Procedure

Trainer Activities
Hydraulic Steering System

Trainer Activity 1

STEERING SYSTEM

1. Study the steering system illustration as shown on Figure 1.1.

2. Complete the diagram (Figure 1.2) to make the steering cylinder rod travel at the same speed
in both directions.
3. Construct the steering circuit as shown on Figure 1.3.

4. Turn the power-unit on.

5. Record the ambient temperature. 74 °F

6. Record the system temperature. 81 °F

7. Using the flow meter test kit, record the pump flow.

8. Set the steering system main pressure relief valve at 500 PSI (34.5 bar).

9. Rotate the steering wheels from the straight-forward position to the left, and then from the
straight-forward position to the right Is the speed at which the wheels turn

10.Turn the power-unit off.

Trainer Activity 2

STEERING SYSTEM

1. Construct the steering circuit (Figure 2.1)

2. Describe what component has been added to the steering system.

Double acting cylinder
Steering system
Oil tempt gauge
Measure gauge
Reservoir
Adjustable orifice
Cross line relief valve
Uni directional pump
Pressure relief valve

3. Describe what purpose the component will serve in the steering circuit.

4. Describe what type of valve is typically used to operate a hydraulic steering system.

5. Refer to Figure 2.2. Complete the blank envelope to reflect the flow configuration when the
orbitrol steering valve is in the neutral position.

6. Rotate the steering wheels from the straight-forward position to the left, and then from the
straight-forward position to the right. Is the speed to the left and right the same? YES/NO Why?

7. Refer to Figure 2.3. Complete the blank envelope to reflect the flow configuration when
turning the steering wheels to the right.

8. Refer to Figure 2.4. Complate the blank envelope to reflect the flow configuration when
turning the steering wheels to the left.

9. If the prime mover speed is variable, describe what will happen to the pump flow if a. the
speed is increased.

10. Describe how flow increases and decreases, caused by changes in prime-mover speed, will
affect the operation of the steering system.

11, A re steering system typically needs a constant oll flow to operate properly. Describe how
flow into a hydraulic system can be kept constant regardless of changes in pump flow

12. Describe what type of valve is most typically used in a hydraulic steering system to maintain
a constant flow regardless of engine speed.

13. Turn the power-unit off

Trainer Activity 3

STEERING SYSTEM

1. Reconfigure the steering circuit (Figure 3.1).

2. Describe what component has been added to the steering system.

3. Describe the function of this component.

4. Turn the power-unit on.

5. Refer to Figure 3.2Draw a line showing the oil flow path through the priority flow divider if it is
set for 8 GPM (30.4 Lpm) and the pump flow is 5 GPM (19 Lpm).

6. Refer to Figure 3.3. Draw a line showing the oil flow path through the priority flow divider if the
valve is set for B GPM (30.4 Lpm) and the pump flow is 10 GPM (38 Lpm).

7. Explain if it is necessary to have a main pressure relief valve in the circuit when using a
bypass-type, pressure-compensated, flow control valve.

8. Describe why a bypass-type, pressure-compensated, flow control valve will not relieve
pressure through port "2" if the flow in port "3" is blocked

9. Refer to Figure 3.4Complete the blank envelope to reflect the flow configuration when the
orbitrol steering valve is in the neutral position.

10. Set the steering pressure relief valve at 650 PSI (44.8 bar).

11Turn the steering wheels to the right.

12Refer to Figure 3.5Complete the blank envelope to reflect the flow configuration when turning
the steering wheels to the right.

13. Using the flow meter test kitrecord the flow entering the inlet side (port 1) of the bypass-type,
pressure-

14Using the flow meter test kit, record the flow exiting the priority flow port (port 3) of the
bypass-type, pressure-compensated, flow control valve.

15Describe what happened to the balance of the pump flow.

16. Describe why the oil flow exiting the priority flow port (port 3)is less than the oil flow entering
the inlet port (port 1) of the bypass-type, pressure-compensated, flow control valve.

17. Turn the steering wheels to the left.

18Refer to Figure 3.6Complete the blank envelope to reflect the flow configuration when turning
the steering wheels to the left.

19Describe what will occur if the flow discharging from the excess flow port (port 2) in a priority
flow divider is blocked.

20What is another name for a bypass-type, pressure- compensatedflow control valve? Why?

21. If the pressure needed to turn the steering wheels is 450 PSI (31 bar)describe what the
approximate pressure at the pump outlet port will be when steering a vehicle.

22Describe what the pressure difference is across the bypass-typepressure-compensated, flow

control valve (port 1 to port 3).

23Describe two advantages of a bypass-type, pressure- compensatedflow control valve

24. Rotate the steering wheel until the wheels are in the full- lock position and hold this position.

25Refer to Figure 3.7. Show the pump flow when the steering cylinders are in the stalled
position.

26. Record the steering pressure.

27. What is the lowest resistance in the steering circuit when the cylinders are stalled.

28Turn the power-unit off,

29Reconfigure the steering circuit (Figure 3.8).

30Describe what type of valve has been added to the steering circuit.

31. Describe why it is necessary to have this type of valve in a steering circuit.

32Describe the status of the oil flow path in the orbitrol steering valve when it is in the neutral
position

33. Describe what is likely to occur if the steering cylinders are subjected to an excessive
external mechanical force when the steering orbitrol valve is in the neutral position.

34. Describe the circuit relationship of the cross-port relief valve to the steering system's main
pressure relief valve when the steering cylinders are moving

35. Set the main pressure relief valve at 700 PSI (48.3 bar).

35. Set the cross-port relief valves at 550 PSI (37.9 bar).

37. Turn the steering wheel until the steering cylinders stall. Hold this position.

38. Record the pressure.

39. Refer to Figure 3.9. Show the oil flow path when the steering cylinders are stalled

40. Turn the power-unit off

41. Describe an advantage of a cross-port relief valve.

42Describe what the term "cross-port relief means.

43. Describe what will occur if this type of steering system is put into operation without a cross-
port relief valve

STEERING SYSTEM

44Refer to Figure 3.10. Write the names of the major components which make up an orbitrol
steering valve.

45Describe the purpose of the check valve inside an orbitrol steering valve.
46. Describe the purpose of the metering unit inside an orbitrol steering valve

47. Describe why it is critical that service, repair, and troubleshooting on steering systems be
done by trained, authorized, personnel.

48. Describe what will happen if any of the steering components fail.
Trainer Activity 1

HYDROSTATIC (closed-loop) SYSTEM

1. Study the schematic (Figure 1.1)

2. Describe what must be done to reduce the speed of the hydraulic motor.

3. If the pump flow is 10 GPM (37.85 Lpm) and the flow to the motor is restricted to 5 GPM (18.9
Lpm) explain what happens to the excess flow.

4. If the pressure needed to drive the motor is 450 PSI (31 bar), record the pressure Indicated
on pressure gauge 1 and pressure gauge 2.
5. Describe what happens to the fluid energy at the pressure relief valve.

6. Describe the distinct disadvantage of this type of speed control

7. Study the schematic (Figure 1.2).

8. Describe how many motor speeds this configuration will yield.

9. Complete the symbol to show the slowest motor speed. Draw a line to show the flow
through the circuit.

10. Study the schematic (Figure 1.3).

11. Complete the symbol to show the intermediate motor speed. Draw a line to show the flow
through the circuit.

12. Study the schematic (Figure 1.4)

13. Complete the symbol to show the highest motor speed. Draw a line to show the flow through
the circuit.

14Describe if this is an open-loop drive, or a closed-loop drive

15Compare this type of drive to a closed-loop driveList three distinct disadvantages.

Trainer Activity 2

HYDROSTATIC (closed-loop) SYSTEM

1.Construct the closed-loop circuit (Figure 2.1).

2. Describe the most unique advantage of a closed-loop system

3. Describe what the term "over-center" means with respect to a hydraulic pump.

4. Describe a critical pre-start safety procedure which must be done before starting a closed-
loop system

5Describe briefly why a closed-loop system "brakes" when the pump displacement control
mechanism is moved to the neutral position.

6. Describe two (2) important pre-start steps which must be taken before starting a new over-
center pump

8. Describe how long after starting an over-center pump it should take for charge pressure to
stabilize

7. Describe three (3) functions of a charge pump.

9. Describe what will most likely occur if an over-center pump runs without charge pressure.
10. Describe the approximate flow relationship between a charge pump and an over-center
pump.

11. Turn the power-unit on

12. Record the system oil temperature.

13. Record the charge pressure.

14Refer to Figure 2.2 and show the following: a) Use a green pencil/marker and draw a line
showing the oil flow on the inlet side of the charge pump

b) Use a blue pencil/marker and show the oil flow in the charge circuit. Use blue dots to show
static lines

c) Use a yellow pencil/marker and draw a line showing the case drain flow.

15. Describe why there is no flow in the closed-loop.

16. Move the pump control lever gradually to the forward positionStop when the flow is 2.0 GPM
(7.57 Lpm)

17. Describe what is unique about the relationship of the control lever to the flow.

18. Describe the difference, with regard to flow control, between a fixed-displacement pump and
a needle valve, and an over- center pump.

19Describe what component is necessary when regulating flow from a fixed-displacement pump
with a needle valve.

20. Describe the distinct disadvantage of regulating flow from a fixed-displacement pump with a
needle valve.

21. Describe what critical step must be taken when towing a vehicle which is propelled with a
closed-loop transmission.

22. Describe what will most likely occur if the over-center pump manufacturer's recommended
towing distance is exceeded

23. Turn the power-unit off.

24. Remove the transmission line and place it in the hose caddy.

HYDROSTATIC (closed-loop) SYSTEM

Trainer Activity 3
1. Construct the closed-loop circuit (Figure 3.1).

2. Turn the power-unit on

3. Record the system oil temperature.

4. Record the charge pressure.

5. Move the pump control lever gradually to the forward positionStop when the flow is 2.0 GPM
(7.57 Lpm)

6. Record the motor speed.

7. Refer to Figure 3.1 and show the following:

a) Use a green pencil/marker and draw a line showing the inlet oil flow.

b) Use a red pencil/marker to show the oil flow in the high pressure side of the loop.

c) Use a blue pencil/marker to show the oil flow in the low pressure side of the loop.
d) Use a yellow pencil/marker and draw a line showing the case drain flow

8. Move the pump control lever to the reverse positionStop when the flow is 1.0 GPM (3.785
Lpm)

9. Record the motor speed.

10. Move the pump control lever to the neutral position

11. Turn the power-unit off.

Trainer Activity 4

HYDROSTATIC (closed-loop) SYSTEM

1. Construct the closed-loop circuit (Figure 4.1)

2. Describe the flow relationship between the wheel motors

3. Turn the power-unit on

4. Record the system oil temperature.

5. Record the charge pressure.

6. Move the pump control lever gradually to the forward positionStop when the flow is 2.0 GPM
(7.57 Lpm)

7. Record the motor speed.

8Move the pump control lever gradually to the reverse positionStop when the flow is 2.0 GPM
(7.57 Lpm)

9. Record the motor speed.

10Refer to Figure 4.1 and show the following: a) Use a green pencil/marker to show the oil flow
in the pump inlet.

b) Use a red pencil/marker to show the oil flow in the high pressure side of the loop.

c) Use a blue pencil/marker to show the oil flow in the low pressure side of the loop.

d) Use a green pencil/marker to show the oil flow in the charge circuit.

e) Use a yellow pencil/marker and draw a line showing the case drain flow

11Describe the advantage of connecting hydraulic motors in series.

12Describe the disadvantage of connecting hydraulic motors in series.

13. Move the pump control lever to the neutral position.

14. Refer to Figure 4.2 and show the following:

a) Complete the symbol for the towing bypass valve in the towing position.

b) Use a blue pencil/marker and draw a line showing the oil flow when the vehicle is being
towed (engine disabled

15. Turn the power-unit off

16. Remove the transmission lines and store them in the hose caddy.

Trainer Activity 5
HYDROSTATIC (closed-loop) SYSTEM

1. Construct the closed-loop circuit (Figure 5.1).

2. Describe the flow relationship between the wheel motors

3. Turn the power-unit on.

4. Record the system oil temperature.

5. Record the charge pressure.

6. Move the pump control lever gradually to the forward positionStop when the flow is 2.0 GPM
(7.57 Lpm).

7. Record the motor speed.

8. Move the pump control lever gradually to the reverse positionStop when the flow is 2.0 GPM
(7.57 Lpm).

9. Record the motor speed.

alter Activity
10Refer to Figure 5.1 and show the following:

a) Complete the symbol to represent the forward pressure relief valve when the motors are
stalled.

b) Use a red pencil/marker and draw a line showing the oil flow path in the high pressure side of
the loop when the motors are stalled

c) Use a blue pencil/marker to show the oil flow in the low pressure side of the loop.

d) Use a green pencil/marker to show the oil flow in the charge circuit

e) Use a yellow pencil/marker and draw a line showing the case drain flow

11. Move the pump control lever to the neutral position

12Describe why the motor speed has decreased approximately 50% when comparing activity 4
and activity 5.

13. Describe the advantage of connecting hydraulic motors in parallel.

14Describe the disadvantage of connecting hydraulic motors in parallel.

15. Move the pump control lever to the neutral position.

16. Turn the power-unit off

17. Remove the transmission lines and store them in the hose caddy.