JLG DVSP Series Service Manual - Manual (Page 106)

SECTION 5 - MAST COMPONENTS
5-18 – JLG Lift – 3121136
16. Assemble one of the narrow chains sets (#444) and
to the small chain equalizer anchor plate using the
pins, washers and cotter keys. Set aside.
17. Locate the chain anchor block and slide it onto the
hydraulic cylinder rod end sticking out the top of
mast section 2.
18. Lay out the chain(#444)/anchor plate assembly with
anchor plate end towards mast, (be certain floor sur-
face is clean and free of any metal chip or debris
which may stick to lubricated chains or lay chains in
a clean bucket).
19. Assemble the chain/anchor plate assembly and the
chain anchor block to the cylinder rod end using the
anchor plate/block attach pin and snap ring.
20. Assemble chain sheaves on chain assembly anchor
block (attached to cylinder rod end) and attach to
mast section-2 using following steps;
a. Insert sheave pin through anchor block and cyl-
inder rod on cylinder rod end.
b. Load three 1" flat washers onto the sheave pin
on each side of the anchor block.
c. Place sheave wheels (for wide #544 chain) on
sheave pin, one each side of anchor block.
d. On the outside of each sheave wheel, place
another 1" flatwasher, a roll pin (into the slot in
each end of the pin), and then place a sheave
pin support bar (rectangular plate with threaded
holes on each side of pin bore hole).
e. Slide the whole anchor block/cylinder assembly
with sheave pin, wheels and pin support bars
into top of mast section-2.
f. Align the threaded holes in the attach bars on
each side of the mast and attach to top of mast
section-2 using two (2) 3/8"-16UNC x 1/2" long
socket head-countersunk-flathead cap screws
each side. Coat threads with Loctite #171 and
tighten.
21. Remove the cylinder mount cap - shoulder screws
and apply Loctite #242 to the threads. Install the
screws and torque to 85 ft. lbs.
22. Tighten the center lift cylinder mount screw, this
screw keeps the cylinder assembly from rotating in
the mount.
23. Slide mast section-2 back into section-1 until top
and bottom ends are even.
MAST SECTION 3 - ASSEMBLY
NOTE: When sliding mast sections together, be careful not
to scratch or score the anodized finish in the slide
pad channels.
24. Carefully slide mast section-3 into section-2 until
ends are even.
25. Insert slide pads into the top end mast rails between
section-2 and -3, (one on each side of the mast),
with beveled surface facing inward towards section-
3. (Same as Figure 5-8.)
NOTE: Before fastening and shimming the slide pad on the
top left side of the mast, install a sequence cable
bracket against the mast under the flatwasher.
Install Chain/Anchor Block to Top of Lift Cylinder
1. Attach Pin 4. Attach Pin - Snap Ring
2. Chain/Equalizer Assembly 5. Cylinder Rod (Extended)
3. Chain/Anchor Block
1
2
3
4
5
Mast Section 2 - Chain/Anchor Block
(Sheave Wheel Assembly)
1. Support Bar Screws(a) 4. Sheave Wheel Assy.
2. Pin Support Bars 5. Sheave Pin
3. Narrow Washer 6. Square Keys
Note: (a) Apply Loctite #242 to threads.
1 1
2 2
3 3 3 5
6
3 4 4