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PROGRAMA: MANTENIMIENTO DE EQUIPO PESADO CICLO : 5

CURSO: ANALISIS DE SISTEMAS HIDRAULICOS LABORATORIO: 1

ACTIVIDAD: EVALUACION DEL SISTEMA DE IMPLEMENTOS DEL CARGADOR FRONTAL 924G

ALUMNOS: APELLIDOS NOMBRES

Seccin
Observaciones La actividad se desarrolla en grupos de Max 5 integrantes.
# Grupo

OBJETIVOS:
Identificar y reconocer los componentes del sistema de Implementos del Cargador
frontal 924G.
Reconocer los puntos de presin y evaluar la presin del sistema de implementos del
Cargador Frontal 924 G.
Anlisis y diagnstico de las evaluaciones tomada en el taller de mquinas.
Investigar conceptos relacionados al sistema de implementos del Cargador Frontal 924G.

TAREAS A REALIZAR EN EL CARGADOR FRONTAL 924G:

Parte I Evaluacin del sistema de implementos del Cargador Frontal 924G

Primero: Todo grupo deber realizar el ATS (ANALISIS DE SEGURIDAD DE TRABAJO) de


manera obligatoria antes de realizar cualquier inspeccin o evaluacin en el equipo
correspondiente.

Segundo: solicitar CHECK LIST y la llave de arranque del equipo correspondiente.


Observacin: no arrancar si la autorizacin del instructor, la llave solo se solicita para
colocar en la posicin de contacto y realizar una inspeccin al tablero, luces, etc.
LABORATORIO N 1 Pg. 2 PFR

Tercero: Reconocer con el plano hidrulico los componentes del sistema de implementos del
cargador frontal 924G.

THE HYDRAULICA TANK

IMPLEMENT SYSTEM
THE IMPLEMENT SYSTEM IS COMPOSED OF THE FOLLOWING COMPONENTS:

ACCUMULATOR FOR THE RIDE CONTROL,


RIDE CONTROL SOLENOID VALVE,
TILT CYLINDER,
LIFT CYLINDERS,
BANK VALVE,
PILOT VALVE,
ACCUMULATOR FOR PILOT OIL,
PRESSURE REDUCING VALVE,
SCREEN,
SHUTOFF VALVE FOR THE PILOT CONTROL VALVES,
PISTON PUMP AND
HYDRAULIC TANK.

ANALISIS DE SISTEMAS HIDRAULICOS TECSUP


LABORATORIO N 1 Pg. 3 PFR

ILLUSTRATION 4
LEFT SIDE OF THE MACHINE
(3) TILT CYLINDER. (17) HYDRAULIC TANK. (16) PISTON PUMP. (2) RIDE CONTROL SOLENOID VALVE. (1)
ACCUMULATOR FOR THE RIDE CONTROL. (4) LIFT CYLINDERS.
ACCESS TO THE PISTON PUMP (16) IS ACHIEVED BY REMOVING PANELS UNDER THE PLATFORM. THE
LIFT CYLINDERS (4) ARE MOUNTED UNDER THE LIFT ARMS IN THE FRONT FRAME. THE RIDE
CONTROL SOLENOID VALVE (2) IS MOUNTED ON THE LEFT SIDE OFTHE MACHINE.

ILLUSTRATION 5
RIGHT SIDE VIEW OF THE MACHINE
(12) ACCUMULATOR FOR THE PILOT VALVES. (8) PILOT VALVES. (11) SHUTOFF FOR THE PILOT
VALVES. (14) MANIFOLD. (7) BANK VALVES. (10) SCREEN.
(15) BACK PRESSURE VALVE. (13) PRESSURE REDUCING VALVE.
ACCESS TO THE ACCUMULATOR (12) IS ACHIEVED BY OPENING THE DOOR TO THE ENGINE
COMPARTMENT. ACCESS TO THE BANK VALVES (7) IS ACHIEVED BY REMOVING AN ACCESS PANEL.
ACCESS TO THE PRESSURE REDUCING VALVE (13) IS ACHIEVED BY REMOVING THE ACCESS PANELS
UNDER THE PLATFORM. THE MANIFOLD (14) IS MOUNTED IN THE CENTER OF THE MACHINE ON THE
PISTON PUMP.

ANALISIS DE SISTEMAS HIDRAULICOS TECSUP


LABORATORIO N 1 Pg. 4 PFR

ILLUSTRATION 6
CONTROL LEVERS
(11) SHUTOFF FOR THE PILOT VALVE. (18) LIFT LEVER AND TILT LEVER. (19) AUXILIARY FOR THE
THIRD FUNCTION LEVER. (20) AUXILIARY FOR THE FOURTH
FUNCTION CONTROL.
THE WORK TOOL HYDRAULIC SYSTEM FEATURES CONTROL VALVES THAT ARE PILOT OPERATED.
THE CONTROL VALVES ARE CLOSED CENTER VALVES. THE SYSTEM IS LOAD SENSING WITH A
VARIABLE DISPLACEMENT PUMP.
THE WORK TOOL HYDRAULIC SYSTEM IS LOAD SENSING AND THE SYSTEM HAS PRESSURE
COMPENSATION. THE CONTROL VALVES ARE PARALLEL TO EACH OTHER.

HYDRAULIC OIL FILTER

ILLUSTRATION 1
OPEN THE ENGINE ACCESS DOOR IN ORDER TO GAIN ACCESS TO THE HYDRAULIC OIL FILTER.

ANALISIS DE SISTEMAS HIDRAULICOS TECSUP


LABORATORIO N 1 Pg. 5 PFR

ILLUSTRATION 2
OIL FILTER COMPONENTS
(1) INLET LINE FROM THE OIL COOLER. (2) SCHEDULED OIL SAMPLING PORT. (3) HOUSING ASSEMBLY.
(4) LINE TO THE FAN MOTOR. (5) FILTER ELEMENT.

ILLUSTRATION 3
(6) OUTLET PASSAGE RETURNS TO THE TANK.

ANALISIS DE SISTEMAS HIDRAULICOS TECSUP


LABORATORIO N 1 Pg. 6 PFR

PISTON PUMP (IMPLEMENT PILOT, STEERING)

ILLUSTRATION 1

REMOVE THE PANELS IN ORDER TO GAIN ACCESS TO THE PISTON PUMPS.


THE PUMPS ARE LOCATED ON THE LEFT SIDE OF THE MACHINE.

ILLUSTRATION 2

(A)THE PISTON PUMP SUPPLIES OIL TO THE PILOT SYSTEM AND THE STEERING SYSTEM. (B) THE PISTON
PUMP SUPPLIES OIL TO THE WORK TOOLS.

ANALISIS DE SISTEMAS HIDRAULICOS TECSUP


LABORATORIO N 1 Pg. 7 PFR

ILLUSTRATION 3
(1) PISTON PUMP FOR THE PILOT SYSTEM AND THE STEERING SYSTEM
(2) MARGIN SPRING
(3) PRESSURE AND FLOW COMPENSATOR VALVE
(4) PASSAGE FROM THE BANK VALVES FOR THE LOAD SENSING SIGNAL
(5) FLOW COMPENSATOR SPOOL
(6) ACTUATOR PISTON
(7) BIAS SPRING
(8) DRIVE SHAFT
(9) SWASHPLATE
(10) CYLINDER BARREL ASSEMBLY
(11) PUMP INLET
(12) PUMP OUTLET
(13) PISTON PUMP FOR THE WORK TOOLS
(LL) TANK OIL

THE PISTON PUMP FOR THE WORK TOOLS (13) AND THE PISTON PUMP FOR THE PILOT SYSTEM AND
THE STEERING SYSTEM (1) HAVE THE FOLLOWING CHARACTERISTICS: VARIABLE DISPLACEMENT,
LOAD SENSING, COMPENSATION FOR PRESSURE AND COMPENSATION FOR FLOW. THESE PISTON TYPE
PUMPS HAVE VARIABLE FLOW AND PRESSURE. THE FLOW AND PRESSURE ARE DEPENDENT ON THE
SYSTEM DEMANDS THAT ARE SENSED BY PRESSURE AND FLOW COMPENSATOR VALVES (3). THE
PRESSURE AND FLOW COMPENSATOR VALVE FOR THE PISTON PUMP FOR THE WORK TOOLS (13) IS
NOT SHOWN.

WHEN THE ENGINE IS OFF, THERE IS NO LOAD SENSING SIGNAL (4) TO PRESSURE AND FLOW
COMPENSATOR VALVE (3). MARGIN SPRING (2) PUSHES FLOW COMPENSATOR SPOOL (5) COMPLETELY
TO THE RIGHT. ANY PRESSURE THAT IS BEHIND ACTUATOR PISTON (6) IS VENTED TO THE CASE
DRAIN ACROSS FLOW COMPENSATOR SPOOL (5) .WHEN THERE IS NO PRESSURE BEHIND ACTUATOR
PISTON (6), BIAS SPRING (7) IS ABLE TO HOLD SWASHPLATE (9) AT THE
MAXIMUM ANGLE. WHEN THE ENGINE IS STARTED, DRIVE SHAFT (8) STARTS TO ROTATE. OIL FLOWS
INTO THE PISTON BORE FROM PUMP INLET (11). OIL IS FORCED OUT OF PUMP OUTLET (12) AND INTO
THE SYSTEM AS CYLINDER BARREL ASSEMBLY (10) ROTATES.

ANALISIS DE SISTEMAS HIDRAULICOS TECSUP


LABORATORIO N 1 Pg. 8 PFR

PILOT HYDRAULIC SYSTEM


OIL FOR THE PILOT CIRCUIT COMES FROM THE STEERING PUMP SECTION. THE OIL FLOWS FROM THE
PUMP. THE OIL FLOWS THROUGH A PRESSURE REDUCING VALVE. THE OIL THEN FLOWS THROUGH A
SCREEN IN THE PILOT CONTROL VALVES. THE RETURN OIL FLOWS BACK TO THE HYDRAULIC OIL
TANK.

ILLUSTRATION 1
COMPONENT LOCATIONS
(1) TEST PORT FOR THE PILOT OIL PRESSURE IN THE PRESSURE REDUCING
VALVE. (2) COMBINATION VALVE 924G. (3) PRESSURE REDUCING VALVE. (4)

TEST PORT FOR THE STEERING PRESSURE IN THE PRESSURE REDUCING VALVE.
THE PRESSURE REDUCING VALVE IS LOCATED ON THE RIGHT SIDE OF THE MACHINE UNDER THE
OPERATOR'S PLATFORM. THE VALVE CONTROLS THE PRESSURE IN THE PILOT SYSTEM.
THE TEST PORT (1) FOR THE PILOT OIL PRESSURE IS LOCATED ON THE PRESSURE REDUCING
VALVE.WHEN A PILOT CONTROL VALVE IS MOVED OUT OF THE HOLD POSITION, THE PILOT CONTROL
VALVE DIRECTS THE FLOW OF PILOT OIL TO A VALVE SPOOL IN THE BANK VALVE. THIS CAUSES THE
VALVE SPOOL TO SHIFT IN ORDER TO ALLOW HIGH PRESSURE OIL FROM THE PISTON PUMP TO FLOW
TO THE WORK TOOLS.

ANALISIS DE SISTEMAS HIDRAULICOS TECSUP


LABORATORIO N 1 Pg. 9 PFR

ILLUSTRATION 2

(5) LIFT CONTROL AND TILT CONTROL LEVER. (6) AUXILIARY CONTROL LEVER. (7) AUXILIARY
CONTROL LEVER. (8) SHUTOFF FOR THE PILOT VALVE.JOYSTICK CONTROL (5), CONTROL LEVER (6),
AND CONTROL LEVER (7) ARE LOCATED ON THE RIGHT SIDE OF THE OPERATOR STATION.
THE SHUTOFF FOR THE PILOT VALVE (8) IS LOCATED ON THE RIGHT SIDE OF THE OPERATOR STATION
NEXT TO THE SEAT. AUXILIARY CONTROL LEVER (6) ACTUATES THE OPTIONAL AUXILIARY PILOT
VALVE. AUXILIARY CONTROL LEVER (7) ACTUATES THE OPTIONAL AUXILIARY PILOT VALVE.
THE STANDARD WORK TOOL HYDRAULIC SYSTEM CONSISTS OF A JOYSTICK CONTROL FOR THE LIFT
CONTROL AND THE TILT CONTROL.

THE JOYSTICK IN THE LIFT POSITION CAUSES OIL TO FLOW INTO THE HEAD END OF THE LIFT
CYLINDERS IN ORDER TO RAISE THE WORKTOOL. THE JOYSTICK IN THE LOWER POSITION CAUSES
OIL TO FLOW INTO THE ROD END OF THE LIFT CYLINDERS IN ORDER TO LOWER THE WORK TOOL.
THE 924G MACHINE USES A VERSALINK FRONT END. BECAUSE OF THE VERSALINK DESIGN, THE
ORIENTATION OF THE TILT CYLINDER IS DIFFERENT FROM THE 924GZ MACHINE WITH Z BAR FRONT
END.

THE JOYSTICK IN THE DUMP POSITION CAUSES OIL TO FLOW INTO THE HEAD END OF THE TILT
CYLINDER IN ORDER TO DUMP THE BUCKETFOR THE 924G MACHINE.
THE JOYSTICK IN THE TILT BACK POSITION CAUSES OIL TO FLOW INTO THE ROD END OF THE TILT
CYLINDER IN ORDER TO TILT BACK THE BUCKETFOR THE 924G MACHINE.
THE JOYSTICK IN THE DUMP POSITION CAUSES OIL TO FLOW INTO THE ROD END OF THE TILT
CYLINDER IN ORDER TO DUMP THE BUCKETFOR THE 924GZ MACHINE.
THE JOYSTICK IN THE TILT BACK POSITION CAUSES OIL TO FLOW INTO THE HEAD END OF THE TILT
CYLINDER IN ORDER TO TILT BACK THE BUCKETFOR THE 924GZ MACHINE.
THE SHUTOFF FOR THE PILOT VALVE (8) IS USED IN ORDER TO BLOCK THE FLOW OF OIL TO THE
PILOT VALVES. PULL THE SHUTOFF FOR THE PILOT VALVE (8) ALL THE WAY BACKWARD. THE
SHUTOFF FOR THE PILOT VALVE (8) IS IN THE LOCKED POSITION. THE PILOT OIL TO THE PILOT
CONTROL VALVES IS BLOCKED. THIS PREVENTS OPERATION OF THE BUCKET OR THE WORK TOOLS
EVEN THOUGH THE OPERATOR CAN STILL MOVE THE CONTROL LEVERS.

A MACHINE THAT IS EQUIPPED WITH A WORK TOOL HYDRAULIC SYSTEM WITH A THIRD FUNCTION
HAS AN AUXILIARY CONTROL VALVE.
MOVE THE LEVER FORWARD FOR THE THIRD FUNCTION HYDRAULIC ARRANGEMENT. THIS CAUSES
OIL TO FLOW INTO THE ONE SIDE OF THE AUXILIARY CIRCUIT.
MOVE THE LEVER BACKWARD FOR THE THIRD FUNCTION HYDRAULIC ARRANGEMENT. THIS CAUSES
OIL TO FLOW INTO THE OTHER SIDE OF THE AUXILIARY CIRCUIT.
A MACHINE THAT IS EQUIPPED WITH A WORK TOOL HYDRAULIC SYSTEM WITH A FOURTH FUNCTION
HAS AN AUXILIARY CONTROL VALVE. MOVE THE LEVER FORWARD FOR THE FOURTH FUNCTION
HYDRAULIC ARRANGEMENT. THIS CAUSES OIL TO FLOW INTO THE ONE SIDE OF THE AUXILIARY
CIRCUIT. MOVE THE LEVER BACKWARD FOR THE FOURTH FUNCTION HYDRAULIC ARRANGEMENT.
THIS CAUSES OIL TO FLOW INTO THE OTHER SIDE OF THE AUXILIARY CIRCUIT.

ANALISIS DE SISTEMAS HIDRAULICOS TECSUP


LABORATORIO N 1 Pg. 10 PFR

BANK VALVE

ILLUSTRATION 1
SCHEMATIC FOR THE 924G BANK VALVE

(1) COUPLER CYLINDER. (2) COUPLER CONTROL VALVE. (3) COMBINATION VALVE. (4) MANIFOLD. (5)
CONTROL VALVE FOR THE TILT CIRCUIT. (6) TILT CYLINDER. (7) ACCUMULATOR FOR THE RIDE
CONTROL SYSTEM. (8) SOLENOID VALVE FOR THE RIDE CONTROL SYSTEM. (9) LIFT CYLINDERS. (10)
CONTROL VALVE FOR THE LIFT CIRCUIT. (11) CONTROL VALVE FOR THE AUXILIARY CIRCUIT. (12)
CONTROL VALVE FOR THE AUXILIARY CIRCUIT. (13) COVER. (14) PILOT VALVES. (15) PRESSURE
REDUCING VALVE. (16) HYDRAULIC TANK. (17) PISTON PUMP. (A) TEST PORT FOR THE SIGNAL
PRESSURE OF THE PISTON PUMP FOR THE WORK TOOL. (B) TEST PORT FOR THE PISTON PUMP FOR THE
STEERING SIGNAL PRESSURE. (C) TEST PORT FOR THE PRESSURE OF THE PISTON PUMP
FOR THE WORK TOOL. (D) TEST PORT FOR THE STEERING PRESSURE. (E) TEST PORT FOR THE PILOT
OIL PRESSURE IN THE PRESSURE REDUCING VALVE. (F) TEST PORT FOR THE PRESSURE FOR THE
FLOAT DETENT.

THE OIL FLOWS FROM THE PISTON PUMP (17) INTO THE BANK VALVES. THE BANK VALVES CONTROL
THE FLOW OF HYDRAULIC OIL FROM THE PUMP TO THE CYLINDERS. THE VALVES ALSO SEND SIGNAL
OIL BACK TO THE PISTON PUMP.
THE OIL FLOWS INTO THE BANK VALVE. THE OIL FLOWS INTO THE CONTROL VALVE FOR THE TILT
CIRCUIT (5) FIRST.

ANALISIS DE SISTEMAS HIDRAULICOS TECSUP


LABORATORIO N 1 Pg. 11 PFR

EACH VALVE OPERATES DIFFERENTLY, BUT ALL OF THE VALVES SHARE THE SAME BASIC
COMPONENTS. A COMMON PASSAGE CARRIES PRESSURE OIL FROM THE PISTON PUMP TO ALL OF THE
CONTROL VALVES. ALSO, A COMMON PASSAGE CARRIES RETURN OIL AWAY FROM THE CONTROL
VALVE TO THE TANK.

THE RESOLVERS DETERMINE THE FUNCTION THAT HAS THE HIGHEST DEMAND IN ALL OF THE
VALVES. THEN, THE SIGNAL FOR THE HIGHEST DEMAND IS SENT TO THE PUMP. THE PUMP USES THE
SIGNAL OIL IN ORDER TO DETERMINE THE AMOUNT OF FLOW THAT IS REQUIRED. THE RESOLVERS
CONSIST OF TWO BALL CHECK VALVES WITHIN EACH BANK VALVE.

EACH VALVE HAS POPPETS WHICH ACT AS LOAD CHECK VALVES. THE POPPETS CLOSE OFF THE
PORTS SO THAT THERE IS ALMOST ZERO DRIFT OF THE WORK TOOLS ON THE MACHINE. PASSAGES IN
THE POPPET ALLOW A RESTRICTED AMOUNT OF OIL TO FLOW FROM THE PORT IN THE VALVE. THIS
RESTRICTED OIL FLOWS TO THE BACK SIDE OF THE POPPET.

EVERY POPPET IS CONTROLLED BY AN AREA CONTROL SPOOL THAT IS LOCATED DIRECTLY BEHIND
THE POPPET. PILOT OIL OPENS THESE SPOOLS BY FORCING THE SPOOL UPWARD. MOVING THE SPOOL
UPWARD DECREASES THE PRESSURE ON THE BACK SIDE OFTHE POPPET BY ALLOWING THE OIL TO
DRAIN TO TANK. THE POPPET IS OPENED BY THE AREA CONTROL SPOOL IN ORDER TO ALLOW
THE RETURN OIL TO FLOW FROM THE PORT TO THE MAIN CONTROL SPOOL.

THE MAIN CONTROL SPOOL IS CONTROLLED BY THE PILOT OIL FROM THE PILOT VALVES.

ILLUSTRATION 2
LOCATION FOR THE BANK VALVE

(4) MANIFOLD. (5) CONTROL VALVE FOR THE TILT CIRCUIT. (10) CONTROL VALVE FOR THE LIFT
CIRCUIT. (11) CONTROL VALVE FOR THE AUXILIARY CIRCUIT.
(12) CONTROL VALVE FOR THE AUXILIARY CIRCUIT. (13) COVER. (C) TEST PORT FOR THE PRESSURE
OF THE PISTON PUMP FOR THE WORK TOOLS. (F) TEST PORT FOR THE PRESSURE FOR THE FLOAT
DETENT.

ANALISIS DE SISTEMAS HIDRAULICOS TECSUP


LABORATORIO N 1 Pg. 12 PFR

CONTROL VALVE (LIFT)

ILLUSTRATION 1

SCHEMATIC FOR THE LIFT CONTROL VALVE (1) ACCUMULATOR FOR THE RIDE CONTROL. (2)
SOLENOID FOR THE RIDE CONTROL. (3) LIFT CYLINDERS. (4) AREA CONTROL SPOOL. (5) RESOLVER. (6)
AREA CONTROL SPOOL. (7) BALL CHECK VALVE. (8) FLOAT SELECTOR VALVE. (9) MAKEUP VALVE.
(10) POPPET. (11) MAIN CONTROL SPOOL. (12) RELIEF VALVE. (13) BYPASS VALVE FOR LOWERING THE
LOADER ARMS. (14) POPPET. (A) DRAIN LINE FOR THE AREA CONTROL SPOOL. (B) PUMP SUPPLY LINE.
(C) SIGNAL PRESSURE. (D) LINE TO THE PILOT VALVE. (E) LINE TO THE PILOT VALVE. (F) TEST PORT
FOR THE PRESSURE IN THE FLOAT DETENT. (G) RETURN OIL LINE. (H) RETURN OIL LINE.

HOLD Position

IN THE HOLD POSITION, THE MAIN CONTROL SPOOL (11) BLOCKS THE PASSAGES TO THE PRESSURE
PASSAGES. IN THE HOLD POSITION, THE MAIN CONTROL SPOOL (11) BLOCKS THE PASSAGES TO THE
TANK. THE POPPETS (10) AND THE POPPETS (14) ARE CLOSED.

ANALISIS DE SISTEMAS HIDRAULICOS TECSUP


LABORATORIO N 1 Pg. 13 PFR

RAISE Position

ILLUSTRATION 2
FLOW OF OIL IN THE RAISE POSITION

(4) AREA CONTROL SPOOL. (5) RESOLVER. (6) AREA CONTROL SPOOL. (7) BALL CHECK VALVE. (8)
MAKEUP VALVE. (9) FLOAT SELECTOR VALVE. (10) POPPET. (11) MAIN CONTROL SPOOL. (12) MAKEUP
VALVE. (13) BYPASS VALVE FOR LOWERING THE LOADER ARMS. (14) POPPET. (A) RETURN LINE TO
THE TANK. (B) PUMP SUPPLY LINE. (C) LINE TO THE HEAD END OF THE CYLINDER. (D) LINE TO THE
ROD END OF THE CYLINDER. (E) LINE TO THE PILOT VALVE. (F) TEST PORT FOR THE PILOT PRESSURE
FOR FLOAT DETENT.

IN ORDER TO RAISE THE WORK TOOL, PILOT OIL IS SENT TO THE LEFT END OF THE MAIN CONTROL
SPOOL (11). THE SPOOL SHIFTS TO
THE RIGHT. THIS CONNECTS THE PRESSURE PASSAGE (B) TO POPPET (14) AND THIS CONNECTS THE
RETURN PASSAGE TO POPPET (10).
THE PRESSURE OIL FLOWS PAST THE SPOOL AND THE PRESSURE OIL ENCOUNTERS THE RESOLVER (5).
THE RESOLVER SENSES THE OIL PRESSURE AND THE RESOLVER SENDS THE APPROPRIATE SIGNAL TO
THE PUMP. IF NECESSARY, THE PUMP UPSTROKES.

PRESSURE OIL OPENS POPPET (14). THE OIL FLOWS TO THE HEAD END OF THE CYLINDER. AS
PRESSURE OIL FLOWS TO THE CYLINDER, THE PRESSURE OF THE RETURN OIL INCREASES. THE
RETURN OIL PUSHES ON THE FRONT OF THE POPPET (10).

THE POPPET OPENS. PILOT OIL FLOWS THROUGH AN EXTERNAL LINE TO THE BOTTOM OF THE AREA
CONTROL SPOOL (6). THIS CAUSES THE
SPOOL TO SHIFT UPWARD. THE OIL FLOWS FROM THE BACK OF THE POPPET (10) TO THE DRAIN FOR
THE AREA CONTROL SPOOL AND THE OIL FLOWS TO THE TANK. THE AREA CONTROL SPOOL DRAINS
TO THE TANK. THE FORCE THAT IS EXERTED BY THE PRESSURE ON THE FRONT SIDE OF THE POPPET
IS GREATER THAN THE FORCE THAT IS PRODUCED BY THE PRESSURE AND BY THE SPRING ON THE
BACK SIDE OF THE POPPET (10). RETURN OIL FLOWS FROM THE ROD END OF THE CYLINDER TO THE
TANK. SUPPLY OIL CONTINUES TO FLOW PAST POPPET (14). THE OIL CONTINUES TO FLOW TO THE
HEAD END OF THE CYLINDER. RETURN OIL FLOWS PAST POPPET (10). THE CYLINDER EXTENDS AND
THE BOOM RAISES.

ANALISIS DE SISTEMAS HIDRAULICOS TECSUP


LABORATORIO N 1 Pg. 14 PFR

LOWER Position

ILLUSTRATION 3
FLOW OF OIL IN THE LOWER POSITION

(4) AREA CONTROL SPOOL. (5) RESOLVER. (6) AREA CONTROL SPOOL. (7) BALL CHECK VALVE. (8)
MAKEUP VALVE. (9) FLOAT SELECTOR VALVE. (10) POPPET. (11) MAIN CONTROL SPOOL. (12) MAKEUP
VALVE. (13) BYPASS VALVE FOR LOWERING THE LOADER ARMS. (14) POPPET. (A) RETURN LINE TO
THE TANK. (B) PUMP SUPPLY LINE. (C) LINE TO THE HEAD END OF THE CYLINDER. (D) LINE TO THE
ROD END OF THE CYLINDER. (E) LINE TO THE PILOT VALVE. (F) TEST PORT FOR THE PRESSURE IN THE
FLOAT DETENT.

IN ORDER TO LOWER THE WORK TOOL, PILOT OIL IS SENT TO THE RIGHT END OF THE MAIN CONTROL
SPOOL (11). THE SPOOL SHIFTS TO THE LEFT. THIS CONNECTS THE PRESSURE PASSAGE TO POPPET (10)
AND THIS CONNECTS THE RETURN PASSAGE TO POPPET (14).
THE PRESSURE OIL FLOWS PAST THE SPOOL AND THE PRESSURE OIL ENCOUNTERS THE RESOLVER (5).
THE RESOLVER SENSES THE OIL PRESSURE AND THE RESOLVER SENDS THE APPROPRIATE SIGNAL TO
THE PUMP. IF NECESSARY, THE PUMP UPSTROKES.
PRESSURE OIL OPENS POPPET (10). THE OIL FLOWS TO THE ROD END OF THE CYLINDER. AS PRESSURE
OIL FLOWS TO THE CYLINDER, THE PRESSURE OF THE RETURN OIL INCREASES. PILOT OIL FLOWS
THROUGH AN EXTERNAL LINE TO THE BOTTOM OF THE AREA CONTROL
SPOOL (4). THIS CAUSES THE SPOOL TO SHIFT UPWARD. THE OIL FLOWS FROM THE BACK OF THE
POPPET (14) TO TANK.

THIS CAUSES THE POPPET TO OPEN. RETURN OIL FLOWS FROM THE HEAD END OF THE CYLINDER TO
THE TANK. SUPPLY OIL CONTINUES TO FLOW PAST POPPET (10). THE OIL CONTINUES TO FLOW TO THE
ROD END OF THE CYLINDER. RETURN OIL FLOWS PAST POPPET (14). THE CYLINDER RETRACTS AND
THE BOOM LOWERS.

ANALISIS DE SISTEMAS HIDRAULICOS TECSUP


LABORATORIO N 1 Pg. 15 PFR

FLOAT POSITION

ILLUSTRATION 4
FLOW OF OIL IN THE FLOAT POSITION

(4) AREA CONTROL SPOOL. (5) RESOLVER. (6) AREA CONTROL SPOOL. (7) BALL CHECK VALVE. (8)
MAKEUP VALVE. (9) FLOAT SELECTOR VALVE. (10)
POPPET. (11) MAIN CONTROL SPOOL. (12) MAKEUP VALVE. (13) BYPASS VALVE FOR LOWERING THE
LOADER ARMS. (14) POPPET. (A) RETURN LINE TO THE TANK. (B) PUMP SUPPLY LINE. (C) LINE TO THE
HEAD END OF THE CYLINDER. (D) LINE TO THE ROD END OF THE CYLINDER. (E) LINE TO THE PILOT
VALVE. (F) TEST PORT FOR THE PILOT PRESSURE FOR FLOAT DETENT. (G) DRAIN LINE FOR THE AREA
CONTROL SPOOL.

FOR THE FLOAT OPERATION, THE PILOT PRESSURE (E) PUSHES THE SPOOL (11) ALL THE WAY TO LEFT.
THIS BLOCKS BOTH PRESSURE PASSAGES AND THIS OPENS POPPET (10) AND POPPET (14) TO THE
TANK. THE PILOT OIL FLOWS TO THE BOTTOM OF THE AREA CONTROL SPOOL (4).

PILOT OIL AT THE RIGHT END OF THE SPOOL FLOWS THROUGH A HOLE TO THE FLOAT SELECTOR
VALVE. THE OIL BUILDS PRESSURE AND THE OIL OPENS THE FLOAT SELECTOR VALVE. THE PILOT OIL
FROM THE FLOAT SELECTOR VALVE PUSHES THE BALL. THIS BLOCKS PILOT OIL TO THE LEFT SIDE OF
THE SPOOL. THEN, THE OIL FLOWS INTO THE CAVITY UNDER THE AREA CONTROL SPOOL AND THE
OIL PUSHES THE AREA CONTROL SPOOL UPWARD. THE RIGHT POPPET OPENS.

POPPETS (10) AND POPPETS (14) ARE OPEN. THE SPOOL CONNECTS THE ROD END OF THE CYLINDER
AND THE SPOOL CONNECTS THE HEAD END OF THE CYLINDER TO THE RETURN PASSAGE. THE BOOM
CAN NOW FLOAT.

ANALISIS DE SISTEMAS HIDRAULICOS TECSUP


LABORATORIO N 1 Pg. 16 PFR

CONTROL VALVE (TILT)

ILLUSTRATION 1
SCHEMATIC OF THE TILT CIRCUIT FOR THE 924GZ MACHINE

COMPONENTS FOR THE CONTROL VALVE FOR THE TILT CIRCUIT


(1) TILT CYLINDER. (2) AREA CONTROL SPOOL. (3) POPPET. (4) RESOLVER. (5) POPPET. (6) AREA
CONTROL SPOOL. (7) RELIEF VALVE. (8) ORIFICE. (9) MAIN CONTROL SPOOL. (10) ORIFICE. (11) MAKEUP
VALVE AND RELIEF VALVE.

ILLUSTRATION 2
COMPONENTS FOR THE CONTROL VALVE FOR THE TILT CIRCUIT ON THE 924GZ MACHINE
(2) AREA CONTROL SPOOL. (3) POPPET. (4) RESOLVER. (5) POPPET. (6) AREA CONTROL SPOOL. (7)
RELIEF VALVE. (9) MAIN CONTROL SPOOL. (11) MAKEUP VALVE AND RELIEF VALVE.

ANALISIS DE SISTEMAS HIDRAULICOS TECSUP


LABORATORIO N 1 Pg. 17 PFR

DUMP POSITION

ILLUSTRATION 3
FLOW OF OIL IN THE DUMP POSITION

(2) AREA CONTROL SPOOL. (3) POPPET. (4) RESOLVER. (5) POPPET. (6) AREA CONTROL SPOOL. (7)
RELIEF VALVE. (9) MAIN CONTROL SPOOL. (11) MAKEUP VALVE AND RELIEF VALVE. (A) PASSAGE TO
THE TANK. (B) PASSAGE FOR THE PUMP PRESSURE OIL. (C) LINE TO THE ROD END OF THE CYLINDER.
(D) LINE TO THE HEAD END OF THE CYLINDER. (E) PILOT SUPPLY OIL.

THE PILOT SUPPLY OIL (E) FLOWS TO THE END OF THE SPOOL (9). THE SPOOL STARTS TO SHIFT TO
THE LEFT. THE PUMP PRESSURE OIL PUSHES ON THE POPPET (3). THE POPPET (3) OPENS. THE PASSAGE
FOR THE PUMP PRESSURE OIL (B) CONNECTS TO PORT (C) FOR THE ROD END OF THE TILT CYLINDER.
THE RETURN OIL PUSHES ON THE POPPET (5). THE RETURN OIL CONNECTS TO PORT (D) FOR THE HEAD
END OF THE TILT CYLINDER.
PILOT OIL (E) FLOWS THROUGH AN ORIFICE TO THE BOTTOM SIDE OF THE AREA CONTROL SPOOL (6).
THIS CAUSES THE AREA CONTROL SPOOL (6) TO SHIFT UPWARD. THIS ALLOWS THE OIL FROM THE
BACK OF POPPET (5) TO FLOW INTO THE TANK. THE PRESSURE ON THE FRONT OF THE POPPET (5) IS
HIGHER THAN THE PRESSURE ON THE BACK OF THE POPPET. THIS CAUSES THE POPPET TO OPEN.
THE PRESSURE OIL FLOWS PAST THE SPOOL (9) AND PUSHES AGAINST THE RESOLVER (4). IF THE
PRESSURE OIL IN THE VALVE IS AT A HIGHER PRESSURE THAN THE SIGNAL PASSAGE, THE PUMP
UPSTROKES.

THE POPPET (3) OPENS DUE TO THE PRESSURE OIL. THE OIL FLOWS OUT OF THE VALVE AT PORT (C)
TO THE ROD END OF THE CYLINDER.
PRESSURE OIL FLOWS OUT OF PORT (C). THIS CAUSES THE PRESSURE OF THE RETURN OIL IN PORT (D)
TO INCREASE. OIL FROM THE BACK SIDE OF THE POPPET (5) FLOWS INTO THE TANK.

ANALISIS DE SISTEMAS HIDRAULICOS TECSUP


LABORATORIO N 1 Pg. 18 PFR

TILT BACK POSITION

ILLUSTRATION 4
FLOW OF OIL IN THE TILT BACK POSITION

(2) AREA CONTROL SPOOL. (3) POPPET. (4) RESOLVER. (5) POPPET. (6) AREA CONTROL SPOOL. (7)
RELIEF VALVE. (9) MAIN CONTROL SPOOL. (11) MAKEUP VALVE AND RELIEF VALVE. (A) PASSAGE TO
THE TANK. (B) PASSAGE FOR THE PUMP PRESSURE OIL. (C) LINE TO THE ROD END OF THE CYLINDER.
(D) LINE TO THE HEAD END OF THE CYLINDER. (E) PILOT SUPPLY OIL.
THE PILOT SUPPLY OIL (E) FLOWS INTO THE LEFT END OF THE SPOOL (9). THE SPOOL STARTS TO SHIFT
TO THE RIGHT. THE PUMP PRESSURE OIL PUSHES ON THE POPPET (5). THE POPPET (5) OPENS. THE
PASSAGE FOR THE PUMP PRESSURE OIL (B) CONNECTS TO THE LINE FOR THE HEAD END OF THE TILT
CYLINDER (D).

PILOT OIL (E) FLOWS THROUGH AN ORIFICE TO THE BOTTOM SIDE OF THE AREA CONTROL SPOOL (2).
THIS CAUSES THE AREA CONTROL
SPOOL (2) TO SHIFT UPWARD. THE OIL FROM THE BACK SIDE OF THE POPPET (3) RETURNS TO THE
TANK. AS THE PRESSURE FLOWS INTO THE HEAD END OF THE CYLINDER, THE PRESSURE OF THE
RETURN OIL INCREASES. THIS RETURN OIL
FROM THE ROD END OF THE CYLINDER PRESSES AGAINST THE POPPET (3). BECAUSE THE FRONT OF
THE POPPET IS A HIGHER PRESSURE THAN THE BACK OF THE POPPET, THE POPPET (3) OPENS. AS THE
POPPET OPENS, THE RETURN OIL FLOWS TO THE TANK.
THE SUPPLY OIL FLOWS PAST POPPET (5). THE SUPPLY OIL FLOWS INTO THE HEAD END OF THE
CYLINDER. THE RETURN OIL FLOWS PAST THE POPPET (3). THE OIL RETURNS TO THE TANK. THIS
CAUSES THE CYLINDER TO EXTEND AND THIS CAUSES THE WORK TOOL TO TILT BACK.

ANALISIS DE SISTEMAS HIDRAULICOS TECSUP


LABORATORIO N 1 Pg. 19 PFR

Cuarto: En el taller de maquina el INSTRUCTOR ESPECIALISTA tendr que explicar y realizar lo


siguiente:

1. Realizar un diagrama hidrulico del sistema de implementos del 924G (usar la pizarra
acrlica).
2. Explicar el funcionamiento de los componentes y las vlvulas del sistema de implementos del
924G.
3. Analizar y generar algunas fallas en el sistema de implementos del 924G.
4. Medir las siguientes presiones, (en la maquina)
Pressure stand by
Pressure cut out
Pressure pilotaje
Pressure margin

Quinto: Tomar FOTOS de los datos siguientes.

Tomar foto de lo siguiente:


Vista frontal del equipo, cucharon a nivel del suelo.
Vista posterior del equipo, cucharon a nivel del suelo.
Vista lateral derecha del equipo, cucharon a nivel del suelo.
Vista lateral izquierda del equipo, cucharon a nivel del suelo.
Vista frontal del equipo, cucharon extendido hacia arriba.
Componentes del sistema de implementos, sealizar con flechas.
Tomar la tomas de presin del sistema de implementos.

Sexto: Realizar un VIDEO.

Realizaran un video de 5-10 minutos como mximo, donde explicarn la evaluacin que el
instructor designe a cada grupo.

Indicaciones sobre el video:

El video debe de tener lo siguiente:

1. Introduccin y presentacin del grupo (EPP obligatorio y todos deben participar en


esta seccin).
Mencionar el camargrafo, el operador, y los dems integrantes.

2. Procedimiento de evaluacin en equipo (EPP obligatorio y todos deben participar en


esta seccin).

3. Anlisis o diagnostico hidrulico. (NO es obligatorio sus EPP y puede participar del
grupo un solo alumno como mnimo.

Si no realizan el video NO tendrn nota de laboratorio

Sptimo:

En el plano hidrulico del cargador 924G pintar en PAINT


1. Posicin bajar
2. Posicin de flotamiento

ANALISIS DE SISTEMAS HIDRAULICOS TECSUP


LABORATORIO N 1 Pg. 20 PFR

Octavo: INVESTIGAR EL SIGUIENTE CUESTIONARIO:

Ver el plano hidrulico 924G y responder las siguientes preguntas

1. Explicar que funcin cumple la vlvula que est marcada en crculo?

2. Explicar que funcin cumple las vlvulas marcadas?

ANALISIS DE SISTEMAS HIDRAULICOS TECSUP


LABORATORIO N 1 Pg. 21 PFR
3. Explicar que funcin cumple las vlvulas marcadas?

4. Explicar que funcin cumple la vlvula marcada?

ANALISIS DE SISTEMAS HIDRAULICOS TECSUP


LABORATORIO N 1 Pg. 22 PFR
5. Explicar que funcin cumple los componentes marcados

6. Si tuvieras que evaluar las valvulas marcadas en el 924G explicar los pasos que realizarias ?

ANALISIS DE SISTEMAS HIDRAULICOS TECSUP


LABORATORIO N 1 Pg. 23 PFR
7. Si tuvieras que evaluar las valvulas marcadas en el 924G explicar los pasos que realizarias ?

8. Porque la vlvula reductora tiene 3 vas y porque vlvula se descarga la presin de los
acumuladores?

ANALISIS DE SISTEMAS HIDRAULICOS TECSUP


LABORATORIO N 1 Pg. 24 PFR
Responder con respecto a las presiones en el sistema de implementos 924G

9. Que funcin cumple la SENSING PRESSURE y que beneficios encontramos en otros sistemas que
no encontramos la presin de sensado? , Fundamentar.

10. Que funcin cumple la MARGIN PRESSURE y que sucede si el valor medido est por debajo de lo
que establece el fabricante (fuera de rango)? , Fundamentar.

11. Que funcin cumple la CUT OFF PRESSURE y que sucede si el valor medido est por debajo de lo
establecido por el fabricante (fuera de rango)? , Fundamentar.

12. Que funcin cumple la STAND BY PRESSURE y que sucede si el valor medido est por debajo de
lo establecido por el fabricante (fuera de rango)? , Fundamentar.

13. Que funcin cumple la PILOT PRESSURE y que sucede si el valor medido est por debajo de lo
establecido por el fabricante (fuera de rango)? , Fundamentar.

ANALISIS DE SISTEMAS HIDRAULICOS TECSUP


LABORATORIO N 1 Pg. 25 PFR
Analizar algunos problemas que puede suceder en el sistema de implementos 924 G

14. THE HYDRAULIC POWER IS LOW, EXPLAIN WHAT HAPPENS?

15. NONE OF THE FUNCTIONS WILL OPERATE OR ALL OF THE FUNCTIONS OPERATE SLOWLY,
EXPLAIN WHAT HAPPENS?

16. YOU DO NOT HAVE POWER, WHEN YOU RAISE THE BOOM OR WHEN LOWER THE BOOM,
EXPLAIN WHAT HAPPENS?

17. YOU DO NOT HAVE POWER, WHEN YOU TILT THE BUCKET IN EITHER DIRECTION,
EXPLAIN WHAT HAPPENS?

18. THE OIL TEMPERATURE IS TOO HIGH, EXPLAIN WHAT HAPPENS?

19. THERE ARE AIR BUBBLES IN THE OIL, EXPLAIN WHAT HAPPENS?

20. THE CYCLE TIMES ARE NOT CORRECT,


EXPLAIN WHAT HAPPENS?

ANALISIS DE SISTEMAS HIDRAULICOS TECSUP


LABORATORIO N 1 Pg. 26 PFR

ANALISIS DE SISTEMAS HIDRAULICOS TECSUP