SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS
5-12
3121200
Assembly
INSPECT ALL COMPONENTS AS DESCRIBED UNDER INSPECTION. CLEAN ALL
COMPONENTS WITH A LINT-FREE CLOTH. THE BARREL SHOULD BE FLUSHED
OUT AND DRAINED. COMPRESSED AIR MUST BE USED TO BLOW OUT THE BAR-
REL BORE AND ALL PORTS. LUBRICATE ALL SEALS WITH HYDRAULIC FLUID
PRIOR TO ASSEMBLY.
HEAD GLAND ASSEMBLY
1.
Install rod seal. Check for proper orientation.
2.
Install wear rings on gland ID if required.
3.
Rod wipers are installed by snapping the wiper into the
groove.
4.
Install the backup ring and o-ring with the backup ring
nearest the head gland threads.
PISTON ASSEMBLY
1.
Install wear rings onto piston.
2.
Install piston seal into central groove on piston OD. A
clean, small cross-section o-ring or a thin elastic bland
may be wrapped around seal to help stretch it over the
piston.
3.
Install piston seal backup rings on both sides of seal.
Make sure the backup rings are oriented so that lips on
the side lock into grooves in the sides of the seal.
ROD, GLAND, PISTON ASSEMBLY
1.
Lubricate ID of head gland assembly with hydraulic
fluid, and slide onto rod (rod wiper end first) using cau-
tion not to damage rod wiper or seal on rod end.
2.
Slide stop tube (if equipped) onto rod. Do not scratch
rod chrome.
3.
Apply Loctite #7471 (Primer-T) to piston and rod
threads. Allow primer to evaporate then apply two
beads of Loctite #222 Thread Adhesive axially across the
threads of the piston ID.
4.
Screw threaded piston onto rod end and torque to 100
ft. lbs. (136 Nm). An optional method for tightening the
threaded piston is to turn until the piston bottoms out,
then set in place by hitting the spanner wrench handle
with a hammer; the piston should rotate slightly.
5.
For all non-threaded pistons, install the piston assembly
onto the threaded end of the rod. Torque the locknut to
the following specification:
FINAL ASSEMBLY
1.
Ensure all rags, etc. are removed from the barrel bore.
Apply Loctite #7471 (Primer-T) to the barrel bore and
gland threads. Lubricate the barrel bore and piston
assembly with hydraulic fluid. Avoid getting any oil on
the barrel threads.
2.
Align the rod with the barrel assembly. Insert the piston
into the barrel opening. Use care to avoid damaging the
wear rings, seals, and piston surface on the barrel.
3.
Lubricate the o-ring and backup ring on the head gland
using hydraulic fluid. Avoid getting oil on the threads.
Apply two beads of Loctite #222 Thread Adhesive axially
across the head gland threads. Screw the gland into the
barrel and torque to 100 ft.lbs. (135 Nm). An optional
method for tightening the head gland is to turn until the
head gland bottoms out, then set in place by hitting the
spanner wrench handle with a hammer, the head gland
should rotate slightly.
TESTING
1.
Set the test apparatus to test the pressures as listed
below.
2.
Connect pressure lines to the proper ports.
3.
Extend and retract the cylinder to full stroke position
three times.
4.
Check for leakage in each position at all weld joints,
between the head gland and the barrel, and between
the head gland and rod.
5.
Drain all hydraulic fluid and cap or plug all ports.
Table 5-1. Torques of Locknut
Cylinder
Torque
Telescope, Platform Level, Master
350 ft.lbs. (475 Nm)
Lift
150 ft.lbs. (203 nm)
Cylinder
Working Pressure
PSI
Bar
Telescope
1000
69
Platform Level
1050
72
Master
1050
72
JIB
1600
110
Lift
2500
172
Outrigger
2400
165
Summary of Contents for T500J
Page 1: ...Service and Maintenance Manual Model T500J PN 3121200 July 25 2018 Rev I AS NZS...
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Page 36: ...SECTION 2 GENERAL 2 8 3121200 NOTES...
Page 143: ...SECTION 3 CHASSIS TURNTABLE 3121200 3 107 Figure 3 45 Battery Charger Schematic...
Page 234: ...SECTION 5 BASIC HYDRAULIC INFORMATION SCHEMATICS 5 60 3121200 NOTES...
Page 246: ...SECTION 6 JLG CONTROL SYSTEM 6 12 3121200 Figure 6 5 System Test Flow Chart Platform Tests...
Page 304: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 32 3121200 NOTES...
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