F
ORM
N
O. 29813 •
I
MPLEMENT
C
IRCUIT
P
ERFORMANCE
C
HECKS (C & D Series Material Handlers)
S
ERVICE
B
RAKE
V
ALVE
•
SET UP
1.
Install a 10,000 PSI gauge, hose and adapter to the test port on
the service brake system. Make sure you can see the gauge
from the operator’s cab.
2.
With the park brake engaged and the transmission in “Neutral”,
start the material handler.
•
CHECK
1.
With the engine running at low idle (800-900 RPM) and while
depressing the service brake pedal fully, observe the gauge.
2.
The gauge should read:
522, 524, 532C-6, 534C-6, 522D, 524D, 534D-6 .................. 1250 ± 150 PSI
534C-9, 534C-10 ......................................................... 1400 ± 100 PSI
534D-9, 534D-10 ........................................................ 1650 ± 150 PSI
544C-10, 544D-10 ....................................................... 1675 ± 75 PSI
3.
If the gauge does not read correctly, check the following
components:
522, 524, 532C-6, 534C-6, 544C-10 and all D-Series Material Handlers
1.
Brake pedal is misadjusted or bent.
2.
Brake Valve is not functioning correctly.
3.
Brake Flow Divider Valve is not adjusted properly or is
malfunctioning.
4.
Air is trapped in the hydraulic lines.
5.
Leaking hydraulic fittings, tubes and hoses.
6.
Leaking or bypassing Axle Pistons or Calipers.
534C-9 and 534C-10 Material Handlers
1.
Brake pedal is misadjusted or bent.
2.
Brake Valve is not functioning correctly.
3.
Service Brake Relief Valve is malfunctioning.
4.
Service Brake Pump is faulty.
5.
Air is trapped in the hydraulic lines.
6.
Leaking hydraulic fittings, tubes and hoses.
7.
Leaking or bypassing Axle Pistons or Calipers.
•
ADJUSTMENT OF THE BRAKE FLOW DIVIDER VALVE
1.
The Relief Valve is located below the return line elbow. If
adjustment is required, the elbow must be removed to gain
access to the relief valve.
2.
Loosen and remove the top hex-head nut to gain access to
the shims (available in .021” and .005” thickness - install
thinner shims against the spring).
3.
If adjustment is required,
stop the engine
and remove the
elbow from the relief valve.
4.
Open the valve between the hex-head nuts to gain access to
the shims.
5.
Add or remove shims as required and assemble.
D-SERIES SERVICE BRAKE TEST PORT
BRAKE FLOW DIVIDER VALVE
NOTE!
The Service Brake Test Port
may be in one of three
different locations:
1. Under the cab by the
Brake Valve.
2. Along the left-hand frame
rail in the Battery
Compartment.
3. In the Battery
Compartment behind the
differential (see picture).
NOTE!
Only the 522, 524, 532C-6,
534C-6, 522D, 524D and
534D-6 Brake Flow Divider
Valves are adjustable. The
544C-10, 534D-9, 534D-10
and 544D-10 Brake Flow
Divider is not adjustable and
is mounted on the frame rail
along the left-hand side of the
engine. The 534C-9 and
534C-10 do not have a Brake
Flow Divider Valve.
NOTE!
Make sure you install the
elbow before testing.
10.0
Summary of Contents for GRADALL 522
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