BI618561

Bucyrus
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BUCYRUS
R

Technical Manual

BI618561

DUMP CYLINDERS

UNIT RIG

DUMP CYLINDERS
DESCRIPTION AND LOCATION

of damage.

The dump cylinders are two-stage, double-acting, hydraulic cylinders. The cylinders are mounted with the
rod end attached to the frame and the base end to the
dump body.

4. If the cylinder seals are suspected of bypassing, the

by-pass flow may be measured as follows:

NOTE: There are two separate versions of the dump

cylinders. Descriptions and identification of each is
contained in the Inspection and Repair portion of this
module.

OPERATION

a. With the dump body resting on the body pads,

park the truck in a SAFE POSITION. It must be secured by means other than the friction brake system.
b. Stop the engine and allow the system to release
all entrapped pressure. Verify that the Dump Controller
lever is in the Float position.

The dump cylinders raise and lower the dump body.

c. Remove the hose from the extend port side of

the cylinder to be tested where it connects to the dump
valve.

The cylinders are positioned so that they lift the front of

the dump body, which pivots at the rear. The oil is directed into and out of each cylinder through a pair of
ports on the piston rod (lower) end of the cylinder.

d. Place the end of the hose in a clean empty container.

To raise the body (extend the cylinders), the hydraulic

oil is directed from the dump valve into the extend port
of each cylinder. The oil moves up the center tube pressurizing the first and second stage pistons of each cylinder, causing the cylinders to extend. The first and
second stages extend together until the first stage bottoms out. The second stage then extends out from the
first stage. The oil from the rod end of the cylinder
flows out through the retract lines in the center tubes,
exits through the retract port, and returns to the hydraulic tank through the dump valve.
In the lower or retraction cycle, the pressurized oil is
routed into the cylinders retract ports, up the center tube
passage to the rod end of the cylinders. The second
stage retracts first, followed by the first stage. The oil
from the base end of the cylinder exits through the extend port and to the tank through the dump valve.

MAINTENANCE AND ADJUSTMENT

e. Start the truck engine and once operating, accelerate to rated speed.
f. Move the Dump Controller lever to the Lower or
Power Down position and hold. Maintain for 30 seconds.
g. Return the Dump Controller lever to the detented
Float position.
h. Measure the fluid captured from the cylinder.
(1) For new cylinders, it should be less than
one-half gallon (1.9 liters).
(2) For used cylinders it should be less than
one and one-half gallons (5.7 liters).

NOTE: Flows in excess of these levels (for 30 second

test) indicate excessive seal by-pass is occurring and
service is recommended.

Periodic maintenance should include the following steps.

i. Reinstall the hose on cylinder.

1. Clean each dump cylinder, especially any contamination from the rod and cylinder tube.

j. Bleed entrapped air before returning to service.

2. Inspect for wear, leakage, or damage. Repair or replace as required.

3. Verify that the cylinder connections to the frame and
dump body are lubricated, secured properly, and free

11/10/2000

REMOVAL (Figure 2)
NOTE: It is recommended that the cylinders be removed and serviced in pairs. Note the direction that the
extend and retract ports face on the cylinder, so that the
cylinder will be installed in the same position.

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01.
02.
03.
04.
05.
06.
07.
08.
09.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.

KEY
Body
Socket Head Capscrew
Hardened Flatwasher
Capscrew (Grade 8)
Packing Gland
Piston Wear Ring
Piston Seal
Piston Seal
Piston Wear Ring/Bushing
Piston
1st Stage Rod Assembly
2nd Stage Rod Assembly
Rod Wear Ring
O-ring
Back-up Ring
Rod Wear Ring
Rod Seal
Rod Seal
Rod (Wiper) Seal
Rod (Wiper) Seal

85080A

The dump cylinders may be removed as follows:

1. Park the truck in a SAFE POSITION. It must be
secured by means other than the friction brake system.
2. Drain the system or relieve all pressure before loosening any lines. Place the Dump Controller lever in the
Float position.

Never loosen any pressurized lines or components.

Always drain the system, or relieve all pressure first.
3. Close the hydraulic fluid supply valve at the hydraulic tank.
4. Disconnect the hydraulic lines from the cylinder. Label
each to ensure proper reassembly. Install clean caps
and plugs on all open fittings.

NOTE: The dump body may have to be blocked up

slightly to allow clearance for the dump cylinder to be
removed.
5. Secure the cylinder in place with the shipping brackets (see Figure 2), a chain, or equivalent.
6. Remove capscrew assembly (7 and 8), upper pin
retainer plate (6), and upper pivot pin (4).
FIGURE 1 - DUMP CYLINDER (85080A)

7. Remove capscrew assembly (7 and 8), lower pin re-

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DUMP CYLINDERS

UNIT RIG
TABLE 1 COMPONENT WEAR TOLERANCES

Replace if the inside diameters or bores of the following are worn to a dimension greater than:
85080A

85080B

Inches

(mm)

Inches

(mm)

Body Tube

14.06

357.1

14.06

357.1

1st Stage Rod

10.003

254.0

11.003

279.5

1st Stage Piston

13.919

353.5

13.919

353.5

Replace if the outside diameters of the following are worn to a dimension less than:
1st Stage Rod

11.498

292.8

12.720

323.8

2nd Stage Rod

8.498

215.9

8.498

215.9

2nd Stage Piston

9.890

251.2

10.915

277.2
13770

8. Remove the rod and wiper seals (18, 19, and 20)
from the first stage assembly.

tainer plate (6), pin (4), and spacers (5).

NOTE: It may be necessary to use a puller to assist in

removal of the pins.

9. Remove the packing gland (5) from the first stage

rod (11).

8. Remove the cylinder assembly.

10. Remove the wear rings (13), rod and wiper seals
(17 and 19), and O-ring seal and back up ring (14 and
15) from the packing gland.
Use care to prevent the cylinder from extending
during removal.

11. Remove any remaining parts.

DISASSEMBLY (Figure 1)

INSPECTION AND REPAIR

The cylinder may be disassembled as follows:

The cylinder may be serviced as follows:

1. Position the cylinder horizontally in a clean work area

of sufficient size to allow for easy access and disassembly.

1. Before proceeding, determine the configuration of

the dump cylinder that is being worked on. This identification can be readily made by measuring the outside
diameter of the first stage rod assembly (item11, Figure
1):

2. Remove capscrews (4) and hardened flatwashers (3)

securing the packing gland (5).
3. Remove the 1st and 2nd stage subassembly from
the body tube.
4. Remove the socket head capscrews (2) and hardened flatwashers (3) securing the piston assembly (10)
to the 1st stage rod (11).
5. Remove the piston assembly (10).

Early versions (denoted by an A suffix on the part number) are identified by an 11.5 inch (292 mm) O.D.
Later versions (denoted by a B suffix on the part number) are identified by a 12.75 inch (324 mm) O.D.

NOTE: Some cylinders originally configured and identified as A may have been later modified to the B configuration.

6. Remove the wear ring (6) and piston seal (7).

7. Remove the second stage rod assembly from first
stage.

11/10/2000

NOTE: The first stage rod assembly is the lager diameter (outer) assembly, just inside of the main body tube.

2. Clean all metal components with solvent (especially

seat and ring grooves and other passages). Inspect for

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scoring wear or damage. Repair or replace as required.

See Table 1 for detailed information.
3. Inspect all seals and wear rings for evidence of damage, then discard.

b. Install the rod wiper seal (19).

c. Install the rod seal (18) with the O-ring toward
the inside.

4. Inspect all threaded components for evidence of damage. Repair or replace as required.

d. Lube the seals and wear rings with hydraulic oil

or lubricant mixture compatible with the oil to be used
in the trucks hydraulic system.

5. Inspect the mounting bushings and retainers for evidence of wear or damage. Repair or replace as required.

4. Carefully install the second stage rod assembly into

the center of the first stage using care not to damage
the components.

ASSEMBLY (Figure 1)

5. Assemble the piston as follows:

a. Install the piston seal (7) on the piston (10).

IMPORTANT: It is recommended that all gaskets and

seals be replaced each time the cylinder is disassembled.

b. Install the wear ring (6).

NOTE: Prior to assembly coat each surface and/or

seal with hydraulic oil compatible with that in the system in which it will operate.
The cylinder may be assembled as follows:

c. Lube the seals and wear rings with the hydraulic

oil or lubricant mixture compatible with the oil to be used
in the trucks hydraulic system.

a. Install the O-ring seal (14) with back-up ring (15).

6. Install the piston assembly (10) onto the 1st stage

rod (11). Use two of the socket head capscrews (2) and
hardened flatwashers (3) (inserted 180 apart) to draw
the piston (10) against the second stage rod (12).

b. Install the rod seals (17 and 19) with the sealing
lips outward (to act as wiper rings).

NOTE: Use care not to allow the seals to bind during

assembly.

NOTE: The O-ring on the rod seal (17) should be to-

7. Install the remaining socket head capscrews/hardened flatwashers. Torque to 680 to 690 ft-lbs. (920 to
935 Nm) in stages of 200, 400 and 680 to 690 ft-lbs.
(265, 540, and 920 to 935 Nm) using a criss-cross or
X pattern.

1. Assemble the packing gland (5):

ward the inside.

c. Install the wear rings (13).
d. Lube the seals and wear rings in the packing gland
and the end of the first stage rod (11) with hydraulic oil,
or lubricant mixture compatible with the oil to be used
in the units hydraulic system.
2. Install the packing gland assembly on the first stage
rod (11). Slide on several inches (mm) past the end.

NOTE: The gland should not bind on the rod in any

position.
3. Assemble the first stage rod assembly as follows:
a. Install the rod wiper seals (20) in the rod assembly with the seal lip out to act as a wiper ring.

NOTE: The O-ring on the wiper seal (20) should be

toward the outside.

8. Lube the piston seals in the chamber of tube and the

piston seals and bearings and wear rings with the hydraulic oil or lubricant mixture compatible with the oil to
be used in the trucks hydraulic system.
9. Install the 1st and 2nd stage subassembly in the body
(1).
10. Install the Grade 8 capscrews (4) and hardened
flatwashers (3). Torque to 680 to 690 ft-lbs. (920 to 935
Nm) in stages of 200, 400, and 680 to 690 ft-lbs. (265,
540, and 920 to 935 Nm) using a criss-cross or X pattern. Lockwire in pairs when complete.
11. If removed, install the self aligning bushings (2, Figure 2) the upper and lower mounting positions and secure with retainer rings (3, Figure 2).

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BI618561

DUMP CYLINDERS

UNIT RIG

01. Dump Cylinder

02. Self Aligning Bushing
03. Internal Retaining Ring
04. Pin
05. Bearing Spacer

KEY
06. Pin Retainer
07. Capscrew
08. Hardened Flatwasher
09. Cylinder Support Block*
10. Lockwasher *
* For shipment and maintenance use only.

A85290

11. Capscrew *
12. Clamp*
13. Capscrew*
14. Flatwasher*
15. Locknut*

FIGURE 2 - DUMP CYLINDER INSTALLATION (A85290)

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12. If possible, proof test the cylinder to 3000 psi (20

000 kPa) as outlined in the instructions in Maintenance
and Adjustment in this module.

NOTE: If the cylinder is not being installed immediately plug all ports with push in split flange plugs or bolted
cover plates and coat bearings to prevent corrosion.

7. Remove the chain securing the cylinder retracted.

Extend the cylinder until the upper yoke is in position
between the dump body flanges. Install the pin (4) and
secure with pin retaining plate (6) capscrews (7) and
hardened flatwashers (8).
8. Connect the hydraulic hoses.
9. Bleed the entrapped air from the cylinder as follows:

INSTALLATION (Figure 2)

a. Start the truck and operate at low idle.

The cylinder may be installed as follows:

1. Inspect the upper and lower mounting pins for evidence of wear or damage. Repair or replace as required.
2. Inspect the upper and lower mounting brackets/bushings for evidence of wear or damage. Repair or replace as required.
3. Verify that both of the dump cylinders to be used on
the truck are of the same configuration. See the information in step 1 of Inspection and Repair for detailed
identification information.

b. Move the Dump Controller lever to Lower and

hold for several seconds.
c. Move the lever to Raise and allow the body to lift
slightly off of the frame assembly.
d. Move lever to Lower, release and allow the body
to float down until it rests on the frame.
e. Repeat steps b through d in 2 ft (0.7 m) increments until all air is purged from the system.
f. Refill the hydraulic reservoir.

4. Secure the cylinder with a chain or other suitable

means to prevent it from extending when lifted.

10. Test the operation of the dump system as outlined

in Section 5 - Hydraulic System.

5. Lift the cylinder into position on the lower pivot pin

with the larger or extend port to rear.
6. Install the lower pin (4) with spacers (5) on each side.
Secure with the pin retaining plate (6), capscrews (7),
and hardened flatwasher (8).

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