Testing
The most effective method for isolating problems in the
hydraulic system is by using hydraulic test equipment
such as pressure gauges and flow meters in the circuits
during various operational checks (see Special Tools
section in this Chapter).
1. Thoroughlycleanthevehiclebeforedisconnectingor
disassembling any hydraulic components. Always keep
in mind the need for cleanliness when working on hy-
draulic equipment. Contamination will cause excessive
wear of hydraulic components.
2. Review all test steps before starting the test proce-
dure.
CAUTION
3.
open or exposed during testing or removal of compo-
nents.
Put metal caps or plugs on any hydraulic lines left
Failure to use gauge with recommended pres-
sure (psi/bar) rating as listed in test procedures
could result in damage to gauge and possible
personal injury from leaking hot oil.
4. The engine must be in goodoperating condition. Use
a tachometer when making a hydraulic test. Engine
speed will affect the accuracy of the tester readings.
Before Performing Hydraulic Tests
5.
On Workman HD vehicles, the hydraulic gear pump
All obvious areas such as oil supply, filter, binding link-
age, loose fasteners or improper adjustments must be
checked before assuming that a hydraulic component is
the source of the problem being experienced.
is belt driven. Before performing any hydraulic test on
Workman HD vehicles, check for proper gear pump
drive belt adjustment.
6.
To prevent damage to tester or components when
Precautions For Hydraulic Testing
using tester with pressure and flow capabilities, the inlet
and the outlet hoses must be properly connected and
not reversed.
WARNING
7.
To minimize the possibility of damaging components
when using tester with pressure and flow capabilities,
completely open load valve in hydraulic tester before
starting engine.
Before disconnecting or performing any work
on the hydraulic system, all pressure in the
systemmustberelievedbystoppingtheengine,
rotating the steering wheel in both directions,
lowering or supporting the bed and operating
other hydraulic accessories.
8. Install fittings finger tight, far enough to insure that
they are not cross--threaded, before tightening the fit-
tings with a wrench.
Keep body and hands away from pin hole leaks
or nozzles that eject hydraulic fluid under high
pressure. Use paper or cardboard, not hands, to
search for leaks. Hydraulic fluid escaping under
pressure can have sufficient force to penetrate
skin and cause serious injury. If fluid is injected
into the skin, it must be surgically removed
within a few hours by a doctor familiar with this
type of injury. Gangrene may result from such
an injury.
9. Position the tester hoses so that rotating vehicle
parts will not make contact with them and result in hose
or tester damage.
10.Check
and adjust the oil level in the hydraulic reser-
voir after connecting hydraulic test equipment.
11.
All hydraulic tests should be made with the hydraulic
oil at normal operating temperature.
12.After
testing is completed, check and adjust the oil
level in the hydraulic reservoir before returning the ve-
hicle to service.
CAUTION
All testing should be performed by two (2)
people.Onepersonshouldbeintheseattooper-
ate the machine and the other should read and
record test results.
Workman HD Series
Page 9 -- 19
Hydraulic System
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