JLG 45e Service Manual - Manual (Page 40)

SECTION -
-14 – JLG Lift – 3120861
Inspection.
1. Inspect boom pivot pin for wear, scoring or other
damage, and for tapering or ovality. Replace pin as
necessary.
2. Inspect lift and master cylinder pins for wear, scoring
or other damage, and for tapering or ovality. Ensure
pin surfaces are protected prior to installation.
Replace pins as necessary.
3. Inspect telescope cylinder rod attach pin for wear,
scoring or other damage. Replace pin as necessary.
4. Inspect inner diameter of boom pivot bushings for
scoring, distortion, wear or other damage. Replace
bushings as necessary.
5. Inspect wear pads for wear as shown in paragraph
2-6, Wear Pads.
6. Inspect all threaded components for damage such
as stretching, thread deformation, or twisting.
Replace as necessary.
7. Inspect structural units of boom assembly for bend-
ing, cracking, separation of welds, or other damage.
Replace boom sections as necessary.
Assembly.
1. Install power track to the attach point on the inside
of the base boom section. Secure power track with
hardware.
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
section. Secure power track with hardware.
6. Using suitable lifting equipment, slide fly boom sec-
tion out to gain access to telescope cylinder attach
pin hole.
7. Measure the distance between the telescope cylin-
der 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
cylinder’s approximate center of gravity, and lift the
cylinder to the aft end of the boom assembly.
WHEN INSERTING THE TELESCOPE CYLINDER INTO THE BOOM,
CARE MUST BE TAKEN NOT TO DAMAGE THE POWER TRACK
ASSEMBLY.
11. Slowly slide the telescope cylinder into boom
assembly, align rod end with attach point in fly sec-
tion. 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 cyl-
inder with hardware.
13. Install wear pads at end of base boom section.
Adjust the adjustable wear pads to zero clearance.
Adjust pads alternately side to side, so that fly boom
section is centered in base boom section.
14. Retract boom section fully. Adjust wear pads at aft
end of boom section to zero clearance. Adjust pads
alternately side to side, so that fly boom section is
centered in base boom section.
15. Disconnect auxiliary power source from telescope
cylinder.
Installation.
1. Using suitable lifting equipment, position boom
assembly on upright so that boom pivot holes in
both boom and upright 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 lift-
ing equipment in order to position boom lift and
master cylinders so that holes in cylinder rod ends
and boom structure are aligned. 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 slave leveling cylinder to the boom
assembly.
7. Install the platform to the boom assembly.
8. Connect all hosing and wiring at platform control
station.
9. Using all safety precautions, operate machine sys-
tems and extend and retract boom for four or five
cycles.
10. Shut down machine systems and check for leakage.