Dumping mechanism

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14 DUMPING MECHANISM
14.1 Hydraulic system operation principle
Dumping mechanism is of hydraulic type, with electrohydaraulic control; it ensures raising, sinking and
stopping of the body in any intermediate position. Dumping mechanism consists of two hydraulic telescopic
cylinders Ц1 и Ц2 (figure 14.1), gear-type pumps Н1 - Н3, control panel A1, control unit A2, oil tank and oil
pipelines. Hydraulic systems of steering ГРУ is fed with working fluid from hydraulic system of dumping mecha-
nism.
Dumping mechanism is controlled from the cab by electrical switch placed on instrumentation panel.
Control panel A1 changes working fluid flow direction from pumps Н1 - Н3 of hydraulic system to rod and pis-
ton spaces of hydraulic cylinders Ц1 and Ц2 or to drain line to oil tank depending on spool-valve position in hy-
draulic distributor Р1 of control panel A1.
Hydraulic distributor Р3 with electric magnets controls body raising and sinking and its stopping at any
intermediate position. Hydraulic distributor Р4 with electric magnets ensures “floating” position of hydraulic
cylinders Ц1 and Ц2, connecting piston spaces to drain line when step of hydromechanical gear is put in.
Safety valve КП1, adjusted for working fluid pressure of 13 МPа, protects hydraulic system from over-
loading while body raising and connects piston spaces of hydraulic cylinders Ц1 and Ц2 with drain line to oil
tank when step of hydromechanical gear is put in.
With the switch in the neutral position, both electromagnets of control unit A2 hydraulic distributor P3 are
de-energized and its spool valve is in the middle position, closing hydroline channel from pump H3. The pres-
sure hydroline of pumps H1 and H2 is connected with drain line to fluid tank. The working fluid from pump H3
moves into steering hydraulic system.
When the switch on the control panel is set to “RAISE” position the electromagnet shifts the spool valve
of hydraulic distributor Р3 into the extreme right-hand (in the figure) position. The working fluid from pump H3
flows into the left (in the figure) head end of hydraulic distributor P1 spool valve and moves it into the extreme
right-hand (in the figure) position. Simultaneously spool valve of pump H3 valve, connecting steering system to
dumping mechanism hydraulic system, moves into extreme right (in figure) position. Working fluid flows from
pumps Н1 -- Н3 along hydraulic lines into piston spaces of hydraulic cylinders Ц1 and Ц2, which members ex-
pand and raise body.
At sliding out of the last (fourth) segments of hydraulic cylinders working fluid from head ends flows
through throttle into drain hydraulic line. Throttle in sinking hydraulic line provides working fluid pressure in hy-
draulic cylinders head ends of 2.5 — 3.0 МPа that is necessary to slowdown the body in the end of raising.
When the body reaches maximum raising angle its center of gravity moves backwards, closer to axle. At
the same time the force necessary for body raising gets decreased and working fluid pressure in raising hy-
draulic line gets decreased correspondingly.
When hydraulic cylinders are fully stretched pressure-relief valves mounted in pistons get opened and
working fluid flows from head to rod ends and along sinking hydraulic line to oil tank.
In case of hydraulic system overloading while body raising safety valve КП1 gets opened and connects
space behind valve throttle with drain line. Pressure difference created by fluid flow through the throttle upsets
safety valve balance. It gets opened and connects piston spaces of hydraulic cylinders with hydraulic drain
line. Working fluid, fed by pumps, is being drained to oil tank through hydraulic distributor P2 and safety valve
KП1.
When the switch on the instrumentation panel is set in “Sinking” position spool valve of hydraulic distrib-
utor P3 moves into extreme left position (in figure). Working fluid from pump H3 flows through hydraulic control
line to right (in figure) spool valve space of hydraulic distributor P1 and moves it to extreme left (in figure) posi -
tion. Working fluid flow from pumps Н1 and Н2 is being fed through hydraulic line into rod spaces of cylinders
Ц1 and Ц2, which members contract and body is being sunk. At this procedure piston spaces of hydraulic
cylinders are connected with hydraulic distributor P1 ensuring oil drain into oil tank. Working fluid supplied by
pump H3 moves to steering hydraulic system. After rod spaces of hydraulic cylinders Ц1 and Ц2 been filled
working fluid from pumps Н1 and Н2 flows through hydraulic distributor P1 to oil tank through throttle and body
starts sinking under its own weight.
To stop body in any intermediate position it is necessary to set the switch on instrumentation panel in
“NEUTRAL” position.

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Figure 14.1 – Flow diagram of dumping mechanism hydraulic system:

Ц1, Ц2 -- dumping mechanism hydraulic cylinders; Н1, H2, Н3 – pumps operation volume 51…56 cm3; A1 – control panel;
A2 – control unit; KO1, KO2 – check valves; КП1 – safety valve; P1, P2, Р3, Р4 -- hydraulic distributors; A3 – oil filter; Ф1 – Regotmass
631B-1-19;К1 – valve; ГРУ – steering hydraulic system

14.2 Dumping mechanism units structure

14.2.1 Hydraulic cylinders
Hydraulic cylinders are of four-segment telescopic type (figure 14.2).
Hydraulic cylinder comprises three telescopic tubes 8, 19 and 20, external tube 21 and immovable rod
with piston 7. Conjugations of movable parts are sealed with rubber rings 22 of circular section that are pre-
served by protective washers 23 from being pushed out. Safety rings 24 of special section are installed in
grooves of tubes and bushings 6. The rings clean outer surfaces of tubes when hydraulic cylinder is pressed.
At body raising the working fluid moves through inner tube 5 into head end VI. First, outer tube 21
moves upwards then, in sequence, second 20, third 19 and fourth 8 telescopic tubes. Fourth telescopic tube
moves together with bushing 6 that slides over rod.
Piston incorporates pressure-relief valve comprising ball 10, pusher 9 and mortise 11. When the fourth
telescopic tube 8 and bushing 6 reach their upper position the bushing shifts the pusher upwards, ball 10 rises
and piston chamber VI connects with rod end chamber III and through channels IV and II with drain hydraulic
line. Cylinder stops sliding out.
Fluid supplied into piston head end chamber VI through valve and radial channel IV in piston rod, cham-
ber V between rod and inner pipe 5 through drain channel II moves to sinking hydraulic line channel I and
drains into hydraulic tank.
Lower and upper supports are set at hinged bearings (figure 14.3). Hinged bearings are sealed with
glands and lubricated through greasers.

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Figure 14.2 — Dumping mechanism hydraulic cylinder

1 — lower support head; 2 — locking washer; 3, 4, 13, 18, 22 — sealing rings; 5 — inner tube; 6 — bushing; 7 — rod with piston; 8 — fourth
telescopic tube; 9 — pressure-relief valve pusher; 10 — pressure-relief valve ball; 11 — pressure-relief valve mortise; 12 — upper support head;
14 — cover; 15 — restricting rings; 16 — piston guide ring; 17, 23 — safety washers; 19 — third telescopic tube; 20 — second telescopic tube; 21
— outer tube; 24 — safety rings; 25 — ring; 26 — bolt;
I — sinking hydraulic line channel; II, IV, V — drain channels; III — rod (under piston) end chamber; VI — piston chamber; VII — raising hydraulic
line channel
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Figure 14.3 – Installation of dumping mechanism cylinder:

1 — lower support; 2 — hydraulic cylinder; 3 — upper support; 4 — clamping plate; 5 — collet; 6, 20 — glands; 7, 19 — hinged
bearings; 8, 15, 18 — locking rings; 9 — spacing bushing; 10, 17 — greasers; 11 — upper support pin; 12 — nut; 13 — washer;
14 — lower support pin; 16 — cover

14.2.2 Pumps
Dumping mechanism hydraulic system comprises three gear pumps with operation capacity of 51…56
сm3. Pumps have connection dimensions according to the standard SAE. Rotation direction of the driving shaft
is right side.
List of applied pumps is given in the table 14.1
Table 14.1 – The gear pumps with connection dimensions according to the standart SA E

Designation Operation capacity, см3 Manufacturer

AZPG-22-056RDC07MB 56 Bosch Rexroth, Germany

or
QHD0-51R-S08D13-SE05E04-N 51 Jihostroj a.s., Czech
or
X1A5056B21A1H1FC 56 David Brown Hydraulics, England

Pumps are installed on the hydromechanical transmission (figure 14.4).

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Figure 14.4 – Installation of pumps:

1 – hydromechanical transmission; 2 – bolt; 3 – washer; 4 – gear pump AZPG-22-056RDC07MB; 5 – gasket

A gear pump with external engagement (figure 14.5) converts mechanical energy (torque and speed)
into hydraulic energy (volumetric flow and pressure.). The supply of external energy is carried out on the driv-
ing gear, which, by rotation due to the teeth, drives the driven gear. As a result of opening the teeth chambers,
the working fluid enters the suction chamber through the pump inlet and in the hollows between the teeth of
the two gears is transferred to the pressure chamber. In the pressure chamber, the teeth of the gears engage
and push the liquid out of the hollows and then the liquid enters the pump outlet

Figure 17.5 – Gear pump with external engagement with axial clearance compensation

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Figure 14.6 - Gear pump with operation capacity of 56 см3 manufac-

tured by “Bosch Rexroth”:
1 - locking ring; 2 - the shaft sealing ring; 3 - front cover; 4 - sliding bearing; 5 - center -
ing pin; 6 - gear; 7 - gear (driving); 8 - sealing ring of the housing; 9 - pump housing; 10 - bear -
ing shell; 11 - axial sealing; 12 - supporting element; 13 - rear cover; 14 - connecting screws

The main components of the gear pump AZPG-22-056RDC07MB (figure 14.6) manufactured by “Bosch
Rexroth” are the gear pair 6, 7 installed on the bearings shells 10, as well as the housing 9 with the front 3 and
rear 13 covers. The drive shaft sealed with ring 2 passes through the front cover 3. The perceived load is
transmitted to sliding bearings 4 which are designed for high-pressure operation and have excellent extreme-
pressure characteristics - specially for low speed rotation. Gears 6, 7 have 12 teeth. This helps to reduce un-
even flow and reduces noise. Internal sealing of the working chamber is carried out by forces which are pro-
portional to the developed pressure. This ensures optimal efficiency. On the reverse side of the bearing 4, the
movable liners 10 are loaded with working pressure and pressed against the gears 6, 7. Loaded pressure
fields are limited by special seals 11. Impermeability between gears 6, 7 surface and the housing 9 around the
perimeter is provided by a minimal gap, which is formed depending on the pressure between the gears and the
housing.

14.2.3 Control unit

Figure 14.7 – Control unit:

1, 4 — hydraulic distributors; 2 — casing; 3 — valve; 5 — plug; 6 — sealing ring

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Control unit. Control unit is intended for control of body raising, sinking and stop in intermediate posi-
tions; it ensures “floating” position of hydraulic cylinders. It consists of casing 2 (figure 14.7) to which hydraulic
distributors P3 and P4 with electromagnetic control are attached.

Control panel (figure 14.6) incorporates hydraulic distributor that ensures distribution of working fluid
flows during raising and sinking of the body.
Control panel consists of control panel body 1, valve of cylinders 10 control, spool valve of pump switch-
ing (body 1 — spool valve15), two check valves, safety 9 and auxiliary 8 valves.
Controlling flow of working fluid from control hydraulic line (from control unit) is supplied to channels III,
IV, spool valve moves and connects piston head or rod end spaces of hydraulic cylinders correspondingly with
pressure hydraulic line of pumps. Besides, at body raising controlling flow of working fluid from control hy-
draulic line is supplied to channel IX, spool valve 15 moves and connects steering pump to hydraulic system of
body raising.

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Figure 14.6 – Control panel:

1 — body of control unit; 2, 4 — brackets; 3 – adaptor; 4 – knee-piece; 6 – drain branch-pipe; 7 – adapting plate; 8 — auxiliary
valve; 9 — safety valve; 10 -- valve of cylinders control; 11 – tee; 12, 16 — plugs; 13 — cover; 14, 22 — springs; 15 — spool valve;
17 – ring; 18 — special joining pipe; 19 – spring of check valve; 20, 21 — balls
I — channel of pressure hydraulic line to control unit; II — channel for fluid supply from pump to steering hydraulic system;
III — control hydraulic line channel of body “raising”; IV — control hydraulic line channel of body “sinking”; V — control panel drain chan -
nel; VI — pressure hydraulic line channel of body “sinking”; VII — control unit drain channel; VIII — fluid supply channel from steering
pump; IX — control hydraulic line channel of body “raising” (connected with channel III); X — drain channel; XI — throttle channel;
XII — pressure hydraulic line channel (from pumps); XIII — “raising” hydraulic line channel

Oil tank. Oil tank is of welded design, mounted on the right frame spar.
Working fluid from the tank moves to the pumps through branch pipe with the open shutter 19
(figure14.7). The cap 23 should be tightened up to the stop.
Working fluid at steering operation drains into the tank through drain branch pipe and further through fil-
ters, and at dumping mechanism operation – through check valve 10.
Check valve 10 prevents working fluid leakage from tank at hose replacement.
The level of working fluid in the tank is controlled by rod indicator. Working fluid level should be between
extreme marks on the indicator.
Prior to remove suction connections of pumps it is necessary to block the oil tank with the shutter 19.
The shutter is closed by turning the cap 23 anticlockwise. Prior to start the engine after the hydraulic system
repair it is necessary to open the shutter, as with the shutter closed working fluid will not come to the pumps
and they will be damaged.
There is oil filter installed in tank body. The filter is of single step type and it is mounted into steering
drain line. Filter is equipped with pressure-relief valve 5, which is actuated when the filter element becomes
clogged.

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Figure 14.7 – Oil tank:

1 — tank body; 2 — spring; 3, 4, 8, 11 — sealing rings; 5 — pressure-relief valve; 6 — filter element; 7 — gasket; 9 — nipple;
10 — check valve; 12 — cover; 13 — filter cover; 14 — drain hole plug; 15 — filling branch pipe; 16 — breather body; 17 — breather filter
element; 18 — oil level measuring device; 19 — shutter; 20 — drain hole magnetic plug; 21 — refilling hole plug; 22 — gasket seal;
23 — cap; 24 — screen filter body

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Refilling of tank with working fluid is to be carried out under pressure only through refilling branch pipe
mounted in filter cover. To do this unscrew nut with plug from refilling branch pipe. Other methods of refilling,
bypassing filter, are not allowed. Tank topping-up and bringing working fluid level to required one is to be car-
ried out through screen filter 24 closed with plug 21.
To drain working fluid from tank put reservoir under oil tank, remove cover 12 and unscrew nipple 9 by
3 – 4 turnovers. Working fluid will flow out with thin flush.
If there is a need to drain working fluid from tank rapidly close the shutter first, then, unscrewing special
nut 20 anticlockwise to the stop, carefully disconnect hoses from branch pipes as there is fluid in shutter body,
and only after that open the shutter again. It is recommended to drain fluid residue through hole, closed with
magnetic plug 20.
14.3 Dumping mechanism maintenance
Dumping mechanism maintenance includes checking the impermeability and timely re-torque of oil pipe
lines and hoses, checking the level and replacing the working fluid and filter elements of oil filters and breather,
washing of the tank.
It is necessary to perform external examination of pump every day prior to start and after finishing of
dump truck operation. During examination make sure that there is no leakage of working fluid in places of con-
nection of hydraulic lines to pump, in places of pump parts joints and in place of pump connection with flange
drive. Besides, it is necessary to check reliability of fastening of pump with flange drive and of cover with pump
body.
In case of working fluid leakage through cup-type seal replace cup as follows:
- remove pump from dump truck;
- check condition of pump and hydraulic system pipe lines assembly;
- remove retaining and spring rings of pump;
- check condition of cup working edge and remove it in case of inoperability, clean spindle from dirt and
oil, make sure there are nicks and lubricate with consistent grease;
- wash new cup in pure oil, lubricate with consistent grease and install in pump;
- mount retaining and spring rings;
- mount pump on dump truck.
The level of working fluid should be between marks of the oil level indicator. When replacing the oil
clean the magnetic plug of drain hole
Contaminated working fluid is the main reason of premature wear and malfunctions of dumping mecha-
nism, steering and brake systems units, in particular of high-pressure pumps. That’s why it is necessary to use
for hydraulic system of dumping mechanism the working fluid with cleanness grade not less than 12 according
to GOST 17216. When refilling the tank with working fluid and during its filling-up exclude the possibility of for -
eign substances and water ingression into internal chambers of hydraulic systems.
As working fluid in dump truck hydraulic system mineral petroleum-based oils should be used. These
oils should provide nominal tenacity of 30 — 70 mm2/s and minimal tenacity of 15 mm2/s at working fluid tem-
perature range from 0 to 70 оС.
At temperature of ambient air below zero working fluid should be warmed up to yield state. Yield state is
determined by formation and separation of working fluid drops from probe taken out from oil tank.

1 IT IS F O R B I D D E N TO OPERATE DUMP TRUCK AT TEMPERATURE AND TENACITY OF WORKING

FLUID IN HYDRAULIC SYSTEM EXCEEDING THE SPECIFIED VALUES, AND WITH WATER AND MECHANICAL
SUBSTANCES EXCEEDING THE SPECIFIED NORM.
2 IT IS F O R B I D D E N TO UTILIZE ALREADY USED OIL WITHOUT PRIOR CHECK OF ITS CONFORMITY
WITH STANDARDS AND SPECIFICATIONS REQUIREMENTS.

Refill the tank with oil only through refilling branch pipe mounted on the filter cover. As the filter resis -
tance may reach 0.4 MPa, refill the hydraulic tank under pressure using special refilling device including
НШ-10 or НШ-32 pump driven by an electric motor of at least 0.5 kW power. To connect the refilling device, an
end-piece with thread М27х1.5 or М33х2 is provided in the filter cover.

AFTER THE ENGINE OPERATION OVER EACH 20000 MOTOR HOURS OR AFTER EACH THREE YEARS OF
DUMP TRUCK OPERATION (WHICH OCCURS EARLIER) PERFORM SCHEDULED REPLACEMENT OF HIGH
PRESSURE HOSES IN THE INTEGRAL HYDRAULIC SYSTEM.

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14.4 Dumping mechanism troubleshooting

To define possible causes of dumping mechanism defects follow the table 14.1.
The table characterizes only steps for elimination of possible defect causes that relate to certain part or
system and do not eliminate possibility of the same defect repetition.
In order to define true cause of defect in part, unit or system, and in order to eliminate possibility of the
same defect repetition it is necessary to perform its thorough examination observing all safety precautions.

Table 14.1 — Dumping mechanism troubleshooting

Trouble and its symptom Possible reason Troubleshooting

Body fails to be raised Insufficient level of working fluid in the oil Restore the level of the working fluid,
tank eliminate the leakage
Power supply circuit of hydraulic distribu- Eliminate the electric circuit fault
tors control unit is damaged
Spool valve of hydraulic distributor or Eliminate the fault
control panel in raising hydraulic line is
blocked
Hydraulic cylinder pressure-relief valve is Eliminate the fault
blocked
Time of loaded platform raising to the ex- Pumps are worn-out. Replace the pumps
treme position exceeds 35 seconds Non-hermetic pressure-relief valves of Calk the valves
hydraulic cylinders
Platform is raised jerkily Insufficient level of working fluid in the oil Restore the level of the working fluid,
tank eliminate the leakage
Air inflow in intake line of pumps (working Tighten the joint members of hydraulic
fluid in tank froths) lines

Platform sinks down spontaneously from Non-hermetic pressure-relief valves of Calk the valves
neutral position hydraulic cylinders

Platform fails to sink down Power supply circuit of sinking hydraulic Eliminate the electric circuit fault
distributor is damaged

The spool valve of hydraulic distributor in Eliminate the fault

sinking hydraulic line is jammed
Oil leakage in places of hydraulic lines con- Fastening is loosen Tighten appropriate joints and check in-
nections in joints of pump parts tegrity of locking

Rubber “O” ring is damaged Replace ring

Oil leakage through cup-type seal of pump Cup-type seal of pump drive shaft is out Replace cup-type seal of pump drive shaft
drive shaft of order

Noise intensification and froth through Air inflow in hydraulic system Eliminate air inflow
breather hole of oil tank

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