Second Section Boom Installation; Boom Installation - JLG G5-18A Service Manual

8. Inspect the boom and welds. Consult your local JLG
distributor if structural damage is detected.
9. Inspect hoses, hardware, wear pads, mounting
points and other components visible with the first
boom section. Replace any item if damaged.
10. Inspect all wear pads for wear. (Refer to Section
3.4.1, "Wear Pad Inspection.")
3.3.7

Second Section Boom Installation

1. If previously removed, insert the extend/retract
cylinder through the rear of the second boom section
and attach the pin and clip to the barrel end.
2. Install the bottom rear wear pads, washers and bolts
into the second boom section. Apply Loctite
and torque to 66 lb-ft (90 Nm).
®
Note: Apply Loctite #242 to all wear pad bolts prior to
installing wear pads.
3. Grease the inside of the first boom section on areas
where the second boom section wear pads will slide.
4. Using a suitable sling, carefully slide the second
boom section 3 ft to 4 ft (1 m to 1.5 m) into the front
of the first boom section. Set the second boom
section head onto suitable supports and reset sling
under the boom head of the second section.
Carefully slide the second section into the first
section. Leave 6 in to 8 in (15 cm to 20 cm) of the
second section out to be able to install wear pads in
front of the first boom section.
5. With the sling still under the boom head, install the
top wear pads, washers and bolts in the front of the
first boom section. Apply Loctite
to 66 lb-ft (90 Nm). Raise the second boom section
and install the bottom wear pads, backing plates,
shims and bolts in the front of the first boom section
®
Apply Loctite #242 and torque to 66 lb-ft (90 Nm).
Install the left and right side front wear pads, backing
plates, shims and bolts in the front of the first boom
section. Apply Loctite
(90 Nm).
6. Install the top rear left and right side wear pads,
backing plate and bolts (do not shim or tighten
bolts). Install the left and right side rear wear pads,
backing plates and bolts, do not shim or tighten
bolts).
Note: Light lubrication of the boom wear surfaces with a
factory authorized grease is recommended to keep the
boom wear surfaces lubricated properly.
7. Tighten all rear wear pad bolts after ensuring the
minimum gap requirements have been met. Refer to
G5-18A, 2505
®
®
#242 and torque
®
#242 and torque to 66 lb-ft
Section 3.4.1, "Wear Pad Inspection."
8. Slide the tilt and auxiliary hoses between the boom
sections.
9. Insert the pin and secure the rod end of the extend/
retract cylinder in place with the bolt and locknut.
10. Install both tubes to the rear of the extend/retract
cylinder.
11. Lift the tilt cylinder into place and insert the pins and
clips to secure the cylinder to the boomhead.
12. Uncap and reconnect the tilt and auxiliary hoses and
attach to their appropriate locations.
3.3.8

Boom Installation

#242
Note: Light lubrication of the boom wear surfaces with a
factory authorized grease is recommended to keep the
boom wear surfaces lubricated properly. Light lubrication
of the boom wear surfaces is also recommended when
the machine is stored, to help prevent rusting.
1. Park the machine on a hard, level surface, place the
transmission control lever in (N) NEUTRAL, engage
the park brake and shut the engine OFF.
2. Place an Do Not Operate Tag on both the ignition
key switch and the steering wheel, stating that the
machine should not be operated.
3. Open the engine cover. Allow the system fluids to
cool.
Note: Grease the boom pivot bore, compensating
cylinder rod ends, lift/lower cylinder rod end and pins
before installing.
4. Using suitable slings, balance the boom assembly,
lift and carefully guide the boom into place. Align the
frame pivot bore with the boom assembly pivot bore.
Install boom pivot pin (4) and lock bolt. Apply
®
Loctite #242 and torque to 66 lb-ft (90 Nm).
Boom
3-7