JLG 510AJ Service Manual - Manual (Page 247)

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS
3121181 – JLG Lift – 5-27
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 retaining ring (5) and O-ring (4) in cylinder head
grooves.
2. Install seal (7) and wiper (6) in cylinder head grooves.
3. Install O-ring (12) in outside groove closest to top of cyl-
inder head.
4. Install back-up ring (8), O-ring (9), and O-ring (11) in out-
side diameter cylinder head grooves.
Figure 5-58. Cylinder Head Assembly
5. Carefully install head on rod. 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. Slide bushing (13) on rod.
8. Install O-ring (14) in piston (15).
9. Apply JLG Thread Locking Compound P/N 0100011 to
rod threads. Thread piston on cylinder rod. Do not dam-
age or dislodge O-ring.
10. Install seal (17) on piston.
11. Install bushing (12) and sleeve (18) on rod.
12. Install nut (19) on rod. Torque to 147 ft-lb (200 Nm)
13. Install retaining ring (20).
Figure 5-59. Piston And Bushings 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
368 ft-lb (500 Nm).
Figure 5-60. Cylinder Head Installation
18. Install two cartridge valves (3) with new O-rings in valve
block. Torque to 33 ft-lb (45 Nm).
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5
6
7
12
10
8
9
11
13
15
14
16
17
18
19
20
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