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.

Tech-Tip 70 11 Released: 07/30/2021
Tech Tips
Step 11
After assembly, operate the unit through its full
range of motion from the lower controls to bleed
air out of the hydraulic hoses and cylinder.
Verify correct operation of the extension
cylinder.