reel spool movement, sidelay, oscillation and lifting

Reel Spool Movement, Sidelay,Oscillation and Lifting

Symbol DescriptionP1 Pump

46 GPM, variable displacement, pressure compensating, externally

drained, piston type pump that supplies oil to the relief pressure

cylinders. The pump volume may also flow through the O5FV5 check

valve combining with the P2 and P3 pumps’ volumes to supply the

other winder circuits. The P1 pump will supply maximum volume until

less oil is required. The pressure will then build to the setting of the

compensator 2030 PSI. The compensator spool will then shift

allowing the pump to de-stroke and deliver only the amount of oil

required to maintain the compensator spring setting. There are two

adjustments located on the pump. The compensator is the

adjustment closest to the pump housing. A load sensing spool is

mounted on top of the compensator housing but is not used in this

system.

Troubleshooting Papermill Hydraulics

Reel Spool Movement, Sidelay, Oscillation and Lifting

If the compensator spool were to stick open then the pump would

deliver a near 0 GPM flow rate and a low pressure would be read on

the gauge. If this were to occur the pump should be turned off and the

pressure gauge checked to verify that the pressure has bled down to

0 PSI. The compensator spool can then be removed and inspected

for contamination. Also verify that the spring is not warped, broken, or

damaged.

There are checks that can be made to determine that the pump is

delivering the proper volume. The first is to remove the case drain line

and run it into a container of known size. Normal bypassing for this

pump should be ½ – 1 ½ GPM. Another test that can be made is to

record the temperature difference between the suction and case

drain lines. Multiply the outlet pressure times .0092. Divide the

resulting number into the temperature difference of the suction and

case drain lines. A temperature of 28ºF will indicate that the pump is

bypassing 1 ½ GPM. A severe increase above this temperature

indicates a badly worn pump.

There is a manual volume adjustment on this pump. The adjustment

is located on the end of the housing. By turning the adjustment

clockwise, the maximum volume that the pump can supply will be

reduced.

P2 Pump

46 GPM, variable displacement, externally drained, pressure

compensating, piston type pump. This pump will supply 46 GPM to all

circuits on the winder except the relief pressure cylinders. If less oil is

required then the pressure will build to the setting of the compensator

at 2320 PSI. The compensator spool will then shift allowing the pump

to de-stroke and only deliver enough oil to maintain the setting of the

compensator spring.









damaged.

There are two checks that can be made to determine that the pump is













reduced.

P3 Pump

46 GPM, variable displacement, externally drained, pressure

compensating, piston type pump. This pump will supply 46 GPM to all

circuits on the winder except the relief pressure cylinders. If less oil is

required then the pressure will build to the setting of the compensator

at 2175 PSI. The compensator spool will then shift allowing the pump

to de-stroke and only deliver enough oil to maintain the setting of the

compensator springs.









damaged.

There are two checks that can be made to determine that the pump is













reduced.

P4 Pump

This 10 GPM, fixed displacement gear type pump continuously

re-circulates oil through the water cooler and RF2 filter. Maximum

pressure in this circuit will be determined by the sum of the O5FV4

and RF2 bypass check valves’ springs.



PF Pressure Filter

This ten micron element filters the oil to all circuits on the winder

except the relief pressure cylinders. A pressure switch is mounted on

the filter housing. When the pressure drops across the element

reaches the switch setting, an electrical signal will be sent.

Depending upon the electrical programming, a warning or shut down

condition will occur. The element should be changed after this switch

actuates since there is no internal bypass check valve in the filter

housing.

RF1 Return Filter

The oil that exhaust out of the directional valves’ tank lines is ported

through this filter before returning back to the tank. In the event that

the element becomes contaminated then the pressure switch will

electrically indicate the condition. If the element is not changed and

the inlet pressure builds to the internal check valve’s spring rating the

oil would return directly back to the tank unfiltered. The element

should be changed as soon as possible after the pressure switch

indicates a dirty element. The filter can also be set up on a regular



filter maintenance schedule. This can be determined by an effective

oil analysis program.

RF2 Filter

The P4 pump volume can 10 GPM, is continuously re-circulated

through this filter’s element. If the element becomes contaminated

then the pressure switch will actuate and electrically indicate the

condition. The element should be changed as soon as possible after

the switch actuates. If the element is not changed and the inlet

pressure builds to the rating of the check valve’s spring 43 PSI, then

oil will return to the reservoir unfiltered. The element can be set up on

a regular maintenance schedule. This can be established through an

effective oil analysis program.

O5FV1 Check Valve

The valve will permit free flow from the pump to the system. The valve

will block any pressure spikes to the hydraulic pump.

O5FV2 Check Valve



OF5V3 Check Valve



O5FV4 Check Valve

This check valve will provide a flow path around the cooler in the

event of a cold oil condition or contamination inside the shell. The

check valve has a spring rating of approximately 65 PSI. Under

normal operating conditions the tank line of the valve should be cold

or cool.



O5FV5 Check Valve

This check valve will permit free flow from the No. P1 pump to

combine with the P2 and P3 pumps’ volumes. The check valve will

block flow from the P2 and P3 pumps to the relief pressure cylinders.

O5HV1 Manual Valve

During normal operation this valve is in the open position. When

necessary to change the pump, the valve should be closed. Be

certain to reopen the valve prior to starting the pump.

O5HV2 Manual Valve


necessary, to change the pump the valve should be closed. Be


O5HV3 Manual Valve


necessary to change the pump, the valve should be closed. Be


O5HV10 Manual Valve

During normal operation this valve directs oil in the reservoir to the P4

pump suction. When neccesary to refill the reservoir a hose can be

connected and the valve shifted to allow the P4 pump to fill the tank

from a 55 gallon drum.

O5HV11 Manual Valve

During normal operation the valve directs the P4 pump volume

through the heat exchanger and filter. A hose can be connected to

the third port when necessary to sample the oil or to pump oil out of

the reservoir.

O5HV12 Manual Valve

The oil that exhaust out of the directional valve tank lines in the relief

pressure cylinders is directed through this manual valve before



entering the reservoir. The valve should be closed when necessary

to change the RF1 filter.

O5HV13 Manual Valve

The oil that is ported out of the directional valves’ tank lines on all

circuits except the relief cylinders will flow through this valve before

entering the reservoir. The valve should be closed when necessary

to change the RF1 element.

O5HV15 Manual Valve

This valve permits flow from the pumps to the roll release station and

rider roll raising and lowering cylinders. When necessary to block

flow to the cylinders the valve should be closed.

O5HV16 Manual Valve

This valve permits flow to the O5 PCV6 pressure reducing valve for

supplying oil for several circuits on the winder. Please refer to each

individual schematic for the circuits that can be isolated by closing

this valve.

O5HV17 Quick Disconnect

This connection is used when necessary to either sample the oil or

read the pressure immediately upstream of the RF1 filter.

O5HV18 Quick Disconnect

This connection is used when necessary to either sample the oil or

read the pressure immediately upstream of the RF1 filter.

O5PCV1 Relief Valve

This valve is used to absorb shock spikes in the system as well as act

as an extreme safety device. In the event that one of the pump

compensator spools were tostick in the closed position, the pump

would deliver maximum volume at all times. Once the pressure builds

to the setting of this relief, the spool should shift open dumping the

excess volume back to the tank. It is important that this relief valve be

set a minimum 200-250 PSI above the setting of the pumps’



compensator setting. If the compensator spring on either pump were

adjusted above the spring setting, then the pump would deliver

maximum volume at all times. The excess oil not required by the

system would once again return back to the tank through the relief

valve. Heat would be created if this were to occur. Please refer to our

Maintainance Hydraulics Troubleshooting manual, hydraulic pumps

section, pages 15-16 for the proper adjustment procedure of this

relief valve. If this valve were to fail in the open position, then the

winder circuits would operate slower or possibly not at all.

O5PS5 Pressure Switch

This switch is mounted on the PF pressure filter. The switch will

electrically indicate when the pressure drop across the element

reaches approximately 72 PSI. The element should be changed as

soon as possible after the switch actuates to prevent collapsing of the

element. The filter can also be set up on a regular maintenance

schedule.



O5TCV1 Water Modulating Valve

A capillary tube senses the oil temperature in the reservoir and

directs it to this valve. When the temperature reaches 113ºF the

modulating valve will shift open a small amount. This permits a low

volume of water to flow through the cooler tubes. As the oil

temperature increases the valve will shift more to the open position.

This allows more water flow for cooling the oil.

O5YU3 Filter

This filter removes contaminants from the water prior to being

directed through the modulating valve and water cooler. This filter

should be cleaned regularly to insure a good transfer of heat from the

oil to the water.


This switch is used to indicate a low pressure condition in the system.

The setting of the switch is 580 PSI. This low pressure could be

caused by a failure of one of the pumps the O5PCV1 valve sticking

open, or a leak in the line.

O543PS4 Return Filter

The switch is mounted on the RF2 filter housing. When the filter

becomes contaminated the inlet pressure will increase. Once the

pressure reaches the setting of the switch an electrical signal will be

sent. The element should be changed as soon as possible after the

switch actuates. If the element is not changed and the inlet pressure

builds to the check valve spring rating, 43 PSI, the P4 pump volume

will bypass the filter. This can cause failure of the pumps and other

components in the system. The filter can be set up on a regular

maintenance schedule. This schedule can be established through an

oil analysis program.




This switch is used to electrically indicate when the RF1 filter is

contaminated A light or other warning device will indicate to the

operator that the element needs to be changed. If the element is not

changed and the inlet pressure builds to the rating of the internal

check valve spring, 43 PSI, then the return oil will flow directly back to

tank unfiltered.


This switch is used to electrically indicate when the pressure to the

relief pressure cylinders drops below 870 PSI. Depending on the

electrically programming a warning or shut down condition will occur.

This low pressure can be caused by a defective pump, the O5PCV1

valve sticking open, or a leak in the line.


This switch is used to electrically indicate when the RF1 filter is

contaminated A light or other warning device will indicate to the

operator that the element needs to be changed. If the element is not

changed and the inlet pressure builds to the rating of the internal

check valve spring 43 PSI, then the return oil will flow directly back to

tank unfiltered.

13FCV1 Flow Controls

These flow controls control the speed of the sidelay operation. The

valves are connected in a meter out type arrangement. Oil will free

flow when ported from the directional valve to the hydraulic motor. If

the sidelay speed is too slow then one of these flow controls may be

contaminated. Rotate the adjustment of each valve several turns

counterclockwise. Then energize the “A” and “B” solenoids

alternating on the No. 13 SV1 directional valve. Many times the trash

will blow out of the orifices. Be certain to reset the valves back to the

their original position. Both valves are located in one block which is

mounted underneath the directional valve.




These valves are used to control the speed that the reel spool

oscillates. The valves are connected in a meter out type

arrangement. Oil will free flow through the internal bypass check

valve when ported from the directional valve into the motor. If

contaminated, these valves can cause a slow down of the oscillating

speed. Refer to the 13FCV1 description for the procedure for

removing contaminates from these valves. Both valves are located in

one block which is mounted underneath the directional valve.


These valves control the speed that the motor moves the reel spool

machine both forward and backward. The valves are connected in a

meter out type arrangement. Oil will free flow through the internal

bypass check valve when ported from the directional valve into the

motor. Please refer to the No. 13 FCV1 description for the procedure

for removing contamination in the valves. Both valves are located in

one block which is mounted underneath the directional valve.

13FV1 Check Valve

This check valve will maintain oil in the lines on both sides of the

sidelay and oscillation motor when the 13SV2 directional valve is

de-energized. The check valve will also block any flow surges from

other circuits to the sidelay and oscillation motor.

13HV1 Manual Valve

This valve can be used to block flow to the sidelay and oscillation

motor.

13PCV1 Crossport Relief Valves

When the 13SV3 valve is energized to move the reel spool machine

an initial pressure spike will occur when the oil is ported to the motor

inlet. The specific crossport will shift open when the spring setting

(2320 PSI) is reached. This prevents damage to the machine and

hydraulic components. These valves are located in one block

underneath the directional and float control valves. If one of these



valves were to stick open, then the reel spool machine would move

slower or not at all.

13SV1 Directional Valve

This valve is energized to move the reel spool either towards the

drive or tending side. Energizing the “A” solenoid (straight arrows)

ports fluid for rotating the motor to move the spool to the drive side.

The “B” solenoid ( crossed arrows) energizes to port fluid to the

opposite port for moving the spool to the tending side. 13SV1 is a

closed center, three position, four way, double solenoid, spring

centered, directional valve.


This valve is energized into the “A” or “B” positions to oscillate the reel

spool from one side to the other. 13 SV2 is float center, three position,

four way, double solenoid, spring centered, directional valve.


This valve is used to move the reel spool machine to the forward or

backward position. When the A solenoid is energized, the spool will

shift into the ‘A” position (straight arrows).The motor will rotate to

move forward. Energizing the “B” solenoid will direct oil to the

opposite side of the motor for moving the machine backwards.

No.13SV3 is a float center, three position, four way, double solenoid,

spring center, directional valve.

14FCV1

14FCV2 Counterbalance Valves

These valves are located at the reel spool lifting cylinders. When the

cylinders are extending, oil will free flow through the internal bypass

check valves then into the full piston sides. When the cylinders are

fully raised and there is no voltage on the No.14SV1 proportional

valve oil will be locked in the full piston sides of the cylinders. The

setting of the valve springs should be slightly higher than what is

required to hold the spool in the raised position.



There are two pilot lines that are used to shift the spool open. The

internal pilot line acts on a smaller square inch area than does the

external pilot line. This means that a higher pressure is required to

shift the spool open with the internal pilot line. When the cylinders are

extended the spring is set above the pressure exerted on the internal

pilot line. This permits the spool to remain closed.

When the No.14 SV1 proportional valve energizesto retract the

cylinders, pilot pressure is directed to a larger area on the end of the

spool to shift the valve open. Since this area is larger than the area

than the internal pilot passage acts upon the spool will be shifted

open at a lower pressure. Although no ratio was given for the external

and internal pilot areas a 3:1 or 4:1 ratio are common. This simply

means that the internal pilot area requires three or four times the

pressure to shift the spool open than does the external remote line.

When the spool is lowering the cylinders may tend to retract faster

than oil is supplied into the cylinders’ rod sides. This would cause the

pressure to drop in the remote pilot line. This will permit the valve

spools to shift partially closed restricting the oil out of the cylinders.

This prevents a freefalling effect when lowering the spool. For safety

purposes the cylinders should be fully retracted before either of these

valves are removed for troubleshooting or replacement.

14FCV3 Flow Control

When the No. 14 SV1 proportional valve is de-energized after

retracting the cylinders this flow control will control the rate that the

counterbalance spools shift back to the closed position. Oil will free

flow through the internal check valve when shifting the valve open for

lowering the lifting arms.

14FV1 Check Valve

This check valve will maintain oil in the lines to the cylinders when the

No.14SV1 proportional valve is de-energized. The check valve will

also block any high flow surges in the tank line to the lifting arms

cylinders.



14HV1 Manual Valve

This valve can be closed to block flow from the pumps to the reel

spool lifting arms cylinders.

14HV2 Manual Valve

When this valve is closed flow is blocked from the No.14SV1

proportional valve to the full piston sides of the cylinders.

14HV3 Manual Valve

When this valve is closed flow is blocked from the No.14SV1

proportional valve to the rod sides of the cylinders.

14PCv1 Pressure Reducing Valve

This valve is used to reduce the system pressure down to the

No.14SV2 T port as well as the rail gate waiting station stoppers, and

the reel spool coupling and locking circuits. The valve will shift

between fully opened and fully closed allowing only enough oil

through the valve to maintain the setting of the valve spring, 725 PSI.

14SV1 Proportional Valve

To extend the cylinders a DC voltage is applied to the “A” coil on the

pilot valve. The pilot valve will shift directing pressurized fluid to one

end of the main spool. The higher the voltage the higher pressure

that is ported to the spool. The amount that the spool shifts is

determined by the applied pilot pressure. The speed that the lifting

arms raise is determine by the amount that the main spool shifts.

Therefore the higher the voltage to the pilot valve the faster the

cylinders will extend to lift the spool.

To retract the cylinders a voltage is applied to the “B” solenoid. Once

again the pilot pressure directed to the B side of the main spool is

proportional to the applied voltage. The amount of flow ported to the

rod sides of the cylinders is proportional to the amount that the main

spool shifts.



There are manual actuators on the end of each solenoid which can

be actuated to determine if the problem is electrical or hydraulic. If the

cylinders operate when the manual override is depressed then there

is either a bad coil or other electrical problem which is preventing the

cylinders from operating.

14SV2 Directional valve

When necessary to extend the cylinders and raise the spool the “B”

solenoid on the pilot valve energizes. Internal pilot pressure is then

directed to hydraulically shift the main spool into the “B” position

(crossed arrows). This directs high pressure from the P2 and P3

pumps to the P port of the No.14SV1 proportional valve. The

proportional valve will shift into the “A” position to extend the

cylinders and raise the spool.

To lower the spool the A solenoid on the pilot valve energizes. Pilot

pressure is directed internally to shift the main spool into the “A”

position (straight arrows). The reduced pressure supply through

No.14PCV1 of 725 PSI is then directed through the spool and to the P

port of the No. 14SV1 proportional valve. The proportional valve is

shifted into the B position to retract the cylinders. No.14 SV2 is a

closed center, three position, four way (with a pipe plug in the “A”

port), double solenoid controlled, internally hydraulic piloted,

externally drained, spring centered, directional valve.



reel spool movement, sidelay, oscillation and lifting

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