Car Dumper-Operating Instruction Manual

Car Dumper

Operating InstructionNo.：A270100203YMS

（Chapter 8 Hydraulic）

DHI·DCW Group Co., Ltd

April 2011

Please read this instruction before erection and operation.

Operating Instruction for Car Dumper Hydraulic

Preface

Dear customer,

Thank you for choosing our product!

Please read this operating instruction carefully for proper assembling, safe and fault-free operation of the car dumper, especially pay attention to the chapters with safety caution and safety rules given in this instruction.

Please put this operating instruction in places convenient for access for timely consulting in case of doubt.

This operating instruction is delivered to the user of the machine and the copy right is reserved by DHI·DCW Group Co., Ltd. The technical specification, drawing and sketch provided shall not be wholly or partially copied, distributed, used for competition or provided to the third party without our authority or approval.

Please keep this operating instruction properly during the service life of the machine.This operating instruction is applicable for car dumper.This operating instruction consists of the following chapters:

—— Chapter 1 Product Overview；—— Chapter 2 Safety；—— Chapter 3 Erection, Commissioning；—— Chapter 4 Operation；—— Chapter 5 Service, Maintenance；—— Chapter 6 Other；—— Chapter 7 Electrical；—— Chapter 8 Hydraulic

This document is “Chapter 8 Hydraulic”. If you can not find the solution for your doubt in this document, please contact us, we will be very glad to provide assistance to you.Contact information of our company:Address: 169 Bayi Road, Xigang District, Dalian, Liaoning Province Postcode: 116013Website: http://www.dhidcw.comReception Telephone：0411-86852188 E-mail：[email protected] Service Center: 0411-62999688 Fax：0411-86852553 E-mail：[email protected]

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Chapter 1 Product Overview

Contents1.1 Characteristic..................................................................................................................................................2

1.2 Main Purpose and Applicable Scope..............................................................................................................2

1.3 Technical Feature...........................................................................................................................................2

1.4 Ambient Condition.........................................................................................................................................3

1.5 Operating Condition.......................................................................................................................................3

1.6 Influence on Environment and Energy...........................................................................................................3

1.7 Structural Feature and Operating Principle.....................................................................................................4

1.7.1 Overall Structure and Operating Principle, Operating Feature....................................................................4

1.7.2 Structure, Function and Operating Principle of Main Component or Functional Unit................................5

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Overview

1.1 Characteristic

The hydraulic station of the car dumper is perfect in control of level, oil temperature and medium

contamination, which assures the hydraulic system is in normal operating condition. The main hydraulic

elements are produced and manufactured by REXROTH Germany and YUKEN Japan. The pump, valve

selected conform to international standard in installation dimensions and have advantages, e.g. compact

structure, high flow capacity, small volume, etc.

1.2 Main Purpose and Applicable Scope

The hydraulic station of the car dumper consists of pump station, clamping device, positioning device, air

cooling device and piping accessories. The pump station provides power source for the whole system. The

positioning device drives the positioning plate forward and backward mainly through control of actuation of

positioning cylinder. The clamping device drives the clamping beam to lift and lower mainly through control

of actuation of clamping cylinder. The air regulator assures reliable operation of the oil pump under enclosed

oil tank state.

1.3 Technical Feature

See Table 1 for technical feature of the hydraulic system.

Table 1 Technical Feature of Hydraulic System

Work pressure 3～5 MPa

Work flow ~330 L/min

Volume of oil tank 2000 L

Degree of contamination 9 NAS1638

Work medium Anti-friction hydraulic oil 46#

Pump stationL×W×H 2990×1600×1650 mm×mm×mm

Weight 2225 kg

Hydraulic pump

Type PV2R24-33-237-F-RAAA-30

Max.work pressure 17.5 MPa

Theoretical

displacement270 mL/r

Electric motor

Type Y225S-4 B35 37kW speed 1480r/min 415V 50Hz top

outgoing line IP55 class F

Speed 1480 r/min

Power 37 kW

Power supply 415,50 V,Hz

Type OKAF-EL8S/69/3.0/M/415-50/DF280/4/1

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Oil cooling fan

Power supply 415,50 V,Hz

Motor power of fan 1.5kW

Motor power of

pump2.2 kW

See Table 2 for data of each mechanism of the hydraulic system.

Table 2 Data of Each Mechanism of Hydraulic System

Working medium

High-temperature alarming 65 ℃

High-temperature

pump stop alarming75 ℃

Lowest levelDistance to bottom of oil

tank 500mm

Table 2（continued）

Highest levelDistance to top of oil tank

120mm

Overflow valve of pump Setting value for high pressure 3.5～5 MPa

Overflow valve of pump Setting value for low pressure 2～3 MPa

Pressure relief valve for

positioning Setting value 0.35～1 MPa

Pressure relief valve for

clamping Setting value 2～3 MPa

Clamping relay

detection pressure Setting value 2～3 MPa

Pressure of sequence

valve for clamping

compensation

Setting value 5～6 MPa

Oil cooling fan start Setting value ＞55° ℃

Oil cooling fan stop Setting value ＜45° ℃

1.4 Ambient Condition

Refer to relevant technical agreement.

1.5 Operating Condition

·　 The mechanical actuating mechanism is free from interference and blocking.；·　 The electrical control program has been improved；·　 The hydraulic system has been tested and accepted.

1.6 Influence on Environment and Energy

·　 Noise of the pump device of the hydraulic system operating will cause pollution to the

environment；

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·　 Improper disposal of leaking hydraulic medium will cause pollution to the environment.

1.7 Structural Feature and Operating Principle

1.7.1 Overall Structure and Operating Principle, Operating Feature

·　 The hydraulic system of the car dumper consists of pump station, clamping device, positioning device as well as their piping. Refer to Figure 1.

Figure 1 Hydraulic System of Car Dumper

·　 Refer to Figures 2, 3, 4 for schematic diagrams of hydraulic system of the car dumper.

Figure 2 Schematic Diagram of Pump Station

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Clamping device (16)

Positioning device (8)

Hydraulic pump station (2)


Figure 3 Schematic Diagram for Positioning

Figure 4 Schematic Diagram for Clamping

1.7.2 Structure, Function and Operating Principle of Main Component or Functional Unit

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Figure 5 Pump Station

Note：This system totally includes 2 symmetrical pump stations, only one of them is introduced here, the other one is completely the same as this one in arrangement and type.

The pump is equipped with enclosed oil tank：

On the top：oil feeder，from where the working medium is filled in the tank and the medium filled in

must be filtered to reach the required contamination degree；straight-through return oil filter, when the strainer core is clogged by contaminant, the by-pass valve at the underside will start to work

automatically to assure the oil filter and hydraulic system are in normal working condition； pre-compressed air filter, when the pressure in the tank is lower than the preset pressure, the one-way

exhaust valve is in closed state, this can maintain the preset pressure in the tank and improve the suction

capacity of the oil pump itself to avoid possible fault, e.g. cavitation erosion, etc. of the pump due to

shocking and turbulence of the hydraulic oil in the tank; when the pressure in the tank is higher than the

preset pressure, the one-way exhaust valve will be started automatically to exhaust and will not be closed

until the pressure in the tank is equal to the preset pressure. Circulation in this way can not only protect

the normal operation of the hydraulic system but also extend the service life of the working medium and

component.

·　 On the front side：manhole cover, from where the oil tank is cleaned；level and temperature indicator, convenient for observing the level and temperature of medium in the tank. Electric

motors of the pump，connecting the oil tank with the pump device through the butterfly valve and

oil suction filter； the butterfly valve is equipped with signal switch, when the butterfly valve opens, the signal switch will send a signal, the pump device will be started to work, and the motor

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Return oil filter

Butterfly valve for air cooling fan

Nameplate for schematic diagram

Ball valve for oil discharging

Pressure regulator

Level and temperature indicator

Tank cleaning hole

Pump device

Oil drain

Air regulator

Butterfly valve for oil suction

Pre-compressed air filter

Oil feeder Oil filter


shall not be started without receiving the signal ； air regulator, during action of actuating mechanism of the system, as the double-action cylinder with single piston rod is used, when the

cylinder acts, the volume of oil entering the cylinder is not equal to that discharged from the

cylinder, therefore the level of oil in the tank is in variable state during this process ； to compensate the pressure variation in the oil tank caused by rising and lowering of oil level, the air

regulator is used to ensure reliable operation of the oil pump under enclosed oil tank state.

·　 On the left side：the ball valve is located at the oil drain of the tank；butterfly valve of the

air cooling fan， the butterfly valve is equipped with signal switch, when the butterfly valve opens, the signal switch will send a signal, the air cooling fan will be started to work, and the air

cooling fan shall not be started without receiving the signal；manhole cover, from where the oil

tank is cleaned；·　 On the right side：the pressure regulating valve block is installed on the oil tank, it can be

used to set the maximum working pressure for the system， the pressure regulated can be

observed from the pressure gauge directly and clearly； temperature sensor, 4～20mA analog output, for controlling the stop and start of the oil cooling fan and high-temperature alarming of

the oil；·　 See Figure 6 for outline diagram of pressure regulating valve block.

Figure 6 Pressure Regulating Valve Block

·　 See Table 3 for energizing and de-energizing of the electromagnet in system operation.Table 3 Action of Electromagnet

Number

NameYH1 YH2 YH6

Overflow valveHigh pressure + - +

Low pressure - + -

Note： In the table above, “+”indicates the electromagnet is energized,“-”indicates the electromagnet is de-energized.

·　 See Figure 7 for outline diagram of valve block for positioning.

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Double-stage ＆ pressure-regulating electromagnetic overflow valve

Plate-type check valve

Pressure measuring point of chamber P

Electromagnetic overflow valve

Pressure measuring point of chamber T

Plate-type check valve


Figure 7 Valve Block for Positioning

·　 See Table 4 for energizing and de-energizing of the electromagnet in actuation of each cylinder.

Table 4 Action of Electromagnet

Number

NameYH4a YH4b

Positioning

cylinder

Extension + -

Retraction - +


Refer to Figure 8 for positioning device. It is used to control the action of each positioning cylinder;

throttle valve and pressure relief valve are provided above the positioning device to adjust the speed of

each positioning cylinder and the positioning pressure respectively.

Figure 8 Positioning Device

Note：This system includes 8 same positioning devices, only one of them is introduced here, the rest of the 7 are the same as this one in arrangement and function.

·　 See Figure 8 for valve block for clamping.

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Plate-type throttle valve

Pressure relief valve

Solenoid directional valve

Pressure measuring point of chamber A

Pressure measuring point of chamber B

Throttle valve

Valve block for positioning


Figure 9 Valve Block for Clamping

·　 See Table 5 for energizing and de-energizing of the electromagnet in actuation of each cylinder.

Table 5 Action of Electromagnet

Number

NameYHa1 YHb1 YHa2

Clamping cylinderLifting + - +

Lowering - + -


Refer to Figure 10 for clamping device. It is used to control the action of each clamping cylinder; pressure

valve is provided above the clamping device to adjust the pressure of the system and the control circuit;

the pressure relay is used for system pressure detection, and the sequence valve is used for adjustment of

compensated pressure.

Figure 10 Clamping Device

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Pressure relay

Sequence valve

Pressure relief valve Solenoid ball valve

Solenoid directional valve

Pressure measuring point of chamber B

Pressure measuring point of chamber A

Pressure measuring point of chamber C

Pressure measuring point of chamber PPlate-type throttle valve

Valve block for clamping


Note：This system includes 16 same clamping devices, only one of them is introduced here, the rest of the 15 are the same as this one in arrangement and function.

·　 Refer to Figure 11 for air cooling fan. When the temperature of oil in the hydraulic system is high, it is used to cool down the oil in the tank to reduce the oil temperature so as to assure normal

operation of the system.

Figure 11 Air Cooling Fan

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Chapter 2 Safety

Contents2.1 Matters to Be Observed and Prohibited........................................................................................................12

2.2 Definition and Position of Warning Sign and Caution Sign.........................................................................12

2.3 Indication for Hazardous Area and Precaution for Access to Hazardous Area............................................14

2.4 Safety Device................................................................................................................................................15

2.5 Disposal in Case of Accident........................................................................................................................15

2.6 Measures to Prevent Unauthorized Personnel from Operating the Equipment.............................................16

2.7 Disposal of Hazardous Material...................................................................................................................16

2.8 Other Safety Precautions and Measures.......................................................................................................16

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Safety

2.1 Matters to Be Observed and Prohibited

This chapter mainly describes the danger and potential risks that may occur during installation,

commissioning, operation and maintenance of the hydraulic system. Its purpose is to prompt and warn the

persons engaged in aforesaid work to prevent personal injury, equipment damage and environment pollution.

The persons concerned must carefully read this chapter, realize the hazard, and the construction company and

the user must keep the ‘Safety Manual’ properly for convenience of reference at any time.

The fundamental condition to ensure safe and trouble-free operation of the hydraulic system is to master, know

and follow the safety rules. Everyone who works on the hydraulic system must read and follow the rules,

especially pay attention to the safety instructions on installation and commissioning. In addition, the

installation department and the user shall establish detailed rules and safety protection regulations to prevent

accident according to actual situation.

2.2 Definition and Position of Warning Sign and Caution Sign

2.2.1 Definition of Signs and Sign Plates

During erection, commissioning and operation of the car dumper, it is required to hang relevant warning sign

and caution sign on some positions to avoid accident. See Table 6 for graphic symbol and definition.

Table 6 Symbol and Definition of Warning Sign and Caution Sign

Graphic Symbol Description

Graphic symbol indicating safety helmet must be worn.If not observed, the

head or other parts of the human body may be knocked or scratched by falling

object, edge of the equipment, etc., and life may be threatened in serious cases.

Graphic symbol indicating working clothes must be worn.If not observed, the

clothes may be subject to burning, leaking, scratching, etc. and other part of the

clothes may be drawn in by rotating parts, and life may be threatened in

serious cases.

Graphic symbol indicating fire is prohibited. If not observed, there may be

danger of lighting up of inflammables or combustibles around, as a result

causing equipment damage or personal injury. Life may be endangered and

equipment damaged in serious cases.

Graphic symbol indicating that smoking is prohibited. If not observed, there

may be danger of lighting up of inflammables or combustibles around, as a

result causing equipment damage or personal injury. Life may be endangered

and equipment damaged in serious cases.

Graphic symbol indicating touching is prohibited. It indicates it’s forbidden to

touch this item directly or indirectly, and if not observed, there may be danger

of being scratched, electric-shocked, liquid-corroded, burnt, drawn in by

rotating parts, etc., and life may be endangered and equipment damaged in

serious cases.

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Graphic symbol indicating passing is prohibited. It indicates this area is

dangerous, and if not observed, there may be danger of personal injury, and life

may be threatened in serious cases.

Graphic symbol indicating caution is required. It indicates there is danger or

potential danger in such area or during operation, and if not observed, it may

cause equipment damage or personal injury, and life may be endangered and

equipment damaged in serious cases.

Graphic symbol indicating caution of falling. If not observed, there may be

danger of falling down from the platform, handrail,high-elevation platform, and

life may be threatened in serious cases.

Table 6（continued）Graphic Symbol Description

Graphic symbol indicating caution of fire. It indicates it’s possible to burn in

such area or for this item to burn, if not observed, fire may occur, and life may

be endangered and equipment damaged in serious cases.

Graphic symbol indicating caution of electric shock. It indicates there’s

possibility of electrification or electric leakage in such area or in this item, if

not observed, electric shock may occur, as a result causing equipment

shortcircuiting and personal injury, and life may be endangered and equipment

damaged in serious cases.

Graphic symbol indicating caution of corrosion. It indicates it’s possible for

such item to corrode the equipment, human body,environment,etc., if not

observed or care is not taken, the equipment may be damaged, person injured,

environment polluted, and life may be endangered and equipment damaged in

serious cases.

2.2.2 Hanging Position of Sign Plate

See Table 7 for hanging position of graphic symbol plate.

Table 7 Hanging Position of Graphic Symbol Plate

Graphic Symbol Plate Description Hanging Position

Wear safety helmet,

wear working clothes.Access at the ladders to car dumper

Danger:falling. Edge of platform, walkway, handrail

No flame, no smoking. Operator’s room, electrical room

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Danger:fire. Electrical room

Danger: electric shock,

no touchingAll the live positions

High temperature and

inflammable,

danger: corrosion

Hydraulic room

Danger: electric shock,

no passingAccess at the ladders to power supply device

No passing

Area for platform and handrail, etc. on

which the work haven’t been finished, lifting

area, mechanism actuating area as well as

the walkway area where the parts are being

assembled above, etc., and these areas shall

be isolated by warning ribbon.

2.2.3 Sign for Prompting Reader of This Instruction

The following prompt symbols will appear in the instruction of this car dumper.See Table 8 for details on

definition and function of each prompt symbol.

Table 8 Definition and Function of Prompt Symbol

Graphic Symbol Definition Description

Attention!

This graphic symbol indicates there’s important matter to prompt relevant personnel.If not

observed, vital equipment damage and casualty may occur during erection, commissioning,

operation, maintenance.

Warning !

This graphic symbol indicates there’s important matter to prompt relevant personnel. If not

observed, equipment damage and casualty may occur during erection, commissioning, operation,

maintenance.

Danger!

This graphic symbol indicates there’s important matter to prompt relevant personnel. If not

observed, it may lead to wrong installation, equipment damage during erection, commissioning,

operation, maintenance, and casualty may occur in serious cases.

This graphic symbol indicates there’s suggestive matter to prompt relevant personnel.If not

observed,it may lead to non-ideal operation, inadequate maintenance, non-timely servicing, etc.for

the machine.

2.3 Indication for Hazardous Area and Precaution for Access to Hazardous Area

Personnel who are authorized to work on the car dumper must know the hazardous area of the machine and

remember it by heart, to avoid casualty. See Table 9 for hazardous area of the car dumper.

Table 9 Hazardous Area of Car Dumper

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Hazardous Area Specific Position Precaution to Avoid Hazard

Hazard for Injury Clamping device Pay attention to the clamping device in operation.

Positioning device Pay attention to the positioning device in operation.

Hazard for FallingStairs leading to equipment Hold the handrails tight.

Edge of the platform near the handrail Do not stretch the body out above the handrail.

Hazard for Electric

Shock

In the transformer room, inside the electric

cabinet in the electrical room, outside

electrical component

It’s forbidden to touch the electrical part.

Hazard for Dust

ExplosionMaterial transfer area

It’s strictly forbidden to weld in operation, smoke

around and be with open flame. Servicing work can

be performed only after the dust is thoroughly

cleaned and ventilation is maintained.

Hazard of

combustible

material

In the hydraulic room （ if combustible

hydraulic oil is used）

It’s forbidden to smoke and be with open flame;

check if the circuit is aged regularly.

Around the lubrication pump It’s forbidden to smoke and be with open flame;

check if the circuit is aged regularly.

2.4 Safety Device

·　 Check if all safety devices are installed properly and if they are in good operating condition

regularly；·　 The safety devices may be dismounted under the following conditions：——after it is confirmed that the power supply is off；——when appropriate measures are taken to ensure the hydraulic system will not accidentally start

operating again；——when maintenance or repair work is to be performed by trained specialist.

All the existing safety devices must be checked at regular intervals.

2.5 Disposal in Case of Accident

·　 If the hydraulic pump fails, in such case, check the pressure meter for operating pressure；·　 If it is needed to change certain hydraulic valve, pipe fitting, etc. in the hydraulic system, it

must be assured to release the high pressure in the hydraulic circuit; relevant components can be

demounted only after the pressure at related position shows“0” when it is detected by pressure

measuring device；

·　 When dismounting the hydraulic pump and related hydraulic valve, close the ball valve on the oil tank and the high-pressure ball valve in the piping to prevent the hydraulic oil from leaking

out too much； When the hydraulic oil leaks out due to breakage of the hydraulic rubber pipe near the cylinder, the high-

pressure ball valve on the cylinder must be closed immediately.

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Improper operation may result in serious personal injury and equipment damage.

2.6 Measures to Prevent Unauthorized Personnel from Operating the Equipment

·　 Only properly trained and educated personnel can undertake the work for maintenance of

hydraulic station；·　 During training, special emphasis should be given to training on hazards and the required

safety measures；·　 It is mandatory to periodically assess the personnel qualification, at least once a year；·　 Responsibilities of operation and maintenance personnel must be clearly specified；·　 It should be assured that only authorized personnel can work on this machine；·　 Designate a equipment manager and specify his responsibility and permit him to refuse to

implement the third party’s instruction that violates the safe operation；·　 Only personnel with specialized hydraulic knowledge should be allowed to perform the

commissioning and maintenance work for the hydraulic system.

See Table 10 for job division of various personnel (√ indicates allowed，X indicates not allowed).Table 10 Job Division of Various Personnel

Job division Trained operatorQualified

technicianQualified fitter

Qualified

electrician

After-sales

personnel

Equipment

operation√ x x x x

Fault finding x √ √ √ √

Mechanical

fault

maintenance

x √ √ x √

Electrical fault

maintenancex x x √ √

Daily

maintenance

and repair

x √ √ √ √

2.7 Disposal of Hazardous Material

After installation and commissioning of the hydraulic system, some leftover bits and pieces of material

such as iron and steel product, rubber product, oil and grease and the like will remain. Some wastes such as

deteriorate grease, replaced wear parts, spare parts, etc. will generate during subsequent operation. The wastes

generated during above mentioned process, if not disposed of properly, will cause environment (air, water and

soil) pollution, and must be classified and properly disposed of according to the national environmental

protection regulations and meanwhile meet the following principles：·　 Recycling and reuse principles shall be firstly considered in disposal of these materials；·　 The dismantled wear parts and spare parts should be cleaned to remove grease from the

surfaces, and treated as scrap steel if it is confirmed that they can not to be reused；

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·　 If the dismantled parts contain steel, non-ferrous metals or rubbers, they must be classified

and separately disposed of after dismantling；·　 The dismantled rubber and plastic parts must be disposed of in compliance with relative

national environmental protection laws and regulations；·　 Dust, waste residue, waste water and waste liquid generated during the above process must be

disposed of according to related national laws and regulations；·　 If the above mentioned waste materials cannot be disposed of timely, they must be stored

properly to ensure no pollution is caused to the air, water and soil.

2.8 Other Safety Precautions and Measures

2.8.1 The site installation, commissioning departments and the user shall observe the following matters:

·　 Only personnel who know basic safety rules and the accident prevention regulations and have been trained on operation of the hydraulic system are authorized to operate the machine. Other

unauthorized persons should stay away from the machine and installation area; the full-time staff

can operate the machine only when it is rerquired by work and must observe the operating rules

strictly；·　 Only personnel who have relevant knowledge on safety operation of the machine and have

read, understood the safety rules and warning signs specified in this document may work on the

car dumper. Other unauthorized persons should stay away from the machine and installation

area；·　 This machine is operated by full-time operator. Two operation modes, i.e. onboard operation

mode and remote operation mode are available. Even if the machine is not in working state, it may

be started and operated at any time. Therefore, it’s not allowed for anyone to stay around the

machine without approval；·　 During installation, commissioning, operation, unauthorized personnel must be kept away

from the machine and work area；·　 Personnel who work on the car dumper shall wear necessary safety protections（ safety

helmet, safety belt, working clothes, shoes for climbing, etc.）；·　 Personnel who work on the car dumper shall wear specified clothes, it’s not allowed to have

the long hair exposed and wear loose clothing, jewellery, etc. to prevent them from being pulled

by the machine as a result causing personal injury；·　 The user and the erection＆commissioning department shall check if their working personnel

observe the safety rules irregularly；·　 The user and the erection＆commissioning department shall assure the safety documents are

always kept on the car dumper for reference at any time；·　 The user and the erection＆ commissioning department shall observe the local laws and

regulations and the requirements for safety and environmental protection；

·　 The user and the erection＆commissioning department shall supplement the operating rules, supervision report and supervisor’s inspection report, etc. in the technical and safety management

documents of this machine according to the demand of the client；·　 Check if all the safety devices are installed properly and if they are in good operating

condition regularly；

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·　 During operation, it’s forbidden to stay at the following hazardous area：——In front of the machine；——Material dumping area；

·　 Provide fire extinguisher in area liable to fire, the staff on the machine must know the exact position (in the operator’s room, electrical room, hydraulic room, water pressure room)of the fire

extinguisher and be able to use it expertly；·　 The car dumper can be started only when it is confirmed all the safety equipment and devices

(safety protection device, safety limit switch, emergency stop pushbutton, silencer, anti-explosion

facility, etc.) are at normal installation position and under normal working condition；·　 Before starting the car dumper, assure anyone will not be injured during starting and

operating；·　 Check the hazard warning sign outside the car dumper; check the safety device for normal

operation at least once a day；·　 Any change liable to happen, including change in operation, etc., shall be reported to the

chief of relevant department immediately. When necessary, stop the machine immediately and

protect it (for example, shut off the main switch or press the emergency stop switch, etc.)；·　 In case of fault, cut off the power supply for the car dumper immediately and take suitable

measures to prevent the machine from being powered on again and eliminate the fault

immediately；·　 Follow the provisions in the document, observe the switching procedures for indication lamp,

indicator, etc.；·　 After starting the controller, keep hands away from all switches or pushbuttons to avoid

danger of misoperation due to pressing；·　 During normal operation of the car dumper, do not switch any safety device on；·　 Only have qualified electrician or personnel properly trained perform installation,

commissioning, maintenance work, etc. for the electrical equipment of the car dumper under the

supervision of a qualified electrician according to the electrical engineering specification and

rule；·　 Check the electrical equipment of the car dumper regularly, tighten all the loose connections,

change any aged, broken cable；·　 Assure the electrical cabinet is in locked state at any time, only authorized person holding

keys can open the electrical cabinet；·　 Original fuse wire with correct amperage must be used；·　 In case of fault of power supply or power failure, close the main power control box of the car

dumper immediately；·　 Before checking, servicing and repairing, the components must be discharged. First, use

electrical instrument to check if the component has been discharged, then perform grounding and

shortcircuiting and isolate them from adjacent live part；·　 It is of vital danger to work on the live part. If the work must be performed in live condition,

it shall be assured the second person is at present. In case of emergency, this person shall press the

emergency cut off switch or shut off the main switch, as a result the power supply is cut off. Close

the working area with warning ribbon and set up warning sign plate. During working, insulated

tools must be used；

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·　 The workshop shall prepare relevant tools necessary for erection and maintenance；·　 The machine shall be adjusted, maintained and checked as specified by qualified personnel in

due time；

·　 Before any maintenance or repair, be sure to inform the operator and nominate a supervisor；·　 During maintenance, inspection and repair, shut off the power supply of the car dumper and

take proper measures to assure it is not re-energized due to misoperation, the procedures are as

follows：——Lock the main control device, take the key away, the key shall be kept by maintenance and

repair personnel；——If the main control device can not be locked due to some reasons, disconnect the main switch

and the emergency disconnecting switch and provide warning sign between the two switches；——For necessary place, close with warning ribbon.

·　 When it is needed to install or change single component or large part, tie it to suitable lifting equipment carefully and provide protection to ensure no danger will happen. Be sure to use

suitable lifting equipment and tools and ensure they have sufficient carrying capacity and are in

good technical condition. It is not allowed to stand under the lifted items, even not to work under

them；·　 Be sure to have experienced personnel tie the items and send instruction to the crane driver.

The person giving instruction must be able to see the operator or contact with the operator；·　 When performing assembling work at high altitude, use ladder, platform or other climbing

tools, be sure to assure safety. It’s not permitted to climb onto the component or equipment. When

performing the assembling and inspection work, take proper measures to protect the component to

be installed or removed and the tool to prevent them from falling down；·　 If the safety device/safety equipment must be removed for installation, maintenance or repair,

they must be immediately reinstalled after such maintenance or repair; and they must also be

checked according to the following requirements to make them be in good working condition：

——Ensure all the loose bolts are retightened；

——Ensure the consumables and replaced components are disposed of in appropriate and safety

condition；

——Protect the switches and control devices to prevent the weather, water and dust, etc. from

affecting them；

——Be sure to use the tools that are qualified in performance, applicable and designated in some

cases (e.g. tools, etc. for electrical installation)；

——It should be particularly noted that all the turning or open components are subject to danger of

crushing and blocking；

——Do not store tools or other external material on the equipment.

·　 Subject to danger of fire and explosion, welding, flame cutting and grinding work shall be performed on the car dumper under the approval of safety department and supervision of safety

19


personnel. Before carrying out any welding, flame cutting or grinding work, clean the car dumper

and its adjacent area, remove all the scale and flammables and ensure good ventilation；·　 When welding work is performed, grounding must be connected directed to the welding

position, otherwise, the electrical component may be damaged；·　 When working in narrow area, the requirement of the current laws and regulations of the state

shall be met；·　 When handling the oil, grease and other chemical, the requirement of the current safety laws

and regulations for the product shall be observed.

2.8.2 Safety-related Change

If safety-related change occurs to the machine, stop the machine immediately and report to the chief of

the department! Without authorization of the supplier, no one shall make any change to the machine,

including：·　 Any modification, addition or conversion affecting safety shall not be made to the machine

without prior authorization of the supplier；·　 Installation and adjustment of the safety devices and welding on load-carrying parts shall not

be performed without prior authorization of the supplier；·　 The spare parts must meet the technical requirements as specified by the manufacturer；

In some cases, installation and use of other supplier’s products may affect the performance of the

components or the entire machine. We are not responsible for any loss whatsoever caused by use of such

parts.

20


Chapter 3 Erection, Commissioning

Contents3.1 Transportation and Storage...........................................................................................................................22

3.1.1 Precautions to Lifting and Transportation.................................................................................................22

3.1.2 Storage Condition, Storage Period and Precautions..................................................................................22

3.2 Package Opening Inspection.........................................................................................................................22

3.2.1 Precautions to Package Opening................................................................................................................22

3.2.2 Inspection Content.....................................................................................................................................22

3.3 Technical Requirement for Foundation, Erection Condition and Erection...................................................22

3.4 Erection Procedures, Methods and Precautions............................................................................................23

3.5 Commissioning Procedures, Methods and Precautions................................................................................25

3.6 Acceptance and Test Items, Methods and Criteria after Erection, Commissioning......................................25

3.7 Preparation before Test Run, Test-run Start-up, Test Run............................................................................26

21


Erection, Commissioning

3.1 Transportation and Storage

3.1.1 Precautions to Lifting and Transportation

During lifting operation of the hydraulic equipment, safety caution work must be performed

properly in the lifting area. Personnel working in this area must pay attention to safety. During

lifting, it shall be assured that the hydraulic station remains upright and avoid knocking and

scratching. During transport, avoid stacking heavy object on the hydraulic station.

3.1.2 Storage Condition, Storage Period and Precautions

If the installation work can not be performed immediately after the equipment are delivered to

the site, they must be stored properly. The exposed and bundled parts shall be stored on high,

level land to assure no water accumulates on the ground during storage; for position where

turning parts are located, waterproof and rust protection measures shall be taken properly to

prevent ingress of water in the bearing as a result corroding the interior surface; equipment

packed in boxes shall be put in dry, rainproof places, and the packing status shall be checked in

time, repair immediately in case of breakage.

3.2 Package Opening Inspection

3.2.1 Precautions to Package Opening

During package opening, note not to scratch the surface of the hydraulic station and assure the package is

removed under the condition that the hydraulic station is intact.

3.2.2 Inspection Content

During package opening, check if there’s part missing according to the packing list, and if there’s part

damaged during lifting and transport; check if the sealing plugs of the oil ports of the hydraulic system are

intact, if the seal is broken, check the oil port for ingress of contaminant carefully.

3.3 Technical Requirement for Foundation, Erection Condition and Erection

·　 Before installation, study the technical documents related to installation, e.g. installation drawing, installation plan and installation process, etc. to clarify the task and review the drawing

and installation plan jointly with related departments (mainly the civil work department) so as to

find the problems in design and installation plan in advance and discuss the issue for mutual

cooperation；·　 Work out the network chart for construction（construction procedures and progress）；·　 Prepare various tools, fixtures and hoisting machinery for installation；·　 Establish the precautions for safety, fire prevention, cold resistance, wind proof, rainproof,

etc. for installation；·　 Establish special organization for inspection and acceptance to assure the erection quality of

each type of work；

22


·　 Count the items completely according to the packing list before installation. Check the components for completeness, damage during transportation, stain or rust during storage.

Structural part which is obviously deformed during transportation shall be corrected, and

components which are stained or rust shall be cleaned carefully with kerosene to remove the stain,

rust；·　 Check the transportation route according to max. weight and max. size of the component to

confirm the road wide, limit height of the buildings around, aerial bridge and pipiline, especially

at the corner, whether the component affects transportation. Check the road foundation on the

transportation route for bearing capacity for meeting the requirement of weight of component to

be transported. Correct immediately in case of nonconformity. For example, when automobile

crane is used, check the land for soil bearing capacity for bearing the pressure applied by the

outreaching legs of the automobile crane and consider to support the legs with timber or steel

plate.

3.4 Erection Procedures, Methods and Precautions

3.4.1 Installation of Hydraulic Station

Safety caution work must be performed properly in the lifting area of the crane during lifting

operation of the hydraulic equipment. Persons who work in this area must take care.

The installation requirements are as follows：

·　 The hydraulic piping can be installed only after the hydraulic parts are completely installed；·　 During installation, make overall consideration for routing of the piping; the piping shall be

arranged reasonably and neatly to prevent from interfering with other parts. The fluid hoses shall

be proper in length which shall not only meet the requirement for actuation and travelling distance

but also not interfere with other parts；·　 Carry out installation and construction according to the piping drawings of the hydraulic

system. Ensure all the steel pipes have been degreased, pickled and neutralized before installation.

3.4.2 Assembling of Hydraulic Piping for the Second Time

·　 The exterior hydraulic piping has already been prepared before delivery from the shop and it is only needed to install the piping for the second time on the site. Before connecting the piping,

check the inside of the pipe carefully, blow the pipe with clean compressed air to ensure no

foreign matter inside；·　 Check the flange connection surface for damage and the sealing ring for intactness carefully.

The piping can be connected only after all the requirements are met；·　 If the piping needs to be welded on the site, foreign matters, e.g. welding slag, etc. on the

weld seam must be thoroughly removed；·　 Other items which are not described shall conform to related provisions of JB/T5000.11-

2007.

3.4.3 Flushing of Hydraulic Piping

·　 The pipes of the hydraulic system must be flushed following acceptable pickling. Circulation

method is adopted for flushing；

23


·　 The hydraulic cylinder, accumulator must be separated from the flushing circuit when the circulation flushing circuit is formed at the installation position for the pipes of the hydraulic

system; the proportional valve shall be replaced by flushing plate; the throttle valves, stop valves,

pressure reducing and overflow valves in the circuit shall be adjusted to the maximum degree of

opening; the steel pipe for temporary use purpose shall also be acceptably pickled before it is

connected to the flushing circuit；·　 The flushing oil shall be working medium with suitable viscosity or equivalent fluid; the

pump, tank and filters for flushing prepared by the erection party shall be applicable for the

flushing oil to be used；·　 The oil tank shall be checked for any visible contaminant before the flushing oil is filled in;

the flushing oil shall be filtered when it is filled into the tank, and the filtering precision shall be

not less than 10μm；·　 During flushing, the flushing oil shall be in turbulent condition. The flushing effect can be

enhanced through change of flushing direction or vibration；·　 The acceptable criteria for flushing shall be not lower than grade NAS7；·　 Flushing records shall be prepared following flushing.

During flushing, be sure to keep cleanliness and ensure no ingress of foreign matter into the

hydraulic elements when the elements are assembled or disassembled. In case of ingress, the

hydraulic element may become ineffective, it’s also possible to lead to damage of the equipment in

severe condition. Therefore, the inner cleanliness must reach grade NAS7.

It is strictly forbidden to use the hydraulic pump station as the power source for

flushing of exterior piping and for pressure test.

3.4.4 Pressure Test of Hydraulic Piping

·　 The system pressure test shall be performed after acceptable flushing, complete assembling and adjustment of the system, positioning and fixing of all the supports by welding. The hydraulic

cylinders, pressure relays, pressure gauge with electric contact as well as the accumulators shall

not participate in pressure test. For pressure test value, refer to the design drawings；·　 10μm Work medium is used for pressure test. The filtering accuracy of the filter shall be not

lower than 10μm when the medium is filled into the oil tank；·　 During pressure test, low-pressure circulation shall be performed first to discharge the air

inside the system thoroughly; the temperature of oil for pressure test shall be within the oil

temperature range under normal working condition；·　 Test rules shall be available for pressure test. The test pressure shall be increased gradually

by 5 MPa for each stage and held for 2~3 minutes for each increase. When the test pressure is

reached, hold it for 10 minutes, and then lower it to the work pressure for complete check. The

system is deemed acceptable when all weld seams and joints are free from leaking and the piping

is free of permanent deformation. Pressure test records shall be prepared following test；

24


·　 In case of fault that needs to be handled during pressure test, release the pressure first. It’s strictly forbidden to operate under pressure. If there’s weld seam needs to be re-welded, such pipe

must be dismantled and the oil shall be discharged thoroughly before welding.

During pressure test, visible signs shall be available in the test area. It’s strictly forbidden for non-

working personnel to enter the test area. The working personnel and test equipment must be kept

far away from the test piece for a distance of 5~10 m and safety protection facility shall be

available. It is required by the safety rules that JB/T5000.11-2007 “General Technical Conditions

for Heavy Machinery – Piping” shall be followed strictly for pressure test.

3.4.5 Repair and Touch-up Painting of the Coated Surface

After all the components on the site have been installed, repair and make touch-up painting for the coated

surface that was damaged during transportation and welding. Clean the rust, grease, etc. on the damaged

surface thoroughly with manual or electric derusting tool, then perform coating work according to the

following thickness requirement：·　 Primer coat：2 layers, iron red epoxy resin H06-2，each film thickness 35μm；·　 Intermediate coat：2 layers，iron red epoxy resin H06-2，each film thickness 30μm；·　 Finish coat：1 layer，polyurethane, film thickness 20μm；·　 Total film thickness 150μm.

3.5 Commissioning Procedures, Methods and Precautions

·　 Read Chapter 2—Safety carefully to know the danger existing during commissioning；·　 Fill proper amount of fluid medium in the position where it is required；·　 Clean the site after erection. Thoroughly clean the leftovers, rejected material, etc. generated

during erection. It’s not permitted to place the equipment that affect the safety of personnel at the

passageway；·　 The electrical wiring shall be absolutely correct and be checked one by one. Power can be

supply for commissioning only when everything is correct. The electrical wiring shall be provided

with ground protection, and all the terminals shall be insulated；·　 During commissioning, safety isolation measures and conspicuous warning signs shall be

available in machine operation area and mechanism actuation area；·　 Check if there are bolts, stops that haven’t been tightened yet during erection and if each

safety device is located in correct position carefully.

3.6 Acceptance and Test Items, Methods and Criteria after Erection, Commissioning

·　 “General Rules for Safe and Sanitary Design of Production Equipment” GB 5083-1999；·　 “General Rules for Construction and Acceptance of Machinery Installation Project” JBJ23-

96；·　 “General Rules for Construction and Acceptance of Metallurgical Machinery Installation

Project --- Hydraulic, Pneumatic and Lubrication System” YBJ207-1985；·　 “Technical Agreement”；·　 “Schematic Diagram of Hydraulic System”；·　 "Final Assembling Drawing of Hydraulic System” (incl. equipment, elements, components

and technical requirements).

25


3.7 Preparation before Test Run, Test-run Start-up, Test Run

3.7.1 Checks before Operation

·　 Check if the connections of each part, fastening bolt, flange and pipe connections, etc. are

tightened；·　 Check if the level of oil in the tank and the condition of medium reach the requirement. It

shall also be noted that all the actuation elements and pipes are filled with oil when the test run

starts；·　 Check if all the elements performing opening and closing function are placed at specified

position and if the installation directions of all the elements are correct. Prevent discontinuous

flow and overload from occurring. See Figure 12 for direction for opening the ball valve at the

suction port of the oil pump；

Figure 12 Ball Valve at Suction Port of the Oil Pump

·　 Check if the rotation direction of the pump accords with the specified direction. Adjust immediately if the rotation direction is not correct. See Figure 13 for rotation direction of the

motor.

Figure 13 Electric Motor of Pump

3.7.2 Operation Method

·　 Keep the pump in no-load condition, run the pump intermittently and repeatedly. Observe the pressure gauge and listen to the sound from the oil pump and system. Start the trial running after it

is confirmed that the circuits of the pump and the overflow valve are in normal condition；·　 If the oil temperature is lower than 10 , start the pump under no-load condition for 5℃

seconds, stop it for 10 seconds, then keep the pump running for 20s. Perform the said operation

repeatedly until all the elements inside the pump are sufficiently lubricated, then run the pump

continuously；

26

Rotation directionof motor

The ball valve is opened by rotating in this direction.


·　 During test run, set the pressure regulating valve to 0.5~1.5MPa first, keep the pump running continuously for 10~30 minutes, then increase the pressure intermittently. Listen to the sound of

pump running, pressure, temperature as well as vibration, leaking of all the components and pipes,

if no abnormality is found, put into full-load running. There may be air inside the piping of the

cylinder. Before operation, open the exhaust valve of each actuating element and exhaust the air

under proper pressure to make the piping be full of oil；·　 Set both the pressure valve and the flow valve to actual operation value. Check the oil level

again, finally put into normal operation.

27


Chapter 4 Application and Operation

Contents4.1 Preparation and Inspection Before Operation...............................................................................................29

4.2 Safety, Safety Protection, Safety Sign and Description before and in Operation.........................................29

4.3 Operating Method and Precautions...............................................................................................................29

4.4 Monitoring and Recording in Operation.......................................................................................................29

4.5 Operating Procedures, Method and Precautions for Shutdown....................................................................30

4.6 Common Fault and Disposal........................................................................................................................30

28


Application and Operation

Declaration：

Before installation and operation for the first time, be sure to read all the documents accompanied with the

machine carefully. This will be helpful for you to use the machine better. For losses arising thereof due to

operation not in compliance with the requirements of this manual book, DHI·DCW will not assume any

responsibility.

As we are not able to control the understanding of the client for this instruction book, therefore DHI·DCW will

not assume any responsibility for accident caused to the professional maintenance personnel of the client or

approved by the client but not from our company during installation, commissioning, operating, maintenance

or losses arising thereof.

The illustrative images concerned in this instruction book shall be the schematic diagrams which are subject to

actual interface of the machine.

Further notification will not be made for changes in the instruction book of the client.

4.1 Preparation and Inspection before Operation

·　Check the connection of each component, fastening bolt, flange, pipe fitting, etc. for loose；·　Check whether the oil level of the tank is at normal height；·　Check whether the medium temperature is normal；·　Check for leaking；·　Check whether the butterfly valve at the suction port of the pump is open；·　Check whether all the signal indicating lamps are normal.

4.2 Safety, Safety Protection, Safety Sign and Description before and in Operation

It is strictly forbidden to adjust the pressure valve which has already been set before and during operation

of the hydraulic system. It is forbidden to regulate the flow valve of the hydraulic system during

operation. Unprofessional working personnel shall keep away from the hydraulic station.

4.3 Operating Method and Precautions

Before the hydraulic pump is started, confirm again that no solenoid valve is energized and the butterfly

valve at the suction port of the pump is open. The hydraulic pump can be started for the next step of work

only when everything is normal.

See relevant descriptions in “Chapter 7 Electrical” for operation method and precautions for the operator

to operate the operation panel of the hydraulic system.

4.4 Monitoring and Recording in Operation

During operation of the hydraulic system, the status (oil level, sound, setting value, work condition)

under normal operating condition shall be known, detailed management rules shall be established and

29


records shall be made properly. In case of abnormality, refer to this operating instruction and find the

reason for fault to maintain normal operation of the system or extend its service life.

When the hydraulic system is just put into operation, check the system for work condition regularly. It is

preferable to change the work medium within one or two months after the system is put into operation.

4.5 Operating Procedures, Method and Precautions for Shutdown

·　 Shut off the power supply for the hydraulic station；·　 Check the pump, valve of the hydraulic station for abnormality；·　 Check the hydraulic oil for leaking；·　 Lock the hydraulic room.

4.6 Common Fault and Disposal

4.6.1 See Table 11 for reasons and solutions for too-loud noise of the pump.

Table 11 Reasons and Solutions for Too-loud Noise of the Pump

Reasons Solutions

The oil viscosity is too high

（low oil temperature）.Check the oil temperature, replace with suitable medium.

The connection between the oil pump and oil-

suction pipe leaks.Check the leaking position, reinforce or change the washers.

The drive shaft of the pump is not tightly

sealed.

Oil the end of the drive shaft. Change the shaft seal in case of variation

of noise.

The assembling quality is not good, the

component becomes loose due to wear.Disassemble the pump, trim or change the component.

The oil pump is not concentric with the shaft

of the electric motor. The non-coaxiality tolerance is permitted to be 0.10mm.

There’s bubble in the oil. Check whether the oil return pipe is in the oil and whether the oil

4.6.2 See Table 12 for reasons and solutions for heating-up of the hydraulic system.

Table 12 Reasons and Solutions for Heating-up of the Hydraulic System

Reasons Solutions

The oil in the tank is not enough. Observe the level indicator. Refill the tank when the oil is not enough.

The oil viscosity is too high. Check the type of medium, replace with medium specified. By design.

The pressure of overflow valve is not set

properly.Reach the specified set pressure.

Too much interior leaking in component Change the component or sealing ring.

4.6.3 See Table 13 for reasons and solutions for abnormal displacement of the oil pump.

Table 13 Reasons and Solutions for Abnormal Displacement of the Pump

Reasons Solutions

The level of oil in the tank is low. Check the level. Refill the tank when the oil is not enough.

30


The pump rotates too slowly.Check the electric motor for rotation speed and make the speed

higher than minimum specified speed.

The oil viscosity is too high

（low oil temperature）.Check the oil temperature, replace with suitable medium.

The oil-suction pipe is clogged or the

resistance is too much.Eliminate the piping clogging.

Air accumulates in the oil inlet piping.Discharge from the connection at the oil discharge side. Rotate the oil

pump to make it suck the oil and discharge the air.

The oil inlet pipe leaks.Washer, etc. are damaged or the piping is loose. Change the washer

and tighten the bolt.

The shaft or vane is damaged. Replace with new one.

4.6.4 See Table 14 for reasons and solutions for abnormal work pressure of the hydraulic system

Table 14 Reasons and Solutions for Abnormal Pressure of the Hydraulic System

Phenomena Reasons Solutions

The pressure

is too high

or too low.

No oil is pumped out from the oil pump Refer to 5.7.1.

The pressure is not set properly. Set the pressure as specified.

The pressure regulating valve doesn’t function

properly.

Disassemble the valve and wash.

The setting value for variable point of constant-

pressure variable displacement pump is not proper.

Set the pressure as specified.

The pressure gauge is damaged. Change the pressure gauge.

Table 14 （continued）Phenomena Reasons Solutions

The pressure

is not stable.

Ingress of air in the piping Discharge the system.

There’s dust in the oil. Disassemble and wash. Change in case of severe

oil contamination.

The core of the pressure regulating valve doesn’t

function properly.

Disassemble, wash or change the pressure

regulating valve.

4.6.5 See Table 15 for reasons and solutions for leaking of hydraulic oil.

Table 15 Reasons and Solutions for Leaking of Hydraulic Oil

Reasons Solutions

The connection is loose. Tighten the connecting position..

The sealing ring is damaged or deteriorated. Change the sealing ring.

The pressure rating of the sealing ring is not

proper.

Check and change relevant sealing ring if it is not proper.

The component is assembled improperly or

worn.

Re-assemble or change the worn part.

4.6.6 See Table 16 for reasons and solutions for hydraulic fault.

31


Table 16 Reasons and Solutions for Fault

Reasons Solutions

Control valveThe control valve doesn’t

function properly.

Check the slide part and the core in the valve for fitting. Interior

leaking results in back pressure and foreign matter, rust, etc. exist

inside. Correct or change.

The speed can

not reach the

specified

value.

The flow is insufficient. Check the flow regulating valve and oil pump for displacement.

The pressure is insufficient. Check the pressure regulating valve and pump for pressure.

The speed is

not stable.

The viscosity changes due to

temperature change. Adjust the oil temperature appropriately.

32


Chapter 5 Servicing and Maintenance

Contents5.1 Routine Maintenance, Servicing, Calibration...............................................................................................34

5.2 Maintenance and Servicing in Operation......................................................................................................35

5.3 Maintenance Period......................................................................................................................................35

5.4 Normal Maintenance Procedures..................................................................................................................36

5.5 Inspection and Maintenance of Working Medium.......................................................................................38

5.6 Maintenance and Servicing during Long-term Shutdown............................................................................39

33


Servicing and Maintenance

5.1 Routine Maintenance, Servicing, Calibration

The hydraulic system is used in bad condition where it is high in temperature, dusty and with vibration, etc.

In order to enable normal operation of the machine and fully exert its roles, routine maintenance and

servicing are of vital importance. The user shall establish mandatory and perfect rules for maintenance and

servicing. Be sure to follow the maintenance rules established and make proper inspection (maintenance)

records.

5.1.1 Servicing and Management of Working Medium

To make the contamination degree of the medium in the system reach the specified value, the following

requirements shall be followed for servicing：·　 Circulate and filter the medium in the oil tank and check and wash the oil filter and air filter

regularly. Check them often to avoid clogging by foreign matter, especially after initial operation and

maintenance of the system；·　 Check regularly to avoid leaking. Non-immediate disposal of leaking will cause the level of oil in the

tank to lower obviously as a result affecting the operation of oil pump. Especially for the purpose of

environment on the site, in order to prevent pollution and fire, extend the service life of equipment

and increase the economic benefit, there must also be no leaking；·　 Observe the level indicator, maintain the level at about the reference level at all time. If the level

lowers obviously, cavitation may occur easily during suction of oil pump, which causes bubbles in

the system so as to lead to vibration, noise, even abnormal operation, as a result a serial of unsafe

factors and faults such as failure to operation, temperature rise of work medium, etc. occur；·　 Check whether the temperature of working medium is within normal range. If the temperature is too

low, the viscosity of working medium will increase, which is not good for operation of the oil pump,

even may damage the pump. If the temperature is too high, the viscosity of working medium will

decrease, which causes the leakage rate of the system both internally and externally to increase, even

speeds up the oxidative deterioration of working medium to make it lose the performance, as a result

the system can not work normally；·　 In order to maintain the performance of the system and keep it in normal operation and extend its

service life, each part of the whole system must be checked regularly. Observe the liquid level,

temperature, variation of pressure, sound of pump running, leaking as well as contamination of the

oil filter according to the period specified in Maintenance Period Table. Check the bolt at each joint

for loose and the work medium in the tank for contamination degree, leaking, etc. Replace with new

medium filtered in case of severe contamination；·　 When changing the working medium, drain the old medium in the oil tank off completely first, then

clean the tank up and fill in the new working medium of anti-friction hydraulic oil 46# that has been

filtered to the reference level；·　 During normal operation, the pump gives a clear sound. In case of abnormal sound, stop the pump,

check and eliminate the fault to make it run normally；

34


·　 When the component has to be changed or disassembled, refer to the operating instruction book and the structural drawings of the component. The hydraulic components belong to precision elements,

be sure to prevent contamination. In the event that the mechanism is not known clearly, never carry

out major disassembling for the components to avoid much leaking and severe accidents.

5.1.2 Routine Inspection of Hydraulic System

Routine inspection is the most important thing for reducing the fault of hydraulic system. It should be

carried out every day under normal operating condition. The abnormal phenomena such as abnormal level

of oil in the tank, leakage, unstable pressure, higher temperature rise, abnormal sound, discoloration of

oil, clogging of filter, etc. can be found out through inspection at an earlier stage, meanwhile check the

status of pump before and after startup, during operation and stop.

5.1.3 Overall Inspection

Overall inspection is a thorough maintenance and repair for the whole system. It should be carried out

once a year according to the situation of equipment in operation. It includes disassembling of all the

components, elements, pipeline and auxiliary devices, etc., inspection of disassembled parts,

identification of wear, accuracy and performance of each element, re-estimation of service life. Carry out

necessary repair and replacement according to the result of inspection and identification. During repair,

especially pay attention to the wear parts or positions where it is liable to occurrence of fault, e.g. sealing

ring at the leaking position, throttling orifice as well as strainer core of the oil filter etc.

5.2 Maintenance and Servicing in Operation

·　 It’s absolutely not permitted to operate the hydraulic system when the level of oil in the tank does

not reach the specified level；·　 Pay attention to the condition of working medium in the oil tank often. If the working medium is

deteriorated or severely contaminated, replace with new medium that has been filtered

immediately；·　 Check the oil filter regularly at least once a month. Washed or changed the strainer core immediately

in case of problem；·　 Do not change the rotating direction of the oil pump；·　Change of setting values for the regulating valve of the hydraulic station will not only affect the

regulating valve itself but also influence other elements, components, including hydraulic pump,

electric motor, cylinder as well as actuating mechanism. When the setting value is changed, it should

be done with caution and it’s not allowed to exceed the working pressure of the system；·　 The status (oil level, sound, setting value, working condition) during normal operation shall be

known and detailed management rules shall be established. In case of abnormality, refer to this

operating instruction and find the reason for fault to maintain normal operation of the system or

extend its service life；·　 When the hydraulic system is just put into operation, it shall be noted to check the system for work

condition. Change the work medium within one or two months after the system is put into operation.

5.3 Maintenance Period

Refer to Table 17 for period and method for maintenance of hydraulic system

35


Table 17 Maintenance Period

Inspected ItemsMaintenance

Period Inspection Method and Content

Noise of Oil Pump Daily Check for ingress of air, abnormal wear etc. auditorily.

Temperature of Shell of Oil

PumpWeekly

Check the parts for wear and the bearings, etc. by hand or

thermometer.

Pressure at Outlet of Oil

Pump

Every half a

month

Check the oil pump and determine its internal wear by using

pressure gauge.

Noise of Coupling Monthly Check for abnormal wear auditorily and by using dial gauge.

Adhesive Substance on Oil

FilterMonthly Flush by solvent or clean by blowing.

Indication of Each Pressure

GaugeQuarterly

Check and calibrate the pointer of pressure gauge for abnormal

movement, check relevant components for abnormal operation or

wear.

Speed of Actuating

MechanismQuarterly

Check each component for abnormal operation and degree of

internal leakage due to wear.

Noise of Change-over Valve

and Pressure ValveQuarterly

Check the valve core for clogging or damage auditorily or by sound

level meter.

LeakageMonthly to

quarterly

Check related joints and sealing positions for leaking, especially the

pump shaft, piston rod of cylinder and sleeve visually and by hand.

Vibration Every 6 monthCheck the bolts of each component, pipe support and couplings for

loosening visually and auditorily.

Whole Oil Pressure System Yearly Detection and maintenance of each components, washing of pipe

and oil tank

Characteristic and

contamination of MediumQuarterly Check for degree of contamination and deterioration.

Oil Temperature Daily Check the temperature of oil in the tank by thermometer.

Level of Oil in the TankWeekly to

monthlyChecked the amount of oil and leakage.

Insulation Impedance of

Electrical SystemYearly

Check if the rated value of electric motor, solenoid valve, pressure

relay is low.

Supply Voltage Quarterly The voltage valve should be within specified range.

5.4 Normal Maintenance Procedures

5.4.1 Preparation and Precaution before Disassembling of Hydraulic System

When it is confirmed that the hydraulic system is faulty and it’s necessary to disassemble the hydraulic

element for servicing and replacement, the following matters must be noted during servicing and

replacement：

·　 Before maintenance, inspection and repair, shut off the power of the hydraulic system and take appropriate measures to assure the hydraulic pump is not started again due to accidental reenergizing

during maintenance；

36


·　 Confirm that all the mechanisms driven by hydraulic cylinders have been reliably fixed at safety position and can not malfunction due to disassembling of relevant hydraulic element so as to

endanger the safety of operating and maintenance personnel and damage relevant equipment；·　 During maintenance of the hydraulic pump, the ball valve on the oil suction pipe of the pump shall

be closed；·　 During maintenance of the control valve block in the pump station, the high-pressure ball valve on

the outlet piping of the valve block shall be closed；

·　 During maintenance of the cylinder, outer piping, both the high-pressure ball valves on the control

valve block of the cylinder and at the outlet of the pump station shall be closed；·　 Release the residual pressure in the section of piping that needs to be maintained by using pressure

measuring hose

5.4.2 Description on Maintenance of Hydraulic Element and Piping

5.4.2.1 Preparation and Precaution in Disassembling of Hydraulic Element and Piping

The fault in general purchased hydraulic element shall be handled on the site as far as possible. But, for

items that can not be repaired or not suitable to repair on the site, never perform repair reluctantly.

Attention must be paid to the following points when repairing on the site：·　 Select a clean place, release the oil pressure to prevent the oil from spurting；·　 The pipes must be marked in advance before disassembling to prevent mixing up in subsequent

assembling；·　 Wash the disassembled oil pipes with cleaning oil and then dry them in the air. Close both ends of

the pipe with plastic plug to prevent ingress of foreign matters. It shall be noted that the threads of

pipe and O-rings slot in the flanges must be protected against scratching；·　 Prevent ingress of foreign matters or the machined face from being scratched. The holes and

openings in the element should be closed by plastic plugs or adhesive tape；·　 The small parts shall be assorted and kept and prevent from lost or damage；·　 The opening of oil tank should be closed to prevent ingress of dust. The oil discharged should be

placed in separate clean barrel. In case of reuse, the oil shall be filtered before filled in the oil tank.

5.4.2.2 Principle for disassembling of Hydraulic Component

After the faulty hydraulic component is determined over careful study and eduction and such faulty

component has been dismounted from the hydraulic system, when it must be disassembled for repair over

diagnosis, the following principles shall be followed：·　 The structural drawings of components must be fully understood. The assembling relationship,

sequence and method for disassembling shall be well known；·　 Clean the disassembled part carefully, keep them in the original assembling state, arrange them well

respectively and prevent from lose and damage；·　 When it is found that the surface shape or color is abnormal, maintain the part in its original state for

convenience of analysis of the cause of failure；·　 For parts that will be kept in a disassembled state for a long time, they should be coated with anti-

rust oil and placed in the box for storage；

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·　 The parts disassembled shall be carefully observed with a magnifier for wear, scratching and rust. Check the sliding position for blocking and the fitting position for poor contact, etc. carefully. The

main parts shall be measured for deformation, wear, hardness, etc.; the spring shall be detected for its

bending and performance; the seal rings shall be checked for surface breakage, cutting trace, wear,

hardening and deformation, etc. After check, repair according to the degree of damage. The parts

that can not be repaired can be match-made or replaced.

5.4.2.3 Principle for Re-assembling of Hydraulic Component

When reassembling the hydraulic element which has been disassembled and repaired, the following

principles shall be followed：·　 Clean the rust, scratching, bur and adhesive substance, etc. on the part thoroughly；·　 Apply oil before assembling；·　 For sliding parts such as the slide valve, etc., do not assemble by force. Assemble according to fitting

requirements and rotate by hand until it is deemed to be able to work normally；·　 When tightening the bolts, tighten evenly in diagonal sequences, but do not tighten too much. If

over-tightened, the main body may be deformed or the sealing rings may be damaged and fail.

5.5 Inspection and Maintenance of Working Medium

5.5.1 Characteristic of Anti-friction Hydraulic Oil #46

·　 The anti-friction hydraulic oil #46 used in this hydraulic system has the following characteristics：·　 High viscosity index, good viscosity-temperature performance, high adaptability to environment；·　 High oil film strength, excellent anti-friction and lubrication performance, reliable protection to oil

pump；·　 Extremely low pour point, very good lower temperature performance；·　 Good oxidation stability and heat stability, low aging speed, long service life；·　 Favorable anti-corrosion performance, good adaptability to metal and nonmetal material of the

hydraulic system；·　 Favorable defoaming and demulsification performance.

5.5.2 Main Items for Routine Maintenance

·　 Checked whether the temperature of oil in the tank is controlled within the permissible range；·　 Check the filter often and change the strainer core in time；·　 Remove the residual oil (originally remained in the system or leaking in for some reasons) on the

liquid surface regularly；·　 Check for contamination by other liquids；·　 Pay attention to the change in viscosity and maintain it in normal viscosity；

Check the index of physical chemical properties regularly by sampling. Sampling and inspection can

be made once every one or two months at the initial stage of operation. Sample for routine inspection

once every six months following normal operation of the system.

The most important thing among all the maintenance work is to maintain the cleanliness of

the system. Take measures immediately to strengthen filtering after it is measured that the

cleanliness decreases. This is an absolutely necessary step to maintain normal operation of the

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system.

5.5.3 Replacement of Hydraulic Medium

The system needs to be washed before replacement of medium and this is absolutely necessary to ensure

normal operation of the system. The medium to be changed must be checked for emulsification before formal

replacement. In case of emulsification, it is suggested to add an intermediate washing process, i.e. replacement

of emulsified medium by anti-friction hydraulic oil #46, before formal washing of the system.

The principle for system cleaning is to drain the residual medium in the system thoroughly as far as possible.

Remove the oil sludge and deposit in the oil tank; manage to eliminate the residual oil in all the pipes and

valve pockets; drain the residual oil in the tank and clear the oil sludge, deposit away, then clean the oil tank

with fibre-free cloth, meanwhile, change the strainer core of the filter.

Fill the new anti-friction hydraulic oil #46 that has been filtered in the system and then make preparations for

test running. It is recommended that the oil is sampled and tested for the physical chemical index before the

system is put into production.

Stop the pump after one week of operation and check the tank for floating oil. The operation can be continued

after the floating oil is eliminated.

5.5.4 Safety and Disposal of Waste Liquid

The anti-friction hydraulic oil #46 doesn’t contain any harmful ingredient and is nontoxic, safe for

operation, with biodegradation function. The waste liquid can be discharged into the waste water disposal

system of the workshop after diluted by large amount of industrial waste water.

5.6 Maintenance and Servicing during Long-term Shut-down

·　 Shut off all the power supplies；Drain off the medium in the oil tank. Discharge the residual medium in the pipeline and hydraulic

station as thoroughly as possible, blow with compressed air and protect by spraying oil. The

compressed air used must be dry and clean；·　 Perform rust resistant treatment to the hydraulic system.

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Documents

Car Dumper-Operating Instruction Manual