JLG 800S Service Manual - Manual (Page 230)

SECTION 4 - BOOM & PLATFORM
4-14 – JLG Lift – 3121139
Installation
1. Using a suitable lifting device, position boom
assembly on upright so that the pivot holes in both
boom and upright are aligned.
2. Install boom pivot pin, ensuring that location of hole
in pin is aligned with attach point on upright.
3. If necessary, gently tap pin into position with soft
headed mallet. Secure pin mounting hardware.
4. Connect all wiring to the ground control box.
5. Connect all hydraulic lines running along side of
boom assembly.
6. Using all applicable safety precautions, operate lift-
ing device in order to position boom lift cylinder so
that holes in the cylinder rod end and boom struc-
ture are aligned. Insert the lift cylinder pin, ensuring
that location of hole in pin is aligned with attach
point on boom.
7. Align holes in boom structure with hole in master
cylinder. Insert the master cylinder pin, ensuring that
location of hole in pin is aligned with attach point on
boom.
8. Adjust retract and extend cables to the proper
torque. Refer to Section 4.3, Boom Rope Torquing
Procedures.
9. Using all applicable safety precautions, operate
machine systems and raise and extend boom fully,
noting the performance of the extension cycle.
10. Retract and lower boom, noting the performance of
the retraction cycle.
Telescope Cylinder/Boom Cable Removal
1. Make sure the machine is on a firm, level surface.
2. Raise the boom to a horizontal position.
3. Extend the boom approximately 2 feet (0.6 m). This
will enable access to the bolts that secure the cable
mount block to the boom fly section.
4. Tag and disconnect all hydraulic hoses running to
the telescope cylinder. Cap or plug all openings to
prevent any foreign matter from entering the hydrau-
lic system.
5. Using a 3/8 drive extension approximately 4 feet (1.2
m) long, remove the bolts and washers securing the
cable mount block to the boom fly section.
6. Remove the four bolts, shims, and attachment
blocks that secure the telescope cylinder barrel to
the boom mid section.