TRACTORS 8794-G MAINTAINING HYDRAULIC SYSTEMS Introduction Hydraulics, in a strict sense, is the science of fluid forces. In modern usage, hydraulics means the use of fluid to transfer power or to change a power source into useful force. There are several branches of hydraulics, but the branch that deals with farm equipment centers around enclosed liquids under pressure. Tractor hydraulics center around the use of oil as the system’s fluid. Oil is similar to other liquids in that it cannot be compressed or forced into an area smaller than the area it originally occupied. Since oil is a liquid, it takes the shape of its container. Most tractor hydraulic oil is a light grade of motor oil, This oil contains anti-rust, anti-foam, and anti- wear additives. The basis for today’s application of fluid hydraulics comes from an early French scientist by the name of Pascal. Pascal found that compressed fluid in a rigid container exerted equal pressure along the inside of the container. From this he developed a scientific fact called Pascal’s Law. Pascal’s Law ~ pressure applied to a fluid in a closed container is transmitted with equal pressure throughout the liquid and at right angles to the surface container. ‘THE FUNDAMENTALS OF HYDRAULICS PASCAL'S LAW STATES THAT PRESSURE. STATE THAT LIQUIDS CANNOT BE. EXERTED ON FLUID IN AN ENCLOSED COMPRESSED. ‘CONTAINER IS TRANSMITTED WITH EQUAL FORCE THROUGHOUT THE FLUID AND AT RIGHT ANGLES TO THE CONTAINER WALLS. Most farm tractors are equipped with some type of hydraulic system. Hydraulic controls make the tractor versatile by raising, lowering, and controlling the depth of equipment. In addition, power steering, power brakes, differential lock, remote cylinders, transmissions, and hydraulic seats are all served by the hydraulic system.Fewer REMOTE ‘STEERING| CONTROL Valve” | VALVE accumutator Power | ut (equipment conTRot} = MAIN yDRauuc REMOTE conTRoL CYLINDER STEERING CYLINDER MODERN TRACTORS USE HYDRAULICS TO PERFORM A NUMBER OF FUNCTIONS. IN ADDITION TO CONTROLLING INTEGRAL MOUNTED AND PULLED EQUIPMENT, THE SYSTEM ALSO CONTROLS THE POWER BRAKES, POWER STEERING, AND THE ADJUSTABLE OPERATOR'S SEAT. Hydraulic remote controls are used for operating power shovels, dozer blades, post hole diggers, manure loaders, hay rakes, fork lifts, disk harrows, plows, mowers, sprayers, and many other types of equipment. There are many reasons for hydraulic use. Some of the reasons for hydraulic use are: control is placed at the operator's finge 85 large amounts of force can be exerted with minimal effort; hydraulic lines are more simple and direct than mechanical linkages; fluid force can be routed around corners whereas mechanical power cannot; and hydraulic components are slow to wear out because the oil from the system helps to lubricate the components. Basic Hydraulic System Parts The function of the basic parts of the hydraulic system include: Pump - The major function of the pump is to develop pressure which moves the oil to the cylinder. The most common types of pumps are piston, gear, rotor, and vane. Cylinder and Piston - Hydraulic force is transmitted to the leverage of the equipment or machine by the proper function of these two parts (cylinder and piston). The Fehydraulic power of the oil is converted into mechanical power by the operation of these parts. Oil Reservoir - Oil is stored for the hydraulic system’s use im the reservoir or sump. This storage unit may be located above or below the hydraulic oil pump. il Lines - Oil lines handle the flow of oil from the reservoir to the pump, from the pump to the valves, from the valves to the cylinder, and from the cylinder to the filter where it re-enters the reservoir. Control Valves - These valves regulate pressure and direct the flow of oil to and from the cylinder by opening and closing oil passages. Usually the control valves are operated by hand levers. ‘Check Valves - These valves permit oil to flow in one direction. They hold the oil in the reservoir between cylinder strokes. Types of Hydraulic Systems The two most common types of hydraulic systems found on tractors are the open-center and closed-center systems. The characteristics of each system follow. PUMP OIL RETURNS TO RESERVOIR A Ww NEUTRAL OL FLows ‘THROUGH ConTROU VALVE THE VALVE ‘THE PUM RUNS CONSTANTLY Open-Center System in Neutral CYLINDER ‘THE OPEN-CENTER SYSTEM REQUIRES THE HYDRAULIC PUMP TO RUN ANY ‘TIME THE ENGINE IS OPERATING. Open-center system - The hydraulic oil pump operates any time the engine is running. Oil flows from the reservoir to the pump, through the valve, and back to the reservoir when the system is in neutral. The oil is diverted by a control valve when the system is used for work, Closed-center system - The oil is maintained in the system at full pressure. The pump does not function when the system is in neutral unless the pressure drops below full system pressure. The control valve stops the flow of oil from the pump when the pressure reaches the maximum limit, The closed system has been replacing the open-center system since the demand has increased for power brakes, power steering, and different types of remote cylinders. aBUT ou stave Pressure | PISTON CONTROL VALVE PLACE Closed-Center ystem in Neutral CYLINDER ‘THE CLOSED-CENTER SYSTEM ALLOWS THE HYDRAULIC PUMP TO STOP IF ‘THE SYSTEM IS NOT BEING USED. The closed-center system holds one significant advantage over the open-center system. The main advantage of the closed-center system is that more power is available for many other uses due to the application of a smaller capacity hydraulic pump that operates only when the system is in use. Since the pump is not operating at all times, more horsepower is available for the job the tractor is doing. This is important because modern tractors use a large amount of power to operate the hydraulic system. This makes it very important for the pump to shut off and save engine horsepower whenever the hydraulic system is not being used. Principles of Operation The operator’s control of the hydraulic system is relatively simple since so much power and ability is placed at the operator's fingertips. Hand levers allow the operator to move the control valve and direct the flow of hydraulic oil, resulting in the raising or lowering of tractor implements. The control valve sends fluid from the system to remote cylinders by way of the remote couplings that are located at the rear of the tractor. The remote couplings are the sockets that the cylinder hoses are placed into in order to connect the implement control with the tractor hydraulic system. These remote couplings have a response control that allows the operator to manipulate the rate of speed at which the implement is raised or lowered. The setting can be turned to the left, the turtle symbol on many tractors, or to the right, the rabbit symbol on many tractors. The turtle symbol designates a slower rate of implement control whereas the rabbit designates a faster rate of implement control. RESPONSE CONTROL, REMOTE COUPLINGS, DUST PLUGS ‘THE RESPONSE CONTROL ALLOWS THE OPERATOR TO MATCH THE MACHINERY NEEDS WITH THE TRACTOR'S HYDRAULIC SYSTEM.The rate or speed of implement control is crucial to field time efficiency and also to life expectancy of the equipment. Operator manuals give suggested settings for the response control of the tractor. For example, lighter implements can be raised or lowered more quickly without damage to the implement. However, heavier equipment must be raised and lowered more slowly to prevent damage to the implement and also to insure the safety of the operator. For safe tractor operation and proper implement care, select the response control settings according to manufacture suggestions for the size of tractor and implement being used. ‘The remote couplings serve as the remote cylinder attachment center to the hydraulic system of the tractor. The operator is able to control the attached implements because the implements incorporate the use of a remote cylinder that is attached to the remote couplings flexible hoses. The attached implements are raised, lowered, folded, unfolded, retracted, extended, or turned over with operator control from the seat of the tractor. The operator is able to move the control lever that is attached to the control valve and direct hydraulic fluid into the remote cylinder. The pressure of the hydraulic fluid entering the cylinder causes the change in impiement status. Implement control is possible as the operator moves the control lever. The control lever moves the spool valve. Spool valve movement results in hydraulic fluid being pushed through the spool valve to the remote couplings. Proper hose connection allows the fluid to be sent from the remote couplings into the flexible hoses. The hoses carry the fluid into the remote cylinder. The hydraulic fluid pressure in the remote cylinder turns fluid pressure into mechanical pressure as the implement is controlled by the operator. Hydraulic System Coolers and Connective Lines When hydraulics first became incorporated as part of implement control, the circulation of oil throughout the system served as the means of cooling for the oil. However, in today’s modern, sophisticated tractors, the simple circulation of oil between the remote cylinders, remote couplings, and control valves is far from an adequate way to cool the high pressure hydraulic oil system. The increase in working pressure is associated with increased temperature, so this additional heat must somehow be removed from the hydraulic system. This need for fluid cooling has led to the development and use of oil coolers in many of today’s tractors. ‘coouNs ou our INS {Ht mn y | AIR-TO-OIL COOLERS USE THE ENGINE FAN TO SUPPLY THE COOLING AIR THAT HELPS J) DIsstaTE HYDRAULIC FLUID HEAT. on aR ‘t-To-o1L cooten FAN Oil coolers come in two basic types--the air-to-oil coolers, and the water-to-oil coolers. Air- to-oil coolers use moving air to release oil heat as the oil circulates through coils that are subjected to a blast of ambient temperature air. In most applications, the air-to-oil coolers are located directly in front of the tractor radiator and incorporate the suction of the engine fan to supply the passing surge of air to help dissipate heat through the radiating fins of the cooler. Water-to-oil coolers use some form of water to remove the heat of the hydraulic oil. The water enters the cooler and flows through tubes. The hydraulic oil surrounds these tubes and dissipates heat through the tubes. This heat is absorbed by the water since heat always flows from the hotter to the cooler substance. Generally, engine water is used in water to oil coolers so the heat will be dissipated to the outside air by way of the suction of the engine fan.WATER-TO-OIL COOLERS UTILIZE THE TRACTOR'S ENGINE COOLANT TO HELP DISSIPATE HYDRAULIC FLUID HEAT, OIL, COOLERS ARE LOCATED IN FRONT OF THE ENGINE FAN. Some advantages of hydraulic force is the ability of the fluid to be routed around corners and the simple, direct connections of the hydraulic lines. Many hydraulic connections are made with hoses because: hoses allow flexibility and motion; hoses help absorb vibrations and noises of system use; hoses can withstand system pressure surges; and hoses are easy to route and connect. Hydraulic hoses are comprised of three layers of material, each serving a specific purpose and combining with the other two to provide a long and lasting connection. The innermost layer is called the inner tube and is comprised of a synthetic oil resistant rubber layer. This inner tube is smooth, flexible, heat and corrosion resistant. The outer layer is called the outer cover and is responsible for protecting the reinforcement layers from damage. Most hoses use a rubber outer covering because the rubber aids in reducing vibration, flexibility, and resistance to abrasion and weather degradation, The composition of the middle layers vary according to the type and application of the hose. The pressure rating of the hose dictates whether the middles layers incorporate synthetic fibers, braided wire, or a combination of the two. ‘OUTER COVER REINFORCEMENT avers HYDRAULIC HOSES ARE CONSTRUCTED TO WITHSTAND SYSTEM PRESSURES AND ENDURE berrgel e WORKING CONDITIONS. Hoses are connected to each other with metal couplers, Some metal couplers are designed to be quick couplers, such as those that plug into the remote couplings located at the rear of the tractor. Other connections are used to connect hoses to each other, connect hoses to pipes, or hoses to remote cylinders. o-Remote Cylinders Implement control is possible because the operator is able to direct hydraulic fluid flow into one side of the remote cylinder and bring about a mechanical action through the use of the hydraulic fluid. Remote cylinders are the link that converts the fluid forces into mechanical forces and bring about the desired change in the location, position, or depth of the implement. The principles of remote cylinder operation are quite simple. As the operator moves the control lever, the spool valve is moved in relation to fluid flow restriction and the hydraulic pump is engaged. As the pump is engaged, fluid flows through the opened path created by the relocation of the spool valve, through the remote couplings, and into the remote cylinder. The fluid moves to the remote cylinder via one of the two connective hoses, enters the cylinder on one end, causes the plunger to relocate and push the hydraulic fluid out of the opposite end of the cylinder. The fluid pushed out of the cylinder travels through the other connected hose, to the remote coupling, to another chamber of the control valve and is re-deposited into the system reservoir. THE HYDRAULIC SYSTEM PUMP PUSHES FLUID THROUGH THE SPOOL VALVE, THROUGH THE CONNECTIVE HOSE, AND INTO ONE END OF THE CYLINDER. THE RELOCATION OF THE CYLINDER PLUNGER CAUSES FLUID ON THAT SIDE OF THE PLUNGER TO FLOW BACK INTO THE SYSTEM RESERVOIR. cyunoer No PRESSURE my LOWERING THE EQUIPMENT UTILIZES THE SAME PRINCIPLES AS EQUIPMENT RAISING BUT THE OTHER CONNECTIVE HOSE 18 USED AND FLUID RETURNS TO THE RESERVOIR FROM THE OPPOSITE END OF THE CYLINDER. a.conrRot Fupdste conto. bay COUPLERS. A SIMPLIFIED ILLUSTRATION OF EQUIPMENT DEPTH CONTROL SHOWING ‘THE FLOW DIRECTION AND RESULTING MECHANICAL CHANGE THROUGH FLUID FORCE, It is this simple relocation of fluid that performs the job of raising, lowering, adjusting, extending, retracting, or turning the trailing equipment whenever the operator sees the need. System Mainten: ce The hydraulic system is another system of the tractor and must be maintained is much the same manner as the engine lubrication system. The hydraulic system must receive filter changes, fluid level checks, fluid additions, and proper operating procedures. The most important points for a tractor operator to be aware of in mi taining the hydraulic system are: proper operation of the system is a requirement, and oil that is clean and of the proper grade is necessary to help the system to function properly and trouble free. Perhaps the most simple maintenance task is the fluid level check. Most tractors use a dipstick, similar to the engine oil dipstick but much longer, to allow hydraulic reservi level monitoring. This dipstick is usually located in the rear of the tractor above the remote couplings or under the operator seat. Regardless of location, the dipstick should be used to check the fluid level in the reservoir every time the tractor is used,To check the fluid level: pull the dipstick out; wipe it clean with a lint free cloth; reinsert the dipstick; and pull it out once again and check the oil mark against the marks on the dipstick. (The hydraulic oil dipstick has marks similar to the engine oil dipstick - add, safe). The hydraulic system on today’s tractors is a very vital component of the tractor. Hydraulic systems control many of the tractor functions and is solely responsible for implement control, These reasons support the importance of keeping the system maintained and functioning. Hydraulic systems may be damaged by the following causes: dirty oil, use of improper grade or quality of oil in system, lack of the proper level oil in the reservoir, loose intake lines, dirty or clogged oil filters, too much pressure in the system, too much heat in the system, or operating the system too fast. Many of these problems can be limited with awareness of potential problems and a conscious attempt to minimize system contamination. Store new oil in a clean and dry location. Use only clean funnels and containers which have a fine mesh screen when filling the system reservoir. Thoroughly wipe all contaminated areas before removing components of the hydraulic system. Be sure to use dust protectors to keep dirt and foreign matter from entering the remote couplings whenever hoses are not installed.‘TYPES OF HYDRAULIC-COUPLING DUST PROTECTORS (A) SCREW-TYPE CAP (B) RUBBER PLUGS HELD BY GRIPPING ACTION THAT RELEASES WHEN TRACTOR END OF HOSE IS PULLED IN ‘THE DIRECTION OF THE CONNECTION. The system should be monitored for internal and external fluid leaks. Internal leaks are noticeable by sluggish reactions. External leaks can be seen as oil deposits on the machinery. CAUTION: NEVER PLACE A HAND OR FINGER OVER A PINHOLE IN A HYDRAULIC HOSE SINCE THE FLUID IS UNDER PRESSURE. HYDRAULIC OIL MAY ACTUALLY GET PUSHED IN THROUGH YOUR SKIN. Refer to the operator's manual for suggested maintenance schedules, including filter change, system flushing, and oil change. Refer to operator's manual for proper procedure in bleeding air from system whenever the system is refilled with oil Prevent the operational hazard of oil overheating. This can be done by keeping the oil at the proper level in the reservoir, keeping the lines and cooler free of dirt or foreign matter, and keeping the relief valves in proper working condition. ‘System Trouble-Shooting Trouble-shooting of the hydraulic systems of today’s tractors can prove to be an endless task. Modern tractors incorporate such finely metered valves and pressure regulated systems that simple line replacement can become difficult. The operator’s manual can offer some insight into common system maintenance and some tips to system failure. In addition to the operator's manual, the following will suggest a reference point to begin system failure diagnosis. HOWEVER, CONSULT A QUALIFIED SERVICEMAN IF YOU DO NOT KNOW WHAT THE PROBLEM IS. SERIOUS PERSONAL INJURY MAY RESULT IF UNQUALIFIED PERSONS TRY TO SERVICE THE HIGH PRESSURE COMPONENTS OF THE SYSTEM. The following chart is courtesy of AAVIM "Hydraulics, Care and Operation, Volume I.” -10-TROUBLE SHOOTING GUIDE Complaint Observation or Symptom Likely Source of Trouble Probable Cause ‘Corrective Action Required Pump shat or chive | Out of alignment Replace pump shaft or Nothing broken dive. Mappen’—pump does ae Pump tae Faulty pump, oF operator] Repair oF replace [eed pump, Revew Sperating procedures. Repair or apace Purp worn out Norma wear. Improper | pump. Fatow proper fencing. Operator | Eevee procedures atu heck system fod capi. [Control vane broken, | Too tat, ut of ‘heck, clean and/or Pump operates, bt | stuck or improper” | algnment replace conta vate. Piston Goes not move. | adjusted System doesnot Wrong operating | Controls not operated | Review operating work procedures propery procedures No noise frm Fluid iow sternal lake. "Ado fuid. Check for bobby tee and reper. Purp operates, but piston does not move, it roves too slowly. or itis jerky and erratic Ai in system (Foamy fic), ‘ir leak or ater working fon system, Repair, and bleed air from system, Pump speed too stow. Engine speed too slow: (Check operating speed, and correct, Wirong replacement Pump displacement too low Replace with correct pump installed pump. Pump screen restricted, | Need servicing Service system. Internal uid Yeakes. | Normal wear or broken | Repair, parts. Seal failure. ‘system does not work Noise from reliet valve(s). Pump operates but piston does not move, or ‘roves to slo. Friter clogged. [cold Temperature ‘Allow to warm up. Fiuid cold Needs servicing Service system, Equipment binding. Mechanica intererence. Linkage warped. Tie ‘downs intact (Check and adjust Load t00 heavy. Overioaced ‘Check load capacity ne‘TROUBLE SHOOTING GUIDE (Continued) Observation or Symptom Likely Source of Trouble Probable Cause ‘Spring broken, valve oF Reliet vate, stat damaged, or out of | Check and repair ‘system does not ee eee work. Pump operates but piston doesnot move, oF] i vt on Nose trom rener | NES 10 showy logged ontice. z lean valve(s). Valves sticking. ust, wear, nicks. (Check and repaie System works, Hose oF tne Connections reversed. | Attach lines correctly. but in wrong Oyler retracts when it | Connestions Girecton should extend, extends No noise from | When it should retract. | Control valves not | Wrong operating Review operating rebel valet). operated propery. | procedure procedures Oritice valve Oritice worn, Repair or replace ‘system operates 100 fast ‘oyinder extends andor retracts t00 fast Flow control valve. Flow control valve spring broken or out of adjustment Repair or replace, No noise trom incorrect replacement | yy, \ncorrest replace rong choice of Replace wih correct rele valves), pump, Too m Teotement pone. | poo ump speed too fast. | Engines ast. | Reduce engine speed to Pump speed too fast. | Engine speed too fast. | corectspecicalons. Contra ever not Worn or damaged —_| Repair or replace centering. linkage or springs. | inkage a Worn seas, bad gaskets | Look for leaks. Repair or aoa cor lose fitings replace Wil not support ‘he bed Load drops when controt| Internal eak. Circuit No noise trom | 8 neutral reli valve leaking. | Wom parts. Repair or replace. rele! valves). Control vate worn. | Worn pers. Repair or replace. a Scored eyiner oF piston] repair or replace — roof faulty seals | PePRw © ren Check hid ui ‘Wrong type of id Overheating le kid specications. No noise from | 30M operation vol vate), Dirty tia Fiuid needs changing. | Change tu -12-TROUBLE SHOOTING GUIDE (Continued) ca no seaais ccame] Carctve Ron ‘Observation or Symptom Lk Source of Trouble] Probable cing a ing fan not working | Bt sping or fon shat | Chek on operatons Cold . * | broken. |and repair. Overeating | Burned oder Inteat damage. | Worn pats. Repait er repace. No noise tim | Chred paint. reel ve). Fi oa. Cooler cloese Fin ogee. clean Fl eve ow Extra! ea, internat | Lok er eks and ten rep Operator holds contol [pevew operation retest | Slow operation. pertinence. |v m ower peton | Rey toon Noise trom eet | Burned odor. : Charred paint. Load too heavy. Over loading. | Check load capacity. ‘Check operating speeds. Engine or ump | ENB speed to aor Check sumo opernting ootest, | Pumpand engine "| Seren and Overheating repace Noise from relief | Fluid foamy. Relief valve out of Needs adjusting. [Check and adjust. valets) adjustment Iterat etton. | in cen ciean rm canines | Moston besoge, Sram cotinues | Noite inst ses | Pump reel ave. [Presi seting co | aust. and bent rods. high. Foamy one speciation. | Replace ti Fite. ees seri. | Serice System. Pump whines, ri rid ow _ Ney pmo Resticionm pump | Or or kinked or | Clean repair or Sot isd opus Mechanical nie. Pump drive. Normal wear, or out of | Repair. alignment. -13-References: “Hydraulics, Care and Operation, Volume 1," American Association for Vocational Instructional Material, Athens, Georgia. "Fundamentals of Machine Operation - Tractors,” Deere and Company, Moline, Illinois. "Fundamentals of Service - Hydraulics," Deere and Company, Moline, Illinois. SUGGESTED STUDENT ACTIVITIES TRUE OR FALSE: Place a T or F in the blank. |. Since oil is a liquid, it can be compressed. ——__.2._ One reason for hydraulic use is the operator has the ability to control large amounts of work from his fingertips. 3. In the closed center system the hydraulic fluid is circulated through the system and the hydraulic pump is running all the time the engine is running. 4, Hydraulic forces help transmit fluid forces into mechanical forces. 5. The oil cooler is incorporated into the hydraulic system to increase the fluid holding capacity of the system. FILL IN THE BLANK: Complete the following statements. 1. Hydraulic systems add to a tractor’s versatility by . sand the depth of equipment. 2. The fundamentals of hydraulics state that liquids cannot be 3. The major function of the hydraulic pump is to develop__—=—— sto move the oil to the remote cylinder. 4. The permit the hydraulic only one direction. to flow in 5. The two most common types of hydraulic systems found on tractors are the system and the system. -14-SHORT ANSWER: Answer cach of the following questions in the space provided. 1, List several of the functions or operations that hydraulic systems serve on modern day tractors. 2. Explain the difference between the open-center and closed-center hydraulic system. 3. List the basic parts of the hydraulic system and briefly describe the functions of each part. 1s.4. Name the two types of hydraulic oil coolers and discuss how each helps to reduce oil temperature, Discuss the principles of remote cylinder operation. List the causes of hydraulic system damage and list any suggestions that may help reduce system damage. ALL RIGHTS RESERVED Reproduction prohibited without written permission. Instructional Materials Service Texas A&M University FE. Box 2588 College Station, Texas 77843-2588 N1989 ae