JLG 450A_AJ Series II Service Manual - Manual (Page 73)

SECTION 3 - CHASSIS & TURNTABLE
3121290 – JLG Lift – 3-33
20. Install orifice poppet (30).
21. Install shift spool (31).
22. Install spring retaining washers on springs (32 and 33).
23. Carefully install centering springs (34, 35, and 36).
24. Install new O-rings (37, 38, and 39).
25. Using a 5/8" wrench, torque plug (40) to 20 ft-lb (27 Nm).
26. Using a 11/16" wrench, torque plugs (41 and 42) to 27 ft-
lb (37 Nm).
Initial Start-Up Procedures
Follow this procedure when starting up a new motor or after
reinstalling a motor.
Prior to installing motor, inspect for damage incurred during
shipping or storage. Make certain all system components (res-
ervoir, hoses, valves, fittings, heat exchanger, etc.) are clean
before filling with fluid.
1. Fill reservoir with recommended hydraulic fluid. Always
filter fluid through a 10 micron filter when pouring into
reservoir. Never reuse hydraulic fluid.
2. Fill inlet line leading from pump to reservoir. Check inlet
line for properly tightened fittings and be certain it is
free of restrictions and air leaks.
3. Fill pump and motor housing with clean hydraulic fluid.
Pour filtered oil directly into upper most case drain port.
4. Install case drain lines into upper most case drain ports
to ensure pump and motor stay filled with oil.
5. Install a 0 to 500 psi (0 to 35 bar) gauge in charge pres-
sure gauge port of pump to monitor system pressure
during start up.
6. Watch pressure gauge and run engine at lowest possible
speed until system pressure builds to normal levels
(minimum 160 psi [11 bar]). Once system pressure is
established, increase to full operating speed. If system
pressure is not maintained; shut down engine, deter-
mine cause, and take corrective action.
7. Operate hydraulic system at least fifteen minutes under
light load conditions.
8. Check and adjust control settings as necessary after
installation.
9. Shut down engine and remove pressure gauge. Replace
plug at charge pressure gauge port.
10. Check fluid level in reservoir; add clean filtered fluid if
necessary. Motor is now ready for operation.
39
40
34
30
41
37
36
33
42
38
35
32
31
(27 Nm)
20 ft.lbs.
5/8 in
(37 Nm)
(37 Nm)
27 ft.lbs.
27 ft.lbs.
11/16 in
11/16 in
30. Orifice Poppet
31. Shift Spool
32. Spring
33. Spring 34. Spring
35. Spring
36. Spring 37. O-ring
38. O-ring
39. O-ring 40. Plug
41. Plug
42. Plug
Figure 3-28. Loop Flushing Spool