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When maintaining a JLG 310 SJ aerial lift, one of the most common issues that may arise is hydraulic leaks in the stabilizer cylinders. These cylinders play a crucial role in maintaining the stability of the lift, and when they start to leak, it can cause instability, affect the performance, and even pose a safety risk. Fortunately, re-sealing the stabilizer cylinder is a manageable repair that can restore the equipment to peak performance.
In this guide, we’ll walk through the process of re-sealing the stabilizer cylinder on a JLG 310 SJ, explain common causes of leaks, and provide tips for ensuring your stabilizer cylinders remain in good condition.
Why Re-seal the Stabilizer Cylinder?
The stabilizer cylinders on a boom lift, like the JLG 310 SJ, extend and retract to level the machine during operation. These cylinders are hydraulic, meaning they rely on pressurized fluid to control their movement. Over time, the seals within the cylinders can wear out or become damaged due to the constant pressure and friction from the hydraulic fluid.
Signs that the stabilizer cylinder needs re-sealing include:
Tools and Materials Needed for Re-sealing
Before starting the re-seal job, gather all the necessary tools and materials:
Steps to Re-seal the Stabilizer Cylinder
1. Safety First
As with any hydraulic repair, safety should always be your top priority. Start by ensuring that the equipment is turned off, the key is removed, and the area around the cylinder is clear of any obstacles. Make sure the lift is on level ground, and the stabilizers are deployed before starting any work.
2. Release Hydraulic Pressure
Before dismantling the stabilizer cylinder, it’s important to relieve the hydraulic pressure to avoid any accidents. This is typically done by using the hydraulic release valve or by cycling the hydraulic system to release all pressure in the lines.
3. Remove the Stabilizer Cylinder
To begin removing the stabilizer cylinder, use a wrench to disconnect the hydraulic lines from the cylinder. Be prepared for some residual hydraulic fluid to spill, so have a container and rags handy for cleanup.
Once the hydraulic lines are disconnected, use the appropriate tools to remove any mounting bolts or pins securing the cylinder to the frame. Carefully slide the cylinder out of its mount. This step may require two people depending on the size and weight of the cylinder.
4. Disassemble the Cylinder
Now that the stabilizer cylinder is removed, disassemble it by carefully removing the end caps, bolts, and other hardware. Use the snap ring pliers to remove any snap rings holding the rod and piston in place. Take note of the order in which parts are removed for easier reassembly.
5. Inspect the Cylinder for Damage
Before replacing the seals, thoroughly inspect the cylinder for any damage or wear. Look for any cracks, scratches, or excessive corrosion, which could affect the performance of the new seals. If the cylinder has significant damage, it may need to be professionally refurbished or replaced entirely.
6. Remove and Replace the Seals
Once the cylinder components are disassembled, remove the old seals from the piston and rod. Inspect the grooves where the seals sit to ensure they are clean and free of debris. Any dirt left in these grooves can cause the new seals to fail prematurely.
Install the new seals, making sure they are seated correctly in their grooves. It’s essential to use the correct seals for your specific model to ensure proper function. Lubricate the seals with hydraulic fluid before assembly to reduce friction and prevent damage during reinstallation.
7. Reassemble the Cylinder
After replacing the seals, reassemble the stabilizer cylinder in reverse order of disassembly. Carefully install the piston and rod back into the cylinder, securing them with the snap rings and bolts. Ensure that all parts are tightened to the manufacturer’s specifications using a torque wrench.
8. Reinstall the Stabilizer Cylinder
Once the cylinder is reassembled, reinstall it back onto the frame of the lift. Reconnect the hydraulic lines to the cylinder and ensure they are properly tightened to avoid leaks.
9. Refill Hydraulic Fluid
Check the hydraulic fluid levels and top them off if necessary. It’s essential to ensure that the system is filled to the correct level for optimal performance.
10. Test the Stabilizer
Before returning the machine to service, test the stabilizer cylinders by operating the lift. Check for smooth extension and retraction of the stabilizers. Make sure there are no leaks around the seals, and the stabilizers lock into position as expected.
11. Clean Up and Dispose of Old Parts
Finally, clean up any spilled hydraulic fluid and dispose of the old seals and any other discarded parts responsibly. Dispose of any contaminated fluids in accordance with local regulations.
Common Problems with Stabilizer Cylinders
While re-sealing can restore the function of the stabilizer cylinders, there are other issues to keep an eye on:
Re-sealing the stabilizer cylinder on a JLG 310 SJ is an essential maintenance task that can help extend the lifespan of your aerial lift and ensure it operates safely. By following the steps outlined above, you can restore the stability and efficiency of the lift while minimizing the risk of hydraulic leaks and other issues. Regular maintenance and timely seal replacements are critical for keeping your equipment in top condition and avoiding costly repairs down the line. Always remember to use high-quality seals, and if you encounter any major damage, don’t hesitate to consult a professional for assistance.
In this guide, we’ll walk through the process of re-sealing the stabilizer cylinder on a JLG 310 SJ, explain common causes of leaks, and provide tips for ensuring your stabilizer cylinders remain in good condition.
Why Re-seal the Stabilizer Cylinder?
The stabilizer cylinders on a boom lift, like the JLG 310 SJ, extend and retract to level the machine during operation. These cylinders are hydraulic, meaning they rely on pressurized fluid to control their movement. Over time, the seals within the cylinders can wear out or become damaged due to the constant pressure and friction from the hydraulic fluid.
Signs that the stabilizer cylinder needs re-sealing include:
- Visible Leaks: Hydraulic fluid leaking around the cylinder shaft or from the seal.
- Reduced Performance: The stabilizers may not extend or retract as efficiently, or they may fail to lock into position properly.
- Weak Stability: When the stabilizers cannot hold the weight or pressure, the lift may become unstable.
Tools and Materials Needed for Re-sealing
Before starting the re-seal job, gather all the necessary tools and materials:
- Replacement seals for the stabilizer cylinder
- Hydraulic fluid (if necessary)
- Sealant (for external leaks)
- Wrenches and socket set
- Snap ring pliers
- Hydraulic cylinder pulling tools (if required)
- Torque wrench
- Clean rags and containers for hydraulic fluid
- Safety equipment (gloves, safety glasses)
Steps to Re-seal the Stabilizer Cylinder
1. Safety First
As with any hydraulic repair, safety should always be your top priority. Start by ensuring that the equipment is turned off, the key is removed, and the area around the cylinder is clear of any obstacles. Make sure the lift is on level ground, and the stabilizers are deployed before starting any work.
2. Release Hydraulic Pressure
Before dismantling the stabilizer cylinder, it’s important to relieve the hydraulic pressure to avoid any accidents. This is typically done by using the hydraulic release valve or by cycling the hydraulic system to release all pressure in the lines.
3. Remove the Stabilizer Cylinder
To begin removing the stabilizer cylinder, use a wrench to disconnect the hydraulic lines from the cylinder. Be prepared for some residual hydraulic fluid to spill, so have a container and rags handy for cleanup.
Once the hydraulic lines are disconnected, use the appropriate tools to remove any mounting bolts or pins securing the cylinder to the frame. Carefully slide the cylinder out of its mount. This step may require two people depending on the size and weight of the cylinder.
4. Disassemble the Cylinder
Now that the stabilizer cylinder is removed, disassemble it by carefully removing the end caps, bolts, and other hardware. Use the snap ring pliers to remove any snap rings holding the rod and piston in place. Take note of the order in which parts are removed for easier reassembly.
5. Inspect the Cylinder for Damage
Before replacing the seals, thoroughly inspect the cylinder for any damage or wear. Look for any cracks, scratches, or excessive corrosion, which could affect the performance of the new seals. If the cylinder has significant damage, it may need to be professionally refurbished or replaced entirely.
6. Remove and Replace the Seals
Once the cylinder components are disassembled, remove the old seals from the piston and rod. Inspect the grooves where the seals sit to ensure they are clean and free of debris. Any dirt left in these grooves can cause the new seals to fail prematurely.
Install the new seals, making sure they are seated correctly in their grooves. It’s essential to use the correct seals for your specific model to ensure proper function. Lubricate the seals with hydraulic fluid before assembly to reduce friction and prevent damage during reinstallation.
7. Reassemble the Cylinder
After replacing the seals, reassemble the stabilizer cylinder in reverse order of disassembly. Carefully install the piston and rod back into the cylinder, securing them with the snap rings and bolts. Ensure that all parts are tightened to the manufacturer’s specifications using a torque wrench.
8. Reinstall the Stabilizer Cylinder
Once the cylinder is reassembled, reinstall it back onto the frame of the lift. Reconnect the hydraulic lines to the cylinder and ensure they are properly tightened to avoid leaks.
9. Refill Hydraulic Fluid
Check the hydraulic fluid levels and top them off if necessary. It’s essential to ensure that the system is filled to the correct level for optimal performance.
10. Test the Stabilizer
Before returning the machine to service, test the stabilizer cylinders by operating the lift. Check for smooth extension and retraction of the stabilizers. Make sure there are no leaks around the seals, and the stabilizers lock into position as expected.
11. Clean Up and Dispose of Old Parts
Finally, clean up any spilled hydraulic fluid and dispose of the old seals and any other discarded parts responsibly. Dispose of any contaminated fluids in accordance with local regulations.
Common Problems with Stabilizer Cylinders
While re-sealing can restore the function of the stabilizer cylinders, there are other issues to keep an eye on:
- Internal Damage: If the cylinder’s internal components are damaged, seals may wear out quickly, leading to leaks and reduced efficiency.
- Seal Contamination: If contaminants like dirt or debris enter the cylinder, it can damage the seals and cause premature failure. Regular inspection and maintenance are essential to prevent this.
- Hydraulic System Overload: Overloading the lift can put excessive pressure on the stabilizer cylinders, leading to seal failure. Ensure the lift is not being used beyond its rated capacity.
Re-sealing the stabilizer cylinder on a JLG 310 SJ is an essential maintenance task that can help extend the lifespan of your aerial lift and ensure it operates safely. By following the steps outlined above, you can restore the stability and efficiency of the lift while minimizing the risk of hydraulic leaks and other issues. Regular maintenance and timely seal replacements are critical for keeping your equipment in top condition and avoiding costly repairs down the line. Always remember to use high-quality seals, and if you encounter any major damage, don’t hesitate to consult a professional for assistance.
