HYDRAULIC TESTING A B C D E F
Contents
1. s below the hydraulic pump Fig 1866 4 Using a 15 16 wrench remove the hydraulic hose from the pump fitting Fig 1864 Fig 1866 PICT 3411 Fig 1864 PICT 3403 7 Plug the test gauge into the test port Fig 1867 5 Thread the test port fitting onto the hydraulic pump and tighten using a 15 16 wrench Fig 1865 Fig 1867 PICT 3412 Fig 1865 PICT 3410 TX525 Service Manual Rev 000 9 13 HYDRAULIC TESTING 8 Start the engine and run at full rpm If adjustment is needed a Remove the RH control panel cover 9 Move the loader arm handle so the tilt cylinder is retracted into the cylinder barrel Hold the handle b Using a 19mm wrench and a 5mm Allen wrench and take the pressure psi reading from the gauge adjust the pressure adjustment screw Fig 1869 Fig 1868 and Fig 1870 e Turn the screw clockwise to increase the pressure e Turn the screw counter clockwise to decrease the pressure Fig 1868 PICT 3413 10 Recommended specification is 2400 50 psi 165 3 4 bar Fig 1869 PICT 4326 11 Release the handle on the loader valve and shut engine off Fig 1870 PICT 4327 9 14 Rev 000 TX525 Service Manual HYDRAULIC TESTING c Ifthe recommended pressure specification can not be reached replace or rebuild the valve d Install the RH control panel cover 12 Check hydraulic fluid and add as needed 13 Start unit and check for leaks 14 Release park brake 15 Shu2. Fig 1877 Note Slight creeping of tracks in the forward or reverse drive with tracks off the ground can be a normal condition Fig 1878 fig 37a A Traction rods B Jam nuts 6 Start the traction unit and set the engine throttle to 1 3 engine throttle speed 7 Ifthe left track moves lengthen or shorten the right traction rod until the track stops moving 8 Ifthe right track moves lengthen or shorten the left traction rod until the track stops moving 9 Tighten the jam nuts 10 Close the rear access cover Fig 1877 PICT 1026 11 Stop the engine and lower the traction unit to the ground 12 Test for proper operation 9 18 Rev 000 TX525 Service Manual Purging Air Procedure Due to the effects air has on efficiency in hydrostatic drive applications it is critical that air is purged from the system These purge procedures should be implemented any time a hydrostatic system or hydraulic line has been opened to facilitate maintenance or any additional oil has been added to the system Air creates inefficiency because it has compression and expansion rates that are higher than that of oil Trapped air in the oil may cause the following symptoms 1 Noisy operation 2 Lack of power or drive after short term operation 3 High oil temperature and excessive expansion of oil Before starting make sure the reservoir is at the proper oil level If it is not fill to the vehicle specifications refer
3. HYDRAULIC TESTING TX525 A 8 B 2 Spool Valve Hose Fitting and Coupler Fig 1838 Introduction Valve Hose Fitting 13 16 16 ORFS 90 amp 45 Valve Hose Fitting Coupler 13 16 16 x 13 16 Due to the many types and manufacturers of test ORFS equipment the test hoses and fittings needed will vary Refer to the connection information at each hydraulic Note ORFS O ring Face Seal test location Test hose specifications must exceed maximum system flow and pressure and must be compatible with the type of fluid in the hydraulic system Flow Testing The five components listed A B C D and E are the primary testing locations for the TX models Fig 1837 Fig 1838 PICT 3521a C LH Drive Hydrostat Pump Pump Fitting 1 14 ORFS 90 Female Fig 1839 Fig 1837 PICT 4310a A 2 Spool loader valve C LH Hydrostat 90 fitting D RH Hydrostat B 2 Spool loader valve E Flush face coupler 45 fitting F Flow meter Fig 1839 DSC 0576a TX525 Service Manual Rev 000 9 1 HYDRAULIC TESTING D RH Drive Hydrostat Pump Test Gauge 3 4 16 37 Female Fig 1842 Pump Fitting 13 16 16 ORFS Straight Female Fig 1840 Fig 1842 DSC 0577a Fig 1840 DSC 0579a Test hoses Length PSI Rated E Couplers 3 91 4cm 5000 Coupler End 7 8 14 UNF 2B O ring Seal Fig 1841 E Flow Tester Fig 1843 Fig 1841 DSC 0580a Fig 1843 PICT 3520a A Pressure gauge C Restr
4. TX525 Service Manual Rev 000 9 11 HYDRAULIC TESTING Loader Circuit Pressure Test This test determines if the loader valve relief is properly set or working correctly The components involved in this test are gear pump hydraulic lines loader valve and test port fitting If the pressure can not be adjusted to meet specification then the loader valve or relief valve will need to be repaired or replaced If the pressure meets specification the loader valve is not the problem The lift or tilt cylinder could be at fault System flow test should be completed to assure proper flow from the pump is obtained 1 Cycle the hydraulic oil until warm 2 Parkthe unit on level ground 3 Setthe park brake 4 Cycle the loader valve to relieve any pressure from the circuit Note There is no hydraulic test port for the drive or loader circuits Test port fittings need to be purchased at a local hydraulic supplier 9 12 Rev 000 Pressure Test 1 Listed below are the Parker Hydraulics part numbers to make the test port for hydraulic pressure testing Fig 1862 Fig 1862 PICT 3409c A 8R6LO S Tee fitting o ring faced B 8 6TRLON S Adaptor C PD36BTL Fitting Pressure Tester Fig 1863 PICT 3523a Fig 1863 TX525 Service Manual HYDRAULIC TESTING 2 Remove the rear access panel 6 Thread the hydraulic hose previously removed onto the test port fitting and tighten using a 15 16 wrench 3 Place absorbent towel
5. ake 4 Cycle the loader valve to relieve any pressure from the circuit Note One hydraulic fitting adaptor needs to be purchased at a local hydraulic supplier Parker part number 8HLO 13 16 16 ORFS x 13 16 16 ORFS 5 Remove the rear access panel 6 Place absorbent towels s below hydraulic pump 7 Using a 15 16 wrench disconnect the hydraulic hose from the pump fitting Fig 1852 PICT 3403 Fig 1852 9 8 Rev 000 8 Thread a flow meter hydraulic hose to the hydraulic pump fitting and tighten with a 15 16 wrench Fig 1853 Fig 1853 PICT 3404 9 Thread the adaptor fitting to the other flow meter hydraulic hose Tighten using a 15 16 wrench on the Ifow meter hose and a 7 8 wrench on the adaptor fitting Fig 1854 PICT 3405 Fig 1854 TX525 Service Manual HYDRAULIC TESTING 10 Thread the hydraulic pump hose previously removed 12 Start the engine and run at full rpm from the pump fitting onto the adaptor on the flow meter hose Tighten the hose using a 15 16 wrench 13 Take the flow reading from the gauge Fig 1857 and 7 8 wrench on the adaptor fitting Fig 1855 Fig 1857 PICT 3408 Fig 1855 PICT 3406 14 With no restriction the flow specification is 5 5 gpm 11 Using a 7 8 wrench tighten both hoses to the flow 20 8 Ipm gauge Fig 1856 15 Slowly turn the restrictor on the flow meter to simulate a hydraulic load on the circuit Note Watch the flow gp
6. ent s may not be functioning correctly Loader Circut Oil is drawn from the hydraulic tank by the front section of the dual gear pump farthest from engine and flows into the loader valve The loader valve relief restricts the hydraulic oil which creates system pressure psi When the loader valve is moved forward or back from neutral position it directs the hydraulic oil to the lift cylinder When the loader valve is moved left and right it directs hydraulic oil to the tilt cylinder TX525 Service Manual HYDRAULIC TESTING Auxiliary Circuit Oil is drawn from the hydraulic tank by the rear section of the dual gear pump closest to the engine and flows into the auxiliary valve The auxiliary valve relief restricts the hydraulic oil which creates system pressure psi The auxiliary valve directs the hydraulic oil to the couplers When the auxiliary lever is moved toward the drive handle the female coupler is pressurized which runs the attachment in forward drive When the auxiliary lever is moved away from drive handle the male coupler is pressurized and the attachment runs in reverse drive Drive Circuit The drive system uses two hydrostatic pumps and two wheel motors The hydrostatic pumps are supplied with low pressure oil returned from the loader valve This oil is filtered and then fed to the hydrostat pumps A 5 psi 0 34 bar check valve on the return hose between the filter and tank is used to ensure a constant supply
7. ference bar noting in which direction the traction unit veers 2 Release the traction control Note When the traction control is stroked fully forward and the unit has severe pull to the left or right a problem with the pump control linkage or a hydraulic component is indicated Fig 1876 fig 38a Left jam nut B Operator handle Note When the traction control is stroked fully and Reference bar a gradual pull happens the tracking adjust ment can be made A very slight tracking error is considered normal O gt o Repeat steps 1 through 4 until the traction unit drives 3 If the traction unit veers left loosen the right jam Straight in the full forward position nut and adjust the tracking set screw on the rear of traction control Fig 1875 Fig 1875 fig 38a A Right jam nut B Operator handle C Reference bar TX525 Service Manual Rev 000 9 17 HYDRAULIC TESTING Traction Control Neutral Adjustment 5 Loosen the jam nuts on the traction rods under the control panel Fig 1878 If the traction unit creeps forward or backward when the traction control is in neutral and the unit is fully warmed up make the neutral adjustment 1 Park the traction unit on a flat surface and lower the loader arm 2 Stop the engine and remove the key 3 Lift support the traction unit so that both tracks are off of the ground Refer to Lifting Unit for Service on page 7 1 4 Open the rear access cover
8. iction valve B Flow gauge 9 2 Rev 000 TX525 Service Manual Hydraulic Testing Hydraulic testing needs to be done in a systematic manner with a basic understanding of the hydraulic system and functions It is recommended that you have the hydraulic schematic for the model and serial number being tested Schematics can be obtained from this service manual or from the Toro Operator Manual or Parts Catalog provided with the unit The TX525 hydraulic system utilizes a dual gear pump to push oil to all the hydraulic components of the unit The TX525 hydraulic systems can be separated into three circuits loader auxiliary and drive These hydraulic systems are open circuit systems that allow oil to flow when the valves and hydrostatic pumps are in neutral position The dual gear pump draws the oil from the hydraulic tank and pushes the oil through the hydraulic lines hoses and valves The pump creates the flow gallons per minute gpm The auxiliary and loader circuits are separate circuits which operate at their own pressure and flow Return line oil from the loader circuit is used to supply oil to the two drive system hydrostatic pumps The recommended flow gpm and pressure psi values for each of the different circuits are located in the specification section of this manual Refer to those values to properly troubleshoot each circuit The tests in the following section need to be done at various locations to determine which compon
9. m as the load increases psi increases the engine rpm and gpm should slowly decrease as load increases psi increases If a sudden drop in flow results the pump should be replaced Do not increase the load psi beyond 2400 50 psi 165 3 4 bar 16 Slowly turn restrictor out until the psi on the gauge reads zero Shut the engine off Fig 1856 PIC T 3407 TX525 Service Manual Rev 000 9 9 HYDRAULIC TESTING Flow Gauge Removal 5 Using a 1516 wrench on the hose and a 7 8 wrench on the adaptor remove the adaptor from the flow meter hose Fig 1859 1 Let the engine and hydraulic oil cool prior to loosen ing any hydraulic fittings 2 Cycle the loader valve handle to relieve any pres sure in the system 3 Place an oil drain pan under the flow meter hydraulic connections 4 Disconnect the hydraulic pump hose from the adaptor fitting using a 7 8 wrench on the adaptor fitting and a 15 16 wrench on the pump hose Fig 1858 Fig 1859 PICT 3405 6 Using a 15 16 wrench disconnect the flow meter hose from the hydraulic pump Fig 1860 Fig 1858 PIC T 3406 Fig 1860 PIC T 3404 9 10 Rev 000 TX525 Service Manual HYDRAULIC TESTING 7 Using a 15 16 wrench connect the hydraulic hose to the hydraulic pump Fig 1861 Fig 1861 PICT 3403 8 Start the engine and cycle the loader valve Inspect for leaks 9 Release the park brake 10 Properly discard all oily towels
10. of oil to the hydrostatic pumps When the drive handle is moved out of the neutral position hydraulic oil is pumped to the wheel motors that drive the tracks Hydrostatic Testing Procedures WARNING Certain procedures require the vehicle engine to be operated and the vehicle to be raised off the ground To prevent possible injury to the servicing technician and or bystanders ensure the vehicle is properly secured WARNING Do not attempt any adjustments with the engine running Use extreme caution while working in or around all vehicle linkage Follow all safety procedures outlined in the Operators Manual The purpose of the flow test is to isolate and determine if there is a problem with either the hydrostatic pump or the wheel motor CAUTION Ensure all fittings and hoses are attached securely This test is being completed on the vehicle s high pressure lines Failure to perform this test properly could result in bodily injury Rev 000 9 3 HYDRAULIC TESTING Auxiliary Circuit Pressure Test Note Make sure the engine RPM is checked and set properly prior to any hydraulic testing This test checks the auxiliary circuit system pressure The components involved in this test are gear pump auxiliary valve auxiliary couplers and hoses A pressure test can be done by using a flow type or a non flow type tester Each tester has its own advantages and disadvantages Flow Type Advantages of a flow type teste
11. r are that pressure and flow can be obtained with this one tester and the hydraulic load can applied slowly to compare the relativity between pressure and flow Restrictor on flow meter can be adjusted prior to activating the hydraulic valve for pressure testing Disadvantages of flow type tester are the expense and the hydraulic load is slowly applied so engine rpm can be overcome prior to reaching recommended system pressure Non Flow Type Advantages of a non flow type tester are they are simpler less expensive and fewer steps to obtain test results The hydraulic load is applied quickly and system pressure can be obtained prior to engine rpm being overcome Disadvantage of non flow type tester is it can only be used for pressure testing 8 This manual will be using a flow type tester for the hydraulic testing A non flow tester can also be used to 9 obtain hydraulic pressure readings 10 9 4 Rev 000 Cycle the hydraulic oil until warm Park the unit on level ground Set the park brake Shut the engine off Cycle the auxiliary valve to relieve any pressure from the circuit Wipe the couplers clean Push the pressure gauge male coupler into the female coupler on the traction unit Fig 1844 Fig 1844 PICT 3401 Start the engine and run at full throttle Activate the auxiliary valve handle and hold View the pressure gauge and take a reading Specification is 3000 psi 206 8 bar TX525 Service Man
12. t engine off TX525 Service Manual Rev 000 9 15 HYDRAULIC TESTING Test Gauge Removal 5 Using a 15 16 wrench remove the test port fitting from the hydraulic pump Fig 1873 1 Letthe engine and hydraulic oil cool prior to loosening any hydraulic fittings 2 Cycle the loader valve handle to relieve any pressure in the system 3 Using a 15 16 wrench disconnect the test gauge from the test port fitting Fig 1871 Fig 1873 PICT 3410 6 Connect the hydraulic hose to the hydraulic pump and tighten with a 15 16 wrench Fig 1874 Fig 1871 PICT 3412 4 Using a 15 16 wrench loosen and remove the hydraulic hose from the test port Fig 1872 Fig 1874 PICT 3403 7 Start the engine cycle the loader valve and inspect for leaks 8 Release the park brake Fig 1872 PICT 3411 9 Properly discard all oily towels 9 16 Rev 000 TX525 Service Manual HYDRAULIC TESTING Traction Control Tracking Adjustment Full 4 If the traction unit veers right loosen the left jam Forward Position nut and adjust the tracking set screw on front of the traction control Fig 1876 If the traction unit does not drive straight when you hold the traction control against the reference bar complete the following procedure Note Whenever an adjustment is made check to make sure the set screws contact stops in the full forward position 1 Drive the traction unit with the traction control against the re
13. tem flow of the auxiliary circuit the flow gpm gauge take reading The components involved in this test are gear pump auxiliary valve auxiliary couplers and hoses When the traction unit tests to the recommendation the attachment may be at fault 10 Flow specification is 14 gpm 53 Ipm 11 Lower engine rpm 12 Shut the engine off Auxiliary Flow Testing 1 Cycle the hydraulic oil until warm Troubleshooting 2 Park the unit on level ground mM If the gpm does not meet the specification then replace 3 Setthe park brake the hydraulic pump 4 Shutthe engine off 5 Cycle the auxiliary valve to relieve any pressure from Flow Meter Removal the circuit 1 Letthe engine and hydraulic oil cool 6 Wipe the couplers clean 2 Cycle the auxiliary valve to relieve any pressure in 7 Plug the flow meter couplers into the TX couplers the circuit Fig 1850 3 Push back on the female coupler locking collars to separate fittings Fig 1851 Fig 1850 PICT 3400a Fig 1851 PICT 3400a 4 Release the park brake TX525 Service Manual Rev 000 9 7 HYDRAULIC TESTING Loader Circuit Flow Testing This test determines the flow output of the gear pump The components involved in this test are hydraulic line and pump If the gear pump flow test meets speci fications then the loader valve or hydraulic line may be at fault 1 Cycle the hydraulic oil until warm 2 Park the unit on level ground 3 Set the park br
14. to the Hydraulic Reservoir Tank Checking the Hydraulic Fluid section on page 3 4 TX525 Service Manual Rev 000 HYDRAULIC TESTING The following procedures should be performed with the vehicle drive tracks off the ground and then repeated under normal operating conditions 1 Lift support the unit so that both tracks are off the ground and free to rotate Refer to Lifting Unit for Service on page 7 1 2 Start the engine and run it at slow idle engine speed for about 20 seconds 3 Push the traction control to the full forward position and hold The tracks should begin to slowly rotate Once the tracks begin to rotate smoothly run for 20 more seconds Pull the traction control to the full reverse position and hold Again the tracks should begin to slowly rotate in reverse Once the tracks begin to rotate smoothly allow to run for 30 more seconds 4 Raise and lower the loader arm 4 complete cycles Raise the loader arm and put it into the float position The loader arm should drop 5 Cycle the dump cylinder 4 complete cycles 6 Stop the engine and check the oil level in the reservoir Add as necessary 7 It may be necessary to repeat steps 2 through 6 until all the air is completely purged from the system 9 19 HYDRAULIC TESTING THIS PAGE INTENTIONALLY LEFT BLANK 9 20 Rev 000 TX525 Service Manual TX525 Service Manual Form No 492 9195
15. ual HYDRAULIC TESTING Removal of Pressure Gauge Prior to adjusting pressure relief flow test should be done If adjustment of the auxiliary pressure relief valve 1 Let the engine and hydraulic oil cool is required continue on If not skip to step 8 a Unlatch and open the rear access panel Fig 1846 2 Cycle the auxiliary valve to relieve any pressure in the circuit 3 Push back on the female coupler locking collar to sparate the fittings Fig 1845 Fig 1846 PICT 1026 Fig 1845 PICT 3402 b Using a 13mm wrench loosen the jam nut on the auxiliary valve pressure adjustment screw Fig 1847 4 Release the park brake Fig 1847 PICT 4315a TX525 Service Manual Rev 000 9 5 HYDRAULIC TESTING c Using a 4mm Allen wrench adjust the pressure adjustment screw Fig 1848 e Turn the screw clockwise to increase the pressure e Turn the screw counter clockwise to decrease the pressure Fig 1848 PICT 4316a 9 6 Rev 000 d After achieving the recommended 3000 psi 206 89 bar tighten the jam nut to lock the pressure adjustment screw in place Fig 1849 Fig 1849 PICT 4315a e If pressure can not be adjusted to the recom mended specification replace or rebuild the valve or valve relief TX525 Service Manual HYDRAULIC TESTING Auxiliary Circuit Flow Test 8 Start the engine and run at full rpm 9 Activate the auxiliary valve handle and hold View This test checks the sys
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