Inspection; Assembly - JLG 600AJ Service And Maintenance Manual

Inspection

NOTE: Replace worn or damage components as needed.
1. Inspect tower boom pivot pin for wear, scoring, tapering
and ovality, or other damage. Replace pins if necessary.
2. Inspect tower boom pivot attach points for scoring,
tapering and ovality, or other damage. Replace pins if
necessary.
3. Inspect inner diameter of tower boom pivot bearings for
scoring, distortion, wear, or other damage. Replace pins
if necessary.
4. Inspect lift cylinder attach pin for wear, scoring, tapering
and ovality, or other damage. Ensure pin surfaces are
protected prior to installation. Replace pins if necessary.
5. Inspect inner diameter of upright attach point bearings
for scoring, distortion, wear, or other damage. Replace
bearing if necessary.
6. Inspect all threaded components for stretching, thread
deformation, twisting, or other damage. Replace if nec-
essary.
7. Inspect structural units of tower boom assembly for
bending, cracking, separation of welds, or other dam-
age. Replace boom sections if necessary.
8. Inspect powertrack for cracking, wear, or other damage.
Replace links or assembly, if necessary.

Assembly

NOTE: When installing fly section wear pads, install same number
and thickness of shims as were removed during disassem-
bly.
1. Measure inside dimensions of tower base section to
determine number of shims required for proper lift.
2. Install side, top and bottom wear pads to front end of
tower fly section. Shim evenly to measurements of the
inside of base boom section.
ENSURE BOOM SLIDING AREAS ARE CLEAR OF CHAINS, TOOLS, AND OTHER
OBJECTS WHEN ASSEMBLING BOOM SECTIONS.
3. Align upright leveling cylinder with attach holes in
tower fly boom. Using a soft head mallet, install the cyl-
inder pin into tower fly boom and secure with mounting
hardware.
4. Install side, top, and bottom wear pads to the aft end of
tower fly section; shim evenly to the measurements of
the inside of the base boom section.
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SECTION 4 - BOOM & PLATFORM
5. Align tower telescope cylinder with attach holes in
tower fly boom. Install cylinder pin in tower fly boom
using a soft head mallet. Secure with mounting hard-
ware.
6. Secure the sling and lifting device at the tower fly boom
assembly's approximate center of gravity.
7. Slide tower fly boom assembly into the tower base
boom section. Shim boom, if necessary, for a total of 1/
16 in. (0.062) clearance.
8. Install wear pads in forward position of the tower base
boom section. Shim boom, if necessary, for a total of 2/
10 in. (0.20) clearance.
9. Align telescope cylinder with slots at aft end of tower
base boom section. Secure cylinder with mounting
hardware.
10. Install cover plate to attach point on the tower base
boom section, then secure with mounting hardware.
11. Install powertrack to attach point on the tower base
boom section, then secure with mounting hardware.
12. Attach push tubes to the powertrack and attach point
on the tower fly boom section with mounting hardware.
13. Properly route hoses and wiring harnesses through
bracket at aft end of tower base boom section.
14. Pull hoses and wiring harnesses through hose bracket to
mark on hoses and harnesses from disassembly. Clamp
for proper length.
15. Route hoses and harnesses through powertrack. Push
tubes through holes in side of tower fly boom nose.
Secure hoses and harnesses with hoses brackets.
Hose & Cable
Bracket
Cover Plate
Figure 4-9. Tower Boom Powertrack Components
Push Tubes
Hose Clamp
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