Warnings
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Sudden movement of the machine or release of oil under pressure can cause injury to persons on or near the machine. To prevent possible injury, perform the procedure that follows before testing and adjusting the power train. |
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Hot hydraulic oil under high pressure can remain in the components of the hydraulic system or the power train system after the engine has been stopped. The uncontrolled release of the hydraulic oil can cause sudden machine movement and can also result in the following conditions:
If hydraulic oil penetrates body tissue, the injury must be treated immediately by a doctor who is familiar with this type of injury. Use a board or a piece of cardboard to check for a hydraulic oil leak. Make sure that all of the attachments have been lowered to the ground and that all trapped pressure has been released from the hydraulic system and the power train system. Also, make sure that the hydraulic oil is cool before the removal of any components or lines. Remove the hydraulic oil filler cap only when the engine is stopped and the filler cap is cool enough to touch with your bare hand. |
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Personal injury or death can result from not engaging the parking brake. Transmission engagement alone will not prevent machine from rolling when the engine is stopped. |
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Personal injury can result if the machine moves while testing. If the machine begins to move during test, reduce the engine speed immediately and engage the parking brake. |
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| NOTICE |
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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "AVSpare Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on AVSpare products. Dispose of all fluids according to local regulations and mandates. |
General Procedure
- Know the Machine.
Understand the operation and the interaction of the machine systems. Know if the symptom is a characteristic of normal operation or if the symptom is a problem.
Refer to the Specification, Systems Operation, Testing and Adjusting manual.
For D5R2 models refer to the latest revision of Specifications, Systems Operation, Testing and Adjusting, UENR4119 .
For D6R2 models refer to the latest revision of Specifications, Systems Operation, Testing and Adjusting, UENR4109.
- Identify the Symptom.
- Speak with the operator about the symptom.
- Ask about the performance of the machine prior to the problem.
- Determine the time that the symptom first occurred.
- Determine the operating conditions at the time of the problem.
- Ask the operator about the sequence of events prior to the failure. Determine the order of the occurrences.
- Ask the operator about the steps that have been taken to troubleshoot the machine.
- Check the history of repairs of the machine.
- Ask about the preventive maintenance of the machine.
- Ask about the performance of the machine prior to the problem.
- Inspect the machine. Look for problems. Notice any unusual odors in the air. Listen for unusual noises.
Complete the steps in Troubleshooting, "Visual Inspection".
If you complete the visual inspection and the problem is not identified, perform the appropriate tests and/or adjustments in Specifications, Systems Operation/Testing and Adjusting for your machine.
- Speak with the operator about the symptom.
- Troubleshoot the faults with the service codes.
Determine if the ECM has detected any faults. A service code is used to specify each detected fault.
Each of the components such as switches and sensors are referenced by a unique CID (component identifier).
To read a diagnostic code, refer to Troubleshooting, "Diagnostic Capabilities" in the beginning of this manual.
- Troubleshoot using the description of the symptom.
If you troubleshoot the service codes and the problem is not resolved, continue troubleshooting using the symptom. Identify the component that is the most probable cause of the symptom.
- After the problem is resolved, prepare the machine for operation. Complete a maintenance record for the machine: problem, symptom and repairs.
Refer to the instructions in the Operation and Maintenance Manual for your machine.
Troubleshooting the Implement, Steering and Brake, and the Hydraulic Fan Systems
- Move the machine to a smooth, horizontal location that is away from operating machines and away from personnel.
- Permit only one operator on the machine. Keep all other personnel away from the machine or in the sight of the operator.
- Place the steering control lever in the NEUTRAL position.
- Engage the parking brake.
- On Track-Type Tractors and Track-Type Loaders, lower the attachments to the ground. On Pipelayers, make sure that there is not a load on the hook. Then, fully retract the counterweight.
- Stop the engine.
- Turn the key to the ON position, but do not start the engine.
- Verify that the implement shutoff control is not activated.
- Move the control levers through the full range of travel several times. This action will relieve any pressure that may be present in the implement hydraulic system.
- Loosen the filler cap on the hydraulic tank so that the pressure in the tank is released. The machine may be equipped with a breaker valve. The breaker valve will be located on top of the tank. To release the pressure of the tank, press the button on top of the breaker valve.
- Tighten the filler cap on the hydraulic tank.
- Make sure that the pressure in the entire hydraulic system has been released.
Note: The monitoring system (if equipped) for your machine accesses many values that are useful in troubleshooting the hydraulic system. When the situation is appropriate, use the monitoring system to find a pressure or determine a system problem.
Note: During a diagnosis of the implement hydraulic system, remember that correct oil flow and pressure are necessary for correct operation. Oil pressure is caused by resistance to the flow of oil.
Troubleshooting the Power Train System
Before you troubleshoot, complete the following procedure.
- Move the machine to a smooth, horizontal location that is away from operating machines and away from personnel.
- Permit only one operator on the machine. Keep all other personnel away from the machine or in the sight of the operator.
- Place the steering control lever in the NEUTRAL position.
- Engage the parking brake.
- On Track-Type Tractors and Track-Type Loaders, lower the attachments to the ground. On Pipelayers, make sure that there is not a load on the hook. Then, fully retract the counterweight.
- Stop the engine.
- Turn the key to the ON position, but do not start the engine.
- Verify that the implement shutoff control is not activated.
- Move the control levers through the full range of travel several times. This action will relieve any pressure that may be present in the implement hydraulic system.
- Loosen the filler cap on the hydraulic tank so that the pressure in the tank is released. The machine may be equipped with a breaker valve. The breaker valve will be located on top of the tank. To release the pressure of the tank, press the button on top of the breaker valve.
- Tighten the filler cap on the hydraulic tank.
- Make sure that the pressure in the entire hydraulic system has been released.
Note: The monitoring system (if equipped) for your machine accesses many values that are useful in troubleshooting the power train system. When the situation is appropriate, use the monitoring system to find a pressure or determine a system problem.