Please read this instruction before erection and operation.

Car Dumper

Operating Instruction
No.A270100203YMS Chapter 8 Hydraulic

DHIDCW Group Co., Ltd

April 2011

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 DHIDCW 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: 116013 Website: http://www.dhidcw.com Reception Telephone0411-86852188 E-mailgsbw@dhidcw.com Customer Service Center: 0411-62999688 Fax0411-86852553 E-mailfwzx@dhidcw.com

Operating Instruction for Car Dumper

Hydraulic

Chapter 1 Product Overview Contents

1.1 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

Operating Instruction for Car Dumper

Hydraulic

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 Work flow Volume of oil tank Degree of contamination Work medium Pump station LWH Weight Hydraulic pump Type Max.work pressure Theoretical displacement Electric motor Type Speed Power Power supply Type Oil cooling fan Power supply 35 ~330 2000 9 Anti-friction hydraulic oil 46# 299016001650 2225 PV2R24-33-237-F-RAAA-30 17.5 270 Y225S-4 B35 37kW speed 1480r/min 415V 50Hz top outgoing line IP55 class F 1480 37 415,50 OKAF-EL8S/69/3.0/M/415-50/DF280/4/1 415,50 V,Hz r/min kW V,Hz MPa mL/r mmmmmm kg MPa L/min L NAS1638

Operating Instruction for Car Dumper Motor power of fan 1.5

Hydraulic kW

Motor pump

power

of

2.2

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 High-temperature pump stop alarming Lowest level 65 75 Distance to bottom of oil tank 500 mm

Table 2continued
Highest level Overflow valve of pump Overflow valve of pump Pressure relief valve for positioning Pressure relief valve for clamping Clamping relay detection pressure Pressure of sequence valve for clamping compensation Oil cooling fan start Oil cooling fan stop Setting value for high pressure Setting value for low pressure Setting value Setting value Setting value Setting value Setting value Setting value Distance to top of oil tank 120 3.55 23 0.351 23 23 56 55 45 mm MPa MPa MPa MPa MPa MPa

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 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.
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Clamping device (16)

Positioning device (8)

Hydraulic pump station (2)

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

Figure 3 Schematic Diagram for Positioning

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Figure 4 Schematic Diagram for Clamping 1.7.2 Structure, Function and Operating Principle of Main Component or Functional Unit
Return oil filter Pressure regulator

Butterfly valve for air cooling fan Nameplate for schematic diagram Ball valve for oil discharging

Level and temperature indicator Tank cleaning hole

Pump device

Oil drain

Butterfly valve for oil suction

Oil feeder

Oil filter

Pre-compressed air filter Air regulator

Figure 5 Pump Station NoteThis 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 topoil feederfrom where the working medium is filled in the tank and the medium filled in
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must be filtered to reach the required contamination degreestraight-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 precompressed 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 sidemanhole cover, from where the oil tank is cleanedlevel and temperature indicator, convenient for observing the level and temperature of medium in the tank. Electric motors of the pumpconnecting 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 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 sidethe ball valve is located at the oil drain of the tankbutterfly 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 signalmanhole cover, from where the oil tank is cleaned On the right sidethe 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.

Operating Instruction for Car Dumper

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Double-stage pressure-regulating electromagnetic overflow valve

Pressure measuring point of chamber T

Pressure measuring point of chamber P

Electromagnetic overflow valve

Plate-type check valve

Plate-type check valve

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 Name Overflow valve High pressure Low pressure + + + YH1 YH2 YH6

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.
Pressure measuring chamber B point of

Pressure relief valve

Plate-type throttle valve

Solenoid valve

directional

Pressure measuring point of chamber A

Throttle 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 Name Positioning cylinder Extension Retraction + + YH4a YH4b

Note In the table above, +indicates the electromagnet is energized,-indicates the electromagnet is de-energized. Refer to Figure 8 for positioning device. It is used to control the action of each positioning cylinder;
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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.
Valve block for positioning

Figure 8 Positioning Device NoteThis 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.

Pressure measuring point of chamber P

Plate-type throttle valve Pressure measuring chamber A Solenoid ball valve Solenoid directional valve Pressure measuring point of chamber B point of

Pressure relay Pressure relief valve Sequence valve Pressure measuring point of chamber C

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 Name Clamping cylinder Lifting Lowering YHa1 + YHb1 + YHa2 + -

Note In the table above, +indicates the electromagnet is energized,-indicates the electromagnet is de-energized. 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;
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the pressure relay is used for system pressure detection, and the sequence valve is used for adjustment of compensated pressure.
Valve block for clamping

Figure 10 Clamping Device NoteThis 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

Operating Instruction for Car Dumper

Hydraulic

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Chapter 2 Safety Contents

2.1 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 its 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. 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.

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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 6continued
Graphic Symbol Description

Graphic symbol indicating caution of fire. It indicates its 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 theres 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 its 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 Wear safety helmet, wear working clothes. Danger:falling. Hanging Position Access at the ladders to car dumper

Edge of platform, walkway, handrail

No flame, no smoking.

Operators room, electrical room

Danger:fire.

Electrical room

Danger: electric shock, no touching

All the live positions

High temperature inflammable, danger: corrosion

and

Hydraulic room

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Operating Instruction for Car Dumper Danger: electric shock, no passing

Hydraulic

Access at the ladders to power supply device

No passing

Area for platform and handrail, etc. on which the work havent 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 This graphic symbol indicates theres important matter to prompt relevant personnel.If not observed, vital equipment damage and casualty may occur during erection, commissioning, operation, maintenance. This graphic symbol indicates theres important matter to prompt relevant personnel. If not observed, equipment damage and casualty may occur during erection, commissioning, operation, maintenance. Warning ! This graphic symbol indicates theres 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. Danger! This graphic symbol indicates theres 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.

Attention!

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
Specific Position Clamping device Positioning device Hazard for Falling Stairs leading to equipment Edge of the platform near the handrail Hazard for Electric In the transformer room, inside the electric Shock cabinet in the electrical room, outside electrical component Hazard for Dust Material transfer area Explosion Hazard of combustible material In the hydraulic room if combustible hydraulic oil is used Around the lubrication pump Hazardous Area Hazard for Injury Precaution to Avoid Hazard Pay attention to the clamping device in operation. Pay attention to the positioning device in operation. Hold the handrails tight. Do not stretch the body out above the handrail. Its forbidden to touch the electrical part. Its 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. Its forbidden to smoke and be with open flame; check if the circuit is aged regularly. Its forbidden to smoke and be with open flame; check if the circuit is aged regularly.

2.4 Safety Device

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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 shows0 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.

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 partys 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 allowedX indicates not allowed). Table 10 Job Division of Various Personnel
Job division Trained operator Qualified technician Qualified fitter Qualified electrician After-sales personnel

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Operating Instruction for Car Dumper Equipment operation Fault finding Mechanical fault maintenance Electrical fault maintenance Daily maintenance and repair x x x x x x x x x x

Hydraulic 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 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

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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, its 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, its 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 erectioncommissioning department shall check if their working personnel observe the safety rules irregularly The user and the erectioncommissioning 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 erectioncommissioning department shall supplement the operating rules, supervision report and supervisors 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 During operation, its 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 operators 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
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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 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. Its not permitted to climb onto the component or equipment. When performing the assembling and inspection work, take proper measures to protect the component to
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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 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 suppliers 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.

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Chapter 3 Erection, Commissioning Contents

3.1 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

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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 theres part missing according to the packing list, and if theres 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 constructionconstruction 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 Count the items completely according to the packing list before installation. Check the
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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 The hydraulic cylinder, accumulator must be separated from the flushing circuit when the
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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 10m 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, its 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 10m Work medium is used for pressure test. The filtering accuracy of the filter shall be not lower than 10m 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 In case of fault that needs to be handled during pressure test, release the pressure first. Its strictly forbidden to operate under pressure. If theres weld seam needs to be re-welded, such pipe must be dismantled and the oil shall be discharged thoroughly before welding.
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During pressure test, visible signs shall be available in the test area. Its strictly forbidden for nonworking 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 coat2 layers, iron red epoxy resin H06-2each film thickness 35m Intermediate coat2 layersiron red epoxy resin H06-2each film thickness 30m Finish coat1 layerpolyurethane, film thickness 20m Total film thickness 150m. 3.5 Commissioning Procedures, Methods and Precautions Read Chapter 2Safety 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. Its 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 havent 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). 3.7 Preparation before Test Run, Test-run Start-up, Test Run 3.7.1 Checks before Operation
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Operating Instruction for Car Dumper

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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

The ball valve is opened by rotating in this direction.

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.

Rotation direction of 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 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,
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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.

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Operating Instruction for Car Dumper

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Chapter 4 Application and Operation Contents

4.1 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

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Operating Instruction for Car Dumper

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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, DHIDCW will not assume any responsibility. As we are not able to control the understanding of the client for this instruction book, therefore DHIDCW 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
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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 The oil viscosity is too high low oil temperature. The connection between the oil pump and oilsuction pipe leaks. The drive shaft of the pump is not tightly sealed. The assembling quality is not good, the component becomes loose due to wear. The oil pump is not concentric with the shaft of the electric motor. Theres bubble in the oil. Solutions Check the oil temperature, replace with suitable medium.

Check the leaking position, reinforce or change the washers.

Oil the end of the drive shaft. Change the shaft seal in case of variation of noise. Disassemble the pump, trim or change the component. The non-coaxiality tolerance is permitted to be 0.10mm. Check whether the oil return pipe is in the oil and whether the oil return pipe is sufficiently separated with the oil inlet pipe.

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 The oil in the tank is not enough. The oil viscosity is too high. The pressure of overflow valve is not set properly. Too much interior leaking in component Solutions

Observe the level indicator. Refill the tank when the oil is not enough. Check the type of medium, replace with medium specified. By design. Reach the specified set pressure. 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 The level of oil in the tank is low. The pump rotates too slowly. Solutions Check the level. Refill the tank when the oil is not enough. Check the electric motor for rotation speed and make the speed higher than minimum specified speed.

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Operating Instruction for Car Dumper The oil viscosity is too high low oil temperature. The oil-suction pipe is clogged or the resistance is too much. Air accumulates in the oil inlet piping. The oil inlet pipe leaks. The shaft or vane is damaged.

Hydraulic

Check the oil temperature, replace with suitable medium. Eliminate the piping clogging. Discharge from the connection at the oil discharge side. Rotate the oil pump to make it suck the oil and discharge the air. Washer, etc. are damaged or the piping is loose. Change the washer and tighten the bolt. 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 The pressure is too high or too low. Reasons No oil is pumped out from the oil pump The pressure is not set properly. The pressure regulating valve doesnt function properly. The setting value for variable point of constantpressure variable displacement pump is not proper. The pressure gauge is damaged. Solutions Refer to 5.7.1. Set the pressure as specified. Disassemble the valve and wash. Set the pressure as specified. Change the pressure gauge.

Table 14 continued
Phenomena The pressure is not stable. Reasons Ingress of air in the piping Theres dust in the oil. The core of the pressure regulating valve doesnt function properly. Solutions Discharge the system. Disassemble and wash. Change in case of severe oil contamination. 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 The connection is loose. The sealing ring is damaged or deteriorated. The pressure rating of the sealing ring is not proper. The component is assembled improperly or worn. Solutions Tighten the connecting position.. Change the sealing ring. Check and change relevant sealing ring if it is not proper. Re-assemble or change the worn part.

4.6.6 See Table 16 for reasons and solutions for hydraulic fault. Table 16 Reasons and Solutions for Fault
Control valve The speed can not reach the specified value. The speed is not stable. Reasons The control valve doesnt function properly. The flow is insufficient. The pressure is insufficient. The viscosity changes due to temperature change. Solutions 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. Check the flow regulating valve and oil pump for displacement. Check the pressure regulating valve and pump for pressure. Adjust the oil temperature appropriately.

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Chapter 5 Servicing and Maintenance Contents

5.1 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

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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
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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 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
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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 Its 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 its 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 Table 17 Maintenance Period
Inspected Items Noise of Oil Pump Temperature of Shell of Oil Pump Pressure at Outlet of Oil Pump Noise of Coupling Adhesive Substance on Oil Filter Indication of Each Pressure Gauge Speed of Mechanism Actuating Maintenance Period Daily Weekly Every half a month Monthly Monthly Quarterly Quarterly Quarterly Monthly to quarterly Every 6 month Inspection Method and Content Check for ingress of air, abnormal wear etc. auditorily. Check the parts for wear and the bearings, etc. by hand or thermometer. Check the oil pump and determine its internal wear by using pressure gauge. Check for abnormal wear auditorily and by using dial gauge. Flush by solvent or clean by blowing. Check and calibrate the pointer of pressure gauge for abnormal movement, check relevant components for abnormal operation or wear. Check each component for abnormal operation and degree of internal leakage due to wear. Check the valve core for clogging or damage auditorily or by sound level meter. Check related joints and sealing positions for leaking, especially the pump shaft, piston rod of cylinder and sleeve visually and by hand. Check the bolts of each component, pipe support and couplings for loosening visually and auditorily.

Noise of Change-over Valve and Pressure Valve Leakage Vibration

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Operating Instruction for Car Dumper Whole Oil Pressure System Characteristic and contamination of Medium Oil Temperature Level of Oil in the Tank Insulation Impedance Electrical System Supply Voltage of Yearly Quarterly Daily Weekly to monthly Yearly Quarterly

Hydraulic

Detection and maintenance of each components, washing of pipe and oil tank Check for degree of contamination and deterioration. Check the temperature of oil in the tank by thermometer. Checked the amount of oil and leakage. Check if the rated value of electric motor, solenoid valve, pressure relay is low. 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 its 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 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
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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 antirust oil and placed in the box for storage 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
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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 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 doesnt 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
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compressed air used must be dry and clean Perform rust resistant treatment to the hydraulic system.

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