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Hydraulic System Diagnose Malfunctions

No Hydraulic Functions Diagnostic Procedure

1 Hydraulic Enable Switch in Off Position

Action:

Check position of hydraulic enable switch.

Is switch in off position?

Result:

YES: Move switch to on position.

NO: Go to Hydraulic Enable Switch Malfunction.

2 Hydraulic Enable Switch Malfunction

Action:

Perform hydraulic control enable circuit check. See Operational Checkout. (Group 9005-10.)

Check hydraulic control enable switch and circuit. See System Functional Schematic and Section Legend. (Group
9015-10.)

Are switch and circuit working correctly?

Result:

YES: Go to Hydraulic System Relief Valve Stuck Open.

NO: Repair or replace hydraulic enable switch and circuit.

3 Hydraulic System Relief Valve Stuck Open

Action:

Check hydraulic system pressure. Perform Hydraulic System Relief Valve Test. (Group 9025-25.)

Is relief valve adjusted to specification?

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Result:

YES: Go to Pilot Control Pressure Low.

NO: Replace relief valve.

4 Pilot Control Pressure Low

Action:

Check pilot control pressure. Perform Pressure Reducing Valve Pressure Test and Adjustment. (Group 9025-25.)

Is pressure reducing valve adjusted to specification?

Result:

YES: Go to Pump Load Sense Differential and System Pressure Low.

NO: Replace pressure reducing valve.

5 Pump Load Sense Differential and System Pressure Low

Action:

Check pump load sense differential and system pressure. Perform Pump Load Sense Differential and System
Pressure Test and Adjustment. (Group 9025-25.)

Is pump control valve adjusted to specification?

Result:

YES: Checks complete.

NO: Replace pump control valve.

Hydraulic Functions Slow Diagnostic Procedure

1 Hydraulic Oil Cold

Action:

Check hydraulic oil temperature.

Is hydraulic oil at normal operating temperature?

Result:

YES: Go to Engine Speed Slow.

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NO: Warm-up hydraulic oil.

2 Engine Speed Slow

Action:

Check engine speed. See Diagnose Engine Malfunctions—9.0L. (Group 9010-15.)

Is engine speed to specification?

Result:

YES: Go to Pump Suction Line Air Leak.

NO: Follow engine diagnostic procedure.

3 Pump Suction Line Air Leak

Action:

Check for foamy hydraulic oil. See Check Hydraulic Oil Level. (Operator's Manual.)

Is hydraulic oil foamy?

Result:

YES: Repair pump suction line leak.

NO: Go to Hydraulic Oil Level Low.

4 Hydraulic Oil Level Low

Action:

Check hydraulic oil level. See Check Hydraulic Oil Level. (Operator's Manual.)

IMPORTANT:

If machine is equipped with winch, check oil level in winch. A malfunction of winch hydraulic
components can transfer hydraulic oil to winch and reduce the hydraulic oil level of machine.

Is hydraulic oil level to specification?

Result:

YES: Go to Oil Viscosity Wrong.

NO: Add recommended oil. See Transmission and Hydraulic Reservoir Oil. (Operator's Manual.)

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5 Oil Viscosity Wrong

Action:

Check reservoir oil. See Transmission and Hydraulic Reservoir Oil. (Operator's Manual.)

Is correct oil used?

Result:

YES: Go to Hydraulic Lines Blocked or Damaged.

NO: Replace reservoir oil with recommended oil.

6 Hydraulic Lines Blocked or Damaged

Action:

Inspect hydraulic lines. See Main Hydraulic Component Location. (Group 9025-15.)

Are any hydraulic lines blocked or damaged?

Result:

YES: Repair or replace damaged lines.

NO: Go to Hydraulic Cylinders Leaking Internally.

7 Hydraulic Cylinders Leaking Internally

Action:

Check cylinders for leakage. Perform Lift and Tilt Cylinder Function Drift Test. (Group 9025-25.)

Are any cylinders leaking?

Result:

YES: Repair or replace leaking cylinders.

NO: Go to Hydraulic System Relief Valve Stuck Open.

8 Hydraulic System Relief Valve Stuck Open

Action:

Check hydraulic system pressure. Perform Hydraulic System Relief Valve Test. (Group 9025-25.)

Is relief valve adjusted to specification?

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Result:

YES: Go to Pilot Control Pressure Low.

NO: Replace relief valve.

9 Pilot Control Pressure Low

Action:

Check pilot control pressure. Perform Pressure Reducing Valve Pressure Test and Adjustment. (Group 9025-25.)

Is pressure reducing valve adjusted to specification?

Result:

YES: Go to Pump Load Sense Differential and System Pressure Low.

NO: Replace pressure reducing valve.

10 Pump Load Sense Differential and System Pressure Low

Action:

Check pump load sense differential and system pressure. Perform Pump Load Sense Differential and System
Pressure Test and Adjustment. (Group 9025-25.)

Is pump control valve adjusted to specification?

Result:

YES: Go to Hydraulic Control Valve Spool Binding.

NO: Replace pump control valve.

11 Hydraulic Control Valve Spool Binding

Action:

Inspect and repair control valve. See Hydraulic Control Valve Disassemble and Assemble. (Group 3260.)

Is control valve spool binding?

Result:

YES: Repair or replace control valve.

NO: Go to Hydraulic Pump Worn or Damaged.

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12 Hydraulic Pump Worn or Damaged

Action:

Check pump Flow. Perform Hydraulic Pump Flow Test. (Group 9025-25.)

Is pump flow to specification?

Result:

YES: Checks complete.

NO: Repair or replace pump as necessary.

Hydraulic Pump Noisy Diagnostic Procedure

1 Pump Suction Line Air Leak

Action:

Check for foamy hydraulic oil. See Check Hydraulic Oil Level. (Operator's Manual.)

Is hydraulic oil foamy?

Result:

YES: Repair pump suction line leak.

NO: Go to Hydraulic Oil Level Low.

2 Hydraulic Oil Level Low

Action:

Check hydraulic oil level. See Check Hydraulic Oil Level. (Operator's Manual.)

IMPORTANT:

If machine is equipped with winch, check oil level in winch. A malfunction of winch hydraulic
components can transfer hydraulic oil to winch and reduce the hydraulic oil level of machine.

Is hydraulic oil level to specification?

Result:

YES: Go to Oil Viscosity Wrong.

NO: Add recommended oil. See Transmission and Hydraulic Reservoir Oil. (Operator's Manual.)

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3 Oil Viscosity Wrong

Action:

Check reservoir oil. See Transmission and Hydraulic Reservoir Oil. (Operator's Manual.)

Is correct oil used?

Result:

YES: Go to Hydraulic Lines in Contact with Frame.

NO: Replace reservoir oil with recommended oil.

4 Hydraulic Lines in Contact with Frame

Action:

Inspect line routing.

Are any lines against frame?

Result:

YES: Adjust lines as necessary.

NO: Go to Hydraulic Pump Worn or Damaged.

5 Hydraulic Pump Worn or Damaged

Action:

Check pump flow. Perform Hydraulic Pump Flow Test. (Group 9025-25.)

Is pump flow to specification?

Result:

YES: Checks complete.

NO: Repair or replace pump as necessary.

Blade Float Does Not Work Diagnostic Procedure

1 Pilot Control Pressure Low

Action:

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Check pilot control pressure. Perform Pressure Reducing Valve Pressure Test and Adjustment. (Group 9025-25.)

Is pressure reducing valve adjusted to specification?

Result:

YES: Go to Pilot Controller Detent Malfunction.

NO: Replace pressure reducing valve.

2 Pilot Controller Detent Malfunction

Action:

Inspect pilot controller. See Hydraulic System Schematic. (Group 9025-15.)

Is pilot controller worn or damaged?

Result:

YES: Repair or replace pilot controller.

NO: Go to Hydraulic Control Valve Spool Binding.

3 Hydraulic Control Valve Spool Binding

Action:

Inspect and repair control valve. See Hydraulic Control Valve Disassemble and Assemble. (Group 3260.)

Is control valve spool binding?

Result:

YES: Repair or replace control valve.

NO: Checks complete.

One Hydraulic Function Does Not Work Diagnostic Procedure

1 Pilot Control Pressure Low

Action:

Check pilot control pressure. Perform Pressure Reducing Valve Pressure Test and Adjustment. (Group 9025-25.)

Is pressure reducing valve adjusted to specification?

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Result:

YES: Go to Circuit Relief Valve Stuck Open.

NO: Replace pressure reducing valve.

2 Circuit Relief Valve Stuck Open

Action:

Check circuit relief valves. See Hydraulic Control Valve Disassemble and Assemble. (Group 3260.)

Is circuit relief valve worn or damaged?

Result:

YES: Repair or replace circuit relief valve.

NO: Go to Anticavitation Valve Stuck Open.

3 Anticavitation Valve Stuck Open

Action:

Check anticavitation valves. See Hydraulic Control Valve Disassemble and Assemble. (Group 3260.)

Is anticavitation valve worn or damaged?

Result:

YES: Repair or replace anticavitation valve.

NO: Go to Hydraulic Lines Blocked or Damaged.

4 Hydraulic Lines Blocked or Damaged

Action:

Inspect hydraulic lines. See Main Hydraulic Component Location. (Group 9025-15.)

Are any hydraulic lines blocked or damaged?

Result:

YES: Repair or replace damaged lines.

NO: Go to Hydraulic Cylinders Leaking Internally.

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5 Hydraulic Cylinders Leaking Internally

Action:

Check cylinders for leakage. Perform Lift and Tilt Cylinder Function Drift Test. (Group 9025-25.)

Are any cylinders leaking?

Result:

YES: Repair or replace leaking cylinders.

NO: Go to Hydraulic Control Valve Spool Binding.

6 Hydraulic Control Valve Spool Binding

Action:

Inspect and repair control valve. See Hydraulic Control Valve Disassemble and Assemble. (Group 3260.)

Is control valve spool binding?

Result:

YES: Repair or replace control valve.

NO: Checks complete.

Function Drifts Down Diagnostic Procedure

1 Hydraulic Cylinders Leaking Internally

Action:

Check cylinders for leakage. Perform Lift and Tilt Cylinder Function Drift Test. (Group 9025-25.)

Are any cylinders leaking?

Result:

YES: Repair or replace leaking cylinders.

NO: Go to Circuit Relief Valve Stuck Open or Leaking.

2 Circuit Relief Valve Stuck Open or Leaking

Action:

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Check circuit relief valves. See Hydraulic Control Valve Disassemble and Assemble. (Group 3260.)

Is circuit relief valve worn or damaged?

Result:

YES: Repair or replace circuit relief valve.

NO: Go to Anticavitation Valve Stuck Open or Leaking.

3 Anticavitation Valve Stuck Open or Leaking

Action:

Check anticavitation valves. See Hydraulic Control Valve Disassemble and Assemble. (Group 3260.)

Is anticavitation valve worn or damaged?

Result:

YES: Repair or replace anticavitation valve.

NO: Go to Hydraulic Control Valve Spool Leaking.

4 Hydraulic Control Valve Spool Leaking

Action:

Inspect and repair control valve. See Hydraulic Control Valve Disassemble and Assemble. (Group 3260.)

Is control valve spool worn or damaged?

Result:

YES: Replace control valve.

NO: Checks complete.

Oil Overheats Diagnostic Procedure

1 Oil Viscosity Wrong

Action:

Check reservoir oil. See Transmission and Hydraulic Reservoir Oil. (Operator's Manual.)

Is correct oil used?

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Result:

YES: Go to Hydraulic System Relief Valve Stuck Open or Leaking.

NO: Replace reservoir oil with recommended oil.

2 Hydraulic System Relief Valve Stuck Open or Leaking

Action:

Check hydraulic system pressure. Perform Hydraulic System Relief Valve Test. (Group 9025-25.)

Is relief valve adjusted to specification?

Result:

YES: Go to Circuit Relief Valve Stuck Open or Leaking.

NO: Replace relief valve.

3 Circuit Relief Valve Stuck Open or Leaking

Action:

Check circuit relief valves. See Hydraulic Control Valve Disassemble and Assemble. (Group 3260.)

Is circuit relief valve worn or damaged?

Result:

YES: Repair or replace circuit relief valve.

NO: Go to Anticavitation Valve Stuck Open or Leaking.

4 Anticavitation Valve Stuck Open or Leaking

Action:

Check anticavitation valves. See Hydraulic Control Valve Disassemble and Assemble. (Group 3260.)

Is anticavitation valve worn or damaged?

Result:

YES: Repair or replace anticavitation valve.

NO: Go to Hydraulic Lines Blocked or Damaged.

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5 Hydraulic Lines Blocked or Damaged

Action:

Inspect hydraulic lines. See Main Hydraulic Component Location. (Group 9025-15.)

Are any hydraulic lines blocked or damaged?

Result:

YES: Repair or replace damaged lines.

NO: Go to Hydraulic Cylinders Leaking Internally.

6 Hydraulic Cylinders Leaking Internally

Action:

Check cylinders for leakage. Perform Lift and Tilt Cylinder Function Drift Test. (Group 9025-25.)

Are any cylinders leaking?

Result:

YES: Repair or replace leaking cylinders.

NO: Go to Hydraulic Pump Worn or Damaged.

7 Hydraulic Pump Worn or Damaged

Action:

Check pump Flow. Perform Hydraulic Pump Flow Test. (Group 9025-25.)

Is pump flow to specification?

Result:

YES: Checks complete.

NO: Repair or replace pump as necessary.

OUO1010,00009D9-19-04APR07

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