Troubleshooting; Disassembly Information; Disassembly Procedure - JLG 1200SJP Service And Maintenance Manual

SECTION 3 - CHASSIS & TURNTABLE

Troubleshooting

The following table is provided to help locate problems in the
gearbox.
Symptom
From the lifetime seal
From the end cover
From the plugs
Hydraulic noise (during the slowing down
of the motor speed)
Inside the gearmotor (reductions)
Overheating
Insufficient braking torque
Wheel Locked

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 3-30.
thru Figure 3-33.
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.
3-36
Table 3-6. Troubleshooting
Causes
External oil leakage:
a)Lifetime seal damaged
a)O-ring seal damaged
a)Plug seal damaged
b)Plugs or screws loose
Too much noise:
a)Hydraulic circuit malfunctioning
a)Internal damage
Other:
a)Insufficient oil level
b)Hydraulic oil too warm
c)Brake not fully released
Parking brake malfunctioning
a)Brake discs worn
b)Damaged parts
a)Parking brake locked
b)Mechanical components damaged
NOTE: Below are all the steps to follow during Disassembly and
Remedies
a)Replace lifetime seal
a)Replace O-ring seals
a)Replace plug seal
b)Tighten the plugs/screws
a)Verify hydraulic circuit
a)Check the gearbox
a)Check the oil level and refill if necessary
b)Check the hydraulic circuit
c)Check brake release pressure
a)Replace brake disc pack
b)Check brake components
a)Check the complete brake release
b)Replace damaged parts
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

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).
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