Jlg 40H Service Manual User Manual download pdf (Page 38)

SECTION 2 - PROCEDURES

2-18 – JLG Lift – 3120240

22. Align the cylinder rod-end attachment holes with the

boom fly section attachment holes; install the pin

and secure the pin by installing washers and bolts.

23. 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.

24. 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

chains. Shim the top of the mid section for a total of

1/16 inch (.062) clearance.

25. Install wear pads into the forward portion of the base

section. Shim boom, if necessary, for a total of 2/10

inch (.20) clearance.

26. 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.

NOTE: Step 27 applies to 2 Section Boom Only.

27. Align the cylinder base-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. Secure pin by installing setscrew.

28. 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. Secure pin by installing setscrew.

29. Align the chain attachment assembly holes with the

threaded mounting holes at the aft end of the boom

by installing the bolts and washers.

30. 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.

31. Assemble and install the retraction chain attachment

and adjustment assembly as follows:

a. Place clevis bolt on bottom plate and place top

plate onto clevis assembly. Secure clevis bolt

with clevis pins, washers and new cotter pins.

b. Insert chain attach blocks between clevis plates

ensuring attachment points are properly aligned.

Secure block in position with bolts, nuts and

new cotter pins.

c. Align retraction chains with clevis attach blocks;

secure chains with clevis pins, washers 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.

32. Adjust retract and extend chains to the proper

torque. (See step a. adjusting procedures of para-

graph 2-6).

33. 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 powertrack 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 powertrack end with

the attachment point of the fly section carrier

tube; install the bolts, washers, lock washers

and nuts which secure the powertrack to the car-

rier tube.

c. Carefully feed the remaining hose and cable

ends aft through the base section carrier tube.

Properly align the remaining powertrack end

with the attachment point of the base section

carrier tube; install the bolts, washers, lockwash-

ers and nuts which secure the powertrack to car-

rier tube.

d. Ensure all hoses and cables are properly routed

through the carrier tube and powertrack. Tighten

or install all clamping or securing apparatus to

the hoses or cables, as necessary.

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Jlg 40H Service Manual User Manual Page 38

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