BIL-JAX 36XT
26
LIFT CYLINDER REPLACEMENT
Use the following procedure to remove and replace
faulty or damaged hydraulic cylinders on the boom
lift:
WARNING
Repair and removal of the hydraulic cylinders
requires the use of lifting straps and an
overhead crane or lifting gear to support the
boom lift and hydraulic cylinders. Personnel
should be thoroughly trained in the operation of
these devices before attempting installation or
removal. Hydraulic cylinders are heavy and may
have hydraulic oil on their surface. Failure to use
proper equipment or to securely support boom
and boom cylinders can result in damage to lift
components, serious injury or death.
Lower the boom until it is resting in a stowed position.
When removing the slave cylinder, extend the
articulating boom section until all pivot pins are
exposed (approximately two feet).
Press and hold the emergency lowering valve on the
back of the jib boom section to relieve all hydraulic
pressure to the cylinder. Repeat this process for the
upper and lower boom sections. Refer to the 4527A
Operator’s Manual for emergency lowering valve
locations and operating procedures.
Turn key switch to the OFF position and remove the
key.
Locate the piston rod end of the cylinder to be
removed (Figure 4-1). Unbolt and remove the retainer
plate from each side of the pivot pin.
Verify that the cylinder is supported by lifting straps
and an overhead hoist.
Remove the pivot pin using a hammer and a brass or
hardwood drift.
Use an overhead crane or lifting gear to raise the
boom section. Adequate clearance is necessary to
reach the cylinder valve block and hydraulic hose
ports.
Unplug the appropriate emergency lowering valve
solenoid.
Tag and number all hydraulic hoses that attach to the
cylinder valve block. Use a marker to label the valve
block ports with the appropriate hose numbers.
Place absorbent cloths below the cylinder ports and
detach hydraulic hoses from the cylinder. Elevate
hoses to prevent leakage. Plug or cap exposed hose
fittings and cylinder ports.
At the base of the cylinder, unbolt and remove
retainer plate from each side of the pivot pin.
Remove the pivot pin using a hammer and a brass or
hardwood drift.
Lift and remove the cylinder using an overhead hoist
and lifting straps.
Replace or reinstall the cylinder by following the
above instructions in the reverse order of removal.
Actuate the hydraulic system and check for leakage.
Tighten hydraulic fittings as needed.
Bleed trapped air from the hydraulic system by raising
and lowering the boom with the reservoir fill port cap
on but not tightened. Allow several minutes for
trapped air to escape. Repeat as needed.
RETAINING
PLATE
CYLINDER
PIN
PISTON ENDBASE END
Figure 4-1. Lift Cylinder Replacement
