Hydraulic cylinder

Operation and Maintenance of DeppKaler Dump Truck Hydraulic System

1. General Requirements of Standard Operation and Maintenance
1.1 General Instruction
● All DeppKaler hydraulic cylinders are only used for lifting, do not have other functions, Whensoever, the cylinders must not be applied to supporting anything.
● Whenever, the cylinders must not be used under the condition of overloading and unbalance loading. It is terribly dangerous.
● When lifting, hydraulic cylinders tube cannot be exposed in the air at more than 2 hours (while in the wet air cannot exceed 30 minutes).
● The disassemble and adjustment of overflow valve on lifting valve is prohibited, otherwise may cause severe accidental, even risk human life or wealth safety.
1.2 Safe Lifting
It is dangerous to operate dump truck incorrectly, and accidents may be caused. In order to play the best efficiency of hydraulic cylinders and assure the safety of dump truck, please strictly obey the following operation standards:
1.2.1 Safe Usage Environment
● Please inform the man in charge and submit to the site management, arriving at the appointed location.
Only when driver makes sure it is safe, then he can load or unload. Driver takes the main responsibility for the vehicle safety when operating. If driver has different ideas with the user, please consult with the employer. Whenever the truck is prone to rollover, lifting the body and unloading cargo is forbidden.
● Unload is forbidden, if the land condition at the working location is unclear.
● Make sure that the land around the vehicle is solid enough.
Make sure the vehicle keeps horizontal; Please do not lift the cylinder when goes downhill as much as possible; When lifting the semi-trailer/trailer, please keep the main vehicle and trailer in one straight line.
● When the Cabin is lifting or under hoisting condition, anyone must not stand or walk at the working location, and also the driver must not leave from the operation area.
● The operator must carefully observe around the vehicle for the presence of obstacles, especially above the vehicle, no relying on other field staff’s warning.
● Please pay attention to the effect of lateral wind, which may cause the rollover of the vehicle.
● Ensure that place the cargo into the Cabin in a balance way. It will be good at avoiding rollover. If the cargo is loaded at the front too much, hydraulic system will overload.
● Anyone must not stand on the Cabin, when the vehicle is being loaded or waiting for load.
1.2.2 Standard Operation
● When the vehicle is in gear, please do not connect with PTO. After lifting, PTO must separated from transmission box.
● Please do not make engine rotate much more fast, the over speeding rotation will cause lack of oil, then burning the pump.
● Make sure the rear door is open before the Cabin lifts up at 10 °.
● Please drop down the Cabin first before cleaning the rest obstacles in it. If the cargo height is higher than the rear door, please make sure it will not get the door stunk, as the overloading of cargo at the vehicle tail may cause the rollover.
● Please do not stand beneath the Cabin, unless it is supported enough.
● Please note that some kind of cargo is easy to be freezing when encountering cold and stick at any side of the vehicle, which cause the unbalance load during unloading.
● Note that the uneven density of cargo may result in unbalance discharging, then rollover of vehicle.
● When Cabin fall down completely, please keep the pneumatic hand shank at the position “DOWN” for 30 seconds, then adjust to the position “STOP”. Must not drive the vehicle when the pneumatic hand shank is at the position of “DOWN”.
● Please do not use reverse gear, when discharging the cargo. The reverse rotation of PTO and pump is easy to damage pump and seal kits.
● Please do not drop down the heavy Cabin rapidly when lifting.
● Keep the cabinet empty completely. Please do not start the truck before dropping down the cabin and locking the rear door. When the body is lifting, must not unload the stick cargo by starting the truck and then suddenly braking.
1.2.3 Risk Management
● When the body or vehicle encounter the high voltage power lines,
Please jump down the truck.
Dial the local emergency number.
Must not touch the ground and vehicle at the same time; otherwise the close circuit will be formed and result in heavy injury or even death.
Allow nobody return to the vehicle before cutting off the power.
● If the lifting angle has reached at 25 °(the body has lifted at the half stroke), the cargo still cannot be loaded, please stop and check the reason. When walking to the rear door, watch out of other vehicles and cargo.
● If rollover is thought happen, please stop lifting and drop down the Cabin slowly and check the vehicle.
● If rollover happens, it is safer to stay into the operating cabin. Keep your body to the seat back closely and hold the steering wheel tightly. Never jump out of the side turning vehicle.

Please take care of your dump truck carefully. Time for maintenance is the safest investment.

2. Maintenance Guide

Type	Contents	Objects	Period
Type	Contents	Objects	Per day	Per week	Per half-year
General maintenance	Pneumatic system	Pneumatic tube	Check if any breakage and leakage happens.
	Pneumatic system	Pneumatic control valve	Check if running is normal and any breakage and leakage happens.
	Hydraulic system	Hydraulic cylinder	Check its running, any breakage and leakage.	Clean the surface of cylinder.
		Oil Pump		Check if any leakage happen in leakage telltale hole.
		Oil hose and connector	Check if any breakage, leakage and any loose for all connectors happen.
		Lifting valve	Check if any breakage and leakage happens.
	Oil tank Ass.	Oil level	Check oil level; add if oil is not enough.
		Return oil filter element		Check if there is any sundries.	Change the filter element.
		Air filter element		Check if there is dust, hydraulic oil, or water on it.	Change air filter element.
		Hydraulic oil tank		Check if there is any leakage on oil tank.	Clean oil tank.
		Hydraulic oil		Check if oil changes color or goes bad.	Change hydraulic oil.
Lubricating points	Fastening of bolts and nuts	bolts and nuts		Check if bolts and nuts get the specified torque. Bolt and nut torque table shows detailed torques. Should self-locked bolts loose, change it in time.
	Cabin	All types		Lubricate reversal axle
		Three-side dump truck		Lubricate front hinges.
		Rear door machinery		Lubricate mechanical lock of rear door.
	Auxiliary parts	Lock device on cabin, Scissor type stability system, Lubrication points on cylinder mounting brackets		Lubricate the lock hook shaft and three fixed points of rotation.