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.
Drive machine at 8 km/hr and
switch parking brake ON.
LOOK/FEEL : Machine must
come to a stop within 2 meters(6
feet) when parking brake is
engaged at 8 km/hr.
Transmission must shift to neutral.
Parking brake
transmission lockout
check
Engine running.
Turn parking brake to ON.
Place transmission in 1st forward.
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.
Operate brake pedal approximately 20
NOT OK
times.
Check
for brake circuit
Start engine and run at low idle.
leakage.
Record number of seconds
required for low brake pressure Go to next page.
indicator lamp to go out.
IF OK
LOOK : Indicator lamp must go Install a cap on line
out in less than 4 seconds from connected to inlet of brake
valve and repeat pump
time engine starts.
flow check.
NOTE : Indicator will not come on
approximately 1 second after If time does not decrease,
check for worn brake
starting engine.
pump. Go to brake pump
flow test.
Turn clutch cut-off switch OFF.
Service brake capacity
check
Engine running.
OK
Check completed.
Apply service brakes, release
park brake and put transmission NOT OK
Check brake pressure.
in 2nd forward.
Increase engine speed to high IF OK
Inspect brake disk, see
idle.
group 3.
LOOK : Machine may not move or
move at a very slow speed.
Repeat check three times to
ensure accurate results.
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Item
Description
Service action
Start and run engine for 30 OK
seconds.
Check completed.
Brake accumulator
precharge check
The axles and
hydraulic oil must be at
operating temperature
for this check.
Stop engine and turn start switch NOT OK
to ON and wait 5 seconds.
Make sure brake pedal is
not binding and keeping
NOTE : Engine oil pressure lamp
brakes partially engaged.
will be on due to no engine oil
pressure.
Bleed brakes in group 3.
Count the number of times the Check brake system
brake pedal can be fully depressed pressure.
before the low brake pressure
NOT OK
warning lamp comes ON.
If light comes on with
LOOK : Warning lamp must come engine
running,
on in 1-5 applications.
accumulator has lost it's
charge.
Inspect and
Start engine and operate at low
recharge accumulator.
idle.
Observe cluster while applying
brake pedal with maximum force.
LOOK/LISTEN : Brake pressure
indicator must not come ON.
Brake system leakage
check
ON
Start engine and wait 30 seconds.
Stop engine.
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
Service and parking
brake system drag
checks
Engine running
Description
Slowly depress brake pedal.
Service action
OK
Check completed.
Listen for a hissing noise that
indicates oil is flowing to brake NOT OK
pistons.
Inspect for debris under
brake pedal. Inspect
LISTEN/FEEL : A hissing noise
clutch cut-off linkage.
must be heard when pedal is
depressed.
Position machine on gradual OK
slope.
Check completed.
Lower bucket approximately
NOT OK
50mm(2 in) from ground.
Adjust park brake, go to
Release parking and service group 3.
brakes.
NOT OK
LOOK : Machine must move or
Check
floor
mat
coast.
interference to pedal or
NOTE : If machine does not debris build-up.
move, check brake pedals to be
sure they fully release when feet IF OK
are removed from pedals.
Check for brake pressure
when brake is released.
Drive machine at high speed for
about 5 minutes.
Go to brake pressure test.
Brake drag is indicated if brake
areas in differential case are hot.
NOTE : Observe parking brake.
If disk is hot, parking brake drag is
indicated.
Clutch cut-off check
Place clutch cut-off switch in ON OK
position.
Check completed.
Release parking brake.
Run engine at half speed in 1st
forward.
Firmly depress brake pedal.
FEEL : Transmission must
disengage when brake pedal is
depressed at 30% of pedal stroke.
NOTE : Clutch cut-off pressure
switch can be adjusted to operator
preference to match your loading
needs.
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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
Brake accumulator charge low
Do brake accumulator check.
Brake pump standby pressure Do brake pump standby pressure test.
low
Aggressive brakes
Brake pressure low
Do brake valve pressure test.
Air in system
Bleed brakes.
Worn brake surface material
Inspect brake surface material.
Leakage in brake valve
Do brake valve leakage test.
Leakage in brake piston seal
Check for an over filled differential.
Apply brakes and check for leakage from check
plug.
IIt is normal for the oil level to be slightly
above the check plug.
Internal restriction in circuit
Remove lines and components.
Clutch cut-off switch out of Adjust switch.
adjustment
Brakes drag
Brake valve malfunction
Disassemble and inspect.
Low oil level
Check oil level.
Brake pedal not returning Inspect floor mat and pedal.
properly
Debris holding valve partially Do brake valve pressure test.
open in brake valve
Brakes lock up
Warped brake disk
Inspect brake disk.
Stuck brake piston
Repair.
Brake valve malfunction
Clean or replace brake valve.
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Problem
Brakes chatter
Cause
Remedy
Air in brake system
Do brake bleed procedure.
Worn brake surface material
Inspect brake surface material.
Wrong oil in differential
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
Do brake system components leakage tests.
Worn brake pump
Do brake pump flow test.
Leakage in parking brake Do parking brake pressure test.
solenoid
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2) PARKING BRAKE MALFUNCTIONS
Problem
Brake will not hold
Cause
Remedy
Pads not adjusted correctly
Adjust parking brake.
Malfunctioning parking brake Inspect and replace.
solenoid
Worn brake disk and / or brake Disassemble, inspect, repair.
pads
Brake disk overheats
Brake piston hangs up in bore
Remove and inspect. Repair.
Pads out of adjustment
Adjust parking brake.
Brake not released
Release parking brake.
Disassemble, inspect brake.
Repair if necessary.
Inspect for loosen or broken lines between brake
pressure switch and indicator on dash.
Parking brake indicator Faulty wiring or switch
in monitor does not
come on when brake
applied
Inspect for loose or broken lines between brake
pressure switch and indicator on dash.
Inspect for a faulty indicator on dash. Replace if
necessary.
Brake will not apply
Adjust parking brake.
Pads out of adjustment
Malfunctioning wiring, switch, or Check electric circuit.
solenoid
Restriction between brake valve Remove hose and inspect. Replace.
and brake
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