Extend/Retract Cylinder Removal; Extend/Retract Cylinder Installation - JLG G5-18A Service Manual

Boom
13. Remove the Do Not Operate tags from both the
ignition key switch and the steering wheel.
3.3.11

Extend/Retract Cylinder Removal

1. Remove any attachment from the quick attach
assembly. Refer to Section 3.5, "Quick Attach
Assembly."
2. Park the machine on a hard, level surface, extend
the boom to gain access to the extend/retract
cylinder pin in the second boom section
(approximately 3 ft (1 m), level the boom assembly,
place the transmission control lever in (N)
NEUTRAL, engage the park brake and shut the
engine OFF.
Note: The boom must be properly aligned (level) with
the access hole at the rear of the frame to allow removal
of the extend/retract cylinder barrel mounting pin.
3. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the
machine should not be operated.
4. Open the engine cover. Allow the system fluids to
cool.
5. Remove the battery negative (-) cable from the
battery negative (-) terminal.
6. Remove the cylinder rod eye retaining clips and
mounting pin (2) at the side of the second boom
section.
7. Loosen and remove the hose clamps and cover
plate (3) from the rear of the boom assembly.
8. Label and disconnect the tilt and auxiliary hydraulic
hoses attached to the machine at the tubes on top of
the boom (4). Plug and cap the hose ends to prevent
dirt and debris from entering the hydraulic system.
9. Loosen and remove the extend/retract cylinder tubes
at the rear of the first boom section. Plug the tube
ends to prevent dirt and debris from entering the
hydraulic system.
3-10
10. Loosen and remove both fittings from the bottom of
11. Loosen and remove the locking bolt on the cylinder
12. Remove the cylinder barrel pin (5). Note the location
13. Attach a sling or other suitable lifting device to the
Note: The tilt hoses and if equipped, the auxiliary hoses
may need to be moved during removal of the extend/
retract cylinder.
14. Place the extend/retract cylinder in a designated
3.3.12
Note: The tilt hoses and if equipped, the auxiliary hoses
may need to be moved during installation of the extend/
retract cylinder.
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the extend/retract cylinder barrel. Plug the openings
in the extend/retract cylinder barrel.
barrel mounting pin.
of the spacers and washers.
extend/retract cylinder and carefully pull the extend/
retract cylinder free of the machine through the rear
of the boom/chassis assembly.
area for the next operation.

Extend/Retract Cylinder Installation

1. Carefully install the extend/retract cylinder into the
rear of the boom and line up the barrel end of the
cylinder with the pin bores on the first boom section.
2. Install the mounting pin (5), spacers and washers
through the frame access hole on the chassis and
the first boom section bore and cylinder barrel.
Secure with retaining clips.
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3
3. Remove the plugs in the bottom of the extend/retract
cylinder and install the previously removed fittings.
4. Uncap and connect the tubes to the previously
labeled fittings at the extend/retract cylinder. Apply
Loctite 545 to the fittings.
®
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G5-18A, 2505