Service Manual Owner's manual

SECTION 4 - BOOM & PLATFORM
3121139 – JLG Lift – 4-41
Tools Required for Assembly/Disassembly
Upon assembly and disassembly of the actuator there are
basic tools required. The tools and their intended func-
tions are as follows:
1. Flashlight- helps examine timing marks, component
failure and overall condition.
2. Felt Marker- match mark the timing marks and out-
line troubled areas.
3. Allen wrench- removal of port plugs and setscrews.
4. Box knife- removal of seals.
5. Seal tool- assembly and disassembly of seals and
wear guides.
6. Pry bar- removal of end cap and manual rotation of
shaft.
7. Rubber mallet- removal and installation of shaft and
piston sleeve assembly.
8. Nylon drift- installation of piston sleeve.
9. End cap dowel pins- removal and installation of end
cap (sold with seal kit.
The seal tool is merely a customized standard flat head-
screwdriver. To make this tool you will need to heat the flat
end with a torch. Secure the heated end of the screwdriver
in a vice and physically bend the heated end to a slight
radius. Once the radius is achieved round off all sharp
edges of the heated end by using a grinder. There may be
some slight modifications for your own personal prefer-
ence.
Disassembly
1. Remove the cap screws (113) over end caplock pins
(109).
2. Using a 1/8” (3.18mm) drill bit, drill a hole in the cen-
ter of each lock pin to a depth of approximately 3/
16” (4.76mm).
3. Remove the lock pins using an “Easy Out” (a size
#2 is shown). If the pin will not come out with the
“Easy Out”, use 5/16” drill bit to a depth of 1/2”
(12.7mm) to drill out the entire pin.