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 : Troubleshooting
Group 3 : Tests and adjustments

6-37

 Hydraulic oil must be at operating temperature for these checks(Refer to page 6-52).
Item
Hydraulic system warmup procedure
Run engine at high idle.
Refer to page 6-52.

Description

Service action

Hold a hydraulic function over OK

relief to heat oil.(Don't keep relief Check completed.
condition over 5 seconds at a
time)
Periodically cycle all hydraulic
functions to distribute warm oil.
Repeat procedure until oil is at
operating temperature.
FEEL : Hydraulic tank must be
uncomfortable to hold your hand
against.
(Approximately 40~50
C)

Hydraulic pump
performance check
Heat hydraulic oil to
operating temperature.
Run engine at high idle.

With bucket flat on ground, OK

actuate boom raise. Time how Check completed.
long it takes to raise boom to full
NOT OK
height.
Go to steering unit high
LOOK : Boom must raise to full pressure check at page
height in less than 6.5 seconds.
5-25.
IF OK
Do steering unit leakage
check at page 5-24.
IF OK
Do main hydraulic pump
flow test in group 3.

Control valve lift check

Run machine at low idle.

With bucket partially dumped, OK

lower boom to raise front of Check complete.
machine.
NOT OK
Slowly move boom control Repair lift checks in main
lever(RCV lever) to boom lower control valve.
position.
Slowly move bucket control lever
to bucket dump position.
LOOK : Boom must not raise
before moving down.
Bucket must not rollback before
dumping.

6-38

Item

Description

Bucket rollback circuit

relief valve check

Service action

Position bucket at a 45angle OK

Check complete.
against an immovable object.
Engage transmission in 3rd speed NOT OK
Replace boom lower
forward.
check valve.
L OOK : Bucket angle must not
change.
Raise front of machine which OK
bucket at 45angle.
Go to next check.

Bucket dump circuit

relief valve low pressure
check

Backdrag with bucket while NOT OK

observing bucket angle.
Do loader system and
circuit relief valve test in
LOOK : Bucket must not rollback
group 3.
With the bucket partially dumped,
lower boom to raise front of
machine.
Push control lever to the float detent
position and release lever.

Pilot control valve float

check
Run engine at low idle.

OK
Check complete.
NOT OK
Do pilot control valve
pressure test in group 3.

LOOK : Front of machine lower to

the ground and valve must remain
in float position when lever is
released.
Set the boom and bucket horizontal, OK
then stop the engine.
Check complete.

Boom cylinder and

bucket cylinder drift
check
Heat hydraulic oil to
operating temperature.

Stop the engine, wait for 5 minutes, NOT OK

then start measuring.
Go to next check.
B
A

Measure the amount the lift and

dump cylinder rods retract during 15
minutes.(Unloaded bucket)
A : Retraction of boom cylinder
rod
B : Retraction of bucket cylinder
rod
Boom cylinder must drift less than
30mm(HL740-7A); 40mm(HL740TM-7A)

Bucket cylinder must drift less than

30mm.

6-39

Item
Boom cylinder leakage
check
Heat hydraulic oil to
operating temperature.

Description

Service action

Dump bucket until teeth or cutting OK

edge is perpendicular to the Drift is approximately the
ground.
same between first and
second measurement.
Raise boom until cutting edge is
about 1m(3ft) above ground.
Repair main control valve
or circuit relief valve.
Stop engine. Measure drift from
tooth or cutting edge to ground for NOT OK
1 minute.
If drift is considerably less
on second measurement,
Wait 10 minutes.
repair cylinder.
Measure drift from tooth or cutting
edge to ground for 1 minute.
LOOK : Compare the drift rate
between the first measurement
and the second measurement.

Bucket cylinder leakage

check
Heat hydraulic oil to
operating temperature.

Raise bucket about 1m(3ft) off OK

ground with bucket level.
Drift is approximately the
same between first and
Stop engine. Place a support
second measurement.
under boom.
Repair main control valve
Measure drift from tooth or cutting
or circuit relief valve in
edge to ground for 1 minute.
group 3.
Wait 10 minutes.
NOT OK
Measure drift from tooth or cutting Drift is considerably less
edge to ground for 1 minute.
on second measurement.
LOOK : Compare the drift rates Repair cylinder.
between the first measurement
and the second measurement.

Check valve of safety

valve leakage check
Heat hydraulic oil to
operating temperature.

Put bucket level and position OK

about 1.2m(4ft) above ground.
Check complete.
Place a piece of tape on cylinder NOT OK
rod at least 51mm(2in) from rod Check or replace safety
guide.
valve.
Run engine at low idle in safetyrelease position.
LOOK : Bucket must not drift up.

Pilot control valve

(RCV lever) check

Stop engine. Turn key switch to OK

Check completed.
OFF position.
Move control lever to all positions
and then release.
LOOK : Lever must return to
neutral when released from all
positions.

6-40

NOT OK
Repair pilot control valve.

Item

Description

Bucket leveler
(Positioner) check
Run engine at low idle.

Service action

Position bucket fully dumped just OK

above ground level.
Check complete.
Move control lever to bucket NOT OK
leveler detent position and Do bucket leveler checks
release.
in group 3.
LOOK : Bucket must rollback to
the level position and control lever
must return to neutral.
If bucket is in a rolled back
position when key is turned ON,
control lever must be returned to
neutral manually if placed in the
bucket leveler detent position.
After bucket is dumped once,
bucket leveler will work normally.

Boom height kickout

check
Run engine at low idle.

Position bucket flat on ground.

Move control lever to boom raise
detent position and release.

OK
Check complete.

NOT OK
Do boom height kickout
LOOK : Boom must raise to the
check in group 3.
set height and stop.
Control lever must return to
neutral.

Cycle time check

Heat hydraulic oil to
operating temperature.
Run engine at high idle.

Function

Operating condition.

Maximum cycle time

HL740-7A HL740TM-7A

Boom raise

Bucket flat on ground to full height.

6.5sec

6.5sec

Boom lower

Full height to level ground.

3.2sec

3.2sec

Bucket dump

Boom at full height.

1.5sec

1.7sec

Bucket rollback

Boom at full height.

2.0sec

2.5sec

Steering(No. of Frame stop to frame stop.

turns)

2.5sec(4.5 turns)
OK
Check complete.
NOT OK
Go to slow hydraulic
functions.

6-41

 MEASURING BOOM AND BUCKET CYCLE TIME

1. MEASUREMENT CONDITION
Coolant temperature : Inside operating range
Steering position
: Neutral
Hydraulic temperature : 40~50$
Bucket
: Unloaded
Engine speed
: High idling

2. MEASURING TOOL
Stop watch(1 EA)

3. MEASURING PROCEDURE
Lowering time of boom

1) LIFTING TIME OF BOOM

Set the bucket near the maximum tilt back
position and at the lowest position on the
ground. Raise the bucket and measure the
time taken for bucket to reach the maximum
height of the boom.
7407AWE18

2) LOWERING TIME OF BOOM

Set the bucket horizontal with the boom at
the maximum height, lower the bucket and
measure the time taken for the bucket to
reach the lowest position on the ground.

Lifting time of boom

7407AWE19

3) DUMPING TIME OF BUCKET

Raise the boom to the maximum height and
measure the time taken for the bucket to
move from the maximum tilt back position
to the maximum dump position

Dumping time of bucket

Rollback time of bucket

4) ROLL BACK TIME OF BUCKET

Raise the boom to the maximum height and
measure the time taken for the bucket to
reach the maximum tilt back position.

7407AWE20

6-42

2. TROUBLESHOOTING
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
Noisy hydraulic pump

Cause

Remedy

Low oil supply or wrong viscosity.

Fill reservoir with recommended oil.

Plugged or pinched suction line.

Clean or replace line.

Air in oil.

Check for foamy oil. Tighten

connections.
Replace O-rings and or lines.

No or Slow hydraulic
functions

Loose or missing hydraulic line clamps.

Tighten or replace clamps.

Hydraulic lines in contract with frame.

Inspect and repair.

Worn or damaged pump.

Do hydraulic pump performance check

in group 2. Do hydraulic pump flow test
in group 3.

Failed or worn hydrualic pump.

Do performance check.

Cold oil.

Warm oil up.

Slow engine speed.

Adjust engine speed control linkage.

Check high idle speed.

Suction line air leak.

Check for foamy oil.

Low oil supply.

Add recommended oil.

Wrong oil viscosity.

Use recommended oil.

Oil leaking past cylinders or control

valve.

Check cylinder drift in group 3.

Blocked or damaged line.

Inspect lines.

Faulty or misadjusted pilot oil supply

unit.

Do pilot oil supply unit pressure test in

group 3.

Faulty pilot control valve(RCV).

Do pilot control valve(RCV) pressure

test in group 3.

Binding main control valve spool.

Inspect valve.

Faulty priority valve.

Check priority valve specification.

6-43

Problem
No steering or hydraulic
function

No hydraulic functions
steering normal

Boom float function

does not work

One hydraulic function

does not work

Low hydraulic power

Cause

Remedy

Low oil level.

Add recommended oil.

Failed hydraulic pump.

Remove and inspect return filter for

metal pump particles.

Failed main hydraulic pump drive.

Remove main hydraulic pump and

inspect drive gear.

Failed hydraulic pump.

Remove and inspect return filter for

metal pump particles, or replace the
pump.

Failed pilot line filter.

Remove and inspect line filter for RCV.

Faulty safety valve.

Safety valve leakage test or ON, OFF

function test.

Stuck open system and port relief

valve.

Replace relief valve.

Faulty or misadjusted pilot supply unit.

Do pilot supply unit pressure test in

group 3.

Low pilot control pressure.

Do pilot supply unit pressure test in

group 3.

Faulty pilot control valve(RCV).

Do pilot control valve pressure test.

Main control valve spool binding in

bore.

Do pressure reducing valve pressure

test.

Faulty pilot control valve(RCV).

Do pilot control valve pressure test.

Stuck open port relief valve.

Replace relief valve.

Oil leaking past cylinder packings.

Do boom and bucket cylinder leakage

test in group 3.

Blockage in oil lines or valve.

Inspect lines for damage.

Disconnect and inspect lines for internal
blockage.

Main control valve spool stuck in bore.

Inspect and repair valve.

Leakage within work circuit.

Do cylinder drift check in group 3.

Low system relief valve(Main relief

valve) setting.

Do loader system and port relief valve

pressure test in group 3.

Low port relief valve setting.

Do loader system and port relief valve

pressure test in group 3.

Faulty or misadjusted pilot oil supply

unit .

Do pilot oil supply unit pressure test in

group 3.

Leaking system relief valve.

Remove and inspect valve.

Worn hydraulic pump.

Do hydraulic pump performance check.

Faulty pilot control valve(RCV).

Do pilot control valve(RCV) pressure

test in group 3.

6-44

Problem
Function drifts down

Cause

Remedy

Leaking cylinders.

Do cylinder leakage checks in group 3.

Leaking seals in circuit relief valve(Port

relief valve) or valve stuck open.

Inspect seals. Replace relief valve.

Leaking loader control valve.

Repair or replace valve section.

Boom drifts up

Leakage in boom down spool.

Remove and inspect boom down spool.

Boom down does not

work
Engine off.

Safety valve not operated.

Operate valve.

Stuck pilot control valve.

Inspect.

Faulty line filter.

Remove and inspect filter.

Accumulation not operated.

Inspect.

Main control valve spool stuck.

Inspect and repair valve.

Low oil viscosity in hot weather.

Use recommended oil.

Excessive load.

Reduce load.

Holding hydraulic system over relief.

Reduce load.

Leakage in work circuit.

Do boom and bucket cylinder leakage

test in group 3.

Plugged fins in oil cooler.

Inspect and clean oil cooler.

Internally plugged oil cooler.

Do hydraulic oil cooler restriction test.

Incorrect system or circuit relief valve

setting.

Do loader system and circuit relief valve

pressure test in group 3.

Restriction in oil lines or main control

valve.

Inspect for dented or kinked lines.

Do hydraulic system restriction test in
group 3.

Pinched or restricted priority valve LS

line.

Run engine at low idle. Steer machine

back and forth. If engine load
decreases while steering, a restricted
LS line or priority valve malfunction is
indicated.
Do priority valve LS port flow test in
group 3.

Malfunctioning priority valve.

Do hydraulic system restriction test in

group 3.

Leaking system main relief valve.

Remove and inspect valve and seals.

Worn hydraulic pump(Internal leakage).

Do hydraulic pump performance check.

Stuck open lift check valve.

Do control valve lift check in group 2.

Oil overheats

Function drops before

raising when valve is
activated

6-45

Problem
Hydraulic oil foams

Remote control valve

(RCV) leaking

Cause

Remedy

Low oil level.

Add recommended oil.

Wrong oil.

Change to recommended oil.

Water in oil.

Change oil.

Loose or faulty suction lines(Air leak in

system).

Tighten or install new lines.

Leaking plunger seals.

Remove, inspect and replace plunger

seals.

6-46

 Followings are general precautions for the hydraulic system and equipment.
1) Every structure has its limit of strength and durability. The relief valve is installed to limit the
pressure on the hydraulic equipment and protect various parts of the wheel loader from possible
damage. Therefore, never change the preset pressure of the relief valve unless absolutely
necessary.
2) Since the hydraulic equipment is built with precision, the presence of only the slightest amount of
dust and/or other particles in the hydraulic circuit might cause wear and/or damage, resulting in
unstable functions and/or damage, resulting in unstable functions and/or unexpected accidents.
Therefore, always keep hydraulic oil clean. Periodically, check the filter in the return circuit and
replace the element as necessary.
3) Extract about 200cc of hydraulic oil from the tank as a sample every 6 months. If possible, have it
analyzed by a specialist to confirm that the oil can still be used. Never extract the oil for sampling
until the oil temperature has become the normal operating temperature. Since the replacement
period varies depending on operating conditions, refer to Operator's manual and change oil.
4) Should the equipment get damaged due to the presence of metal particles and/or foreign matter in
the circuit drain out the hydraulic oil and carry out flushing. Also, replace the filter element and
clean the hydraulic tank. Change the hydraulic oil entirely.
5) When checking the filter, if found metal particles in the element, drain out the hydraulic oil entirely,
flush the whole circuit, and then fill with new oil. The presence of metal particles may indicate
internal damage to the equipment. In such a case, check carefully before flushing, and repair or
replace as required.
6) To add and/or change the hydraulic oil, always use recommended oil.(Refer to the list of
recommended oils and lubricants at page 1-24, Recommended lubricants.) Never mix oil of
different makes of kinds.
7) To change the hydraulic oil, use a clean vessel and funnel for pouring it into the tank. Never use
cloth because it might cause the presence of lint in the circuit.
8) When removing the hydraulic equipment, be sure to put plugs or caps on hoses, tube lines and
ports. Also, enter mating marks for later identification.
9) Disassemble and/or assemble the hydraulic equipment only in a clean place free of dust. When
disassembling, be careful about the interchangeability of parts, and clean the disassembled parts
with pure and clean mineral cleansing oil. Clean the internal passages as well. After the parts
have dried, wipe them off with a clean lint-free cloth.
10) When overhauling the hydraulic equipment replace all O-rings, backup rings, etc. with new ones.
Assemble O-rings with grease or vaseline applied.
11) After installing the equipment, add more hydraulic oil to make up for that lost during disassembly.
12) Tighten joints correctly. Loose joints will cause the hydraulic oil to leak. If the oil leaks, the tank oil
level drops and air gets sucked in, so the pump will break down. Also loose joints in suction lines
will take air in and might cause abnormal noise, malfunction or damage to pumps.

6-47