JLG 510AJ Service Manual - Manual (Page 97)

SECTION 3 - CHASSIS AND TURNTABLE
3121181 – JLG Lift – 3-55
20. Install orifice poppet (30).
21. Install shift spool (31).
22. Install spring retaining washers onto springs (32 and 33).
23. Carefully install centering springs (34, 35, and 36).
24. Install new O-rings (37, 38, and 39).
25. Using 5/8" wrench torque plug (40) to 20 ft-lb (27 Nm).
26. Using 11/16" wrench, torque plugs (41 and 42) to 27 ft-
lbs (37 Nm).
Initial Start-up Procedures
Follow this procedure when starting-up a new motor or when
installing a motor that has been removed.
Prior to installing motor, inspect for damage incurred during
shipping. Make certain all system components (reservoir,
hoses, valves, fittings, heat exchanger, etc.) are clean prior to
filling with fluid.
1. Fill reservoir with recommended hydraulic fluid. Always
filter fluid through a 10 micron filter when pouring into
the reservoir. Never reuse hydraulic fluid.
2. Fill inlet line leading from pump to the 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 in upper most case drain port.
4. To ensure pump and motor stay filled with oil, install
case drain lines in upper most case drain ports.
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. While watching pressure gauge, 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 the prime mover,
determine cause, and take corrective action.
7. Operate hydraulic system for at least fifteen minutes
under light load conditions.
8. Check and adjust control settings as necessary after
installation.
9. Shut down prime mover and remove pressure gauge.
Replace plug at charge pressure gauge port.
10. Check fluid level in reservoir; add clean filtered fluid if
necessary. The 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 3-46. Loop Flushing Spool