Issuu on Google+

CTR314SCD Wholetree Processor

Hydraulic System Supplement Manual

P.O. Box 252 Silver Creek, WA 98585-0252 Ph. 360-985-7112 Fax 360-985-7935


Hydraulics General Information HYDRAULIC PUMPS ..................................................................................................................................................................3 Hydraulic Pumps Circuits....................................................................................................................................................3 Circuit Routing.....................................................................................................................................................................3 SAW CIRCUIT [LARGE PUMP] ...................................................................................................................................................5 Saw Operation .....................................................................................................................................................................5 Side Saw circuit................................................................................................................................................................................... 5 Topping Saw circuit ............................................................................................................................................................................ 5

Saw Bar Down .....................................................................................................................................................................6 Side Saw Circuit.................................................................................................................................................................................. 6

Saw Bar Up..........................................................................................................................................................................7 Both Side and Topping Saw Circuits................................................................................................................................................... 7

Chain Lube Circuit ..............................................................................................................................................................8 Bar down cycle.................................................................................................................................................................................... 8 Bar up cycle......................................................................................................................................................................................... 8

OPERATIONS CIRCUIT [SMALL PUMP] ......................................................................................................................................9 Main Control Systems ..........................................................................................................................................................9 Pilot Control Circuit ..........................................................................................................................................................10 Pressure Reduction Control Valve Manifold..................................................................................................................................... 10 Pilot Control Valve Manifold ............................................................................................................................................................ 10 Electrical-Hydraulic Actuators .......................................................................................................................................................... 10

DELIMBER KNIFE CIRCUIT [OPENED] .....................................................................................................................................11 Inner Control Circuit ......................................................................................................................................................................... 11

DELIMBER KNIFE CIRCUIT [CLOSED] .....................................................................................................................................12 Accumulator Response...................................................................................................................................................................... 12

Individual Circuits Defined MAIN SECTIONAL VALVE ASSEMBLY .....................................................................................................................................13 GRESEN SAW VALVE SECTION [MODEL V42 W/ACTUATOR INSTALLED}................................................................................14 Port Location Drawings ....................................................................................................................................................14 Saw Valve Parts .................................................................................................................................................................15

2

Copyright 2001 [all rights reserved]


Hydraulics

General Information Hydraulic Pumps Hydraulic Pumps Circuits The system is open centered flow, provided by a Commercial-Shearing Model 25X dual stage, gear type pump. There are [2] circuits that this pump supplies oil for. The 55-gpm [shaft end, front of pump] provides oil to the Saw Circuits. The 23gpm [smaller section] provides oil to all remaining circuits, [delimber knives, stabilizers, throttle control, and the pilot operating circuit].

Circuit Routing Unfiltered hydraulic oil is drawn from a 48-gallon tank to both stages of the hydraulic pump assembly. At full engine throttle, system line pressure sustains 500+-psi @ ambient operating temp of at least 130째 degrees. When a function is activated, the system pressure is routed to that function until it ends a cylinder stroke, or has felt external resistance. The main system relief located at the end of the directional control valves assembly will then relieve and sustain at 2800-psi +or- [System relief setting]. All relieved and returning oil is routed back through an oiler cooler in front of the engine assembly. The cooled hydraulic oil is then sent to dual 25-micron filter units, [mounted on the tank] and flows into the reservoir tank assembly.

Copyright 2001 [all rights reserved]

3


Hydraulics

4

Copyright 2001 [all rights reserved]


Hydraulics

Saw Circuit [Large Pump] Saw Operation The Saw Circuit requires a full throttle, 55-gpm-oil flow for more efficient and productive operations. When the saw circuit, electrical-hydraulic actuators are functioned, the saw directional control spool is pushed, or pulled to route line pressure to its assigned ports. Side Saw circuit The delimber knives have to be in their open position for this circuit to work. Pressured oil is routed through the saw directional control valve, to the saw selector valve assembly. Pilot oil pressure from the open knife circuit, slides the saw selector valve spool over against spring pressure, which opens the port to the side saw circuit. For detailed oil routing in the saw circuit, go to the Saw Bar Down, Side Saw circuit schematic [Pg. 6]. After the saw bar down is cancelled, the remote radio system will automatically engage the auto bar up circuit. The electrical-hydraulic actuator pushes in, the saw valve spool. Pressure oil then flows to a relief valve manifold to control the amount of pressure to return the saw bar to its park position. Detailed oil routing is shown in the Saw Bar up, Side Saw circuit schematic. [Pg. 7] Topping Saw circuit When the delimber knives are closed for delimbing, the pilot pressure to the saw selector valve drops off. Spring pressure in the selector valve then slides its spool back over, to port line pressure oil to the topping saw circuit. All functions then become the same as the side saw, for topping saw bar down and up. Notice also the chain oiler functions during each up and down cycles of the saw bars. Oiler circuits are detailed in dark and light gray colors. [Pages 6 & 7] Figure 1 Saw Circuits [Static]

Topping Saw Circuit

Side Saw Circuit

Copyright 2001 [all rights reserved]

5


Hydraulics

Saw Bar Down Side Saw Circuit When the saw bar down circuit is functioned, oil flows from the 55-gpm pump to the saw motor and through to return. Down pressure on the saw bar is accomplished during this time, by routing a portion of this return, through a tee to the rod end of the saw bar cylinder. A control valve manifold, is located inline of this saw motor return oil. [Topping saw, and Side saw] In this manifold is the saw bar down cartridge relief, set at 500-psi + or -. During the saw bar down function, line pressure between the saw motor return oil and the control valve manifold builds to this rated pressure. Oil is then pushed through the tee to the rod end of the saw bar cylinder to pull the rod in, and lower the saw bar. The lines to and from the saw cylinder are routed through and adjustable orifices mounted near their respective cylinders. Adjustments of these valves, limit the bar speed, up and down. When the saw bar and chain come in contact with the log that you are cutting, the chain and bar speed slows. This will cause line resistance between the saw bar down cartridge relief setting and the saw motor return to decrease. Upon doing so the bar down pressure is also decreased, allowing the chain speed to increase to its maximum. Depending on the wood that is being cut, you may fine-tune this operation, by adjusting the saw bar down cartridge relief + or -, and or regulate the adjustable orifices to slow or speed up the bar action. Below is a schematic of the Side Saw circuit [boxed in red] functioned to cut a log. All pressures are marked accordingly. The Topping Saw circuit [boxed in blue] is built exactly like the Side Saw. This circuit is functioned whenever the delimber knives are closed. The selector valve is moved by spring pressure to its other position allowing pump pressure to be routed to the Topping Saw circuit. Saw Valves.

Side Saw motor and control

Figure 2 Side Saw [bar down circuit] Saw Selector Valve Main pressure [2250-psi] Return to tank [non-restricted] Saw Motor Outlet pressure [500-psi] Bar Down pressure [as required] Bar Down return [as required] Pilot oil pressure [400-psi] Chain lube oil [65-psi] Suction oil Bleed return oil [non-restricted] System Pilot pressure. 400-psi

Saw Selector Valve Saw Motor

500psi

]

6

Copyright 2001 [all rights reserved


Hydraulics

Saw Bar Up Both Side and Topping Saw Circuits When the saw bar up function is activated, pressured oil is routed through an adjustable flow orifice to the piston end of both the side, and topping saw cylinders simultaneously. Accordingly to which saw is being used, the cylinder rods are extended, and the saw bar is returned to its park position. Line pressure builds at this time to function the saw bar up relief valve mounted inline between the saw Control valve and the bar cylinders. Returning oil from the rod end of the bar cylinder is then pushed through an adjustable flow orifice to maintain the speed of the retracting bar. Complete description of the chain lube circuit function during the saw bar up and down, are described in a schematic on page 8.

Bar up relief valve manifold’s location, inside battery access compartment, and mounted on the right side inner wall.

Figure 3 Saw Bar Up

800 Psi

Copyright 2001 [all rights reserved]

7


Hydraulics

Chain Lube Circuit Bar down cycle Pressured oil from the saw bar down circuit is shared with the saw chain oiler assembly. Line pressure to the saw bar cylinder is routed through a tee fitting to the piston end of the oiler. This chain lube oiler assembly, is a small two-way cylinder that incorporates a reservoir cavity on the rod end of the cylinder. During the saw bar down cycle, the cylinder rod is extended into the reservoir. The rod then displaces lube oil that is already in this cavity. Displaced lube oil is pushed out of the reservoir, through a 65-psi inline check valve to the sprocket end of the saw bar assembly, which then disperses it onto the bar rail. Bar up cycle Upon functioning of the auto bar up, the lube oil circuit reverses that of the saw bar down. Pressured oil to the saw bar up is then shared again, with the chain oiler assembly. This shared oil is routed through a tee fitting to the rod end of the lube oiler assembly. The rod is retracted out of the reservoir cavity. The outlet check valve to the saw sprocket is then closed, and a inlet check valve of the lube oil tank assembly is opened replenishing the displaced lube oil. Figure 4 Saw Chain Lube Schematics Saw Bar down cycle

Saw Bar up cycle

Lube Oil Displaced

Lube Oil Replenished

Saw bar oiler assembly locations Lube oil bleeder port plug. Lube oiler volume adjustment screw Lube oil reservoir cavity Two-way cylinder end.

8

Copyright 2001 [all rights reserved]


Hydraulics

Operations Circuit [Small Pump] Main Control Systems The control systems are supplied oil from the small section of the dual stage, Commercial-Shearing, open-center hydraulic pump assembly. These [4] circuits are completely separate from the saw circuit. The four circuits covered in this section consist of, the Pilot Control, Delimber Knives, Throttle Up, and Stabilizer Cylinders. The control systems oil volume of 23-gpm flows from the main pump small section, to the Gresen model V20 directional control valve bank. This open-center line pressure flows through this main system control bank and on to the tank return. The inlet cap section of this valve bank incorporates the main system relief valve. Externally adjusted, this valve sustains any of the valve banks circuit relief’s to system pressure relief rate specification of 2800-psi + or -. All the sectional bodies have manual control levers, for manual function of their individual circuits. These circuits consist of the stabilizer cylinders up, and down, and the delimber knives, [opening only]. The delimber knife circuit is the only sectional valve in this bank that incorporates a radio controlled electrical-hydraulic actuator valve that is attached to the bottom end of the delimber knife spool assembly. Note: It is recommended that the Delimber Knife and Saw, manual control levers be omitted from being installed during normal operations. Upon action of the spool valve being pushed to activate their circuits, the pressure excerpted from the lever being attached will damage the internal parts of the hydraulic actuator. Please detach the lever and tie wrap it to the adjoining hoses above the valve assembly.

Gresen model V20 directional control valve assembly

Pressure reduction relief valve manifold. Supplies reduced system pressure to the pilot circuit. Delimber control valve, with the manual lever detached from spool.

System relief valve Adjustment 2800-psi Stabilizer control valves locations.

Main systems Directional control, Valve bank location.

Copyright 2001 [all rights reserved]

9


Hydraulics

Pilot Control Circuit All circuits that are remotely functioned from the Remote Radio Control are activated from supply oil provided by the Pilot Control Circuit. This oil comes from line pressure before the Main Control valve bank. Pressure Reduction Control Valve Manifold A pressure reduction control valve manifold is installed adjacent to the sectional body inlet port cap assembly. Oil provided by this valve is a reduced, sustained line restriction for the pilot and throttle systems to work correctly. This manifold incorporates an adjustable relief valve that is adjusted to 200-psi @ engine idle speed of at least 800-rpms. The [B] outlet port of this manifold is routed through to the main selector control valve component assembly. Pilot Control Valve Manifold This manifold is attached to the inner wall of the machines main frame, inside on the left, through the left-hand access door that you remove to service the main control valve bank. This manifold incorporates the adjustable relief valve needed to sustain line pressure of 400-psi to both the Saw, and Delimber Knife opening, hydraulic actuators. Electrical-Hydraulic Actuators These are the units mounted onto the rear, or bottom of the directional control valve assembly that it controls. There are two solenoids per control valve assembly. An electrical current is sent to the solenoid valve that controls the pilot pressure for the spool activation requested. An energized coil creates a magnetic field around the shaft end of the actuators small spool valve. This pulls up and opens the normally spring closed valve, to allow pilot pressure oil into one side of a small cylinder assembly. The oil moves the piston assembly that is attached to the bottom of the directional control valve spool, in or out to function the circuit as needed. The directional control valve itself is spring-centered to return the spool and actuator piston back to center. Test Port

Pilot control valve Manifold location

Figure 5 Pilot Circuit [Static] Directional Control Valve Component Assembly, 23-gpm Hydraulic Throttle assembly

Throttle Control Valve assembly.

Stabilizer Control Valves

Pilot Control Valve Manifold 400-psi @ full throttle

Pressure Reduction Valve Manifold, 200-psi @ engine idle of 800-rpm’s

Pilot Pressure Line To Delimber and Saw valves.

Pressure line to Delimber circuit.

Delimber Control Valve

10

Copyright 2001 [all rights reserved]


Hydraulics

Delimber Knife Circuit [Opened] Inner Control Circuit This circuit is composed separately of all the other control circuits. Pressured oil routed through the delimber knife selector valve, flows to the double relief valve manifold and also the rod end of the knife cylinders. This action opens the knife assemblies. The oil returning from the piston end is then pushed into a nitrogen gas filled accumulator that is inline of the circuit. This charges the accumulator to the opening pressure setting. When the operator releases the opening functions, a check valve inline between the selector control valve, and the double relief valve manifold will seat and block any oil back to the control valve assembly. Internal pressure trapped within this circuit then relieves down to the accumulator response closing pressure. This pressure will be sustained always until the circuit is manually drained through the accumulator discharge valve located externally of the double relief valve manifold. Note: Anytime you do repair work on the delimber knives, it is required that you drain and relief the accumulator response oil pressure. This oil can do bodily harm under pressure release of a hose or fitting. Looking into the L.H. side of the delimber head with the service panel removed.

Vickers dump valve Looking from underneath the machine. Double relief valve manifold Looking through the back fold down, light panel door.

Figure 6 Delimber Knife Circuit [Opening] Pressured oil from Delimber Selector Control valve Opening relief set at between [1100 –1500-psi] Vickers dump valve shifts closed when knives are

Opening Relief Valve

Closing Relief Valve

Double Relief Valve Manifold [Opening & Closing]

Accumulator discharge valve

Accumulator Opening Charge Pressure [Opening relief adjusted 1100 – 1500-psi.] Nitrogen Gas filled Accumulator [250-psi]

Copyright 2001 [all rights reserved]

11


Hydraulics

Delimber Knife Circuit [Closed] Accumulator Response Knife opening oil flow fills the accumulator until the pressure inside equalizes to both sides of its bladder. The accumulator bladder is pre-charged with 250-psi of nitrogen gas, which creates the force to sustain the line pressure to close the knife assemblies. Normally this opening pressure is set at between 1100 to 1500-psi. When the knives are closed around a tree to be pulled through the knives, this opening pressure is then “dumped” to tank. Pressure on the inlet side of the opening relief valve cartridge, drops to [0-psi] and the oil between outlet side and the closing relief valve cartridge becomes trapped. The trapped oil relieves down to the closing relief valve pressure that is set between 500 – 800-psi. This internally controlled accumulator pressure will stay the same while the tree is being pulled through the knives. As the tree stem becomes smaller in diameter, the knife openings close down upon the tree stem with the same amount of force that it started out with. When the tree has been delimbed, the operator opens the knives again for the next cycle. Opening pressure again floods into the accumulator while opening the knife cylinders and the circuit is ready for the next tree stem to enter. Note: Anytime you do repair work on the delimber knives, it is required that you drain and relief the accumulator response oil pressure. This oil can do bodily harm under pressure release of a hose or fitting. Accumulator cylinder location Looking from underneath and towards the rear of the machine.

Looking from underneath, towards the rear of the machine

Figure 2 Delimber Knife Circuit [Closed] Static oil in line from Delimber Selector Control valve. Vickers dump valve Shifts when knives are closed.

Opening Relief Valve

Closing Relief Valve

Double Relief Valve Manifold [Opening & Closing]

Accumulator discharge valve

Accumulator Response Closing Pressure [Closing relief adjusted 500 – 800-psi.] Nitrogen Gas filled Accumulator Bladder [250-psi] 12

Copyright 2001 [all rights reserved]


Hydraulics

Individual Circuits Defined Main Sectional Valve Assembly Pressure Reduction manifold and relief valve cartridge, view looking from underneath to the front of the machine.

Electrical Solenoids for routing pressured pilot oil to function that is activated. Only one is wired and used to push the valve spool out. View is looking from underneath to the front of the machine.

Hydraulic Actuator mounted on rear of Delimber valve section

200 psi @ idle speed of at least 800 rpm’s

Illustration is of looking down onto the top of the selective control bank

Test port adapter 0-3000 psi gauge required

Front of machine.

Lever omitted as explained on page 9.

Main System Relief valve. System pressure 2800 psi @ 2200 engine rpm’s.

Figure 7 Main System Section Valve Bank

Copyright 2001 [all rights reserved]

13


Hydraulics

Gresen Saw Valve section [Model V42 w/actuator installed} Port Location Drawings Drawing shows valve section in centered neutral position. All port descriptions are as follows. Please note the call to area of the spool screw, and the functioning of the spool itself. This has always be a problem spot for Saw valve and Delimber valve sections alike. If the manual lever is installed to manually function the valve for test purposes, it sometimes is forgotten to be removed. The force exerted on moving the valve back and forth is very smooth and fast. The coupling of the handle on the end clevis does not fit tightly enough to move in tandem with the spool, thus causing a backlash action of the lever handle. Results of leaving it installed over a period of time, causes abnormal wear and fatigue of the coupling end of the spool screw. The screw coupler breaks causing loss of only the saw bar down function, due to it being able to still push the spool out to function the saw bar up.

Model 25P Electrical-Hydraulic actuator assembly 2

Figure 8 Saw Valve Sectional with Hydraulic Actuator

3 V42 [4-way, 3-position work section] 4

1

Pilot pressure inlet. Pressure setting @ 400 psi. Full throttle

Saw Bar down port location

14

Saw Bar up port location

Copyright 2001 [all rights reserved]

5


Hydraulics

Saw Valve Parts Gresen Model V42 Directional Control Valve Parts Item 1

CTR Parts Number N/A

Gresen Parts Number CK28077

1 2 3 4

200442 N/A N/A N/A

5

200436

N/A 8512-001 CK-6083 8045-xxx [They will request a casting #no.] N/A

15

Description Actuator [complete w/out solenoid cartridges] Actuator [complete] Coil only [12v] Solenoid Valve Cartridge [complete] Work section only Saw Valve assembly complete [w/ end caps, system relief valve, directional valve, electrical-actuator assembly]

Copyright 2001 [all rights reserved]


Hydraulics

Gresen System Control Valve section [

16

Copyright 2001 [all rights reserved]


CTR 314 SCD Delimber Hydraulic Repair Manual