JLG 800A_AJ Service Manual - Manual (Page 309)

SECTION 5 - HYDRAULICS
3120858 – JLG Lift – 5-27
Upright Level Cylinder Installation
1. Place the leveling cylinder in position in the tower
boom, then align holes in tower boom and leveling
cylinder. Install leveling cylinder rod end attach pin,
using a suitable rubber mallet.
2. Secure pin to tower boom with mounting hardware.
3. Remove cylinder port plugs and hydraulic line caps
and correctly attach lines to cylinder ports.
4. Using all applicable safety precautions, operate the
overhead crane to move upright assembly into
proper position.
5. Align holes in upright and barrel end of level cylinder
and install level barrel end pin, using a suitable rub-
ber mallet. Secure pin with mounting hardware.
THE UTMOST SAFETY PRECAUTIONS ARE TO BE TAKEN AT THIS
POINT, LIFTING THE UPPER BOOM TO ATTACH TO THE PIVOT
POINT OF THE UPRIGHT
6. Using all applicable safety precautions, operate the
crane to lift upper boom assembly into proper posi-
tion.
7. Align holes in upright and upper boom and install
upper boom pivot pin, using a suitable rubber mal-
let. Secure pin with mounting hardware.
8. Align the mounting holes of the upper lift cylinder
and the upper boom. Install the upper lift rod end
pin, using a suitable rubber mallet. Secure pin with
mounting hardware.
9. Align the mounting holes of the master cylinder and
the upper boom. Install the master cylinder pin,
using a suitable rubber mallet. Secure pin with
mounting hardware.
10. Remove hydraulic line caps and correctly attach all
tagged hydraulic and electrical lines.
11. Remove overhead crane from upper boom. Activate
hydraulic system.
12. Using all applicable safety precautions, operate the
boom functions. Check for correct operation and
hydraulic leaks. Secure as necessary.
13. Check fluid level of hydraulic tank and adjust as nec-
essary.
Tower Boom Lift Cylinder Removal
1. Place machine on a flat and level surface. Place the
upper boom in a horizontal position with the tele-
scope cylinder fully retracted. Place the tower boom
in a fully elevated and fully retracted position.
2. Support the upper boom, upright, and tower boom
with adequate overhead crane.
3. Adequately support the tower lift cylinder.
4. Remove mounting hardware securing the lift cylin-
der rod pin to the tower boom. Using a suitable
brass drift, drive out the tower lift cylinder rod attach
pin.
5. Using all applicable safety precautions, operate aux-
iliary power, activate tower lift down and fully retract
lift cylinder.
6. Tag, disconnect and cap the tower lift cylinder
hydraulic lines and ports.
7. Remove mounting hardware securing the tower lift
cylinder barrel pin to the turntable. Using a suitable
brass drift, drive out the tower lift cylinder barrel pin.
8. Carefully remove the tower lift cylinder from turnta-
ble. Place in a suitable work area.