Oshkosh JLG 1500SJ, Service And Maintenance Manual

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SECTION 3 - CHASSIS & TURNTABLE
3-22 – JLG Lift – 3121262
Troubleshooting
The following table is provided to help locate problems in the
gearbox.
Disassembly Information
It is also important that this procedure is undertaken in a
workshop that is equipped with the proper tools. As well as
normal workshop tools it will be necessary to use special tools
that can be made (see special tools attachment) or may be
requested from the manufacturer.
Special Tools:
Puller...............................................Code/: 6689960240
Tool for lifetime seal assembly........Code/: 6689960300
Puller for brake disassembly..........Code/: 6689960310
Torque multiplier............................Code/: ATZ.09.016.0
To be able to produce these special tools refer to Figure 3-18.
thru Figure 3-21.
It is important to strictly adhere to all the procedures for disas-
sembling and reassembling the gearbox. Proceed with these
instructions using all the necessary safety measures, for exam-
ple:
1. Plug all the Hydraulic ports on the gearbox to avoid the
introduction of any foreign particles in the circuit and
the gearbox.
2. Making sure that the coupling surfaces are not dam-
aged.
3. Handle with care so as to be sure that there are no risks
for personnel safety and to guarantee the reliability of
the gearbox.
4. Making available a work area that is in line with work
and health safety in the workplace guidelines.
Disassembly Procedure
NOTE: Below are all the steps to follow during Disassembly and
Assembly. Numbers in brackets in the text correspond to
the references in the exploded view.
Initial inspection can be made without disassembling the hub
from the machine. Before wheel drive disassembling, make
sure that the oil is drained from the hub.
Unscrew and remove the nos. 2 screws M12, grade 8,8, and
remove the hydraulic motor and its O-ring seal (48).
Table 3-5. Troubleshooting
Symptom Causes Remedies
External oil leakage:
From the lifetime seal a) Lifetime seal damaged a) Replace lifetime seal
From the end cover a) O-ring seal damaged a) Replace O-ring seals
From the plugs a) Plug seal damaged a) Replace plug seal
b) Plugs or screws loose b) Tighten the plugs/screws
Too much noise:
Hydraulic noise (during the slowing down
of the motor speed) a) Hydraulic circuit malfunctioning a) Verify hydraulic circuit
Inside the gearmotor (reductions) a) Internal damage a) Check the gearbox
Other:
Overheating a) Insufficient oil level a) Check the oil level and refill if necessary
b) Hydraulic oil too warm b) Check the hydraulic circuit
c) Brake not fully released c) Check brake release pressure
Parking brake malfunctioning
Insufficient braking torque a) Brake discs worn a) Replace brake disc pack
b) Damaged parts b) Check brake components
Wheel Locked a) Parking brake locked a) Check the complete brake release
b) Mechanical components damaged b) Replace damaged parts