GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING

1. OPERATIONAL CHECKS
1) BRAKE PIPING
(1) Check pipes, hoses and joints for damage, oil leakage or interference.
(2) Operate brake pedal and check operating force when pedal is depressed. Check also change in
operating force, and change in position of pedal when pedal is kept depressed.
2) The brakes generate a high temperature when operating, this means that the casing will be hot to
touch, this condition is normal.

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2. TROUBLESHOOTING

Problem Cause Remedy

Insufficient braking force ·Hydraulic system leaks oil. ·Repair and add oil.
·Hydraulic system leaks air. ·Bleed air.
·Disk worn. ·Replace.
·Hydraulic system clogged. ·Clean.
Brake acting unevenly. ·Tires unequally inflated. ·Adjust tire pressure.
(Machine is turned to one ·Brake out of adjustment. ·Adjust.
side during braking.) ·Disk surface roughened. ·Repair by polishing or replace.
·Wheel bearing out of adjustment. ·Adjust or replace.
·Hydraulic system clogged. ·Clean.
Brake trailing. ·Pedal has no play. ·Adjust.
·Piston cup faulty. ·Replace.
·Hydraulic system clogged. ·Clean.
·Wheel bearing out of adjustment. ·Adjust or replace.
Brake chirps ·Brake trailing. ·See above. Brake trailing.
·Piston fails to return. ·Replace.
·Disk worn. ·Replace.
·Disk surface roughened. ·Repair by polishing or replace.
Brake squeaks ·Disk surface roughened. ·Repair by polishing or replace.
·Disk worn. ·Replace.
Large pedal stroke ·Brake out of adjustment. ·Adjust.
·Hydraulic line sucking air. ·Bleed air.
·Oil leaks from hydraulic line, or lack ·Check and repair or add oil.
of oil.
·Disk worn. ·Replace.
Pedal dragging. ·Twisted push rod caused by improp- ·Adjust.
erly fitted brake valve.

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 Problem Cause Remedy
One or more brakes do not ·Master cylinder fault. · Check master cylinder in single and
apply. (Brake travel not exces- coupled pedal modes to identify fault
sive, brake not pulling to one area, service as required.
side) ·Friction and free plate distortion. · Check friction and free plates.
Pedal travel excessive. (But ·Air in hydraulic system. · Check fluid reservoir level. Check for
not touching floor) fluid and air leaks, repair as required.
·Leak in hydraulic system. · Check for fluid loss at master cylinder
and brake piston, all pipes and
fittings for loose connections. Repair
as required.
·Friction and free plate distortion. · Renew friction and free plates - both
sides.
Applying one brake (pedal · Valve stem seal inside (non active) · Renew master cylinder piston.
u n l o cke d ) a l s o p a r t i a l l y master cylinder piston not sealing.
engages the other brake.
Pedal hard to operate. · Tightness at pedal pivot. · Inspect pedal pivot. Free-off and
lubricate.
· Fluid contamination and seal damage. · Flush system and renew all hydraulic
seals.
· Misaligned push rod or pedal. · Check and repair as required.
· Kinked or crushed brake pipes. · Check and renew brake pipework.
Pedal touches floor under · Master cylinder fault. · Check master cylinder in single and
constant pressure-no fluid coupled pedal modes to identify fault
loss. area, service as required.
· Friction and free plate distortion. · Renew friction and free plates - both
sides.
· Air in hydraulic system. · Check fluid reservoir level. Check for
fluid and air leaks, repair as required.
Pedal touches floor under · External fluid leaks. · Visually check brake circuit for fluid
constant pressure-and fluid loss, service as required.
loss. · Internal fluid leaks. · Do brake piston seal leakage test.

Pulling to one side when · Compensating feature not working. · Inspect master cylinder compensating
pedals locked together. operation. Check if blockage in
bridging pipe. Service as required.
· Braking system inoperative on one · Unlatch pedals to test circuits
side. individually.
· Friction plates worn beyond limits or · Renew friction and free plates - both
distorted on one side. sides.
· Badly adjusted push rods. · Adjust push rod (1mm minimum)

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 Problem Cause Remedy
Poor braking (not pulling to · Friction plates worn beyond limits or · Renew friction and free plates - both
one side). distorted. sides of relevant axle.
· Master cylinder fault. · Check master cylinder in single and
coupled pedal modes to identify fault
area, service as required.
· Incorrect or low axle oil. · Fill axle with correct type of oil.

Brakes not releasing. · Brake pedal spring fault. · Fit a new spring.
· Master cylinder fault (plunger stuck in · Check master cylinder in single and
bore). coupled pedal modes to identify fault
area, service as required.
· Blocked hole in master cylinder · Fit a new reservoir cap.
reservoir cap.
· Brake pedal free travel incorrect. · Adjust pedal free travel.
· Fluid contamination and seal · Flush system and renew hydraulic
damage. seals.
· Kinked or crushed brake pipes. · Check and renew pipes as required.
· Friction and free plates not free on · Check friction and free plates for free
splines or dowels. movement, renew if required - both
sides of relevant axle.
Excessive brake noise in · Deterioration of axle oil or wrong type · Change axle oil.
operation. of axle oil.
· Axle oil loss. · Refill axle with correct oil and check
for leaks.
· Friction plates worn beyond limits. · Renew friction and free plates.
· Friction and free plates in poor · Check for distortion or surface pitting
condition. and roughness of friction and free
plates (annular grooving of free
plates is acceptable).
Fluid loss when machine · Severe damage or slight cut or nick · Strip axle, replace seal.
s t a n d i n g fo r i n s t a n c e - in the brake piston seal. Do brake
overnight. piston seal leakage test.

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