Disassembly; Inspection; Assembly - JLG TOUCAN 10E Service And Maintenance Manual

SECTION 7 - HYDRAULICS

Disassembly

NEVER USE COMPRESSED AIR TO EXTRACT THE ROD FROM
THE BARREL OR TO CYCLE THE CYLINDER.
NOTICE
DISASSEMBLY OF A CYLINDER SHOULD BE PERFORMED ON A
CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.
NOTICE
IF USING A VISE TO HOLD CYLINDER BARREL, NEVER CLAMP
THE BARREL TUBE WITH THE WISE'S JAW'S.
1. Drain oil from the cylinder.
2. Place the cylinder barrel into a suitable holding fix-
ture.
3. Using a appropriate tool (Pin Wrench or C-Wrench),
loosen the barrel head gland by turning it in counter-
clockwise direction.
4. Withdraw the rod assembly from the barrel taking
care not to damage the chrome surface of the
rod(s).
5. Steer cylinder only: place the rod assembly into a
suitable holding fixture.
6. Steer cylinder only: loosen the piston attachment
locknut. Remove piston parts and withdraw barrel
head gland from the rod.
Mast and Jib Cylinders: remove the rod guide (No
need for removing the snap ring from the mast cylin-
der rod). Withdraw barrel head gland from the rod.
7. Remove and discard seals, O-rings, back-up rings
and guide bands from the piston and the barrel
head gland.
8. Align discarded seals and rings in the order of disas-
sembly as reminder for new seals and rings installa-
tion.

Inspection

1. Clean all parts thoroughly with an approved clean-
ing solvent.
2. Inspect the cylinder rod for scoring, tapering, ovality
or other damage. If necessary, dress rod with
Scotch Brite or equivalent. Replace cylinder if nec-
essary.
3. Inspect threaded portion of the rod for excessive
damage. Dress threads as necessary.
4. Inspect the inner surface of the cylinder barrel tube
for scoring or other damage. Check inside diameter
for tapering or ovality. Replace cylinder if necessary.
5. Inspect threaded portion of the barrel for damage.
Dress threads as necessary.
7-10
6. If applicable, inspect piston surface for damage and
scoring and for distortion. Dress piston surface as
necessary.
7. If applicable, inspect piston grooves for burrs and
sharp edges. Dress applicable surface as neces-
sary.
8. Inspect cylinder head gland inside diameter for scor-
ing or other damage and for ovality and tapering.
Replace cylinder if necessary.
9. Inspect threaded portion of cylinder head gland for
damage. Dress threads as necessary.
10. Inspect seals grooves in head gland for burrs and
sharp edges. Dress applicable surfaces as neces-
sary.
11. Inspect cylinder head gland outside diameter for
scoring or other damage and ovality and tapering.
Replace cylinder if necessary.
12. If applicable, inspect rod and barrel bushings for
excessive wear or damage. Replace as necessary.
13. Inspect the oil ports for blockage or the presence of
dirt or other foreign material. Repair as necessary.

Assembly

NOTE: Prior to cylinder assembly, ensure that the proper
cylinder seal kit is used. See your JLG Parts manual.
Apply a light film of hydraulic oil to all components
prior to assembly.
1. Install new seal(s), backup ring(s) and guide bands
into the applicable cylinder head gland groove(s).
Mast and Jib cylinder only: install guide bands so
that the splits are not in alignment with each other.
2. Use a soft mallet to tap a new wiper seal into the
applicable cylinder head gland groove (the flat part
of seal must be facing into head).
3. Jib and steer cylinders only: place new O-rings and
backup rings in the applicable outside diameter
grooves of the cylinder head.
4. Carefully install the head gland on the rod, ensuring
that the wiper and rod seals are not damaged or dis-
lodged.
5. Steer cylinder only: install O-ring, piston seal,
angled guides and split backup rings on piston parts
and slide the piston assembly on the rod. Secure the
piston assembly with the locknut.
Mast cylinder only: install a new rod guide.
6. Position the barrel in a suitable holding fixture.
EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE
CYLINDER ROD, HEAD AND PISTON. AVOID PULLING THE ROD
OFF CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON
AND CYLINDER BARREL SURFACES.
7. With the barrel clamped securely, and while ade-
quately supporting the rod, insert the piston end into
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NOTICE
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