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ProCore 648 Hydraulic SystemPage 4 – 17
Testing
The most effective method for isolating problems in the
hydraulic system is by using hydraulic test equipment
such as pressure gauges and flow meters in the circuits
during various operational checks (see Special Tools
section in this Chapter).
CAUTION
Failure to use gauges with recommended pres-
sure (PSI/Bar) rating as listed in test procedures
could result in damage to gauge and possible
personal injury from leaking hot oil.
Before Performing Hydraulic Tests
All obvious areas such as oil supply, filter, binding link-
age, loose fasteners, improper adjustments or improper
operation must be checked before assuming that a hy-
draulic component is the source of the problem being
experienced.
Precautions For Hydraulic Testing
Before disconnecting or performing any work
on the hydraulic system, all pressure in the
system must be relieved. See Relieving Hydrau-
lic System Pressure in the General Information
section of this chapter.
Keep body and hands away from pin hole leaks
or nozzles that eject hydraulic fluid under high
pressure. Use paper or cardboard, not hands, to
search for leaks. Hydraulic fluid escaping under
pressure can have sufficient force to penetrate
skin and cause serious injury. If fluid is injected
into the skin, it must be surgically removed
within a few hours by a doctor familiar with this
type of injury. Gangrene may result from such
an injury.
WARNING
1. Thoroughly clean the machine before disconnecting
or disassembling any hydraulic components. Always
keep in mind the need for cleanliness when working on
hydraulic equipment. Hydraulic system contamination
will cause excessive wear of hydraulic components.
2. Put caps or plugs on any hydraulic lines left open or
exposed during testing or removal of components.
3. The engine must be in good operating condition. Use
a tachometer when making a hydraulic test. Engine
speed will affect the accuracy of hydraulic test results.
4. Because the hydraulic pump is belt driven, check for
proper pump belt adjustment before performing any hy-
draulic test. Check pump speed with a phototac when
performing hydraulic pump flow tests.
5. To prevent damage to tester or components, the inlet
and the outlet hoses must be properly connected, and
not reversed (when using tester with flow and pressure
capabilities).
6. When using hydraulic tester with flow and pressure
capabilities, completely open load valve in hydraulic
tester before starting engine. This will minimize the pos-
sibility of component damage.
7. Install fittings finger tight, far enough to insure that
they are not cross–threaded, before tightening with a
wrench.
8. To prevent hose or tester damage, position the tester
hoses so that moving machine parts will not make con-
tact with them.
9. Check and adjust the oil level in the reservoir after
connecting hydraulic test equipment.
10.Check the control linkage for improper adjustment,
binding or broken parts. Make sure control linkage is
functioning properly before conducting hydraulic tests.
11. All hydraulic tests should be made with the hydraulic
oil at normal operating temperature.
Hydraulic
System