Service Manual Instruction Manual

SECTION 4 - BOOM & PLATFORM
4-4 – JLG Lift – 3121616
INSTALLATION
1. Use a suitable lifting device to position boom assembly
on turntable. Align pivot holes in boom and turntable.
2. Install boom pivot pin. Ensure location of hole in pin is
aligned with attach point on turntable.
3. Gently tap pin in position with soft headed mallet.
Install pin mounting hardware.
4. Connect all wiring connectors.
5. Connect all hydraulic lines running along side of boom
assembly.
6. Using all applicable safety precautions, operate lifting
device and position boom lift cylinder so holes in cylin-
der rod end and boom structure are aligned. Insert lift
cylinder pin. Ensure location of hole in pin is aligned
with attach point on boom.
7. Align holes in boom structure with hole in master cylin-
der. Insert master cylinder pin. Ensure location of hole in
pin is aligned with attach point on boom.
8. Using all applicable safety precautions, operate machine
systems and raise and extend boom fully. Note exten-
sion cycle performance.
9. Retract and lower boom. Note retraction cycle perfor-
mance.
4.2 TOWER BOOM
Remove Tower Upright
1. Tag and disconnect hydraulic lines to upper lift cylinder
(1). Use suitable container to retain any residual hydrau-
lic fluid. Cap hydraulic lines and ports.
2. Support upper lift cylinder using suitable lifting device.
3. Remove bolt and keeper pin from upper lift cylinder bar-
rel end pin (2). Remove pin using a suitable brass drift
and hammer.
4. Tag and disconnect hydraulic lines to master cylinder
(3). Use a suitable container to retain any residual
hydraulic fluid. Cap hydraulic lines and ports.
5. Remove bolt and keeper pin from master cylinder barrel
end pin (4). Remove pin using a suitable brass drift and
hammer.
6. Disconnect wiring hardness to two horizontal limit
switches (5) and dual capacity limit switch (6).
7. Support tower upright (7) with suitable lifting device.
8. Remove mounting hardware and hose bracket (8) from
tower upright.
9. Remove bolt and keeper pin from upright level cylinder
(9) barrel end pin (10). Remove pin using a suitable brass
drift and hammer.
10. Remove bolt and keeper pin from upright pivot pin (11).
Remove pin using a suitable brass drift and hammer.
Remove upright from tower boom assembly.
Figure 4-3. Tower Upright Components
1
2
3
4
11
8
6
5
9
10
7
5