Replacing Hydraulic Hoses on JLG Boom Lift 800A

[MikePhua]

Hydraulic systems are the backbone of many heavy equipment machines, and the JLG Boom Lift 800A is no exception. This lift, commonly used for aerial work platforms, relies heavily on its hydraulic system to control movement and operation. One of the most common maintenance tasks for this type of equipment is the replacement of hydraulic hoses. Understanding how to replace these hoses, ensuring proper connections, and maintaining the system can extend the life of the lift and improve its operational efficiency. This article will delve into the process of replacing hydraulic hoses on a JLG Boom Lift 800A, covering the steps, safety precautions, and key tips.
Why Hydraulic Hose Replacement is Necessary
Hydraulic hoses in equipment like the JLG 800A Boom Lift are subjected to high pressure and frequent movement. Over time, these hoses can wear out due to factors such as:

• Age: Rubber hoses degrade over time, especially if exposed to harsh environmental conditions like UV rays, extreme temperatures, or chemicals.
  
• Wear and Tear: Frequent flexing or vibration can cause fatigue in the hoses, leading to cracks or leaks.
  
• Over-pressurization: Excessive pressure can strain the hoses, especially if the lift operates under heavy load conditions.
  
• Damage from External Forces: Objects, sharp edges, or abrasive surfaces can damage the hoses, leading to hydraulic fluid leaks.
  

Replacing these hoses is vital to maintaining the lift's efficiency, preventing hydraulic fluid leaks, and ensuring operator safety.
Step-by-Step Guide to Replacing Hydraulic Hoses on JLG 800A
Replacing hydraulic hoses on a JLG Boom Lift requires careful planning, proper tools, and a systematic approach to ensure everything is done correctly. Here’s a step-by-step guide to help with the replacement process:

1. Preparation and Safety
   • Safety First: Before working on the hydraulic system, make sure the lift is turned off and positioned securely. Ensure the lift is in a stable position, and engage the emergency brakes.
     
   • Hydraulic Pressure Relief: Depressurize the hydraulic system. This is critical to avoid injury or damage to the system. Most JLG boom lifts have a valve or process for relieving system pressure.
     
   • Tools and Materials: Gather all necessary tools and parts before beginning. You’ll need wrenches, hydraulic hose crimping tools, replacement hoses (matching the specifications of the original), fittings, and hydraulic fluid.
     
2. Remove the Old Hoses
   • Locate the hydraulic hoses that need replacement. This may include hoses running to and from the boom, bucket controls, or the drive system.
     
   • Use the appropriate wrench to disconnect the hoses at both ends, ensuring you have proper drainage for any residual hydraulic fluid.
     
   • Inspect the hose for signs of wear, damage, or cracks. This can help you understand the cause of the failure, which might be useful when replacing the hose.
     
3. Clean the Area
   • Before installing the new hoses, clean the connections and the surrounding area. Dirt or debris around the hydraulic fittings can lead to contamination of the system and premature failure of the new hoses.
     
4. Install the New Hoses
   • Measure and cut the new hose to the correct length, if necessary. It's crucial that the hose is the correct length to prevent it from being stretched or causing kinks.
     
   • Install the new hose at both ends using the proper fittings. Make sure that the fittings are tight and secure, but avoid overtightening, as this can damage the hose or fitting.
     
   • For crimped hose connections, use a hydraulic hose crimping tool to ensure that the hose is securely attached to the fittings. Improper crimping can lead to leaks.
     
5. Check for Leaks
   • After installing the new hoses, check for leaks by gently operating the system. If any leaks are detected, immediately shut down the system, tighten connections, and test again.
     
   • It’s important to ensure the hydraulic fluid levels are topped off after replacing the hoses.
     
6. Test the Lift
   • Once everything is securely in place and there are no leaks, test the lift's functionality. Ensure the hydraulic system operates smoothly and that the boom, bucket, and other components function as expected.
     

Troubleshooting Common Hydraulic Hose Issues
While replacing hydraulic hoses is typically straightforward, it’s important to be aware of a few issues that may arise during the replacement process:

• Incorrect Hose Sizing: Make sure the replacement hose matches the specifications of the original hose, including diameter, pressure rating, and material. Incorrect sizing can lead to improper fluid flow or failure under pressure.
  
• Improper Fitting Connections: Check that all fittings are tightly secured, and there are no leaks. Loose fittings can cause the hose to disconnect under pressure, potentially damaging the system and causing downtime.
  
• Air in the System: If air gets trapped in the hydraulic system during the hose replacement, it can affect the lift’s performance. Purge any trapped air by operating the lift’s hydraulic functions gently and checking for consistent pressure.
  

Tips for Maintaining Hydraulic Hoses
Maintaining the hydraulic hoses on a JLG 800A Boom Lift is crucial for preventing frequent replacements and ensuring optimal performance. Here are some tips for prolonging the lifespan of your hydraulic hoses:

• Routine Inspection: Regularly check the hoses for any signs of wear, such as cracks, abrasions, or bulges. Catching issues early can help you replace hoses before they fail completely.
  
• Keep Hoses Clean: Dirt and contaminants can damage the hydraulic system. Clean hoses regularly to remove dirt, grease, or debris that may cause friction or wear.
  
• Avoid Overloading the Lift: Excessive pressure from overloading can strain the hydraulic system and cause premature failure of hoses and components.
  
• Protect Hoses from Damage: Ensure that hoses are not exposed to sharp edges or rough surfaces that can cause them to wear out faster. Use protective covers if necessary.
  

Conclusion
Hydraulic hose replacement on a JLG 800A Boom Lift is a vital maintenance task to ensure the lift operates safely and efficiently. By following the proper procedures, using the correct tools, and regularly inspecting and maintaining the hydraulic system, operators can extend the life of the equipment and minimize downtime. Regular checks and timely repairs help maintain the boom lift’s reliability, ensuring it can perform effectively in various work environments, from construction sites to industrial applications.