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A: added pneumatic truck pedal height adjustment
Troubleshoot - G5 Brake System
1. BRAKE FADE ON LONG RUNS:
1.1. Change the drive axle oil if it has not been changed per recommendations.
1.2. API TO-4 SAE 30 wt. is the correct oil for the drive axle. Do not use SAE 50 wt. oil
as previously recommended.
Refer to Technical Bulletin Code 7500, SUBJECT:
RECOMMENDED OIL LIST, Rev. 10/20/03
2. CHECK BRAKE & INCHING LINKAGE ADJUSTMENTS:
2.1. Set height of pedals to correct position.
2.2. Make certain the brake valve spool is not extended:
2.2.1. If connecting link (A211483 & A211485) is loose - setting is good.
2.2.2. If connecting link is tight - reposition the spool clevis up or down the brake
valve spool threads so the connecting link is loose.
2.3. Check the inching linkage.
2.3.1. Set inching - brake pedal pick up point.
3. IF BRAKES FEEL SPONGY AND AIR IS IN THE SYSTEM:
3.1. Check all pump suction lines for loose connections and brake lines for leaks -
tighten fittings if loose.
3.2. Check linkage for proper adjustment, see step 1 above.
3.3. Bleed the brakes:
3.3.1. Trucks with separate brake and steering return oil lines bleed as normal.
3.3.2. Trucks with common steering and brake oil return lines, follow bleed
procedure described in Technical Bulletin Code 4200, SUBJECT: NEW
BRAKE VALVE REQUIRES NEW BLEED PROCEDURE, OCT. 23, 2000 to
include cycling of steering wheel.
3.3.3. If bleeding still does not resolve the problem:
3.3.3.1. Check top port of brake valve for common steering/brake oil return
fitting:
3.3.3.1.1. If brake valve has a tee fitting - follow Technical Bulletin Code
4200, SUBJECT: BRAKES DRAGGING WHILE STEERING, AUG. 8,
2001 explaining how to separate the return lines.
3.3.3.1.2. If brake valve has an elbow fitting - no further action is required.
4. TEST BRAKE VALVE:
4.1. Remove outlet tube and plug brake valve - bleed while tightening plug - apply
pedal force:
4.1.1. If it holds pressure and pedal does not drop - assume brake valve is good.
4.1.2. If it does not hold pressure and pedal drops - replace brake valve.
5. CHECK FOR POSSIBLE WHEEL PISTON SEAL LEAKAGE:
5.1. Check axle oil level:
5.1.1. If normal - assume no leaks.
5.1.2. If oil level is high - check for possible piston seal leaks:
5.1.2.1. Remove brake line at one wheel end and install plug into tube -
bleed line while tightening plug - apply pedal force:
5.1.2.2. If the pedal goes down - assume the piston seals on the unplugged
side are bad - replace them.
5.1.2.3. If the pedal holds - assume seals are good and repeat test on the
opposite side.
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