JLG | Compact Crawler Booms X13JP - X370AJ - Boom Maintenance

Remove the platform and platform support as follows:

• Disconnect electrical cable from control console.

• Tag and disconnect the hydraulic lines running to the rotate cylinders. Cap the hydraulic lines and ports.

• Using an overhead crane or suitable lifting device, use nylon support straps to support the platform/support.

NOTE: When removing the retaining pin from the rod end of the level cylinder, make sure the cylinder is properly supported

• Remove bolts and keeper pins that secures the retaining pins. Using a suitable brass drift and hammer, remove the retaining pins from the platform support.

Remove the boom from the turntable as follows

• Disconnect wiring harness from ground control harness connector.

• Tag and disconnect hydraulic lines from boom to control valve. Use a suitable container to retain any residual hydraulic fluid. Cap all hydraulic lines and ports.

• Using a suitable lifting equipment, adequately support boom weight along entire length.

• Remove the bolts and keeper pins securing the lift cylinder pivot pin. Using a suitable brass drift and hammer, remove the pivot pin from the lower boom.

• Remove hardware securing the level link pivot pin. Using a suitable brass drift and hammer, remove the pin from the level link and turntable.

• Remove hardware securing the lower boom pivot pin. Using a suitable brass drift and hammer, remove pin from the turntable.

• Using all applicable safety precautions, carefully lift boom assembly clear of turntable and lower to ground or suitable supported work surface.

NOTICE: HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DISCONNECTING LINES TO AVOID ENTRY OF CONTAMINANTS INTO SYSTEM.

Disassembly of the Main Boom

• Loosen jam nuts on aft end of fly boom wear pad adjustment and loosen adjustments.

• Using a portable power source, attach hose to telescope cylinder port block. Using all applicable safety precautions, activate hydraulic system and extend cylinder to gain access to cylinder rod retaining pin. Shut down hydraulic system

• 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

• Remove hardware securing telescope cylinder to the fly boom section, then remove pin from fly.

• Remove hardware securing telescope cylinder to the base boom section.

• NOTICE: WHEN REMOVING TELESCOPE CYLINDER FROM BOOM SECTIONS. CARE SHOULD BE TAKEN NOT TO LEAVE CYLINDER REST ON POWERTRACK WHICH COULD CAUSE DAMAGE TO POWERTRACK.

• Using a suitable lifting device, remove telescope cylinder from boom sections.

• Using a piece of tape, mark the length of hoses and wires from front of fly boom and bottom of base boom for reassembly.

• Remove hardware securing the front wear pads on base boom section, remove wear pads

• Remove hardware securing the powertrack to the aft end of the fly boom section.

• Using a suitable lifting device, remove fly boom from boom section.

• Remove hydraulic lines and electrical cables from powertrack

• Remove hardware securing powertrack to the base boom section. Remove powertrack.

Boom and Platform

Inspect all boom pivot pins for wear, scoring or other damage, and for tapering or roundness. Replace pins as necessary.

• Pass
• Flag
• Fail

Inspect lift cylinder pins for wear, scoring or other damage, and for tapering or roundness. Ensure pin surfaces are protected prior to installation. Replace pins as necessary

• Pass
• Flag
• Fail

Inspect telescope cylinder rod attach pin for wear, scoring or other damage. Replace pin as necessary.

• Pass
• Flag
• Fail

Inspect inner diameter of boom pivot bushings for scoring, distortion, wear or other damage. Replace bushings as necessary.

• Pass
• Flag
• Fail

Inspect wear pads for wear

• Pass
• Flag
• Fail

Inspect all threaded components for damage such as stretching, thread deformation, or twisting. Replace as necessary.

• Pass
• Flag
• Fail

Inspect structural units of boom assembly for bending, cracking, separation of welds, or other damage. Replace boom sections as necessary.

• Pass
• Flag
• Fail

Assembly of the Main Boom

• Install powertrack to the attach point on the base boom section. Secure powertrack with the attaching hardware

• Install hydraulic lines and electrical cables into the powertrack.

• Install wear pads to the aft end of the fly section.

• Using suitable lifting equipment, slide fly section into the base section until powertrack attach point aligns with holes in side of base section.

• Attach the powertrack to the aft end of fly boom section. Secure powertrack with the attaching hardware

• Using suitable lifting equipment, slide fly boom section out to gain access to telescope cylinder attach pin hole.

• Measure the distance between the telescope cylinder port block attach point on base boom section and the attach point on fly boom section.

• Connect a suitable auxiliary hydraulic power source to the telescope cylinder port block.

• Extend the telescope cylinder the distance of the two attach points.

• Secure the sling and lifting device at the telescope cylinder’s approximate center of gravity, and lift the cylinder to the aft end of the boom assembly.

• NOTICE: WHEN INSERTING THE TELESCOPE CYLINDER INTO THE BOOM, CARE MUST BE TAKEN NOT TO DAMAGE THE POWERTRACK ASSEMBLY.

• Slowly slide the telescope cylinder into boom assembly, align rod end with attach point in fly section. Insert pin and secure with retaining ring.

• Slowly slide the telescope cylinder into boom assembly, align barrel end with attach point in fly section. Insert pin and secure with retaining ring.

• Install wear pads at front of base boom section. Adjust the wear pads to zero clearance.

• Adjust pads alternately side to side, so that fly boom section is centered in base boom section (lower wear pad with 1 mm gap).

Removal

• NOTE: If the platform is removed only track movement is allowed.

• Remove the platform/remote control box from the mounting support.

• Loosen and remove the aluminium caps that secure the platform to the jib platform mounting posts.

• Lift the platform off the mounting posts in an upward direction. Place platform aside for later installation.

Installation

• Lift the platform and align the platform mounts with the jib mounting posts and lower until seated.

• Secure the platform to the jib mounting posts with the aluminum threaded caps. Do not overtighten.

• Re-install the platform/remote control box into the mounting support on the platform.

The purpose of this instruction is to install a SkyGuard system on JLG Compact Crawler Boom (platform capacity of one person) models listed below and with below pictured SkyGuard Bracket

It is recommended that you read and thoroughly understand these instructions before starting this procedure.

NOTICE: USE ALL APPLICABLE SAFETY PRECAUTIONS WHILE WORKING ON, AROUND OR UNDER ANY MACHINERY.

Options/Accessories Prohibited When Installing This Kit:

• None

Tools & Equipment Required:

• Standard mechanic tools including 5/16 in. & 7/32 in. Allen Wrenches

• Tie Straps

Personnel Required:

• Qualified JLG equipment mechanic

Parts List:

Procedure:

• Park the machine on the firm level surface, fully retract & lower the boom.

• Extend all the four outriggers, set them to the auto levelling mode and set the machine to rest position.

• Remove the key and shut the engine OFF.

• Allow the machine and system fluids to cool.

• Disconnect the battery power from the machine

For Reference:

Installation:

• 1. Install the SkyGuard Support Bracket (8) onto the welded mounts on platform rails. Secure the support bracket using four Bolts (2), relevant Washers (7) and Nuts (3). See Figure 4-11.

NOTE: Ensure the correct position of Shear Block Support (10) before installation.

NOTE: Tighten the Bolt (5) using appropriate allen wrench.

8. Repeat Steps 4 through 7 to secure SkyGuard switch assembly on the other side of the SkyGuard support bracket ensuring correct position of the shear block support before installation.

CAUTION: WHEN THE SKYGUARD IS PUSHED WITH EXCESSIVE FORCE THE SENSOR SUPPORTS (ITEM 10 - FIGURE 4-13.) WILL BREAK. REPLACE WITH NEW SENSOR SUPPORTS BEFORE CONTINUING OPERATION OF THE MACHINE.

11. POWER ON the machine.

• Press button 6 (service) on the remote control

• Press button 7 (set up)

• Press button 5 (password)

• Enter password “4 7 7 1" then press button 9 (OK)

• Press button 3 (extra)

• Press button 1 (optional)

• Press button 8 (next)

• Press button 4 (SkyGuard)

• Press Button 1 (ON)

• Press button 9 (esc)

• Remote control screen should be on main icon page

NOTICE: IF PLATFORM REMOVAL WILL BE NECESSARY, SKY GUARD EXTERNAL CONNECTOR HAS TO BE DISCONNECTED. THEN RECONNECTED WHEN THE PLATFORM IS INSTALLED ON THE MACHINE.

NOTE: If further information is required, please contact the JLG Service Department.

The purpose of this instruction is to install a SkyGuard system on JLG Compact Crawler Boom (platform capacity of one person) models listed below and with below pictured SkyGuard Bracket.

• It is recommended that you read and thoroughly understand these instructions before starting this procedure

NOTICE: USE ALL APPLICABLE SAFETY PRECAUTIONS WHILE WORKING ON, AROUND OR UNDER ANY MACHINERY.

Options/Accessories Prohibited When Installing This Kit:

• None

Tools & Equipment Required:

• Standard mechanic tools including 5/16” & 7/32” Allen Wrenches

• Tie Straps

Personnel Required:

• Qualified JLG equipment mechanic

Parts List:

Procedure:

• Park the machine on the firm level surface, fully retract & lower the boom.

• Extend all the four outriggers, set them to the auto levelling mode and set the machine to rest position.

• Remove the key and shut the engine OFF.

• Allow the machine and system fluids to cool.

• Disconnect the battery power from the machine.

For Reference:

NOTE: Ensure the correct position of Shear Block Support (10) before installation.

NOTE: Tighten the Bolt (5) using appropriate allen wrench.

CAUTION: WHEN THE SKYGUARD IS PUSHED WITH EXCESSIVE FORCE THE SENSOR SUPPORTS (ITEM 10 - FIGURE 4-21.) WILL BREAK. REPLACE WITH NEW SENSOR SUPPORTS BEFORE CONTINUING OPERATION OF THE MACHINE.

11. POWER ON the machine.

• Press button 6 (service) on the remote control

• Press button 7 (set up)

• Press button 5 (password)

• Enter password "4 7 7 1" then press button 9 (OK)

• Press button 3 (extra)

• Press button 1 (optional)

• Press button 8 (next)

• Press button 4 (SkyGuard)

• Press Button 1 (ON)

• Press button 9 (esc)

• Remote control screen should be on main icon page

NOTICE: IF PLATFORM REMOVAL WILL BE NECESSARY, SKY GUARD EXTERNAL CONNECTOR HAS TO BE DISCONNECTED. THEN RECONNECTED WHEN THE PLATFORM IS INSTALLED ON THE MACHINE.

NOTE: If further information is required, please contact the JLG Service Department.