Hydraulic System Training for

Wide-Body Dumper

TOUGH WORLD. TOUGH EQUIPMENT.

极限工况 强悍设备
目录 CONTENTS

I. DW90A Principle and Characteristics Introduction

II. DW90A Lifting System Structures

III. DW90A Steering System Structures

IV. Service and Maintenance

V. Case Studies
I. DW90A PRINCIPLE AND CHARACTERISTICS INTRODUCTION

Introduction to the DW90A hydraulic system characteristics:

Ø Full-time PTO, simple operation; confluence system, energy-saving and efficient.

Ø Full-hydraulic steering, time-saving and labor-saving, easy operation.

Ø Lifting explosion-proof is designed to prevent safety accidents caused by oil pipe bursting and body falling.

Ø The lifting mounting structure is optimized, which is safer and more reliable.

Ø Equipped with large flow valve to prevent high system temperature.

3
I. DW90A PRINCIPLE AND CHARACTERISTICS INTRODUCTION
Lifting Lifting cylinder parameters:
cylinder Bore for at each stage, mm:
Steering
179/157/137/118
cylinder
Steering cylinder Stroke at each stage, mm:
parameters: 1180/1205/1210/1210
Pneumatic
Bore diameter: 70mm
control valve
Rod diameter: 40mm
Travel: 405mm Lift valve

Metering
pump

Limit valve

Priority
valve

Return oil filter Main parameters:

element Displacement of duplex pump:
83.6ml/r+41.8ml/r
Dual gear Maximum system flow rate:
pump 250l/min
Breather filter Maximum working pressure:
element 22MPa
Lifting Time,≤ 19s
Lowering time,≤ 21s
目录 CONTENTS

I. DW90A Principle and Characteristics Introduction

II. DW90A Lifting System Structures

III. DW90A Steering System Structures

IV. Service and Maintenance

V. Case Studies
II. DW90A BODY LIFTING SYSTEM STRUCTURES
Ø The confluence flow system can ensure the steering oil, reduce the flow of the lift pump and reduce the cost.
Ø The cylinder-mounted lift valve has an explosion-proof function to prevent safety accidents caused by oil pipe
bursting and body falling.
Ø Add the cylinder protective device to ensure more safety of the driver.
Ø The tank is well-matched, with a more precise filtration and a more flow return filter, with a pollution warning device,
which allows for a higher level of fluid cleanliness. Increase the reliability of the hydraulic system.

DW90A DW90A-H
II. DW90A BODY LIFTING SYSTEM STRUCTURES (15Y2116)
The lifting system mainly consists of a gear pump, a lifting valve, a pneumatic
control valve, a limit valve, a cylinder, a hydraulic tank, etc.
Pneumatic
control valve
Oil return hose
Hydraulic
Air Filter cylinder

Upper bracket

Hydraulic tank
Limit valve

Tank support
Lift
valve

Lower
support
High-pressure Dual gear pump
hose
II. DW90A BODY LIFTING SYSTEM STRUCTURES (15Y4013)

Lifting
cylinder Lift valve

Return oil filter Bracket as

Pneumatic
Air Filter control valve

Dual gear pump

Level gauge

Metering
pump
Hydraulic tank

Priority
valve
Steering A
cylinder A
Stop valve

Oil draining
line
II. DW90A BODY LIFTING SYSTEM STRUCTURES
1. Gear Pump

The gear pump is installed on the power

take-off (PTO) of the engine or transmission.
It supplies oil to the lift control valve as well
as to the steering system.
Adopts the duplex gear pump

Return back

Parameters:
Technical
Front pump Rear pump
parameters
Theoretical
displacement (ml/r)
83.6 41.8 One-way fixed
Direction of rotation Right rotation displacement pump
Rated/maximum
speed (r/min)
2200/2500 Two-way variable
Rated/maximum
pressure (MPa)
23/28 displacement pump
Floor area rate (≥%) 92
II. DW90A BODY LIFTING SYSTEM STRUCTURES
2. Lift valve
The lifting valve is a three-position three-way reversing valve, which mainly includes lifting
position, holding position and lowering position. When the vehicle runs normally, the lift valve
should be in the descending position to ensure the safe running of the vehicle.
The lift valve is used to guide hydraulic oil to the lift cylinder to lift or drop the carriage. There
are currently two types of installation modes commonly used on wide-body dumpers, one is
to install the valve directly at the cylinder inlet port; and the other is to install the valve in the
tank return port.

Lift valve mounted Lift valve mounted

on the fuel tank on the cylinder
II. DW90A BODY LIFTING SYSTEM STRUCTURES
2. Lift valve (12C8162)

Mounted directly at SAE inlet of the cylinder to achieve the safety

performance of explosion-proof valves

1. Hydraulic pump interface (p)

2. Tank return port (T)
3. Cylinder interface (C)
4. Pneumatic operated valve/lifting interface
5. Pneumatic operated valve/lowering interface
6. Relief valve
7. Pressure gauge interface (G1/4“)
 II. DW90A BODY LIFTING SYSTEM STRUCTURES
2. Lift valve (12C9906)
The lift valve is connected to the cylinder by a hose.

Height of mounting
hole

Through-hole
II. DW90A BODY LIFTING SYSTEM STRUCTURES
3. Limit valve

1. Air intake (to pneumatic operated valve, port 22)

2. Air outlet (to lift valve)
3. Emptying port

The air circuit is controlled by manipulating the pneumatic operated valve. When the gear pump works, hydraulic oil is pumped
into the lifting cylinder through the lifting valve to push the carriage. When the body lifting to the designed maximum corner
position, the adjusting bolts of the pneumatic-operated limit valve will cut off the air circuit when hitting the limit block, causing
the lift valve to return to the neutral position and the lifting is stopped. And it can effectively prevent the cylinder from being lifted
to the topmost to damage the cylinder and cause a shock.
II. DW90A BODY LIFTING SYSTEM STRUCTURES
4. Pneumatic control valve

The pneumatic valve is located in the cab, on the right side of the side, and the driver
can operate the movements of the body by controlling the pneumatic valve.
There are three positions: lift, middle, and lower
II. DW90A BODY LIFTING SYSTEM STRUCTURES

4. Pneumatic control valve schematic

Schematic diagram of air circuit

22- Lifting
1 - Inlet
21 - Falling
3 - Air
bleeding

Air source port

Emptying port

Lowering port

(To lift valve)

Lifting port

(To lift valve)

II. DW90A BODY LIFTING SYSTEM STRUCTURES
5. Lifting cylinder

The lifting cylinder is the device to execute lifting and lowering the body. Wide-
body dumpers generally adopt the single-acting four-stage cylinders.
II. DW90A BODY LIFTING SYSTEM STRUCTURES
6. Check valve

It is mounted at the lift valve inlet to prevent the body from jerking during lifting.
 II. DW90A BODY LIFTING SYSTEM STRUCTURES
7. Joint block and pipeline (44C4979)

Oil inlet
joint block From the
priority valve
Valve port EF
block inlet (confluence)
(i.e. pump
To lift valve
outlet)
port P
Lifting
pressure
From lift
measurin
valve port T
g point
From the
Oil return steering gear
joint block port T
From the
priority valve
port T
II. DW90A BODY LIFTING SYSTEM
STRUCTURES
7. Joint block and pipeline (44C6301)

Lift valve
oil return

Steering gear and

priority valve oil
return
II. DW90A BODY LIFTING SYSTEM STRUCTURES
8. Hydraulic tank

Air Filter

Return oil filter

Level gauge

Tie

Carrier

Return oil filter: filters the oils and guarantees the oil cleanliness.
Air filter: Changes in the tank level will allow the air inside to exchange with the outside. The
air filter will filter the air to prevent outside contaminants from entering the tank.
II. DW90A BODY LIFTING SYSTEM STRUCTURES
8. Hydraulic tank (continued)

Air filter: Ensure that the air entering the hydraulic tank is clean.
Pressure indicator: The pressure indicator needle swings when the return filter
element is clogged, servicing the filter element through the pressure indicator.
Stop valve: Close the stop valve in the event of leaking in the pipeline to prevent
large amounts of hydraulic oil loss.
II. DW90A BODY LIFTING SYSTEM STRUCTURES
9. Schematic diagram

① In neutral position
When the pneumatic
operated valve is in the Lifting
Intake
neutral position, the lift valve
Low Exhaust
spool is also in the neutral ering

position, and the hydraulic oil

pumped through the spool is
centered and returned to the
reservoir through the return
filter element, and the lifting
cylinder does not operate.

From the priority valve

EF confluence port
II. DW90A BODY LIFTING SYSTEM STRUCTURES
9. Schematic diagram

② Body lifting
The pneumatic operated
Lifting Intake
valve handle is pulled back,
the compressed air is moved Low
ering
Exhaust

through the pneumatic

operated valve going up, the
limit switch left part is
entering into the left of the
lift spool, pushing the spool
to the left, and the oil from
the pump pushes the check
valve open to access the lift
cylinder through the spool to
From the priority valve
the right. The cylinder barrel EF confluence port

is stretching out.
II. DW90A BODY LIFTING SYSTEM STRUCTURES
9. Schematic diagram
③ The body is lifted to the highest
position
When the body is lifted to the highest Lifting Intake
position and the handle of the
Low Exhaust
ering
pneumatic operated valve is still in the
rear position, the limit valve rod is
pressed and the valve spool moves to
the left. At this time, the air circuit of
the pneumatic operated valve is cut off,
at the same time, the right end of the
lift valve spool is connected to the
atmosphere, the valve spool returns to
the neutral position under the action of
spring force, and the lifting cylinder From the priority valve
EF confluence port
stops working.
II. DW90A BODY LIFTING
SYSTEM STRUCTURES
9. Schematic diagram

④ Body lowering
The pneumatic operated
valve handle is pushed Lifting
Intake
forward, the spool is Lowering Exhaust
operated in the lowering
position, the compressed air
flows through the spool to
the left side of the lift spool,
pushing the spool to the
right, and connects the
cylinder inlet port to the
reservoir. The cylinder is
lowered.
From the priority valve EF
confluence port
目录 CONTENTS

I. DW90A Principle and Characteristics Introduction

II. DW90A Lifting System Structures

III. DW90A Steering System Structures

IV. Service and Maintenance

V. Case Studies
III. DW90A STEERING SYSTEM STRUCTURES

1. Steering system function

The steering system on LiuGong DW90A wide-body dumper is a fully hydraulic
type. The system is a non-reactive closed dynamic load sensing system, which
has the functions of anti-backflow and anti-vacuum overload, etc.
2. Steering system classification
Mechanical part: steering gear assembly, steering articulated system.
Hydraulic part: steering control line, steering line
III. DW90A STEERING SYSTEM STRUCTURES
3. Schematic diagram

Working process:
① when no steering motion

Lifting confluence
III. DW90A STEERING SYSTEM STRUCTURES

3. Schematic diagram

Working process:
② Left turn action

Lifting confluence
III. DW90A STEERING SYSTEM STRUCTURES
3. Schematic diagram

Working process:
③ Right turn action

Lifting confluence
III. DW90A STEERING SYSTEM STRUCTURES
4. 3D layout:
Joint block
Steering
wheel Hydraulic
Oil Pipe
tank

Pump
Metering Priority
pump valve

Steering
cylinder
III. DW90A STEERING SYSTEM STRUCTURES
5. Steering System Parts Introduction - Steering Gear

Control the vehicle to turn left and right, and keep the vehicle in
a fixed position by using full hydraulic steering
The steering gear is integrated: one-way valve prevents
pressure backflow of load oil circuit, safety valve prevents
system overload, buffer valve reduces overload impact of
cylinder, and oil replenishing valve prevents system from
generating vacuum. The integration of these valves effectively
improves the reliability of the vehicle steering system.

Displacement changing
characteristics of the steering gear
Main technical parameters of
the steering gear Inlet check valve: yes
Displacement ml/r

Product No.: 470-0064-001 LS Safety valve: 16Mpa

Dynamic signal load non- Overload valve pressure: 21Mpa
reactive type Oil refilling valve: including
Flow amplifying 1.6 times steering moment: 1.3 - 2.5Nm
Equivalent displacement: Recommended fluid
640ml/r contamination: ISO 22/18/13
Max. pressure at inlet: Paint: Black
17.5Mpa
Max. continuous back
Speed, rpm pressure 2.1MPa
Max. system temperature:
93°C
III. DW90A STEERING SYSTEM STRUCTURES
6. Steering System Parts Introduction - Priority Valve

It is matched with coaxial flow amplification steering

gear, which constitutes a load sensing and steering
system. Under the condition of system load change
and steering wheel speed change, it can give priority
to ensuring the flow required by steering gear. The
valve adopts dynamic signal control, and the hydraulic
oil in LS control oil circuit is always flowing. Its
advantage is that the steering signal feedback is faster
when working in cold areas.

Product model: VLE-150

Product No.: 882-2902-000-H
Nominal flow: 150L/min
Dynamic signal: control pressure 8.6Bar
Ports P, EF: M27X2 cone seal
CF port: M22X1.5 cone seal
Ports LS, T: M12X1.5 cone seal
Recommended fluid cleanliness: ISO-/18/13
III. DW90A STEERING SYSTEM STRUCTURES
6. Steering System Parts Introduction - Priority Valve
From oil outlet of steering pump

Steering pressure
measuring point

Relief valve

To hydraulic
tank

From steering
gear LS port

Lifting
pressure
measuring
point To confluence To steering
valve block gear port p
III. DW90A STEERING SYSTEM STRUCTURES
7. Steering System Parts Introduction - Steering Cylinder

It is an actuating element of the steering system and realizes the left/right steering by
pushing hinge pins through the action of the piston rod of the left and right steering
cylinder.
目录 CONTENTS

I. DW90A Principle and Characteristics Introduction

II. DW90A Lifting System Structures

III. DW90A Steering System Structures

IV. Service and Maintenance

V. Case Studies
IV. Service and Maintenance - Maintenance and Precautions
1. Hydraulic tank filling: When filling hydraulic oil for the first time, Add to
the middle position of the level gauge. After starting for operation, fill the
oil to the middle position of the level gauge. Also, check the hydraulic oil
level every day before starting up to ensure the oil level is centered on the
gauge.

Note: When filling

or changing oil,
avoid water
entering the tank,
especially on The hydraulic
rainy days, and fill oil level scale
the tank indoors
is located in
or in a rain-
protected area.
the middle.
IV. Service and Maintenance - Maintenance and Precautions
2. When driving, place the pneumatic operated valve in the lowering position, and do not lift the body during
driving.
3. The first replacement time of the oil return filter element is 500 hours, and the subsequent replacement cycle is
1000 hours.
4. The cylinder shall not be in the lifted status for a long time. For long-term shutdown, the body shall be lowered
to ensure that the cylinder is in the retracted status, so as to protect the cylinder piston rod from being damaged
by the external environment. It is also easy to check the hydraulic oil level on next day.
5. The high-pressure pipe needs to be replaced regularly (every two years) to avoid the risk of aging and blasting.

The high-
pressure
pipe
needed
to be
replaced
regularly
IV. Service and Maintenance - Maintenance and Precautions
7. Hydraulic oil: Apply the HM-46 anti-abrasive hydraulic oil in summer, HV-46 anti-
abrasive hydraulic oil in winter. For the oils applicable to the extremely cold and hot
environment as well high altitude, please consult your local dealer.
8, Regularly (20 hours/week) lubricate the cylinder support (hinge point pin shaft)
9. All seals such as O-rings, oil seals, joint washers, etc. that have been removed,
must be replaced and must not be reused.

3
1

2
4
IV. Service and Maintenance - Maintenance and Precautions

10. Drain the hydraulic tank: when the engine is cut out, unscrew the drain
plug at the tank bottom, drain the hydraulic oil, and collect with a container.

Drain plug
IV. Service and Maintenance - Maintenance and Precautions

Check items Period

Check whether vehicle is not worn. Check every day
Check the oil face and level gauge in the hydraulic tank. Check every day
Check whether the cylinder support and the big nuts on the top are not
Check every day
loose and whether the clearance of the cylinder support is reasonable.
For lifting the cylinder with an empty vehicle, the cylinder is not tilted. Check every day
Check the bolts on the tank and pump are not loose. Check every week
Check the limit valve works properly. Check every week
Replace the return oil filter element and air filter element. Check every six months
Check the lifting angles Check every day
Sealing inspection of oil and gas pipelines Check every week
Replace the hydraulic oil Check every year

Once the problem occurs, timely repair and replace!

IV. Service and Maintenance - Maintenance and Precautions

Maintenance intervals for hydraulic system

Intervals

50
Service item 10 hours 100 hours 250 hours 500 hours 1000 2000
If hours or
or every or every 2 or every or every 3 hours or hours or
necessary every
day weeks month months half a year 1 year
week

Hydraulic oil level - checking

Hydraulic oil - refilling

Hydraulic oil - replacing ★★★

Heavily contaminated hydraulic oil

- replace

Hydraulic tank air filter - cleaning

Hydraulic tank return oil filter

★★★
element - replace

Hydraulic tank - cleaning

Note: ★★★ It shows the date of first maintenance cycle.

目录 CONTENTS

I. DW90A Principle and Characteristics Introduction

II. DW90A Lifting System Structures

III. DW90A Steering System Structures

IV. Service and Maintenance

V. Case Studies
V. Case Study - PT Valve Oil Mixing

Symptom: Oil leakage at the pilot valve or PT valve air tube.

Field solution: After the PT valve is replaced, the oil leakage will be solved, but
many times, the same fault will occur after using for a period of time.

Analysis: The sealing rings of the PT valve chamber and pilot chamber are
damaged, resulting in hydraulic oil entering the pilot pipeline, resulting in leakage.
V. Case Study - Steering Gear, Priority Valve

Symptom: Steering gear leaking oil, heavy steering;

Field solution: Replace the steering gear or priority valve, then
the problem will be solved.

Analysis: After disassembling the steering gear and priority valve, it was found that the internal
cleanliness was not reaching the standard, resulting in seals worn, valve stuck, etc. It is required to strictly
check the internal cleanliness of steering gear and priority valve, and strictly control the cleanliness of
hydraulic tank.
V. Case Study - Gear Pumps
Symptom: Bucket not tipping when vehicle idling, slow tipping at heavy
load or not tipping.
Field solution: Replace the gear pump, and the vehicle is restored to normal.
Figures:

The pump body and bearing The side-panel end face is

inner chamber are overburning overburning and badly worn, and
the back E-ring seal is burned out.

Gear overburning There is mud sand in the pump

chamber

Analysis: After analyzing the disassembly of the gear pump, it was found that the inner chamber of the
pump was burned, the end face of the gear and side plate burned and badly worn, the bearing was
burned and damaged, and some sealing parts were burned, finally causes internal leakage and does
not lift properly.
 谢谢 THANK YOU
TOUGH WORLD. TOUGH EQUIPMENT.
极限工况 强悍设备