Boom Lift Cylinder Rebuild — Ames Hydraulics

Boom Lift Cylinder Rebuild — Main Boom, Jib, Tilt, Level, Outrigger

Boom lift cylinder rebuild is a specialty job. Boom lifts run 6-10+ hydraulic cylinders each — main boom, jib, tilt, level, basket, outrigger — and every one of them is a big-ticket item because boom lift cylinders are longer, heavier, and higher-pressure than skid steer cylinders. When one leaks, the lift often can’t be certified safe to use. Boom lift cylinder rebuild puts the lift back in service without replacing the whole cylinder.

Our shop is in Ames, Iowa. We do boom lift cylinder rebuild on JLG 400S/600S/800S articulating booms, JLG 40E/45E electric booms, Genie Z-boom and S-boom lifts, Skyjack SJ lifts, Terex/Genie GTH telehandlers with boom cylinders, Snorkel and Haulotte lifts, and older Grove and CondorLift equipment. Every rebuild uses the same fundamentals — pull the cylinder, disassemble, inspect, replace seals, hone if needed, reassemble, pressure test — but the parts and sizes vary widely between machines.

Main Boom Cylinders

The main boom cylinder is the biggest cylinder on a boom lift — often 5-6 inch bore with a 6-8+ foot stroke on 60-foot and larger booms. It carries the entire weight of the boom sections, jib, basket, and operator. Boom lift cylinder rebuild on a main boom cylinder is a serious job — the cylinder is long, heavy (200-400+ pounds), and requires bench equipment to disassemble safely. We have the bench, hoist, and rod-polishing setup for cylinders this size.

Jib And Tilt Cylinders

Jib cylinders extend the reach at the end of the main boom. Tilt cylinders angle the basket. Both are smaller than the main boom cylinder but cycle more frequently — the operator uses them constantly during work. Failure modes are the same: rod seals fail, piston seals blow, rods pit from UV and salt exposure. Boom lift cylinder rebuild on jib and tilt cylinders is a routine bench job.

Level Cylinders

Level cylinders keep the basket level as the main boom articulates through its range. There are usually two — a master and a slave — connected in a closed hydraulic loop. When they leak or lose sync, the basket tilts unpredictably as the boom moves. Boom lift cylinder rebuild on level cylinders often requires rebuilding both master and slave together because they work as a matched pair.

Outrigger Cylinders

Larger boom lifts and telehandlers have outrigger cylinders that stabilize the machine when the boom is extended. They cycle less than the boom cylinders but sit exposed to weather and road debris when the machine transports. Rods pit fast on outrigger cylinders because the wipers are down at ground level. Rod replacement is more common on outrigger rebuild than on any other cylinder type.

Basket And Auxiliary Cylinders

Some boom lifts have a hydraulic cylinder for basket rotation or basket leveling in addition to the main level cylinders. Rebuild is straightforward but requires the correct seal kit for the machine.

Brand-Specific Notes

JLG cylinders use widely-available seal kits from JLG parts network and aftermarket. Genie cylinders are similar — good parts availability. Skyjack cylinders less commonly needed but seal kits available with a few days lead time. Terex cylinders on GTH telehandlers are similar to their skid-steer cousins in size. Older Grove and CondorLift work is trickier because parts get scarce — sometimes we have to source seal kits from specialty suppliers or fabricate spec kits from stock O-rings.

Chrome Rod Repair

Boom lift cylinder rebuild very often includes rod repair. Boom lift rods sit exposed to UV, dirt, and cold-start moisture cycles. Rod pitting is the most common damage. Light pitting we polish. Deeper pitting requires re-chroming (adds a week to timeline). Severely damaged rods we replace new. Every boom lift cylinder rebuild ships back with a rod in serviceable condition.

Bench Pressure Testing

Boom lifts run 3,000-3,500 psi operating pressure. We bench test every rebuild at rated pressure — both extend and retract, with a hold soak — before it ships back. Boom lift cylinders that fail bench testing don’t leave the shop.

Cost And Turnaround

Standard boom lift cylinder rebuild runs $400-$900 per cylinder for jib, tilt, level, and outrigger cylinders. Main boom cylinder rebuild runs $700-$1,500 depending on size. Add $500-$1,200 if the rod needs re-chroming. Add $300-$800 for barrel hone or replacement. Turnaround is 5-10 business days for a standard rebuild, 2-3 weeks if the rod needs re-chrome. Priority scheduling available for rental fleets and downed contractor units.

Independent Scope

We are not a JLG, Genie, or Skyjack dealer. We don’t do warranty work or ANSI recertification. We do the hydraulic side — cylinder rebuild — and provide documentation of the rebuild that the customer can present to their ANSI-certifying inspector when the lift goes back into service. If your lift is under warranty, the manufacturer’s dealer network handles that.

Central Iowa Coverage

Our shop is in Ames, 30 minutes north of Des Moines on I-35. Boom lift cylinder rebuild customers come from all over central Iowa. For rental fleets and contractors within roughly 60 miles of Ames we can arrange cylinder pickup and delivery. Cylinders ship well by freight from anywhere in the Midwest.

Common Questions About Boom Lift Cylinder Rebuild

Do I have to pull the cylinder off the lift myself? Usually yes — most customers pull the cylinder on their end and bring or ship it to us. For rental fleets and local contractors we can arrange to pull it at our shop or on site.

Can you match ANSI certification requirements? Boom lift cylinder rebuild by us provides the hydraulic side of the certification. Full ANSI recertification requires an inspector — we provide rebuild documentation the inspector needs.

What if my lift is an older Grove or CondorLift and parts are scarce? We can usually source or fabricate seal kits for legacy equipment. Adds a week or two to timeline but boom lift cylinder rebuild on older equipment is doable.

Get A Quote

Call or text 515-292-2599. Tell us the lift make and model, cylinder location, and what’s leaking or damaged. Text a photo of the cylinder and the leak if you can. We’ll ballpark the boom lift cylinder rebuild cost over the phone.