JLG 510AJ Service Manual - Manual (Page 231)

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS
3121181 – JLG Lift – 5-11
ASSEMBLY
NOTE: Use proper cylinder seal kit for cylinder assembly. See your
JLG Parts Manual. Apply a light film of hydraulic oil to all
components before assembly.
IMPROPER SEAL INSTALLATION CAN CAUSE CYLINDER LEAKS AND IMPROPER
CYLINDER OPERATION.
1. Install three wear rings (11) in cylinder head grooves.
2. Install seal (7) and wiper (6) in cylinder head grooves.
3. Install retaining ring (5) and O-ring (4) in cylinder head
grooves.
4. Install O-ring (12) in outside groove closest to top of cyl-
inder head.
5. Install back-up ring (9) and O-ring (10) in outside diame-
ter cylinder head grooves.
Figure 5-19. Cylinder Head Assembly
6. Carefully install head on rod. Make sure wiper and rod
seals are not damaged or dislodged. Push head along
rod to rod end.
7. Using suitable protection, clamp cylinder rod in a vise or
similar holding fixture near piston location.
8. Install O-ring (13) inside spacer (14). Slide spacer assem-
bly on rod.
9. Install O-ring (15) in piston (16).
10. Apply JLG Thread Locking Compound P/N 0100011 to
rod threads. Thread piston on cylinder rod. Do not dam-
age or dislodge O-ring. Torque to 759 ft-lb (1030 Nm).
11. Install seal (17) in outside groove of piston.
12. Install nut (18) on rod.
13. Install retaining ring (19).
Figure 5-20. Piston And Spacer Assembly
14. Remove cylinder rod from holding fixture.
15. Position cylinder barrel in suitable holding fixture.
INSERTING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL
SURFACES. USE CARE WHEN INSTALLING CYLINDER ROD, HEAD, AND PISTON.
16. Clamp barrel securely and support rod. Insert piston end
into barrel cylinder. Do not damage or dislodge piston
O-rings and backup ring.
17. Continue pushing rod into barrel. Grease threads on bar-
rel and cylinder head. Screw in cylinder head. Torque to
737 ft-lb (1000 Nm).
Figure 5-21. Cylinder Head Installation
18. Install cartridge valve (3) with new O-ring in valve block.
Torque to 33 ft-lb (45 Nm).
10
9
11
7
12
6
5
4
19
18
16
17
15
14
13
. .