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

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※Hydraulic oil must be at operating temperature for these checks(Refer to page 6-50).

Item Description Service action

Parking brake capacity Start engine. OK

check 20 30 Check completed.
Fasten seat belt.
Seat belt must be worn 10 40
10 20
NOT OK
while doing this check to Release parking brake and put
0 0
mph
30
50 Inspect parking brake. Go
prevent possible injury Km/h
transmission in 2nd gear forward.
to group 3.
when machine stops
Drive machine at 8 km/hr and
suddenly.
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 Turn parking brake to ON. OK

transmission lockout Check completed.
Place transmission in 1st forward.
check
NOT OK
Engine running. 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 Description Service action

Service brake pump Stop engine. OK

flow check Check completed.
Operate brake pedal approximately 20
※ Hydraulic oil must be at NOT OK
times.
operating temperature Check for brake circuit
Start engine and run at low idle.
for the check. leakage.
Engine OFF. 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
time engine starts. valve and repeat pump
flow check.
NOTE : Indicator will not come on
approximately 1 second after If time does not decrease,
starting engine. check for worn brake
pump. Go to brake pump
flow test, in section 3.

Turn clutch cut-off switch OFF. OK

Service brake capacity Check completed.
Apply service brakes, release
check
park brake and put transmission NOT OK
Engine running. Check brake pressure in
in 2nd forward.
group 3.
Increase engine speed to high
idle. IF OK
Inspect brake disk, see
LOOK : Machine may not move group 3.
or move at a very slow speed.
Repeat check three times to
ensure accurate results.

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 Item Description Service action
Brake accumulator Start and run engine for 30 OK
precharge check seconds. Check completed.
※ The axles and
Stop engine and turn start switch NOT OK
hydraulic oil must be at
to ON and wait 5 seconds. Make sure brake pedal is
operating temperature
not binding and keeping
for this check. 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 in group 3.
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.
group 3.
Observe cluster while applying
brake pedal with maximum force.
LOOK/LISTEN : Brake pressure
indicator must not come ON.

Brake system leakage ON Start engine and wait 30 seconds. OK

check Check completed.
Stop engine.
NOT OK
Wait 2 minutes.
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
valve and brake valve. If
warning lamp must not come on
brake leakage is indicated
within 2 minutes after stopping
with brakes applied, check
engine.
for leakage at brake valve
and brake pistons.
Check individual
component leakage.

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 Item Description Service action

Service brake pedal Slowly depress brake pedal. OK

check 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.

Service and parking Position machine on gradual OK

brake system drag slope. Check completed.
checks
Lower bucket approximately
Engine running 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 on group 3.
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. NOT OK
Adjust clutch cut-off switch,
Run engine at half speed in 1st
see group 3.
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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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 Cause Remedy

Poor or no brakes Brake accumulator charge low Do brake accumulator check.

Brake pump standby pressure Do brake pump standby pressure test.
low
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.
※It is normal for the oil level to be slightly
above the check plug.

Aggressive brakes Internal restriction in circuit Remove lines and components.

Clutch cut-off switch out of Adjust switch.
adjustment
Brake valve malfunction Disassemble and inspect.
Low oil level Check oil level.

Brakes drag Brake pedal not returning Inspect floor mat and pedal.
properly
Debris holding valve partially Do brake valve pressure test.
open in brake valve
Warped brake disk Inspect brake disk.
Stuck brake piston Repair.

Brakes lock up Brake valve malfunction Clean or replace brake valve.

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 Problem Cause Remedy

Brakes chatter 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
Brake accumulator pressure too Recharge accumulator.
long 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
Do brake system components leakage tests.
Leakage in brake system
Do brake pump flow test.
Worn brake pump
Do parking brake pressure test.
Leakage in parking brake
solenoid

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2) PARKING BRAKE MALFUNCTIONS

Problem Cause Remedy

Brake will not hold 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 piston hangs up in bore Remove and inspect. Repair.

Brake disk overheats 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 Inspect for loose or broken lines between brake
in monitor does not pressure switch and indicator on dash.
come on when brake Inspect for a faulty indicator on dash. Replace if
applied necessary.

Brake will not apply Pads out of adjustment Adjust parking brake.
Malfunctioning wiring, switch, or Check electric circuit.
solenoid
Restriction between brake valve Remove hose and inspect. Replace.
and brake

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