Lab 8 sistemas hidrostatico d3 g

PROGRAMA: MANTENIMIENTO DE EQUIPO PESADO CICLO : 5
CURSO: ANALISIS DE SISTEMAS HIDRAULICOS LABORATORIO: 8
ACTIVIDAD:
EVALUACION DEL SISTEMA HIDROSTATICO CON CONTROL
ELECTRONICO DEL TRACTOR D3G
ALUMNOS: APELLIDOS NOMBRES
1
2
3
4
5
Observaciones La actividadse desarrollaengruposde Max 5 integrantes.
Sección
# Grupo
OBJETIVOS:
 Identificaryreconocerloscomponentesdel tractorD3G.
 Reconocerlospuntosde presiónyevaluar lapresión del TractorD3G.
 Análisisydiagnóstico de lasevaluacionesenel tallerde máquinas.
 Investigarconceptosrelacionadosal TractorD3G.
TAREA A REALIZAR EN TRACTOR D3G.
PRIMERO:
Todo grupo deberá realizar el ATS (ANALISIS DE SEGURIDAD DE TRABAJO) de manera
obligatoria antes de realizar cualquier inspección o evaluación en el equipo correspondiente.
SEGUNDO:
Solicitar CHECK LIST y la llave de arranque del equipo correspondiente.
Observación: no arrancar sin la autorización del instructor, la llave solo se solicita para
colocar en la posición de contacto y realizar una inspección al tablero, luces, etc.

LABORATORIO N° 8 Pág. 2 PFR
ANALISIS DE SISTEMAS HIDRAULICOS TECSUP
TERCERO:
Reconocer con el plano hidráulico los componentes del tractor D3G.

FIGURA 1: RECONOCER COMPONENTES

FIGURA 2
PEDAL DECELERADOR
FRENO DE SERVICIO
FIGURA 3
PALANCA DE ACELERADOR MANUAL
PALANCA DE TRANSMISION HIDROSTATICA

FIGURA 4
RECONOCER TOMAS DE PRESION
FIGURA 5
BOMBAS HIDROSTATICAS

FIGURA 6
BOMBA HIDROSTATICA
FIGURA 7
MOTOR HIDROSTATICO

FIGURA 8
MOTOR HIDROSTATICO
FIGURA 9
MOTOR HIDROSTATICO

FIGURA 9
MOTOR HIDROSTATICO
FIGURA 10
CIRCUITO BOMBA / MOTOR

WORK TOOL HYDRAULIC SYSTEM
ILLUSTRATION 1
HYDRAULIC SYSTEM SCHEMATIC
(1) RIPPER CYLINDERS (IF EQUIPPED)
(2) LEFT ANGLE CYLINDER
(3) RIGHT ANGLE CYLINDER
(4) LIFT CYLINDERS
(5) TILT CYLINDER
(6) COOLING CIRCUIT FOR THE BEARINGS OF THE DRIVE MOTORS
(7) OIL COOLER BYPASS MANIFOLD
(8) OIL COOLER
(9) OIL COOLER BYPASS VALVE
(10) LINE RELIEF VALVE
(11) RETURN OIL PASSAGE
(12) MAIN RELIEF VALVE
(13) REMOTE PRESSURE TAP
(14) END SECTION
(15) RIPPER CONTROL VALVE (IF EQUIPPED)
(16) ANGLE CONTROL VALVE
(17) PARALLEL FEEDER PASSAGE
(18) COMMON PASSAGE
(19) LIFT CONTROL VALVE
(20) TILT CONTROL VALVE
(21) GEAR PUMP
WHILE THE ENGINE IS RUNNING, GEAR PUMP (21) DRAWS OIL FROM THE HYDRAULIC TANK. THE OIL
FLOWS FROM GEAR PUMP (21) INTO THE INLET PORT OF THE BANK VALVE. WHEN THE CONTROL
LEVERS ARE IN THE HOLD POSITION, THE OIL FLOWS FROM THE INLET PORT THROUGH PARALLEL
FEEDER PASSAGE (17) THROUGH THE FOLLOWING CONTROL VALVES AND THROUGH COMMON

PASSAGE (18) THROUGH THE FOLLOWING CONTROL VALVES: TILT CONTROL VALVE (20), LIFT
CONTROL VALVE (19), ANGLE CONTROL VALVE (16) AND RIPPER CONTROL VALVE (15) THE OIL
FLOWS FROM THE CONTROL VALVES INTO END SECTION (14). THEN, THE OIL FLOWS BACK THROUGH
RETURN PASSAGES (11) OF THE CONTROL VALVES TO THE OUTLET PORT OF THE BANK VALVE. THEN,
THE OIL FLOWS TO OIL COOLER (8) AND TO OIL COOLER BYPASS MANIFOLD (7).
IF THE OIL TEMPERATURE IS LOW, THE OIL FLOW CAUSES OIL COOLER BYPASS VALVE (9) TO
UNSEAT. WHEN THE BYPASS VALVE OPENS, OIL FLOWS THROUGH THE BYPASS VALVE DIRECTLY TO
THE HYDRAULIC TANK. AS THE OIL TEMPERATURE RISES, THE BYPASS VALVE CLOSES AND THE OIL
FLOWS THROUGH OIL COOLER (8) TO THE HYDRAULIC TANK OR TO THE COOLING CIRCUIT FOR THE
BEARINGS OF THE DRIVE MOTORS. THE OIL COOLER BYPASS VALVE OPENS AT 662 KPA (96 PSI). THE
MOTOR BEARING BYPASS VALVE OPENS AT 65 KPA (9 PSI).
MAIN RELIEF VALVE (12) PROTECTS THE HYDRAULIC PUMP FROM EXCESSIVE PRESSURES. THE MAIN
RELIEF VALVE ALSO PROTECTS THE SYSTEM WHEN THE INDIVIDUAL CIRCUITS REACH FULL TRAVEL.
REFER TO SYSTEMS OPERATION, "RELIEF VALVE (MAIN)" FOR ADDITIONAL INFORMATION ON THE
MAIN RELIEF VALVE.
LINE RELIEF VALVE (10) PROTECTS THE RIPPER CIRCUIT IF THE RIPPER IS PULLED DOWNWARD BY AN
EXTERNAL FORCE. REFER TO SYSTEMS OPERATION, "RELIEF VALVE (LINE)" FOR ADDITIONAL
INFORMATION ON THE LINE RELIEF VALVE.
PISTON PUMP (HYDROSTATIC)
ILLUSTRATION 1

(1) ACTUATOR PISTON
(2) FEEDBACK LEVER
(3) SOLENOID
(4) PASSAGE
(5) SERVO VALVE
(6) PRESSURE OVERRIDE VALVE (POR VALVE)
(7) PORT FOR THE DRIVE LOOP
(8) INPUT SHAFT
(9) SWASHPLATE
(10) PISTON
(11) BARREL
(12) SPRING
(13) PORT PLATE
(14) PORT FOR DRIVE LOOP
(15) CHARGE PUMP
THE TANDEM PUMPS FOR THE HYDROSTATIC DRIVE SYSTEM ARE VARIABLE DISPLACEMENT PISTON
PUMPS. THE TANDEM PUMPS ARE MOUNTED TO THE REAR OF THE ENGINE. THE INPUT SHAFT OF THE
FRONT PUMP ENGAGES A COUPLING THAT IS MOUNTED TO THE FLYWHEEL OF THE ENGINE IN ORDER
TO DRIVE THE TANDEM PUMPS.
WHEN THE ENGINE IS RUNNING, SHAFT (8) AND BARREL (11) ARE ROTATING. THERE ARE NINE
PISTONS (10) IN BARREL (11). PORT PLATE (13) AND SWASHPLATE (9) ARE STATIONARY WITHIN THE
PUMP HOUSING. PORT PLATE (13) AND SWASHPLATE (9) DO NOT ROTATE. SPRING (12) MAINTAINS A
FORCE AGAINST BARREL (11) AND PORT PLATE (13). WHEN BARREL (11) IS ROTATING, EACH PISTON
(10) FOLLOWS THE ANGLE OF SWASHPLATE (9).
IF THE ANGLE OF SWASHPLATE (9) IS ZERO, PISTONS (10) DO NOT MOVE IN AND OUT OF BARREL (11)
AND THERE IS NO OIL FLOW. CHARGE OIL FROM CHARGE PUMP (15) MAINTAINS OIL PRESSURE IN THE
PUMP IN ORDER TO PERFORM THE FOLLOWING TASKS:
KEEP BARREL (11) FULL OF OIL. LUBRICATE THE PUMP COMPONENTS.
PROVIDE MAKEUP OIL FOR INTERNAL LOSS OF OIL THAT IS DUE TO LEAKAGE.
PROVIDE PILOT OIL TO SERVO VALVE (5) IN ORDER TO SHIFT ACTUATOR PISTON (1) AND CHANGE
THE ANGLE OF SWASHPLATE (9).
IN ADDITION TO THE ABOVE TASKS, THE CHARGE PUMP OF THE REAR PISTON PUMP ALSO PROVIDES
OIL IN ORDER TO RELEASE THE PARKING BRAKE.
FOR ADDITIONAL INFORMATION, REFER TO "CHARGE PUMP".
THE POSITION OF SWASHPLATE (9) IS DETERMINED BY ACTUATOR PISTON (1). THE SPEED AND
DIRECTION CONTROL THAT IS LOCATED ON THE LEFT CONSOLE SENDS SIGNALS TO THE ELECTRONIC
CONTROL MODULE (ECM). THE ECM INTERPRETS THE SIGNALS AND THE ECM SENDS PULSE WIDTH
MODULATED SIGNALS TO SOLENOIDS (3) ON EITHER SIDE OF SERVO VALVE (5). AS SERVO VALVE (5)
IS SHIFTED TO EITHER DIRECTION, SIGNAL OIL FROM PASSAGE (4) IS DIRECTED TO THE
CORRESPONDING END OF ACTUATOR PISTON (1) .
AS ACTUATOR PISTON (1) BEGINS TO MOVE, THE ANGLE OF SWASHPLATE (9) BEGINS TO INCREASE.
AS PISTON (10) FOLLOWS SWASHPLATE (9), PISTONS (10) BEGIN TO MOVE IN AND OUT OF BARREL (11).
AS PISTON (10) MOVES OUT OF BARREL (11), OIL IS DRAWN FROM THE PASSAGE OF PORT (7) OF THE
DRIVE LOOP THROUGH PORT PLATE (13). AS PISTON (10) FOLLOWS SWASHPLATE (9) AND THE PISTON
MOVES INTO BARREL (11), THE OIL IS PUSHED THROUGH PORT PLATE (13) INTO THE PASSAGE TO
PORT (14) OF THE DRIVE LOOP. AS THE ANGLE OF SWASHPLATE (9) INCREASES, THE OUTPUT FLOW OF
THE PUMP ALSO INCREASES.

CHARGE PUMP
ILLUSTRATION 2
CHARGE PUMP
(1) PRESSURE OVERRIDE VALVE (POR VALVE)
(2) ORIFICE
(3) PASSAGE
(4) CROSSOVER RELIEF VALVE
(5) OIL FILTER
(6) PASSAGE
(7) PASSAGE
(8) PASSAGE
(9) RING GEAR
(10) PASSAGE
(11) SUPPLY PASSAGE FOR THE CHARGE PUMP
(12) FILTER BYPASS PASSAGE
(13) PASSAGE
(14) RESOLVER
(15) CHARGE RELIEF VALVE
(16) PASSAGE
(17) CROSSOVER RELIEF VALVE
(18) SUPPLY PASSAGE FOR CHARGE OIL FROM THE HYDRAULIC TANK
(19) PINION GEAR
(A) DRIVE LOOP CIRCUIT TO THE PISTON MOTOR
(B) DRIVE LOOP CIRCUIT FROM THE PISTON MOTOR
THE CHARGE PUMPS ARE GEROTOR PUMPS THAT ARE LOCATED ON THE REAR OF EACH PISTON
PUMP. THE CHARGE PUMPS PROVIDE OIL FOR THE HYDROSTATIC DRIVE SYSTEM WHEN YOU START
THE MACHINE. CHARGE OIL IS ALSO USED AS MAKEUP OIL FOR THE DRIVE LOOPS. CHARGE OIL IS
ALSO USED FOR LUBRICATION OF PUMP COMPONENTS AND OF MOTOR COMPONENTS AND FOR
COOLING OF PUMP COMPONENTS AND OF MOTOR COMPONENTS. IF THE MACHINE IS EQUIPPED WITH
A WINCH, THE CHARGE PUMP OF THE FRONT PISTON PUMP ALSO PROVIDES PILOT OIL FOR THE
WINCH CONTROL VALVE.
AS GEAR (19) AND GEAR (9) ROTATE, OIL IS DRAWN FROM SUPPLY PASSAGE (18). THE OIL IS FORCED
OUT OF PASSAGE (16) TO HYDRAULIC OIL FILTER (5). FOR ADDITIONAL INFORMATION REGARDING
THE HYDRAULIC OIL FILTER, REFER TO SYSTEMS OPERATION, "HYDRAULIC OIL FILTER".
THE OIL RETURNS FROM HYDRAULIC OIL FILTER (5) THROUGH PASSAGE (6) TO PASSAGE (8). THE OIL
FLOWS FROM PASSAGE (8) TO SUPPLY PASSAGE (11). THE OIL FLOWS FROM SUPPLY PASSAGE (11)
THROUGH PASSAGE (10) TO ORIFICE (2). THE REDUCED OIL FLOWS FROM ORIFICE (2) THROUGH
PASSAGE (3) TO THE SERVO VALVE OF THE PISTON PUMP.
THE OIL ALSO FLOWS FROM SUPPLY PASSAGE (11) TO THE FOLLOWING COMPONENTS:
CROSSOVER RELIEF VALVE (4)
CHARGE RELIEF VALVE (15)
CROSSOVER RELIEF VALVE (17)
REFER TO THE FOLLOWING TOPICS FOR ADDITIONAL INFORMATION:
SYSTEMS OPERATION, "RELIEF VALVE (CROSSOVER)"
SYSTEMS OPERATION, "RELIEF VALVE (CHARGE PRESSURE)"

PISTON MOTOR (HYDROSTATIC)
ILLUSTRATION 1
PISTON MOTOR
(1) DRIVE SHAFT
(2) MOTOR CASE
(3) PORT
(4) RETAINER
(5) SPEED SENSOR
(6) PISTON
(7) MINIMUM DISPLACEMENT SCREW
(8) HEAD
(9) SOLENOID
(10) PIVOT PIN
(11) RING GEAR
(12) SPRING
(13) BARREL
(14) MAXIMUM DISPLACEMENT SCREW
(15) CONTROL LENS
THE PISTON MOTORS CONVERT HYDRAULIC POWER INTO MECHANICAL POWER. THE PISTON MOTORS
ARE MOUNTED TO THE BRAKES THAT ARE LOCATED ON THE REAR FRAME. THE PISTON MOTORS ARE
INFINITELY VARIABLE AND THE SPEEDS OF THE PISTON PUMPS ARE CONTROLLED BY THE MOTOR
DISPLACEMENT SERVO VALVE IN HEAD (8). FOR ADDITIONAL INFORMATION REGARDING THE
OPERATION OF THE DISPLACEMENT CONTROL VALVE, REFER TO SYSTEMS OPERATION, "SERVO
VALVE (MOTOR DISPLACEMENT)".
THE FOLLOWING COMPONENTS ROTATE WITHIN THE PISTON MOTOR:
DRIVE SHAFT (1)
RETAINER (4)
PISTONS (6)
BARREL (13)
THE FOLLOWING COMPONENTS DO NOT ROTATE WITH THE PISTON MOTOR:
MOTOR CASE (2) HEAD (8) CONTROL LENS (15) SPRING (12) PUSHES BARREL (13) AGAINST CONTROL
LENS (15) IN ORDER TO ENSURE A HIGH PRESSURE SEAL BETWEEN BARREL (13) AND CONTROL LENS
(15) AND BETWEEN CONTROL LENS (15) AND HEAD (8).
CONTROL LENS (15) HAS TWO OIL CONTROL SLOTS. ONE CONTROL SLOT IS FOR THE HIGH PRESSURE
LOOP. THE OTHER CONTROL SLOT IS FOR THE LOW PRESSURE LOOP.

WHEN THE HIGH PRESSURE OIL IS AT THE HIGH PRESSURE LOOP PORT, OIL FROM THE PORT FLOWS
TO THE CONTROL SLOT IN CONTROL LENS (15). OIL IN THE CONTROL SLOT FLOWS INTO THE
CYLINDERS OF BARREL (13) THAT ARE OVER THE CONTROL SLOT.
THE SPHERICAL PISTON HEADS ARE HELD IN THE SOCKETS IN THE DRIVE SHAFT (1) BY RETAINER (4).
SEVEN PISTONS (6) ARE HELD BY BARREL (13). BARREL (13) ROTATES AROUND PIVOT PIN (10) WHICH
IS AT AN ANGLE TO THE AXIS OF DRIVE SHAFT (1). AS A RESULT OF THE BENT AXIS RELATIONSHIP
BETWEEN THE BARREL AND THE SHAFT, THE SEVEN PISTONS MOVE IN AND OUT OF THE CYLINDERS
AS PRESSURE OIL ENTERS THE CYLINDERS AND PRESSURE OIL LEAVES THE CYLINDERS. THIS
MOVEMENT FORCES THE PISTONS, THE BARREL AND THE DRIVE SHAFT TO ROTATE.
WHILE THE PISTONS, THE BARREL AND THE DRIVE SHAFT CONTINUE TO ROTATE, PISTON (6)
REACHES THE FULLY RETRACTED POSITION. AT THE SAME TIME, THE CYLINDER BEGINS TO
OVERLAP THE CONTROL SLOT IN CONTROL LENS (15) ON THE LOW PRESSURE SIDE OF THE LOOP. AT
THIS POINT, THE PISTON STARTS TO MOVE BACK INTO BARREL (13). AS PISTON (6) MOVES BACK INTO
BARREL (13), PISTON (6) PUSHES OIL OUT OF THE CYLINDER THROUGH THE CONTROL SLOT TO THE
LOW PRESSURE SIDE OF THE LOOP.
THE MOTOR BEARINGS RECEIVE OIL FOR LUBRICATION AND FOR COOLING FROM THE HYDRAULIC
OIL COOLER. THE OIL FLOWS FROM THE HYDRAULIC OIL COOLER THROUGH PORT (3) TO THE MOTOR
BEARINGS. THE REMAINDER OF THE INTERNAL COMPONENTS ARE LUBRICATED BY THIS OIL AND BY
NORMAL LEAKAGE FROM PISTONS (6) AND FROM BARREL (13).
SPEED SENSOR (5) SENDS TWO SIGNALS BACK TO THE ECM AS THE TEETH OF RING GEAR (11) ROTATE
PAST SPEED SENSOR (5). THE SIGNALS THAT ARE PRODUCED BY SPEED SENSOR (5) DETERMINE THE
SPEED OF THE MOTOR AND THE DIRECTION OF THE MOTOR.

CUARTO:
En el tallerde maquinael INSTRUCTOR ESPECIALISTA tendráque explicaryrealizarlosiguiente:
1. Realizarundiagramahidráulicodel TractorD3G (usar la pizarra acrílica).
2. Explicarel funcionamientode loscomponentes ylasválvulasdel sistemadel tractorD3G.
3. Analizarygeneraralgunasfallasen el tractor D3G.
4. Medirlas siguientes presiones, (enlamaquina)
MACHINE PREPARATION FOR TROUBLESHOOTING
1. MOVE THE MACHINE TO A SMOOTH HORIZONTAL LOCATION. MOVE AWAY FROM OTHER
MACHINES AND PERSONNEL. LOWER ALL WORK TOOLS TO THE GROUND.
2. PERMIT ONLY ONE OPERATOR ON THE MACHINE. KEEP ALL OTHER PERSONNEL AWAY FROM
THE MACHINE.
3. ENGAGE THE PARKING BRAKE.
4. STOP THE ENGINE.
5. MOVE THE HYDRAULIC CONTROL LEVERS TO ALL POSITIONS SO THAT THE PRESSURE IN THE
HYDRAULIC SYSTEM IS RELEASED.
6. LOOSEN THE FILLER CAP ON THE HYDRAULIC TANK SO THAT THE PRESSURE IN THE TANK IS
RELEASED.
7. TIGHTEN THE FILLER CAP ON THE HYDRAULIC TANK.
8. THE PRESSURE IN THE SYSTEM HAS NOW BEEN RELEASED AND LINES OR COMPONENTS CAN
BE REMOVED.
DURING A DIAGNOSIS OF THE HYDRAULIC SYSTEM, REMEMBER THAT CORRECT OIL FLOW,
TEMPERATURE, AND PRESSURE ARE NECESSARY FOR CORRECT OPERATION. THE OUTPUT OF THE
PUMP (OIL FLOW) INCREASES WITH AN INCREASE IN ENGINE SPEED (RPM) AND DECREASES WHEN
ENGINE SPEED (RPM) IS DECREASED. OIL PRESSURE IS CAUSED BY RESISTANCE TO THE FLOW OF OIL.
USE 1U-5481 PRESSURE GAUGE GROUP, 1U-5482 PRESSURE ADAPTER GROUP, 4C-4890 HYDRAULIC TEST
GROUP, A WATCH, A MAGNET, A THERMOMETER, AND A RULER IN ORDER TO PERFORM THE TESTS.

RELIEF VALVE (MAIN) - TEST AND ADJUST
REFER TO TESTING AND ADJUSTING, "TOOLING PREPARATION" FOR ADDITIONAL INFORMATION FOR
TOOLING ASSEMBLY AND FOR ALTERNATE METHODS OF TESTING.
ILLUSTRATION 1
1. OPEN THE ACCESS DOOR ON THE RIGHT SIDE OF THE MACHINE.
ILLUSTRATION 2

2. CONNECT ONE END OF THE 1777862 HOSE AS TO REMOTE PRESSURE TAP "6".
3. CONNECT THE 8T0860 PRESSURE GAUGE TO THE OTHER END OF THE HOSE.
4. ENTER THE MACHINE.
5. FASTEN THE SEAT BELT.
6. START THE ENGINE AND INCREASE THE ENGINE SPEED TO HIGH IDLE.
7. RAISE THE BLADE OFF THE GROUND.
8. OPERATE THE BLADE CONTROL LEVER IN ORDER TO INCREASE THE HYDRAULIC OIL
TEMPERATURE TO AN OPERATING TEMPERATURA OF 38° TO 65°C (100° TO 149°F).
9. RAISE THE BLADE UNTIL THE LIFT CYLINDERS ARE COMPLETELY RETRACTED.
10. WHILE YOU OBSERVE THE GAUGE, MOVE THE BLADE CONTROL LEVER TO THE RAISE POSITION.
11. RECORD THE PRESSURE OF THE WORK TOOL SYSTEM ONTO THE WORKSHEETS. REFER TO TESTING
AND ADJUSTING,
"WORKSHEET TROUBLESHOOT".
THE PRESSURE SETTING OF THE MAIN RELIEF VALVE SHOULD BE 20600 ± 350 KPA (2990 ± 50 PSI).
NOTE: DO NOT HOLD THE BLADE CONTROL LEVER IN THE RAISE POSITION FOR MORE THAN FIVE
SECONDS WHILE YOU ARE
CHECKING THE RELIEF VALVE SETTING.
12. LOWER THE BLADE TO THE GROUND.
13. STOP THE ENGINE AND EXIT THE MACHINE.
ILLUSTRATION 3

ILLUSTRATION 4
14. IF THE PRESSURE SETTING OF MAIN RELIEF VALVE (2) IS NOT SET TO THE CORRECT
SPECIFICATION, PERFORM THE FOLLOWING ADJUSTMENT PROCEDURE.
ILLUSTRATION 5
A. LOOSEN LOCKNUT (3).
B. TURN ADJUSTING SCREW (4) CLOCKWISE IN ORDER TO INCREASE THE PRESSURE SETTING OR
TURN THE ADJUSTING SCREW
COUNTERCLOCKWISE IN ORDER TO DECREASE THE PRESSURE SETTING.
C. WHILE YOU HOLD THE ADJUSTING SCREW, TIGHTEN THE LOCKNUT TO A TORQUE OF 9.5 ± 1.4 N·M
(84 ± 12 LB IN).
D. REPEAT STEP 4 THROUGH STEP 13.
15. WHEN THE PRESSURE SETTING IS CORRECT, REMOVE THE TEST EQUIPMENT UNLESS ADDITIONAL
TESTS ARE REQUIRED.

WORKSHEETS
Table 1
LIFT CYLINDER DRIFT TEST
Length of the rod at the beginning of the
test
Length of the rod after five
minutes
Specified
Drift
Actual
Drift
Table 2
TILT CYLINDER DRIFT TEST
test
minutes
Specified
Drift
Actual
Drift
Table 3
RIPPER CYLINDER DRIFT TEST
test
minutes
Specified
Drift
Actual
Drift
Table 4
LIFT CYLINDER SPEED TEST
Specification Actual
Table 5
TILT CYLINDER SPEED TEST
Table 6
ANGLE CYLINDER SPEED
TEST
Table 7
RIPPER CYLINDER SPEED
TEST
Table 8
MAIN RELIEF VALVE TEST
Specification Tolerance Actual
Table 9
LINE RELIEF VALVE TEST
Specification Tolerance Actual

INITIAL PRESSURE TESTS
INITIAL TEST
1. IF THE ENGINE IS RUNNING, STOP THE ENGINE.
2. MOVE ALL OF THE HYDRAULIC CONTROLS IN ORDER TO RELIEVE ANY PRESSURE WITHIN THE
HYDRAULIC SYSTEM.
3. EXIT THE MACHINE.
ILLUSTRATION 1
4. TURN SCREWS (2) COUNTERCLOCKWISE AND REMOVE PANEL (1).
ILLUSTRATION 2
5. CONNECT THE COMMUNICATION ADAPTER TO SERVICE TOOL CONNECTOR (3).

ILLUSTRATION 3
ILLUSTRATION 4
7. USE THE FOLLOWING TABLE TO CONNECT THE PROPER HOSES AND GAUGES TO TEST
PANEL (4).

Table 2
GAUGES CONNECTIONS
Port
Number
Port Designation Gauge Assembly (3)
"3" Charge Pressure for the Rear
Pump
8T-0855 Pressure Gauge (0 to 4,000 kPa (0 to
580 psi))
"4" Charge Pressure for the Front
Pump
8T-0855 Pressure Gauge (0 to 4,000 kPa (0 to
580 psi))
"5" Case Drain Pressure 8T-0853 Pressure Gauge (0 to 400 kPa (0 to
58 psi))
"6" Implement System Pressure 8T-0855 Pressure Gauge (0 to 4,000 kPa (0 to
580 psi))
"7" Parking Brake Pressure 8T-0855 Pressure Gauge (0 to 4,000 kPa (0 to
580 psi))
"8" Cooling Loop Pressure 8T-0854 Pressure Gauge (0 to 1,000 kPa (0 to
145 psi))
10. START THE ENGINE AND RUN THE ENGINE AT LOW IDLE.
NOTE: THE RELIEF VALVE SETTING FOR THE WORK TOOL SYSTEM IS 20600 ± 350 KPA (2990 ± 50 PSI).
DO NOT MOVE THE BULLDOZER CONTROL DURING THIS TEST. DO NOT MOVE THE RIPPER CONTROL
DURING THIS TEST. DAMAGE TO THE GAUGE COULD RESULT OR DAMAGE TO THE PRESSURE SENSOR
COULD RESULT. DUE TO THE LOW PRESSURE READINGS THAT ARE TAKEN DURING THIS TEST, THE
8T0855 PRESSURE GAUGE MUST BE INSTALLED.
11. DISENGAGE THE PARKING BRAKE.
12. RECORD THE FOLLOWING READINGS ONTO THE WORKSHEETS: ENGINE SPEED, CHARGE
PRESSURE FOR THE FRONT PUMP, CHARGE PRESSURE FOR THE REAR PUMP, COOLING LOOP
PRESSURE, CASE DRAIN PRESSURE, IMPLEMENT SYSTEM PRESSURE AND PARKING BRAKE
PRESSURE. REFER TO TESTING AND ADJUSTING, "WORKSHEETS TROUBLESHOOT".
A. THE ENGINE SPEED SHOULD BE 850 ± 50 RPM.
B. THE CHARGE PRESSURE FOR THE FRONT PUMP AT PRESSURE TAP "4" SHOULD BE 2375 ± 300 KPA
(340 ± 40 PSI).
C. THE CHARGE PRESSURE FOR THE REAR PUMP AT PRESSURE TAP "3" SHOULD BE 2375 ± 300 KPA (340
± 40 PSI).
D. THE COOLING LOOP PRESSURE AT PRESSURE TAP "8" SHOULD BE 200 ± 100 KPA (29 ± 15 PSI).
E. THE CASE DRAIN PRESSURE AT PRESSURE TAP "5" SHOULD BE 35 ± 20 KPA (5 ± 3 PSI).
F. THE IMPLEMENT SYSTEM PRESSURE AT PRESSURE TAP "6" SHOULD BE 300 ± 200 KPA (44 ± 29 PSI).
NOTE: IF THE MACHINE IS EQUIPPED WITH A GRADING CONTROL SYSTEM, THE IMPLEMENT SYSTEM
PRESSURE AT PRESSURE TAP "6" SHOULD BE 1450 ± 400 KPA (210 ± 60 PSI).
G. THE PARKING BRAKE PRESSURE AT PRESSURE TAP "7" SHOULD BE 2375 ± 300 KPA (340 ± 40 PSI).
13. INCREASE ENGINE SPEED TO 2200 ± 20 RPM.
14. RECORD THE FOLLOWING READINGS ONTO THE WORKSHEETS: ENGINE SPEED, CHARGE
PRESSURE FOR THE FRONT PUMP, CHARGE PRESSURE FOR THE REAR PUMP, COOLING LOOP
PRESSURE, CASE DRAIN PRESSURE, IMPLEMENT SYSTEM PRESSURE AND PARKING BRAKE
PRESSURE.

A. THE CHARGE PRESSURE FOR THE FRONT PUMP AT PRESSURE TAP "4" SHOULD BE 2550 ± 200 KPA
(370 ± 30 PSI).
B. THE CHARGE PRESSURE FOR THE REAR PUMP AT PRESSURE TAP "3" SHOULD BE 2550 ± 200 KPA (370
± 30 PSI).
C. THE COOLING LOOP PRESSURE AT PRESSURE TAP "8" SHOULD BE 550 ± 150 KPA (80 ± 22 PSI).
D. THE CASE DRAIN PRESSURE AT PRESSURE TAP "5" SHOULD BE 90 ± 60 KPA (13 ± 9 PSI).
E. THE IMPLEMENT SYSTEM PRESSURE AT PRESSURE TAP "6" SHOULD BE 1400 ± 400 KPA (205 ± 58 PSI).
NOTE: IF THE MACHINE IS EQUIPPED WITH A GRADING CONTROL SYSTEM, THE IMPLEMENT SYSTEM
PRESSURE AT PRESSURE TAP "6" SHOULD BE 2900 ± 800 KPA (420 ± 120 PSI).
F. THE PARKING BRAKE PRESSURE AT PRESSURE TAP "7" SHOULD BE 2550 ± 200 KPA (370 ± 30 PSI).
15. INCREASE ENGINE SPEED TO HIGH IDLE.
16. RECORD THE ENGINE SPEED ONTO THE WORKSHEETS. THE ENGINE SPEED SHOULD BE 2400 ±
40 RPM.
17. DECREASE ENGINE SPEED TO LOW IDLE.
18. ENGAGE THE PARKING BRAKE.
19. STOP THE ENGINE.IF THE ENGINE SPEED IS NOT WITHIN SPECIFICATIONS, CHECK FOR THE
FOLLOWING AND PERFORM THE INITIAL TEST AGAIN.CHECK THE ADJUSTMENT OF THE
GOVERNOR SPEED SETTING. REFER TO SYSTEMS OPERATION, TESTING AND ADJUSTING,
SENR6457, "GOVERNOR SPEED SETTING".CHECK THE ADJUSTMENT OF THE CABLES TO THE
DECELERATION PEDAL. REFER TO TESTING AND ADJUSTING,"CABLE (DECELERATION PEDAL)
ADJUST".IF THE CHARGE PRESSURE IS NOT WITHIN SPECIFICATIONS, ADJUST THE CHARGE
RELIEF VALVE FOR THAT CIRCUIT AND PERFORM THE INITIAL TEST AGAIN. REFER TO
TESTING AND ADJUSTING, "CHARGE OIL PRESSURE ADJUST".IF THE IMPLEMENT PRESSURE IS
NOT WITHIN SPECIFICATIONS, ADJUST THE IMPLEMENT RELIEF VALVE AND PERFORM THE
INITIAL TEST AGAIN. REFER TO SYSTEMS OPERATION, TESTING AND ADJUSTING, RENR7315,
"RELIEF VALVE (MAIN) TEST AND ADJUST".IF THE COOLING LOOP PRESSURE IS TOO LOW, A
BYPASS VALVE COULD BE IMPROPERLY ASSEMBLED OR THE VALVE IN THE RETURN
MANIFOLD COULD BE STUCK OPEN. IF THE COOLING LOOP PRESSURE IS TOO HIGH, A BYPASS
VALVE COULD BE STUCK IN THE CLOSED POSITION. ALSO, A HYDRAULIC LINE MAY BE
RESTRICTED OR A HYDRAULIC COMPONENT MAY BE RESTRICTED. FIND THE SUSPECT
COMPONENT AND PERFORM THE NECESSARY REPAIRS. THEN, PERFORM THE INITIAL TEST
AGAIN.IF THE CASE PRESSURE IS TOO HIGH, INSPECT THE PUMP FOR A LEAKING LIP SEAL.
CHECK FOR LEAKS ON THE MOTOR CASE. CHECK FOR A FLUSHING VALVE THAT IS STUCK
OPEN. CHECK FOR A RESTRICTED HYDRAULIC LINE OR FOR A RESTRICTED COMPONENT.
ONCE THE SUSPECT COMPONENT IS FOUND, PERFORM THE NECESSA RY REPAIRS AND
PERFORM THE INITIAL TEST AGAIN.
20. REMOVE THE GAUGE ASSEMBLY FROM THE HOSE THAT IS CONNECTED TO TEST PORT "6".
21. PROCEED TO THE NEXT TEST. REFER TO TESTING AND ADJUSTING, "SERVICE BRAKE PEDAL
TEST".

IMPLEMENT STALL TEST
ILLUSTRATION 1
ILLUSTRATION 2

2. CONNECT THE HOSE ASSEMBLY TO TEST PORT "6".
3. CONNECT THE 8T0859 GAUGE ASSEMBLY TO THE OTHER END OF THE HOSE ASSEMBLY.
6. START THE ENGINE AND INCREASE THE ENGINE SPEED TO HIGH IDLE.NOTE THE ENGINE SPEED
AND RECORD THE ENGINE SPEED ONTO THE WORKSHEETS. REFER TO TESTING AND ADJUSTING,
"WORKSHEETS TROUBLESHOOT".
6. RAISE THE BLADE OFF THE GROUND UNTIL THE LIFT CYLINDERS BOTTOM OUT.
7. CONTINUE TO HOLD THE BULLDOZER CONTROL IN THE RAISE POSITION.
NOTE: DO NOT STALL THE BULLDOZER CONTROL FOR MORE THAN 15 SECONDS.
8. CHECK THE ENGINE SPEED AND THE IMPLEMENT PRESSURE. RECORD THESE VALUES ONTO
THE WORKSHEETS.
A. SUBTRACT THE SECOND ENGINE SPEED FROM THE FIRST ENGINE SPEED IN ORDER TO CALCULATE
THE ENGINE LUG.THE ENGINE LUG SHOULD BE 65 ± 40 RPM.
B. IMPLEMENT PRESSURE AT PRESSURE TAP "6" SHOULD BE 20600 ± 350 KPA (2990 ± 50 PSI).
9. LOWER THE BLADE TO THE GROUND AND RETURN THE BULLDOZER CONTROL TO THE HOLD
POSITION.
10. DECREASE ENGINE SPEED TO LOW IDLE.
11. STOP THE ENGINE.
12. MOVE ALL OF THE CONTROLS IN ORDER TO RELIEVE ANY PRESSURE WITHIN THE HYDRAULIC
SYSTEMS.
13. EXIT THE MACHINE. IF THE ENGINE LUG IS NOT WITHIN SPECIFICATIONS, THE ENGINE MAY
BE SUSPECT. DIAGNOSE THE ENGINE AND PERFORM THE IMPLEMENT STALL TEST AGAIN.IF
THE IMPLEMENT PRESSURE IS NOT WITHIN SPECIFICATIONS, ADJUST THE MAIN RELIEF
VALVE OF THE IMPLEMENT SYSTEM. REFER TO SYSTEMS OPERATION, TESTING AND
ADJUSTING, RENR7315, "RELIEF VALVE (MAIN) TESTAND ADJUST".
14. PROCEED TO THE HYDROSTATIC STALL TEST. REFER TO TESTING AND ADJUSTING,
"HYDROSTATIC STALL TEST".
NOTE: DO NOT REMOVE ANY HOSES OR THE COMMUNICATION ADAPTER AT THIS TIME.

HYDROSTATIC STALL TEST
ILLUSTRATION 1
ILLUSTRATION 2
PRESSURE TAP "1"

ILLUSTRATION 3
PRESSURE TAP "2"
2. CONNECT HOSE ASSEMBLIES TO PRESSURE TAP "1" AND TO PRESSURE TAP "2".
3. CONNECT A 8T0861
GAUGE ASSEMBLY TO THE END OF EACH HOSE ASSEMBLY.
6. START THE ENGINE AND RUN THE ENGINE AT LOW IDLE.
7. DEPRESS THE SERVICE BRAKE.
8. SET THE PARKING BRAKE.
ILLUSTRATION 4

9. USE THE ELECTRONIC TECHNICIAN (ET) IN ORDER TO PERFORM THE TRANSMISSION STALL TEST.
SELECT THE "DIAGNOSTICS"OPTION FROM THE ELECTRONIC TECHNICIAN (ET) MENU. THEN, SELECT
"DIAGNOSTIC TESTS" FROM THE DROPDOWN MENU. SELECT THE "TRANSMISSION STALL" FROM THE
SELECTION MENU. FOLLOW THE INSTRUCTIONS THAT ARE PROVIDED.
10. RELEASE THE PARKING BRAKE.
11. ENSURE THAT THE PARKING BRAKE INDICATOR IS ON.
12. RELEASE THE SERVICE BRAKE.
13. SELECT THE LOWEST MAXIMUM GROUND SPEED.
14. INCREASE THE ENGINE SPEED TO HIGH IDLE.
15. NOTE THE ENGINE SPEED AND RECORD THE ENGINE SPEED ONTO THE WORKSHEETS. REFER TO
TESTING AND ADJUSTING,"WORKSHEET TROUBLESHOOT".
16. MOVE THE SPEED AND DIRECTION CONTROL TO THE FORWARD POSITION. THE TRACKS SHOULD
NOT MOVE. NOTE: DO NOT STALL THE DRIVE SYSTEM FOR MORE THAN 15 SECONDS.
17. CHECK THE ENGINE SPEED, THE DRIVE PRESSURE OF THE FRONT PUMP AND THE DRIVE PRESSURE
OF THE REAR PUMP. RECORD THE DATA ONTO THE WORKSHEETS.
A. SUBTRACT THE SECOND ENGINE SPEED FROM THE FIRST ENGINE SPEED IN ORDER TO OBTAIN THE
ENGINE LUG. THE ENGINE LUG SHOULD BE 55 ± 30 RPM.
B. THE DRIVE PRESSURE FOR THE FRONT PUMP AT PRESSURE TAP "2" SHOULD BE (6400 ± 150 PSI).
C. THE DRIVE PRESSURE FOR THE REAR PUMP AT PRESSURE TAP "1" SHOULD BE (6400 ± 150 PSI).
18. RETURN THE SPEED AND DIRECTION CONTROL TO THE HOLD POSITION.
19. MOVE THE SPEED AND DIRECTION CONTROL TO THE REVERSE POSITION.
NOTE: DO NOT STALL THE DRIVE SYSTEM FOR MORE THAN 15 SECONDS.
20. CHECK THE ENGINE SPEED, THE DRIVE PRESSURE OF THE FRONT PUMP AND THE DRIVE PRESSURE
OF THE REAR PUMP.
RECORD THE DATA ONTO THE WORKSHEETS.
A. SUBTRACT THE SECOND ENGINE SPEED FROM THE FIRST ENGINE SPEED IN ORDER TO OBTAIN THE
ENGINE LUG. THE ENGINE LUG SHOULD BE 55 ± 30 RPM.
B. THE DRIVE PRESSURE FOR THE FRONT PUMP AT PRESSURE TAP "2" SHOULD BE (6400 ± 290 PSI).
C. THE DRIVE PRESSURE FOR THE REAR PUMP AT PRESSURE TAP "1" SHOULD BE (6400 ± 290 PSI).
21. RETURN THE SPEED AND DIRECTION CONTROL TO THE HOLD POSITION.
22. SET THE PARKING BRAKE.
23. ENSURE THAT THE PARKING BRAKE INDICATOR IS ON.
24. DECREASE THE ENGINE SPEED TO LOW IDLE.
25. STOP THE ENGINE.
26. MOVE ALL OF THE CONTROLS IN ORDER TO RELIEVE ANY PRESSURE WITHIN THE HYDRAULIC
SYSTEMS.
27. EXIT THE MACHINE.
28. DETERMINE IF THE STALL RPM OR DRIVE PRESSURE IS NOT WITHIN THE CORRECT
SPECIFICATIONS IN BOTH TRAVEL DIRECTIONS. IF THE STALL RPM OR DRIVE PRESSURE IS NOT
CORRECT IN BOTH TRAVEL DIRECTIONS, THE PRESSURE OVERRIDE VALVE (POR VALVE) NEEDS
ADJUSTMENT. REFER TO TESTING AND ADJUSTING, "PRESSURE OVERRIDE VALVE ADJUST". THEN,
PERFORM THE HYDROSTATIC STALL TEST AGAIN. IF THE DRIVE PRESSURES ARE CORRECT BUT THE
STALL RPM IS NOT CORRECT, CHECK THE ENGINE. REFER TO SYSTEMS OPERATION, TESTING AND
ADJUSTING, SENR6457.ADJUST THE CROSSOVER RELIEF VALVE (COR VALVE) IF ONE OF THE
FOLLOWING CONDITIONS EXIST. THE STALL RPM IS WITHIN SPECIFICATIONS IN REVERSE BUT THE
STALL RPM IS NOT WITHIN SPECIFICATIONS IN FORWARD.
THE STALL RPM IS WITHIN SPECIFICATIONS IN FORWARD BUT THE STALL RPM IS NOT WITHIN
SPECIFICATIONS IN REVERSE. THE DRIVE PRESSURE IS WITHIN SPECIFICATIONS IN REVERSE BUT THE
DRIVE PRESSURE IS NOT WITHIN SPECIFICATIONS IN FORWARD.
THE DRIVE PRESSURE IS WITHIN SPECIFICATIONS IN FORWARD BUT THE DRIVE PRESSURE IS NOT
WITHIN SPECIFICATIONS IN REVERSE. EXCHANGE THE TWO CROSSOVER RELIEF VALVES. REFER TO
TESTING AND ADJUSTING, "CROSSOVER RELIEF VALVE ADJUST" FOR THE PROCEDURE TO REMOVE
THE CROSSOVER RELIEF VALVES. PERFORM THE HYDROSTATIC STALL TEST AGAIN AND DETERMINE
IF THE CONDITION FOLLOWS THE CROSSOVER RELIEF VALVE THAT IS SUSPECT. IF THE CROSSOVER
RELIEF VALVE REQUIRES ADJUSTMENT, PERFORM THE NECESSARY ADJUSTMENTS AND PERFORM
THE HYDROSTATIC STALL TEST AGAIN. REFER TO TESTING AND ADJUSTING, "CROSSOVER RELIEF
VALVE ADJUST" FOR THE ADJUSTMENT PROCEDURE.
29. PROCEED TO THE HYDROSTATIC TEST AND THE IMPLEMENT STALL TEST. REFER TO TESTING AND
ADJUSTING, "HYDROSTATIC AND IMPLEMENT STALL TEST".
NOTE: DO NOT DISCONNECT ANY HOSES AT THIS TIME. DO NOT DISCONNECT THE COMMUNICATION
ADAPTER AT THIS TIME.

QUINTO:
En el tallerde máquinas cada grupo deberá Tomar FOTOS de los datos siguientes.
 ComponentesdelTractorD3G.
 Tomar la tomasde presióndel TractorD3G.
SEXTO:
Realizar un VIDEO.
Realizaranunvideode 5-10 minutoscomomáximo,donde explicaránlaevaluaciónque el
instructordesigne acada grupo.
Indicacionessobre el video:
 El videodebe de tenerlosiguiente:
1. Introducciónypresentación del grupo (EPPobligatorioytodosdebenparticiparen
estasección).
Mencionarel camarógrafo,el operador,ylos demásintegrantes.
2. Procedimientode evaluación enequipo(EPPobligatorioy todosdebenparticiparen
estasección).
3. Análisisodiagnosticohidráulico. (NOesobligatoriosusEPPypuede participardel
grupoun soloalumnocomomínimo.
 Si no realizanel videoNOtendránnotade laboratorio
SÉPTIMO:
En el plano hidráulico de Tractor D3G.
 Posición REVERSA
 Posición REEL IN POSITION-POSICION DE ENROLLAR
OCTAVO:
Investigar el cuestionario que el instructor designe luego de culminar el laboratorio 8.

Lab 8 sistemas hidrostatico d3 g

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