Service Manual

SECTION 5 - MAST COMPONENTS
3121231 – JLG Lift – 5-9
Tool Use - Angled Style Fittings (continued)
5.5 HYDRAULIC LIFT CYLINDER - REMOVAL,
INSPECTION AND REBUILD
HYDRAULIC CYLINDERS ARE DESIGNED TO HOLD HYDRAULIC
FLUID UNDER HIGH PRESSURE. ENSURE ALL APPROPRIATE
MEASURES ARE TAKEN TO RELIEVE RESIDUAL PRESSURE IN
THE CYLINDER BEFORE DISCONNECTING LINES.
Lift Cylinder Removal
Removal of the hydraulic lift cylinder without removing the
mast from the machine requires laying the machine on it’s
back (hood side) with the platform end on top.
1. Remove the following components from the
machine before laying machine on it’s back:
•Rear Covers (See Section 4)
•Batteries (See Section 3)
• Drive Motor Cover (See Section 3)
2. Seal the vented cap on the hydraulic fluid reservoir
by removing the cap, covering the hole with a few
layers of plastic wrap or equivalent. Then install and
tighten the cap over the plastic wrap to prevent leak-
age of hydraulic oil from the reservoir while machine
is in a layed back position.
3. Use a forklift truck or overhead crane and carefully
lay the machine on it’s back, place a support under
the mast end, keeping mast close to level. (See Fig-
ure 5-3.)
Step 4. Gently push hose assembly into coupling
body (see directional arrow).
Step 5. While maintaining slight pressure on the
hose assembly, actuate the tool (see arrow).
Step 6. Pull on hose assembly to complete discon-
nection.
Figure 5-3. Machine Positioned for Cylinder
Removal.
1. Be Careful of Control Components in this Area
2. Support Mast Here - Keep Mast Approximately Level