Beruflich Dokumente
Kultur Dokumente
Operation Manual
Note:
This manual is correct at the time of print and may be updated at any time without notice.
While every attempt is made to ensure that the information in this manual is correct, no
liability can be accepted by the authors or publishers for loss, damage or injury caused by
any errors in, or omissions from, the information given.
______________________________________________________________________
i
______________________________________________________________________
ii
2. 2.
If skip bucket needs to be lifted, the axis pin of the safety lock on the rear of skip bucket
must be taken off first, then connect this axis pin between the hole on the connecting
plate and towing boss on the vehicle frame (for safety purpose). Return the position of
axis pin and connecting plate after maintenance.
2. 3.
Stop up the cartwheel to prevent vehicle from moving during maintenance, especially
when maintaining the brake system.
2. 4.
When discharging hot cooling fluid, beware of scald. Keep in mind that the hot engine
cooling fluid has pressure. Wait until the fluid is cool enough then manually unscrew
lids of expansion chamber and radiator.
2. 5.
Maintenance should not be done when the engine is still in operation. If engine
operation is required, beware of all the spinning and scorching parts (fan, belt roller,
rotation axis, exhaust system etc).
2. 6.
Engine should be stopped when maintaining fuel system or effusing fuel. Remove all
the fire resources and rub up spill over fuel. Fuel tank must not be soldered, because
the spark will ignite the fuel steam.
2. 7.
When maintaining the pressure system, before disassembling and loosening the parts,
the pressure must be discharged fully.
2. 8.
Beware of eye protection when using and effusing electrolyte, antifreeze fluid, brake
fluid and fuel.
2. 9.
Stand at the side when pumping the tyre to prevent blast injury.
2. 10. Use rigid pull rod to drag this vehicle. Stand at distance when using rope or steel wire to
drag other vehicles.
______________________________________________________________________
iii
Dress properly when driving. Drivers must know the labels and marks on mine, building
state and road well, as well as traffic rules.
3. 2.
Read the operation manual carefully to understand the capability and working principle
of this vehicle. Acquire the height, width and turning radius of the vehicle for task in
narrow space.
3. 3.
Examine the vehicle according to chapter 2-2 in the operation manual before operation.
No operation allowed if any loss or damage on the parts or insufficient fuel or
unregulated pressure.
3. 4.
Drivers must have driving license. No disqualified person is allowed to drive the vehicle.
No traveling by in outdoor. Beware of the people in the surrounding.
3. 5.
Warning should be given to the nearby personnel when starting the engine and moving
the vehicle.
3. 6.
Avoid driving near a ravine or cliff. Choose the appropriate gear for downgrade. Strictly
prohibit over speed operation of the engine. Drive slowly in dirt or fog condition, and
use headlight or foglight.
3. 7.
Follow the traffic rules. Flash signal when steering. Remember the braking distance
under different speed. When driving at night, use appropriate light and watch the road
signs.
3. 8.
Skip bucket must be fully lowered before traveling to prevent accidents caused by
collision with bridges, culverts or scraped electrical wires.
3. 9.
Make sure the vehicle is not overloaded and the materials does not spill over during
traveling.
3. 10. Park in safe places. Avoid parking on the slope. If need to do so, stop up the vehicle
and use parking brake.
______________________________________________________________________
iv
______________________________________________________________________
v
01
10
16
17
21
23
Chapter 3 Lubrication
29
Chapter 4 Clutch
4.1 Summary And Technical Data
4.2 Clutch Function
4.3 Clutch Structure And Working Principle
4.4 Clutch Usage And Maintenance
4.5 Clutch Regulation And Abrasion Limit
4.6 Clutch Breakdown Analysis And Troubleshooting
34
34
34
36
37
39
Chapter 5 Transmission
5.1 Summary And Technical Data
5.2 Transmission Function
5.3 Transmission Structure And Working Principle
5.4 Transmission Operation And Lubrication Maintenance
5.5 Transmission Breakdown Analysis And Troubleshooting
5.6 Transmission Assembly / Disassembly Technical Requirement
40
42
42
50
51
53
68
68
69
71
71
72
73
74
75
82
82
______________________________________________________________________
vi
83
83
84
86
87
88
90
92
93
100
103
106
110
113
114
122
128
129
132
133
134
137
138
139
140
141
141
142
142
143
______________________________________________________________________
vii
144
144
144
145
148
149
152
153
159
159
162
163
165
173
176
176
______________________________________________________________________
viii
Chapter 1
Technical Specification
1.1 General Technical Specification
Model
Type
Drive mode
Cab
BJZ3364
one side (left) cab,
biaxial dump truck
4X2
one side (left),
upside/downside
separable, full metal
frame
Weight
Load mass
Dry mass (fuel & water inclusive)
Full loaded total mass
Axle gross mass distribution (Front Axle No Load Mass)
Axle gross mass distribution (Front Axle Full Load Mass)
Axle gross mass distribution (Rear Axle No Load Mass)
Axle gross mass distribution (Rear Axle Full Load Mass)
Mass utilization index (Load mass/Dry mass)
Overall Dimension
20000 kg
16000 kg
36000 kg
7750 kg
11000 kg
8250 kg
25000 kg
1.28
Length
7365mm
Width
Height (full load)
2909mm
3110mm
3145mm
Track front
2328mm
2070mm
Ground clearance
385mm
18000mm
Angle of Approach
32
Angle of Departure
42
45 2
6300mm
940mm
3600mm
______________________________________________________________________
Page - 1 - of 178
Cummins
NT-855-C250
6 cylinders in-line
water-cooled 4-stoke
diesel engine
Exhaust turbo
6-140mmx152mm
14L
15:1
186kw (250hp) / 2100
turns/min
1019Nm(104kgForce
meter) /1500 turns/min
2100turns/min/2400tu
rns/min
625turns/min
anti-clockwise
1-5-3-6-2-4
1258kg
1570mm x 925mm x
1246mm
Pressure-feed
lubrication
(2100tunrs/min)241-3
45kpa
No less than 102kpa
Gear pump
Side stream oil filter
CD-15W/40
Closed circulating
water-cooler with
expansion chamber
and water softening
plant
Centrifugal
PT(G)-AFS fuel pump
8 holes
96700kpa
0.178mm
Gear pump
Primary & Secondary
Two plate mechanical
control
______________________________________________________________________
Page - 2 - of 178
9.999pa(75mm
mercury column)
125mm diameter
25volt(accelerating
relay inclusive)
Generator
24volt35amp(voltage
regulator inclusive)
Shockproof rubber
blanket
L1PE14-2DLB
14 inches, double
blades, dry (china
power metallurgy
friction disk inside)
Mechanical pedal
control
Control type
Transmission
Model
BJC-6-154-100
(normal speed
gear)/BJC-6-115
(overdrive gear)
Mechanical in-gear
overdrive gear, 6 D
drives, 1 reverse gear
1128Nm
2300turns/min
154mm
Velocity
ratio for
each
gear
Gear
Reverse
6.44
4.11
2.62
1.62
1.0
0.76
5.92
Velocity ratio
7.42
4.73
3.12
2.0
1.3
1.0
6.84
______________________________________________________________________
Page - 3 - of 178
1005mm x 390mm x
550mm
about 324kg
2 nodes, tubular open,
with needle roller
bearing universal joint
collapsible pipe
Mass
Transmission shaft type
447.5mm
20.5mm
1046mm
+43, -50mm
2 levels transmission,
level 1 is circular-tooth
spiral bevel gear, with
transmission ratio
1.38, level 2 is
cylindrical bevel gear
with transmission ratio
3
1:4.14
2 half-axle straight
bevel gear and 4
planetary cone gear
differential
Full floating wheel
reduction
4 cylindrical planetary
gear reduction
1:3.33
1:13.78
Half-axle
Type
Reduction ratio
Rear axle total speed ratio
Wheel Alignment
Caster angle
0o
9o
0o
0-3mm
Turning hub
Rim
Tyre
______________________________________________________________________
Page - 4 - of 178
Bi-directional
cylindrical fluid shock
absorber, double slide
symmetrical
half-elliptic leaf main
spring and two point
symmetrical rubber
auxiliary spring,
transmission rod
Double slide
symmetrical
half-elliptic leaf main
spring and two point
symmetrical rubber
auxiliary spring,
transmission rod
Rear suspension
GX110C crossover
circulation
Integral booster with
booster cylinder
23.27
Double pipeline brake
shoe chamber
Double gas deflation
spring effect brake
show chamber
750kpa
Bucket type, high
strength steel welding,
possessing exhaust
heat up device
Dumping device
Lifting cylinders
One-way 3 stages
extensible hydraulic
pressure cylinder, two
side symmetric layout,
placed upside down
on the external vehicle
frame
Double and parallel
connected gear pump,
reduction ratio 2.15
(1000turns/min hour)
215L/min
8336kpa
Fuel pump
Nominal flow rate
Rating working pressure
______________________________________________________________________
Page - 5 - of 178
Electrical system
Circuitry connection
Mongline negative
earth
24V
2 in series
6-Q-195
195amphour
Rating voltage
Accumulator pile
Model
Capacity
Others
Front axle
Rear axle
Chassis
Operation Data
Max travel speed (overdrive gear transmission)
Max speed
First gear (overdrive gear transmission)
Second gear (overdrive gear transmission)
Third gear (overdrive gear transmission)
Fourth gear (overdrive gear transmission)
Fifth gear (overdrive gear transmission)
Sixth gear (overdrive gear transmission)
Reverse gear (overdrive gear transmission)
Max climbable gradient
Brake distance (full load, dry flat road, 30km/hour)
Brake distance (no load, dry flat road, 30km/hour)
Turning gradient
Fuel cost (full load road travel)
Cargo lifting time (no load)
Descending time
38km/hour
(50km/hour)
(n=2100turns/min)
5.09km/hour
(5.92km/hour)
7.92km/hour
(9.3km/hour)
12.10km/hour
(14.56km/hour)
18.87km/hour
(23.55km/hour)
29.04km/hour
(38.15km/hour)
38km/hour
(50.19km/hour)
5.52km/hour
(6.44km/hour)
29%
No longer than 14m
No longer than 8m
>16%
72L/100km
20sec
20sec
______________________________________________________________________
Page - 6 - of 178
______________________________________________________________________
Page - 7 - of 178
______________________________________________________________________
Page - 8 - of 178
______________________________________________________________________
Page - 9 - of 178
Chapter 2
Normal Use and Maintenance
2.1 CONTROL SYSTEM AND NAVIGATIONAL PANEL
2.1.1 Control System Location (See Figure 5)
Gearlever is at right side of the driver seat. Step on two feet clutch to switch gear. Using
first gear to start when with heavy load, second gear with no load, when speed up or speed
down, do not switch gear with more than one level. Gearlevers of transmission case with
overdrive gear and with normal gear have different position at fifth gear and sixth gear. See
Figure 6 and 7.
______________________________________________________________________
Page - 10 - of 178
______________________________________________________________________
Page - 12 - of 178
01 Ampere meter
02 Two-pointer barometer
03 Fuel meter
04 Oil pressure meter
05 Speedometer
06 Signal indicator
07 Tachometer
08 Hazard light switch
09 Fan switch
10 Lift switch
11 Headlight switch
12 Working light switch
13 Handbrake switch
14 Dipped headlight switch
15 Front foglight switch
16 Width indicator switch
17 Lift valve
18 Ignition switch
19 Engine hour meter
20 Fuse case
21 Water temperature gauge
22 Engine Cutoff switch
23 Start button
24 Socket for external light
______________________________________________________________________
Page - 13 - of 178
As shown above, two 6-join seesaw switches have blank covers at first two positions.
Driver can use seesaw switches when in need. Meanwhile the indicator will be on.
This is followed by hazard light switch, fan switch, lift switch, head light switch, width
indicator switch, front foglight switch, dipped headlight switch and working light switch.
Combinational switches are used for turning left/right indicator, far/near light switching,
horn and wiper.
______________________________________________________________________
Page - 14 - of 178
______________________________________________________________________
Page - 15 - of 178
______________________________________________________________________
Page - 16 - of 178
2nd
6.5-6.7
7.5-7.7
3rd
4th
5th
6th
______________________________________________________________________
Page - 19 - of 178
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Clean all the paths for lubricants and all the filters including: air filter, engine first
and secondary filter, filter for fuel tank, filter for turning oilcan and filter for lifting
fluid pressure fuel.
Replace all the lubricants and engine machine oil, secondary filter and filter core
for air filter.
Measure the pressure of engine air cylinder. The pressure of each cylinder should
be no less than 3550kpa when 600 turns/min. The pressure difference of each
cylinder should be no larger than 175kpa.
Following the rule center first, then around, fasten the bolts of air cylinder shell
2-3 times. Screw down moment is 235-251Nm.
For normal diesel engines iron cast cylinder shell, first warm-up, then check the
tightness of air cylinder shells bolts to prevent bad sealing condition of cylinder
shell due to thermal expansion of the bolts. This bad sealing condition will lead to
damage of liner of air cylinder shell.
Fasten the exposed related bolts (refer to maintenance in the run), eliminate their
looseness and undesired clearance.
Check efficiency of brake system, adjust brake drum clearance to 0.3-0.5mm,
eliminate gas leak of brake pipelines.
Check and adjust clutch pedal free play.
Check and adjust the technical condition of front axle assemblys turning device
Check and adjust front tyre toe (5-7)mm.
Check and adjust the steering drag link and steering tie rod, eliminate any possible
clearance in between.
Fasten related bolts and nuts of the turning system.
Check and adjust fans, elasticity of engine belt.
Check the fastness of tie-ins in the accumulator and electric circuits.
______________________________________________________________________
Page - 20 - of 178
Good
Moderate
Bad
Hard, smooth
Smooth
Large
Middle
>3miles
Tiny
No
Normal
Normal
6-8hours
<18tons
Moderate
Few
Continuous
Very experienced
Good
Few
Moderate
Normal
Normal
12-16hours
18-20tons
Moderate
Normal
Continuous
Experienced
Normal
High
Many
High
High/low
18-24hours
20tons
Bad
Too many
Discontinuous
Less experienced
Bad
Regulations on the maintenance of the vehicle are built on Moderate condition. If the real
situation differs, then the regulations differ too.
Purpose of maintenance: slow down the wear and tear of the parts, prevent accidents,
lengthen lifespan of the vehicle.
Three categories for maintenance:
A. Duty Visit Maintenance
This is further classified into 2 categories:
1. Daily checks. Normally once in a day and night time.
2. Duty visit within 400 hours. It is divided into intervals of 50, 100, 200, 400 hours.
______________________________________________________________________
Page - 23 - of 178
______________________________________________________________________
Page - 25 - of 178
______________________________________________________________________
Page - 26 - of 178
D. Lining assembly
1. Metal lining for adjusting purpose and gasket surface should be smooth. Use
oiled cloth to clean it before assembly.
2. Dip the paper gasket for sealing into clean engine lubricant or gelatinize and lead
oil before assembly.
E. Screw Thread Connection
1. During assembly, beware of any drop of spring gasket, uncork pin or other
locking or stopping accessories. Replace them if damaged.
2. When using steel wire for lock up, tighten the wire according to the regulations to
guarantee the lock-stop function.
3. At the joint surface of multi bolts, except for special situation, the bolts should be
tightened in decussation (do not screw one bolt to the regulated torque at one
time).
4. Keep the screw thread clean, clean the oil and mud. Avoid massy button of nuts
with large diameter. Use file to repair if there is damage on screw thread.
______________________________________________________________________
Page - 28 - of 178
Chapter 3
Lubrication
Lubricating the vehicle correctly can greatly reduce the wear and tear of the parts and
vehicles frictional resistance.
Clean the lubricating parts before lubrication to avoid mixture of lubricants and dirt.
When replace assembly machine oil, wait till the vehicle to stop and the temperature of
assembly is not cooled down yet, so that all the dispose oil and dirt will be discharged.
Clean the lubricating nozzle before applying the lubricants, grease gun should be open up
and clean in the coal oil once in a while.
After lubrication, rub out the spilled lubricants on the parts to avoid deposit of dirt on the
parts.
BJZ3364 Dump Truck uses specified lubricants (refer to table 1). Table 2 provided the
recommended periods for replacement of lubricants and washing for engine and chassis.
In different mine areas, roads or working condition, please refer to this table according to
the local situation and decide the replacement period of the lubricants.
Table 1 - Dump Truck oil specifications, parts, capacity and period for washing and
replacement
#
Parts
Fuel tank
Engine
machine oil
chassis
Water tank
3
4
5
6
7
8
9
Turning
hydraulic
oil tank
Transmissi
on
Rear axle
main
reducer
Rear tyre
planetary
reducer
Lifting oil
tank
Pole type
shock
absorber
Capacity (litre)
BJZ3
361
200
BJZ3
363
200
BJZ3
364
200
17
23.7
2326
50
50
52
10
10
17
Specification
Interval
(hours)
Replacement
period
Daily
Every 1500
hours
Every 200
hours
Daily
10
17
17
Every 100
14
14
14
Every 100
95
95
95
1.2
1.2
1.2
Daily
Every 800
hours
Every 100
Every 400
hours
Every 100
Every 800
hours
Every 800
hours
Every 800
hours
Every 4500
hours
Every 4500
hours
______________________________________________________________________
Page - 29 - of 178
Quantity
Time table
Every 50
hours
Diesel oil
filter core
Engine
machine oil
filter core
Air filter filter
core
Primary1
Secondary1
Primary1
Socondary1
Power
turning filter
core
Lifting oil filter
web
Inner1
Outer1
Every 100
hours
Wash
Wash
Every 200
hours
Wash
Wash
Replace
Replace
Wash
Wash
Every 400
hours
Replace
Replace
Every 800
hours
Replace
outer filter
core
Replace
Replace
inner filter
core
Wash
Location
#
points
Lubricant
specification
Fan belt
shaft
Accelerator pedal
shaft
Cab door
ream
shaft
Clutch
and
brake
pedal
shaft
Clutch
fork shaft
#3 lithium
SY1412-75
#1 or #2
calcium
sodium
SY1403-77
Same as
above
Clutch
main
detached
shaft
Steering
tie rod
and
steering
drag link
reamer
Front
transmiss
ion shaft
and
gimbal
3
4
5
6
Every
50
hours
Every
100
hours
Every
200
hours
Every
400
hours
Every
800
hours
Every
1500
hours
Same as
above
Same as
above
2
3
#2 lithium
SY1412-75
#1 or #3
calcium
sodium
SY1043-77
Same as
above
______________________________________________________________________
Page - 30 - of 178
Location
#
points
Lubricant
specification
Rear
transmiss
ion shaft
and
gimbal
Front
axle main
pin
Front
board
spring
front pin
Front
board
spring
rear pin
Rear
board
spring
rear pin
Push
lever
shaft pin
Front
brake
shoe
shaft pin
Front
brake
lobe pin
Rear
brake
shoe
shaft pin
Rear
brake
lobe pin
Lifting
cylinder
up down
bearing
Carriage
shaft
bearing
Front tyre
hub
bearing
Rear
tyre hub
bearing
Same as
above
Same as
above
Same as
above
Same as
above
Same as
above
Same as
above
Same as
above
Same as
above
Same as
above
Same as
above
Same as
above
Same as
above
#2 lithium
SY1412-75
#1 or #3
calcium
sodium
SY1403-77
#10 machine
oil
GB443-64
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Engine
bearing
Every
50
hours
Every
100
hours
Every
200
hours
Every
400
hours
Every
800
hours
Every
1500
hours
______________________________________________________________________
Page - 31 - of 178
Location
24
Steel
plate
spring
25
Front
rear
brake
room
Accumul
ator polar
stack
26
#
points
Lubricant
specification
Every
50
hours
Every
100
hours
Plumbaginous
calcium
between reeds
SY1405-65
Industrial
Vaseline
SY1607-77
Every
200
hours
Every
400
hours
Every
800
hours
Every
1500
hours
Wash
wash
Same as
above
PS: Lubrication
______________________________________________________________________
Page - 32 - of 178
______________________________________________________________________
Page - 33 - of 178
Chapter 4
Clutch
4.1 SUMMARY AND TECHNICAL DATA
4.1.1Technical Data
Type-14 inches double blade
Control mode-Mechanical feet pedal control (clearance between separating lever
and separating bearing is 3mm, peak load of separating bearing is
2667N).
Pedal freedom path - 25-34mm
Pedal force - No larger than 240N
4.2 CLUTCH FUNCTION
4.2.1Clutch Function
Clutch is a composing part of vehicle transmission system, transmission system connects
to engine through clutch. Clutchs function is to transmit and cut power to ensure:
1. When launching, connect engine and transmission system smoothly for a steady
launch.
2. When shifting gear, separate engine and transmission system completely to
reduce the impact between transmission gears.
3. When taking too much load during work, protect transmission system by skidding
clutch, avoid damage of parts due to overload.
4.3 CLUTCH STRUCTURE AND WORKING PRINCIPLE
4.3.1 Clutch Structure
This vehicle uses double blade dry friction clutch, refer to Fig 04-3-1 for its structure. It
consist of initiative platen, middle platen, driven plate with friction flake, 3 separating
levers, 15 impact springs, separating fork, orientation sleeve and separating bearing etc.
Clutchs initiative platen and middle platen are castiron, driven plate is made of steel flake
and by riveting it connects to spline firm with inner spline, also by riveting the two sides of
steel flake are symmetrically connect to powder metallurgy friction blade.
Driven plate is assembled on spline of clutch principal axis and movable along the spline.
Pressure of initiative platen is produced by 15 compressed springs around it.
Clutchs separating lever is assembled to clutch shell through ball bearing of its pivot. Its
one end connects to platen by circular pin, the other end touches the separating bearing.
______________________________________________________________________
Page - 34 - of 178
9 Separating bearing
10 Clutch shaft
11 Separating fork
12 Oil nozzle
13 Clutch shell
14 Vitta assembly
15 Ventilation window lid
______________________________________________________________________
Page - 35 - of 178
Lubricating position
Nozzle in the middle
below clutch shell, inject
to principle axis
Nozzle at up right
position of clutch shell,
inject into separating
bearing
Inject into 3 nozzles at
separating fork shaft
14
1
2
3
Interval
Every 50 hours
Every 100 hours
______________________________________________________________________
Page - 37 - of 178
______________________________________________________________________
Page - 38 - of 178
Problem
Skidding of clutch
Phenomenon: when
need to speed up, its
speed does not increase
as engine turning speed
increases
Analysis
Troubleshoot
1. Clutch spring pressure is Replace clutch spring
weakened or softened
due to oversliding or
overheating
2. Oil dirt or heavy corrosion Find out the source of dirt
on friction flake surface
and use machine oil to
wash. Or replace
3. Clutchs pedal freedom
Adjust accordingly
path is too small
4. Wear and tear of friction
Replace
flake
1. Pedal freedom path is too Adjust to 25-34m
large
2. Inconsistent height of 3
Adjust the regulating nuts on
separating lever
separating bolts to make
separating levers small end
in the same plane,
difference in level is
+0.15
0.10 mm
3. Driven plate is warp
Adjust or replace
4. Middle platen is out of
Abrading. If after abrading
shape
the dimension differs too
much, replace
5. Wear and tear in
Replace
separating shaft sleeve or
stick onto position sleeve
1. Wear and tear and
Disassemble clutch to
collision of accessories
check, replace when
due to long time use
necessary
2. Lack of grease on
Add grease
separating bearing or
separating fork shaft
3. Wear and tear of driven
If spline cooperated
plate spline and spline
clearance exceeds 0.35mm,
shaft, not working
carry out a heavy repair
normally
______________________________________________________________________
Page - 39 - of 178
Chapter 5
Transmission
5.1 SUMMARY AND TECHNICAL DATA
5.1.1 Summary
Transmission device consists of transmission assembly, dragging system, distant control
system and gear oil pump control pump. Refer to Figure 15 for assembly of transmission
onto the vehicle. Front dragging beam assembly is connected and fastened with 6 bolts of
transmission front shell, then connected to vehicle frame through dragging system.
The rear end connects to vehicle frame by ream connection. The 3 points are all
semi-elastic connection. In order to lower the rear axle transmission shafts angle and
improve the transmission efficiency, incline the transmission assembly by 28 to the
upper plane of vehicle frame, with front end higher and rear end lower.
For easier checking and repair of transmission assembly, a middle transmission shaft
assembly is installed in between engine and transmission, at the same time change the
transmission control mode to distant lever turning handle.
Transmission assembly has two speed ratio in order to adapt for different speed
requirements, one is standard mode, the other is overdrive mode. Both have the same
structure. Switching between the two modes just requires changing of some gears and the
accessories for two modes can be used for assembly for both.
5.1.2 Technical Data
Technical data Standard mode
Overdrive mode
Model
BJC-154-100
BJC6-154-115
Max allowable 980.6 Nm
1127.7Nm
torque input
2300rpm
2300rpm
Max allowable
rotation speed 154mm
154mm
input
1005mm*390mm*550mm
1005mm*390mm*550mm
Transmission
About 324kg
About 324kg
center
distance
Outline
dimension
Transmission
weight
1
2
3
4
5
6
R
1
2
3
4
5
6
R
Each
gear
gear
Speed 7.42 4.73 3.12 2.0 1.3 1.0 6.84 6.44 4.1 2.62 4.62 4.0 0.76 5.92
Speed ratio
ratio
______________________________________________________________________
Page - 40 - of 178
______________________________________________________________________
Page - 41 - of 178
In order to enhance the rigidity of middle axis, a 92215 bearing is added to the
middle axis, with 92312 bearing installed on the two ends. To simplify power output
device, a lifting oil pump connecting axis 26 with power output meshing 27 is
installed on the rear end of middle axis.
2. Control mechanism consists of 3 parts: detaching fork gear shifting mechanism,
gear switching control mechanism and control device. The above 3 parts switch
gear through gear shifting handle and control pipe subassembly and other linkage
mechanism and moving gear shifting control axis 37 dialing gear shifting mode, so
that driven gear shifting fork will dial axis twos teeth cover to switch gear.
To prevent gear disorder and automatic gear drop, positioning spring, steel ball and
lockpin are separately installed in the middle of dial fork mechanism bracket 39s
gear shifting fork axis 8, to form a mutual lock self lock device.
A reverse gear position restriction spring 42 is installed on gear shifting control axis,
so that when gear shifting handle is at neutral gear, it will stay at 3rd and 4th gear,
and make the driver easier to choose gear according to the road condition. The
control mechanism is a connecting mechanism which enables distant gear shifting
control of transmission, it will provide the driver with handy gear shifting.
3. Basic accessories are: shell body, front shell, rear shell and upper shell. They are
fixed together by bolts and nuts with different specification. There are gaskets in
between each connecting plane, and they are sealed by leak proof glue to prevent
leakage of splashing gear lubricants from connecting plane.
Magnetic oil drain plug 31 is installed on the bottom of shell body, it will adsorb
metal powder in the oil. Dipstick screw plug 49 is installed on the side of shell body,
it is the indicator of transmission oil height.
When changing oil, the redundant gear lubricants will overflow from here. Ventilate
cap 43 is installed on transmissions upper shell. It enable contact between the
inside of shell body and atmosphere, to prevent heat produced from mechanical
transmission waste, raising of temperature of oil, gas expansion and oil leakage
from spoiling oil seal edge jaw.
Odograph output axis is installed on the side of rear shell, it can record vehicle
speed and mileage when connecting with odograph soft axis or electric sensor. Oil
pump connecting dialing fork axis arm is installed on the bottom of rear shell. It
connects with gear oil pump control pump and dumping can be fulfilled by gas
control. Then whole transmission structure is reasonable and compactable, and it
is easy to disassemble and maintain.
______________________________________________________________________
Page - 43 - of 178
43 Ventilating cap
44 Reverse gear limit tube
45 Reverse gear bearings blocking
cover
46 Reverse gears gear
47 Reverse gears gear blocking
cover
48 Reverse gear axle
49 Oil meter plug
th
th
rd
th
st
1 2
nd
Axis Two
Axis One
Axis Two Flange
______________________________________________________________________
Page - 47 - of 178
______________________________________________________________________
Page - 48 - of 178
______________________________________________________________________
Page - 49 - of 178
______________________________________________________________________
Page - 51 - of 178
P=/4d 7.5kgN/cm 9.8 (P=/44 9.87.5 920N), at this time dial fork
axis root maximum torque M=PO.075=920O.075 69 Nm, it is too large a
torque for dial fork axis root and therefore twist-off happens.
______________________________________________________________________
Page - 52 - of 178
Run-in time
500rpm
1400rpm
1800rpm
2300rpm
Total
8 min
16 min
11 min
7 min
42 min
6th
7th
3min 2min
3min
3min
9min 2min
2. Gear shifting should be flexible. There should not be any abnormal knocking
sound during operation.
3. Temperature of each main bearing must not exceed 80 C.
4. Transmission appearance should be clean. There should not be any leakage at
each connecting plane, oil seal edge and oil plug.
______________________________________________________________________
Page - 53 - of 178
Specification
M14120
M1250
M1255
59Nm
196Nm
39Nm
M1245
59Nm
M1065
M10110
147Nm
40Nm
30Nm
40Nm
30Nm
M1015
30Nm
______________________________________________________________________
Page - 54 - of 178
+ 0.4 To 0.5mm
Output End
Input End
( 91.36-0.175/7 )
-0.11
( 71.08-0.210 /6 )
-0.11
( 70.95-0.175/6 )
-0.11
-0.125
-0.11
______________________________________________________________________
Page - 55 - of 178
-0.11
( 48.10-0.175/3 )
-0.09
______________________________________________________________________
Page - 56 - of 178
42208 Bearing
4 To 4.5mm
______________________________________________________________________
Page - 57 - of 178
To
To
To
Output End
Input End
(65.55-0.175/1)
-0.11
(55.89-0.175/4)
-0.09
(32.3-0.148/3)
-0.11
-0.11
-0.09
20. Clean the burrs and dirt on joint plane when closing bearing shell. Take note that
the matching parts are not interchangeable.
21. When assembling axis two and bearing cover, control the distance between axis
twos front end and shell bodys power input end to be 79.12-81.33. With 392-785
Nm torque, tighten the flange nuts and release two M142 bolts, so that the strain
pull produced on bearing cover can be eliminated. Then with 137-167 Nm torque
uniformly tighten the bolt and then lock onto bearing cover with3 lead wire to
prevent looseness and jumping of bearing cover, which will lead to smash of shell
body, bearing cover, dial fork frame support and gear shifting fork.
+0.01
______________________________________________________________________
Page - 60 - of 178
To
50.13-0.148/4
5. Minimum distance between axis one joint teeth end surface and axis two 5th gear
teeth hub end surface is 1.7mm.
6. 92314 bearing.
7. Oil blocking ring is installed inside front end to raise oil level and lubricate 42308
bearing.
8. M33x15 axis one flange lock nut tighten torque is 343 Nm, then tighten spherical
cylindrical bolt.
______________________________________________________________________
Page - 61 - of 178
______________________________________________________________________
Page - 62 - of 178
A-A Section
______________________________________________________________________
Page - 64 - of 178
______________________________________________________________________
Page - 65 - of 178
Furcation Nut
______________________________________________________________________
Page - 66 - of 178
Control Pump
Assembly
Dial Block
Mesh Cover
Chapter 6
Transmission Shaft
6.1 SUMMARY AND TECHNICAL DATA
6.1.1 Technical Data
6.1.1.1 Middle Transmission Shaft Belt Gimbal Assembly
Sustain working torque
Spline specification
Gimbal cross axis assembly dimension
Installation dimension
Maximum stretching length
Maximum shortening length
- 1020Nm
- 10-50386
- 5O135
- 447.7mm
- 20.5mm
- 20.5mm
- 6570Nm
- 16-60745
- 8910
- 1046mm
- +43mm
- -55mm
______________________________________________________________________
Page - 68 - of 178
______________________________________________________________________
Page - 69 - of 178
6.5.1Lubrication
Serial
number
1
2
3
Lubrication location
Interval
Every 50 hours
Note: do not
add too much
butter
6.5.2 Check-up
After the first 50 hours, check if joint flanges fixed bolt is loose for every 400 hours.
______________________________________________________________________
Page - 71 - of 178
Malfunctions
Joint plane abrased
Causes
Loose bolts, surface phase
movement
Transformation of
transmission shaft tube
Troubleshoot
Wipe clean using sand paper
and repair the joint surface
using file, restore it and tighten
the bolt.
Find the balance or replace
the tube
Find the balance
Replace oil injector or clean
the jam
Clearance should be
0.015-0.14mm as required
______________________________________________________________________
Page - 72 - of 178
Chapter 7
Rear Axis
7.1 SUMMARY AND TECHNICAL DATA
Rear axis consists of:
A. Rear axis casing belt half bearing tube assembly
B. Rear axis main reducer assembly
C. Rear axis differential assembly
D. Rear wheel planetary reducer assembly
Refer to Figure 38 for configuration.
7.2 FUNCTION
Rear axis is the last assembly in vehicle transmission system. Its basic function is to
transmit the input power from transmission to rear axis. The power from transmission into
rear axis is first transmitted to main reducer, by main reducer the torque is magnified,
meanwhile rotation speed is reduced relatively.
The rotation axis line is changed by 90. Power is distributed to left and right half axis
through differential, then to the planetary reducer inside the wheel. When power passes
through rear wheel planetary reducer, its torque is again magnified, meanwhile the
rotation speed is again reduced relatively.
Power is transmitted to left and right wheel through wheel hub. On the other hand, rear
axis has to bear with the weight of rear parts of vehicle. When vehicle is not running on
smooth road or when the vehicle is turning, left and right wheel can rotate with different
rotation speed. Meanwhile driving power and counterforce is transmitted to vehicle frame
through torque.
______________________________________________________________________
Page - 74 - of 178
Figure 40
Figure 41
Figure 42
2 - 7mm
0.8 ~ 1.6mm
______________________________________________________________________
Page - 78 - of 178
Differential is a simple symmetrical straight teeth cone type. It consists of half axis gear,
planetary gear, cross axis, differential shell and gasket slice. Cross axis is separating type.
There is a spline hole in the middle of half axis gear, and it is connected to half axis
involute spline respectively.
When vehicle is running on a smooth and straight road, the resistance on the two wheel
are almost the same, and the rotation speeds are the same, differential inner planetary
gear and half axis gear are rotated by differential shell led by driven cylindrical bevel wheel,
and so drive the vehicle.
When vehicle is turning, resistances on inner and outer wheels are different, and the paths
they go through are with different distances. Two half axis gear produce relative rotation
speed difference though planetary gears rotation to complete the speed difference effect
when turning.
______________________________________________________________________
Page - 79 - of 178
______________________________________________________________________
Page - 80 - of 178
______________________________________________________________________
Page - 81 - of 178
Causes
1. Abrasion of bearing
2. Bad lubrication
Discontinuous noise
Periodic noise
When accelerating or
decelerating
silvery
knock can be heard
Troubleshoot
1. Check or replace
bearing
2. Check oil level make
sure it is sufficient
3. Replace worn gear
4. Re-adjust
1. Re-adjust
2. Check and adjust or
replace
3. Re-adjust
4. Install correctly so it
is parallel
1. Check or replace
2. Change abraded
gears
3. Re-adjust
1. Check or replace
2. Re-adjust
Chapter 8
Front Axle
8.1 SUMMARY AND TECHNICAL DATA
Front axis mainly consists of front axis, knuckle seat, knuckle pin, knuckle axis, turning
straight puller and turning transverse puller. Refer to Figure 47 for the configuration.
Front axis is sub-welding parts of two front axis head 18 and front axis tube 1. Knuckle
seat 9 is in connection with knuckle axis 10 by bolts. Knuckle pin 7 is locked tightly on front
axis head by knuckle pin cork 8.
Rolling needle bearing 6534911K is installed on knuckle pin upper end, rolling needle on
lower end. Knuckle pin 7 is connected to knuckle seat 9 by bearing 6534912K and rolling
column stop push bearing 649912 through rolling needle bearing. 7517 and 7520 single
row cone roller bearings are installed on each side of wheel hub and knuckle axis.
Turning straight and transverse puller assembly is separately connected to turning straight
puller arm 5 and knuckle arm 17 through ball pin.
Front wheel alignment:
1. Knuckle pin inner inclination 730. Configuration is guaranteed and cannot be
adjusted.
2. Knuckle pin back inclination 0. Position is guaranteed by steel board spring
installation and cannot be adjusted.
3. Front wheel extroversion 0 , structure must be guaranteed and cannot be adjusted.
4. Front wheel toe 1-3mm, can be adjusted by turning transverse puller.
8.2 FUNCTION
Front assembly is a driven bridge and fixed on vehicle shelf through front suspension.
Wheels are installed on two sides. The function of front axis is to endure part of load from
front part of vehicle and transmit forces between vehicle frame and each direction of
wheels, meanwhile control turning straight puller assembly through turning system, so it
will move forward and backward and swing of turning straight puller can be fulfilled, front
wheel is turned so that the turning of vehicle is done. On the other hand, front wheel
alignment angle can ensure vehicle travel in a steady and straight manner.
______________________________________________________________________
Page - 83 - of 178
______________________________________________________________________
Page - 84 - of 178
Heavy turning
Deflection during
driving
Swaying sideways
Causes
Troubleshoot
1.Abrasion of knuckle pin stop
1. Replace wearing
push bearing
parts
2.Abrasion of turning puller ball
2. Replace wearing
bowl
parts
3.Bad adjustment of wheel bearing
3. Re-adjust
4.Front wheel toe changes
4. Re-adjust and
5.Looseness of joints between
fasten well
turning droop arm and turning
5. Re-tighten,
puller
eliminate clearance
6.Looseness of turning parts
6. Check and tighten
1. Wrong installation of turning
1. Re-adjust
machine sliding valve in piston
2. Stuck and lag in steering wheel
2. Check and
thread bar
eliminate the stuck
and lag
3. One front wheel brake does not
3. Repair parts which
restore its position
do not restore
position
4. Unequal tightness of two front
4. Re-adjust bearings
wheel bearings
5. Pressure difference too large
5. Increase pressure
between two wheel
according the
requirements
1. Too much abrasion of wheel
1. Replace the tyre
2. Lag in brake of one wheel
2. Eliminate the
lagging part
3. Insufficient pressure of one tyre
3. Increase pressure
according to
requirements
4. One tyres bearing too tight
4. Re-adjust bearing
clearance
1. Front axis not straight
1. Rectify front axis
2. Unequal pressure in tyres
2. Make pressure
equal
3. Unequal abrasion of tyres
3. Replace tyres
4. Too large clearance between
4. Re-adjust
wheel bearings
5. Looseness in steel board
5. Fasten steel board
spring bolt
bolt
6. Shock absorber not working
6. Check and replace
shock absorber
______________________________________________________________________
Page - 86 - of 178
______________________________________________________________________
Page - 87 - of 178
Chapter 9
Steering System
9.1 SUMMARY AND TECHNICAL DATA
: 90
: 5.82
: 4.875
: 23.27
: 9635Nm (14Mpa)
Steering device consists of following parts (shown in Figure 48): power steering device,
steering oil pump, steering oilcan and steering oil pipe. Power steering device is the
executing component for steering system hydraulic power assistance.
Steering oil pump and engine are connected to be the systems hydraulic power source.
Steering oilcan can be used to store, cool down, filter and renew oil. Engine drives
steering oil pump directly, it sucks the oil from oil tank through oil suck pipe, and pump the
pressured oil to steering machine through high pressure oil pipe. The low pressure oil
coming out from the steering machine oil returning jaw will go back to oil tank through oil
returning pipe.
Steering
Steering Pump
Figure 48 - Steering
______________________________________________________________________
Page - 89 - of 178
______________________________________________________________________
Page - 90 - of 178
To Upper Oil
Tank
Input
Axis,
Anti-Clockwise Rotation
Left
Rotation
Middle
Position
To Upper Oil
Tank
Tank
Input
Axis,
Clockwise
Rotation
High
Pressure Oil
Pressure
Low
Oil
Right
Rotation
______________________________________________________________________
Page - 91 - of 178
Road feel is direct feel of road condition and resistance change through steering device
when driver is carrying out the action of steering. When the driver applies force on the
steering wheel, at the same time it is also applied on steering devices tweak pole and
makes it retort and transform. Therefore transformation measure depends on wheel
steering resistance. When steering resistance is large, this transformation measure
increases also. Hence the driver can judge the change in steering resistance from the
force he applies on the steering wheel, and so to obtain road feel effect.
Lamina Pump
Manufacturer Design
Serial Number
Serial Label
Embeded Flux Control And
Overflow Valve
2 Bolt Flange
Throttle Hole Number Flux
6-6USgpm
Note: In the serial number, the second part of number is the pumps flux and pressure.
______________________________________________________________________
Page - 92 - of 178
Stator
Oil Inlet
Rotation
Direction
Oil Outlet
Rotation Direction
Lamina
Oil Outlet
Oil Outlet
Rotator
Oil Inlet
Driving Axis
Oil Inlet
Influent oil will be in between lamina and brought passing the maximum diameter part of
inner ellipse curve. When it goes near oil exit, curve diameter will decrease, oil will be
squeezed out and goes into the system. System pressure outputs into bottom part of
lamina so that during laminas operation it will always cling to the curve surface to ensure
good sealing.
B. Fluid Force Balance
As shown in Figure 49, stators inner ellipse curve is made into two pump cavities: oil suck
cavity and oil compress cavity, they are symmetrically distributed in diameter-direction. So
the side loads on axis from fluid cancel out each other.
Oil Outlet
Stator
Lamina
Rotor
System Back Pressure
Action Position
Axis
Cover
Spring
Core Pressure
Pressure Plate
Figure 50
C. Pressure Plate
The function of pressure plate is shown in Figure 50. Before the system pressure is
established, pressure plate presses it onto pump core stator with help of spring on its back.
When system pressure is established, due to the hydraulic pressure on its back, the
surface area on the back is larger than exposed area at pump core. This unbalance power
will press the pressure plate onto the pump core stator. Seal the pump core and leave a
certain operational axis-direction clearance between rotor and lamina.
______________________________________________________________________
Page - 94 - of 178
______________________________________________________________________
Page - 95 - of 178
To Oil Can
Page - 96 - of 178
Measuring Hole
Confirm Flux
Go To
Pump
Core Oil
Exit Pipe
Safety Valve
Spring
Figure 51B
Pressure Hole
To Oil Can
Resistance Hole
Safety Valve
Overload Valve
Needle Open
Due To Pressure
Decrease In
Measuring Hole,
Spring Cavity
Pressure Is Lower
Than System
Pressure
Figure 51A
Pressure Hole
Safety Valve
Pressure Passing
Through Damp Hole
Right Spring
When Pressure Of
Two Sides Equals,
Spring Keeps
Constant Current
Valve Close
Extra Oil
Flows To
Oilcan
Through
Constant
Current Valve
Figure 51C
Pressure Hole
To Oil Can
______________________________________________________________________
Figure 52
2.
3.
4.
5.
6.
Page - 98 - of 178
O-Ring
Flooding Valve
Sub-Assembly
O-Ring
Jam
Bolt
Standard
Pump Cover
Jam
Jam
O-Ring
Spring
Spring
Pressure
Plate
Lamina
Stator
Jam
O-Ring
Figure 53
Collar
Cover
To Oil Can
Rotor
Pin
Pump
Body
Bolt
Oil
Seal
Collar
Axis
Section View
Bearing
Key
Bottom Frame
______________________________________________________________________
Hooped Spring
Cover
Exit Reference
Standard
Pump Body
(Oil Inlet
Reference)
Figure 54
Figure 55
from
the Pump oil entrance Check filter net of entrance, check oil
pipe partially get condition and discharge the old oil if
stuck
necessary, wash the system, replace with
new oil
Air leakage in pump Check oil entrance pipe joint head and axis oil
oil entrance pipe or seal, locate the position of leakage, tighten
pump axis seal (oil any loosed head, replace with new oil seal if
are
in necessary, monitor oilcans oil level
spumescence)
Pump speed too Operate the oil pump according to the
slow or too fast
regulating rotation speed
Joint
axis
not Check if there is damage of axis, oil seal,
centralized
bearing or other parts, replace broken parts
and re-adjust the central line of pump axis
Different
weight
when
turning left
and right
When fast
steering,
steering
wheels
handle is
heavy
7.
1.
2.
3.
1.
2.
3.
When
steering
sometimes
light
sometimes
heavy
Troubleshoot
1. Check oil level of oilcan, renew
oil accordingly.
2. Exhaust and check oil level and
sealing condition of pipe joint
head.
Jam in filter machine, bad
3. Clean filter machine and filter
cleanness.
core, replace oil.
Insufficient oil pump pressure. 4. Check and repair oil pump.
Serious leakage inside the
5. Check or replace sealing ring.
steering machine.
Front wheel gets stuck (brake 6. Check and repair the position
does not return to its
where brake gets stuck.
position).
Serious overload of vehicle.
7. Reduce the load.
Unequal oil leakage of
1. Replace sealing ring.
steering machine inner
pistons two sides.
Bad adjustment of position
2. Re-adjust.
limit valve or open too early.
Air in the single cavity.
3. Exhaust.
Insufficient oil supply to oil 1. Oilcan lack of oil, renew the oil,
pump.
check and repair oil pump.
Leakage of oil is too large in
2. Replace oil seal.
steering machine inner
pistons two sides, mainly due
to damage of sealing or too
much abrasion.
Air is sucked in.
3. Exhaust, check the sealing
condition of joint parts.
3.
4.
5.
6.
Change oil.
Replace bearing.
Exhaust.
______________________________________________________________________
Page - 104 - of 178
______________________________________________________________________
Page - 105 - of 178
Chapter 10
Braking Device
10.1 Brake System
10.1.1 Summary
Braking device is used to control vehicles motion. It will decelerate the vehicle rapidly, till
the vehicle stops, vehicle can be also parked on the slope.
Braking device is an important mechanism of vehicle. It is a proof of vehicles safety. This
vehicle has two sets of braking device.
1. Foot brake, namely traveling brake. It is a double pipe system and independently
working on front and rear wheels. It is driven by air pressure for decelerating and
parking of vehicle.
2. Handle brake, namely parking brake, is deflation brake. It is also working on rear
axis brake, controlled by handle control valve of cab. It is used for parking. When
foot brake fails, this can be also used as emergency brake.
3. This vehicles brake is air driven. It is characterized by the air reservoir through each
foot brake systems front and rear wheel brake chamber. Handle braking system is
connected to rear braking air reservoir. When any one of front and rear brake pipes
fails, the rest of wheel can still have brake.
4. Figure 57 shows that compressed air can supply vehicle brake, it can also supply air
source for vehicles lifting and electrical control air horn.
10.1.2 Brake System Working Principle
Air compressor (9) sucks the air from filter device, and send the compressed air to front
and rear air reservoir (16), (17) through desiccator (13), 4 loop protecting valve (12) in one
path, and to regenerating air reservoir in another path (15). When desiccator is exhausting,
the compressed air from regenerating air reservoir fills the desiccator, to blow off the liquid
absorbed by desiccation granule in desiccator. When driver steps down foot brake pedal
(3), compressed air goes into front and rear brake sub-pump (10) (19) through foot brake
valve (2), to produce braking effect, and complete the travel brake.
When parking brake is needed, open handle braking valve (1) switch, compressed air in
the pipe goes into the atmosphere through handle control valve (1) and quick release
valve (18). Rear braking sub-pumps spring starts to work and produce parking brake
effect. Air reservoir (16) is connected with electromagnetic valve (6), lifting control valve
(7), electrical control air horn (5), lifting position limit valve (14) and pressure adjustment
valve (8). The readings of manometer (4) directly show the pressure of air reservoir (16)
(17).
Safety pressure of handle brake is shown from instrument panels low pressure indicator.
______________________________________________________________________
Page - 106 - of 178
______________________________________________________________________
Page - 107 - of 178
______________________________________________________________________
Page - 108 - of 178
Brake
feet
does
not
return position
Deflection
brake
in
Causes
Troubleshoot
1. Insufficient system pressure.
1. Check air path and all joints.
2. Bad adjustment of brake feet.
2. Re-adjust.
3. Abrasion or crack of friction 3. Replace new friction slice.
slice.
4. Transformation or scratch of 4. Repair and rub brake drum.
brake drum.
5. Lubricating grease goes into 5. Eliminate oil leakage and
brake drum.
wash the brake.
6. Air leakage or breaking of
6. Check and repair brake
brake chamber.
chamber.
1. Brake cam axis diameter 1. Eliminate the rust and
direction clearance is too small
re-lubricate.
or cam axis is rusty, bad
lubrication.
2. Brake feet support pin or pin 2. Same as above.
hole is rusty or bad lubrication.
3. Brake feet retracting spring 3. Replace new spring.
wears out or damaged.
4. Lag in brake chamber piston 4. Eliminate the lag.
and piston pole.
5. Brake chamber and pipe air 5. Check and eliminate the jam.
circulation is bad, gets stuck.
6. Lag in the joint of brake 6. Eliminate the lag.
chamber and swing arm.
1. Oil remain on a side of wheel 1. Eliminate the oil remains.
brake feet slice and brake
drum.
2. Air leakage of one side of brake 2. Eliminate the leakage.
chamber and pipe.
3. Unequal adjusting clearance 3. Re-adjust or repair brake feet
between left and right brake
friction slice.
feet friction slice and brake
drum or bad contact.
4. Different degree of tightness 4. Re-adjust.
between left and right 4 wheel
hub bearings, difference is
large.
______________________________________________________________________
Page - 109 - of 178
4 Air entrance
5 Air entering valve
6 Air discharge valve
10.2.2Working Principle
Air entering
When piston moves downwards, partial vacuum appears in air cylinder, air is sucked into
air compressor through engine air entering branch pipe or air compressors air filter.
Difference between pressures in air cylinder and atmosphere makes air entering valve
move downwards and leave the valve seat, allow the air go into air cylinder through air
entrance. When piston reaches its lower stopping point in the stroke, pressure of spring is
sufficient to overcome relatively small pressure difference and make air entering valve
sustain valve seat, as shown in Fig 5-36 and 5-37.
Compression
When piston moves upwards, air pressure in the air cylinder increases, and forces air
discharging valve leave the valve seat. After that the piston continues moving upwards,
compressed air goes into air reservoir through air discharging valve. When piston moves
downwards, air discharging valve closes, air entering valve opens (except for when
unloading).
______________________________________________________________________
Page - 110 - of 178
______________________________________________________________________
Page - 111 - of 178
______________________________________________________________________
Page - 112 - of 178
A. Technical Data
Medium
Used temperature range
Working pressure
Weight
: air
: -40C to +90C
: maximum 1Mpa
: 1.2 kg
B.Use
It is used in multi-loop air brake system. When one of the loop fails, the others can still be
charged by this valve and air supply is not affected.
C. Working principle (Figure 59)
Pressure comes in from hole 1, meanwhile it reaches A, D cavity and B, C cavity. When
valve opening pressure is reached, valve 2, 3, 5 and 6 will open, compressed air is
transmitted to air reservoir through hole 21, 23. Hole 22, 24 connect to foot brake valve
and handle brake valve. When a loop, for example loop 21, fails, because of the single
direction effect of valve 3, 5, 6, it will ensure the pressure of loop 22, 23, 24 will not leak
through hole 21.
Meanwhile pressure of hole 22, 23, 24 will act on film 4 and film 1s right hand part, so that
pressure coming from hole 1 will easily open valve 3, 5 and 6 and continue to supply air to
loop 22, 23, 24. When charging pressure reaches or exceeds valve 2s opening pressure,
pressure will then leak through the broken 21 loop, but the rest loops are still working with
normal pressure.
______________________________________________________________________
Page - 113 - of 178
: 150mm
: 74mm
: 750 kpa
B. Use
Wheel break is a device which converts air pressure to pushing brake feet and produce
brake force. The technique parameters and structures of front the rear wheel brake
chambers are totally different. Front wheel is piston type and rear wheel is working brake
together with handle brake, it is a combination of piston and film.
C.Working Principle
This chamber is a piston type. When braking, compressed air goes into this chamber
through end side tie-in, and pushed piston (4) into its motion, meanwhile moves swing arm
and make camshaft rotate, opens up brake feet and produce braking effect.
When braking is released, air in the cylinder is discharged into the atmosphere through
foot brake valve. Position returning spring (6) will push the piston back to its original
position and ready for the next brake. See Figure 60.
10.4.1 Assembly Of Front Brake Chamber
1. Before assembly, all the parts should be cleaned, there should not be any dust, crumbs
or burrs. No scratch should be found on the working surface.
2. Fasten all the firmware, apply a little seal glue on pipe tie-in. Run the sealing test after
assembly.
3. When assembling piston and sealing ring, apply some lubricant lithium MoS2 grease
or industrial Vaseline on the working surface.
4. Assemble the piston assemblys each part of (17)(15)(14)(13)(16)(4)(6)(7) together.
Be ware that some lubricant lithium MoS2 grease should be applied onto piston pole (5)
and spring seat (13) working surface. The position of dustproof cover (4) must be
correct.
5. Apply small amount of grease on air cylinder (15) working surface. When assembling
piston assembly and air cylinder cover (12), use spring seat (13) to planish the
dustproof cover (4). Screw down four fixed bolts (3) covered in spring gasket (2).
Screw down torque is 32 Nm.
6. Be ware of the sealing of screw down tie-in (18). Finally get into pin axis (8) and put on
gasket ring and opening pin (9).
7. After assembly, 50 kpa of compressed air should be filled into brake chamber. At this
moment the piston should be above to push out rapidly with 74mm journey, and return
to its original position under the effect of position returning spring after unloading.
______________________________________________________________________
Page - 114 - of 178
5 Piston pole
6 Position returning spring
7 Dustproof cover
8 Joint fork
______________________________________________________________________
Page - 115 - of 178
: 162mm
: 63mm
: 750 kpa
Handle brake:
Piston diameter
Piston working journey
Working pressure
: 178mm
: 63mm
: 750 kpa
B.Working Principle
This chamber is a combinational brake chamber of both working brake and handle brake.
It is responsible for working brake and parking brake.
1. Normal run: in order to release handle brake, pressure of compressed air should
reach allowable minimum 450 kpa. At this moment move the handle brake valve
and let the compressed air go into handle brake cylinder to push piston and
overcome spring effect and make it compress, and disconnect the handle brake.
See Figure 62.
2. Vehicle should not be started if pressure does not reach the safety minimum value.
______________________________________________________________________
Page - 116 - of 178
Released Handle
Travel Position
Brake
______________________________________________________________________
Page - 118 - of 178
______________________________________________________________________
Page - 119 - of 178
______________________________________________________________________
Page - 121 - of 178
______________________________________________________________________
Page - 122 - of 178
: 462mm
: 180mm
Friction area
: 1584mm
: 22018015mm
: 0.35-0.4
B. Use
Wheel arrester is used to directly produce power torque, and stop wheel rotation and
reduce the speed or stop of vehicle. The parameter and structure of front and rear wheel
arrester are basically the same. They are both simple and non-balance inner expanding
drum type arrester.
C. Working principle
This vehicle uses simple non-balance inner expanding drum type arrester. See Fig 10-5-1.
Two brake feet (3) are supported on the support pin (2). Brake feet (3) is driven by wheel
brake chamber light swing arm (11) and camshaft (6). Brake feet is in contact with brake
cam through rolling wheel (9) to reduce the frictional loss of cam.
When braking during vehicle forward movement, the compressed air opens the two brake
feet (3) through swing arm (11) pushed by brake chamber piston and rotating cam (6), and
press hard on the brake drum (1). It produces a frictional torque to the rotating brake drum
and stops the rotation of wheel so the vehicle starts to slow down.
Figure 68
______________________________________________________________________
Page - 123 - of 178
The clearance between brake feet friction slice (3) and brake drum (1) is adjusted by
triangle spline cover (7). In order to make the clearance at idler wheel between brake drum
and friction slice to be 0.65mm, and 0.35mmat support pin position, we can rotate the
adjusting bolt (8). If the screw thread of this bolt is to the greatest extent, then get off the
adjusting spline cover (7), rotate by one tooth then re-adjust.
______________________________________________________________________
Page - 124 - of 178
Figure 70
3. After riveting the friction slice and brake feet, the maximum partial clearance should
not exceed 0.25mm or use the knocking sound to check the riveting condition.
4. After pressing the lining (4) into feet hole, use support pin (7) to check the
coordinating condition. If there is transformation, use ream knifes ream hole and
install idler wheel axis (5) and idler wheel (6).
5. Wash two support pin (7), apply small amount of grease into front knuckle, at the
same time cover the camshaft (8) with felt ring (9) and install into knuckle. Beware
of the left and right different of camshaft, the direction of cam must follow the
moving direction of wheel.
6. Install the retracting spring (10) and two retracting spring pin (11) on two feet (2),
and then install the two feet together onto front knuckle. Apply some grease on the
support pin and cam surface when assembling, finally install the gasket ring (12)
and axis-use collar (13).
7. Insert the adjusting spline cover (7), install the adjusting bolt (15) and nut (16) into
brake arm (17), then together put into camshaft spline. Beware of the relative
position of brake arm upper end and brake chamber support. Finally install the
axis-use block ring (18).
8. Install the brake drum (19) on front wheel hub, screw down 8 fixed bolts (22). Drip
some loose proof potion when screw down. Beware of the symmetry when
screwing, the screw down torque is 314 Nm.
______________________________________________________________________
Page - 125 - of 178
Unbalance
brake
force,
deflection
in
running
Brake cannot
be released
Scratch
of
brake feet slice
on brake drum
Causes
Troubleshoot
1. Bad adjustment of brake 1. Re-adjust or use sand paper to
feet, small contacting area
smoothen.
2. Crack in friction slice or 2. Replace with new friction slice
burning of surface
3. Scratch or crack in brake 3. If depth of scratch exceeds
drum
0.25mm, re-chop the vehicle.
The maximum chop depth is
1.5-2.5mm.
4. Insufficient rigidity of brake 4. Replace with new brake drum if
drum, transformed
it becomes too thick after
abrasion.
5. Lubricating oil goes into 5. Check the oil leakage part,
brake drum and friction slice
clean the friction slice and
brake drum.
1. Friction slice quality is 1. Replace the friction slice or
unequal, there is light spot
repair the light spot.
or exposure of rivet nail.
2. Air leakage of brake 2. Check the cleaning brake pipe
chamber or brake pipe gets
and brake chamber.
stuck.
3. Uneven abrasions in cam or 3. Check and repair brake cam
idler wheel surface.
and idler wheel.
1. Brake feet retracting spring 1. Replace with new spring.
is worn out or cracked.
2. Air leakage of handle brake 2. Replace with new sealing ring.
seal ring, brake chamber
does not return to its
position.
3. Bad adjustment of clearance 3. Re-adjust, smoothen the brake
of arrester.
feet if necessary.
4. Camshaft is too tight or gets 4. Ream the cam, use sand paper
stuck.
to smoothen the axis.
1. Retracting spring is too 1. Replace with new spring
weak or damaged.
2. Wheel bearing clearance is 2. Check wheel hub bearing,
too larger of jumping.
eliminate jumping.
3. Dust goes into brake drum.
3. Clean and eliminate the dirt on
friction slice.
______________________________________________________________________
Page - 127 - of 178
Working capacity:
Front air reservoir
Rear air reservoir
Regenerating air reservoir
Working pressure
: 55 L
: 60 L
:5L
: 750 Kpa
B. Use
It is used for reserving some compressed air to backup the brake system and other
assisting devices. It can help stabilize pressure, lower the temperature and clean the oil
dirt.
______________________________________________________________________
Page - 128 - of 178
B.Use
Handle brake device is vehicles parking brake device. This vehicle functions directly onto
the rear axis wheel. It is controlled by rear axis double cavity brake chamber. Here the
function of compressed air is to keep the handle brake device in brake releasing state.
Compressed air releasing makes it easy for handle brake device to produce brake effect.
Use instrument panels hand brake valve to control the hand brake device.
Handle brake control valve is usually closed two position three connecting valve. See
Figure 74. This valve is installed on the driver cabs instrument panel. Handle has only two
brake position, right is driving position.
______________________________________________________________________
Page - 129 - of 178
C. Working Principle
The compressed air from rear air reservoir (1) is connected to handle brake control valves
air entrance through pipe. The compressed air goes into air exit through seal ring As
middle hole, and passes through pipe and quick release valve (3) to rear brake chamber
(4). Valve B closes the pathway between air exit and atmosphere, makes the parking
vehicle in the releasing state.
In reverse, when handle pushes to the left, valve B moves downwards, seal the seal ring
As middle hole, closes the pathway between air entrance and air exit. At the same time it
opens the pathway between air exit and atmosphere, so the compressed air form rear
brake pipe will be released to the outside through large air hole, the compressed air from
rear brake chamber is discharged into the atmosphere through quick release valve (3).
Parking brake moves the brake chambers puller under the effect of spring, and carries out
the vehicle brake through arrester.
On the other hand, self dump device should also be controlled by this kind of valve. The
control manner is the same as above. When the compressed air passes through this valve,
lower down the carriage. The opposite procedure is for lifting.
______________________________________________________________________
Page - 130 - of 178
Handle
position
Airflow
pathway
Causes
Troubleshoot
1. When handle in this
1. Repair this valves
position, if valve Bs seal
seal ring and valve
ring and seats sealing
pole
condition is bad or valve
2. Check and repair
pole is not completely back
valve seat
to its position, and air leaks
from large air hole,
insufficient pressure
causes incomplete parking
brake releasing
1. When handle is in a
1. Check this valves
position shown in the
seal ring A, if
figure, it is a parking
transformed or
position (Fig 10-7-1), if
damaged must
valve B and seal ring As
replace with new
sealing condition is bad,
parts.
compressed air will enter
the brake chamber from air
entrance and through air
exit, thus the parking brake
does not work
______________________________________________________________________
Page - 131 - of 178
To Brake Chamber
To Brake Chamber
Air Source
A.Technique Data
Medium
Temperature range for use
Working pressure
: air
: -40C +80C
: maximum 1 Mpa
: P=30 +10
20 Kpa
B. Use
To fulfill flexible control in double loop main brake systems brake process and releasing
process.
C. Working Principle
Control the mandril K and mandril seat a, for the action of brake valve through pedal
control device.
When braking, mandril seat a moves downwards by the pushing from rubber spring b.
Close air discharging gate d, open air entering gate j. Compressed air from gate 11
reaches cavity A. Then from gate 21 output to brake pipe I. Meanwhile airflow reaches
cavity B through hole D and functions on piston f for its downward movement. Close air
discharging gate h, open air entering gate g, the compressed air form gate 12 reaches
cavity c, and from gate 22 outputs to brake pipe II.
When braking is released, the pressure from gate 21, 22 is discharged to atmosphere
separately through air discharging gate d and h and gate 3.
When #1 loop fails, piston f is pushed downwards through valve assembly e. Close air
discharging gate h, open air entering gate g, to make #2 loop works normally. When #2
loop fails, it does not affect the working of #1 loop.
______________________________________________________________________
Page - 133 - of 178
Heightened Belt
______________________________________________________________________
Page - 134 - of 178
Figure 78
Figure 79
3. The compressed nut put on the pipe ends ferrule fitting must be just align when
installing on tie-in (Figure 80), apply a little machine oil.
______________________________________________________________________
Page - 135 - of 178
Figure 80
Stop Point
Figure 81
4. When fasten the compressed nut, beware that must push the air pipe till the bottom
of tie-in then screw down (Figure 81), till it is sealed.
5. For the assembled pipelines, check their sealing condition. Under 750 kpa pressure
use suds to check all the joints, there should not be any leakage.
6. When assembling pipelines tie-in, beware of the assembly order. Assemble the
aluminum made parts first, then the steel made parts, to prevent damage on screw
thread.
______________________________________________________________________
Page - 136 - of 178
Chapter 11
Suspension Device
Suspension device is used for connecting the axis and vehicle frame, and absorb and
eliminate the impact due to bad road condition.
Vehicles front and rear suspension are both half ellipse steel board spring. Both front and
rear suspensions are installed with rubber sub-spring. Front suspension is also equipped
with S65-24A type double direction hydraulic tube shock absorber. Both suspensions are
equipped with push pole.
This suspension device is a traditional structure. It is easily made, and easily repaired and
disassembled.
11.1 Front Suspension
Front suspension has the ability of transverse and portrait orientation and balance the
brake torque.
Front suspension and symmetrical half ellipse steel board spring is the main spring,
auxiliary spring is a double points symmetrical rubber spring, and it is equipped with
double direction hydraulic tube shock absorber, and push pole power transmission device.
See Figure 82.
1. Steel board spring main spring is responsible for absorbing the impact, it consists of
3 main slices and 7 auxiliary slices. Main section surface is 12mm thick and 150mm
wide, auxiliary section is 12mm thick and 150mm wide. Main spring (4) main slice is
connected to front and rear suspend ear (2) and (10) with idler wheel type. This
structure reduces frictional resistance, lengthen the lifespan of steel board spring.
2. Rubber auxiliary spring: rubber auxiliary spring (6) protects the main spring. It is a
substantially rubber part. It has a small initial rigidity and large terminal rigidity.
Hence when traveling on a bad road condition, it can effectively protect main spring
(4), greatly reduce the main springs move and scratch degree and lengthen the
lifespan of steel board spring.
3. Double direction tube shock absorber: see Fig 11-1 part # (7), it consists of hydraulic
cylinder, piston and liquid reservoir. Its main function is to absorb the position energy
of main spring due to wheel jumping, convert the position energy to heat energy. The
effectiveness of shock absorber will directly affect the lifespan of main spring.
______________________________________________________________________
Page - 137 - of 178
Figure 82
1 Front thrust pole
2 Front spring front suspend ear
3 Pin
4 Front main spring
5 Front spring pressing board
See Figure 83. Rear suspension consists of main spring, auxiliary and thrust pole power
transmission mechanism.
1. Rear steel board spring main spring consists of 2 main slices, 6 auxiliary and 1
compressed slice.
2. Auxiliary spring consists of double point symmetrical rubber block.
3. When vehicle parks with full load, rear auxiliary spring has to bear with 40% load of
rear axis. If there is impact during traveling, it has to bear with 60% load, about 16
tons. So once the rear auxiliary spring is broken, must replace with new one in time,
otherwise rear steel board spring main spring has to bear with the whole load. Main
spring will so crack. Must not ignore this point.
4. Thrust pole is shown as part (2) in Figure 83. It is power transmission mechanism. It
transmits the rear axis driving power to vehicle frame. It can also control portrait
location and balance brake torque.
______________________________________________________________________
Page - 138 - of 178
Figure 83
1 Front support
2 Thrust pole
3 Main spring
______________________________________________________________________
Page - 139 - of 178
Steel board
spring is too
soft
Causes
Troubleshoot
1. Lack of lubricants in spring 1. Disassemble steel board spring,
slice
clean the spring slice using
graphite grease or graphite plus
butter, assemble after lubricating
2. Pin in the lining gets stuck
2. Disassemble pin and lining,
clean and check, replace with
new parts if necessary.
3. Shock absorption pole bends 3. Replace the shock absorption
due to large impact, or defect
and check rubber auxiliary
in rubber auxiliary spring.
spring.
1. Spring slice central bolt 1. Disassemble the steel board
broken.
spring, replace with new central
2. Some spring slices broken
bolt, check each slice.
3. Spring worn out
4. Shock absorbers capability
weakens.
5. Wheel gets stuck
Noise in
suspension
2. Disassemble
the
shock
absorber and check, replace
when necessary
3. Check
the
brake
feets
adjustment.
1. Disassemble the spring, add
lubricants.
2. Screw down the nut according to
the regulated torque.
3. Replace the shock absorbers
pin.
4. Repair steel tube of shock
absorber, replace the shock
absorber if necessary.
______________________________________________________________________
Page - 140 - of 178
Chapter 12
Cartwheel And Hub
12.1 Summary And Technical Data
Wheel and wheel load assembly consists of wheel hub, wheel rim and tyre. Wheel rim
specification: 10.00-24, consists of wheel rim, block ring and lock ring (Figure 84).
Wheel hub is steel casting, front wheel hub is supported on front axis knuckle axis by two
single line cone roller bearing. Rear wheel hub is supported on rear axis half axis tube by
two single line cone roller bearing.
Tyre specification: 14.00-24 layers. Charger pressure 638 kpa, load capability 60000N.
Tyre consists of inner tube, shoe and lining.
Tyre and wheel rim assembly are fastened on wheel hub by pressing board, they rely on
frictional force to transmit torque, left and right wheel bolts are both right screw thread.
Tyre 14.00-24
Wheel Rim Assembly
Figure 84
12.2 Function
Vehicle uses charged tyre. Tyres are installed on the wheel rim and directly touch the road.
Functions are:
1. Relax and absorb the impact and shock produced due to bad road condition.
2. Ensure reliable adhesion force between wheel and road surface so it will not slide.
3. Support the whole vehicle weight.
4. Bear with the action force of driving, braking and side sliding.
______________________________________________________________________
Page - 141 - of 178
Insufficient
pressure %
Lifespan
reduced %
16
33
56
50
76
It can be seen that as the pressure decreases, the lifespan will decrease dramatically.
If the pressure is too high, the elasticity of tyre will reduce and impact it takes will increase.
Both high and low pressure will cause the tyre worn out faster, increase abrasion or shoe
blow up. So must keep the tyre pressure normal.
______________________________________________________________________
Page - 142 - of 178
Malfunction
Abrasion of two side tyre
shoulder
Abrasion in the middle of
tyre
Abnormal abrasion on
the inner tyre
Abnormal abrasion on
the outer tyre
Causes
Insufficient charge
Troubleshoot
Charge according to the
requirement
Over charge
Charge according to the
requirement
Insufficient wheel angle Change wheel angle
or front toe too large
Re-adjust front toe
Wheel angle too large or Change wheel angle
front wheel expands Re-adjust front to
outwards (anti-front toe)
______________________________________________________________________
Page - 143 - of 178
Chapter 13
Hydraulic Pressure Dump System
13.1 Technical Data
Rating working pressure
Lifting oil pump nominal flux
Oilcan capacity
Carriage lifting time (with full load)
Carriage lowering down time
Maximum working temperature
: 8335 kpa
: (1000rpm) 215L/min
: 95 L
: not more than 20 seconds
: not more than 20 seconds
: 10OC
13.2 Function
Hydraulic dump mechanism can realize carriage dump by itself. Since this oilcan is a
single direction function can, the carriage is lowered down to its original position by its own
weight.
______________________________________________________________________
Page - 144 - of 178
______________________________________________________________________
Page - 145 - of 178
8 Bearing
9 Pump shell
10 Axis
11 Bolt
12 Oil seal
13 Main axis
Oil pumps rating working pressure is 8335 kpa, the maximum working pressure is 9806
kpa, nominal flux is193 L/min, practical flux is 173 L/min (oil pump rotation speed 900 rpm).
It is better to take about 800 rpm for oil pump rotation speed (oil pump nominal flux is
about 172 L/min, practical flux is 154 L/min, engine rotation speed is less than 1800 rpm).
When oil pump axis rotates, it rotate the driving gear on the pump axis, driven gear will
then rotate under the driving force of driving gear with the same rotation speed. As shown
in Figure 87, when gear rotates it will compress the hydraulic oil from oil pump oil suck
gate through gear teeth into hydraulic distribution valve and hydraulic pressure cylinder.
Oil Exit
Oil Suction
______________________________________________________________________
Page - 147 - of 178
______________________________________________________________________
Page - 148 - of 178
8 Sealing ring
9 Copper cover
10 Sealing ring
11 Felt ring
12 Lower suspend ear
13 Joint bearing
______________________________________________________________________
Page - 149 - of 178
______________________________________________________________________
Page - 150 - of 178
______________________________________________________________________
Page - 151 - of 178
7 Spring
8 Elastic block ring
9 Dust proof cover
10 Valve pole
11 Valve
12 Air returning hole
______________________________________________________________________
Page - 153 - of 178
______________________________________________________________________
Page - 154 - of 178
To Lifting Cylinder
Lifting
Stop
Lowering
Stop &
Descend
Lift
Connect To Handle
Gas Control
(Always Open)
To Air Reservoir Tube
2 Elbow
3 Tie-in
4 High pressure oil exit pipe
6 Limit valve
7 Lifting cylinder
8 Cushion device
10 Oil return pipe 11 High pressure 12 Limit steel thread
oil pipe
______________________________________________________________________
Page - 155 - of 178
Carriage
Distribution Valve
Limit Valve
Vehicle Frame
______________________________________________________________________
Page - 156 - of 178
Causes
1. Lack of oil or no oil in oilcan
2. Oil suck pipe or oil suck filter
gets stuck
3. No gear engagement of
gear-box power obtain device
output axis
4. Gear-box power obtain device
control fork broken
5. Limit valve does not return its
position (due to damage of O
shape rubber ring or valve hole
gets stuck), the path of lifting
cylinder oil entering pipe is cut
by lifting hydraulic pressure
control valve main valve (can
be observed from outlook).
6. Lag in lifting cylinder
Troubleshoot
1. Renew oil and check oil leakage
2. Clean or replace the oil
3. Check the gas path and
electromagnetic gas moving
valve
4. Replace with new parts
5. Disassemble, wash or replace
the O shape ring
______________________________________________________________________
Page - 158 - of 178
Chapter 14
Vehicle Frame, Carriage, Cab And Driver Seat
14.1 Vehicle Frame
Vehicle frame is the basic framework of the vehicle. All the assemblies, parts and carriage
and cab are directly or indirectly assembled onto the frame.
When vehicle travels on a bumpy road, the frame may retort or transform or bend in
transverse plane. The transformation will change the relative position between each part
assembled on the vehicle frame and will affect its normal working. On the other hand, the
vehicle frame has to bear with the force and torque from all the assemblies, hence the
vehicle frame must have good rigidity, especially for heavy self dump vehicle since its load
is very heavy and its working environment is very bad. Thus, the obdurability of vehicle
frame is especially important. Meanwhile, the weight of the frame should be as light as
possible.
This vehicle frame is a C-type structure. Is has two carlings and four beams. The bumper
is connected to the frame by bolt, the structure girder is customized. Main body carling is
customized into C-type structure with dimension 240l30l2mm. For the part of carling
which has to bear with more force, use L-shape girder to strengthen it. Cover a flat board
on upper and lower wing to increase intensity. The external parts are plug welded onto
carling by prefabricate hole. Beam is an 8mm steel plate pressing group welding
component.
The upper and lower reinforce boards of beam and L-shape girder are all plug welded onto
carling. The material of left and right carling and left and right auxiliary girder is 16MnL, the
rest use steer board material of 16Mn.
Frames front and rear ends are both welded with traction pin seat. The length of the frame
is changed from 6730 to 6450. The improved structure is more reasonable and is able to
provide a wider sight view for the driver.
14.2 Carriage
14.2.1 Carriage Structure And Function Summary
Carriage is used to carry ores and clay and other cargo. It is a full steel plate welding
structure. Carriage chassis consists of two girders and five beams. The rear part of
motherboard is warped 830 so that it will prevent sliding of ores from the motherboard.
______________________________________________________________________
Page - 159 - of 178
______________________________________________________________________
Page - 161 - of 178
Figure 100
______________________________________________________________________
Page - 162 - of 178
13 Ladder assembly
14 Wiper assembly
15 Rearview mirror assembly
16 Door lock assembly
17 Front window assembly
18 Left fence assembly
19 Right fence assembly
20 Right window rear glass
21 Rear window glass
22 Door window front glass
23 Door wind rear glass
When checking and repairing the engine, first disassemble the right detachable cover
assembly and left detachable cover assembly.
This driver seat is used for mine-use load truck with large
vibration.
The seat can move forward and backwards by 45mm. It is
suitable for driver with weight 50-100kg. The backrest can
be adjusted to 2, 8, and 14 degree.
It is connected to the cab by bolts. The outline of the seat is
shown in Figure 101.
Figure 101
1 Handle 2 Handgrip
A. How to adjust the seat:
1. Forward and backward adjustment of seat: when the driver sits on the seat, use right
heel to push the handle (2) to the left, left foot steps on the cab floor, apply force onto
the body forwards or backwards to make the seat move forwards or backwards,
then move away right foot from handgrip (2) then the seat will automatically fix its
position.
______________________________________________________________________
Page - 163 - of 178
______________________________________________________________________
Page - 164 - of 178
Chapter 15
Electrical Device
Electrical device consists of one generator, two series accumulators, one electricity
distribution device and electric device. When diesel engine is working, it will drive the
generator to convert mechanical energy to electrical energy and then generate electricity.
The electricity generated is sent to electric devices and charge the accumulator. When
diesel engine works normally, the job of accumulator is the store the extra electricity for
backup use when engine goes off or in low speed operation.
The function of electricity distribution device is to connect all the electric device and
accumulator. Hence the distribution device consists of wires, circuit protection system and
switch.
The function of electric device is to convert electric energy into mechanical energy, heat
and light according to different requirements.
The instruction is divided into 4 parts:
Part 1: starting device, including accumulator, starting machine and starting switch.
Starting device is used for starting the diesel engine.
Part 2: electricity generating device, including generator and voltage regulator. This device
can produce electric energy to supply electric devices, and charge the accumulator.
Part 3: illuminating device.
Part 4: electricity distributing device, including circuit net and its protection.
15.1 Starting Device
Starting device consists of two 12V accumulator in series, one 24V starting machine and
one starting electromagnetic valve, two starting switch in series.
The function of starting device is to use accumulators electric energy to drive the diesel
engines rotation.
15.1.1 Working Principle
Turn the starting switch key (1) to position I (Figure 102) so BAT is connected with ST,
electricity will flow from Figure 102 (1) to starting switch (2) and pull in winding (3), it
makes the starting machines meshing pinion in mesh with flywheel teeth ring. At the same
time the connect-brake touch point (6) is closed.
______________________________________________________________________
Page - 165 - of 178
______________________________________________________________________
Page - 166 - of 178
of 0.02
meters
-0.01
-0.02
-0.03
0.04
For every 0.01 reduction in proportion, it is equivalent to accumulator discharing %6. If the
electrolyte proportion of charged accumulator is known, the discharge extent can then be
estimated from measured electrolyte proportion.
When measuring the proportion, the electrolyte level must reach the required level. On the
other hand, when diesel engine starts and distilled water is added for a few times, should
not measure the proportion immediately.
When use the accumulator in winter, make sure the accumulator is fully charge so that
then proportion will not become too low and get frozen, which will in turn crack the
machine shell, causing problem in pole plate. Because in winter, the capacity of
accumulator decreases, it is necessary to do the warm-up of starting machine. Every
switch on time should not exceed 5 seconds. If need to use continuously, rest for 15
seconds then carry on.
______________________________________________________________________
Page - 167 - of 178
______________________________________________________________________
Page - 168 - of 178
Cannot
charge the
accumulator
Too much
expand of
distilled
water
______________________________________________________________________
Page - 169 - of 178
11 Amperemeter
12 Connection pole
13 Contacting plate
14 Connection pole
15 Ground
16 Starting machine
17 Accumulator
18 Brass cover
19 Starting electromagnetic valve
2. Maintenance
1. Drop machining oil on the oil path sealed by bolts, lubricate 3 bearings.
2. Check the abrasion condition of electric brush, keep the commutating slice clean.
3. Check if the connection is tight, especially on grounding tie-in.
______________________________________________________________________
Page - 170 - of 178
Causes
1. No electricity in accumulator
2. No electricity in pull in winding
3.
4.
Driving pinion
not rotating or
cannot drive
the diesel
engine after
meshing
5.
1.
2.
3.
4.
5.
Driving pinion
and flywheel
teeth ring do
no get
disconnected
1.
2.
3.
4.
Troubleshoot
1. Charge
2. Check circuit, fuse joint and
starting switch
Short circuit or broken circuit in 3. Open pull in winding shell,
pull in winding
tie-in, replace if necessary
Double shoulder pole broken or 4. Replace
transformed
Abrasion of gear
5. Replace
Partial discharge of
1. Charge
accumulator
Connection pole 14
2. Open pull in winding shell,
disconnected
check the joint
Abrasion of brush or
3. Replace
insufficient spring force of
brush frame
Rectifier oxidized or dirty
4. Clean and brush rectifier
Armature winding or field
5. Disassemble starting
inductance short circuited or
machine and check wiring
broken circuited
on the platform, replace
when necessary
Insufficient spring force in gear 1. Replace the spring
positioning spring
Pinion gets stuck in spline
2. Disassemble the gear and
groove
check
Transformation of driving
3. Replace the broken parts
pinions teeth or teeth ring
Long charging of pull in winding 4. Check starting switchs joint
Troubleshoot
Connect them, fix the
touch point
Replace
switch
the
starting
______________________________________________________________________
Page - 173 - of 178
Grounding
Current
Or
Electrical Switch
Adjusting Device
Field Inductance
Armature
Winding
Grounding
______________________________________________________________________
Page - 174 - of 178
3. Engine fails
Too much electricity in 1. Engine fails
accumulator
Troubleshoot
1. Check, repair or replace the
accumulator
2. Check the joints of circuit,
keep the joint pivot clean and
tight, accumulator surface dry
and clean
3. Check and repair
1. Check and repair the engine
voltage adjusting board
______________________________________________________________________
Page - 175 - of 178
Troubleshoot
1. Replace the fuse
2. Connect the broken
circuit
3. Change lights
4. Change wire, eliminate
short circuit
Note: must not use high voltage or other types of light to replace, this is because it may
waste too much electricity, or cause overload in electric device, or reduce the lighting
effect.
15.4 Electrical Distribution Device
15.4.1 Fuse Box
1. Summary
In the fuse box there are 8 fuses and they are responsible for protection of all electric
devices. The box is installed on the front side of instrument panel. The basic protected
wires are shown below in the table.
______________________________________________________________________
Page - 176 - of 178
Serial
#
1
2
3
4
5
Capacity
50A
30A
6A
6A
6A
6
6A
7
6A
8
6A
Note: before
melting point.
Generator
Accumulator
Headlight, width indicator
Wiper system, horn system
Turning system, instrument panel indicator, air pressure
warning indicator
Foglight, back light, lifting system
Fuel system
Brake system, fan system, working light, top light
replacing the fuse, first find out the cause, must not use fuses with high
15.4.2 Circuit
1. Summary
Electric device is connected to power source through wires. The circuit consists of
some copper insulating wires. Its load area is proportional to circuit load.
1. Dial wiring harness: supply electricity to the meters, indicators, and switch buttons
on the instrument panel.
2. Chassis wiring harness: except for front and rear light and odometer, all the electric
device of chassis is supplied by chassis wiring harness.
3. Front light wiring harness: supply electricity for headlight, foglight and turning light.
4. Rear light wiring harness: supply electricity for back combinational light, back
working light and transmit odometer sensors inductance signal.
For easy assembly, rear light wiring harness is divided into rear light wiring harness
(1) and rear light wiring harness (2).
Dial wiring harness, chassis wiring harness, front light wiring harness and rear light wiring
harness are connected through 4 connection devices.
There are also two thick wires in the circuit. They are used for connecting electric bottle
and main gate device, electric bottle and starting, and hence form the whole circuit
system.
Each wire is labeled. The label number used is according to electric circuit principle. If
there is malfunction of the circuit, find out the cause according to electric circuit principle
and do the troubleshooting.
______________________________________________________________________
Page - 177 - of 178
______________________________________________________________________
Page - 178 - of 178