure as necessary.
NOTE: Step 19 applies to 3 Section Boom Only.
19. Cycle (extend/retract) boom several times, then
torque boom chains to 40 ft. lbs. (2.76 Bar). See
Section 2-6 Boom Chains for correct torquing proce-
dure.