JLG 80HX_HX+6_HXER Service Manual - Manual (Page 49)

SECTION 2 - PROCEDURES
3120863 – JLG Lift – 2-27
17. Align the cylinder base-end attachment holes with
the boom mid section attachment holes; install the
trunnion pins and secure the pins by installing bars,
washers and bolts.
18. Slide the mid section into the base section. Allow the
retraction chains to trail between the bottom sur-
faces of boom sections. Ensure that no twists exist
in the chains. Shim the top of the mid section for a
total of 1.5 mm clearance.
19. Install wear pads into the forward portion of the base
section. Shim the boom, if necessary, for a total of 5
mm clearance.
20. Assemble the extension chain attachment and
adjustment assembly (mounted at aft of boom base
section) as follows:
a. Align the attaching holes of the chain attach-
ment clevis bolt with those of the extension
chain end; install the clevis pin through the
attaching holes. Install the washer and cotter pin
which secures the clevis pin through the chain
attachment assembly.
21. Align the cylinder rod-end attachment point with
those of the boom base section. If necessary, use an
auxiliary hydraulic power source to extend and
retract the cylinder rod for alignment. Install the
cross pin through the base boom section and cylin-
der rod. Install the snap rings onto the cross pin.
22. Align the chain attachment assembly holes with the
threaded mounting holes at the aft end of the boom
by installing the bolts and washers.
23. Insert the threaded end of the chain attachment cle-
vis bolt through the large hole of the chain attach-
ment weldment. Loosely install the jam nut and nut
onto the threaded end of clevis bolt.
24. Assemble and install the retraction chain attachment
and adjustment assembly as follows:
a. Place the clevis bolt on the bottom plate and
place the top plate onto the clevis assembly.
Secure the clevis bolt with clevis pins, washers
and new cotter pins.
b. Insert chain attach blocks between the clevis
plates ensuring the attachment points are prop-
erly aligned. Secure the block in position with
bolts, nuts and new cotter pins.
c. Align the retraction chains with the clevis attach
blocks; secure the chains with clevis pins, wash-
ers and new cotter pins.
d. Position the bolt end of the extension-adjust-
ment clevis into the boom mounted bracket.
Secure the chain-adjusting assembly by install-
ing the jam nut and nut.
e. Position the chain adjustment shield over the
chain adjustment assembly; secure the shield
by installing the bolts and washers.
25. Adjust the retract and extend chains to the proper
torque. (See adjusting procedures of Section 2.6).
26. Install the hydraulic hoses, electrical cables, and the
harnessing power track components as follows:
a. Properly position the fly section carrier tube with
carrier tube bracket installed at the side of the
boom. Align the attachment holes the forward
end of the carrier tube with those of the fly sec-
tion mounting plate. Secure the carrier tube by
installing the bolts, washers, lock washers and
nuts. Align the support bracket with attachment
holes in the mid boom and secure with bolts and
washers.
b. Properly position the assembled hoses, electri-
cal cable, and the harnessing power track onto
the base section carrier tube. Carefully feed the
proper hose and cable ends through the fly sec-
tion carrier tube and into the hole in the boom fly
section. Properly align the power track end with
the attachment point of the fly section carrier
tube; install the bolts, washers, lock washers
and nuts which secure the power track to the
carrier tube.
c. Carefully feed the remaining hose and cable
ends aft through the base section carrier tube.
Properly align the remaining power track end
with the attachment point of the base section
carrier tube; install the bolts, washers, lockwash-
ers and nuts which secure the power track to
carrier tube.
d. Ensure all hoses and cables are properly routed
through the carrier tube and power track.
Tighten or install all clamping or securing appa-
ratus to the hoses or cables, as necessary.