JLG 510AJ Service Manual - Manual (Page 239)

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS
3121181 – JLG Lift – 5-19
ASSEMBLY
NOTE: 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 two wear rings (13) in cylinder head grooves.
2. Install seal (9) and wiper (8) in cylinder head grooves.
3. Install retaining ring (7) and O-ring (6) in cylinder head
grooves.
4. Install O-ring (14), back-up ring (11), and O-ring (12) in
outside diameter cylinder head grooves.
Figure 5-38. Cylinder Head Assembly
5. Carefully install head on rod (21). Make sure wiper and
rod seals are not damaged or dislodged. Push head
along rod to rod end.
6. Using suitable protection, clamp cylinder rod in a vise or
similar holding fixture near piston location.
7. Install O-ring (15) inside spacer (16). Slide spacer assem-
bly on rod.
8. Apply Loctite 222 to setscrew. Install setscrew and
torque to 6 ft-lb (8 Nm).
9. Install O-ring (18) to piston (20).
10. Apply JLG Thread Locking Compound P/N 0100011 to
rod threads. Thread piston in cylinder rod. Do not dam-
age or dislodge O-ring. Torque to 221 ft-lb (300 Nm).
11. Install seal (19) in outside groove of piston.
12. Install nut (18) on rod.
13. Install retaining ring (19).
Figure 5-39. 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. Support rod. Insert piston end into barrel cylinder. Do
not damage or dislodge piston O-rings and backup ring.
17. Grease threads on barrel and cylinder head. Screw in cyl-
inder head. Torque to 221 ft-lb (300 Nm).
Figure 5-40. Cylinder Head Installation
18. Install two O-rings (3) in valve block (1). Install valve
block with four bolts (2). Torque to 18 ft-lb (24 Nm).
19. Install cartridge valves (4) with new O-ring in valve
block. Torque to 33 ft-lb (45 Nm).
12
10
13
9
14
8
7
6 11
19
20
17
18
16
15
. .