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SYSTEM MAINTENANCE

SYSTEM MAINTENANCE

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SYSTEM MAINTENANCE
PREVENTIVE MAINTENANCE
Proper hydraulic system maintenance
procedures will keep the system operating at
peak efficiency and reduce down time caused by
unexpected breakdowns. Many problems can be
eliminated with proper maintenance.
Before beginning extensive diagnostic
procedures on a system that is experiencing
problems, there are a few maintenance problem
areas that should be checked first.
r Check oil level.

Figure 55 — FDM Conquest Dipstick/Fill Location

r Check for clogged or restricted filters.

Figure 54 — FDM Victor Sight Glass

Figure 56 — Check for Clogged or Restricted Filters

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SYSTEM MAINTENANCE
r Check for clogged or dirty suction screens
(FDM Victor).
Figure 57 — Check for Clogged or Dirty Suction Screens
(FDM Victor)
FDM suction line filters, as well as early model
FDM Victor return line filters, have a restriction
gauge mounted on the filter head to indicate filter
restriction. Change the filter if the restriction
gauge indicates 10 inches of vacuum.
The key to a properly maintained hydraulic
system is a well-run preventive maintenance
program. Dirt, small particles and other
contaminants can score valves, seize pumps and
clog filters, suction screens and small orifices.
No matter what precautions are taken, some
contaminants will find their way into the system.
Hydraulic fluids contain additives which help hold
particles and dirt in suspension.
Fluids, however, break down and additives lose
their effectiveness. Changing the fluid and filters,
and cleaning the suction screen at regular
intervals will keep the system clean and help
prevent expensive repairs.
This section explains the recommended intervals
for hydraulic system maintenance.
Daily Checks
r Check the oil in the reservoir. Replenish with
the recommended oil if necessary.
If the chassis is equipped with an extended tag
axle, always check reservoir oil level and add oil
to the system with the tag axle raised.
DO NOT add dirt along with the oil. Thoroughly
clean the area around the filler cap before
removing. Use clean containers to store or
transfer hydraulic oil, and use clean funnels
(preferably with a screen in the neck) when
pouring oil into the reservoir.
r Check for leaks (hoses, lines, fittings,
accumulator, etc.).
Every 150 Hours or 45 Days
r Check tag axle accumulator precharge.
Every 600 Hours or 180 Days
r Change the hydraulic oil.
r Change the drum drive pump filter (FDM
Victor models).
r Change the return, or suction line filter.
r Remove, clean and reinstall the suction
screen (FDM Victor models).
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SYSTEM MAINTENANCE
Changing Hydraulic Oil

Always use clean hydraulic oil.

DO NOT add dirt to the system along with the oil.

Store hydraulic oil in clean, covered containers
and keep in a clean, dry location. Use a clean
container to transport hydraulic oil from the
storage location to the vehicle, and keep it
covered during transport. Use a clean funnel
fitted with a fine mesh screen to filter any
contaminants while pouring the oil from the
container into the reservoir. Always use a clean, Figure 59 — FDM Conquest Reservoir Drain Plug
lint-free rag to clean the funnels, containers, filler
necks, etc. before adding or transferring any fluid. 4. After all the oil has drained, clean the drain
plug and reinstall.
5. Refill the reservoir with the recommended
hydraulic oil.
When changing hydraulic oil in a chassis 6. Clean the reservoir breather.
equipped with an extended tag axle, drain and
refill while the axle is raised.

To change the hydraulic oil: The reservoir fill cap on the FDM Victor is a
breather cap. The reservoir on the FDM
1. Operate the system until it reaches normal Conquest chassis uses a breather assembly
operating temperature. mounted on a bracket behind the main pump.
2. Thoroughly clean the area around the filler
cap (dipstick/fill cap on the FDM Conquest).
Remove the cap.
3. Remove the plug from the bottom of the
reservoir and allow the oil to drain.

Figure 58 — FDM Victor Reservoir Drain Plug

Figure 60 — FDM Conquest Reservoir Breather

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SYSTEM MAINTENANCE
7. To purge any air from the system, start the 3. Reach into the reservoir and unscrew the
engine and rotate the drum for suction screen.
approximately 5 minutes. Also, operate the
chute lift and swing functions, or lower and
raise the extended tag axle.
A 1-7/8-inch angle-headed wrench can be used
Suction Screen — FDM Victor to loosen the suction screen.
Remove and clean the suction screen on FDM
Victor models each time the hydraulic oil is
changed. The suction screen is located inside the
reservoir at the outlet port for the auxiliary pump
suction line. It can be accessed through the
inspection hole on top of the reservoir.
After draining all the oil from the reservoir,
remove, clean and reinstall the suction screen as
follows:
1. Thoroughly clean the top of the reservoir,
paying particular attention to the removable
inspection plate under the filler cap.
2. Remove the six capscrews which secure the
inspection cover to the top of the reservoir.
Remove the cover. Figure 62 — Suction Screen

4. Thoroughly clean the suction screen in a

suitable nonflammable solvent and blow dry
with compressed air.
5. Inspect the screen for signs of damage that
might allow the entry of dirt or other particles
into the system.
6. Reinstall the suction screen, and then
tighten.
7. Reinstall the inspection plate and tighten the
capscrews.

Figure 61 — Remove Inspection Cover

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SYSTEM MAINTENANCE
Hydraulic Oil Filter Change
At each hydraulic oil change interval, change all
the hydraulic oil filters. The FDM Victor model
chassis uses a main pump filter. This filter is
located underneath the chassis, mounted on the
main pump. On earlier model FDM Victor chassis,
the main pump filter is located at the back of the
reservoir.
The FDM Conquest does not have a filter on the
main pump.

Figure 64 — FDM Conquest Suction Line Filter

On the FDM Victor chassis, the chute hydraulic

system includes a return line filter. This filter is
mounted to the front pedestal on the right-hand
side of the chassis. Chassis that are not equipped
with an extended tag axle have a spin-on filter.

Figure 63 — Main Pump Filter, Late Model FDM Victor

Chassis

The FDM Conquest chassis includes a spin-on

main pump suction line filter. This filter is located
at the rear of the chassis, mounted on the left-
hand frame rail.

Figure 65 — FDM Victor Return Line Filter — Spin-on

Late model FDM Victor chassis equipped with an

extended tag axle and a tag axle accumulator
have a canister-type filter.

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SYSTEM MAINTENANCE
5. To purge air from the hydraulic system, start
the engine and rotate the drum in either
the charge or discharge direction for
approximately five minutes. Also, operate
the chute hydraulics.
6. Stop the engine and check for leaks. Repair
as necessary.

CANISTER FILTER CHANGE PROCEDURES

Figure 66 — FDM Victor Return Line Filter, Canister Type

The suction line filter on the FDM Conquest

model, and the return line filter on early model
FDM Victor chassis include a restriction gauge
that measures restriction through the filter to
indicate a clogged or dirty filter. The filter should
be changed when the gauge indicates 10 inches
of vacuum.

SPIN-ON FILTER CHANGE PROCEDURES

When changing the main pump filter, use only

replacement filters that meet the pump
manufacturer’s specifications. Some aftermarket Figure 67 — Canister-Type Filter Exploded View
brands of filters may not withstand the case
pressures that develop inside the pump, and may 1. Filter Head 3. Replaceable Filter
2. Square-cut Seal Element
burst during pump operation. 4. Filter Canister

1. Thoroughly clean the area around the filter 1. Thoroughly clean the area around the filter
and the filter mounting area. canister.

2. Using a suitable filter wrench, remove and 2. Using a suitably sized wrench on the hex
discard the filter in an environmentally safe head at the bottom of the filter canister,
manner. unscrew and remove the canister.

3. Apply a thin film of fresh hydraulic oil to the 3. Remove and discard the filter element in an
sealing gasket of the new filter. environmentally safe manner.

4. Install the new filter and tighten BY HAND 4. Thoroughly clean the filter canister in a
3/4 turn after the gasket contacts the base. suitable, non-flammable solvent and blow
dry with compressed air.

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SYSTEM MAINTENANCE
5. Insert a new filter element into the canister. CHECKING ACCUMULATOR PRECHARGE
PRESSURE
6. Remove the square-cut seal from inside the
filter head where the filter canister seats, Check the accumulator precharge pressure as
and install a new seal. follows:
7. Install the canister to the mounting adapter
and tighten.
8. Start the engine and operate the chute and
tag hydraulics several times to purge the Accurate accumulator precharge pressure can
system air from the system. only be made with the hydraulic system pressure
at 0 psi (tag axle raised and the engine not
9. Stop the engine and check for leaks. Correct running).
as necessary.

Tag Axle Accumulator Maintenance

Regularly inspect the accumulator for leakage. If
external leakage is evident, tighten all
connections. If leakage continues, remove the
accumulator, disassemble and replace any faulty
components. Refer to the manufacturer’s service
literature for repair precautions and disassembly/
reassembly procedures.

Nitrogen is the only gas that is acceptable for use

in the accumulator. Do not use oxygen under any
circumstances. Use of oxygen may result in an Figure 68 — Tag Axle Accumulator
explosion. The accumulator, as well as the
hydraulic system, is pressurized and can be
1. Tag Axle Accumulator 3. Pressure Switch
hazardous if proper precautions are not taken. 2. Accumulator Gas Cap
Always wear safety glasses when servicing the
accumulator or the hydraulic system.
1. Remove the cap from the accumulator gas
valve.
The accumulator is precharged to 1,000 psi, and 2. Install a gauge head and regulator assembly
precharge pressure must be checked once per to the gas valve.
month. If precharge is low, inspect the gas valve
for leakage and then recharge. If there is no gas
in the bladder and hydraulic fluid is evident at the
gas valve, remove the accumulator and replace
the gas bladder. For procedures on replacing the Be sure to use a regulator that is compatible with
gas bladder, consult the accumulator nitrogen. Make sure both regulators (gauge
manufacturer’s service literature. supply and nitrogen source) are fully closed.

Use dry nitrogen only. Use of oxygen may

result in an explosion.

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SYSTEM MAINTENANCE
GENERAL MAINTENANCE AND
REPAIR
Eventually, the time will come when service or
repair of the hydraulic system becomes
necessary. The utmost care must be taken to
prevent dirt and other contaminants from entering
the system. Before performing any service that
involves the removal of any components, or the
disconnecting of any hoses or lines, steam clean
the entire mixer.

When using a steam cleaner to clean the mixer,

Figure 69 — Gauge Head Assembly protect the reservoir filler cap and any breathers
to prevent water from entering the system.
1. Accumulator 3. Gauge Head Assembly
2. Nitrogen Source 4. Gauge Regulator
Regulator
When lines or hoses are disconnected, plug the
ends with plastic caps, or equivalent, to prevent
3. Open the gauge regulator fully and note the dirt from entering the openings. Also remember
reading on the pressure gauge. to seal any open ports or other openings if
pumps, cylinders or other actuators have been
4. If the pressure reading is below 1,500 psi, removed.
open the nitrogen source regulator and
charge the accumulator.
5. When the pressure gauge indicates
1,500 psi, close the nitrogen source
regulator and the gauge regulator.
6. Remove the gauge head assembly and
check for gas leaks at the gas valve.
7. Install the gas cap and tighten to 20–25 lb-ft
(27–34 N•m).

For additional service information and a list of

service tools, contact:

Greer Hydraulics
10711 North Second Street
Figure 70 — Plug Open Lines
Rockford, Illinois 61115

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SYSTEM MAINTENANCE

Figure 71 — Plug Open Ports

When it is necessary to disassemble a

component, thoroughly clean the parts in a
suitable nonflammable solvent. Use care to avoid
damaging the closely fitted, finely machined
parts. After cleaning, rinse parts in solvent and
Figure 72 — Suction Line Shut-Off Valve
dry with compressed air. Apply a thin film of rust-
preventing oil. Store small parts in plastic bags
until needed for reassembly. System Leakage
Use tools that are clean and in good condition. If A comprehensive hydraulic system preventive
a hammer must be used, use only those which maintenance program also includes a thorough
are made of plastic, leather or brass to eliminate inspection for signs of leakage. Leaking hydraulic
the risk of getting any metal chips into the fluid is not only unsightly, but also poses a
system. hazard. The first indication of system leakage is
low oil level in the reservoir. When the oil level is
A clean work area is a must when disassembling found to be low, inspect the entire system before
or reassembling any hydraulic components. putting the vehicle into operation.
Remove any dirt, dust, metal particles, and other
debris from the work area before beginning any INTERNAL LEAKAGE
service procedures. Use clean lint-free rags when A certain amount of internal leakage is designed
handling, wiping, cleaning or drying parts. into hydraulic components to provide lubrication
by allowing a thin film of oil to form between
Suction Line Shut-Off Valve — FDM moving parts. No fluid is lost through internal
Conquest leakage, as the fluid eventually finds its way back
to the reservoir. If internal leakage becomes
excessive, however, system operation will
The FDM Conquest has a suction line shut-off
become sluggish, and an increase in system
valve located in the suction line at the reservoir.
operating temperature will be noticed.
This valve may be closed while performing
certain service procedures, such as changing
hydraulic lines, components, filters, etc. Always
remember to open the line and tie-wrap the valve
handle in the opened position when completing
the service and before starting the vehicle
engine.

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SYSTEM MAINTENANCE
Internal leakage is difficult to detect. In most
instances, excessive internal leakage becomes
evident only if the operator notices sluggish
operation, a loss of control through the control
valves, the cylinders begin to drift or the system
seems to be running excessively hot. Testing the
system with a hydraulic system analyzer will aid
in identifying components which may be leaking
internally. For more detailed information, see the
troubleshooting, testing and adjustment sections.

EXTERNAL LEAKAGE
Every joint, connection, hose or pipe in a
hydraulic system is a potential source of leakage.
External leakage results in a large loss of oil,
making it not only costly, but a potential fire
hazard. Oil spraying against a hot engine or other
components can ignite.
Pinhole leaks, which could develop in hydraulic
hoses or lines, can be extremely dangerous. Not
only does the vapor spraying from a pinhole pose
a fire hazard, it also poses a safety hazard.
Figure 73 — Checking for Pinhole Leaks
When connections are leaking, tighten the fitting
until the leak stops. DO NOT overtighten. Fittings
which cannot be tightened may be stripped,
making replacement necessary. If tightening the
fitting cannot stop the leak, disassemble the
fitting and check for a damaged seal or a cracked
line flare.

Hydraulic fluid escaping under pressure can

penetrate the skin and cause serious injury.
Always relieve pressure from the system
before disconnecting any lines or hoses.
Keep the hand and body away from pinholes
or nozzles which may eject fluid under
pressure.
If hydraulic fluid should penetrate the skin, it
must be surgically removed within a few
hours by a doctor familiar with that type of
injury, otherwise gangrene can result.

Search for a pinhole leak in a system by holding a Figure 74 — Tightening Fittings

piece of cardboard around the suspected area.
NEVER use the hands.
Check flexible hydraulic hoses for leaks. If the
rubber covering on the hose is cracked or split,
check the hose carefully for signs of internal
damage. A damp hose is a sure sign of leakage.

While inspecting the hoses and lines for leakage,

take a look at the clamps which secure the lines
to the frame, and check for improper routing of
the hoses and lines. Loose clamps, or improperly
routed hoses or lines, will allow rubbing and
chafing against adjacent parts, and eventually the
hose will rupture.

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SYSTEM MAINTENANCE
Hydraulic Hose Replacement r Avoid Twisting — Hoses that are twisted,
whether from improper installation or during
Flexible hydraulic hoses will eventually fail. operation, will weaken. When a hose is
Premature failure can be avoided by proper installed, always tighten the fitting onto the
selection and installation of replacement hoses. hose, not the hose onto the fitting.
When selecting replacement hoses, make sure
the hose is capable of withstanding the working
pressure of the system.
One of the leading causes of hydraulic hose
failure is improper routing. Hoses that are too
long or too short, are twisted or have sharp
bends, or hoses that rub against other parts, will
fail.
When installing hydraulic hoses, remember these
basic rules:
r Avoid Taut Hoses — Hoses that are taut
have a tendency to bulge, and will weaken
under pressure.

Figure 77 — Avoid Twisting

r Avoid Rubbing — Use clamps whenever

possible, and as necessary. If hoses are
routed through frame crossmembers or body
panels, route the hose away from sharp
edges, clamp as necessary and use hose
guards. Keep hoses away from moving
parts.

Figure 75 — Avoid Taut Hoses

r Avoid Loops — Large loops are not only

unsightly, but may also become tangled.

Figure 78 — Avoid Rubbing

Figure 76 — Avoid Loops

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SYSTEM MAINTENANCE
r Avoid Excessive Heat — Route hoses
away from the exhaust, radiator, engine or
other components which generate large
amounts of heat.
Figure 79 — Avoid Excessive Heat
r Avoid Sharp Bends — Hoses are flexible,
but sharp bends will weaken the hose. When
hoses are installed, particularly on movable
components, use a little extra hose, if
necessary, to avoid sharp bends. If the hose
is installed on a movable cylinder, actuate
the cylinder to both ends of its travel and
observe that the hose does not bend too
sharply or kink.
Figure 80 — Avoid Sharp Bends
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