*READ CAREFULLY BEFORE OPERATION*

INSTRUCTIONS TO ZYT5402TXJ350HPWORKOVER RIG CARRIER

ZYT Petroleum Equipment Co., Ltd.

Sept, 2009

Chapter1 Summary
1.1 Summary
This carrier adopts 8X8 carrier, and engine fitted on top, the dynamical transmission adopts hydraulic and mechanical transmission, and adopts flat head cad of offset style. This carrier should be off when you put other equipments on it, the engine offers dynamic to the special vehicle, and meets the need of fitting, it belongs to the kind of specific vehicle.

1.2 Range of application

ZYT5402TXJ workover rig is mainly used for transporting mast drawworks

hydraulic and water tank and some other equipment of drilling rigs.

drum

1.3 Features of products

This carrier adopts 8X8 carrier, so that it can past and suit any kinds of road when it is driving and working. The features are: 1.3.1 It adopts half-integral cab, which makes the vehicle more beautiful; and separates the electricity units from the driving cab by clapboard, which makes the electricity units examined and repaired easily, and the capability of seal is much better. 1.3.2 It adopts integral steering device, the capability is stabilizer. 1.3.3 Transmission system adopts hydraulic and mechanical transmission, the scope of velocity changing is larger, and its simple to operate and has perfect and stabilized low- velocity capability, so that it can pass any soft roads easily; furthermore, because of the shock absorber of the hydraulic units, the life of engine and transmission system is longer. 1.3.4 Adopt double turning brake system, it improves the stabilizer of the whole vehicle. 1.3.5 Adopt 445/65R22.5 tyre of wide offset (2 front axle), 12.00-20 tyre of narrow offset (2 rear axle). It improves the load capacity.

1.4 The code number of VIN is printed on the vehicle brand where is the middle of crossbeam. 1.5 The carrier of ZYT5402TXJ workover rig should be according to the standard of Q/ZYTC014-2006

special vehicle carrier .

1.6 There are some denotations as follows, predicting the dangerous conditions of operators:

Dangerous!--angerous!---high ---highhigh-grade danger, can lead to badly hurt or death. Warning!--arning!---middle ---middlemiddle-grade ganger, may lead badly hurt and death if operation is not safety.
Attention! ---low ---lowlow-grade danger, can lead to hurt of operators and badly

damage of machine.

Chapter 2 Structure features features and work elements

transmission systemaxle, tyre and wheelframe assembly suspend system steering system brake system electricity system
Main parts: power system driving cab assembly and so on

2.1 Power system

Power system is the dynamical equipment that used for the drive of the whole carrier. Its power is come from the C9

350hp diesel engine which is produced by

Cater pillar. This engine is different from the one of the ordinary vehicle, it not only offers power to carrier, but also offers power to the special equipments on the carrier, so the requirement to the engine is strict. This system is composed by engine, air entering system, fuel offered system, cooling system, throttle operation device, exhaust system and other parts. 2.1.1 Engine The engine of this carrier is C9

350hp of Cater Pillar, about other details of this turbocharger cool machine and

engine, please reference the engine maintenance instructions. 2.1.2 Air intake system

This system is mainly composed by air filter

air entering pipes. Turbocharger can absorb the clear air which is strained by air filter, and then cool it in pipelines; the compressed air gets into cylinder of engine by pipelines and burns with fuel. Attention! The admission port of filter cleaner must keep unblocked, there must be not obstacle around 20mm. 2.1.3 Fuel supplying system

This system is composed by: 400L fuel tank assembly coarse screen junior fuel filter (2 micron, high efficiency) separator and other parts. Attention! There must not be calvous conducting wire joint or electrical equipment which can lead to electric spark around fuel tank and pipes line.

fuel transport pump, hand oil pumpoil-water

engine oil cool machinetorque oil cool machinewater entering pipe water venting pipe side-port nipplesafety valve and other parts. when the coolant heatsaving
This system is mainly compose by heat scatter machine equipment is off, there is not coolant from water vent pipe to heat scatter by side--port nipple; when the water machine, the coolant will enter cool water pump coolant heatsaving equipment is on, a little part of coolant will enter cool

2.1.4 Cooling system

pump, a large part of coolant will enter scatter heat machine by water vent pipe and then get out from it to enter into cool water pump by water pipeline.

Warning! Dont open the lid of coolant for heat sink on condition of the engine is running or shutting off just now, to avoid high temperature liquid scald. 2.1.5 Throttle operation This system is composed by throttle valve

diaphragm cylinder gun switch

long distance operate controller. This part is composed by electricity controlling, foot down the accelerator pedal, the airflow gets into the diaphragm cylinder, under the action of the air pressure, the perch in the diaphragm cylinder gets out and thrust the drawing pole, and the perch runs together with the handle of the long distance operated controller, give signal to the electron adjustable-speed unit, so that control the pump and make it offer oil to engine. 2.1.6 Exhausting system Main parts: sound absorber

exhaust pipe extinguishing cage. Waste gas

produced from engine is discharge to atmosphere through exhaust pipe and sound absorber. Open the extinguishing cage in running and close it in operation. Attention! There must not be inflammable gas or liquid around exhaust system, and cant install the fusible equipment.

transmission mechanical transmission style. The basic compose is hydraulic transmission box derailleurdifferential box and axes speed differential, drive axle and transmission
The system of this carrier adopts hydraulic shaft.

2.2 2.2 Transmission system

transmission

2.2.1 Hydraulic transmission box Hydraulic ransmission Box is a kind of bladed transmission which takes liquid as medium. When is on working, it makes use of reciprocity of the work bladed and the work liquid, and the energy of the machine and the liquid transform with each other to change torque by changing of the liquid momentum torque, so it has ability

of continuously variable speed and torque. So it can be used for CVT device successfully. 2.2.1.1 Features of Hydraulic Transmission Device 1

It has perfect and stabilized lowspeed capability, so it can pass any soft It can avoid engine over loaded and flameout suddenly on the complex and Because of the shock absorber of the hydraulic units, the life of engine and

roads easily, and it is suitable to low-speed traction of drilling rigs hook and the suddenly resistance working conditions; 2

difficult road; 3

transmission system is longer 4

Credibility to operate, life is long and maintenance is simple; 5Be calm when starting, accelerate quickly and equally
2.2.1.2 The basic parameters of hydraulic transmission box To go with the C9

hydraulic ransmission box. The basic parameters are seen as follows. About other details, please reference hydraulic transmission Instructions. Attention! The oil temperature of transmission should not be higher than 1350C, once higher than 1350C, you should stop immediately, adopt idle and other cool methods, do not go on driving until temperature go back to right order. 2.2.2 Drive axle The vehicle drive axle is at the end of transmission, its basic function is to enlarge the torque that sent by transmission axle or by derailleur directly, and then distribute the torque to the left and right drive wheel to make them have the difference velocity ability that meet the requirement of car driving kinematics; at the same time, the drive axle will stand plumb stress, longitudinal stress and transverse stress that acted between road and frame.

350hp engine, the engine chooses the Allison 4700OFS_R

This carrier adopts integral drive axle with wheel-side decelerated and differential device. The second and third ones are pass---through axle. 2.2.2.1 1st

wheel-side decelerated devicesteering institutedrive shaft hub tyrebrake

This axle is the steering axle assisted by hydraulic. Composed by axle dint electric controlling cab. Wheel-side decelerated device will distribute the dynamic equally to left and right wheel, and permits correspondingly rotation of left and right wheel to meet the driving requirements. The structure of brake is hoofed-up, when the compressed air gets into the electric controlling cab, the handspike gets out driving adjustable arm, then the camshaft runs, camshaft drives the hoofed and brushes with dynamic drum to brake the wheel. 2.2.2.2 The second axle

Axle

This axle is the pass---through steering axle assisted by dint of hydraulic. Composed by axle dint, wheel-side decelerated device, rotate institute, drive axle , hub, tyre, arrester, electric controlling cab. The wheel-side decelerated device will distribute the dynamic equally to left and right wheel, and permits correspondingly rotation of left and right wheel to meet the driving requirements. There is a electric lock on the wheel-side decelerated device, so that the left and right wheels combined with each other rigidity and rotation velocity of them are same to improve the pass capability. Combined with the electric lock, the first and second axle combined with each other rigidity and rotation velocity of them are same to improve the pass capability. The structure of brake is in hoofed and drum style, when the compressed air gets into the electric controlling cab, the handspike gets out to driving the adjusting arm, then the camshaft runs, camshaft drives the hoofed and brushes with dynamic drum to brake the wheel.

decelerated device rotate institute drive axle hub tyre brake pneumatic
This axle is the pass---through driving axle. Composed by axle crust wheel-side controlling cab. The wheel-side decelerated device will distribute the dynamic equally to left and right wheel, and permits correspondingly rotation of left and right wheel to meet the driving requirements. There is an pneumatic lock on the wheel-side decelerated device, so that the left and right wheels combined with each other rigidity and rotation speed of them are same to improve the pass capability. The axle-side

2.2.2.3 The third axle

decelerated device will distribute the dynamic equally to rear third axle and forth axle and permit that the rotational speed of third and forth axle is not same to meet the driving requirements and reduce the tire wear. There is an pneumatic lock on the axle-side decelerated device, so that the third and forth axle combined with each other rigidity and rotation speed of them are same to improve the pass capability. Pneumatic brake room brake when there is no gas; it is used at the time of stopping and halting on slope. The structure of brake is hoofed-up, when the compressed air gets into the pneumatic controlling cab, the handspike gets out driving the adjusting arm, then the camshaft runs, and the camshaft drives the hoofed and brushes with dynamic drum to break the wheel. 2.2.2.4 The forth axle This axle is driving axle. Composed by axle crust device rotate institute drive axle

hubtyrebrakepneumatic controlling cab.

wheel-side decelerated

The wheel-side decelerated device will distribute the dynamic equally to left and right wheel, and permits correspondingly rotation of left and right wheel to meet the driving requirements. There is an pneumatic lock on the wheel-side decelerated device, so that the left and right wheels combined with each other rigidity and rotation speed of them are same to improve the pass capability. The pneumatic combination

brake chamber includes diaphragm brake chamber and spring brake chamber. The diaphragm brake chamber can brake via charging air and used for driving, the spring brake chamber is air-break break system and used for stopping and halting on slope. The structure of brake is hoofed-up, when the compressed air gets into the pneumatic controlling cab, the handspike gets out driving the adjusting arm, then the camshaft runs, and the camshaft drives the hoofed and brushes with dynamic drum to break the wheel.

2.2.3 Cardan joint and transmission shaft Cardan joint is used for dynamic transmission between two shafts with different axes or even between the axles which relative position is changing continuously. Among the axles, or between the axle and the differential box, it adopts universal transmission device of cross- axle style. Details as follows (picture2-1 and 2.2)

the first axle(steering axle), 2the first and second axle transmission axle 3the second axle(pass--through steering drive axle) 4the transfer case second axles transmission shafts
P2-1 Front transmission shafts collocation

transmission shaft from transfer gearbox to hang frame 6hang frame 6driving shaft from hang frame to the 3 axle 7the third and forth transmission shafts 8the third axle(pass--through drive axle) 9transmission shaft for the third and forth axle 10the forth axle(driving axle)
5
rd

P2-2 rear transmission shafts collocation

2.3 2.3 Tyre and wheel

The tyre and wheel are important parts of the vehicle. The function are: standing the quality of the car and the droop force from the road; standing drive stress and brake stress when the car is on driving; standing side-counter force to make the car drive on the schedule way when it is steering; absorbing and reducing the moving load and vibration that produced on the bad road. Wheel is composed by spokes and hubs. Tyre is fitted on hubs, and spokes are fixed on the hubs by bolts. Hubs are the basis of the tyres fitting, can support tyre safety, and make it is convenient to fit and dismantle the tyre. The carrier front axle adopt: 445/65R22.5 tyre of wide offset, type 22.5X14.00.AA. Rear axle adopt: 12.00-20 tyre of narrow offset, type 8.5-20. Attention! Gas charging according to established pressure of this tyre, keep pressure of every tyre identity, if there is major pressure difference among those tyre, it may be lead to flat tyre.

2.4 2.4Frame assembly

Frame is the basic load part of the vehicle, it supports the engine transmission

steering machinenon-loaded vehicle body and all related parts about

torque

the spring quality, and stands any kinds of power and torque. So the frame should have enough bending rigidity, to keep the relatively position fixedness during the driving proceed and make the distortion minimize; the intensity of the frame should be strong enough, so that ensure its reliability and life time. The main parts of the carling will not distort and craze in using period. 2.4.1 Structure of frame The structure of this carriers frame is edge-girder style, is mainly composed by two parallel carlings and some beams. It also includes laying table that people can work on it, and racking board that can be folded and shield that preventing operators from dropping. When it is standing the torque, all parts produce the bending torque at the same time. The advantages of it are: it is convenient to fit the vehicle body and disposal others assembly and it is easy to meet the needs of refitting and distortion. Carling is the main standing unit of the frame., its length is closed to the length of the integral vehicle; this frame adopts parallel carling with steel of H style cross section to boost up its bending resistance and welding reinforcement.

2-3

Carling

Beam, it connects the left and right girder to form a frame to guarantee there are enough bending--resistance capacity ; this beam also adopts steel of H style cross section , and some beam is done in arch style to leave moving and jumping space on the top of transmission shaft. Laying table, its structure are made by square steel tubes and checkered steel plate, which lies on the two side of the carling, and used for standing of the equipments fitting people and convenient to walk on. Attention! Keep the frame and laying table surface clean, clean the oil contamination in time, avoid the operators injury. 2.4.2 Features of frame structure This frame is the especially frame, which adopts frame welding structure. Features as follows: 2.4.2.1 Carling and tail girder adopts high grade quality and strength 16MnH steel, Carling welded reinforcement board to boost up its bending resistance capacity, and arrange hydraulic and electric pipes along the inside and outside of the two caring. 2.4.2.2 Laying board adopts square steel tubes, and uses many inclined supporting to reinforcement. There are racking table at the end of the side--girder, it is very convenient for operator to check equipment which can turnover up when it is driving and locked on the two side of the frame. 2.4.2.3 There are four legging cylinders, the front legging cylinder lies on the behind of the fender of the front vehicle axle, and rear legging cylinder is on the two side of the tail girder. 2.4.2.4 Collocations: front and rear trailer bar, many kinds of brackets and supports, for example: front steel board brackets rear balance girder brackets engine

 hydraulic little drawwork bracketsraising oil cylinder supports.

2.5 2.5 Suspending frame

front seat differential box brackets angle gear box brackets dead line supports

Suspending frame, it ensures that there are elasticity relation between wheels or axle and the standing system, and it can pass load relax impact reduce shack and it is the whole name of the position of the vehicle body in the proceed of adjusting driving. The main function of suspending system is to transfer the power and torque between wheels and frame, and eases up the impact that the car pass the bad road, and reduces shake that brought by standing and loading system to ensure the driving is welloff . The suspending frame system of this carrier is composed by front and rear suspending frame. 2.5.1 Front suspending frame It adopts steel plate spring to support the balance suspending frame, reference Fig 2-4, this kind of balance suspend frame has many good points: its craftwork is simple, transmission power is reliable, and has enough spaces to fit transmission structure of steering system.

Fig. 2-4 front suspending frame structure 2.5.2 Rear suspending frame Its balance suspending. The multi-axles and noneindependent suspending frame vehicle usually adopts the balance suspending frame. Advantages are: reduce the changing of vertical load between the two wheels when it is driving on the bad road, make the wheel touch with the earth well. So that it can pass any kinds of road easily.

According to the features of the carrier, the 3rd and 4th axles suspending frame can adopt double-shaft balance suspending frame, and cancel counteractive shank rubber assembly and is replaced by rigidity integral girder, which make the structure simplified, and transmission is much more reliable. Reference pic2-5, this suspending frame puts the board spring on the top of the balance shaft, when the two axles loading is not unanimous, this board spring will run around the center of the balance shaft to balance and compensate the two axles.

Fig. 2-5 rear suspending frame structure

2.7 Steering system

2.7.1 Mechanical steering transmission structure Steering system is the institution that ensures the vehicle drives on the imagine track by matching the corners of the left and right wheels reasonably. It is composed by steering operation institution, redirector and steering transmission structure. Steering operating structure includes steering circle, steering shaft, steering pipe pole. Please reference Fig2-6

Fig 2-6 1

steering wheel 2steering pipe pole 3steering shaft

steering operation institution

Steering transmission institution includes steering rocker, steering vertical pull pole, steering burl arm, steering echelon arm and steering across pull pole. Redirector machine will turn the circling of the steering circle into the swing of the steering rocker, and pass according to the ration of angle transmission and power transmission. This carrier adopts front axle steering, steering transmission institution includes steering echelon and tiebar. Steering echelon, this carrier adopts none-absolute suspending frame, so it adopts integral postposition steering echelon which is composed by steering echelon arm, steering echelon cross pull pole and vehicle front axes. 2.7.2 Dynamical steering system Dynamical steering is also named steering injecting force. The vehicle that has this system can steer not only depending on the drivers hand force on the steering circle, but also depending on dynamical steering device. Which makes the steering became easily, agility, and decreases the tiredness of driver, its helpful to keep safety on the driving road.

Dynamical steering system is composed by steering oil tank steering oil pump integral steering machine and tubes. Oil tank is used for stocking, straining and cooling grease.

Steering oil pump offers high pressure oil by the drive of engine, its structure is

bladed pump. The integral steering machine can organize the steering distributed valve, steering dynamical cylinder and mechanical redirector together to form a integral structure; according to the operation direction of the steering circle, the range of the steering angle and the size of moment, it can change passing the route of the hydraulic transmission and the pressure of the oil and the size of the alleyways area. Attention! When the vehicle stock in a long time or operate, to check the facility of the steering gear through operating the steering gear on site before travelling crane, drain away the air in help system.

2.8 Brake system

Vehicle brake system is used for cars decelerating or stopping, and make the car driving safety when it is driving on slope or halting on original area (including on slope).Going with the development of the highway and increasing of the vehicles speed and increasing of the stream of cars density, and to keep the safety of driving, the reliability of Vehicle brake system is much more important day by day. If a car wants to exert its dynamical capacity, its brake system must reliable. This brake system meets the needs. This brake system should have two absolute brake devices at least: driving brake device and halting brake device; the heavy duty vehicle and the vehicle which is usually driving on mountainous area should fit brake device and auxiliary brake system to meet emergencies. Driving brake device is used for decelerating and stopping of driving car, and makes the car keeping suitable and stabilized speed when the vehicle is driving on the slope. Its driving structure adopts double-turning and multi-turning structure to keep the reliability of driving. The halting brake device is used for the cars halting on some position and slopes without time limit, and is a assistant of the cars starting on the slope. The halting brake device adopts mechanical driving structure change of hydraulic and air pressure, which can avoid a lot of troubles. Auxiliary brake system is fitted on the vehicle which is driving on mountainous areas, and makes good use of engine exhausting brake and electric backset brake. It can keep reducing and keeping the vehicles velocity constantly for a long time when

the vehicle is on the slope or reduces and unchains the load of the brake device. Any set of the brake system of is composed by brake machine and brake driving system. Brake machine has drum style and plate style. Driving brake operates all wheels by pedaling, halting brake usually adopts hand operate staff, and operated by central brake machine or wheels brake. The central brake machine located on the transmission system that behind derailleur, and used for braking the transmissions second axes and the transmission shaft. The driving brake and halting brake should have insulated driving institution and it is necessary to every vehicle. The driving institution of brake device has two styles: hydraulic one and air pressure one. There are brake cylinders, wheels and pipes when the hydraulic passes the operation power; and there are air compressor, air pipes, and air store tank to control the valve and air brake chamber. According to the features of this carrier, the brake system is composed by driving brake system and halting brake system. The air pressure of the brake system should be adjusted to 0.7MPa-0.85MPa, about the brake system of carrier ZYT5402TXJ Workover rig . Reference FIG2-9

relay valve

change valve

air control valve three parts

prevent frostbite pump 9gas processing 10double lock valve 11restriction control cylinder 12foot
7 8

4 differential relay valve

2 electromagnetics change valve

dryer

5 four-turning protective valve

3 electric control 6

restriction control valve

13 air brake master valve fig 2-9.brake system

14

hand brake valve

2.8.1 Driving brake Driving brake is air--charge brake and double-pipeline brake system, namely insulated front and rear axle brake pipeline; the pressure of working is 0.75MPa, the cutting pressure of the pressure-adjustable valve is 0.8MPa; there are foot brake pedal on the floor of the cab which can controls the first two axles brake and the rear three axles brake by the lever institution and double cavity brake valve, and control wheel brake by mechanical transmission at last. Double-pipeline system is safe and reliable. When there are some troubles in one pipeline, the other one can work, so the vehicle cant lose its work capacity completely, which can avoid the serious accidents. The double-cavity brake valve has front and rear cavity room, which can adjust time difference of the first two axles brake and the rear two axles brake to get the best brake effect. This valve has been adjusted well before leaving factory, so customer need not adjust it again. There are light switch in the connection of pipeline, once the signal transmits when the car brakes, switches on circuit, the light on the cabs gauge and brake light on the tail of the car will light up. The driving brake has reliable brake system. The distance should not higher than 12m from the time of stepping the brake pedal to stopping steadily. If it is higher than 12m, you should inspect and adjust the pipeline and the units of brake system. 2.8.2

Halting brake

The halting bake is air cutting brake, hand brake valve is fitted on the side of the drive chair in the cab. There are four assembled spring cavity room in controlling rear axle and quickopening valve and brake light switch. When the air pressure is lower than 0.45MPa, the pull force of the piston isnt enough to compress spring, the piston pole gets out to brake wheels; when the air pressure is higher than 0.45MPa, the spring is compressed, and the rear axle is released, the vehicle can drive. If halting brake is needed, the hand pull brake is put to the brake position, cuts the air source of spring brake room, the quick opening valve ejects air of the brake room quickly, the spring gets out; connect circuit at same time, the signal light on the cabs gauge will light up.

When there are some troubles in the brake system, depending on the pull force of the force-storage spring, it will brake automatically to meet the emergency. Hand brake is double-used for emergency brake and halting brake, it takes effect by the storage brake cylinder of the rear three axles, and its force of brake is controlled into a certain range to auxiliary brake when the loading vehicle is on the emergency brake condition. 2.8.3 Air brake valve Air brake valve parts, are used for driving brake of the vehicle and control sensitively in the proceed of braking and releasing; there are front and rear brake cavity room, which can adjust the time difference of front and rear brake cavity room to get the best effect of brake; the front and rear brake cavity room can control the first two axles and the rear two axles separately, when there are some troubles in one cavity, the other one can work in gear. 2.8.4 Hand brake valve Hand brake valve, air brake valve parts, is used for stopping of vehicle and halting brake, handle of brake valve hand is on the position between driving position and stopping position. It can increase brake capability gradually when the stopping position is locked and the handle is moving between driving position and stopping position. 2.8.5 Front brake chamber Front brake chamber, single-effect chamber structure with form board, is used for driving brake. The air brake signal that emitted from foot brake valve enters into accelerating valve to control front air storage with big drift diameter and compresses air in it, and then gets into the first four brake chambers, compresses the return spring that effects on form board to pull the pole effect on brake arm, and makes the wheel produce brake moment quickly at last. 2.8.6 Rear brake chamber Rear brake chamber is an assembled institution, odd-effect chamber structure with form board is used for driving brake, when it is on driving brake condition, the air brake signal emitted by foot brake valve enters into rear axle argent brake valve, adjusts and controls rear air storage with big drift diameter , and compresses air in it to enter into six assembled brake chamber quickly and sufficiently, and compresses the return spring that effects on form board to pull the pole effect on brake arm, makes the wheel produce brake moment quickly. Spring brake chamber is used for stopping

brake, operated hand brake valve to let the compressed air in the four rear brake chambers spring brake chamber sets free, the brake spring protrudes to drive the pole to take effect on brake arm, and makes the wheels of rear axle produce moment. Attention: Before the starting of the carrier, the pressure of the compressed air in the air pipelines should not higher than 450KPa. There are hydraulic reducer on the ALLISON transmission box, you should step down the switch of hydraulic reducer on the side of the cab when the carrier is driving on the slope, makes the hydraulic oil full of the cavity of the reducer, lets the hydraulic reducer take effect, and reduces the impulsive force that transmitted from the vehicle, reduces speed and avoids the hot of the brake. Attention: the hydraulic reducer on the form driving time will consume power of engine, so please open the switch of the hydraulic reducer when the vehicle is only driving on the long slope.

2.9 Electricity system

The electricity power needed by all electric equipments is offered by battery and generator. When the generator doesnt work, the power is offered by battery. When the generator works, the generator will offer power and transmit the extra power to battery at the same time; when the generator is over loaded, the battery will help it to give power. This carrier adopts silicon commutate three-alternating brushless generator which is brought by CAT-C9

350hp originally, the rated voltage is 28V,

the rated capacity is 1.5kw, and there are voltage adjusting machine in it. Because it adopts brushless and oiliness axletree, it is not necessary to maintenance in usual time, but cleanness is necessary, there shouldnt have metals nearby, for fear the generators output pole laps iron or wraps transmission strap. Wire bind is the connecting parts of all electric equipments and made up of inserting and connecting parts, wire weld tie-in, low-voltage copper electric sire, and insulated enswathed material. There are four roots of wire: wire of cab, wire of front light, crossbeam wire and rear tail light wire. Their general connecting points are fitted on the wire terminal of cabs rear wall. Except terminal, where also fit fuse box and all relay. This kind of collocation makes the repairing and inspecting of the wire and the fuse changing become more convenient. Further more, when making wires, a lot of positions are wrapped by insulated material to avoid grinding and folding, and can insulate heat and oil, which can meet the needs of working in bad environment.

2.9.1

Start motor and start system Instrument system Lighting system dipped headlight front lightback tail light and side sign light.

Start motors direct voltage is 24V; the max work current is 500A. 2.9.2

The instruments and indicator light of the cab and the side of engine are not needed to maintain. If there are some mistakes, please inspect the fuse box and the corresponding sensor. 2.9.3

The circuitry of this part is complex and is founded everywhere of the vehicle. It includes high beam

There are special requirements for maintenance and protection of this part. In the ordinary time, please pay much attention to the switch and button, wires cant be bugled, broken and be closed to hot source. The switches of all lights are fitted on the assembled switch that under the steering wheel, where not only have lights system, but also have electro water--wiper switch, steering switch and trump button. The other switches are centralized on the warping switch of the instrument panel. 2.9.4

Signal system

The requirements of this part is same with the above-mentioned, it mainly includes front

rear and side signal light of the carrier, danger warning light none

triangle front and rear backing flash light and brake light. The main parts of steering and warning signal system is 4DW-002 flash machine which has perfective capability, for example: outside light absenting and trouble showing capability. In addition, the switches of fog light and backup light are the assembled warped board switch on instrument check. 2.9.5

Gear box control system

This part is electric equipment circuit accouplement and vehicle scattered cluster installation and the cluster among gear box, electric control unit (TMC), shift, decelerator control part and connection box (VIM). TCM power line. TCM positive and negative power lines link to vehicle electric power supply through connection box. When arrange TCM power line must be notice: A. Positive links. When the main power switch locates to accumulator positive electrode, TCM positive power line should link to output connector of master switch (but not to link to accumulator positive pole). When there isnt main power switch in accumulator positive electrode, TMC positive power line can link to its positive pole,

and this power line should reduce length, cant bond any other load. B. Negative links. When the main power switch locates to accumulator negative electrode, TCM negative power line should link to output connector of master switch (but not to link to accumulator negative pole ), and this power line should reduce length. When there isnt main power switch in accumulator negative electrode, TMC negative power line can link to its negative pole, and this power line should reduce length C. Must be sure that there is enough passing ability of electric current for gear box computer power line, if add connector on power line, must be sure the same passing ability of electric current for this connector. The connector end must contact reliably, and make sure compression quality between the end and conducting wire. General purpose line connection reference to FIG 2-10 and 2-11, this part cluster install in connection box beside accumulator case.

FIG 2-10 Gear box cluster and vehicle connection box links

FIG 2-11 Gear box control circuit links

Attention! 1. Must make sure that the TCM metal heat sink cant contact with vehicle any other metal part and conducting wire with positive and negative power. When there is welding operation on vehicle, open connection box, pull-up the main cluster plug from TCM to avoid TCM damage. 2. After welding, thrust main cluster plug to TCM, then close the box and make a seal to prevent water, avoid TCM damage. 2.9.6 Auxiliary working parts Main parts: cab warm-up machine

electro rain scraper and compressed dryer.

Power supply is connected with dryer by battery, and heats venting from the air charge switch to the resistance threads, so that it wont freeze and keep the dryer dry. The water vapor that adsorbed in dryer is brought out by the venting redundant air and can be used circling.

2.10 Driving cab assembly

Biasing integral sealed cabs can reduce noise of outside, and it is dust proof and guards against rain; there is a chair which can reduce shakes, and this chair can adjust in the regulated range according to the drivers requirements; and the layout of operation parts is reasonable and operation is simple.

Attention! After startup engine, must check whether display normally for every instrument and signaler before run the carrier.

Chapter 3 Main technical parameters

3.1 3.1Main technical parameters of integral vehicle
No 1 2 3 4 Item Outline dimension(LWH)(mm) Parameter

kg Max masskg
Fross mass Driving form Dynamical factor D1 D0 Front Rear

1376032062830 18000
39970 88 0.568 0.039 2430 2325 1350 1700 3400 27 15 281 45 455 20% 15.5

Tread

mm

7 8 9 10 11 12 13 14 15 16

mm Front suspendingmm Rear suspendingmm

Wheel base Approach angle Departure angle Min. ground Clearance (mm)

55501350

km/h Mileagekm
Max. speed

Min. steering radm

Max. climbing capacity %

3.2 Technical parameters of main parts

3.2.1 Model Max power(KW)/speed(e/min0 Max torque(N.m)/speed(r/min) Min. speed/ max speed(r/min) 3.2.2 Model Lock rate Model of transmission Speed rate 3.2.3

Engine

C9

350hp

261/2200 1554/1400 700/2100

Hydraulic transmission

Allison 4700OFS_R 2.25 TC290 7.63

Assist steering system

3.511.911.431.00-4.80

Max. pressureMPa

Model of oil pump

V10-1P7P-38C20 26.5 13

Displacement of pump L/min

Chapter4 Use and Operation Operation

The carrier adopts multi-axles and self-driving carrier and ALLISON hydraulic transmission, its driving operation is different from the ordinary vehicle. So, when you use this vehicle for the first time, please read technical materials and instrument carefully and operate carefully. The right operation can prolong the life of equipments and keep the capability of the vehicle.

4.1 Operation devices and instruments

The operation devices and instruments are fitted in cab, about their position, action and function, please refer to fig.4.1

Fig 4.1

Instruments board in cab

mileage gauge 5left steering light 6 halting light 7 far light 8 engine alarm light 9 engine tachometer 10 alarm of low system air pressure 11difference speed of wheels light 12difference speed of axles light 13whole driving indicator light 14cool water temperature gauge of engine 15 danger warning light 16 indicating light for charge 17 low oil level indicating gauge 18fog indicating light 19oil pressure gauge of engine 20 hydraulic retarder indicting light 21 back-up switch 22 right steering indicating light 23 ammeter gauge 24 fuel gauge 25 hydraulic retarder switch 26 danger warning light 27 difference speed of axles switch 28 difference speed of wheel switch 29whole driving switch 30fan switch 31back up switch 32
trouble indicating light 4

1 start switch

2 gear box retarder working indicating light

3 gear box retarder

 oil pressure gauge of torque converter 34double-finger air pressure gauge 35 back-up switch 36 far light switch 37 fog light switch 38assist near light switch 39carrier light switch 40electro flameout switch 4.1.2Control device
oil temperature gauge of torque converter 33 The graphics is shift, R is reverse gear, N is slack, D is automatic gear, 1

234 are regular gear, when truck moving or 3 4

running, use automatic gear (D), when there is some special behavior, use regular gear 1 2

Inspect whether the oil in the engine is sufficient. 4.2.2 Inspect whether the oil of transmission and work system is sufficient. 4.2.3Inspect whether the air pressure of wheels is suitable and the nuts and the
4.2.1 main connecting part are fixed, and ensure there are no abnormal condition of frame and mast and other main parts. 4.2.4

4.2 Preparation of starting engine

Inject enough cool water into water tank 4.2.5 Inject enough engine fuel 4.2.6 Inject hydraulic transmission oil 4.2.7 Inject lubricant and grease to any parts that are needed lubricated.
4.3 Starting tarting of engine
If all the inspected works are finished, please start engine according to: 4.3.1 Turn on the power supply switch and put the key into the starting lock, the

charge and pressure light will light. 4.3.2

Turn on the switch of the electricity and inspect whether all gauges and Turn the hand switch of throttle to the flameout position (circumrotate in

lights are on the working condition. 4.3.3

verse to stop the oil supply) 4.3.4

Put the transmission pole to the empty position. 4.3.5Press down the switch of the electro fuel pump about five minutes so that
4.3.6 Step down the accelerate pedal to the one-quarter position, and turn on the

exhaust the air in the pump.

starting switch to start engine, the time of the starting shouldnt be longer than ten seconds, if it cant be started for the first time, please stop for a minute and start again, if you are fail to start it for continuous three time, please inspect and find the troubles and eliminate them. And loosen the starting switch after starting of engine. 4.3.7

After the starting of engine, please reduce the supply of the oil, the charge

light and pressure light will turn off right now, and make the engine rotating at any kind of rotation speed for several minutes to let engine get to the natural work temperature. The peel tyre is prohibited, especially in winter, the temperature is low, you cant inject the speed of engine until the temperature of the cool water begin raising and the pressure of the lubrication is in gear. 4.3.8

In the period of engine pre-heating, the driver should inspect the work

condition of all gauges, and adjusts the throttle, and ensures that the rotation speed of the engine is lower than 500r/min. 4.3.9 When the engine is working at middle speed, if you find it blocks and lags when turning steering circle, please examine or adjust the power auxiliary system. After the adjustable of the steering, let the vehicle drive about one or two km and examine again. When the steering machine is adjusted well, it should be locked by pin firmly, turn the steering wheel left and right by hand to eliminate the air of the

Attention: Attention: 1Steering system is adjusted well before leaving factory, operators operators can cant adjust at will, if the adjustment adjustment is not suitable, the steering auxiliary will lose its function and maladjustment. maladjustment. 2It is not fit for fullfull-load working until the temperature of cool cool water in engine gets to 60 60C. The engine should be stopped after a period of working time, it is necessary to discharge the load and work at low speed for five minutes and turn off at last.

hydraulic auxiliary system, and start driving again.

Note: About the operation and maintenance, please read the operation operation and maintenance manual of the C9350hp engine .
4.4 Driving of the vehicle
4.4.1 Inspection before driving No matter driving on ordinary road or on mountains, please inspect the following items before driving: 4.4.1.1

The finger of oil pressure should be in green area. 4.4.1.2The pressure of air pressure gauge shouldnt lower than 450kPa. This Difference speed lock controlling valve of wheels and axes should be Mutuallock device of up and down machine, please be put to the

vehicle adopts expire spring brake, and the vehicle cant be started when the air pressure is lower than 450kPa. 4.4.1.3

put to the deflate position, and prohibit using difference speed lock. 4.4.1.4

down position. 4.4.2

Starting

Allison transmission is a gear transmission box that fitted with hydraulic torque converter, because the structure is special, the operation is different from the ordinary gear transmission. The driver must be familiar with the operation regulates of this transmission box and operates carefully. This transmission belongs to hand controlling shift , when it is driving on good roads, it can begin driving at the second shift and puts the handle on the second shift, then cheers to make the vehicle start , accelerates and rises shift to get the suitable speed. In proceed of driving, there is no need to change shift frequently and control the speed by throttle. Avoid injecting oil suddenly when it is starting. The driver can use the regular gear if he wants to change the shift according to the condition of the road. 4.4.2.1

If it is shifted on the middle or low position, the speed of the vehicle is If the speed is very quickly and is shifted to high position, the driver

not quickly enough, please dont hurry to shift into the higher one until the speed is quickly enough. 4.4.2.2

should reduce the speed by loosening throttle, the speed will reduce automatically along with the rotation speed of the engine, and shift is permitted to position on low position at this time.

4.4.2.3

Forbid thrusting the transmission handle from enter position to reverse In winter, the temperature is low and viscosity of the oil is thick, so the

gear position when the vehicle is driving, which just can be done when the vehicle is stopped. 4.4.2.4

beginning rotation speed should not too quickly. First, please work with low speed for a period of time, then work at quickly speed and high load when the viscosity is thin. About the operation and maintenance of Allison transmission, please read operator manual. Attention: 1 Forbid reducing speed by shifting down suddenly when it is running with high speed. 2 The body of the vehicle is long, deadweight is great, and the barycenter is high, which requires that the driver cant drive at high speed. The max speed of this carrier is 45km/h. 4.4.3

Stopping 4.4.3.1Uplift the accelerate pedal, and step down the brake pedal slowly, when Move the brake handle to the brake position. 4.4.3.3You should work with idle speed about two minutes before dying of the
4.4.3.2

the car is stopped stead, put the transmission pole to the empty barter position.

engine, cool the temperature of engine, and then step throttle for about two seconds to make any parts get enough oil, the engine flames out at last when turning on the air venting brake operate switch. 4.4.3.4

Turn off the starting switch, pull out the key and turn off the whole

opening switch, cut down the electricity so that can avoid discharging of battery at last.

Use in winter 4.4.4.1The enginetransmissiondifferential boxdrive axles should use lubricant that used in cold area when using in cold temperature of 0-30, please
4.4.4 4.4.4.2 Please dismantle the battery and put it in the room where the temperature

take off the original oil clearly and clean the parts with aviation coal oil when changing the oil of chilliness.

is higher than 0

when this vehicle stopped in cold area.

4.4.4.3 Work at 1500 rotation/minute for a period of time after starting of the engine, and dont let the vehicle starting until the temperature of engine oil raise up.

Attention! 1Do not forget loosening handle handle brake when driving; driving; and the air pressure shouldnt lower than 450 450 KPa, otherwise, it will bring up the troubles of starting and soon damage of the brake. 2Do reduce the speed when steering, forbid flash steering and brake, and especially driving on slope. slope. 3 Forbid high speed driving and which shouldnt be higher than 45km/h. 4Forbid reducing speed by reducing barter when it is running with high speed. 5The water temperature of engine shouldnt be higher than 950C, and the oil temperature of torque converter 135 350C converter shouldnt be higher than 1 when it is driving. 6 It can be used that forerunner and difference speed lock controlling valve of wheels and axes only on miry or spongy road. Cant veer after use them, and cant drive in high speed when use forerunner forerunner and dont veer as far as possible.

Chapter 5
5.1 Run in

Maintenance

The right run in of the new vehicle can prolong the vehicle life, and improves the reliability and economical of the vehicle. The mileage of running in is 200km. the special maintenances are needed in the period of engage: 5.1.1

Before run in 5.1.1.1Inspect the connecting and fixed condition of all parts. 5.1.1.2Inspect engine crankcase, oil level of pump and steering fuel tank,
5.1.1.3

transmission, differential box, drive axle and controlling oil tank. Inject when it is deficient, and inspect all parts to ensure there is no leakage.

Inspect whether brake system is normal and the tie-in of pipeline is Inspect all parts of steering institution and ensure there are no looseness, Inspect electricity equipment, light and gauge, and exam fluid level of

leaking. 5.1.1.4

jam and leakage. 5.1.1.5 the battery.

5.1.1.6

Inspect whether the air pressure of tyre can meet standard. 5.1.2Run in period 5.1.2.1Inspect whether all shifts of transmission are connected right and is Dont drive on very badly road and avoid accelerating and braking Inspect all fixed and connecting parts and notice the temperature of Pay attention to the engine oil pressure and temperature of air cylinder Speed limit

shifted easily. 5.1.2.2 suddenly. 5.1.2.3

engine, transmission, drive axle and brake trig. And inspect whether there are cacophony and over heat, if there are, please find the reasons and resolve. 5.1.2.4 head. 5.1.2.5

To get the best effect of engage, you should keep the engine working in the range of 1600-1850r/min, the max speed shouldnt higher than 45km/h. 5.1.3

Finish of run in

5.1.3.1 lubricant

Clean the bottom of engine oil, and clean oil filter and change the of engine, and inspect the fixed instances of bearing entering and Change steering oil cup hydraulic pressure oil, inspect and eliminate

exhausting pipe. 5.1.3.2 Clean the differential box, driving axle and change lubricant. Inspect the tighten condition of all transmission connecting bolts. 5.1.3.3

leakage phenomena, inspect the fixed condition of arm connecting parts, inspect and adjust former bunch of the former wheel. 5.1.3.4 Inspect the working condition of all devices of brake system. Inspect and eliminate leakage of brake pipeline system. 5.1.3.5

Inspect and tighten the bolts of the front and rear suspending frame. 5.1.3.6 Inspect the height of fluid level of the battery and whether the connecting
5.1.3.7

line is tighten well.

Tighten the bolts of tyre.

5.2 Maintenance
To prolong the life of this carrier, and ensure good technical state and the safety of driving, please do maintenance work according to the regulation during the period of using, the following contents will introduce the interval mileage of the carrier and maintenance items. The operating means and requirements of the engine, please read use instrument of engine. 5.2.1

Inspect after the busywork and long-time halting. 5.2.1.1Clean up tools and sundries on the vehicle and worktable, and prick up Inspect whether the lubricated points are normal, and the lubricant of The coolant in engine cooling water tank should be sufficient. 5.2.1.4The level of oil in engine should meet the regulated range. 5.2.1.5The fuel in the fuel tank should be sufficient, and must be purified and

the operating footplate and lock well.

front middle and rear axle meet the regulation. 5.2.1.3

5.2.1.2

deposited strictly at last 72 hours. 5.2.1.6

Inspect the tighten degree of engines strap. 5.2.1.7 Inspect the height of transmissions oil level

5.2.1.8

The oil in the steering oil cup is enough. 5.2.1.9The bolts of all tyre should fixed well and sufficient, and the pressure of Brake, steer and other operate institution can work well. 5.2.1.11There are no leakages of all oil pipes, windpipes and connecting parts, The electro-fluid levels height of the battery, indicator light, switch Inspect whether the frame of engine, transmission and differential box

tyre should be normal. 5.2.1.10

the off-water valve of air storage canister should be closed well. 5.2.1.12

button and water scrape device are all in gear. 5.2.1.13

is loosen, and the rubber flexible cushion is damage. 5.2.2

Inspect after stopping the vehicle 5.2.2.1Eliminate the troubles that founded in driving and get good ready for the
5.2.2.2

next driving.

Eliminate seeper and dusty in all air storage tank. 5.2.2.3If driving in wind and dusty, please eliminate the dusty in the filter. 5.2.2.4Keep the clearance of vehicle, especially the appearance of wind-cool
5.2.3

engine, other wise it will affect the engines heat scatter.

The maintain items of driving 1000km.

Except the ordinary maintenance, you should do extra maintenance as follows when the vehicle drives for 1000km: 5.2.3.1

Clean appearance of all parts. 5.2.3.2 Inspect and adjust the belt tighten degree of engine. 5.2.3.3Inspect the quality of engine oil, if it is metamorphic, please clean
5.2.3.4

bottom and change engine oil.

Clean and change fuel filter. 5.2.3.5 Inspect transmission and driving axle (including reducer of side wheel)
5.2.3.6

and front driving axle turns to the lubricant level, please clean ventilate plug.

Inspect whether the connecting bolts of transmission are tighten and

fixed.

Inspect and adjust the free journey of brake pedal. 5.2.3.8 Inspect whether the connecting bolts of steering institution are tighten
5.2.3.7

and fixed well. 5.2.3.9

Inspect whether the connecting bolts of the front and rear steel plate

spring are tighten and fixed well. 5.2.3.10

Clean exterior of battery, and inspect level and inject distilled water. 5.2.3.11 Lubricate according to the lubricated gauge. 5.2.4 Maintenance items when the vehicle drives for 3000km. 5.2.4.1Clean filter room on the hydraulic coupling machine of the cooling fans. 5.2.4.2 Clean oil bottom and change engine oil. 5.2.4.3 Clean and change strain core of engine oil filter. 5.2.4.4 Inspect lubricant quality of transmission, differential box and driving Inspect and adjust clearance of brake hoof piece. 5.2.4.6Fix and tighten all bolts and nuts. 5.2.4.7Clean separator of brake valve. 5.2.5Maintenance when the vehicle drives for 5000km
5.2.4.5

axle (including reducer of side wheel), if the quality is not good, please change lubricant and set old oil out when the vehicle is warm.

Except above-mentioned, please do extra maintenance as follows when the vehicle drives for 5000km 5.2.5.1

Clean fuel tank and electro pump filter screen. 5.2.5.2 Change lubricant of transmission, differential
5.2.5.3

box and driving

axle(including reducer of side wheel), and clean the ventilate stopper.

Clean

all axletrees and change grease. (only for vehicle with

none-driving front axle) 5.2.5.4 Clean steering oil tank, take strain core out and decompose to clean. and change the oil. 5.2.5.5

Inspect across, straight pull pole and limit device. 5.2.5.6 Clean and use industrial Vaseline to lubricant all brake room, brake valve
5.2.5.7

and automatic draining pressure adjusting valve and quick expending valve.

Inspect air entering and exhausting branch pipes and carbon in muffler, Clean turbo supercharger.

and clean them. 5.2.5.8

5.2.5.9

Inspect riveting of frame and inspect whether the connection of support Inspect whether the electrical wire and bind are fixed, and ensure there

and suspending frame is fixed. Clean axletree of rear frame central seat and adjust its degree of tighten. 5.2.5.10

are no dusty on the appearance of wire and electricity equipments.

5.3 Maintenance and protection of tyre

The beginning damage of tyre are due to: the charge pressure isnt right, overload, over speed, be impacted and their colligated factors. 5.3.1 Charge pressure

Pressure is the life of tyre, the design of tyre make the tyre can work on the condition the tyre side bend yield and distortion, only the right charge pressure can ensure the distortion of tyre, so that ensure the traction, float and load capability. over-high and low of charge pressure will shorten the life of tyre will due to the damage of early damage. 5.3.1.1 When the charge pressure isnt sufficient, the tyre will soften, which will lead to the distortion of tyre will lead to heating and the tyre of shade line, and the forever damage: a

Because of the heat of excess extortiontyre surface tyre side and shade cloth floorair seal floor and shade cloth floor will escape with each other. bPrick up tyre of shade line, and lead to the rupture and tyre burst. cShade lines are relaxed, especially shoulder. dAbrasion of surface of tyre is not equality, and grinds the tyre shoulder. eNo inner tube leaks air. fTyre circle is grinded gTyre side tyre chaps radial. hBreaches are found in air seal floor.
5.3.1.2 The pressure of charge air is too high, on the one hand, which will reduce the area that tyre touches with area, .when it is working on soft ground, the tyre will sink deeply and the float and draught capability descend, the energy consumption of engine is enlarged; on the other hand, the inner pressure will exceed pull rubber and shade line. All those factors will lead damages as follows: a

The area of driving if enlarged, and it enlarges the contact pressure between

the central part and ground, grind tyre crest. b

The surface of tyre is easy to dissever, perforate and impact inner crack. cThe body of tyre is easy to burst. dExorbitant pressure is injected to the tyre circle, enlarging the latency burst Tyre skids and is found continuous cuttings when it comes cross with sharp
Loading

danger. e

materials. 5.3.2

Over loading will lead to tyres damage as follows: a Because of the heat of excess extortion, tyre surface, tyre side and shade cloth floor, air seal floor and shade cloth floor will escape with each other. b

Prick up tyre of shade line, and lead to rupture. cAugment of the pressure between the driving level with ground and the Overfull stress acts on tyre circle, which results in the damage of the tyre
Speed

displacement will lead celerity abrasion. d circle. e

Enlarge the strain of tyre shade line, which results in burst.

5.3. 3

The average driving speed of tyre is limited by ton km value of per hour, the over speed will lead: a

The heat of inner tyre is higher, lead to heat severing floor. bThe times of urgent brake increases, it will stand more pressure and heat
c Rapid steering makes the tyre abnormal and grind quickly, at the same time it

which is transmitted from brake drum, and which will lead to the damage of grinding, severing and burning.

leads to the side loading of tyre which can result in the damage of tyre circle at last. d

When it comes across rock and other hardy materials, it will be dissevered

and demolished.

Attention! aThe recommendatory tyre charge pressure is cold charge pressure. b The continuous working will make the tyre heating, the air

pressure will rise along with the heat of inner tyre. The tyres type is different, so the amount the pressure which has raise is different too. Which is belong to the ordinary instance, and will not lead to damage. Do not reduce the pressure which is resulted from the continuous working by deflating of the tyre. c During the operation, the tyres pressure is higher than recommendatory pressure about one quarter or much more. Please stop working, and inspect cold charge pressure, pressure, If the cold charge pressure is right, please adopt the way of reducing the driving speed and and loads to reduce the heat of tyre. Other wise it will lead to the sever damage of the over heating. dPlease use pressure gauge to inspect air pressure and adjust the gauge termly. eMouth and hat of the valve should be wear, which can prevent the mud and sand entering the valves insulation effect.
Inspect of the tyres outlook 5.3.4 To avoid the troubles of tyre, the inspects to tyre before the rig solid moving are necessary. 5.3.4.1 Inspect of tyres surface a

wheelvalvepressure

Eliminate all dusty from the tyres surface bIf there are severs, please debus the tyre and inspect whether it is necessary to If the damage of the tyre surface has stretched to shade cloth, please debus the The breach of surface groove may be the exit of leaking, please inspect the air The none- uniformity fray may be resulted from charge pressure. If it is

repair. c

tyre and repair. d

pressure. e

necessary, please do the tyre transposition. f

Please avoid the surface damage where contacts with frame, if it is possible,

please change the parts of frame and repair the damage tyre. g Clean the oil on the tyre.

5.3.4.2 a

Repair the cutting on the tyre shade cloth floor. bFind the reason of breach, for example: charge pressure isnt sufficient, over Clean the oil and the dusty.
5.3.4.3 Inspection of the valve mouth.

Inspection of the tyre shoulder and side

loaded, ozone and cutting extending. If it is necessary, please repair them. c

a If the valve mouth leaks, the mouth pole of valve and the length pole distortion, you should change the valve mouth or other parts. b

Ensure the hat of valve is covered.

5.4 lubricant and coolant coolant 5.4.1 5.4.1form for lubrication

Amount of NO Lubricate parts Kinds of lubricant Drive per 1000km Mobil 1 Engine SAE 15W-40 API CI-4 Hydraulic torque converter CALTEX Texamatic 1888 DEXRON R 3 Differential box 2-3axles difference speed machine 2~3 5 6 7 8 9 10 11 Axles wheel speed reducer Steering assembly Steering arm axes Steering straight pole Brake pedal Transmission shafts Brake camshaft Drive per 3000km 1 Steering circle transmission Engine 3 lithium lubricant Mobil SAE 15W-40 API CI-4 Hydraulic torque 3 converter CALTEX Texamatic 1888 DEXRON R Change hydraulic drive oil 1 Change engine oil 2 Injected by oil spear 3#lithium lubricant 80W/90 oil 80W/90 oil 1 1 11 1 2 9 10 Injected by oil spear 18# Hyperbola gear oil 85W/90 oil 1 Inspect oil level and inject injecting position Remark

Inspect oil level and inject Inspect oil level and inject Inspect oil level and inject Inspect oil level and inject Inspect oil level and inject

Attention ! The lubricant must be add according to the requirement of this sheet, can cant replace with other lubricant optionally or mix to use.
5.4 Lubricant and coolant

5.4.1 5.4.1Lubricated form 5.4.2Coolant

If using antifreeze, please clean the oil, rust and furring of cycling system before injecting antifreeze according to the requirements. And the operator should observe the level height of cycling system and the effect of antifreeze after injecting the antifreeze, do not think everything is ok when there are antifreeze, especially the lowest temperature of environment is closed to 5~10C that is the critical temperature of antifreeze, the operator should observe the changing of antifreeze, and change it when there are some abnormal conditions, in case antifreeze makes equipments getting damage. Collocation of antifreeze should base on the usually experience to collocate, or purchase the required antifreeze directly. If there are glycol, please inject soft clean water according to the following parameters proportion to collocate the suitable antifreeze. C Serial No The lowest environment Tem 1 2 3 4 -10 -20 -30 -40 20 34 44 51 80 66 56 49 Antifreeze% Amount of water%

Attention: Attention:
Do not inject too much antifreeze, its cool effect will descend along with the increasing of the antifreezes proportion. It is best to inject 3% anti-corrosion agent

Chapter 6 Troubles analyzed and trouble shooting

6.1

Engine system Transmission system

Reasons of trouble Shooting methods

The related troubles and trouble shooting should refer to the engine instruction 6.2

The temperature of transmission is too high

1.1 The oil level is too low 1.2

The oil level is too high 1.3Jam of oil pipes and engine oil
radiator

Inject oil to regulated position Set oil to regulated level Dredge oil pipes and change radiator

1.4

Continuous working time is too

Stop working and cool with low speed

Heat of axles different speed box and speed reducer Clean and inspect lubricant system 2.1 Lubricant is not good Adjust or change bearing 2.2 Bearing become loosen Adjust the level of lubricant 2.3Level of lubricant is too low 3Noise in axles different speed box and speed reducer Change the bearing 3.1Wear of bearing Repair and change 3.2Gear wear Change lubricant 3.3Pollution of lubricant 4 Shake of transmission Deliver to repair 4.1 Fall off of the balance block Change bearing and lubricant in time 4.2Wear of bearing Deliver to repair 4.3 Bending of transmission
2 6.3 1

long

Heat of brake hub

Adjust the clearance

Brake system

1.1 Clearance of brake hoof is small

1.2 The new brake piece contact is not Running-in, repair

enough 1.3 1.4 2

Brake failure
Dirty in brake drum

Repair or change brake drum Clean

Run-leaning of brake 2.1Brake clearance of all wheel is

not same Adjust the clearance 2.2

The tyre pressure of one side is

Adjust the air pressure of tyre Repair or change the brake piece Adjust double cavity brake valve inspection Inspect air pipeline

2.4The front axle is braked too early 2.5The air pressure of brake room is
2.3 Wear of brake piece is serious

too low

Brake can not work 3.1Air pressure is not enough 3.2Brake clearance is big 3.3 The wear of brake piece
3 serious 3.4

not same

Inspect and repair pipeline Adjust the clearance is Repair and change brake piece

When the speed is 30km/h, the Speed is too high distance of brake is 12m 4 The air pressure raises slowly after opening, the pressure descends quickly. 4.1

Compressed air machine cant The

pipeline connections are

Inspect

the

work

condition

of

work well 4.2

compressed air machine Screw down connections

loosen 4.3 Brake valve or combination valve cant seal well.

Inspect and change

Stopping brake power is defficient 5.1The clearance of brake hub and Adjust
5 brake piece is too big 5.2

again

according

to

the

There are oil on brake piece 6.4Steering system 1Steering is heavy 1.1Wear of steering oil pump
pressure adjusting valve is low

requirements Clean the brake piece

Inspect and change oil pump

1.2 The pressure of flooding valve, Adjust the pressure of flooding valve, pressure adjusting valve

1.3 Steering oil cylinder and pipeline Inspect steering oil cylinder and

1.4 1.5

Viscosity of hydraulic oil is low

leakage

pipeline Change hydraulic oil

The rotation speed of engine is The rotation speed should lower than 600r/min

low

1.6 Lubricant of ball joint of steering Lubricate ball joint of steering institution is not good. 1.7 Wear seriously of ball joint of Repair and change the ball joint of steering is serious 1.8

The air pressure of front tyre is

steering Reinforce the pressure of the tyre

Steering shake 2.1 There are

2 hydraulic system 2.2 steering is too large 2.3

not sufficient

air in steering Eliminate air and inspect the oil route troubles Adjust ball joint valve of steering

Clearance of ball joint valve of The

axletree is large

clearance of steering Inspect steering axletree

6.5 1

There is no power when the vehicle is started

Electricity system

1.1 The electricity of battery is not Charge for the battery enough 1.2 The connections of cable are not Compact connections tightly

1.3

The carbon brush of engine is The armature loop of engine is The touch switch of power is

compact tightly

Inspect, repair or change the carbon brush.

worn

1.4 The contact of the engines main Screw down connection tightly connection is bad 1.5

Repair the armature loop of engine

short 1.6

Change the touch switch of power

The display of the current gauge is not form

Electrolyte
in battery isnt Inject sufficient battery

fired seriously

2.1 The adjustment of engine adjuster Adjust again is not correct 2.2

enough 2.3

The contact of the connection is

Adjust the connection

bad

2.3 The clearance of steering bearing Repair the steering bearing is large

Lamps and lights 3.1There are no light when the light

switch is turned on 3.2

Inspect the warranty box, wiring harness and wire connected terminals Inspect wiring harness and abnormal lamps Inspect power supply, lamps and connections Inspect the joint iron of lamps

Lamplight is not light The fog light is not light The brightness of the two tail

3.3

3.4

light is not equivalence

3.5

The signal light cant work The vehicle light does not work

Inspect the wiring harness connection and bulb Inspect the wiring harness connection and bulb

3.6

3.7 The one side steering light works Inspect the wiring harness connection and the other side one does not work and bulb

3.8 Urgent warning switch reference Inspect the hub and the reference light cant work 3.9

When steering on the steering

light turn dark resistance Inspect exterior steering light and

light , the steering light will fire after reference lights hub

Horn 4.1Horn cant sound

4

one flash

Inspect

switch,

power

supply

Horn rings for a long time 5Other parts 5.1 No electricity of whole vehicle 5.2The engine doesnt work when
4.2

warranty and relay Inspect switch and horn relay

Inspect the whole switch of power Inspect the power warranty and the starting switch Inspect the gauge power Inspect the gauge, connection lead and sensor Inspect the brake switch and whether there are short circuit Inspect the former wiring harness of brake switch and if there are joint iron

All gauges cant work 5.4Some gauges cant work

5.3 5.5 the fuse is broken 5.6

press down the starting switch

Step down the brake pedal and The fuse is broken once fitted
brake signal

Attention! Attention! 1No barrier within 10m area of stopped vehicle, no flammability and easy exploded materials within 20m, for fear fire when you inspect the circuit.

2Please put a triangle block under the wheel when stopped on slope, do not use fragile material to be the block. 3The front and rear of vehicle should have signal badge with strong brightness when repair on road and at night. 4Use the floodlight of outside connected power, its working voltage must behind the safety voltage 36V. 5Because this vehicle is the special vehicle, and is the transport tool of rigs, please pay much attention attention to affection of the top of the vehicle when working under the crossbeam of the carrier. carrier. 6When charge the battery of the vehicle, please back out the joint iron line between the battery and the vehicle, for fear the suddenly hoist of charge voltage, voltage, and burnout the electric equipments. 7The stopped car should disassemble the cables pigtail of battery. 8When repairing the circuit, you have to do fire blow experiment, in case the turnoff of the lead and badness of the connections contact. 9When hen electric welding is done on vehicle, do turn off the whole switch of electricity, electricity, for fear attack the voltage adjuster.

Chapter 7 Transportation and storage

Transportation: transporting of carrier 7.1.1 Lading by customer and drive back directly; 7.1.2 It can be transported by railway. 7.1.3 Hoist it by two crane at the same time, reference graphic.
7.1

7.2

Storage: the carrier should be started once per month during storage time,

and drive for about 100 kilometers, and operate vehicle entirely and lubricate any parts once per three months, ,and the time of running should not be less than 6

Attention ! After vehicle reach to destination or the store expire, expire, check whether every components are in good condition, whether there there is flexible for bolt, whether there is gas leakage, whether electric equipment system work well.

hours.

Chapter 8 Packing list

8.1 Technical document and tools with carrier
Technical document with truck Name User manual Certificate of quality Diesel engine user manual Diesel engine technical document Hydraulic transmission user manual Tools with truck Name Diesel engine tools with truck Carrier truck Others Triangle board 4kg dry powder fire extinguisher warning 1 tools with Specification 1 Qty. Remarks 1 Qty. 1 1 Remarks

set
1

set set

1 bottle

8.2 Replacement parts

Replacement parts Engine Hydraulic transmission Other Name Oil seal Specification A2300010 Qty. 1 Position Front axle assemble According to the supply of engine manufacture According to the supply of hydraulic transmission manufacture

Oil seal Oil seal Oil seal O-ring Oil seal Oil seal O-ring

A2300030 2300050G 2300070G A2305016 3501110 3501080 HG4-333-66 HG4-692-67 HG4-692-67 HG4-692-67

2 3 4 4 2 2 8 6 6 2

Front axle assemble Front axle assemble Front axle assemble Front axle assemble Camshaft frame Camshaft frame Brake shoe

38X4.6

Oil seal PD25x50x10 Oil seal PG95x130x12 Oil seal PG100x140x12

Transfer case