JLG Lull 1044C-54 II Series Service Manual page 372

Outriggers
10-8
a. Place a socket wrench over each counterbalance valve cartridge
(Items 3 and 8). Wrap a clean shop rag around the socket to cover
the area of the counterbalance valve cartridge.
b. Carefully and slowly, turn the cartridge out of the manifold block to
release pressure in cylinder.
5. Remove the counterbalance valve cartridges.
6. Slowly extend and retract the cylinder by hand to remove most of the
hydraulic oil.
7. Remove two (2) elbows (Item 7) from the cylinder manifold block.
8. Loosen the setscrew (Item 17) and remove the cylinder head (Item 16)
from cylinder barrel (Item 9).
9. Remove the cylinder rod (Item 15) from the cylinder barrel.
CAUTION: To prevent possible damage to components, support the rod
and head; do not wiggle the rod or head back and forth during
removal.
10. Remove the rod nut (Item 10), piston (Item 11), and the cylinder head
(Item 16) from the cylinder rod.
11. Inspect bushings for damage. If necessary, replace the bushings as
follows:
a. Remove two (2) bushings (Item 4) from the cylinder barrel end
and/or remove two (2) bushings (Item 12) from the cylinder rod end
using a bushing driver and hammer or press. Drive one bushing all
the way through to remove other bushing.
b. Install new bushings so they are flush with outer edge boss to 0.02"
below.
c. To ensure proper lubrication, make sure an adequate amount of
grease is applied to the grease fitting(s) after the cylinder is
reinstalled on the machine.
12. If necessary, remove the grease fitting covers (Items 2 and 14) and
grease fittings (Items 1 and 13) from the cylinder. Inspect and replace if
damaged. Install and tighten fittings 1.5 to 3 turns past finger tight.
13. Remove all O-rings, wear rings, and backup rings from the cylinder
components and discard.
14. Thoroughly clean components with solvent; dry with compressed air.
15. Inspect inner surface of barrel, outer surface of piston, and length of
rod for scratches and scoring. If the barrel, piston, or rod are damaged,
they must be replaced.
16. Check the condition of the threads on the rod, nut, and capscrews. Do
not attempt to repair damaged threads.
17. Inspect the counterbalance valve cartridges (Items 3 and 8), including
O-rings, for condition and replace as necessary. Do not disassemble
cartridges. Service to counterbalance valve cartridges is limited to
installing new O-rings and replacing the entire cartridge.
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