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Workman HDX Auto Page 7 − 19 Hydraulic System
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).
CAUTION
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.
Before Performing Hydraulic Tests
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.
Precautions For Hydraulic Testing
Before disconnecting or performing any work
on the hydraulic system, all pressure in the
system must be relieved by stopping the engine,
rotating the steering wheel in both directions,
lowering the bed and operating other hydraulic
accessories.
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.
WARNING
CAUTION
All testing should be performed by two (2)
people. One person should be in the seat to oper-
ate the machine and the other should monitor
testing equipment and record test results.
1. Thoroughly clean the vehicle before disconnecting or
disassembling any hydraulic components. Always keep
in mind the need for cleanliness when working on hy-
draulic components. Contamination will cause exces-
sive wear of hydraulic components.
2. Review all test steps before starting the test proce-
dure.
3. Put metal caps or plugs on any hydraulic lines left
open or exposed during testing or removal of compo-
nents.
4. The engine must be in good operating condition. Use
a tachometer to identify engine speed when making a
hydraulic test. Engine speed will affect the accuracy of
the tester readings.
5. To prevent damage to tester or components when
using tester with pressure and flow capabilities, the inlet
and the outlet hoses must be properly connected and
not reversed.
6. 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.
7. Install fittings finger tight, far enough to insure that
they are not cross−threaded, before tightening the fit-
tings with a wrench.
8. Position the tester hoses so that rotating vehicle
parts will not make contact with them and result in hose
or tester damage..
9. Check and adjust the oil level in the hydraulic reser-
voir after connecting hydraulic test equipment.
10.All hydraulic tests should be made with the hydraulic
oil at normal operating temperature.
11. After testing is completed, check and adjust the oil
level in the hydraulic reservoir before returning the ve-
hicle to service.
Hydraulic
System