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Workman HD Series Page 9 − 37 Hydraulic System
Service and Repairs
General Precautions for Removing and Installing Hydraulic System Components
Before Repair or Replacement of Components
1. Before removing any parts from the hydraulic sys-
tem, park vehicle on a level surface, engage parking
brake and stop engine. Remove key from the ignition
switch.
2. Clean vehicle before disconnecting, removing or dis-
assembling any hydraulic components. Make sure hy-
draulic components, hoses connections and fittings are
cleaned thoroughly. Always keep in mind the need for
cleanliness when working on hydraulic equipment.
CAUTION
Before performing any service or repair on hy-
draulic system components, relieve system
pressure to avoid injury from pressurized hy-
draulic oil. Stop the engine, remove key from the
ignition switch, rotate the steering wheel in both
directions, lower or support the bed and operate
other hydraulic accessories.
3. Put caps or plugs on any hydraulic lines, hydraulic fit-
tings and components left open or exposed to prevent
hydraulic system contamination.
4. Put labels on disconnected hydraulic lines and hoses
for proper installation after repairs are completed.
5. Note the position of hydraulic fittings (especially el-
bow fittings) on hydraulic components before removal.
Mark parts if necessary to make sure they will be aligned
properly when reinstalling hydraulic hoses and tubes.
After Repair or Replacement of Components
1. Check oil level in the transaxle and add correct oil if
necessary. Drain and refill transaxle and change oil filter
if component failure was severe or system is contami-
nated.
2. Lubricate O−rings and seals with clean hydraulic oil
before installing hydraulic components.
3. Make sure caps or plugs are removed from the hy-
draulic tubes, hydraulic fittings and components before
reconnecting.
4. Use proper tightening methods when installing hy-
draulic hoses and fittings (see Hydraulic Hose and Tube
Installation and Hydraulic Fitting Installation in the Gen-
eral Information section of this chapter).
5. After disconnecting or replacing any hydraulic com-
ponents, operate vehicle functions slowly until air is out
of system.
6. Check for hydraulic oil leaks. Shut off engine and cor-
rect leaks if necessary. Check oil level in transaxle and
add correct oil if necessary.
Check Hydraulic Lines and Hoses
WARNING
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
the skin and cause serious injury. If fluid is in-
jected into the skin, it must be surgically re-
moved within a few hours by a doctor familiar
with this type of injury. Gangrene may result from
such an injury.
Check hydraulic lines and hoses daily for leaks, kinked
lines, loose mounting supports, wear, loose fittings or
general deterioration. Make all necessary repairs before
vehicle operation.
Hydraulic
System