Second Section Boom Removal - JLG G5-18A Service Manual

Boom
3. Place an Do Not Operate Tag on both the ignition
key switch and the steering wheel, stating that the
machine should not be operated.
4. Remove the battery negative (-) cable from the
battery negative (-) terminal.
5. Open the engine cover. Allow the system fluids to
cool.
6. Remove the quick switch assembly. Refer to Section
3.5.5, "Quick Attach Removal."
7. Support the boom by placing a sling around the
boom head. Support the lift/lower cylinder and
remove the lock bolt and then the rod end pin. Lower
the lift/lower cylinder onto the frame rails.
8. Label and disconnect the tilt and auxiliary hydraulic
hoses attached to the machine at the tubes on top of
the boom. Plug and cap the hose ends to prevent
dirt and debris from entering the hydraulic system.
9. Label and disconnect the extend/retract hydraulic
hoses at the tubes on the side of the boom.
Note: Tag or identify each hose to the corresponding
fitting it was removed from.
10. Remove the lock bolt and pin (1) from the rod end of
the compensating cylinder on the first boom section.
Rest the cylinder on the machine frame.
MY1980
11. Lower the boom to a level position and place a
suitable support under the rear of the boom.
Reposition the slings to each end of the boom.
12. Remove the lock bolt and pivot pin (2) from rear of
first boom section.
13. Lift the complete boom off machine and set on level
ground or supports being careful not to damage the
tubes on the bottom of the boom.
3-6
3.3.6
1. At the boom head, attach a sling around the tilt
2. Remove the extend /retract tubes from the extend /
3. If equipped, unscrew the auxiliary hoses. Plug the
Note: Tag or identify each hose to the corresponding
fitting it was removed from.
1
4. Remove the lock nut, bolt and pin from rod end of
5. Pull the second boom section out 6 in to 8 in
2
6. Carefully pull the tilt and auxiliary hydraulic hoses (3)
7. Pull out the remainder of the second boom section.

Second Section Boom Removal

cylinder. Remove both hoses from tilt cylinder. Plug
the hose ends and cap the tilt cylinder fittings to
prevent dirt and debris from entering the hydraulic
system. Remove the clip from barrel end of tilt
cylinder pin. Remove the tilt cylinder pin and lower
the tilt cylinder out of the boomhead.
retract cylinder from the rear of the boom.
hose ends to prevent dirt and debris from entering
the hydraulic system.
the extend/retract cylinder.
(15 cm to 20 cm) to be able to loosen and remove all
the bolts and remove all the wear pads, backing
plates and shims from the rear outside of the second
section boom and the front inside of the first section
boom. Tag each pad, backing plate, shim and bolts
from each location.
through the rear of the first boom section.
WARNING
NEVER weld or drill the boom unless approved in
writing by JLG. The structural integrity of the boom
will be impaired if subjected to any repair involving
welding or drilling. Failure to comply could result in
death or severe personal injury.
MY1990
3
G5-18A, 2505