Required Tools; Making A Seal Tool; Before Disassembly - JLG 400S Service And Maintenance Manual

SECTION 4 - BOOM & PLATFORM

Required Tools

Upon assembly and disassembly of the actuator there are
basic tools required. The tools and their intended functions are
as follows:
1.
8.
6.
7.
1. PIPE VISE
2. HEX WRENCH - Removal and replacement of port plugs
and setscrews.
3. ASSORTED SCREWS
4. SAFETY GLASSES
5. END CAP REMOVAL TOOLS (provided with Helac seal
kit).
6. DRILL
7. FLASHLIGHT - Helps to locate and examine timing
marks, component failure and overall condition.
8. RUBBER MALLET - Removal and installation of shaft and
piston sleeve assembly.
9. PLASTIC MANDREL
10. PRY BAR - Removal of end cap and manual rotation of
shaft.
11. FELT MARKER - Highlights the timing marks and outline
troubled areas.
12. T-HANDLE SCREW EXTRACTOR
13. HEX WRENCH SET - Removal and replacement of port
plugs and setscrews (106 &110).
14. SEAL TOOLS - Removal and installation of seals and wear
guides. Directions to make a seal tool are provided
below making a Seal Tool.
15. PUNCH
16. DOWEL PINS - Removal and installation of end cap.
4-36
2.
4.
3.
5.
12.
13.
11.
16.
14. 15.
9. 10.

Making a Seal Tool

The seal tool is merely a customized standard flat head screw-
driver.
TO AVOID INJURY BE CAREFUL WHILE HANDLING THE HOT SCREWDRIVER.
1. Heat the flat end with a torch until it glows.
2. Secure the heated end of the screwdriver in a vise and
bend the heated end to a slight radius.
3. Round off all sharp edges of the heated to a polished fin-
ish. The tool may be modified slightly to your own per-
sonal preference. To avoid injury be careful while
handling the hot screwdriver.

Before Disassembly

Inspect the actuator for corrosion prior to disassembly. Severe
corrosion can make it difficult to remove the lock pins (109)
and unthread the end cap (04). If corrosion is evident, soak the
lock pins and end cap with penetrating oil for several hours
before disassembly.
Disassembly is considerably easier if the actuator is firmly
secured to the work bench. A pipe vise or mounting fixture
work well.
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