JLG 4013PS Service Manual - Manual (Page 129)

8-19 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Hydraulic System
8.7.3 Pump Replacement
a. Pump Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the transmission control lever in (N) NEUTRAL,
engage the park brake and shut the engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the
machine should not be operated.
3. Open the engine cover. Allow the system fluids to
cool.
4. Properly disconnect the battery.
5. Thoroughly clean the pump and surrounding area,
including all hoses and fittings before proceeding.
Note: Cap all hoses as you remove them to prevent
unnecessary oil spillage.
6. Remove the bolts and lockwashers securing the
flange halves to the pump. Remove the inlet hose
and o-ring.
Note: Before removing any fittings from the pump, note
their orientation to ensure correct installation.
7. Remove the bolts and lockwashers securing the
flange halves to the pump. Remove the outlet hose
and o-ring.
8. Disconnect the case drain hose from the fitting.
Disconnect the load sense line.
9. Remove the bolts and lockwashers securing the
pump to the transmission. Remove the gasket
located between the transmission and the pump.
Wipe up any hydraulic oil spillage.
Note: DO NOT disassemble the implement pump. The
pump is pre-set from the manufacturer. Any adjustments
or repairs performed by anyone other than an authorized
dealer could void the warranty.
b. Pump Installation
1. While the pump is still on the bench, install all
fittings, except the outlet hose fitting, orienting them
as noted during removal.
2. Apply Loctite ® 243 TM on the metal seal of the pump
and place into position on the transmission. Align the
pump shaft with the internal transmission gear, so
that the machined teeth mesh together.
3. Align the bolt holes with the pump mount holes.
Secure the pump to the transmission with the bolts
and washers. Torque to 115 Nm (85 lb-ft).
4. If necessary, slide the T-bolt band clamp onto the
pump inlet hose. Secure the hoses to the hydraulic
reservoir outlet connection with the T-bolt band
clamp.
5. Place a new oiled o-ring into position over the pump
opening. Secure the inlet hose with two flange
halves, lockwashers and bolts.
6. Connect the load sense line to the fitting.
7. Place a new, oiled o-ring into position over the pump
opening. Secure the outlet hose with two flange
halves, lockwashers and bolts.
8. Prime the pump by filling the case drain port with
fresh, filtered hydraulic oil from a clean container
before installing the case drain connector and
hoses.
9. Check all routing of hoses and tubing for sharp
bends or interference with any rotating members. All
tube and hose clamps must be tight.
10. Start the engine and run at approximately one-third
to one-half throttle for about one minute without
moving the machine or operating any hydraulic
functions.
11. Inspect for leaks and check all oil levels. The
hydraulic reservoir oil level must be to the middle of
the sight gauge.
12. Properly connect the battery.
13. Close and secure the engine cover.
14. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
c. Pump Test
Refer to Section 8.4.1, “Hydraulic Pressures.”