MT86H Off-Highway Dump Truck. Operation and Maintenance Manual (2017)

MT86H Off-Highway Dump Truck Operation and Maintenance Manual

880*1230 mm sextodecimo

8 printed sheet

3rd edition and printed for the first time in May 2018

LINGONG GROUP JINAN HEAVY MACHINERY CO., LTD

Add: F12,Building 3 LushangGuoao Plaza, 9777 Jingshi Road,Lixia District,Jinan, Shandong,

250000,China

Tel: 86-0531-81663345

Technical service: 86-0531-81666372

Fax: 86-0531-81666853

Accessory sales: 86-0531-67605016

Web: www.lgmg.com.cn

Contents

Foreword

Chapter I Safety

1.1 Basic precautions

1.2 Operation precautions

1.3 Other precautions

1.4 Notices&signs and their pasting positions

Chapter II Product Introduction

2.1 Outline and component name

2.2 Outline dimension

2.3 Application

2.4 Work Environment Requirement

2.5 Vehicle parameters

Chapter III Operation

3.1 Door operation

3.2 Cab interior device

3.3 Cab exterior devices

3.4 Cab suspension

3.5 Cab tilting

3.6 Preparation before driving

3.7 Start-up and gearshift

3.8 Operation at low temperature environment

3.9 Wheel replacement and tire pressure

3.10 Running-in of new vehicle

Chapter IV Operation and Maintenance of Main Assemblies

4.1 Operation and maintenance of engine

4.2 Operation and maintenance of intake system

4.3 Operation and maintenance of clutch control system

4.4 Operation and maintenance of transmission

4.5 Operation and maintenance of front axle

4.6 Operation and maintenance of suspension system

4.7 Operation and maintenance of steering system

103

4.8 Operation and maintenance of brake system

111

4.9 Operation and maintenance of A/C

125

Chapter V Maintenance

135

5.1 Mileage for routine inspection & maintenance interval

137

5.2 Details on mandatory maintenance of MT86 mining off-highway off-highway

dump truck

137

5.3 Key points of maintenance

139

Chapter VI Annex

153

6.1 List of bulbs

154

6.2 List of quick-wear parts of electrical system

154

6.3 Schematic diagram of brake

155

Foreword

Thanks for choosing mining dump trucks manufactured by Lingong Group Jinan Heavy

Machinery CO., LTD., Ltd. This manual describes the mechanism, driving and operating,

maintenance and adjustment, technical parameters and service/adjustment data of the MT86H series

mining dump trucks.

Maximizing the profits from your Off-Highway Dump Truck is our common goal, which is to a

large extent dependent on your familiarity with the truck and a careful and thorough maintenance.

We sincerely hope that you can read through the manual prior to the first start, operation as

well as maintenance and service of the truck and get full understanding of the operations and

maintenances described herein.

All the pictures and descriptions covered herein are correct at time of publication; but

the structures and performances of our products are constantly improved and perfected; therefore,

please understand that the related design, operation and maintenance instructions are subject

to change at any time without prior notice. For the latest information on the dump truck or in

case of any doubts about this manual, please consult LGMG.

This manual is applicable for MT 86H series Off-Highway Dump Truck (standard configuration).

Users shall be in strict accordance with the mileage or time interval in the maintenance schedule

to do maintenance to the assembly and the dump truck.

The manual is a part of the dump truck and thus shall be handed over together when transferring

the ownership or the right of the truck. If the manual is lost, damaged or hard to be recognized,

please replace it in time.

The copyright of this manual is reserved by Lingong Group Jinan Heavy Machinery CO.,

LTD., Ltd. Reproduction or reprinting without written permission by LGMG is prohibited.

WARNING

● Only the specially trained personnel with corresponding qualifications are

allowed to operate and maintain the truck.

● Incorrect operation, maintenance and repair are dangerous, and may lead to

personal injury.

● Before operation, maintenance or repair, the operator shall carefully read

this manual.

● Loading should be done in strict accordance with the rated loading capacity,

and any consequences due to overloading or unauthorized modification shall be the

responsibility of the users.

● The operating procedures and precautions referred to herein are only

applicable to the stipulated operation of the machine. For any operations out of

the specification but not prohibited, always make sure that this operation will not

hurt you or other people.

Safety Attentions

Operators should understand and follow prevailing national and local safety regulations. In case of

no relevant national or local regulation, safety attentions in this manual will be applicable.

Most accidents are caused by failure of following regulations on machine operation and

maintenance. To avoid accident, please read, understand and follow all warning requirement and

notes in the manual and on the machine before operation and maintenance.

Details of safety measures are explained in Chapter I "Safety".

Since it is unable to predict all possible dangers, therefore, safety explanation in the manual and on

the machine may not include all safety precautions. In case of using steps and operation in this

manual, it should be guaranteed that both the operator and others are safe and the operation

would not damage the machine. If the operation safety is uncertain, please consult the company

or dealers.

Precautionary measures on operation and maintenance in the manual are only applicable to using

the machine as specified purposes. If the machine is used beyond the range listed in the manual,

our company will bear no liabilities. All safety liabilities of such operation should be borne by the

user and operator.

Operation prohibited in the manual should not be executed in any circumstance.

Caution signals below are used to indentify safety information in the manual.

! DANGER - If the situation classified as “DANGER” is not avoided, serious injury

or casualties is likely to occur. This word can also be used when the machine may

be seriously damaged if the possible hazard is not avoided.

! WARNING - If the situation to be warned is not avoided, serious injury or

casualties may occur. This word can also be used when the machine may be seriously

damaged if the potential hazard is not avoided.

! CAUTION - If the situation to be noticed is not avoided, minor or moderate injury

may occur. This word is also used when the machine may be damaged or the service life

shortened if the potential hazard is not avoided.

1.1 Basic precautions

The off-highway dump truck described here

is a kind of mining engineering machinery, which

has quite different structure and working

properties compared to ordinary vehicles;

therefore, the safety precautions and operation

Fig. 1-1

instructions described in this manual shall be

followed prior to the operation.

1) While working together with other

operators or site traffic commander, make sure

that all personnel concerned understand the hand

signals.

2) Always do inspection before or after the

Fig. 1-2

operation, so as to eliminate the potential danger

such as leakage of oil, water and air, bolt

looseness, unusual noise or other hazards that

could cause faults and serious accidents.

3) Never enter or stretch your hands between

the moving components, and avoid any rotating

and moving parts. Do not enter between the

cargo body and the frame when the cargo body is

lowering.

4) Always park the truck on a level ground; if

Fig. 1-3

you have to park the truck on a slope, wedge it

with cushion blocks. In this case, please stop the

truck with foot brake, set the transmission control

lever to NEUTRAL or REVERSE position, apply

the hand brake, lower down the cargo body,

shut down the engine and remove the key.

5) Do not place the inflammables and

explosives near the hot parts like turbocharger,

exhaust pipe, muffler and radiator for fear of fire

or other accidents. Before touching the above

parts, make sure that those parts are cooled

Fig. 1-4

down to avoid scald.

1.2 Operation precautions

1) Do not jump up/off the off-highway dump truck

directly, and please get on/off the truck by the

ladder or grip only.

Getting on/off the running truck is prohibited.

2) During normal running, such dangerous driving

Fig. 1-5

behaviors as sudden braking, fast travelling,

sharp turning at a high speed or driving in a

zigzag are not allowed.

3) Before starting the truck, always inspect if the

followings have been done:

● The parking brake is applied;

● The transmission is set to NEUTRAL position;

Fig. 1-6

● The PTO is disengaged.

4) When the truck is working, the operator shall sit

in driver’s seat to do all operations. Operating or

driving in other places than the driver’s seat is

prohibited.

5) When driving on a slope, pay attention to the

change of the truck’s center of gravity.

! When driving the truck under full

load on a slope:

● Do not brake the truck abruptly when

driving downhill;

● Never disengage the clutch or coast

Fig. 1-7

the truck at neutral gear when driving

downhill;

● Do not make a sharp turn.

6) When the truck starts running, the cargo body

is tiltable; thus irrelevant personnel wandering

around the truck is dangerous and shall be

Fig. 1-8

prohibited.

1.3 Other precautions

1) Unauthorized modification is not allowed. Any

modification without permission from the

Company may lead to an accident, and users

shall contact with the Marketing Dept. of the

Company in advance. The Company assumes no

Fig. 1-9

liability for the casualties and damages incurred

therefrom.

2) When lifting the cargo body to repair the

components beneath, the stay bar of the cargo

body should be set to a safe position for support,

and restored once the repair is finished.

3) Always inspect the tyre from the side and never

stay before or behind the rotating tyre.

4) Repair and replacement of tyre shall be done

by the specialized personnel as it is highly risky.

5) Be careful when doing welding around the tyre,

to avoid accidents due to tyre explosion.

6) When welding the truck for repair, always turn

off its master power switch. Do not perform

electric welding or flame cutting to the pipeline

containing flammable liquid. Make sure to clean

with non-inflammable liquid before such

operations.

7) Always lower the cargo body to the subframe

before leaving the truck unattended, and check

that the lifting control lever is in the center, the

parking brake is applied and the transmission

control lever is set to the NEUTRAL position, and

then shut down the engine.

1.4 Notices&signs and their pasting

positions

1) Engine repair Caution: beneath the cab

instrument panel.

2.3 Application

As an off-highway dump truck featuring open cargo body, this machinery is suitable for loading/unloading and

transportation of earth-stones and minerals at ports, docks and various engineering sites, but in no case shall it

be used for works and operations on road,loading/unloading or transportation of combustibles and explosives,

and operations under ground or in environments containing explosive medias.

! WARNING：

● The truck is an off-road dump truck and should not be used on the road.

● When using the truck, please load the truck strictly in accordance with the

standard load limited by the truck. Overloading is prohibited.

● The truck may be used to transport solid materials only. It is strictly

prohibited to load or transport flammable and combustible materials with the truck.

2.4 Work Environment Requirement

The truck is applicable to the following environments:

Item

Altitude

Environment temperature

Fording depth

Parameter

≤4000m

-15℃～+40℃

≤315mm

requirement

The truck is a common engineering machine which could be used for various applications in

normal circumstances described in the manual. In case of being used for other purposes or in

environment of potential hazards such as inflammable or explosive air or regions containing

asbestos dusts, special safety requirements must be followed. Devices of corresponding

applications must also be supplied to the machine.

2.5 Vehicle parameters

2.5.1 Vehicle performance parameter

Items

Parameters

Items

Parameters

Max. total mass (kg)

86000

Overall dimension (mm)

9070×3550×4050

Max. vehicle speed (km/h)

Max. gradeability (%)

Volume of cargo body

Min. turning diameter (m)

≤22

(paperbacked) (m³)

Q/1300LGJ004-2015

Kerb weight (kg)

30700±100

Product standard

《off-road dump truck》

2.5.2 Main dimensions

Items

Parameters

Items

Parameters

2792 (front axle)

3800 (Front-middle)

Track width (mm)

Wheelbase (mm)

2526 (rear axle)

1500 (Middle-rear)

Departure angle

Approach angle (°)

(°)

Min. ground

≥315

No. of axles

clearance (mm)

2.5.3 Engine

Items

Parameters

Items

Parameters

Inline, DI, water-cooled,

Type

No. of cylinders

supercharged and inter-cooled

Rated power

309

Bore/stroke (mm)

126/155

(kW)

Rated speed

Min. fuel-consume ratio

2200

(r/min)

(g/kW.h)

Displacement

11596

Max. torque (N.m)

1750

(mL)

Emission

Consumption rate of

ChinaⅡ GB20891-2007

standard

engine oil and fuel

2.5.4 Transmission system

Items

Parameters/contents

Type

Single-disc, dry, hydraulic remote-operated

Release travel at separated finger end of

12-14

diaphragm spring (mm)

Friction plate outside diameter/inside

Clutch

430/242

diameter (mm)

Max. release force at separated finger

8600

end of diaphragm spring (N)

Release fork lever ratio

1.73

Type

Fixed-shaft

Transmission

Transmission gear

7 forward gears and 1 reverse gear

Front axle

Non-driving steering axle

Welded axle housing

Main decelerate ratio

3.7

Drive axle

Final decelerate ratio

3.478

Items

Parameters/contents

Total decelerate ratio

12.87

Wheel rim spec.

10.0/2.0-25

Wheel

Tire spec.

14.00R25

Tire pressure (MPa)

0.85

Brake pressure (MPa)

0.85

Brake system main brake

Pneumatic, dual-circuit

Brake system

Brake system auxiliary brake

Engine exhaust emission brake

Brake system parking brake

Spring brake & emergency brake

NOTE: All wheel rims shall be subject to the same specification. The tire pressure value indicated in

the table is factory air pressure (no load), and the actual air pressure shall be adjusted according to

“Comparison table of speed, load and air pressure” in 3.9.

2.5.5 Steering system

Items

Parameters/contents

Type

hydraulic steering

Max. turning angle

38°

Safety valve

I/A

Steering pump

Vane pump: displacement28ml/r

Min. turning diameter (m)

System working pressure (Mpa)

2.5.6 Working device

Items

Parameters/contents

Type

pneumatic control

Maximum working pressure

24Mpa

Lifting time of cargo body (full load)

≤25s

Descending time of cargo body (empty bucket)

≤25s

Total time

≤50s

2.5.7 Reference fill capacity

Items

Parameters

Items

Parameters

Fuel

530L

Engine oil

24L

Hydraulic oil

135L

Transmission

23L

Axle (for main driving

46L (intermediate axle)

Brake system

1.5L

and final drive)

37L (rear axle)

Antifreeze

50L

3.1 Door operation

! WARNING: Do not drive unless all

doors are properly closed!

3.1.1 Use door switch outside

Door opening: When the door is unlocked, lift

Fig.3-1

the handle and pull it outward (as shown in Fig.

3-1) to open the door; when the door is locked,

Unlock

lock

insert the key in, turn it anticlockwise for

180º (as shown in Fig. 3-2), lift the handle

and pull it outward to open the door.

Door closing: Close the door directly.

Door locking: After the door is closed, insert

Fig.3-2

the key in, turn it clockwise for 180º, and pull

out the key; or before the door is closed,

insert the key in, turn it clockwise for 180º

and close the door.

After the door is locked, the door could not

be opened by pull the handle outward.

3.1.2 Use door switch inside

Fig.3-3

Door opening: Pull the door push button (as

shown in Fig. 3-3) and push the door open.

Door closing: Close the door directly.

! CAUTION: While leaving the vehicle,

3.2 Cab interior device

3.2.1 Instrument cluster

3 4

Fig.3-4

1. Mileage & travel time display screen

2. Engine tachometer

3. Alarm indication mark

4. Oil pressure

gauge

5. Voltmeter

6. Barometer of brake circuit 1

7. Barometer of brake circuit 2

8. Fuel gauge

9. Coolant thermometer

10. Speedometer

3.2.2 Steering wheel and switch panel

1. Steering wheel 2. Hand brake valve handle 3. Rocker switch

4. Air-condition operation panel

and display screen 5. Transmission gear shift handle

6. Cigarette lighter

3.2.3 Alarm indicators

S/N

Description

Color

S/N

Description

Color

Width lamp on

Parking indicator

Red

Green

indicator

Low gear indicator

Green

High beam indicator

Blue

(reserved)

High gear indicator

Low oil pressure alarm

Green

Red

(reserved)

indicator

Forward gear indicator

Inter-wheel differential

Green

(reserved)

indicator (reserved)

Reverse gear indicator

Bogie differential lock

Red

Green

(reserved)

indicator

Left turn indicator indicator

Yellow

Parking PTO indicator

Red

(reserved)

Transmission high

Exhaust brake indicator

Yellow

Red

temperature indicator

Retarder brake

Door ajar alarm indicator

Red

indicator (reserved)

Rear working lamp on

Transmission fault

Green

Amber

indicator

indicator (reserved)

Cab unlocked alarm

Engine serious fault

Red

indicator (reserved)

indicato

Low fuel level alarm

Engine fault indicator

Yellow

Red

indicator

(reserved)

Storage battery charging

Engine coolant level

Red

indicator

low alarm indicator

Air filter blockage

Parking brake indicator

Red

Yellow

indicator

Cargo lift alarm indicator

Red

Water in oil indicator

Yellow

Low brake pressure alarm

Engine start wait time

Red

White

indicator

Engine diagnostic

OBD indicator

Yellow

Red

indicator

Retarder position indicator

Red

3.2.4 Summary of rocker switch marks and function description (The key switch will be

ineffective when it is set to gear 1, unless otherwise specified.)

3-7

S/N

Name

Condition

Function

Remarks

When the switch is turned to gear 2 and

Clearance lamp ON /

3, the instrument lighting actuation will

headlamp OFF

be effective; and high beam inching will

be ineffective.

Lamp switch

Clearance lamp and

headlamp OFF

High beam inching will be effective; high

clearance lamp /

beam/low beam combination switch will

headlamp ON

be effective.

Front fog lamp

Front fog lamp OFF

switch

Front fog lamp ON

Hazard warning OFF

Hazard warning

The key switch will be effective when it is

switch

Hazard warning ON

turned to gear 1, 2, 3 and 4.

Front working lamp

Front working

OFF

lamp switch

Front working lamp

Front working lamp driven

Cab rear

OFF

working lamp

Cab rear working lamp ON

switch

Rear working lamp

Rear working

OFF

lamp switch

Rear working lamp

The side working lamp is also controlled

by this switch.

OFF

PTO solenoid valve actuated; when PTO

Parking PTO

and switch are set to proper positions, the

switch

corresponding indicator lamps on the

instrument will be on.

S/N

Name

Condition

Function

Remarks

Electric horn

Press down horn on the steering wheel,

Horn

selected

and it will work.

change-over

Press down horn on the steering wheel,

switch

Air horn selected

and it will work.

OFF

Inter-axle differential solenoid valve

Inter-axle

actuated; when inter-axle differential

differential

switch is set to proper position, the

switch

corresponding indicator lamp on the

instrument will be on.

OFF

Exhaust butterfly valve closed, EVB starts

Exhaust brake

to work, the green instrument indicator is

switch

on, the operating cylinder works, and the

engine flames out.

NOTE: The rocker switch with striker has an anti-mistrigger function. It cannot be moved unless the

striker is pulled down; and it will auto reset as long as the striker is released. See figures below for

operation.

Pull down the striker, and

Release the striker, and it

meanwhile, move the switch

will automatically reset

3.2.5 Power switch

1) Main power switch

The main power switch is located outside the

battery compartment of frame side rail.

! CAUTION: If a vehicle will not be

driven for a long time, please turn off

Fig 3-8

the main power switch for the avoidance

of accident. After the engine stops and

the key switch is set to LOCK position,

turn off the main power switch.

2) Key switch

Arrange the key switch to the steering column.

Position

Usage Remarks

Fig 3-9

1(LOCK) Power off the vehicle.

The key can

be pulled out at this time.

2(ACC) Power on consumers when the vehicle is

parked.

3(ON) Driving position

4(START)

Start the engine

Auto reset

to ON gear

3.2.6 Combination switch handle

Fig 3-10

1) Steering lamp operation:

Horizontally move the combination switch handle

forward to turn on the right turn signal

lamp; and horizontally move it backward to turn on

the left turn signal lamp.

When the key switch is set to position 3, move

the handle to turn on the turn signal lamp, and

then a prompt will be heard; when the key switch

is set to position 1 and 2, move the handle to

turn on the turn signal lamp, and then a prompt

will not be heard.

Fig 3-11

2) Headlamp operation:

When the combination switch handle is set to

neutral position, key switch to position 3 and

rocker switch to position 2, the low beam or

high beam will be on. At this time, lift the

Fig 3-12 Press windshield washing system

combination switch handle upward for 4°, and

0-Closed position

J-- Wiper IHT

I-- Wiper low gear II-- Wiper high gear

then high beam and low beam will be both on

(applied for instant lighting for overtaking

or meeting); lift the handle for another 10°

for dimming (high beam to low beam or vice

versa). Release the handle, and it will be

automatically reset.

During daytime overtaking and meeting, lift

the handle upward for 4°, and the high beam

will be on; release the handle, and it will be

automatically reset.

3) Wiper operation

Turn the combination switch to select the

required swing gear for wiper.

Press and hold the windshield washer button,

and the water jet on wiper blade will inject

glass cleaner, and meanwhile, the wiper will

automatically start working at low gear; water

injection will be stopped after the release.

The glass cleaner filler port is located inside

Fig 3-13

the cab left ladderway.

! CAUTION: Always fill the washer via

the filler port with the specialized

glass cleaner instead of plain water or

other cleaning agent for windshield

washing.

3.2.7 Commonly-used switch operation

1) Hazard alarm

Turn on the main power switch and press down

Hazard warning

switch

the hazard warning switch, and all turn signal

Trumpet switch

lamps and turn signal indicators will flash.

Fig 3-14

2) Horn Button

The truck is provided with an electric horn and

Electronic control gas horn button

an electrically controlled air horn, both of

which are switched by a horn change-over

switch.

Fig 3-15

The horn button is set on the combination

switch. Switch off the air horn switch, and

then press the horn button on the combination

switch, to use the electrically controlled air

horn.

Fog lamp

3) Fog lamp operation

Press down the front fog lamp switch to power

on the front fog lamp. Pull the switch, and then

Fig 3-16

the fog lamp will be off.

4) Interior lighting

After the battery box switch is turned on and

the interior ceiling lamp switch is pushed to

one side (both the right and left are ok), the

interior lighting lamp will be on and off (as

Fig 3-17 Interior lighting

shown in left figure).

Items

Parameters

3.2.8 Seat

Seat width

510mm

Seat height

855mm

Height

The seat is designed for construction

0～40mm

adjustment

machinery and mining dump truck. The seat top

Front/rear

adjustment

180mm

and shock absorber are designed under full

travel

consideration of driver’s safety and comfort

0-70°

(backward

Backrest angle

relationship to plumb line)

based on kinematics.

adjustment

0-40°

(forward

relationship to plumb line)

The seat backrest designed as luxurious high

Adjustment

backrest applies the latest principle of human

range of driver’s

50～110kg

weight

environmental science and human kinetics to

effectively support the driver’s shoulder,

thus relieving the fatigue.

Seat adjustment method:

1) Backrest elevation adjustment: move handle

upward forcibly, turn the backrest to the

required angle and release the handle to lock

the backrest.

Range：0～60mm。

2) Horizontal adjustment: pull handle 2 upward

to move the seat forward and backward to the

required position, and release the handle to

lock.

Range：Forward 80mm，Backward 80mm。

3) Front height adjustment: move handle upward

gently to exert to or relieve from the front

end of cushion upwards or downwards an

appropriate force to lower (lift) it to the

required position, and release the handle to

Fig 3-18 Seat adjustment handle

lock.

Range：0～60mm。

4) Load weight adjustment: rotate front handle

forcibly and adjust it appropriately according

to the driver's weight. The rotation direction

corresponding to weight increase and decrease

is marked on the handle.

Range：40～130 kg。

5）Backrest elevation adjustment: move handle

upward forcibly, turn the backrest to the

required angle and release the handle to lock

the backrest.

Range：40°～180°

! CAUTION: While adjusting the seat

backrest, do not lean back too much in

case of hidden danger caused by

triggering rear window.

3.2.9 Transmission gearshift lever

The gearshift lever is installed on the engine

hooding. In this way, the disturbance of cab

vibration and the possibility of disengagement

will be eliminated, and the cab tilting will

not be affected.

3.2.10 Hand brake valve (spring parking

Fig 3-19 Transmission gearshift

brake)

The hand brake valve is located at the right

side of seat (The shown brake valve handle is

located at “BRAKE” position). Provided the

parking brake signal lamp is off, the air

Fig 3-20 Hand brake valve lever

pressure will exceed 0.55 Mpa, the spring brake

will get completely loosened, and the vehicle

can get started.

! WARNING: Before the parking brake

signal lamp is off, never start the

vehicle!

3.2.11 Other interior devices

Fig 3-21 Safety belt

1) Seat belt

Fastening: Hold the latch of seat belt, wrap

the seat belt around the shoulder and insert

the latch into the striker until a click is

heard.

Unfastening: Press down the red button on the

striker of seat belt as shown by the arrow and

pull out the latch, thus the seat belt will be

automatically reset.

! CAUTION: Always fasten the seat

Fig 3-22

1. Radio and tape player 2. groceries box

belt before driving every time! Check the

3. Abat vent

seat belt for condition and function on

daily basis.

2) Radio and tape player, abat vent and

groceries box (bilateral symmetry).

Fig 2-23

3) Cup holder, escape hammer and handrail

1. handrail 2. Cup holder 3. Escape hammer

4) Thermos bottle thermos bottle, fire

extinguisher, sleeper, pinch bar, electric

appliance cabinet

3.3 Cab exterior devices

Fig 3-24

1. Thermos bottle thermos bottle

3.3.1 Radiator cover

2. Fire extinguisher 3. Sleeper 4. Pinch bar

5. Electric appliance cabinet

Open radiator cover: rotate the two knobs as

shown in Figure 3-25.

Close radiator cover: pull down the radiator

cover and rotate the knob in reverse.

! CAUTION: While closing the cover,

do not apply too much force and make sure

that nobody stays within the travel range

of cover in case of pinch.

3.3.2 Left/right rearview mirrors

They are as shown in Fig. 3-26.

Fig 3-25

Regulation method of rearview mirror in

terrace:

1) The lower edge of the rearview mirror in

terrace is 87 ± 5mm from the upper edge of the

bracket. The distance between the upper and

Fig 3-26

1. Left forestall blind mirror 2. Rearview mirror

lower rearview mirrors is 60 ± 5mm.

3. Right back underview mirror

2) Tighten the fixing bolts of the rearview

4. Main rearview mirror in terrace

5. Right front underview mirror

mirror to be reliable.

3) When fine-tunning the rear-view mirror,

press it upwards, downwards, leftwards and

rightwards.

4) When regulating the rearview mirror and the

main rearview mirror in terrace, open the

rear-view mirror casing, and unscrew 4 fixing

bolts to regulate them to a proper angle, and

then tighten thee bolts in place.

Regulation method of rearview mirror:

1) The distance between the upper and lower

rearview mirrors is 40 ± 5mm, and the lower

rearview mirror is at the bend of the bracket.

2) Tighten the fixing bolts of the rearview

mirror to be reliable without looseness.

3) When fine-tunning the rear-view mirror,

press it upwards, downwards, leftwards and

rightwards.

4) When regulating the rearview mirror and the

main rearview mirror in terrace, open the

rear-view mirror casing, and unscrew 4 fixing

bolts to regulate them to a proper angle, and

then tighten thee bolts in place.

! Note: When regulate the visual

angle of the rearview mirror, do not

break the rearview mirror with hands; if

necessary, unscrew the fixing bolts to

regulate the visual angle, and then

tighten the bolts, or regulate the glass

angle.

3.3.3 Working lamp

The positions of working lamps are shown in

Fig.3-27: two at the front top of the cab, trail

and front mudguard respectively. They are

Fig 3-27

arranged symmetrically; one at the rear left

of the cab with angle adjustable. The working

lamps are generally controlled by the

corre-sponding rocker switch inside, and can

be turned on or off at the same time.

3.3.4 Expansion tank

The expansion tank is located at the rear left

side of cab (as shown in Fig. 3-28).The

pressure relief valve maintains a certain

pressure difference between the internal

Fig 3-28

1. Relief valve

2. Scale

pressure of the cooling system and the

atmospheric pressure, to increase the boiling

point of the coolant. The pressure relief valve

is particularly essential in plateau area, so

do not dismantle and replace it at will!

3.4 Cab suspension

3.4.1 Front suspension

Front suspension Rear suspension

The cab front suspension is applied with the

Fig 3-29 suspension

rotating axle together with rubber shock

absorber.

3.4.2 Rear suspension

Both rear suspensions are applied with dual

shock absorber together with Mechanical lock.

! CAUTION: The interchange or mixture

Mechanical lock

of left and right shock absorbers is not

Fig 3-30

allowed due to their distinct models.

3.4.3 Check suspension system

Check if the mechanical lock operates properly.

To prevent the mechanical lock from being

released by vibration of the truck, weld a pin

to the rear suspension, and then insert the pin

from the rear suspension when the mechanical

lock is latched.

3.5 Cab tilting

3.5.1

Hydraulic

power-assisted

tiltingassembly for cab

As shown in Figure 3-31.

3.5.2 Cab tilting operation (Figure 3-32)

Fig 3-31

1. Hydraulic hand pump

2. Pinch bar jack

3. Oil plug

4. Pinch bar

! WARNING: During the whole process

5. Switchover handle

of tilting, personnel are strictly

prohibited to enter the cab, and

personnel without fixed duties are

strictly prohibited to stay around the

cab.

1) Remove unsecured items in the cab before

tilting.

2) Turn over the cab: pull the manual reversion

Fig 3-32 Cab tilting operations

handle of tiltingpump to the position as shown

in the figure, insert the ripping bar and swing

it up and down so as to complete

tiltingoperation; during tiltingoperation,

the position of manual reversion handle shall

not be changed.

3) Turn the cab back: pull the manual reversion

handle of tiltingpump to the position as shown

Fig 3-33 Cab return operations

in the figure, insert the ripping bar and swing

it up and down so as to turn the cab back.

! WARNING: The operation of cab

tilting on a slope is forbidden. Every

time, the cab shall be tilted completely.

In other words, the maintenance and

Fig 3-34

overhaul cannot be done unless the cab

exceeds TDC. When the cab is under

tilting, nobody is allowed to enter the

cab!

3.5.3 Oiling and bleeding of tilting system

1) Open the oil plug, and top up with the

specified hydraulic oil until it is full.

2) Tilt up the cab gradually while continuing

oiling

3) Lower the cab while letting the excessive

oil overflow.

4) Operate the pump to tilt up the cab to return

is back to the original place, check, and top

up.

5) Finally, screw in the oil plug.

WARNING: The oiling and bleeding of

tilting system are not allowed unless the

cab is restored.

The low temperature and wear-resistant

hydraulic oil of 0.5 L L-HV32 GB11118.1 shall

be applied. Before filling, always check the

hydraulic oil for cleanness, and add some oil

if acceptable.

3.5.4 Check tilting system function

1) Tilt the cab forward to TDC, and check if

the cab can fall normally after it exceeds TDC.

If the system works normally, the cab will fall

down gradually under resistance without any

obvious impact.

2) After tilted up for about 30º, the cab shall

be held at this position for 20 min without any

settlement.

3.6 Preparation before driving

WARNING: Keep a good vehicle condition. Do

not drive in case of any

fault!

3.6.1 Preparation

The preparations before driving mainly include:

routine inspection before every driving,

engine start and flameout.

1) Turn on the main power switch (as shown in

Fig. 3-35) to power on the truck.

Fig 3-35

2) Check the working condition of electrical

system. When the key switch is turned on (i.e.

key switch is set to ON), the instrument panels

indicate normally.

3) Check oil/coolant condition of the truck.

a. Check hydraulic oil: park the truck on the

flat road, lift the container continuously for

Fig 3-36 Oil scale

5 times, and then keep it still for 15min. At

this moment, the standard level of hydraulic

oil shall be between 1/4 of the level meter and

MAX. If the oil level is higher than MAX, drain

oil; if it is lower than 1/4 of the level meter,

Fig 3-37 Glass water scale

refill it to the standard level.

b. Check windshield washer fluid: the

windshield washer fluid visually observed

shall be between 1/4 and 3/4 below the clamp.

If it is lower than 1/4, refill it.

! Note: Refill special windshield

Fig 3-38 Fuel oil level inspection

washer fluid instead of ordinary water or

other washing liquid.

c. Check fuel: Open the filler cap, insert the

dip stick until the fuel tank bottom and make

it lean against the upper edge of filler to the

extent that the immersed end of dip stick is

vertical to the tank bottom. At this moment,

the oil trace length shall be between 40mm and

50mm. If it is higher than 50mm, drain the fuel;

if it is lower than 40mm, refill the fuel and

then tighten the cap with the arrow upwards.

d. Check coolant: Start the engine, turn on the

heater to operate for about 2 minutes. At this

moment, the water temperature of the engine

shall be 50 ± 5 ℃, and the coolant level

shall be between MAX and MIN. If it is low,

refill coolant.

When the engine is at low temperature, add the

coolant in two steps:

Step 1: Relieve the high pressure through the

relief valve gradually;

Step 2: Open the cover of relief valve, and add

coolant when the engine runs at idle speed.

! WARNING: Never add coolant when the

engine is still at high temperature!

Fig 3-39 Coolant scale line

e. Check engine oil: Measure the engine oil

MIN

MAX

level before startup. If it has been started,

do not measure the engine oil level until 15

minutes after stalling.

Fig 3-40 Oil dipstick scale

Pull out the dip stick to clean it with cloth,

and then insert it back into original position.

Pull it out to check the oil trace again. The

upper end of the oil trace shall be between MAX

and MIN. If it is higher than MAX, drain oil.

Fig 3-41 Liquid storage tank and scale line

If it is lower than MIN, refill it to standard

of brake fluid

level.

f. Check brake fluid: Check the brake fluid

under the condition that air has been exhausted

from the clutch system. Refill the brake fluid

until the level is between MAX and MIN. If it

is lower than MIN, refill it to standard level.

4) Check if there is water inside the air

Fig 3-42

reservoir of exhaust system, and drain if any.

Park the vehicle, pull down or push up the drain

valve to drain off the water condensed in the

air reservoir. If any oil-water mixture is

found, air dryer is ineffective and the

desiccant of air dryer shall be replaced

immediately.

5) Check the tire pressure. If the pressure is

inappropriate, use a specialized inflation

pump to inflate the tire.

6) Check the lubricant, coolant and air duct

for leakage.

7) Check engine air intake system.

a. Check the primary filter inlet for blockage

by foreign matters to avoid too much negative

pressure present in the air intake system; for

this purpose, insert a thin rod through the

primary filter inlet to move the impeller,

checking if the impeller rotates smoothly.

Otherwise, check or replace the primary filter

to prolong the maintenance interval of air

intake system.

b. Check the air filter outlet to the

supercharger inlet pipeline for damage, and

repair or renew it in time when necessary.

Otherwise, serious early wear will occur to the

engine.

c. Check the air filter blockage alarm

indicator for normal alarming. If the air

Fig 3-43

filter is blocked, this alarm indicator shall

be on. At this time, always check the metal and

paper filter element for blockage, and service

Air filter blockage alarm

or replace it in time.

indicator lamp

10) Before the start-up, check whether there

is any personnel or obstructions in the

vicinity of vehicle.

3.6.2 Engine start

1) Turn on the main power switch and turn the

key switch to ON position, getting ready to

start the engine.

! CAUTION: When the vehicle is

running, do not turn off the key switch.

Fig 3-45

In other words, the key switch shall be

set and held at ON position (driving

Neutral

position).

2) Start-up

Release the hand brake, and set the gearshift

lever to NEUTRAL position. Turn the key switch

to START to start the engine.

Fig 3-46 7DS200

! CAUTION: If the engine cannot get

started successfully for the first time,

set the key switch to ACC, and start the

engine again. The time for each starting

shall be no more than 15 s, and the

interval between two successive

start-ups shall be no less than 60 s.

However, if it is not possible to start

up for three successive times, stop it

until any fault has been identified and

cleared. After the engine has been

started, make it idle for a few minutes,

and then increase the speed to

1,000-1,200r/min, and apply partial load.

Full-load operation is allowed only when

the outlet temperature is higher than

60℃, and the engine oil temperature is

higher than 50 ℃. The load and speed

shall be increased gradually to avoid

sudden load adding or shedding.

3) Oil pressure after start-up

After the engine gets started, observe the

pressure value indicated on the oil gauge.

Meanwhile, the oil pressure indicator lamp

shall be off.

! CAUTION: Never run a cold engine at

a high temperature! If the oil gauge

gives no reading after the engine is

started, immediately shut down the

engine for overhaul.

4) Operation of supercharger

The supercharger is installed at the rear upper

end of engine, consisting of turbine assembly

and pump impeller assembly. The exhaust gas

discharged by the engine will drive the turbine

and the pump impeller on the same shaft to

rotate at a high speed, discharging the

compressed air into the engine air intake pipe

to increase the intake pressure and increasing

the engine power.

The rotor in the supercharger normally runs at

a very high speed (about 70,000-100,000 rpm).

The rotor bearing is forced lubricated with

hydraulic oil provided by engine main oil duct.

The oil supply will be cut off as long as the

engine shuts down.

Precautions during operation:

a. To start the engine, run it at idle speed

for 2-3 min without depressing the accelerator

forcibly in this process, and do not apply load

until the oil pressure and temperature are both

normal (especially for start-up in cold days);

otherwise, the damage caused by early wear can

is likely to occur to bearing and sealing ring

of supercharger.

b. To shut down the engine, always run it at

idle speed for 2-3 min, and shut it down after

the supercharger slows down. Pay special

attention not to depressing the accelerator

forcibly before the engine stops. If the

supercharger will decelerates substantially

due to the sudden rise of engine speed when the

engine shuts down all in a sudden, the oil pump

will stop oil supply immediately; however, the

rotor of supercharger will keep rotating at a

high speed due to its inertia, thus resulting

in quick burnout of rotor shaft, bearing and

sealing ring because of oil shortage.

c. Before starting the engine which has been

withdrawn out of service for a long time,

Fig 3-47

always pre-lubricate the supercharger by

1. Clutch pedal 2. Brake pedal

removing the supercharger oil inlet pipe and

3. Accelerator pedal

adding appropriate amount of clean lubricant

from the filler port. Otherwise, the initial

start-up will lead to parts early wear due to

oil shortage.

3.6.3 Engine shutdown

When the vehicle runs downhill, press down the

exhaust brake switch or depress the exhaust

brake pedal, and then the engine oil supply

will be cut off for exhaust braking.

The engine may be overheated after it runs

overloaded, and in this case, the engine should

be shut down after running at idle speed for

2-3 min.

3.7 Start-up and gearshift

! WARNING：The user is asked to drive

the vehicle according to the

instructions, and the user is conceited

for all the consequences of the illegal

driving.

Fig 3-48 Transmission gearshift lever

3.7.1 Start-up

If the engine is started, and the low pressure

indicator is on and the buzzer keeps sounding,

do not release the brake handle to start the

vehicle until the inflation pressure reaches

0.55 MPa (5.5 bar), low pressure alarm

indicator is off and the buzzer stops sounding.

△!WARNING: Always start the MT86 mining dump

truck at gear 1.

3.7.2 Transmission gears and operation

See "4.4 Operation and maintenance of

Fig 3-49 Differential lock button

transmission" for details.

3.7.3 Differential lock

The drive axle of MT86 mining dump truck is

equipped with bogie differential lock. When

the wheel slips or gets stuck in the mud, the

bogie differential lock can lock the bogie

differential between the intermediate axle and

the rear axle, thus increasing the vehicle

trafficability.

1) Connection of bogie differential lock: Only

when the vehicle is parked or travels straight

at a low speed (equivalent to walking speed)

can the differential lock be engaged.

Press down the bogie differential rocker

switch. When the bogie differential is engaged,

the bogie differential indicator on the

instrument panel will be on.

! WARNING: When the vehicle is

running, always release the clutch

before the connection of bogie

differential lock!

2) Disengagement of bogie differential lock:

Release the accelerator, depress the clutch,

and pull up the bogie differential rocker

switch. When the bogie differential is

disconnected, the bogie differential

indicator on the instrument panel will be off.

3.7.4 PTO operation

! CAUTION: PTO can be used only on the

engine-out condition! It is not allowed

to use the PTO in the low or reverse gear.

This manual only gives introduction to PTO

engagement and disengagement. For operation

and maintenance of the hydraulic lifting

system, refer to the User Manual of Hydraulic

Fig 3-50 Take power device

Lifting System.

1) Container lifting

Depress the clutch pedal, and push the handle

Parking PTO indicator

in the direction indicated by the red arrow to

lamp

engage the power takeoff. At this moment, the

parking and power takeoff indicators on the

dash board turn on. Continuously push the

Fig 3-51 Parking PTO indicator lamp

handle to lift the container.

△!Note: Depress the accelerator pedal (engine

speed ≤ 1,800r/h), pull up the handle to keep

the container lifted (or stop lifting by

releasing the handle).

2) Container lowering

When the handle is pulled down in the direction

indicated by the blue arrow to the extent that

the handle is in the return position, the

container automatically lowers, and the power

takeoff switch automatically opens and

returns.

3.8 Operation at low temperature

environment

3.8.1 Engine cooling system

The long-life antifreeze and anticorrosion

coolant applied by the engine cooling system

Fig 3-52 Air dryer

can be kept unfrozen above -35℃. If the

vehicle has to work in the environment below

-35℃, the coolant concentration should be

increased appropriately.

! CAUTION: The mixture of antifreezes

of two different brands is not allowed.

Before changing the antifreeze,

Fig 3-53 Batter

thoroughly clean the cooling

system.Selection of coolant at different

freezing points based on local ambient

temperature，The selection principle is

the air temperature is about 10C lower

than the freezing point.

3.8.2 Brake system

Drain off the water condensed in the air

reservoir in case of freezing, and note to

check the air dryer for working

condition.Under normal condition, the service

life of desiccant in the air dryer is half a

year. If any oil-water mixture is drained from

air reservoir, air dryer is ineffective and the

desiccant should be replaced immediately.

3.8.3 Battery

The battery applied is maintenance-free. If

the vehicle will not be used for a long time

and the temperature is low, you had better

remove the battery and place it in a warm room.

Check the battery electrode terminal and

conductor connection clamp for looseness and

the battery for normal working condition every

500 km.

! WARNING:

● Before the battery repair, always

keep good ventilation.

● Nobody, other than professional

service personnel, is allowed to repair

and remove the battery without

permission!

● While removing (installing) the

battery, always disconnect (connect) the

negative cable first!

3.8.4 Startup system

Start the engine with an auxiliary startup

device under low temperature. Make the

electronic heating flange operate with a relay

so as to start the engine successfully under

-30　C.

3.8.5 Park

In case of cold climate, do not park until

remove the load firstly and then make it run

at idle speed for 2-3 minutes, and the water

temperature and the oil temperature drop.

After parking, do not drain the coolant

containing anti-freezing additive. If the

coolant contains no anti-freezing additive, it

is necessary to open the water drain valve or

water plug on the engine, the oil cooler cover,

the radiator, the water inlet pipe and the like,

to drain the coolant to prevent the engine from

being frozen.

3.9

Wheel replacement and

tire pressure

1) While replacing the wheels, be careful not

to damage the thread of wheel rim bolt.

2) The fitting surface of brake drum and wheel

rim shall be free from paint, grease or other

contaminants.

3) The seal face of wheel nuts shall be kept

clean without contaminants or oil stain.

4) Before installing the wheels, wipe up the

outer circle matching with the wheel locating

hole and final drive housing, and apply a few

grease.

Air

Speed

Load

5) Apply a few grease, engine oil or other

Level

pressure

km/h

kpa

anti-seize to the threads of wheel bolts and

1200

11500

nuts.

14.00-25

7300

7150

Tire of

6) All wheel nuts have right-handed threads.

construction

7000

850

To install the wheels, pre-tighten the nuts

machinery

6900

36 level

6750

diagonally with the wheels suspended, lower

6700

down the wheels, and tighten the nuts to the

The above data are for

reference only. The specific air

specified torque*.

pressure adjustment shall be

Remarks

subject

Operation

* Specified torque of wheel nuts: Use a 36 mm

Instructions provided by the

hexagon socket to tighten MT86 wheel rim bolt

manufacturer.

to a torque of 700 - 800 Nm.

7) Each time when a tire is refitted, always

tighten the wheel nuts again after the vehicle

travels 50 km. Thereafter, check and tighten

the wheel nuts again every 1,000 km.

8) Please inflate the tire according to the

“Comparison table of speed, load and air

pressure” (see left table).

3.10 Running-in of new vehicle

The running-in mileage is 1,500-2,500 km as

specified.

Before running-in, do routine inspection to

ensure that the vehicle is kept in normal

working condition.

Precautions for running-in:

1) Do not speed up immediately after the engine

gets started. Only when the coolant

temperature reaches normal range can the

engine speed be increased.

2) During running-in, the vehicle shall travel

along a relatively even road with good

condition.

3) Do gearshift in time and engage the clutch

smoothly for the avoidance of sudden

acceleration and emergency brake.

4) Before travelling uphill, engage a low gear

in time in case that engine runs at a too low

speed.

5) A new vehicle cannot travel at full speed

with full load. Always monitor the instruments,

indicator lamps and alarm indicators!

6) Check and control the engine oil pressure

and coolant temperature. Monitor the

temperature of transmission, front/rear axles,

4.1 Operation and maintenance of

engine

4.1.1 Operation and maintenance of engine

See Operation and Maintenance Manual of WD12

Series Diesel Engine for details

4.1.2 Change of engine oil,filter,prefilter

During operation of MT86H, it is necessary to

Fig 4-1

1. Drain plug

periodically replace engine oil, filter and

pre-filter as appropriate to keep the engine

Oil dipstick

operating properly.

1) Change of engine oil

Interval: Within the limited period (mileage)

of the mandatory maintenance, the engine oil

should be changed in strict accordance with the

Fig 4-2 Oil dipstick

period specified in “Mandatory Maintenance of

5.2 MT86H mining dump truck”; while over the

limited period (mileage) of the mandatory

maintenance, refer to the interval specified

in Operation and Maintenance Manual of WD12

Series Diesel Engine for replacement.

a) Pull the drain plug open to drain the oil

off.

Fig 4-3

1. Oil filter

Inspect whether the oil has a normal color and

any foreign materials while draining, and

eliminate timely the fault potential if any.

b) After the oil has been drained off, remove

the foreign materials from the drain plug that

then should be screwed on.

c) Replace with a new oil filter element, and

fill the engine with new oil to the upper limit

Fig 4-4 Change the oil filter

of the dipstick. To avoid starting an

unlubricated engine, when the high pressure

oil pump is set at OFF position, turn the key

switch to start position (4th gear), let the

engine idle for a while, and after the engine

is completed with pre-lubrication, start and

run it at a low speed, and check if the oil

filter is leaking oil.

2) Oil filler

Fig 4-5 Fuel filter

Replacement interval: In the limited period

1. Fuel coarse filter 2. Fuel fine filter

(mileage) of the mandatory maintenance, the

oil filter should be replaced in strict

accordance with the period specified in

“Mandatory Maintenance of 5.2 MT86H mining

dump truck”; while over the limited period

(mileage) of the mandatory maintenance, the

replacement is required every 5000 Km (200h).

Each time the engine oil is changed, the oil

filter should be replaced as well.

Replacement method: Remove the filter with a

special filter wrench before replacement. To

Fig 4-6 Fuel filler（protector）

fit a new filter, clean up the fitting surface

first, fill the filter full with clean media

to be filtered, lubricate the rubber seal ring

with little clean media to be filtered, then

install the filter by hand and screw it for 3/4

circle after the sealing surface bonds with

fitting surface. Start the engine to check if

the sealing surface is leaking oil, and if any,

tighten the filter again until there is no oil

leaking any more.

3) Fuel filter

The replacement interval and replacement

method are the same with “2) Oil filter”.

4) Fuel primary filter

The replacement interval and replacement

method are the same with “2) Oil filter”.

4.1.3

Routine

maintenance

and

considerations

1) Check the coolant level, oil level and fuel

level.

2) Check if the grease is sufficient at

required position.

3) Check for oil, water and gas leakage.

4) Check connection of external connection

pieces and accessories.

5) Check if the fan belt is too tight or too

loose.

6) Check the oil pressure and water temperature

of the diesel engine.

7) Check if the exhaust temperature, color,

sound and vibration are normal, and the speed

is stable.

Refer to "Periodic Inspection and Technical

Maintenance of Diesel Engine" section of

Operation and Maintenance Instruction of WD12

Engine for details.

4.1.4 Maintenance

MT86 engine shall be inspected and maintained

at interval specified in “5.1 Interval

Mileage of Routine Inspection and

Maintenance”. Refer to "Periodic Inspection

and Technical Maintenance of Diesel Engine"

section of Operation and Maintenance

Instruction of WD12 Engine for details.

4.2 Operation and maintenance of intake

system

The working component of the intake system is

the three-stage desert filter, which consists

of the cyclonic prefilter, coarse filter and

fine filter.

4.2.1 Cyclonic prefilter

The cyclonic prefilter is maintenance-free and

is removed for inspection only when there is

abnormal noise, and if necessary, the rotator

should be replaced.

Fig 4-7

4.2.2 Coarse filter

1.Cyclonic prefilter

2. Coarse filter

3.Fine filter

1) Check the dedusting valve frequently, and

clean the coarse filter in the case of

clogging;

2) Remove and clean the coarse filter carefully

every 2-3 months;

Maintenance steps:

① Remove the fixed points around the bottom

cover; ② Remove the bottom cover; ③ Clean

the dust in the bottom cover and dust

collecting duct; ④ Install the bottom cover

to confirm the sealing performance.

! CAUTION: The damaged or ageing seal

ring should be immediately replaced with

a new one; the dedusting valve should be

replaced with a new one immediately in

the cae of loss, ageing or damage.

4.2.3 Fine filter

The fine filter is composed of the main filter

element and the safety filter element.

The main filter should be maintained when the

indicator alarms or every 200-250 working

hours.

The safety filter element is only used as

second protection and may not be cleaned.

Maintenance method:

① Unscrew the fixing nut, and carefully

remove the main filter; ② Blow off the dust

on the main filter element with clean air below

0.5MPa diagonally from the inside to outside;

③ Check the filter element inside and outside

and the seal ring for any damage; ④ Clean the

air filter housing inside, and check the inner

filter element for damage; ⑤ Place the outer

filter element gently back into the filter

housing, and check whether the outer filter

ring comes into contact with the housing; ⑥

Determine that the outer filter element has

been installed in place, and tighten the nut

and insert the spring pin into the pin hole.

The main filter element and safety filter

element should be replaced in the following

conditions:

① The main filter has been damaged; ② After

the indicator is cleaned and installed, it

still alarms:

③ The main filter element has been cleaned for

5 times.

! CAUTION: The safety filter element

cannot be cleaned, and should be replaced

together with the outer filter element.

4.3 Operation and maintenance of clutch

control system

4.3.1 Working principle

The clutch control system is hydraulically

controlled and pneumatically boosted. With the

clutch pedal stepped on, the drive cylinder

push rod pushes the piston to move forward, so

that the brake fluid, which flows along the

fluid pipe into the hydraulic control cavity

Fig 4-8

1. Clutch oil reservoir 2. Clutch master cylinder push

of clutch booster cylinder, provides working

rod 3. Clutch drive cylinder 4. Clutch pedal assembly 5.

pressure on the piston, and besides, serves as

Clutch oil pipe 6. Clutch booster cylinder

control pressure to control the air pressure

in the booster cylinder chamber. When

compressed air gets into the booster cylinder,

the generated force will push the piston to

move the booster cylinder push rod, and drive

the release rocker arm to rotate, such that the

release fork makes the release bearing move

backward, finally to release the clutch

successfully.

The clutch drive cylinder, clutch fluid

reservoir and clutch pedal assembly etc. are

arranged to the front wall of the cab, with the

drive cylinder connected to the clutch booster

cylinder on the chassis through high pressure

hose, and one bracket shared by the clutch

operating part and the brake operating part.

The fluid reservoir is installed directly on

the clutch drive cylinder, and the brake fluid

can be added outside the cab as long as the

radiator cover is uncovered.

4.3.2 Working parameters

1) Working media: compressed air and brake

fluid.

2) Max. working pressure: 4 MPa for the brake

fluid and 0.85 MPa for the compressed air.

3) Working temperature: -40°C~+80°C.

4) Brake fluid: as per DOT3 and DOT4 standards.

5) Pedal travel: a maximum travel ≤ 175 mm.

6) Pedal operating effort: ≤190 N (when

pneumatically boosted).

4.3.3 Installation and adjustment of clutch

and clutch control system

1) Installation of clutch: Put the driven disc

assembly on the spline shaft (with a tool used

for positioning the clutch driven disc to be

installed), with the fly wheel central hole

aligned. Assemble any two holes of the clutch

pressure plate assembly to the two studs on the

fly wheel, then install the other 10 hexagon

bolts respectively, and tighten them

diagonally.

2) Pull-type clutch connection: After a

pull-type clutch is installed with the

procedures above, take the four clamp springs

off the pressure plate assembly, close the

flexible lock ring on the clutch pressure plate

assembly, and install the release bearing and

release fork properly. Since the transmission

has been installed to the engine fly wheel,

apply a backward force to the release fork at

the booster cylinder mounting port (pull

backward through a flexible rope attached to

the upper end of the release fork), and as long

as a sound of clap is heard, the clutch cover

assembly and release bearing are assembled in

place (i.e. the flexible lock ring clamped on

the release bearing), after which, the booster

cylinder should be installed.

3) Inspection and adjustment of clearance

between the drive cylinder push rod and piston:

While adjusting, push the pedal gently by hand

until you feel the drive cylinder push rod

against the piston, adjust the height of stop

bolt to ensure a clearance between the push rod

and piston of 0.5 mm~1 mm, and then tighten the

nut. The clearance hereof should be no more

than 1 mm, or the effective stroke of the drive

cylinder may shorten.

4) Bleeding of hydraulic system: If there is

air in the clutch hydraulic system, the

effective stroke of the booster cylinder push

rod will shorten, resulting in an incomplete

clutch release, as well as gear engagement

difficulty. To add new brake fluid, release the

booster cylinder bleed valve, fill the fluid

reservoir with brake fluid of specified grade,

replenish brake fluid while stepping on the

clutch pedal until it spills out of the bleed

valve, and tighten the bleed valve. Then

depress the clutch pedal for several times, and

hold it, release the booster cylinder bleed

valve until no air comes out, then tighten the

bleed valve. Repeat the steps above for 2~3

times, so that the air in the hydraulic system

can be discharged thoroughly.

4.3.4 Precautions

1) Remember to release the pedal after the

bleed valve is tightened during air discharge

in order to avoid air suction, and allow the

Fig 4-9 Brake fluid

pedal to rise up to the maximum height, so that

the brake fluid in the fluid reservoir is added

into the drive cylinder hydraulic cavity.

2) The working medium for hydraulic system must

be brake fluid of DOT3 and DOT4.

3) To change the brake fluid, the residue in

the hydraulic system has to be cleaned. Then

uniformly change the brake fluid of specified

grand and same lot. The brake fluids of

different grades and lots shall not be mixed.

4) As the brake fluid is corrosive, while

discharging air, try not to spatter any brake

fluid onto human body and vehicle finish.

5) Periodically inspect the brake fluid

reservoir level of clutch master cylinder. If

the brake fluid level is below Min mark, the

brake fluid of a specified type should be added,

until its level is between the scale marks of

Min and Max.

4.3.5Common faults and troubleshooting

Faults

Causes

Solutions

The

transmission

misaligned at re-assembly;

Align the driven disc assembly carefully, and

Clutch

return

The hub is mounted on the

align the clutch with an analog spindle;

difficulty causes

input shaft, and the driven

Do not push the transmission forcibly, but rotate

shift difficulty

disc

assembly

rotates

the flywheel or the input shaft to align it with

through the hub in the

splines of the hub

direction of the input shaft

The weight of the

transmission is completely

It is out of work

Do not load the input shaft or the transmission

loaded on the hub and is

and loud noise

on the driven disc, but support the transmission

damaged due to distortion

occurs after a

with a manual or electric lift for assembling;

after short-term operation;

few

hundred

Do not operate it like a racing automobile.

2. Operate the clutch like a

kilometers

Educate the driver.

racing automobile or tow a

heavy trailer

The clutch slips,

but the control

Check the oil seal of the engine and

system operates

Oil

leaks

from

the

transmission carefully. If there is oil in the clutch

properly,

and

transmission or the engine

housing, replace the oil seal.

the regulation is

correct

The clutch is

Only a certain amount of suitable grease is

shaking at the

There are too much

permitted

initial stage of

copper-based grease on

Warning: copper-based grease dilutes under

the transmitting

splines of the input shaft

high temperature and radiates outwards under

torque

centrifugal force

Improper operation. Shift

It is out of work

5th gear to 2nd gear at 85

Educate the driver

miles

Shift is difficult

The truck starts at a bumpy

or is unavailable

place or starts and tows with

Do not engage 1st gear, but high-speed gear

after the clutch

an inappropriate gear, or the

such as 3rd gear or 4th gear, when the truck

has

been

clutch cover assembly is not

starts at a bumpy place or tows.

operated for a

suitable for the truck

period of time

Fault

Causes

Solutions

The cap assembly drops

Do not use the cover assembly that has ever

Shift is difficult

during assembly so that the

dropped;

or is unavailable

return spring is twisted;

Check the return spring carefully before

after the clutch

The spring (with scratch on

assembling;

has

been

the drive disc) is damaged by

Do not try to insert the drive disc to stop the

changed

tool during assembling

engine with a tool while the engine is running

Shift is difficult

The clutch cover is not

or is unavailable

accurately positioned;

Check the positioning before assembling;

after the clutch

Bolt tightening sequence is

Tighten bolts in proper sequence (diagonally)

is renewed

not proper

The transmission input shaft

Accurately guide the clutch into the

Pedal jitters at

interferes

with

the

transmission input shaft to avoid any

disengaging

disengaging lever during

interference during assembling

assembling

Check all relevant connections thoroughly

It is difficult to

The pre-load of the release

during the clutch assembling; ensure that the

depress

the

bearing is too small or it is

clutch cable operates smoothly throughout

pedal and the

not preloaded;

operation of the clutch; check the self-regulator;

stiffness

The preloaded spring is not

always refer to the installation manual of the

increases with

installed properly or the

manufacturer for proper regulation; keep the

time.

self-regulator has failed

preload between minimum 50N and maximum

80N

The

noise

associated with

Check the cable, related connections and

the

engine

The clutch regulation is

self-regulator systematically, and always refer to

occurs when the

improper

the

the installation manual of the manufactuter for

pedal

self-regulator has failed

proper regulation

depressed

the bottom

The stiffness at

a certain point

in the pedal

Check the fork, or replace it if necessary;

travel is large,

The guide sleeve of the

Replace the guide sleeve of the release bearing

the transmission

release bearing is worn;

if any wear sign;

generates noise,

The fork deforms

Make sure the parts are lubricated

the

clutch

vibrates,

and

the pedal jitters

Fault

Causes

Solutions

The positioning element has

The

clutch

been damaged;

Check the fork and guide sleeve, and replace it if

generates noise,

Mechanical operation errors

any abnormal wear sign;

and the pedal is

during the clutch assembling

Make sure the parts are lubricated;

loose

result in damage to the

Check the clutch cable carefully

locating plate

The

audible

harsh

noise

occurs when the

clutch

The release bearing is stuck

disengaged or

or generates noise from the

throughout

beginning;

Check the clutch cable, related connections,

operation of the

The

release

bearing

fork,

bearing,

preloaded

spring

and

clutch, and the

overheating causes the

self-regulator systematically

noise

level

grease to burn because the

varies with the

preload is incorrect

magnitude of

force

applied

onto the pedal.

Check the clutch regulator periodically, and

Loud noise lasts

Improper regulation causes

always refer to the installation manual of the

for a long time

failure of the release bearing

manufacturer for proper regulation

The

clutch

The driver always puts his

Make sure the clutch is regulated properly, and

slipping

foot on the pedal;

always refer to the installation manual of the

eventually

The clutch regulation is

manufacturer for proper regulation;

results in jitter

improper

Train the driver

The truck and the clutch are

operated rudely;

The driver always puts his

The clutch slips,

foot on the pedal;

and shift is

Educate the driver

Over-slipping

results

unavailable

overheating of all parts,

causing the plate breaking

Fault

Causes

Solutions

The truck is operated rudely;

The clutch is operated too

frequently;

The driver always puts his

Check the release bearing sleeve systematically;

The clutch slips

foot on the pedal;

Educate the driver

The release bearing is stuck

with the sleeve of the input

shaft

Checks the sealing ring of the engine and the

The

truck

transmission systematically. Only little grease is

generates noise

Oil or grease invades into the

permitted on the input shaft;

when the gear is

torsional vibration reduction

Warning: The grease dilutes under high

neutral

system, causing failure

temperature and will then be thrown out at high

position

speed due to centrifugal force

The grease is insufficient or

splines are cleaned with high

Gear can not be

pressure;

shifted rapidly;

If the hub of the driven disc

It is difficult to

assembly is nickel plated,

It is important to refill grease as per instructions

shift it to 1st

greasing the input shaft will

when renewing the clutch

gear

and

cause

adverse

reverse

gear,

consequences, making the

even all gears

lubrication deteriorated and

the driven disc hardly slide

on the input shaft.

Shift is difficult

and gear is

The self-regulator failure or

interred during

When replacing the clutch, check the condition

locking causes insufficient

shifting;

of the self-regulator; adjust the height of the

movement of the cable so

considerable

pedal if necessary, according to the operation

that the clutch can not be

free travel has

regulations of the manufacturer

disengaged completely

to go prior to

disengagement

The guide bearing on the

crankshaft is damaged;

Whistlers occur

The guide bearing does not

Check if the guide bearing status is ideal when

when the pedal

rotate when the clutch is in

the clutch is disassembled;

moves

the operating position, but

Refill the grease if necessary

rotates when the pedal is

depressed.

Fault

Causes

Solutions

Since the self-regulator is

worn to the limit, the release

Periodically check the state of the self-regulator

bearing has no sufficient

and the preload of the release bearing, and

backward travel after the

push the fork of the clutch in reverse;

driven disc assembly has

Check the adjustment allowance, and the

There’s any sign

been worn, which causes the

bearing of the pedal when regulating the pedal;

clutch

pressure lowering,

thus

Automatically regulate cable: Replace it if

slipping

resulting in slipping;

regulation is impossible; for the semi-automatic

For the semi-automatic

regulation device, continuously screw down the

device, open the locking

threads until exceeding the initial position

mechanism,

and

then

indicated by the arrow

reassemble and lock it;

When the clutch

is or has been

When replacing the clutch, pay special attention

disengaged,

to the condition and lubrication of the operating

harsh

noise

There is no grease at

system. In case of any irregular wear mark on

occurs, and the

connections

any part, replace it;

support shaft of

Avoid excessive grease, which may cause

the fork or the

contamination of the friction plate

pedal is stuck

When

the

operator

The moving part of the fork

depresses the

is not well lubricated and

When replacing the clutch, pay special attention

pedal,

harsh

becomes rough, which

to the condition and lubrication of the fork. In

noise

occurs

causes the release bearing

case of any irregular mark or unsmooth

and the pedal is

wear, and the release

movement, replace the parts;

abnormally

bearing presses the input

Avoid excessive grease, which may cause

rigid, which may

shaft, making the sleeve

contamination of the friction plate

cause the clutch

move not smoothly.

jitter

The pedal is

rigid, and the

In case of any abnormality sign on the sleeve of

The release bearing moves

slip time may be

the input shaft, replace it;

not smoothly on the sleeve

prolonged when

Avoid excessive grease, which may cause

of the input shaft

the clutch is

contamination of the friction plate

disengaged

4.4 Operation and maintenance of

transmission

4.4.1 Main performance parameters

The MT86 mining dump truck is applied with the

countershaft and single case structure, which

is designed with seven forward gears and one

reverse gear without synchronizers. The

transmission realizes the gearshift via

Fig 4-10 7DS200 transmission

sliding sleeve, and then the power

transmission through the engagement of the

external and internal splines on the gear with

the sliding sleeves.

The transmission is applied with two parallel

Fig 4-11

countershafts of same structure spaced from

Schematic diagram for tooth alignment of

each other by 180º. The power inputted from the

transmission assembly.

1 Left countershaft gear

input shaft is diverted to the two counter

2 Right countershaft gear

3 Input shaft gear

shafts and finally outputted via the output

shaft after converged. As two countershafts

only transmits 1/2 torque theoretically, the

center distance, gear width, axial size and

weight are reduced accordingly. Thanks to the

twin-countershaft structure, each gear on the

output shaft must be engaged with the two

countershaft gears simultaneously. In

addition, the output shaft gear is radially

floating on the output shaft to make the gear

engaged with the countershaft gear properly

and distribute the load as equal as possible.

Since the output shaft gear floats on the

output shaft, the needle bearing is not

required any more, and the radial forces

applied by the two countershafts to the output

Fig 4-12 Power transmission route diagram

shaft are offset, so that the output shaft only

bears the torque without bending moment, and

the stressing condition of output shaft and

bearing is improved, substantially enhancing

the reliability and durability of the

transmission.

4.4.2 Main performance parameters

Fig 4-13 Shift handle

The maximum input torque is 1,800 Nm, the rated

rotate speed 2,600 r/m, the fuel capacity 23

L, and the gear ratios are given in the table

below.

Gear

7DS200

9.14

6.7

Fig 4-14 Soft shaft control mechanism

4.85

1. Nut 2. Ball hinge 3. Bolt 4. Ball hing

3.6

2.65

1.61

1.00

8.51

The power transmission route is shown in the

figure (left).

4.4.3 Transmission structural parts

1）Installation and adjustment of flexible

shaft control system

The 7DS200 transmission is remotely operated.

The flexible shaft operating system is

installed and regulated as follows:

a. The flexible shaft to be installed to the

truck should have a bending radius not less

than 300 mm, and it is applied within the

temperature range of -40°C~+100°C.

b. The flexible shaft is connected with the

gear shift rocker, and the following

requirements should be met:

1) An included angle of 90 degrees is reserved

between the flexible shaft and the rocker.

2)The guide sleeve and protective pipe joint

of the flexible shaft as well as the pull-push

rod at spatial positions must be in line.

c.The gear and shift flexible shaft shall be

installed to the controller.

! CAUTION: Two flexible shaft ball

joint threads should be screwed down.

d.Position the control lever to neutral

position, measure the flexible shaft at the

transmission end to see if it meets the

requirement. And if not, adjust the connecting

length of flexible shaft ball joint with pull

rod thread so as to adjust the installation

dimension of the flexible shaft.

e. Do gearshift after the installation, and

make sure that all gears can be selected. And

if any gear is difficult to be shifted, inspect

and adjust the installation dimension of shift

flexible shaft at the transmission as above.

f.The adjustment of flexible shaft is detailed

as follows:

If, after the assembly is done, the gears at

the front row cannot be engaged properly during

the running-in period, unscrew the nut ① (or

nut ⑤), and anticlockwise rotate (lengthen)

the spherical hinge ② (or spherical hinge ⑥)

properly. On the contrary if the gears at the

rear row cannot be engaged properly, unscrew

the nut ① (or nut ⑤), and clockwise rotate

(shorten) the spherical hinge ② (or

spherical hinge ⑥) properly. Carry out the

steps above repeatedly for adjustment until

all gears can be engaged in place.

2）Power takeoff mechanism

With the adoption of rear power takeoff for the

MT86 mining dump truck transmission, the

output rotatory direction and the engine

running direction are consistent. The POT

connects the transmission inner cavity, so it

is unnecessary to add lubricating oil.

The MT86 mining dump truck is applied with the

QH70 power takeoff.

4.4.4 Operation and maintenance

1) PTO

First set the transmission control lever at N,

step on the clutch and close the PTO switch.

When the PTO has gotten the gear engaged,

release the clutch slowly, allowing the PTO to

come into work.

2) Transmission

Operate the transmission reasonably and

properly, and maintain it periodically, which

are very important to ensure a safe and

reliable driving and an extended transmission

life, so please follow the operational

requirements below:

a. Lubricating oil grade

The transmission should be filled with GL-5

gear oil specified in SAE 85W/140.

b. Correct oil level

Make sure that the oil level is up to the sight

glass. The oil level can be inspected through

the sight glass of the housing side and add oil

until it spills out of the mouth.

The reference oil capacity of the 7DS200K

transmission is 23 L.

c. Oil level inspection

The oil level should be inspected periodically,

always with the truck parked on a level road.

Due to the volume expansion of hot oil, in order

to avoid any inaccurate measurement, the truck

shall not be inspected immediately after

driving, but be inspected only with a steady

oil level and an oil temperature close to the

normal temperature.

d. Oiling

In order to prevent the lubricating oils of

different types from chemical reaction, always

replenish with the lubricating oil of the same

type with the original one. It is strongly

recommended to use the lubricating oil

approved by LGMG.

e. Lubricating oil change interval

In replacing the lubricating oil of the

transmission, first completely discharge the

existing lubricating oil in the transmission

and clean the strainer assembly. For the new

transmission, after 2,000~5,000 km running,

the lubricating oil has to be replaced. Inspect

the lubricating oil for its level and leakage

after 10,000 km, replenish when necessary and

clean the strainer. If the limited period

(mileage) of the mandatory maintenance is

exceeded, change the lubricating oil after

driving for 25,000 km.

f. Working temperature

The transmission in its continuous working

period should have a maximum temperature not

more than 120°C, and a minimum temperature not

less than -40°C. A working temperature more

than 120°C may decompose the lubricating oil

and shorten the service life of the

transmission.

g. Dragging or sliding

While the transmission is working, its

countershaft drives the oil pump to run, and

with the splash lubrication, it can be

lubricated completely. However, in the case

that the truck is dragged with the rear wheel

grounded and drivetrain connected, the

auxiliary and primary shaft gears of primary

transmission do not rotate, but the primary

shaft rotates relative to its gear, so does the

planetary mechanism, which may seriously

damage the transmission planetary mechanism

and the primary shaft locating elements due to

lack of lubrication.

To avoid such phenomena, notice that: never

step on the clutch pedal to allow the truck

skidding at natural. To drag the truck, either

pull out the axle shaft or release the drive

shaft, or drag with the driving wheel off the

ground.

! WARNING:

●To avoid personal injury or equipment

fault and damage, please operate the

transmission in accordance with the

specified procedures;

●Before driving, sit in the driver's

seat, set the gearshift lever at N and

pull down the parking brake lever;

●To leave the cab before the truck

starts or while the engine is running,

set the gearshift lever at neutral, and

lock the wheel using parking brake;

●To leave the cab before the truck

starts or while the engine is running,

set the gearshift lever at neutral, and

lock the wheel using parking brake;

●Before starting, in the case that the

truck air pressure does not reach to a

correct level, never let the parking

brake lever go to do gearshift;

●While the transmission is set at

neutral，never slide downhill;

●To operate PTO, step on the clutch

pedal to the limit immediately after the

PTO switch is pressed, and release it

after the PTO works as normal;

●To operate PTO, step on the clutch

pedal to the limit immediately after the

PTO switch is pressed, and release it

after the PTO works as normal.

4.5 Operation and maintenance of front

axle

4.5.1 The front steer axle and intermediate

and rear drive axles

The front axle of the MT86 mining dump truck

Fig 4-15 Front alxe

is a two stage drive axle with “central 1st

stage reducer + wheel planetary reducer”, and

equipped with casting axle housing, bogie

differential and inter-wheel differential as

well as bogie differential lock. An evolvent

S-shaped cam drum brake and external

respiration piston spring brake chamber are

adopted.

4.5.2 Operation and maintenance of front

axle

Fig 4-16 Wheel part

Check if the wheel bolts are loose and the oil leaks

from the wheel rim

1）Operation of front axle

! Warning

● It is prohibited to continue

operating when the axle has failed;

● It is prohibited to disassemble the

truck when the axle has failed;

● It is prohibited to change the axle

Fig 4-17 Front Driving Axle

structure.

Check if connecting bolts between the tie rod and tie

rod arm are loose.

a. Reminder

① It is recommended to replace with

accessories from Lingong Group Jinan Heavy

Machinery Co., Ltd.

② Check and maintain the axle at specified

interval.

b.Precautions for wheel replacement:

● Do not damage threads of the wheel bolts,

and keep the mating surface between the brake

drum and the rim, and the clamping surfaces of

the wheel nuts free from paint, grease and

other dirt; apply grease, oil, or other thread

paste to the threads of the wheel bolts and

wheel nuts before installation.

① Clean the matching surface between the

brake drum and the rim, the outer circle

surface between the rim positioning hole and

the wheel rim reduction shell, and the seal

surface of the wheel nut;

Fig 4-18 Front Driving Axle

② Do not damage threads of the wheel bolts,

1. Camshaft support grease nozzle 2. Regulating

and apply grease, oil, or other thread paste

arm grease nozzle

to the threads of the wheel bolts and wheel nuts

before installation;

③ Tighten the wheel nuts diagonally and

evenly, and after each re-assembling of the

tire, the tire nut must be re-tightened after

50 km of travel.

c.Precautions for operation of brake shoe

friction plate:

● When the vehicle has run for the first

5,000km, check the thickness of the brake shoe

friction plate, which shall not to be less than

8mm. The inspection period thereafter may be

shortened as appropriate to avoid other

serious faults due to excessive wear of the

friction plate;

● The clearance between the brake shoe and the

brake drum shall be kept between 0.7 and 1.2

mm, and the clearance between the upper and

lower drums and shoes shall not be greater than

0.3 mm;

● The axle friction plate must be accessories

from Lingong Group Jinan Heavy Machinery Co.,

Ltd.

2) Maintenance of axle

a. Routine maintenance

① Check if the wheel nuts are loose and fasten

them before the truck running;

② Check the axle for oil leakage before the

truck running; repair it if any leakage;

③ Check the brake performance and brake

return condition. The brake clearance shall be

between 0.7 and 1.2 mm. In case of improper

brake clearance or poor brake return, check and

regulate immediately;

④ Check if the regulating arm and the camshaft

are jammed. If so, refill grease immediately

to ensure that they rotate flexibly;

Refill grease to the grease nozzle of the

master pin, the camshaft support and the

regulating arm every 15 days. If it is

difficult to refill grease, check it

immediately and stop operating.

b. First maintenance

The first maintenance shall be carried out

before 5,000 kilometers (or within 1 month).

The first maintenance items are listed as

follows:

① Refill grease to the grease nozzle of the

master pin, the camshaft support and the

regulating arm as required. If it is difficult

to refill grease, check it immediately and stop

operating;

② Check if the connecting bolts between

components outside the axle are loose and

fasten them;

③ Check and regulate the brake clearance,

which shall be between 0.7mm and 1.2 mm;

c. Periodic maintenance

The periodic maintenance shall be carried out

every 20,000 km or 1 year after the first

maintenance. The periodic maintenance items

are listed as follows:

Repeat the first maintenance items;

Lubricate the brake shoe pin and the brake

roller;

Check the friction plate wear degree. The

thickness of the friction plate shall not be

less than 8mm. Replace it if it is less than

8mm.

! Note: When performing inspection

and maintenance, stop the engine, park

the truck on flat road, apply the parking

brake, and set wedges on both wheels of

any axle to avoid safety accidents.

4.5.3 Operation and maintenance of drive

axle

1) Operation of axle

Fig 4-19 Front Axle Part

1. Lower master pin grease nozzle

! Warning

● It is prohibited to continue

operating when the axle has failed;

● It is prohibited to disassemble the

truck when the axle has failed;

● It is prohibited to change the axle

structure.

Fig 4-20 Front Axle Part

1. Upper master pin grease nozzle

a. Reminder

① It is recommended to replace with

accessories from Lingong Group Jinan Heavy

Machinery Co., Ltd.

② Check and maintain the axle at specified

interval.

b. Precautions for differential lock

operation:

The truck shall be stopped or running at low

speed (less than 10 km/h) when the differential

lock is latched to avoid internal gear damage.

When the differential lock between axles is

latched, the truck shall not run for a long time

on undulate road. The differential lock shall

be released in time after the truck has passed

Fig 4-21 Middle axle

the undulate road; otherwise, the internal

parts of the axle may be damaged or the tyre

may be worn.

c.Precautions for wheel replacement:

● Do not damage threads of the wheel bolts,

and keep the mating surface between the brake

drum and the rim, and the clamping surfaces of

Fig 4-22 rear axle

the wheel nuts free from paint, grease and

other dirt; apply grease, oil, or other thread

paste to the threads of the wheel bolts and

wheel nuts before installation.

● Before mounting the wheel, clean the outer

circle between the wheel rim positioning hole

and the wheel rim reduction shell firstly, and

then apply little grease to it.

● Tighten the wheel nuts diagonally and

evenly, and after each re-assembling of the

tire, the tire nut must be re-tightened after

50 km of travel.

d. Precautions for operation of brake shoe

friction plate:

① When the vehicle has run for the first

5,000km, check the thickness of the brake shoe

friction plate, which shall not to be less than

8mm. The inspection period thereafter may be

shortened as appropriate to avoid other

serious faults due to excessive wear of the

friction plate;

② The clearance between the brake shoe and the

Fig. 4-23 Rear Axle Part

brake drum shall be kept between 0.7 and 1.2

1. Regulating arm grease nozzle

mm, and the clearance between the upper and

lower drums and shoes shall not be greater than

0.3 mm;

③ The friction plate for each axle shall be

special accessories from Lingong Group Jinan

Heavy Machinery Co., Ltd.

2) Maintenance of axle

a. Routine maintenance:

① Check if the wheel nuts and the oil plug are

Fig. 4-24 Intermediate Axle Part

1. Drain hole

loose and fasten them before the truck running;

② Check the axle for oil leakage before the

truck running; repair it if any leakage;

③ Check the brake performance and brake

return condition. The brake clearance shall be

between 0.7 and 1.2 mm. In case of improper

brake clearance or poor brake return, check and

Fig. 4-25 Intermediate Axle Part

1. Oil level sightglass

regulate immediately;

④ Check if the regulating arm and the camshaft

are jammed. If so, refill grease immediately

to ensure that they rotate flexibly;

⑤ Refill grease to the grease nozzle of the

axle every 15 days (as shown in figure). If it

is difficult to refill grease, check it

immediately and stop operating.

b. First maintenance:

① Replacement of grease of drive axle (as

shown in figure above)

Unscrew the drain plug of the axle → drain

grease from the axle → tighten the drain plug

again after the grease has been drained →

unscrew the filler plug of the axle → refill

the grease as required in Table 1 → tighten

the filler plug.

② Refill grease to the grease nozzle as

required. If it is difficult to refill grease,

check it immediately and stop operating;

③ Check if the connecting bolts between

components outside the axle are loose and

fasten them;

④ Check and regulate the brake clearance,

which shall be between 0.7mm and 1.2 mm;

⑤ Remove obstacles from the final drive

reducer vent hole of the middle rear axle

Periodic maintenance:

The periodic maintenance shall be carried out every

10000km

year

after

the

first

maintenance. The periodic maintenance items

are listed as follows:

① Repeat the first maintenance items;

② Replace the hub bearing grease of the front

axle assembly;

③ Lubricate the brake shoe pin and the brake

Fig. 4-26 Intermediate Axle Part

roller;

1. Oil filler, oil level sightglass, oil drain hold

④ Check the friction plate wear degree. The

thickness of the friction plate shall not be

less than 8mm. Replace it if it is less than

8mm.

! Note:

● After maintenance, the user needs to

check the oil level of the grease every

additional 5,000km or two months, and

refill it at any time;

● Mixing of grease of different

qualities is prohibited;

● When performing inspection and

maintenance, stop the engine, park the

truck on flat road, apply the parking

brake, and set wedges on both wheels of

any axle to avoid safety accidents.

4.6 Operation and maintenance of

suspension system

! Warning: It is necessary to replace

the thrust rod repair kit after the truck

has run for 4 months, (20,000km). The

Fig4-27 Front suspension system

user will bear consequences of vehicle

1. Front push rod 2. Front bearing of the leaf spring

failures due to thrust rod out of limit.

installation 3. Cylindrical shock absorber

Caution: It is necessary to replace the

Parallel semiellipse leaf spring 5. Stop block 6. Stop

leaf spring seat wear block after the

block Ⅱ 7. Rear bearing of the leaf spring

installation

truck has run for 4 months (20,000kmM).

! Caution:

1. When the clearance between the guide

cover plate and the leaf spring is ≥3mm,

it is necessary to add adjusting shims to

keep the clearance ≤0.5mm;

2. If the wear extent of the guide cover

plate is ≥ 5mm, it is necessary to

replace it.

! Caution:

1. Re-tighten the thrust rod bolts/front

and rear leaf spring bolts periodically

at the interval specified in "5.2 MT86

mining dump truck compulsory maintenance

details". If the engine has operated for

30 hours during the truck shipment

process, the user shall immediately

perform the first re-inspection of the

thrust rod bolts, and re-tighten bolts

every 500 hours (5,000km) after 4-level

maintenance.

2. Push rod bolt re-tightening table

Tightening

Application

Specification

torque^*(Nm)

Front push

M20

690Nm

rod bolt

Upper/ lower

thrust rod

M27

1000Nm

bolt

Transverse

thrust rod

bolt

(depending

M24

900Nm

on actual

truck

configuration)

4.6.1 Front suspension system

The front suspension system mainly consists of

parallel semiellipse leaf spring, cylindrical

shock absorber, stop block and front push-rod,

Failure Analysis of Shock Absorber

1) Specifications of fasteners

MT86H

Failure mode

Analysis and solution

Application

Tightening

Refill

appropriate

Specification

torque^*(Nm)

grease

and then

Front spring

proceed

with

M24

750±50

U-bolt and nut

operation.

the

Spring bracket

surface is hot, the

fixing bolt and

M18×1.5

373±37

The shock absorber is

grease is insufficient.

nut

out of work, and there

At this moment, refill

Wear-resistant

is no resistance inside

it.

Otherwise, the

M12×1.25

85±8

block fixed screw

(the shell temperature

shock absorber must

Shock absorber

is not high enough)

have failed. Check if

upper bracket

damage to the oil seal

M12×1.25

85±8

fixing bolt and

and

the

sealing

nut

washer causes oil

Shock absorber

leakage. If so, change

connecting

the washer.

M16×1.5

262±26

upper bracket

It is resulted from

bolt and nut

collision

of shock

Shock absorber

absorber,

steel leaf

lower bracket

spring and frame,

M16×1.5

220±22

fixing bolt and

The shock absorber

deformation of shock

nut

makes a noise

absorber dust-proof

Shock absorber

tube or insufficient

connecting lower

grease. Replace the

M16×1.5

262±26

bracket bolt and

shock absorber or

nut

refill grease.

Stop block

bracket fixing

M16

220±22

bolt and nut

Wear-resistant

block fixed bolt

M12

85±8

and nut

* indicates recommended value, and the

permissible tolerance is within 6%. To

ensure driving safety, it is required to

regularly check the tightening torque of

above fasteners.

2) Description of front leaf spring

MT86H: 13 pieces in total, in which four main

leaves, reinforced parallel semiellipse front

leaf spring.

The leaf spring configuration for each model

has already been justified by vehicle

Fig 4-28 Front bearing of front leaf spring

performance test. It is not allowed to make

modification without approval; otherwise it

may lead to the system no longer in harmony with

others or vehicle out of control which would

cause unnecessary personal injury and property

loss.

3) Fault diagnosis

The faults in front suspension system may be

Fig 4-29 Rear bearing of front leaf spring

relating to multiple systems, including

steering gear, front axle, tires, wheels, etc.

When abnormal conditions occur during driving

(such as noise, running deviation, vibration

and abnormal damage), stop the vehicle

immediately and do a thorough inspection to

calibrate the items relating to the following:

a. If pressure of tires is normal;

b. If tires have non-uniform wear;

c. If tires are in unbalanced or damaged;

d. If the fasteners of each bracket are loose;

e. If steering components are worn and loose,

such as tie rod ball;

f. If suspension components are damaged and

loose, such as wear resisting washer between

lifting lug and leaf spring eye or bracket;

g. If front axle and wheel alignment is

correct;

h. If lubrication failure and “oil, water or

air leakage”.

i. If the cylinder type shock absorber is

malfunction（ Shock absorber failure analysis

as shown by the left table ）；

4) Service and maintenance

a. Leaf spring plate and clip should be

replaced in time. These components are prone

to be damaged under overload and severe road

conditions. Once damaged parts are found,

replace or repair them immediately; otherwise

it may lead to major accident.

b. Leaf spring stop bolt should be checked and

lubricated timely so as to ensure normal

operating of suspension system.

c.Bolts, nuts and leaf spring center bolts

should be retightened every 1,500 km according

to relevant torque requirements.

d. Once stop block is damaged or missing,

replace it timely; otherwise it may lead to

excessive jumping of axle which will

accelerate break of leaf spring plate.

e.If the wear extent of the wear block exceeds

50% total thickness or it fall off, replace it

immediately; otherwise, the leaf spring seat

will be damaged, thus influencing the service

life of the seat;

f. If resistance is insufficient or any sound

occurs due to insufficient oil or leakage of

telescopic shock absorber, immediately repair

or replace it; otherwise, comfort of the truck

will be greatly degraded and even serious

accidents may occur;

4.6.2 Rear suspension system

Fig 4-30 Rear suspension system

The rear suspension system mainly consists of

1.transverse thrust rod 2. parallel semiellipse

leaf spring

3.guide plate

4. upper push rod

reinforced integral balance shaft, parallel

5.enhanced maintenance-free balance shaft

semiellipse leaf spring, unilateral 4-M30 bolt,

6.bolt 7. lower push rod

and upper/lower push rod.

1）Specifications of fasteners

* indicates recommended value, and the

permissible tolerance is within 6%. To ensure

driving safety, it is required to regularly check

the tightening torque of above fasteners.

Fig.4-31 Disassembly order

MT86H

Application

Tightening

Spec.

torque*(N.m)

Rear spring

M30

1300±50

bolt and nut

Fig.4-32

Stud bolt and

Malfunction table of rear suspension

M18×1.5

373±37

nut

Fault mode

Solutions

Clean the balance shaft

S op block

bracket fixing

M14

140±14

housing cver and ensure

bolt and nut

good cntact flatness with

Oil leakge due

shaft housing. Replace

Stop block

to sealing

fixing bolt

M12

48±4

the U-ring and do the

failure of

and nut

assembly. Replace the

balance shaft

balance shaft housing

Guide plate

housing cover

cover and assemble it

fixing bolt

M14

140±14

and nut

according to the above

procedures.

Push rod

Replace the bolts, apply

upper bracket

M16

262±26

fixing bolt

thread locker on new

and nut

M16×1.5 bolts

bolts, tighten them to

on both ends

required torque, lock the

of balance

stop washer, and install

shaft getting

the balance shaft housing

2) Description of rear leaf spring

broken

cover. Assemble it

according to the above

MT86H: 15 pieces in total, in which five main

procedures.

Replace the whole set of

pieces, reinforced parallel semiellipse leaf

bearing and adjust the

bearing clearance to

prevent bearing from

breaking again due to

Crack in

local stress of bearing

bearing

caused by axial

transmission of shaft

housing. Assemble it

according to the above

procedures.

spring.

Fault mode

Solutions

The leaf spring configuration for each model

Replace the sealing ring.

For specific procedures,

Oil leakage

has already been justified by vehicle

refer to paragraph a.

due to sealing

Removal, installation and

performance test. Modification without

ring failure

adjustment of balance

approval may lead to major fault and loss.

suspension assembly.

Replace the balance shaft

3) The balanced suspension assembly is rubber

Break in

housing and components

balance shaft

and assemble it

maintenance-free balanced suspension. The

housing

according to the above

disassembly and assembly process is as

procedures.

Crack or break

Replace the shaft &

follows:

in bracket

bracket assembly.

Crack or break

a. Disassembly of the suspension:

Replace the shaft &

in balance

bracket assembly.

shaft

① Unscrew the fastening bolts successively

Crack or break

Replace balance shaft

in balance

and evenly with an air wrench, to separate the

housing and components

shaft housing

bearing block from the balance shaft. (Note:

Check center bolt for

Pieces around

break, and replace it in

The disassembly sequence is as shown in the

leaf spring

time; or check and

left figure. When disassembling the bolts, do

retighten bolt and nut.

not completely unscrew a bolt in one time, but

repeat the unscrewing process for many times,

to prevent the threads from being damaged.)

② Use special tools to clamp the bearing

retainer and push the screw against the block at

the external end face of the balance shaft (to

prevent the screw from damaging the threads of

the balance shaft). Disassemble the bearing

retainer, rubber bearing and balance shaft

casing and other parts as a whole by the torque

of the screw, and separate them from the

balance shaft. The sketch map is as shown in

the left figure.

③ Take the rubber bearing out of the balance

shaft casing from the two ends.

b. Assembly of the suspension:

① Put the rubber bearing into the cleaned

balance shaft casing or a new balance shaft

casing.

② Spray fresh water or 10% suds on the

surface of the balance shaft or inside the rubber

bearing, to reduce the resistance of mounting

the balance shaft casing and rubber bearing into

the balance shaft.

③ Mount the balance shaft casing and rubber

bearing into the balance shaft. It is required to

horizontally move them into the balance shaft

and the balance shaft casing can be properly

rotated, to ensure successful assembly. The

mounting surface of the spring of the balance

shaft casing shall be level after the assembly.

④ Apply gear oil or lube on the surface of the

bolts, to prevent ablation of the bolts during the

fastening.

⑤ After the bolts are fastened, the user can test

100

if the end face of the bearing block cling to the

end face of the balance shaft through the upper

and lower measuring holes, if the depth at the

two measuring holes are the same and if the

depth meets or is close to the theoretic depth

(The theoretic depth is 35±0.1 mm).

! Note: Because of large axial

compression of the rubber bearing (more

than 20 mm) and the features of rubber,

when fastening the bolts with an air

wrench, the user needs to repeat the

fastening for many times. It is

recommended to fasten the bolts

alternately with a torque wrench after

the bolts are fastened to a certain

degree (when the fastening effect of air

wrench is not clear), until the torque of

the 7 bolts all reaches 540-600 N.m.

4) Service and Maintenance

a. Frequently check the following parts: check

upper/lower push rod and the connecting bolts

for damage and looseness. Check stop block for

dropping, leaf spring for break or dislocation

and leaf spring pressure block for crack.

b. Besides handling mandatory maintenance,

retighten the nut of bolt every 1,500-2,000 km

according to specified torque requirements.

101

! CAUTION: Do not change the number

of leaf springs or replace them with ones

of different thickness without approval.

What is more important, do not modify the

suspension structure without

authorization! Do not use unaccepted

components by our company such as push

rod, slide plate seat and guide plate.

The modified or replaced parts may not be

applicable to the suspension of this

model, which would lead to unnecessary

fault and loss.

c. Paint lubricating grease around the leaf

spring and the sliding plate every 8,000 to

10,000km. Use the adjusting shim to adjust the

clearance between guide plate and leaf spring

to be 0~1mm;

d. The normal wear limit life of guide plate and

slide plate seat is half a year. If they are in

serious wear, replace them immediately. If slide

plate seat appears as shown left, it indicates it is

in severe wear.

! CAUTION: The guide plate belongs

to the split type and when it has been

worn down for 5mm, replace it

immediately.

102

4.7 Operation and maintenance of

steering system

The steering system consists of a steering control

system and a hydraulic power steering system. The

steering system consists of a steering wheel, a

steering column, a steering drive axle, a pilot valve, a

vane pump, a hydraulic oil, a steering gear, an oil pipe,

a steel pipe, a steering cylinder, etc., as shown in left

Figure 4-33. In order to adapt to harsh operating

conditions, the hydraulic power steering system

consists of an internal power steering system and a

external power steering system.

Fig 4-33 steering system Structure diagram

1. Steering wheel 2. Steering column and steering

4.7.1 Steering control system

drive axle 3. Pilot valve 4. Vane pump 5. Hydraulic oil

tank 6. Steering gear 7. Oil pipe 8. Return steel pipe 9.

It consists of steering wheel and steering column with

Steering cylinder

adjustable height and angle. The diameter of steering

wheel is Φ480 mm.

As shown in Figure 4-34, the steering wheel 1 is

mainly composed of a rim, a spoke and a hub. The

lower part is in wave shape to facilitate the driver grip.

The steering wheel 1 and the steering drive axle 5 are

generally splined and the ends are fixed with nuts.

The steering drive shaft 5 passes through the steering

column 4 with the lower end connected witn the

steering gear 7, to transmit torque between them, for

which the energy absorption type steering axle is

used.

In addition to the conventional steering function, the

steering control system can effectively absorb impact

energy at collision, and buffer the impact of the

steering wheel to the driver. Basic principle: axial

displacement will occur when the steering drive shaft

is subjected to great impact, and energy is absorbed

by the deformation of the steering column or the

dislocation of the steering drive shaft.

Fig 4-34

Steering control system is of continuous and

1. Steering wheel 2. Nut 3. Washer

adjustable type. With this system, the height range of

4. Steering column5. Steering drive axle

steering wheel is ±25mm, and the angle range is ±5°.

6. Support 7. Steering gear

Specific adjusting method: Unscrew adjusting handle

as shown, adjust steering wheel 1 to appropriate

103

operating position, and tighten the adjusting handle .

4.7.2 Hydraulic power steering system

Full-hydraulic steering gear, pilot valve,

hydraulic oil pump, hydraulic oil tank,

steering cylinder, hydraulic pipeline, etc.

The steering cylinder is φ70.

1) Full-hydraulic steering system

construction (as shown in Figure 4-33)

2) Full-hydraulic steering system principle

The steering pump is a vane pump. The engine

Fig 4-35 Structure Diagram of Steering System

is directly connected with a power takeoff at

Operating Device

1. Steering wheel

2. Steering column

the position of engine power take off, and

3. Steering drive axle

4. Universal joint

keeps running. The steering pump sucks oil from

5. Regulating handle

6. Travel limit screw

the hydraulic oil tank and outputs

high-pressure oil to a pilot valve P opening.

The pilot valve has following 5 openings: P,

EF, CF, and Ls. Excessive hydraulic oil of the

steering system returns to the oil tank via EF

opening. CF opening is connected with

full-hydraulic steering gear P opening to

provide high-pressure oil to the steering gear.

Ls opening is connected with steering gear Ls

opening as a control line. When the steering

wheel drives the steering gear to rotate, the

steering gear Ls opening provides a pressure

signal to the pilot valve Ls opening to enable

104

the pilot valve rod operate. When the pilot

valve P opening is connected with CF opening,

the high-pressure oil flows to the steering

gear, passes through the valve element passage

in the steering gear, to the steering gear L

opening or R opening, and to the steering

cylinder. The big cavity of the left steering

cylinder is connected with the small cavity of

the right steering cylinder, and the small

cavity of the left steering cylinder is

connected with the large cavity of the right

steering cylinder. Both oil cylinders operate

jointly to drive the front wheels. When the

steering wheel moves slowly or does not operate,

most of the hydraulic oil from the steering

pump returns to the tank via the pilot valve

EF opening. The pilot valve T opening is

connected with the oil return opening of the

hydraulic oil tank. The steering gear has

following five oil openings: P, R, L, Ls and

T. P opening and Ls opening are connected with

corresponding openings of the pilot valve and

are not described again herein. When the

steering wheel rotates rightwards, R opening

outputs high pressure. R opening is connected

with the rod cavity of the right steering

cylinder (the rodless cavity of the left

105

steering cylinder). L opening is connected

with the rod cavity of the left steering

cylinder (the rodless cavity of the right

steering). The steering gear T opening is

connected with the oil return opening of the

hydraulic oil tank.

3) Full-hydraulic steering system maintenance

a. Check the oil level in the hydraulic oil tank:

First, clean the oil tank and periphery to

prevent dirt contamination. During inspection,

pay attention to the scale on the oil level

gauge. When engine is running, the hydraulic

oil level is even with the central scale of oil

level gauge; when engine does not work, the

hydraulic oil level will be a little higher

than the central scale.

b. It is required to change hydraulic oil for

a new vehicle after it runs 2500km, and

meanwhile clean the filter element. Change

hydraulic oil every 10000km or every year

thereafter.

c. Check oil level every week, and check the

cleanness of hydraulic oil.

d. The method of oil change is as follows:

① Support front shaft;

② Unscrew oil filling breather filter;

③ Start engine, run it at idle speed for 10s,

106

and turn steering wheel left and right to limit

positions for several times to discharge oil

from the oil tank, booster pump, steering gear

and booster cylinder;

④ Retighten the oil return pipe (note that it

is required to keep it clean and prevent dirt

and foreign material contamination), and clean

oil tank, oil filling breather filter and

filter element. It is preferred to replace it

with a new filter element at every oil change.

⑤ When the oil filter is filled with hydraulic

oil, run the engine at idle speed, turn the

steering wheel left and right for several times,

and at the same time, keep supplementing oil

till the oil level does not lower and is within

the range and no bubble appears.

! CAUTION:

● The machine as delivered uses L-HM32

hydraulic oil. The users can change to

the L-HM46 hydraulic oil. It is strictly

prohibited to use the two oils mixed.

e. During maintenance, it is required to check

the clearance between moving parts, such as tie

rod and drag link joints. If the clearance is

too large, replace parts immediately. It is

also required to add grease to each grease tap

107

5) Common fault causes and troubleshooting methods

Common faults

Causes

Troubleshooting methods

1. Oil in oil tank is insufficient

1. Check oil level of oil tank and refill

2. Air invades into oil passage

it as specified

3. Filter or oil passage is blocked

2. Exhaust and check oil level and

4. Oil pump pressure is insufficient

tightness of pipeline connectors

5. Inner leakage of steering gear is

3. Clean filter or dredge or replace

severe

oil passage

Hard steering

Front

wheels

(braking

4. Maintain oil pump

non-return) are blocked

5. Identify leakage and repair

7. Tire pressure is insufficient

6. Regulate or replace it

8. Steering column interferes with

7. Inflate

universal joint

8. Adjust it

9. Overload

9. Reduce load

1. Check and replace oil seal or O

1. Oil seal or O ring is damaged

ring

Steering gear oil

2. Oil pipe is damaged

2. Check and replace oil pipe

leakage

3. Oil pipe joint leaks oil

3. Replace sealing ring and tighten

4. Oil viscosity is insufficient

connectors

4. Use oil properly

1. Level is too high

1. Adjust it

Oil spillage from oil

2. Oil inlet is blocked

2. Dredge oil passage

tank

3. Oil pump is worn

3. Replace it

1. Tire pressure is insufficient

1. Inflate

2. Air invades into oil passage

Perform maintenance and

3. Oil return hose is twisted and

exhaust

Hard steering reversal

blocked

3. Replace it

4. Steering valve is jammed

4. Regulate or replace steering valve

5. Steering gear is too tight

5. Adjust clearance

6. Connection is loose

6. Check and adjust it

1. Steering valve is asymmetric

Regulate or replace valve

2. Control valve is blocked with dirt

assembly

3. Leakage at both sides of steering

Different left-right

2. Clean control valve

gear differs

steering degree

3. Replace sealing ring

4. Air exists in single cavity

4. Exhaust air

5. Master pins and camber of tires

5. Adjust parameters of truck

at both sides are asymmetric

1. Oil in oil pump is insufficient

1. Maintain oil pump and refill oil

2. Inner leakage of steering gear is

2. Maintain and replace seals

Heavy fast steering

severe

3. Check tightness and connections

3. Air invades into oil passage

and exhaust air

109

Common faults

Causes

Troubleshooting methods

1. Oil pipe is bent

1. Clean or replace it

High oil temperature

2. Oil passage is blocked

2. Dredge oil passage

1. Steering shaft has jammed

1. Check jamming position and

2. Steering valve is asymmetric

check if input axle is subjected to

3. Flow of oil pump is excessive

radial shear

4. Oil is too dirty and steering valve

2. Regulate or replace valve

cannot return immediately

assembly

Run-off

5. Wear or pressure of tires on both

3. Regulate or replace oil pump

sides differs greatly

4. Clean and change oil

6. Bubbles exist in oil and direction

5. Replace tire or inflate

is unstable

6. Check and exhaust air

One front wheel (braking

7. Maintain brake

non-return) is blocked

1. Air invades into oil passage

2. Oil level of oil tank is too low,

and oil pump sucks air

3. Steering system connections are

1. Identify leakage and exhaust air

loose or worn severely

2. Identify leakage, refill oil and

4. Flow of oil pump is too low

exhaust air

5. Steering gear control clearance is

3. Maintain or replace connections

Jitter and drift

large

4. Regulate or replace it

6. Steering gear mounting bolt is

5. Adjust clearance

loose

6. Fasten it

7. Tire pressure is insufficient or

7. Inflate

pressure of tires on both sides

8. Replace it

differ

8. Tire is worn severely or wear is

uneven

1. Air invades into oil passage

2. Oil level of oil tank is too low

1. Check air leakage position and

3. System inlet and outlet pipes are

exhaust air

bent, and oil passage is blocked,

Abnormal sound of

2. Identify leakage and refill oil

etc.

steering

3. Dredge oil passage

4. Displacement of oil pump is

4. Replace oil pump

unstable

5. Remove or replace it

Steering

control

valve

performance is poor

110

4.8 Operation and maintenance of brake

system

4.8.1 Composition of brake system

The brake system of MT86 mining dump truck

mainly consists of two-circuit service brake

(foot brake), auxiliary brake (engine exhaust

Fig 4-38

brake) and emergency/parking brake (hand

1. Brake pedal

brake).

The two-circuit pressure brake is operated

through the pedal. Its working pressure is 0.8

Mpa, and the disconnection pressure of

pressure regulating valve is 0.85 Mpa. The

first circuit acts on wheels of middle and rear

axles, and the second circuit acts on the

Fig 4-39 Brake pressure gauge

wheels of front axle. Once the pressure in one

of air reservoirs of the two circuits is below

0.55 Mpa, the low brake pressure warning

indicator on instrument panel will light up,

and at this moment, it is required to stop the

vehicle immediately and find out the causes of

pressure falling.

Continuously and repeatedly applying full

Fig 4-40 Exhaust brake rocker handle

brake in a short time may also lead to pressure

falling below 0.55 Mpa.

Criteria for pressure inspection: Shut off

engine and apply hand brake. In 2h, the

111

pressure falls by 0.05 Mpa at most or in 30 min,

it falls by 0.01 Mpa at most.

! CAUTION: Do not adjust the release

pressure of pressure regulating valve

without approval.

4.8.2 Engine exhaust brake

Fig 4-41 Exhaust butterfly valve

The MT86 mining dump truck is equipped with the

function of engine exhaust brake. After you

press the exhaust brake switch, the running

vehicle can utilize the energy from engine for

auxiliary brake.

When driving down a long slope, be sure to use

the exhaust brake. In case of running on icy

or muddy road, the use of exhaust brake can

reduce the risk of side slide. In the event of

Fig 4-42 Brake chamber

meeting other vehicles or passing through poor

road, it is better to use the exhaust brake to

accelerate. The use of auxiliary brake can

reduce the times of applying main brake, which

will reduce the wear and heat of wheels and

final drive so as to extend their service life,

reduce fuel consumption and increase driving

safety. After driving down a long slope, simply

check the performance of the exhaust brake.

△! CAUTION: When transmission is in neutral

112

and the clutch is released, the auxiliary brake

will not work. When the speed of engine is lower

than

1,100 r/min, the auxiliary brake will not work.

The exhaust braking efficiency is higher at low

gears.

4.8.3 Emergency and parking brake

The hand brake can be used for emergency

braking and parking brake. It works via the

energy storage spring brake chamber of axle.

Parking brake can be realized by operating the

hand brake valve handle. When brake system is

in failure, relying on the push of energy

storage spring, the emergency braking can be

realized automatically. Only when the pressure

in brake system is above 0.55 Mpa and the

parking brake indicator goes out can spring

braking be released.

Apply: Pull the handle. At the same time, the

parking brake indicator on instrument panel

will light up.

Release: Lift the hand brake valve handle and

loosen it, which will return to release

position automatically. At the same time, the

parking brake indicator on instrument panel

will go out.

113

If braking is activated automatically due to

leakage from air pipe connected to the spring

brake chamber, it is only needed to unscrew the

bolt at the rear end of spring brake chamber

to release position, and the braking will thus

be released (see the figure left).

CAUTION:

● When stopping vehicle, be sure to

pull down the hand brake valve handle!

● Before starting the engine, be sure

to place the hand brake valve at braking

position; otherwise after the engine

starts the parking brake will be released

automatically due to pressure rising in

system.

● Before parking brake indicator goes

out, do not start the vehicle.

● Under certain conditions, the

braking force of parking brake may be

insufficient to park a fully loaded

vehicle on a slope. Therefore, when

parking the vehicle on a slope, wedge the

wheels for safety.

114

4.8.4 Quick joint

The pipes of the vehicle are mainly equipped

with Jietong quick joints so as to make the

tightness of brake system better.

! CAUTION: The removal of pipe joint

without using special tools may lead to

component damage, and the air tightness

will not be guaranteed when it is

refitted.

4.8.5 Operation of inflation joint

Due to the installation of combined air drier,

the pressure regulating valve is integrated

with the air drier, and the inflation joint is

installed at the air drier outlet.

Connect the joint to an inflation hose to

inflate tires and supplement air to air pipes

of the vehicle from outside air source.

4.8.6 Inspection and replacement of dryer

The dryer is able to continuously and

effectively absorb the moisture in the

compressed air, so as to keep the brake system

in good operating status. Drying effects of the

installed air dryer have to be regularly

115

checked.

1) Check method: For the truck equipped with

an air dryer, regularly check accumulated

water in the air reservoir (recommended

monthly). When accumulated water is found in

the air reservoir furthest from the dryer, it

indicates that the desiccant has failed, and

the drying cylinder should be replaced.

2) Replacement method: 1) Unscrew the top nut

of the dryer, remove the old drying cylinder,

clean the connecting bolt and the valve body;

2) uniformly apply one pass of grease onto the

sealing and matching parts between the new

drying cylinder and the valve body, and apply

little thread locker onto the matching part

between the new drying cylinder and the

connecting bolt; 3) Screw the new drying

cylinder onto the valve body to the maximum

torque of 15NM.

4.8.7 Maintenance of brake line

When doing welding, cutting or drilling next

to plastic brake pipe, follow the rules below:

1) Bleed air from pipes at first;

2) Cover pipes against sparks, flame and hot

chips;

3) The non-pressure pipe is allowed to be

116

subject to Max. temperature of 130℃ for 1 h.

4.8.8 Braking operation

To stop the vehicle, follow the steps below:

1) When the vehicle is running, first release

the accelerator pedal to reduce vehicle speed.

2) When the vehicle approaches the stopping

position, slightly depress the brake pedal to

stop the vehicle slowly.

3) When the vehicle is stopped stable, engage

the transmission in neutral and pull down the

parking brake valve handle to make the vehicle

in parking brake state. When applying the brake,

note the following:

1) When applying the brake, except for

emergency conditions, do not quickly depress

the brake pedal hard to the bottom and keep

depressing it, which may cause personal injury

or lead to component damage.

2) Avoid continuously depressing the brake

pedal in a short time and for many times so as

to prevent huge consumption of compressed air

in the air reservoir which will affect the

braking performance of vehicle and lead to the

vehicle out of control further.

3) Do not frequently use the service brake;

otherwise it may lead to brake overheat which

117

will significantly affect brake effect.

4) It is not recommended to use the emergency

brake under non-emergency conditions.

Especially when running on a wet and slippery

road, the vehicle may be at a risk of side slide

if the emergency brake is applied.

5) After the vehicle cleaning or vehicle

passing over deep puddle, water may enter the

brake drum, which will reduce the braking

effect of the vehicle. Under this condition,

run the vehicle at a low speed and gently

depress the brake pedal for several times to

drain water so that the brake can work

normally.

6) When the vehicle is running, if the low

pressure warning indicator of brake system

lights up, it is required to stop the vehicle,

find out the causes and do troubleshooting.

4.8.9 Parking

1) After stopping the vehicle, do not shut the

engine off immediately. Always run the engine

at idle speed for 3~5 min before shutting it

off so that the temperature of engine coolant

can decrease. Especially after the engine runs

at heavy load and the vehicle runs at a high

speed, it is required to run the engine at idle

118

speed before shutting it off; otherwise it may

lead to faults such as cylinder scoring and

supercharger damage.

2) After the engine shuts down, disconnect all

switches, and at last disconnect the master

power switch on the body of battery box.

! Warning:

● Avoid parking the vehicle on a steep

slope. If there is no alternative,

besides applying parking brake, choke

the wheels with wooden wedge. In addition,

engage the transmission in 1st gear when

parking the vehicle on uphill and engage

the transmission in R when parking the

vehicle on downhill.

● After the vehicle runs for some time,

the exhaust pipe is hot, so do not park

the vehicle next to flammable material.

● When having a nap in the vehicle, be

sure to shut the engine off so as to

prevent accident contacting gearshift

lever and pedals which will lead to

accidents.

119

4.8.10 Driving on slopes

1) When driving downhill, effectively utilize

the engine exhaust brake and eddy current

retarder to keep the vehicle speed within a

safe range.

2) When vehicle runs at low gear or goes

downhill, the speed of engine should not exceed

the Max. permissible speed.

3) Before travelling down a steep or long slope,

apply the brake once or more to check if it is

normal.

4) When shifting to a low gear, be sure to

inspect and view the speedometer to determine

vehicle speed and use tachometer to inspect and

view the speed of engine.

5) To reduce wear and heat caused by braking,

before travelling down a steep or long slope,

first reduce vehicle speed, and then select a

lower gear.

6) When driving uphill, if the speed of vehicle

decreases gradually, select a lower gear in

time.

! CAUTION: When driving downhill,

never engage the transmission in Neutral

or shut the engine off.

120

4.8.11 Driving on icy road

1) When driving on icy road, please use tire

chains.

2) Always drive at low speed, and avoid sudden

acceleration.

3) Avoid sudden braking and sharp turning,

otherwise the vehicle may be subject to side

slide and drifting, which will cause

accidents.

4.8.12 Driving on rainy road

1) When driving on rainy road, control the

vehicle speed. It is preferred that the speed

not be higher than 35km/h.

2) When driving in rain, water may enter the

brake drum, which will affect braking effect.

Therefore, slightly depress the brake pedal at

times to check braking effect.

3) Avoid sudden braking and sharp turning,

otherwise the vehicle may be subject to side

slide and drifting, which will cause

accidents.

4.8.13 Driving on foggy days

1) Turn on fog lamps, drive it at a low speed,

and pay attention to road markings and tail

121

4.8.14 Brake line troubleshooting

No.

Causes

Root causes

Troubleshooting methods

Start the truck without stalling until the

barometer indicates 0.85 MPa, make it

stall for 10 minutes. If the pressure drops

by more than 0.15MPa, the pipeline may

System pressure is

leak or the air chamber may be damaged.

insufficient

Check the pipeline and the air chamber. If

the pressure reaches up to 0.85 M,Pa (due

to accuracy of barometer), the air dryer

Service brake

and the four-circuit protection valve may

force is

have failed. Replace them.

insufficient or

When air exists in the brake valve inlet,

brake cannot be

depress the brake valve. If no air is

applied

Brake valve is out of work

exhausted from the air outlet, replace the

brake valve.

If there is no problem with the above

valves, depress the brake pedal. If the

Brake air chamber is

brake air chamber 11 opening is smooth

damaged

but the brake air chamber push rod

cannot be pushed out, replace the brake

air chamber.

Start the truck without stalling until the

barometer indicates 0.85 MPa, make it

stall for 10 minutes. If the pressure drops

by more than 0.15MPa, the pipeline may

System pressure is

leak or the air chamber may be damaged.

insufficient

Check the pipeline and the air chamber. If

the pressure reaches up to 0.85 M,Pa (due

Parking brake

to accuracy of barometer), the air dryer

can not be

and the four-circuit protection valve may

release

have failed. Replace them.

When air exists in the brake valve inlet,

depress the brake valve. If no air is

Brake valve is out of work

exhausted from the air outlet, replace the

brake valve.

When air exists in the relay valve inlet (1

Relay valve is out of work

opening) and the brake valve relay valve

(4) but (2), replace the relay valve.

123

No.

Causes

Root causes

Troubleshooting methods

If there is no problem with the above

valves, depress the brake pedal. If the

Parking

brake

Relay valve is out of work

brake air chamber 11 opening is smooth

can

not

Brake air chamber is

but the brake air chamber push rod

release

damaged

cannot be pushed out, replace the brake

air chamber.

Start the truck without stalling until the

barometer indicates 0.85 MPa, make it

stall for 10 minutes. If the pressure drops

Horn does not

by more than 0.15MPa, the pipeline may

work

and

leak or the air chamber may be damaged.

differential

lock

Check the pipeline and the air chamber.

System

pressure

solenoid

valve

Pressure in 21 opening and 22 opening

insufficient

inlet has no air,

can not be increased, so 23 opening and

causing stalling

24 opening can not inflate. If the pressure

failure

reaches up to 0.85 M,Pa (due to accuracy

of barometer), the air dryer and the

four-circuit protection valve may have

failed. Replace them.

124

4.9 Operation and maintenance of A/C

4.9.1 General

The A/C system consists of radiator, compressor,

integrated condenser, evaporator and fan which are

connected as a closed system with pipes. The radiator

utilizes the engine circulating water as heat source,

the compressor is driven by the engine belt, the

power for fan and compressor magnetic clutch is

supplied by the vehicle, and the condenser is cooled

by water tank fan. The adopted refrigerant is R134a

Fig 4-43 The A/C system

which is of environment-friendly fluorine-free type.

1. evaporator 2. condenser 3. compressor

1) Control panel and display content (as shown left)

The air inlet modes are in a circulation of selection.

The air outlet and defrosting air outlet modes

selection are a circulation of head blow, feet blow,

feet blow & defrosting and defrosting.

2) Main technical parameters (see the table below):

Refrigerating capacity

4200W

Refrigerant

R134

Voltage

D.C 24V

Air output

138cc/r

Power

50W

Belt

GB2 A2，GB3 6PK

groove

Clutch

Pitch

GB2 170，GB3

diameter

125

Fig 4-44

of belt

1. Display

2. Temperature setting

Parallel flow

Core

3（10）Air-conditioning

4. Refrigeration

670×438×16mm

Condenser

5. Air outlet modes selection

6. Auto

7. OFF

Windward

0.29m²

8. Air inlet modes selection

area

9. Defrosting air outlet mode selection

Overlapped

Core

390×205×70mm

Evaporator

Windward

0.08m²

area

3) Description of air conditioning

refrigeration and heating principle

125

Refrigeration: after the refrigerant enters

the pipeline of the refrigeration system, it

is pressurized by the compressor into

refrigerant gas of high-temperature and

high-pressure, and then into liquid state

(actually a vapor-liquid mixture) after being

cooled through the condenser. The liquid

refrigerant is throttled by an expansion valve

in front of the evaporation tank, enters the



evaporation tank in the form of fog, absorbs

the surface temperature of the evaporator core

to make it cool. Heat exchange occurs when the

hot air sucked by the air blower passes through

the evaporation tank, it turns into cold air

and enters the cabin from the air outlet.

Heating: A heater box is arranged in the

Fig 4-45

evaporation tank, which is also referred to as

1. Air grade

2.Air inletwighar 6to

a heat exchanger and is directly connected with

3.Air outlet statewighar 6to wighar 6to

the engine water tank via a water pipe; the cold

4.Setting temperature and ambient temperature

air sucked by the blower turns into hot air when

5. AUTO

6.Defrosting

7. Blowing

passing through the surface of the heat

8.Refrigeration

exchanger by absorbing heat, and enters the

cab.

4.9.2 Operating instructions

1) Set your desirable inside temperature

Adjust the temperature setting key to set your

126

desirable inside temperature. Setting range:

LO, 18℃-29℃ and HI. Generally, temperature

set within 22℃-26℃ is appropriate. If you

want that it is cooler inside, set the

temperature at LO. If you want that it is warmer

inside, set the temperature at HI.

2) Set air volume

Fig 4-46

Generally, the system can adjust the air volume

1.Heater unit

2. Heater unit water inlet pipe

based on your setting temperature. You can also

3. Water valve

4. Engine heater unit water inlet pipe

5. Engine

manually set your desired air volume. Air

volume is classified into 9 classes. When you

press the air volume key, the air volume will

be adjusted gradually.

3) Use of hot air

Fig 4-47

1. Switch On Diagram 2. Switch Off Diagram

! Caution: Please turn off the heater

water valve switch before shut down the

heater unit!

When the temperature is too low, the

temperature of the cab can be increased by

using the hot air function.

The heater unit pipeline connection diagram is

shown in Figure 4-47.

As shown in Figure 4-48, turn on the heater

valve switch, and then the heater unit starts

operating. The temperature rise is controlled

by setting the air volume.

127

3) Night vision function

Switch on clearance lamp power, the key symbols

and other symbols are displayed synchronously.

4) Air outlet mode selection

By pressing the air outlet mode selection key

and defrosting selection key, 4 air outlet

modes can be selected, which are head blow,

feet blow, feet blow & defrosting and

defrosting.

5) Air inlet mode selection

In the following circumstances, internal

recirculation can be used for a short time:

● In hot weather, to quickly reduce the

inside temperature;

● In cold weather, to quickly increase the

inside temperature;

● The worse outside air quality, such as much

dirt and bad smell.

4.9.3 Precautions for operation

1) Regularly do maintenance for A/C system.

2) Wipe panel with a soft dry cloth. Wet cloth

or hard material is prone to damaging the panel,

keys or display screen.

3) Do not use finger, oily material or hard

object to contact display screen, otherwise it

may lead to illegible display, strokes missing

128

or display screen damage.

4) The refrigerant filler is on compressor and

pipes. In case of insufficient refrigerant or

poor refrigeration, please contact

professional personnel to supplement

refrigerant. When refrigerant is insufficient,

white foam can be seen through the observation

window on the upper part of pipe. When

refrigerant is sufficient, what you see is

transparent liquid.

5) When it is confirmed that a fault occurs in

the system, please go to an authorized service

station to have an inspection and repair by

professional service personnel.

6) The A/C intake paper filter core should be

Paper filter core

cleaned and replaced according to specific

operation conditions.

7) In the season that A/C is not used, start

Fig 4-48

the refrigeration system of A/C 2~3 times every

month, 10 min per time. The purpose is to

prevent poor sealing performance of rubber

seal ring and shaft seal of compressor in the

pipes of the system due to lack of oil. Poor

sealing performance will lead to compressor

and other movable components of refrigeration

system getting stuck or rusty.

129

4.9.4 Service and maintenance

Maintenance interval

Maintenance items

Description

Weekly

Monthly

Bimonthly

Quarterly

Yearly

Check the amount of

Amount of

refrigerant through

＋

refrigerant

observation window.

Check leakage with

Refrigerant

halogen leak

＋

leakage

detector.

Check hose for

cracking and

＋

damaging.

A/C unit

Check each joint for

Hose and

leakage and check

pipe

－

clamps for

looseness.

Change drying agent

－

and replace filter.

Change with

Refrigeration

corresponding grade

＋

oil

refrigeration oil.

Check oil leakage

Shaft seal

mark with white

＋

－

paper.

Tighten it with

Belt

tension pulley and

＋

Compressor

check it for wear.

unit

Check bolts for

looseness. Do a fully

inspection and

Bolt overhaul

＋

refitting, if

necessary.

Evaporator

Check it for dirt, and

＋

core

clean it if necessary.

Check if it runs

Fan motor

＋

Evaporator,

normally.

condenser

Condenser

Check it for dirt, and

＋

core

clean it if necessary.

Check if it runs

Fan motor

＋

normally.

130

Maintenance

Maintenance interval

Description

items

Weekly

Monthly

Bimonthly

Quarterly

Yearly

Check clip plug for

Connector

＋

looseness.

Thermistor

Check if it works

＋

switch

normally.

Electrical

Check if it meets

Magnetic

element

specified

＋

clutch

requirements.

Magnetic

Replace it if it

clutch

＋

cannot rotate stably.

bearing

Paper filter

Clean or replace it according to specific

Intake filter

Check it for dirt.

element

conditions.

Note: “+” indicates that adjustment is required and do repair if necessary; “-” indicates that

replacement is required.

4.9.5 Fault diagnosis and troubleshooting list

S/N

Symptom

Probable causes

Solutions

System leaks.

Do leakage detection and repair.

Air return valve is closed.

Open it.

There is a lack of refrigerant.

Add refrigerant.

High pressure is

The air return valve of

low

Replace the valve.

compressor leaks.

The leaf valve of compressor is

Replace it.

damaged.

There is air in the system.

Refill the system with refrigerant.

High pressure is too

The condenser is blocked.

Clean the condenser.

high

The exhaust valve is closed.

Open it.

There is excessive refrigerant.

Discharge the extra.

There is a lack of refrigerant.

Add refrigerant.

The compressor piston is worn.

Repair it.

The compressor cylinder gasket

Replace the cylinder gasket.

leaks.

Low air return

The hose is twisted or squeezed

pressure

Replace the hose.

flat.

The air return valve of

Replace the valve plate.

compressor leaks.

There is moisture in the system.

Replace the air drier.

131

S/N

Symptom

Probable causes

Solutions

The sensing bulb of expansion

Tighten the sensing bulb clamp.

valve is loose.

High air return

There is excessive refrigerant.

Discharge the extra.

pressure

The compressor leaf is damaged.

Replace the leaf.

The compressor cylinder gasket

Replace the cylinder gasket.

leaks.

The drive belt is damaged.

Replace the belt.

The clutch conductor is

Replace the conductor.

damaged.

Compressor does

The compressor piston is

Replace the compressor.

not work.

damaged.

The thermostatic switch is in

Replace the thermostatic switch.

failure.

The clutch coil is damaged.

Replace the coil.

The coil is frozen; the set

Turn the thermostatic switch

temperature is too high.

downward to defrost it.

Close the door from which hot air

Hot air enters cab.

comes.

Poor refrigeration

There is a lack of refrigerant.

Add refrigerant.

effect

The high pressure is too high.

Refer to 2.

The return pressure is too low.

Refer to 3.

The return pressure is too high.

Refer to 4.

The thermostatic switch is in

Replace the thermostatic switch.

failure.

The adjustment of thermostatic

Adjust it to operating condition.

Evaporator coil gets

switch is inappropriate.

frozen.

The volume of air via evaporator

Check evaporator fan.

is insufficient.

The belt pulley is not properly

Adjust the axial position of belt

aligned.

pulley.

The belt is too tight or loose.

Adjust it correctly.

Belt is in failure.

The size and specification of belt

Replace it.

is incorrect.

The idler bearing is damaged.

Replace the bearing.

The fan Fuse is burnt out.

Replace it.

The control switch is in failure.

Replace it.

Fan does not work.

The fan motor is damaged.

Replace it.

The motor voltage is low.

Check conductor.

The fan is in poor contact.

Check and repair it.

132

5.1 Mileage for routine inspection & maintenance interval

Schedule of routine inspection & maintenance interval of mining dump truck

Maintenance

Initial

Routine

1st class

Routine

2nd class

Routine

3rd class

Routine

4th class

level

inspection

maintenance

inspection

maintenance

inspection

maintenance

inspection

maintenance

Engine

operating

100

300

500

800

1000

1200

1500

time (hours)

! CAUTION: Users should carry out the initial inspection immediately after

delivery of the truck provided that the engine has worked for 30 h or more on the

way of shipment.

5.2 Details on mandatory maintenance of MT86H mining off-highway off-highway

dump truck

Period

Material code

Material name

Specification

Unit

Qty

Remarks

100h（The

4110000001390

Oil filter

612630010239

Piece

actual work

5301000010

Diesel engine oil

CF-4 15W/40

ontime,dose

Fuel Coarse Filter

Weichai

4110001117322

1000424916

Piece

not include

Element

WD12.420

transit;time

4190002286

Fuel oil filter

1000442956

Piece

2,000 km）

4110000001390

Oil filter

612630010239

Piece

5301000010

Diesel engine oil

CF-4 15W/40

Weichai

Fuel Coarse Filter

4110001117322

1000424916

Piece

WD12.420

Element

4190002286

Fuel oil filter

1000442956

Piece

Air filter

4110001276

Air filter

1000267954

Piece

assembly

500h

5301000007

Gear oil

GL-5 85W-90

Transmission

（7000 km）

Return oil filter

4120001743

SJX-500×10

Piece

element

Lifting system

4120000634

Air filter element

SJXKL10×0.8-0.5

Piece

Center axle

unilateral

5301000007

Gear oil

SAE85W/90GL-5

45.6

wheel

reducer 6.3L

137

Period

Material code

Material name

Specification

Unit

Qty

Remarks

Rear axle

unilateral

wheel

500h

5301000007

Gear oil

SAE85W/90GL-5

36.6

reducer 6.3L

（7000 km）

Rear axle

main

drive:24L

4110000001390

Oil filter

612630010239

Piece

5301000010

Diesel engine oil

CF-4 15W/40

Weichai

Fuel Coarse Filter

1000h

4110001117322

1000424916

Piece

WD12.420

Element

(12000 km)

4190002286

Fuel oil filter

1000442956

Piece

Air filter

4110001276

Air filter

1000267954

Piece

assembly

4110000001390

Oil filter

612630010239

Piece

5301000010

Diesel engine oil

CF-4 15W/40

Weichai

Fuel Coarse Filter

4110001117322

1000424916

Piece

WD12.420

Element

4190002286

Fuel oil filter

1000442956

Piece

1500h

Air filter

（17000km）

4110001276

Air filter

1000267954

Piece

assembly

5301000010

Diesel engine oil

CF-4 15W/40

2.4

Balance shaft

Return oil filter

4120001743

SJX-500×10

Piece

element

Lifting system

4120000634

Air filter element

SJXKL10×0.8-0.5

Piece

! Note:

1. If it is reached mandatory service requirements before delivery the customer, the

service can be performed at the destination.

2. The grade of the hydraulic oil filled at the factory is L-HM32, which can be changed

to L-HM46 hydraulic oil by users.

138

! CAUTION:

● The oil acts as the primary medium to absorb the dust and other particles when

the oil-bath is working, so the clean waste engine oil or gear oil can be applied.

● Two brands of hydraulic oil can be switched, but must not be mixed!

● Please select the conformed lubricating oil according to the specific ambient

temperature.

● Users should take all consequences caused by the use of the oil products for

maintenance that are not specified by our company.

5.3 Key points of maintenance

5.3.1 Routine maintenance items

1) Check the hand brake and the foot brake.

2) Check working conditions of the illumination system, instrument signal system and various indicators (oil

pressure, air reservoir pressure, air filter maintenance indicator and charge indicator).

3) Check working conditions of the starter and the generator as well as the battery electrolyte level.

4) Check the air pressure and state of tires.

5) Check liquid levels of the engine oil, coolant and traversing mechanism hydraulic oil.

6) Discharge water from the air reservoir.

5.3.2 Cleaning and inspection of transmission system parts

1) Cleaning

The parts surface of each assembly of transmission system might be stuck with dirty oil and sludge,

so cleaning parts is indispensable. The common methods are cleanings with steam, gas, acid

solution or alkaline solution, neutral agent and trichloroethylene as well as magnetic cleaning. In

this process, damage to some parts might occur. Therefore, careful inspection must be done in the

process of cleaning.

a. Metal parts

● Cleaning with gas. Unlike other methods, gas can hardly infiltrate or dissolve sludge. Unless

the surface of parts is precisely refined, wire brush or other tools can be used to clean sludge for

twice.

● Alkalization treatment. If parts are made of alloys, they cannot adopt this treatment. The

alkalization treatment used to clean steel castings and iron castings has better effect.

b. Rubber parts

139

No mineral oil can be used. Use alcohol or one piece of clean cloth to wipe impurities.

c. Rust protection

After cleaning all the waste oil and grease on the part surface, smear one layer of clean oil on the

surface to prevent rust.

2) Inspection

Before cleaning parts, use prepared measuring instrument or tools to inspect. Determine whether

the parts are suitable for reuse according to specified maintenance standards. Damaged parts

require maintenance or replacement. If one piece of matched part is severely damaged, and its

assembly clearance exceeds the prescribed limits, replace this part or the matched part as

required.

In the perspective of preventive maintenance, some parts under repair or within wear limits

should be replaced before they exceed the limits.

All the parts should be carefully inspected by visual observation or infrared inspection. If the

following anomalies are found by visual observation, this part can be repaired or replaced as

required.

! Caution: For all the seal rings, such as O-shape ring, oil seal, seal washer,

once dismounted, they are required to be replaced, and should not be reused.

5.3.2 See the following table for all levels of maintenance items:

Maintenance level

Item

Description

Initial

Routine

1^st class

2^nd

3^rd

4^th class

inspection

maintenance

classmaintenance

maintenance

Change engine oil

●

Replace oil filter

Whenever replacing the engine oil

Check and adjust

●

valve clearances

Replace fuel filter

●

element

Clean or replace

Engine

filter element of

●

coarse fuel filter

Check coolant

volume and add

●

when necessary

Change coolant

Once every six months

Tighten cooling

●

pipeline clamps

140

Maintenance level

Item

Description

Initial

Routine

1^st class

2^nd

3^rd

4^th class

inspection

maintenance

classmaintenance

maintenance

Tighten air intake

pipeline hoses

●

and flange

connecting pieces

Check air filter

maintenance

●

indicators

Clean

dust-collecting

●

cup of air filter

Clean main filter

element of air

Once every 250 hours

Engine

filter

Replace safety

filter element of

Whenever replacing the main filter element

air filter

Check

supercharger

●

bearing clearance

Wire harnesses of

electrical

components and

Once at the interval of 250 hours

electrically

controlled system

Check oil level of

●

Transmission

Replace

transmission

Transmission

●

lubricating oil (at

least every year)

Replace air

●

breather

141

Maintenance level

Item

Description

Initial

Routine

1^st class

2^nd

3^rd

4^th class

inspection

maintenance

classmaintenance

maintenance

Check and adjust

clearances of

taper roller

Whenever doing the 1^st class inspection and the 2^nd class maintenance

Front axle

bearing for wheel

hub

Replace grease

●

for wheel hub

Check oil levels of

main reducer and

●

wheel reducer

Check bogie

Whenever doing the 1^st class inspection and the 2^nd class maintenance

differential

Center axle

Replace

lubricating oil for

main reducer and

●

wheel reducer (at

least every year)

Check oil levels of

main reducer and

●

wheel reducer

Replace

lubricating oil for

main reducer and

●

wheel reducer (at

least every year)

Rear axle

Clean air

●

breathers

Check and adjust

clearances of

taper roller

Whenever doing the 1^st class inspection and the 2^nd class maintenance

bearing for wheel

hub

142

Maintenance level

Item

Description

Initial

Routine

1^st class

2^nd

3^rd

4^th class

inspection

maintenance

classmaintenance

maintenance

Re-tighten

propeller shaft

Once every 100 hours

bolts

Propeller

Visually inspect

shaft

connection and

Once every 100 hours

wearing of

propeller shafts

Check actions of

●

wiper

Re-tighten

locking handle of

●

cab

Re-tighten heat

Cab

dissipation shield

●

of engine

Check oil level of

cab tilting manual

●

oil pump

Check adjustment

●

of lifting cylinder

Check fixation of

●

towing hook

Re-tighten

●

crossbeam bolts

Tighten U-bolts

and brackets of

●

front/rear leaf

springs

Chassis

Check and adjust

clearance of

●

baffles of leaf

spring side

Check fixation of

●

wheel nuts

Check fixation of

●

batteries

143

Maintenance level

Item

Description

Initial

Routine

1^st class

2^nd

3^rd

4^th class

inspection

maintenance

classmaintenance

maintenance

Check fixation of

Chassis

●

fuel tanks

Drain air

●

reservoir

Check tightness

of air pressure

●

system (via

barometer)

Check thickness

of friction lining

and adjust

●

clearance of

brake

Clean wheel

●

brake

Brake system

Check positions

of brake pipelines

and hoses that

●

can be easily

scratched.

Check functions

●

of brake chamber

Check

performance of

foot brake, hand

brake and

●

exhaust brake

(during

commissioning)

144

Maintenance level

Item

Description

Initial

Routine

1^st class

2^nd

3^rd

4^th class

inspection

maintenance

classmaintenance

maintenance

Check retarder

system, in which

indicator shall

operate properly,

connecting pieces

Check before each trip

are connected

firmly, and

appearance is

clean

Check clearance

between retarder

Once every months

Brake system

rotor and stator

Check retarder oil

seal, bearing

lubrication status,

manual switch

Once every months

function, relay

wiring and

contact status

Check axial

movement

Once every months

clearance of

retarder

Check working

conditions of

electrical system

(signal lamp,

●

headlamp, height

lamp, wiper,

HVAC and air

Electrical

breather)

system

Check liquid level

and gravity of

battery

electrolyte as

●

well as voltages

of each battery

unit

145

Maintenance level

Item

Description

Routine

1^st class

2^nd

3^rd

4^th class

Initial inspection

inspection

maintenance

classmaintenance

maintenance

Check fixation of

battery wiring

terminals and

●

apply grease to

Electrical

electrodes

system

Check

correctness of

speed displayed

●

in electronic

tachometer

Replace steering

(20000~25000km)

oil

Check and

adjust front

●

wheel

alignment

Check functions

Steering

of steering

●

system

Check clearance

●

of steering lever

Check bolts,

joints and

●

locking pieces of

steering levers

Check for wear

Once every day

of oil pipe

Check oil level in

hydraulic oil

Once every day

tank and level

meter

Lifting

Check for

system

looseness of oil

cylinder bracket

and top big nut,

Once every day

and clearance of

oil cylinder

bracket

146

Maintenance level

Item

Description

Routine

1^st class

2^nd

3^rd

4^th class

Initial inspection

inspection

maintenance

classmaintenance

maintenance

Check for

inclination of oil

cylinder when

Once every day

lifting it without

load

Check for

looseness of

bracket bolts of

Once every week

oil tank and oil

pump

Check if limit

Lifting

valve operates

Once every week

system

properly

Replace oil

return filter

Once every six months

element and air

filter element

Check lifting

●

angle

Check tightness

●

of gas circuit

Check hydraulic

Once every six months

oil

Short-distance

commissioning

●

(include brake

test)

Complete

truck

Visually inspect

●

leakage

Check fixation of

carriages and

●

tighten them

when necessary

Water pump

●

Lubrication

Clutch pedal

●

shaft

147

Maintenance level

Item

Description

Routine

1^st class

2^nd

3^rd

4^th class

Initial inspection

inspection

maintenance

classmaintenance

maintenance

Clutch release

●

bearing

Clutch fork shaft

●

Universal joint

●

Steering

kingpin, front

●

axle

Leaf spring pin

Once every 10 hours

Inspection of

clearance of

baffles at

Once every 10 hours

balance

Lubrication

suspension leaf

spring side

Lower bracket

of shock

●

absorber

Transmission

●

manipulator

Brake camshaft

●

and brake arm

Towing hook

●

Door hinge of

●

cab

Re-treat the cab

against rust as

Once at the interval of 12 months

planned

148

5.3.3 Selection of oil products

Recommended types and

Type

Amount

Part

standards

Ambient temp.≥-15° CF-4 15W/40

Engine oil

27L

Weichai engine

Ambient temp.＜-15°CF-4 15W/40

Heavy-duty vehicle gear oil (GL-5)

Central axle: 45.6L

85W-90

Rear axle: 36.6L

Axle main drive, bogie

Gear oil

Ambient temp.≥-15° Heavy-duty

differential housing, final

vehicle gear oil (GL-5) 85W-140

drive and transmission

Transmission:23L

Ambient temp.≥-26° Heavy-duty

vehicle gear oil (GL-5) 80W-140

L-HM46 hydraulic oil GB11118.1

Hydraulic

135L

Hydraulic oil tank

L-HM32 hydraulic oil GB11118.1

oil

L-HV32 hydraulic oil GB11118.1

0.5L

Cab tilting system

Ambient temp.≥4°C 0# light diesel

GB252

Ambient temp.≥-5°C -10# light

diesel GB252

Fuel

530L

Fuel tank

Ambient temp.≥-14° -20# light

diesel GB252

Ambient temp.≥-29°C -35# light

diesel GB252

Vehicle brake liquid HZY3 (DOT3)

Brake fluid

1.5L

Brake system

GB12981

Pin shaft at each hinged

Grease

2# or 3# lithium grease GB7324

point of working device

Antifreeze

Antifreeze fluid -35#

50L

Radiator system

fluid

149

5.3.4 Reference table of oil products in China and abroad

1) Engine oil

Grade of

Grade of similar foreign brand oil (ranked as per US SAE)

domestic oil

CALTEX

SHELL

MOBIL

ESSO

Diesel engine oil

RotellaSX 40;

MobilDelvacSuper 130

Essolube XT-3;

CD or higher

Rotella TX 40, 20W/40;

(SAE15W-40) (-15°C～

CALTEX Delo

Essolube XT-2

15W-40 GB11122

Rotella DX 40

50°C)

Gold

MobilDelvacSuper 130

Diesel engine oil

Multigrade

Rotella SX30, 10W/30;

(SAE10W-30)

CD or higher

15W-40

Rotella TX30;

Essolube XT-5

(-20°C-40°C); Delvac 1#

5W-30 GB11122

Rotella DX30

(-40°C or higher)

2) Hydraulic oil

Grade of

Grade of similar foreign brand oil

domestic oil

CALTEX

MOBIL

SHELL

CASTROL

ESSO

Hydraulic oil

RANDO OIL

L-HM46

DTE 24

Tellus 32

Hyspin ZZ 32

Nuto H 32

HD32 RANDO

Hydraulic oil

DTE 25

Tellus 46

Hyspin ZZ 46

Nuto H 46

OIL HD46

L-HM32

3) Gear oil (drive axle oil)

Grade of domestic

Grade of similar foreign brand oil (ranked as per US API, GL-5)

oil

CALTEX

FUCHS

MOBIL

ESSO

SHELL

CALTEX

Heavy-duty

Mobil gear

Spirax EP

Super extreme

Gear oil

vehicle gear oil

Titan Gear

HD80W-90(-20°C-40°C)

Heavyduty

pressure gear oil

(GL-5) 85W-90

LS90

HD85W-90

HD90

90 Thuban GL5

85W-90

GB13895

(-10°C-50°C)

HD80W-90

EP 90

4) Brake liquid

Grade of similar foreign brand oil

Grade of domestic oil

Grade

MOBIL

ESSO

SHELL

Vehicle brake liquid

Super brake

Brake Fluid

SAE

HZY3

liquid

Brake Fluid

Disc-Brake

Donax B

1703C

GB12981

DOT3

fluid

150

6.1 List of bulbs

Name

Type

Power

Qty.

Headlamp (high/low)

24V70W/75W

70W/75W

Front fog lamp

24V70W

70W

Side turn signal lamp

24V1W

Front turn signal lamp

24V1W

Height lamp

24V0.4W

0.4W

Front working lamp and rear

B3H3

24V70W

70W

working lamp of cab

Side working lamps

LED 24V3W

12W

Rear

Turn signal lamp

24V 1W

combination

Brake lamp/tail

24V 1W/0.2W

1W/0.2W

lamp

Reversing lamp

LED 24V3W

27W

Indoor illumination lamp

24V10W

10W

6.2 List of quick-wear parts of electrical system

No.

Code

Name

Qty.

4130000007

Pressure switch YK-M10×1-0.3MPa-K↑

Pressure switch

4130000006

YK-M12×1.5-0.55MPa-B↓

4130000250

Head lamp (right)

4130000249

Head lamp (left)

ELECTRICAL PRESSURE SENSOR

4130000420

LG9130773001

4130000309

Ignition lock assembly - LG751

4130000308

Combination switch

4130000592

Electronic mileage sensor C03054-16

4130000003

Oil pressure sensor

4130000375

Fuse ATS-5A

4130000376

Fuse ATS-10A

4130000377

Fuse ATS-15A

4130000378

Fuse ATS-20A

4130000492

Brake light switch YK209KLA

154