JLG 510AJ Service Manual - Manual (Page 33)

SECTION 2 - GENERAL
3121181 – JLG Lift – 2-3
Pressure-Fit Parts
When assembling pressure-fit parts, use an anti-seize or
molybdenum disulfide base compound to lubricate the mat-
ing surface.
Bearings
1. When a bearing is removed, cover it to keep out dirt and
abrasives. Clean bearings in nonflammable cleaning sol-
vent and allow to drip dry. Compressed air can be used
but do not spin the bearing.
2. Discard bearings if races and balls (or rollers) are pitted,
scored, or burned.
3. If bearing is found to be serviceable, apply a light coat of
oil and wrap it in clean (waxed) paper. Do not unwrap
reusable or new bearings until they are ready to install.
4. Lubricate new or used serviceable bearings before
installation. When pressing a bearing into a retainer or
bore, apply pressure to the outer race. If the bearing is to
be installed on a shaft, apply pressure to the inner race.
Gaskets
Check holes in gaskets align with openings in mating parts. If
it becomes necessary to hand-fabricate a gasket, use gasket
material or stock of equivalent material and thickness. Be sure
to cut holes in the right location, as blank gaskets can cause
serious system damage.
Bolt Usage and Torque Application
1. Use bolts of proper length. A bolt which is too long will
bottom before the head is tight against its related part. If
a bolt is too short, there will not be enough thread area
to engage and hold the part properly. When replacing
bolts, use only those having the same specifications of
the original, or one which is equivalent.
2. Unless specific torque requirements are given within the
text, standard torque values should be used on heat-
treated bolts, studs, and steel nuts, in accordance with
recommended shop practices. (See Torque Chart Sec-
tion 1.)
Hydraulic Lines and Electrical Wiring
Clearly mark or tag hydraulic lines, electrical wiring, and their
receptacles when disconnecting or removing them from the
unit. This will ensure they are correctly reinstalled.
Hydraulic System
1. Keep the system clean. If evidence of metal or rubber
particles are found in the hydraulic system, drain and
flush the entire system.
2. Disassemble and reassemble parts on clean work sur-
face. Clean all metal parts with non-flammable cleaning
solvent. Lubricate components, as required, to aid
assembly.
Lubrication
Service applicable components with amount, type, and grade
of lubricant recommended in this manual at specified inter-
vals. When recommended lubricants are not available, consult
your local supplier for an equivalent that meets or exceeds the
specifications listed.
Battery
Clean battery, using a non-metallic brush and a solution of
baking soda and water. Rinse with clean water. After cleaning,
thoroughly dry battery and coat terminals with an anti corro-
sion compound.
Lubrication and Servicing
Components and assemblies requiring lubrication and servic-
ing are shown in the Lubrication Chart in Section 1.
2.3 LUBRICATION AND INFORMATION
Hydraulic System
1. The primary enemy of a hydraulic system is contamina-
tion. Contaminants enter the system by various means,
e.g., using inadequate hydraulic oil, allowing moisture,
grease, filings, sealing components, sand, etc., to enter
when performing maintenance, or by permitting pump
to cavitate due to insufficient system warm-up or leaks
in pump supply (suction) lines.
2. Design and manufacturing tolerances of component
working parts are very close, therefore, even the small-
est amount of dirt or foreign matter entering a system
can cause wear or damage to components and gener-
ally results in faulty operation. Every precaution must be
taken to keep hydraulic oil clean, including reserve oil in
storage. Hydraulic system filters should be checked,
cleaned, and/or replaced as necessary, at the specified
intervals required in the Lubrication Chart in Section 1.
Always examine filters for evidence of metal particles.
3. Cloudy oils indicate a high moisture content which per-
mits organic growth, resulting in oxidation or corrosion.
If this condition occurs, system must be drained,
flushed, and refilled with clean oil.
4. It is not advisable to mix oils of different brands or types,
as they may not contain required additives or be of com-
parable viscosities. Good grade mineral oils, with viscos-
ities suited to ambient temperatures in which the
machine is operating, are recommended for use.
NOTE: Metal particles may appear in oil or filters of new machines
due to the wear-in of meshing components.