User guide

Section I - Trouble Shooting & Guidelines • Page 8
TROUBLE SHOOTING THE HYDRO-BOOST - Part 2
HYDRO-BOOST BRAKE BOOSTERS PROCEDURE FOR EXCESSIVE BRAKE
PEDAL EFFORT, BRAKE PEDAL CHATTER AND PULSATION AND/OR LEAKS.
BASIC TEST
ENGINE (PUMP) OFF, DEPRESS AND RELEASE BRAKE PEDAL FOUR TIMES TO
DEPLETE ALL HYDRAULIC PRESSURE FROM HYDRO-BOOST.
DEPRESS THE PEDAL AND HOLD WITH LIGHT PRESSURE, THEN START THE ENGINE.
IF POWER SECTION IS OPERATING, THE PEDAL WILL FALL SLIGHTLY AND THEN HOLD.
LESS PRESSURE WILL BE NEEDED TO HOLD PEDAL DOWN TO THIS POSITION,
IF POWER SECTION IS NOT OPERATING - CHECK PUMP
RESERVOIR FLUID LEVEL.
IF POWER SECTION IS OPERATING, PERFORM
IN ORDER:
IF FLUID LEVEL IS OK, CHECK
TENSION AND CONDITION OF
DRIVE BELT.
IF BELT IS LOOSE OR DAMAGED,
TIGHTEN OR REPLACE AS RE-
QUIRED AND REPEAT BASIC
TEST.
IF PUMP SPEED IS SLOW,
ADJUST AND REPEAT BASIC
TEST.
IF PUMP SPEED IS OK, PERFORM
PUMP FLOW AND RELIEF PRES-
SURE TEST.
IF PUMP OUTPUT IS BELOW MINI-
MUM SPECIFICATION, REPLACE
AND REPEAT BASIS TEST.
IF ALL TESTS AND CHECKS ARE
OK, THE BOOSTER IS DEFECTIVE
AND SHOULD BE REPLACED OR
REPAIRED.
IF FLUID LEVEL IS LOW, ADD FLUID
AND REPEAT BASIC TEST PLUS
HYDRAULIC LEAK TEST.
STEERING HYDRAULIC LEAK
TEST
THOUROUGHLY CLEAN THE HYDRO-
BOOST UNIT AND ALL HOSE CONNEC-
TIONS.
START THE PUMP AND RUN AT
IDLE SPEED.
IF THE HOSE FITTINGS DO NOT LEAK,
CHECK THE HYDRO-BOOST FOR
LEAKS, APPLY THE BRAKE PEDAL
WITH APPROXIMATELY 100 POUNDS
EFFORT AND HOLD WHILE CHECK-
ING HYDRO-BOOST HOSE FITTINGS
FOR LEAKS. DO NOT HOLD BRAKE
PEDAL AT 100 POUND EFFORT OR
ABOVE FOR MORE THAN FIVE SEC-
ONDS AT A TIME.
IF THE HYDRO-BOOST LEAKS, IT IS
DEFECTIVE AND SHOULD BE RE-
PLACED OR REPAIRED.
IF NO LEAKS ARE FOUND IN THE HY-
DRO-BOOST OR HOSES, DO NOT
REPAIR OR REPLACE HOSES OR HY-
DRO-BOOST,
IF POWER SECTION IS OPERATING, PERFORM IN
ORDER:
HYDRO-BOOST ACCUMULATOR PRESSURE
RETENTION TEST
RUN PUMP TO MEDIUM SPEED, APPLY BRAKE PEDAL
FORCE TO 100 LBS. FOR NOT MORE THAN FIVE SEC-
ONDS. STOP ENGINE (PUMP).
WAIT 90 SECONDS AND APPLY BRAKES, TWO OR
MORE APPLICATIONS SHOULD BE POWER ASSISTED.
IF APPLICATIONS ARE NOT POWER ASSISTED,
THE HYDRO-BOOST IS DEFECTIVE AND SHOULD
BE REPAIRED OR REPLACED.
IF APPLICATIONS ARE POWER ASSISTED, THE
ACCUMULATOR IS FUNCTIONING PROPERLY;
DO THE HYDRAULIC LEAK TEST.
THOUROUGHLY CLEAN THE HYDRO-BOOST UNIT
AND ALL HOSE CONNECTIONS.
START THE PUMP AND RUN AT IDLE SPEED.
IF THE HOSE FITTINGS DO NOT
LEAK, CHECK THE HYDRO-
BOOST FOR LEAKS, APPLY THE
BRAKE PEDAL WITH APPROXI-
MATELY 100 LBS. EFFORT AND
HOLD WHILE CHECKING HY-
DRO-BOOST HOSE FITTINGS
FOR LEAKS. DO NOT HOLD
BRAKE PEDAL AT 100 LBS. OR
ABOVE FOR MORE THAN FIVE
SECONDS AT A TIME.
IF THE HYDRO-BOOST LEAKS, IT IS DEFECTIVE
AND SHOULD BE REPLACED OR REPAIRED.
IF NO LEAKS ARE FOUND IN THE HYDRO-BOOST OR HOSES, DO NOT REPAIR OR
REPLACE HOSES OR HYDRO-BOOST. DO THE HYDRAULIC LEAK TEST.
BRAKE HYDRAULIC LEAK TEST
DEPRESS AND RELEASE BRAKE PEDAL SEVERAL TIMES, THEN
HOLD PEDAL DEPRESSED WITH MEDIUM PRESSURE, 25-35 LBS.
IF PEDAL DOES NOT FALL AWAY, HYDRAULIC SYSTEM IS NOT LEAKING.
IF PEDAL FALLS AWAY, HYDRAULIC BRAKE SYSTEM IS LEAKING. CHECK FOR EXTERNAL LEAKAGE AT WHEEL CYLINDERS, CALI-
PERS, BRAKE HYDRAULIC LINES AND HOSES. IF THERE IS NO EXTERNAL LEAK, THERE MAY BE AN INTERNAL LEAK (MASTER
CYLINDER CUPS) REPAIR OR REPLACE PARTS NEEDED TO CORRECT LEAK.
APPLY BRAKE PEDAL FORCE TO 100 LBS. AND HOLD
WHILE CHECKING HYDRO-BOOST AND HOSE CON-
NECTIONS FOR LEAKS. DO NOT HOLD BRAKE PEDAL
TO 10 LBS. FORCE FOR MORE THAN FIVE SECONDS
AT A TIME.
SECTION I - TROUBLE SHOOTING & GUIDELINES