Oshkosh JLG 1500SJ, Service And Maintenance Manual

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SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS
3121262 – JLG Lift – 5-131
h. Remove charge pressure relief valve from the mid-
dle pump and inspect. Is it damaged?
No - Refit cartridge and proceed to step 2.i
Yes - Clean & inspect cartridge, poppet, springs,
seals to determine cause of damage. Repair or fit a
new cartridge and return to step 2.a
i. Remove and inspect charge pump assemblies. Are
they damaged?
No - Proceed to step 2.j
Yes - Repair and/or replace damaged components
and return to step 2.a
j. Is the charge pump installed for the clockwise rota-
tion?
No - Refit charge pump. Return to step 2.a
Yes - With proper charge pressure and transmission
still does not operate, proceed to step 3.a
3. Transmission does not propel the machine, diesel
engine running properly - Pump Control: (Insure Gener-
ator Drive option is not turned "on")
a. Are the electrical connectors & wiring connected
properly to the pump control solenoids?
No - Connect a ammeter in series with solenoid wir-
ing. Is a current of 400 mA to 1060 mA being
applied. (Current signal varies with joystick position)
Yes - Proceed to step 3.b
b. Are all four of the two-speed motors, mounted in
the wheel drive planetary reduction gearboxes,
shifted to maximum displacement (high torque -
low speed)?
No - Select maximum displacement
Yes - Proceed to step 3.c
c. Actuate the pump control in both directions. Do the
pumps stroke? Do they go to full stroke?
No - Refer to the pump service manual and then
proceed to step 3.d
Yes - Operate the transmission
d. Remove stroking orifices in X
1
and X
2
. Install pres-
sure gauges in X
1
and X
2
(0-500 psi [0 - 35 bar]).
Stroke the pump in both directions. Do the pres-
sures at X
1
and X
2
alternate between 30 & 250 psi (2
& 17 bar)?
No - Remove the EP control module & replace it with
a new unit. Repeat step 3.c
Yes - Proceed to step 3.e.
e. Is the pressure at port "R", case pressure, less than 15
psi (1 bar) gauge pressure?
No - Correct problem restricting case drain oil flow
(oil cooler blockage, pinched hoses, etc.)
Yes - Proceed to step 3.f
f. Stroke pump in both directions, while measuring
pressure at Ma & Mb ports of the pump. Does any
pressure greater than charge pressure alternate
between ports Ma & Mb?
No - Verify that loading the pump will cause system
pressure to increase above charge pressure. Proceed
to step 3.a
Yes - Proceed to step 3.g
g. Is it possible to adjust high pressure relief valves
using 0-6000 psi (0 - 415 bar) gauges to monitor
pressure at Ma & Mb? (Refer to relief valve adjust-
ment)
No - Replace high pressure relief valve and return to
step 3.c
Yes - Adjust high pressure relief valves to 5000 psi
+50 psi, -0 psi (344.7 bar +3.4 bar, -0 bar)
h. Actuate control in both directions. Does transmis-
sion operate?
No - Check that minimum displacement stops on
the wheel drive motors are adjusted properly, check
that the motors stroke between maximum to mini-
mum.
Yes - Operate the transmission
4. Transmission Drive is Sluggish or Erratic
a. Does the "EP" proportional pump control current
vary with joystick movement?
No - Rectify the problem - broken wires, electrical
connector, open solenoid coil, etc.
Yes - Proceed to step 4.b
b. Are all four (4) brakes fully released?
No - Check brake release pressure and insure each
wheel receives correct release pressure.
Yes - Proceed to step 4.c
c. Are the pumps stroking time orifices installed tight
and clean?
No - Remove the Plugs in ports X
1
and X
2
. Remove
orifices with a 3mm allen wrench. Check that orifices
are clean & re-install.
Yes - Proceed to step 4.d
d. Is an motor displacement stroking time orifice
plugged or is the two-speed shift hose pinched?
Yes - Inspect and clean stroking orifice, check two-
speed hose routing
e. Is a flow divider/combiner cartridge stuck in the
Traction Control Manifold? Flow divider/combiner
cartridge # 111 controls the right side wheels, # 112
controls the left side wheels. Also check to insure
bypass orifices #151 (right side) and # 152 (left side
are not plugged.