JLG SkyTrak Einrichtungshandbuch

31200804

1.1 GENERAL GUIDELINES

•This repair procedure provides repair information for

a specific discrepancy. It is the responsibility of the

entity performing the repairs to determine if the

discrepancy can be corrected by this procedure. This

procedure is for the repair of the boom pivot

weldment only.

1.2 PARTS REQUIRED

SkyTrak Boom Pivot Repair Kit:

P/N 1001141603

Note: * The Self Aligning Bearings P/N 8065641 will be

factory installed in the Boom Pivot Plate Weldment P/N

1001141633.

1.3 WELD REPAIR GUIDELINES

•All welding must be in strict accordance with

EN288-3, EN288-4 or ANSI/AWS D1.1 standards.

•Disconnect the battery of the machine being repaired

prior to welding.

•Ground only to the component being welded. Do not

ground to any adjacent component or allow pins,

wear pads, wire ropes, bearings, gears, seals,

valves, electrical wiring, or hoses to be between the

grounding position and the area to be welded.

1.4 TOOLS & EQUIPMENT REQUIRED

1. Stands and lifting equipment capable of lifting/

supporting the affected components

2. Hand-held power grinder

3. Air carbon-arc equipment

4. Electric welding equipment

5. AWS 70 grade, low hydrogen rod or wire

6. Standard welder tools

7. Standard mechanic tools

8. Paint

1.5 PERSONNEL REQUIRED

1. Qualified JLG Equipment Mechanic

2. Certified Welder

1.6 MODELS AFFECTED

SkyTrak 8042, 10042 & 10054

1.7 BOOM PIVOT WELDMENT REMOVAL

1. Park the machine on a firm, level surface, fully retract

the boom, lower the boom, place the transmission

control lever in (N) NEUTRAL, engage the park brake

and shut the engine OFF.

2. Place a Do Not Operate Tag on both the ignition key

switch and steering wheel, stating that the machine

should not be operated.

3. Open the engine doors. Allow system

fluids to cool.

4. Remove components as required to

facilitate repair.

Note: Refer to Service Manual 31200353,

Section 3.4.1 for detailed boom assembly

removal.

5. Protect any hoses, wires and hydraulic

cylinder rods before preparing or welding

in the frame boom pivot area.

6. Safely support the components to

alleviate pressure or stresses at the

affected repair area(s).

CAUTION

Use all applicable Safety precautions while working

on, around or under any machinery.

P/N Qty Description

1001141633 1 Plate, Boom Pivot

8065641* 2 Bearing, Self Aligning

NOTICE

Failure to comply with the above weld repair guidelines

may result in component damage.

SkyTrak Boom Pivot

Repair Instructions

For Kit 1001141603

02/12

31200804

An Oshkosh Corporation Company

2 31200804

SkyTrak Boom Pivot Repair Instructions For Kit 1001141603

7. Using a portable grinder or air carbon-arc equipment,

remove both boom pivot plates (1) from the pivot

tower weldment (2).

8. Inspect the affected area of the pivot tower weldment

for cracks. If any discrepancies are evident, notify

JLG Safety 1-877-554-7233 (877-JLG-SAFE) for

further evaluation.

9. Grind the repair area (3) flush and prepare surfaces

for welding.

10. Locate the Boom Pivot Plate Weldment (4) P/N

1001141633 to the pivot tower weldment (2). See

“Boom Pivot Plate Welding Locations” on page 3.

Tack into place.

11. Completely weld the boom pivot plates to the pivot

tower weldment using the recommended weld

material with types and sizes. See “Boom Pivot Plate

Welding Locations” on page 3.

12. Inspect welds using the magnetic particle or

dye-penetrant inspection methods to assure there

are no cracks or deformities. If any cracks or

deformities exist, grind to remove affected area(s)

and repeat the weld and inspection procedures.

13. Remove the three retaining bars (5) connecting the

two pivot plates.

14. Clean, prime and paint the affected areas.

Note: Refer to Service Manual 31200353, Section 3.4.8

for detailed boom assembly installation.

15. Properly connect the battery.

16. Verify the proper operation of all boom functions

through a minimum of five cycles.

17. Inspect the repair areas for discrepancies. Contact

JLG Safety 1-877-554-7233 (877-JLG-SAFE) for

further evaluation if any discrepancies are found.

18. Close and secure the engine covers.

19. Remove the Do Not Operate Tags from both the

ignition key switch and the steering wheel.

20. Return machine to service.

NOTICE

Do not damage the parent metal during this procedure.

MH7000

MH7020

MH7010

31200804

SkyTrak Boom Pivot Repair Instructions For Kit 1001141603

1.8 BOOM PIVOT PLATE WELDING LOCATIONS

A. 5.220 - 5.340 in (134,1 - 135,6 mm)

B. 20.320 - 20.440 in (516,1 - 519,1 mm)

C. 2.180 in (55,3 mm)

D. 16.270 in (413,2 mm)

0.50

MH7030

4 31200804

SkyTrak Boom Pivot Repair Instructions For Kit 1001141603

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