JLG 450A_AJ Series II Service Manual - Manual (Page 111)

SECTION 3 - CHASSIS & TURNTABLE
3121180 – JLG Lift – 3-61
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 dur-
ing shipping or storage. Make certain all system compo-
nents (reservoir, 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
pressure 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 nor-
mal 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, determine 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 3-46. Loop Flushing Spool