Disassembly; Inspection; Assembly - JLG E450A Service And Maintenance Manual

Disassembly

1. Loosen jam nuts on aft end of fly boom wear pad adjust-
ment and loosen adjustments.
2. Using a portable power source, attach hose to telescope
cylinder port block. Using all applicable safety precau-
tions, activate hydraulic system and extend cylinder to
gain access to cylinder rod pin #1. Shut down hydraulic
system.
3. Carefully disconnect hydraulic hose from retract port of
cylinder. There will be initial weeping of hydraulic fluid
which can be caught in a suitable container. After initial
discharge, there should be no further leakage from the
retract port.
4. Remove hardware securing telescope cylinder #1 to the
fly boom section, then remove pin from fly.
5. Remove hardware securing telescope cylinder to the
base boom section.
WHEN REMOVING TELESCOPE C YLINDER FROM BOOM SECTIONS. CARE
SHOULD BE TAKEN NOT TO LET CYLINDER REST ON POWERTRACK WHICH
COULD CAUSE DAMAGE TO POWERTRACK.
6. Using a suitable lifting device, remove telescope cylin-
der from boom sections.
7. Using a piece of tape, mark the length of hoses and
wires from front of fly boom and bottom of base boom
for reassembly.
8. Remove hardware securing the front cover on base
boom section.
9. Loosen jam nuts on front wear pad adjustments and
loosen adjustments.
10. Remove hardware securing the front wear pads on base
boom section, remove wear pads.
11. Remove wire clamp on the inside of the fly nose.
12. Manually push the fly boom section into base boom sec-
tion to gain access to the powertrack attachment bolts
on the right side of the base boom section.
13. Remove hardware securing the powertrack to the aft
end of the fly boom section.
14. Using a suitable lifting device, remove fly boom from
boom section.
15. Remove hydraulic lines and electrical cables from pow-
ertrack.
16. Remove hardware securing powertrack to the base
boom section. Remove powertrack.
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SECTION 4 - BOOM & PLATFORM

Inspection

1. Inspect boom pivot pin for wear, scoring or other dam-
age, and for tapering or ovality. Replace pin as neces-
sary.
2. Inspect lift and master cylinder pins for wear, scoring or
other damage, and for tapering or ovality. Ensure pin
surfaces are protected prior to installation. Replace pins
as necessary.
3. Inspect telescope cylinder rod attach pin for wear, scor-
ing or other damage. Replace pin as necessary.
4. Inspect inner diameter of boom pivot bushings for scor-
ing, distortion, wear or other damage. Replace bushings
as necessary.
5. Inspect wear pads for wear as shown in Section 4.5,
Wear Pads.
6. Inspect all threaded components for damage such as
stretching, thread deformation, or twisting. Replace as
necessary.
7. Inspect structural units of boom assembly for bending,
cracking, separation of welds, or other damage. Replace
boom sections as necessary.

Assembly

1. Install power track to the attach point on the inside of
the base boom section. Secure power track with hard-
ware.
2. Install hydraulic lines and electrical cables into the
power track.
3. Install wear pads to the aft end of the fly section.
4. Using suitable lifting equipment, slide fly section into
the base section until power track attach point aligns
with holes in side of base section.
5. Attach the power track to the aft end of fly boom sec-
tion. Secure power track with hardware.
6. Using suitable lifting equipment, slide fly boom section
out to gain access to telescope cylinder attach pin hole.
7. Measure the distance between the telescope cylinder
port block attach point on base boom section and the
attach point on fly boom section.
8. Connect a suitable auxiliary hydraulic power source to
the telescope cylinder port block.
9. Extend the telescope cylinder the distance of the two
attach points.
10. Secure the sling and lifting device at the telescope cylin-
der's approximate center of gravity, and lift the cylinder
to the aft end of the boom assembly.
WHEN INSERTING THE TELESCOPE CYLINDER INTO THE BOOM, CARE MUST BE
TAKEN NOT TO DAMAGE THE POWER TRACK ASSEMBLY.
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