Terex TL48 User manual

Tech-Tip 70 1 Released: 07/30/2021

Tech Tips

Service Call:

Removing Extension Cylinder for a TL48

Tools Required:

Simple hand tools

Nylon Strap

Hoist/Overhead Crane

Model(s):

TL48

Tech-Tip 70 2 Released: 07/30/2021

Tech Tips

Tech Tip Safety Rules

Danger

Failure to obey the instructions and safety rules in the appropriate

Operator's Manual and Service Manual for your machine will result in

death or serious injury. Many of the hazards identified in the operator’s

manual are also safety hazards when maintenance and repair

procedures are performed.

Do Not Perform Maintenance Unless:

•You are trained and qualified to perform maintenance on this

machine.

•You read, understand and obey:

omanufacturer’s instructions and safety rules

oemployer’s safety rules and worksite regulations

oapplicable governmental regulations

•You have the appropriate tools, lifting equipment and a suitable

workshop.

The information contained in this tech tip is a supplement to the service

manual. Consult the appropriate service manual of your machine for

safety rules and hazards.

Tech-Tip 70 3 Released: 07/30/2021

Tech Tips

Step 1

Position the upper boom in a horizontal position

with no load in the platform.

A stand will need to be placed at the end of the

steel section of the upper boom. This can be

done by using a piece of tube and outrigger

pads or wood blocks. If possible, use a 6x6 tube.

This will fit into the boom latch weldment and

help with keep the tube from moving.

Note: Placing the tube directly on the floor may

cause damage, use an outrigger pad or wooden

blocks

Steel tube

Outrigger

pad or

block of

wood

Tech-Tip 70 4 Released: 07/30/2021

Tech Tips

Step 2

Extend the boom to allow access to the opening

on the inner boom. Remove the cylinder end

support bracket. After the support has been

removed, retract the inner boom.

Location of opening in inner boom

Location of screws that

need to be removed

Tech-Tip 70 5 Released: 07/30/2021

Tech Tips

Step 3

Remove the upper boom pivot pin. Place the

shim, spacer and pivot pin in a safe place for

reuse.

If possible, use a short stub of a pin on one side

and leave the pin partially in the boom and the

elbow pin hole to maintain alignment. This will

save time during reassembly.

Boom will need to be supported if the pin is completely

removed.

Location of

spacer/pin

Pin Keeper

Tech-Tip 70 6 Released: 07/30/2021

Tech Tips

Step 4

Tag the hydraulic lines on the extension

cylinder. Remove the hydraulic lines and cap

and plug the fittings.

Escaping fluid under pressure can penetrate skin causing

serious injury.

Relieve pressure before disconnecting hydraulic lines. Keep

away from leaks and pin holes. Use a piece of cardboard or

paper to search for leaks. Do not use your hand.

Note: Hydraulic oil will cause permanent marker

to rub off. Make sure the hoses are marked in a

way that won’t be removed with hydraulic oil.

Tech-Tip 70 7 Released: 07/30/2021

Tech Tips

Step 5

Remove the 4 fasteners that hold the extension

cylinder to the inner boom.

Tech-Tip 70 8 Released: 07/30/2021

Tech Tips

Step 6

Remove the set screw for the base end

extension cylinder pin.

Set Screw

Location

Tech-Tip 70 9 Released: 07/30/2021

Tech Tips

Step 7

Remove the cylinder pin. Slide the cylinder

slowly out the rear of the upper boom. Support

the cylinder as it is removed with a suitable

lifting device.

The boom assembly, including the platform, will have to be

supported with a suitable lifting device prior to removal of

cylinders.

Do not scratch or mar surface of fiberglass. Use rope slings

or other soft material - never use chains or wire rope directly

on fiberglass.

Care should be exercised when removing cylinders, as they

are heavy. Cylinders should be removed by means of a hoist,

if available.

Step 8

Once the cylinder is removed, it provides a good

opportunity to perform inspection on it. Also

inspect the bushings, replacing any that are

worn.

Step 9

If cylinder is dissembled for any reason, it will

need to be cycled to fill the cylinder with oil.

Deadhead the cylinder in each direction multiple

times to purge air out of the cylinder.

Tech-Tip 70 10 Released: 07/30/2021

Tech Tips

Step 10

Reassemble the boom in reverse order. Use

blue Loctite for the four screws securing the rod

to the inner boom. Lubricate the pins before

reassembly. Do not use your fingers in the bore

to see if boom is aligned.

Note:Prior to installation of cylinder pins,

inspect for any nicks or burrs and remove if

found. Damage to the bearings/bushing will

result if not repaired at this time.

Note:Check bearings for wear whenever

maintenance or repair is being performed at

cylinders or linkage. Replace any worn

components. Always lubricate prior to assembly.

Consult the unit specific lubrication chart.

Use caution when positioning hydraulic hoses. Sharp bends

will create kinks and cause unnecessary repairs later.

The cylinder will be empty of oil and full of air after repair,

which may make initial operation dangerous. Thus, the

cylinder should be purged of air. After purging, fill the

hydraulic reservoir to the full level, if needed, with all cylinders

retracted. From the lower controls, cycle the boom fully three

(3) times before operating from the platform. Do not ride the

platform while air is being purged - SERIOUS INJURY OR

DEATH COULD RESULT.

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