Group 2 Operational Checks and Troubleshooting
Group 2 Operational Checks and Troubleshooting
Group 2 Operational Checks and Troubleshooting
1. OPERATIONAL CHECKS
This procedure is designed so the mechanic can make a quick check of the system using a minimum
amount of diagnostic equipment. If you need additional information, read structure and function,
Group 1.
A location will be required which is level and has adequate space to complete the checks.
The engine and all other major components must be at operating temperature for some checks.
Locate system check in the left column and read completely, following the sequence from left to right.
Read each check completely before performing.
At the end of each check, if no problem is found(OK), that check is complete or an additional check is
needed. If problem is indicated(NOT OK), you will be given repair required and group location.
If verification is needed, you will be given next best source of information:
Chapter 2
Group 3
: Troubleshooting
: Tests and adjustments
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Hydraulic oil must be at operating temperature for these checks(Refer to page 6-52).
Item
Parking brake capacity
check
Seat belt must be worn
while doing this check to
prevent possible injury
when machine stops
suddenly.
Description
Start engine.
Fasten seat belt.
Release parking brake and put
transmission in 2nd gear forward.
Service action
OK
Check completed.
NOT OK
Inspect parking brake. Go
to group 3.
Parking brake
transmission lockout
check
Engine running.
OK
Check completed.
NOT OK
Slowly increase engine speed to
Go to transmission control
high idle.
circuit in section 3.
LOOK : Machine must not move.
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Item
Service brake pump flow
check
Hydraulic oil must be at
operating temperature
for the check.
Engine OFF.
Description
Stop engine.
Service action
OK
Check completed.
OK
Check completed.
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Item
Description
Service action
Brake accumulator
precharge check
The axles and
hydraulic oil must be at
operating temperature
for this check.
ON
OK
Check completed.
NOT OK
If brake leakage is
Turn start switch to ON and wait 5 indicated with brakes
seconds.
released, check leakage at
accumulator inlet check
LOOK : Brake oil pressure warning
valve and brake valve. If
lamp must not come on within 2
brake leakage is indicated
minutes after stopping engine.
with brakes applied, check
for leakage at brake valve
and brake pistons.
Wait 2 minutes.
Check individual
component leakage.
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Item
Service brake pedal
check
Description
Slowly depress brake pedal.
Service action
OK
Check completed.
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NOT OK
Adjust clutch cut-off switch.
2. TROUBLESHOOTING
1) SERVICE BRAKE
Diagnose malfunction charts are arranged from most probable and simplest to verify, to least likely,
more difficult to verify. Remember the following steps when troubleshooting a problem :
Step 1. Operational check out procedure(See section 1)
Step 2. Operational checks(In this group)
Step 3. Troubleshooting
Step 4. Tests and adjustments(See group 3)
Problem
Poor or no brakes
Cause
Remedy
Aggressive brakes
Air in system
Bleed brakes.
Brakes drag
Brakes lock up
Repair.
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Problem
Brakes chatter
Cause
Remedy
Drain. Refill.
Hissing noise when Leakage in brake valve, or brake Do brake system leakage test.
brake pedal is held with piston
engine stopped
Brake pressure warning Malfunction in brake low Replace switch.
light will not go out or pressure warning switch
stays on excessively long
Brake accumulator pressure too Recharge accumulator.
after start-up
low
Low brake pump standby Do brake pump standby pressure test.
pressure setting.
Leakage in pressure reducing Do pressure reducing valve manifold leakage test.
manifold block
Leakage in brake system
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Cause
Remedy
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