GPM Hydraulic Consulting, Inc. P.O. Box 689. Social Circle, GA Hydraulic Consulting, Inc

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1 Hydraulic Consulting, Inc This special promotional CD is to demonstrate how your hydraulic troubleshooting manual can be ordered as an Adobe Acrobat ebook. It can be installed on any computer with the included Acrobat Reader and viewed wherever it will be the most helpful. Your ebook can be distributed across a Local Area Network, or copies can be made for distribution to all technical staff. Reader software is even included to download it to a PDA or Palmtop. Click the button to zoom in on portions of the document Click the button to search the entire document for any phrase or keyword Click the button to either show or hide the navigation pane. Click the button to print all or part of the document Call, Write or Fax GPM today for pricing and other details The document may be navigated either by clicking the Bookmarks tab to view by subject or click the Thumbnails tab to see miniature pictures of each page: GPM Hydraulic Consulting, Inc. P.O. Box 689 Social Circle, GA gpm@gpmhydraulic.com

2 Gang Symbol Description 1. Pump Variable displacement, pressure compensating, externally drained pump. The compensator should be set 200 PSI above the maximum operating pressure of the system. The pump will deliver maximum volume when the system requires the full output. If the system requires less volume, the pressure will build to the compensator setting. The compensator spool will then shift open and de-stroke the pump, reducing the output volume. The pump will now only supply the volume required by the system. If the compensator fails in the open position the pump volume will be reduced to near 0. The system pressure will also be at a low level. One check that can be made is to remove the compensator and disassemble it. The orifices in the compensator housing and spool Troubleshooting Sawmill Hydraulics Page 19

3 Pump Isolation Check Valves should be clean. If the compensator were to fail closed the system pressure will build to the No. 2 relief setting. The oil not required by the system will return to tank through the valve at high pressure creating heat. The flow out of the case drain line can be checked to determine if the pump is badly worn. Normal bypassing is 1 3% of the total volume. A severe increase in this flow indicates that the internal tolerances in the pump have increased which reduces the pump output volume. There is a manual volume adjustment on the pump which, when turned clockwise, reduces the maximum pump volume. 2. Relief Valve The valve is used as an extreme safety device in this system. In the event the pump compensator fails closed, the pump will deliver maximum volume at all times. When the oil is not being used, in this case, the excess flow will return to tank through this relief. Heat will be created when this occurs. A good troubleshooting check to Page 20 Troubleshooting Sawmill Hydraulics

4 make is to feel the tank line of the relief valve. It should be cool at all times. If severe heat is felt then either the compensator has failed, the system is misadjusted, or the spool is stuck partially open. The valve will also absorb momentary pressure spikes in the system. Proper setting of this relief is 500 PSI (as recommended by the manufacturer) above the compensator setting. 3. Pump Fixed displacement type pump that continuously recirculates the reservoir fluid through a filter and an air cooler. The maximum Troubleshooting Sawmill Hydraulics Page 21

5 pressure in this circuit is limited by the cooler and filter bypass check valves springs. 4. Check Valve The valve and filter s bypass check valve limits the maximum pressure in the filtering and cooling pump circuit. In the event the cooler were to plug up with contamination, then pressure would build to the setting of this check. The valve would then open and dump the No. 3 pump volume back to tank. The valve spring is normally set at PSI. 5. Heat Exchanger The No. 3 pump volume is continuously recirculated through this cooler. The fins should be steam cleaned and degreased regularly to ensure a good transfer of heat from the oil to the air. 6. Filter The No. 3 pump will continuously recirculate the reservoir fluid through this filter. If the element plugs up, the oil will flow through the internal bypass check valve. This filter should be checked on a regular basis and changed as necessary. A regular filter Page 22 Troubleshooting Sawmill Hydraulics

6 maintenance schedule can be established for this filter by oil analysis. 7. Accumulator This accumulator will supply a high volume of oil to the system when the valves are energized. When the accumulator is operating properly the shell will be warmer in the lower half that the top half. Another check that can be made is to observe the pressure gauge while the actuators are operating. The gauge should normally not drop more than PSI. If either of the previous two conditions are not normal then the accumulator pre-charge may be too high or too low or the bladder may have ruptured. Care should be taken to verify that pressure has been bled down out of the accumulator before working on or around the machine. Troubleshooting Sawmill Hydraulics Page 23

7 7A. Accumulator These bladder type accumulators are pre-charged with dry nitrogen. The proper nitrogen pre-charge should be approximately one half the pump compensator setting. Only pre-charge the accumulator when there is 0 PSI in the hydraulic system. This can be achieved by turning the pump off, permitting the No. 9 dump valve to shift open. The accumulator will supply oil to the system at a high flow rate when the No. 20 proportional valves are energized. One method of checking to make sure the accumulator is delivering the proper volume is to observe the system pressure gauge. The pressure gauge should normally not drop more than PSI. Another check that can be made is to feel the sides of the accumulator shell. The shell should be hotter in the lower half or two thirds of the shell than the top part. Prior to working on or around the GANG, you should verify that the pressurized fluid in the accumulator has bled down to 0 PSI through the dump valve. Page 24 Troubleshooting Sawmill Hydraulics

8 Case Drain Flow Meter 8. Flow Meters These meters will give a visual indication of the amount of oil that bypasses inside the pumps. Normal bypassing is 1 3%ofthe maximum pump volume. These meters should be checked regularly to verify that the pumps are delivering the proper flow of oil. 9. Accumulator Dump Valve The purpose of the valve is to permit the pressurized fluid in the accumulator to automatically dump back to the tank when the hydraulic pumps are turned off. This permits the pressure in the line to drop to 0 PSI. When the pimps are started, pilot pressure will shift and hold the valve in the closed position. Flow is now blocked from the accumulator back to the tank. The tank line of this valve should be cool at all times. This valve is of the cartridge type and is located near the accumulator. Troubleshooting Sawmill Hydraulics Page 25

9 10. Check Valve This check valve prevents the No. 7A accumulator from discharging back to the rollcase, chain drives, pre-positioners and clam lid cylinders. The accumulator is only used to supply oil to the slab slasher, gang skew, and translate and saw change circuits. The check valve is located in the same block as the No. 9 accumulator dump valve. 11. Hydrostat The purpose of this valve is to maintain a constant pressure drop across the No. 12 proportional valve. This is necessary so that a constant flow will be maintained to the hydraulic actuator regardless of the size and weight of the cant. The valve is normally set at 200 PSI or lower. 12. Proportional Valve This valve operates off of a variable D.C. voltage. A positive voltage will shift the valve into one position (for example, the A position ) and a negative voltage will shift the valve into the opposite position. The amount that the spool shifts is determined by the applied voltage. Therefore, the speed and direction of the actuator is determined by this valve. 13. Shuttle Valve This ball will shift and direct the highest pressure in the lines to the spring side of the hydrostat spool. The pressure acting on the opposite end of the spool has to overcome the pressure driving the motor as well as the hydrostat spring before the valve can start regulating the flow. 14. Hydraulic Motor The chain drive and rollcase motors are one direction, internally drained, gear type motors. If the motor is driving too slow, then there may be excessive bypassing between the internal tolerances inside the motor. This can be determined by comparing the temperature of Page 26 Troubleshooting Sawmill Hydraulics

10 the inlet line with the outlet line. If the outlet line is a great deal hotter then the motor is bad and should be changed. 15. Linear Positioner The cylinder contains a hollow rod and a magnet bolted on to the cylinder piston. The transducer probe fits down inside the hollow rod. An electrical pulse will be sent through the wire and once it reaches the magnet, the pulse is returned. The amount of time from when the pulse started and returned indicates the position of the cylinder. The transducer will convert that signal into a digital pulse which is fed back to the PLC. Normally this feedback signal can be read on the operator s screen. If the probe is thought to be bad, it can be removed from the cylinder and a magnet run up and down the length of the probe. If the numbers change on the operator s screen, this normally means that the transducer is good. A cracked magnet will give an erratic feedback signal causing the cylinder to hunt for position. 16. Flow Control The setting of this valve determines the speed that the clam lid raises and lowers. Because the valve is pressure compensating a constant flow will be ported to the cylinders at all times. The valve is connected in a meter in type arrangement. 17. Directional Valve This valve is actuated when necessary to raise and lower the clam lid. When the handle is released the spool will spring center to the closed position. No. 17 is a closed center, three position, four way, manually actuated, spring center, directional valve. 18. Counterbalance Valves These valves will lock oil in the full piston sides of the clam lid cylinders when in the raised position. The valves should be set slightly above what is required to hold the lid in the up position. To set the valve turn the pumps off and shift the No.17 valve into the B position. Make sure the pressure in the No. 7 accumulator has beld Troubleshooting Sawmill Hydraulics Page 27

11 down to 0 PSI. Rotate the adjustment to reduce the pressure setting of the spring. Some valves made by Sun are rotated clockwise to reduce the spring pressure. Once the cylinder starts to lower rotate the adjustment in the opposite direction. When the directional valve is shifted to lower the lid pilot pressure in the remote pilot line will shift the specific valve to the open position. If the lid starts dropping faster than oil is supplied in to the cylinders, the counterbalance valve will partially close restricting the oil flow. This prevents the lid from free falling. 19. Hydraulic Motor These rollcase motors are connected in a series type arrangement. This permits each motoe to rotate at the same speed. If one motor is bypassing, then it will rotate at a slower speed. The other motor will not be affected. If one motor were to mechanically stall, then all motors would stop rotating. To find the bad motor connect the inline hose of the first motor to the inline hose of the second motor. If the motors rotate then, obviously the first inline motor is locked up. Repeat this procedure until the bad motor is found. 20. Proportional Valve Page 28 Troubleshooting Sawmill Hydraulics

12 This valve operates off of a positive and negative 10 volt D.C. signal. When a D.C. voltage is applied to the pilot valve coil, internal pilot pressure is directed to hydraulically shift the main spool. As the spool shifts, an LVDT (linear variable differential transformer) will electrically indicate the amount that the spool shifts. On most proportional valves when the voltage to the pilot valve and the LVDT feedback voltage equals 0, the main spool will stop shifting and hold position. This permits the flow through the valve to be proportional to the applied voltage. Once the positioner electrically indicates that the desired position has been reached, the valve is electrically shifted into the closed position. In the event of a power failure, the spool will spring return to the closed position. If the positioner cylinders are not operating properly, then the valve can be driven with a battery box made by Bosch. By driving the valve with the battery box, it can be determined if the problem is with the proportional valve, mechanical linkage or transducer. 21. Flow Control This valve determines the speed that the saw change cylinder extends and retracts. The valve is connected in a meter in type arrangement. The valve is pressure compensating which means a constant flow will be ported to the cylinder regardless of pressure changes in the system. If the valve becomes contaminated then the cylinder will operate slower or possibly not at all. 22. Directional Valve To extend the saw change cylinders, a voltage is applied to the B solenoid. Flow from the pumps and accumulator is then directed through the valve and into the full piston side of the cylinders. As the cylinder extends, the oil that is forced out of the rod side will return to the tank through the A and T ports of the valve. To retract the cylinder, the A solenoid energizes, which directs fluid to the rod side of the cylinder. The oil that is pushed out of the full piston side will return to the tank through the B and T ports of Troubleshooting Sawmill Hydraulics Page 29

13 the valve. No. 22 is a two position, four way, single solenoid, spring return, directional valve. 23. Pilot Operated Check Valves These valves are used to lock oil in on both sides of the saw change cylinder. When the directional valve is energized to extend the cylinder oil will free flow through the inline check valve, then into the full piston side of the cylinder. At the same time pilot pressure will shift the check valve open in the rod side line. This permits the oil that is forced out of the rod side to reverse flow through the check valve and return back to the tank through the directional valve. 24. Crossport Relief Valves These cartridge type relief valves protect the Rollcase Motor from shock as it is started and stopped. Since the No. 13 directional valve has a closed center, high pressure fluid is introduced rapidly to the motor when it is started under a load. The resulting shock spike could be very large. This spike will be limited to the spring setting of the relief at the inlet of the motor. Similarly, when the motor is stopped, high pressure fluid is suddenly deadheaded. The relief at the outlet of the motor will limit this spike to its setting. The proper setting for these valves is PSI above the pressure required to move the heaviest load. Please see the Motors section of our Maintenance Hydraulic Troubleshooting manual for detailed instructions on setting these valves. 25. Proportional Flow Controls These flow controls limit the flow into and out of the Rollcase motor according to the signal applied. This allows the speed of the Rollcase motor to be controlled electronically. Flow through each valve is proportional to the signal that is sent, so an increase in the signal will open the flow control to cause a corresponding increase in speed. Page 30 Troubleshooting Sawmill Hydraulics

14 Schematics Troubleshooting Sawmill Hydraulics Page 31

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