Initial Start-Up Procedures - JLG 800A Service And Maintenance Manual

SECTION 3 - CHASSIS & TURNTABLE
20. Install orifice poppet (30).
39
34
30
40
5/8 in
20 ft.lbs.
(27 Nm)
31
32
35
38
42
11/16 in
27 ft.lbs.
(37 Nm)
30. Orifice Poppet 34. Spring
31. Shift Spool 35. Spring
32. Spring 36. Spring
33. Spring
Figure 3-29. Loop Flushing Spool
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 a 5/8 in wrench torque plug (40) to 20 ft.lbs. (27
Nm).
26. Using a 11/16 in wrench, torque plugs (41 and 42) to 27
ft.lbs. (37 Nm).
3-32
37
36
33
41
11/16 in
27 ft.lbs.
(37 Nm)
37. O-ring 40. Plug
38. O-ring 41. Plug
39. O-ring 42. Plug

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 the motor, inspect for damage incurred dur-
ing shipping. Make certain all system components (reservoir,
hoses, valves, fittings, heat exchanger, etc.) are clean prior to
filling with fluid.
1. Fill the reservoir with recommended hydraulic fluid.
Always filter fluid through a 10 micron filter when pour-
ing into the reservoir. Never reuse hydraulic fluid.
2. Fill the inlet line leading from the pump to the reservoir.
Check the inlet line for properly tightened fittings and
be certain it is free of restrictions and air leaks.
3. Fill the pump and motor housing with clean hydraulic
fluid. Pour filtered oil directly into the upper most case
drain port.
4. To ensure the pump and motor stay filled with oil, install
case drain lines into the upper most case drain ports.
5. Install a 0 to 500 psi (0 to 35 bar) gauge in the charge
pressure gauge port of the pump to monitor system
pressure during start up.
6. While watching the pressure gauge, run the engine at
the lowest possible speed until system pressure builds
to normal levels (minimum 160 psi [11 bar]). Once sys-
tem 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 the hydraulic system for at least fifteen minutes
under light load conditions.
8. Check and adjust control settings as necessary after
installation.
9. Shut down the prime mover and remove the pressure
gauge. Replace plug at the charge pressure gauge port.
10. Check the fluid level in the reservoir; add clean filtered
fluid if necessary. The motor is now ready for operation.
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