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Section E
85 - 2
Dismantling and Assembly
- Loader Lift Ram
- Loader Shovel Ram
- Boom Ram
- Bucket Ram
- Stabiliser Ram
Dismantling
The numerical sequence shown on the illustration is intended
as a guide to dismantling.
For assembly the sequence should be reversed.
Place ram assembly on a locally manufactured strip/rebuild
bench as shown.
Slacken end cap 1 using special spanner (see Service
Tools), and remove the piston rod assembly 2 from the
cylinder.
! WARNING
If air or hydraulic pressure is used to force out the piston
assembly, ensure that the end cap is securely fitted.
Severe injury can be caused by a suddenly released
piston rod.
HYD 1-2
Position piston rod assembly on bench in place of ram
cylinder. Remove seal 4 and wear rings 3 and 5 from piston
head.
Extract dowel 6 from the piston head using a metric screw
(M3, M4, or M6 depending on ram size) threaded into the
extractor hole.
Remove piston head from rod using special spanner (see
Service Tools).
Remove gland bearing and end cap 1 from piston rod and
remove the 'O' ring 9, wiper seal 10 and rod seal 11. Check
t he end c ap b earing for d am age, sc ores or nic ks. If
damaged, the bearing must be replaced as part of the end
cap assembly.
Ensure that metal components are free from scoring, nicks
and burrs. A damaged rod will impair the life of the seals.
Check the bore of the ram cylinder for damage.
9803/3280
Hydraulics
Hydraulic Rams
S263670
Purchased from www.WorkshopManuals.co.uk
Assembly
Clean threads of piston rod, piston head, end cap and
cylinder using a wire brush. Use JCB Cleaner/Degreaser to
ensure that all threads are free from grease, hydraulic oil and
sealant. Allow 15 minutes for solvent to dry before applying
JCB Threadlocker and Sealer (High Strength).
Ensure that lubricants used during assembly do not come
into contact with the JCB Threadlocker and Sealer (High
Strength).
Refer to JCB Ram Sealing Procedure for the correct
method of fitting seals to the end cap and piston head.
Apply JCB Activator to threads of end cap and cylinder.
Allow Activator to dry for 15 minutes before bringing into
c ont ac t w it h t he JCB Thread loc ker and Sealer (High
Strength).
Note: Neither the JCB Threadlocker and Sealer (High
Strength) nor Activator must be allowed to contact seals,
bearing rings, or 'O' rings.
Fit locking dowel 6 to piston head/rod as follows:
1
Fit 'O' ring 8 into piston head 7.
2
Fit piston head to piston rod and torque tighten to 405
Nm (300 lbf ft).
3
New ram Shaft and piston head fitted.
-
If both are required, the following procedure should
be followed:
a
Drill through piston head into piston rod. Use an
undersized diameter drill first as a guide and then
drill with the correct size diameter drill to suit; refer
to the table for drill diameters and depths.
Remove all swarf and contamination. Insert dowel 6
b
into drilled hole, make sure tapped extractor hole is
to outside.
4
New piston head fitted on a pre-drilled piston rod.
-
Re- drill and dowel BOTH the piston head and
piston rod at 90° from the existing drilled dowel
hole in the piston rod. Follow the procedures
described in step 3.
5
New piston rod fitted to a pre-drilled piston head.
-
Use the pre-drilled hole in the piston head. Care
must be taken not to elongate the existing hole in
the piston head.
a
Use a drill the same diameter as the pre-drilled hole
in the piston head to make a 'centre mark' in the
piston rod. DO NOT drill the piston rod at this
stage.
Section E
85 - 2
...........continued
Issue 1
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