BJZ3364 Dump Truck for Mine Use Operation Manual
Operation Operation Manual Manual o f Dump Truck BJZ336 BJZ3364 4 PREFACE The improved BJZ3364 Dump Truck for Mine Use is based on the former 3364 truck. BJZ3364 Dump Truck is a 4x2 biaxial dump truck, equipped by fluid backward-curved cargo. It can be used in mine, water and electricity project and transportation of ores and loosened materials in infrastructure department. The vehicle uses Chongqing Cummins NT-855-C250 diesel engine, and BJC-6-154-100/115 (over speed) transmission. Firstly, we have improved on the underpan, so that the structure is more reasonable and the field of vision is wider. Improvements on cab structure and inner decoration enhance the intensity and coziness. Secondly, we have also changed the instrument panel panel and the steering system, so that the interaction between the driver and the vehicle is more convenient and flexible. Furthermore, the improvement on brake system makes the distribution of brake pipelines more clear and reasonable, the maintenance more reasonable and the brake system’s lifespan longer. After improving the carriage structure, the intensity has also been improved. Hence, the improved BJZ3364 Dump Truck for Mine Use will have a much better performance. This manual consists of instructions on structures of each assembly, their capability, technique parameters and requirements on use and maintenance. It has a list of troubleshoots on common breakdowns. It provides basic methods for disassembling/assembling the parts. For the engine component, please refer to “Cummins diesel engine (NT-855-C250), manual for use and maintenance”. maintenance”. The instructions on engine will therefore not be given in this manual. In order to make the best use of this vehicle, drivers and the maintenance people should read this manual carefully and understand the structure and operational characteristics well. Please strictly follow the regulations in the manual, or our company will not be responsible for any loss due to misuse. We would like our customers to provide any feedback for us, so that we can keep improving on our product and hence serve the customers better.
Note: This manual is correct at the tim e of print and may be updated at at any time with out not ice. While every attempt is made to ensure that the information in this manual is correct, no liability can be accepted accepted by the authors or pu blish ers for loss , damage damage or injur y caused by any errors errors i n, or omission s from, the information gi ven.
Organization: ZhongHuan DongLi (Beijing) Heavy Vehicle Co . , Ltd . Technology Department. Ad dr ess :
Beishenshu Village, Taihu Town, Tongzhou District, District , Beijing (Ciqu industry west section).
Postal Code: Code: 101111 Telephone: 010-81502672/2788 Fax: Fax:
010-81502540
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Operation Manual o f Dump Truck BJZ3364
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Operation Manual o f Dump Truck BJZ3364 SAFETY GUIDELINE This guideline provides instructions on driving and maintaining the vehicle. Please read it carefully before using this vehicle. 1. Driving and maintenance of this vehicle should be done by the specialized operators. Strict and throughout training must be provided to these operators. 2. The operators must study this safety guideline well and know the safety requirements when carrying out the maintenance. 2. 1.
Dress appropriately during operation. Working suit is preferable. Maintenance must be done on firm ground and under good light condition.
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.
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Operation Manual o f Dump Truck BJZ3364
2. 11. Maintain the cleanliness of the maintenance field and surrounding environment. 2. 12. Safety is the operators’ responsibilit y. Keep in mind with the safety guidelines, be clear-minded. Safety always comes first. 3. To prevent accidents, please read the following notices for safe driving carefully. 3. 1.
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.
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Operation Manual o f Dump Truck BJZ3364 3. 11. After driving, besides flameout the engine, also cut off the power supply, lock up the vehicle doors and clean the vehicle. 3. 12. Regularly inspect the fastness of joints between breaking lines, especially under cold and hot weather, ensure the brake’s agility and efficiency.
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Operation Manual o f Dump Truck BJZ3364 CONTENTS Chapter 1 Technical Specif icatio n
01
Chapter 2 Normal Use And Maint enance 2.1 Contro l System And Navigati onal Panel 2.2 New Vehicl e Check -Up 2.3 New Vehicle Run In And Maintenanc e 2.4 Regulati ons On Normal Drivin g Operatio n 2.5 Maintenanc e
10 16 17 21 23
Chapter 3 Lubr icatio n
29
Chapter 4 Clutch 4.1 Summary And Techn ical Data 4.2 Clutch Functi on 4.3 Clutch Structu re And Working Princi ple 4.4 Clutch Usage And Maintenanc e 4.5 Clutch Regulati on And Abrasi on Limi t 4.6 Clutch Breakdown Analysi s And Troub leshoot ing
34 34 34 36 37 39
Chapter 5 Transmi ssio n 5.1 Summar y And Techni cal Data 5.2 Transmi ssi on Functi on 5.3 Transmi ssio n Structu re And Working Princi ple 5.4 Transmi ssi on Operatio n And Lubr icatio n Maint enance 5.5 Transmi ssio n Breakdown Analysi s And Troub leshoot ing 5.6 Transmi ssio n Assembl y / Disassembly Technical Requir ement
40 42 42 50 51 53
Chapter 6 Transmi ssio n Shaft 6.1 Summary An d Techn ical Data 6.2 Transmi ssio n Shaft Functi on 6.3 Transmi ssi on Shaft Structu re And Working Princi ple 6.4 Transmis sion Shaft Assembl y And Operatio nal Notice 6.5 Transmissi on Shaft Maintenanc e 6.6 Transmi ssi on Shaft Breakdown Analysi s And Trou bleshoo tin g
68 68 69 71 71 72
Chapter 7 Rear Axle 7.1 Summ ary And Techni cal Data 7.2 Funct ion 7.3 Rear Axle Assembl y And Regulati on 7.4 Rear Axl e Breakdown Analysi s And Trou bleshoo t 7.5 Rear Axl e Maintenanc e
73 74 75 82 82
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Operation Manual o f Dump Truck BJZ3364 Chapter 8 Front A xle 8.1 Summary And Techni cal Data 8.2 Funct ion 8.3 Front Axl e Assembl y And Regul ation 8.4 Front Axle Breakdown Analysi s And Trou bleshoo tin g 8.5 Front Axl e Maintenanc e
83 83 84 86 87
Chapter 9 Steering Syst em 9.1 Summary And Techni cal Data 9.2 Working Princi ple 9.3 Power Steering Pump 9.4 Structu re And Working Princi ple 9.5 Operatio nal And Regul ation Notice 9.6 Breakdown Analysi s And Troub leshoot ing
88 90 92 93 100 103
Chapter 10 Braking Device 10.1 Braking System Summary 10.2 Air Compr essor 10.3 4 Loo p Protecti on Valve 10.4 Cartwh eel Brake Chamber 10.5 Cartwh eel Arrest er 10.6 Air Reservoi r 10.7 Hand Br ake Valve 10.8 Quick Release Valve 10.9 Foot Br ake Valve 10.10 Pipeli ne And Tie-In
106 110 113 114 122 128 129 132 133 134
Chapter 11 Suspension Device 11.1 Front sus pensi on 11.2 Rear sus pension 11.3 Assembl y/disassembl y noti ce 11.4 Breakdown analysi s and tro ubl eshoot
137 138 139 140
Chapter 12 Cartwh eel An d Hub 12.1 Struc ture Summary And Techni cal Data 12.2 Funct ion 12.3 Ass embly Noti ce 12.4 Cartwh eel Use And Maintenanc e 12.5 Breakdown Analysi s And Troub leshoot ing
141 141 142 142 143
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Operation Manual o f Dump Truck BJZ3364 Chapter 13 Hydraul ic Pressur e Dump Syst em 13.1 Technical Data 13.2 Funct ion 13.3 Assembl y And Working Princi ple 13.4 Lift Pump 13.5 Lifti ng Vat 13.6 Distri but ion Valve 13.7 Lim it Valve 13.8 Operation On Lift System
144 144 144 145 148 149 152 153
Chapter 14 Vehicl e Frame, Carri age, Cab And Driver Seat 14.1 Vehicl e Frame 14.2 Carri age 14.3 Cab 14.4 Driver Seat
159 159 162 163
Chapter 15 Electri cal Device 15.1 Start ing Device 15.2 Electr ical Generating Device 15.3 Illu mi nation Device 15.4 Electrici ty Distri but ion Device
165 173 176 176
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Operatio n Manual of Dump Truc k BJ Z3364
Chapter 1 Technical Specification 1.1 General Techni cal Specifi cati on Model Type Drive mode
BJZ3364 one side (left) cab, biaxial dump truck 4X2 one side (left), upside/downside separable, full metal frame
Cab Weight Load mass Dry mass (fuel & water inclusive) Full loaded total mass
20000 kg 16000 kg 36000 kg
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
7750 kg 11000 kg 8250 kg 25000 kg 1.28
Length
7365mm
Width
2909mm
Height (full load)
3110mm
Height (no load) Wheel base
3145mm
Track front
2328mm
Track rear (Central line distance between two tyres)
2070mm
Ground clearance
385mm
Min. turning radius (According to centre of front felloe)
18000mm
Angle of Approach
32 º
Angle of Departure
42 º
Carriage max lift angle
45 º ±2 º
Lifted carriage- ground maximum height
6300mm
Lifted carriage- ground minimum height
940mm
Carriage dimension- Normal loaded (heightened carriage)
10.7 m3(13.0 m3)
Carriage dimension- Pile loaded (heightened carriage)
13.9 m3(16.2 m3)
3600mm
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Operatio n Manual of Dump Truc k BJ Z3364 Engine Model Type
Aspiration Number of Cylinder – radius × travel distance Total emission Condensation ratio Max output power/rotate speed
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
Max torque/rotate speed
1019Nm(104kgForce· meter) /1500 turns/min
Rating rotate speed/max no load rotate speed
2100turns/min/2400tu rns/min 625turns/min anti-clockwise 1-5-3-6-2-4 1258kg 1570mm x 925mm x 1246mm
Idling speed Crank turning direction (facing side of flywheel) Ignition order (clockwise) Total mass (with standard accessory) Dimension (length x width x height) Lubrication Device – Engine Type
Pressure-feed lubrication (2100tunrs/min)241-3 45kpa No less than 102kpa Gear pump Side stream oil filter CD-15W/40
Lube oil pressure Idling lube oil pressure Lube oil pump Lube oil filter Lube oil model Coolin g Device - Engi ne Type
Closed circulating water-cooler with expansion chamber and water softening plant
Circulation water pump Fuel System Fuel injection pump Type Nozzle pressure Nozzle hole diameter Feed pump Fuel filter Speed controller
Centrifugal PT(G)-AFS fuel pump 8 holes 96700kpa 0.178mm Gear pump Primary & Secondary Two plate mechanical control
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Operatio n Manual of Dump Truc k BJ Z3364 Ai r Fil ter Type Max All owed Admission Drag When clean When dirty Exhaust Type
Dry air filter 3.726kpa 6.178kpa T-46 exhaust turbo
Max allowed back pressure
9.999pa(75mm mercury column)
Exhaust pipeline normal pressure dimension Electrical Device Starter
125mm diameter 25volt(accelerating relay inclusive)
Generator
24volt35amp(voltage regulator inclusive)
Engine supporting equipment
Shockproof rubber blanket
Clutch Model Type
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
Type and gear number
Allowed input max torque Allowed input max rotate speed Transmission’s center distance
Velocity ratio for each gear
Gear
1
2
3
4
5
6
Reverse
Velocity ratio (overspeed)
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
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Operatio n Manual of Dump Truck BJZ3364 Dimension (length x width x height)
1005mm x 390mm x 550mm about 324kg 2 nodes, tubular open, with needle roller bearing universal joint collapsible pipe
Mass Transmission shaft type
Center Transmission Shaft (clutch - transmission ) Assembly dimension Allowed stretching amount Rear Axle Transmi ssi on Shaft (transmi ssio n - rear axle) Assembly dimension Allowed stretching amount Rear axle Final drive 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
Final drive ratio Differential Type
Half-axle Type Reduction ratio Rear axle total speed ratio Wheel Alignment Caster angle
0 o
Kingpin inclination angle
9 o
Front wheel camber
0 o
Toe-in of Front Wheel (measured at peripheral rim)
0-3mm
Turning hub
No 35 steel cast piece
Rim
Steel sheet welding
Tyre
14.00-24.24 level, inflation pressure 650±50kpa, load capability 6000kg
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Operatio n Manual of Dump Truck BJZ3364 Suspension System Front suspension
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
Steering And Brake Redirector type Assist type Transmission ratio when redirector travels straight Foot brake Hand brake
Working pressure Carriage Carriage
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
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Operatio n Manual of Dump Truck BJZ3364 Cab Cab
Single left side integral full metal structure
Electrical system Circuitry connection
Mongline negative earth 24V 2 in series 6-Q-195 195amp•hour
Rating voltage Accumulator pile Model Capacity Others Front axle
Thick wall seamless welded steel pipe structure Whole steel cast, flanged fixed shaft stub at two sides C-type girder and L-type auxiliary girder with side plug welding
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
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Operatio n Manual of Dump Truck BJZ3364
Figure 1 - BJZ3364 Dump Truck fo r Min e Use
Figure 2 - NT-855-C250 Diesel Engine
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Operatio n Manual of Dump Truck BJZ3364
n o i s n e m i D k c u r T p m u D 4 6 3 3 Z J B 3 e r u g i F
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Operatio n Manual of Dump Truck BJZ3364
Figure 4 - BJ374 Dump Truck Travelin g Perform ance
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Operatio n Manual of Dump Truck BJZ3364
Chapter 2 Normal Use and Maintenance 2.1 CONTROL SYSTEM AND NAVIGATIONAL PANEL 2.1.1 Contro l System Lo cation (See Figur e 5)
Figure 5 - Cont rol System Sketch Map 1 Transmission gear lever 2 Accelerator pedal 3 Brake pedal 4 Clutch pedal 5 Steering wheel 6 Instrument console 7 Combinational switch
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
Operatio n Manual of Dump Truck BJZ3364
Figure 6 - Positi on Of Gearlever Of Norm al Gear Transmiss ion Case
Figure 7 - Positio n Of Gearlever Of Overdri ve Gear Transmiss ion Case ______________________________________________________________________ Page - 11 - of 178
Operatio Operatio n Manual of Dump Truck BJZ3364 BJZ3364
1 Up/down seat position adjust handle 2 Front/back seat position adjust handle Figure 8 - Driver seat
1 Red signal when filter is covered with dust 2 Indicator reset button
Figure 9 – Air Cleaner Mechanical Mechanical Indi cator
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Operatio Operatio n Manual of Dump Truck BJZ3364 BJZ3364 2.1.2 2.1.2 Cab Cab Inst rument ru ment Panel
Figure 10 - Instr Instr ument p anel Sketch Sketch Map Map
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
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Operatio Operatio n Manual of Dump Truck BJZ3364 BJZ3364 2.1. 2.1.3 3 Sign Sign al Indicator Explanation
1. Turning left indicator: on on when combinational combinational switch is turned to left 2. High beam: on when when using combination combination switch to change change front headlight to far light 3. High water temperature temperature warning indicator: on when when engine water temperature is above 120 4. Low pressure indicator: indicator: on when failure in arrester or pressure pressure lower than 450kpa 450kpa 5. Low oil pressure pressure indicator: on on when engine engine oil pressure pressure is too low 6. Parking brake indicator: on when when using hand brake for parking 7. Travel switch indicator: on when when carriage is lifted and travel travel switch is on 8. Turning right indicator: indicator: on when when combinational combinational switch is turned to right
2.1.4 2.1.4 Swi Switc tch h Usage
As shown above, two 6-join seesaw seesaw switches have blank 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
Operatio n Manual of Dump Truck BJZ3364 Ignition switch - insert key into the switch and turn it (clockwise) to level 1 to electrify all devices, turn to level 2 and push the start button to electrify the engine, both levels are immediate switch and release the turning when ignited. If starting fails, try again in 2 minutes. To cut off engine, push the extinguishing button, the engine will be extinguished. 2.1.5 Instrum ent Panel Indi cators 1. Barometer: Indicate air reservoir pressure. 2. Ampere Meter: Indicate direction - positive or negative depend on if it is an input accumulator or output accumulator. 3. Speedometer: indicate traveling speed and cumulated travel mileage. 4. Tachometer, hour meter: indicate engine speed and accumulated working hour. 5. Fuel meter: indicate fuel level in the fuel tank. 6. Water thermometer: point between 75 ºC -90ºC under normal condition. 7. Fuel barometer: Indicate engine fuel pressure. When it is below standard value, warning switch is closed, low pressure indicator is on. Parking inspection is required.
2.1.6 Use Of Control Handle and Socket For Worki ng Li ght 1. When lifting carriage, firstly connect the electromagnetic valve then lower the lifting handle. After carriage reaches certain height, the lifting indicator is on. 2. When using hand brake for idling parking, the corresponding indicators should turn on. 3. Socket for external light can be used for subsidiary maintenance light. Although accumulator capacity suffices the use of each electrical device, for longer lifespan of the battery and wiring harness, and reducing the cost, try t o avoid simultaneous working of the electrical devices. If any device is not working, firstly check if the f use is broken. If the device is still not working after replacement of the fuse, refer to the device theory map to solve the problem.
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Operatio n Manual of Dump Truck BJZ3364 2.2 NEW VEHICLE CHECK-UP Simple road tests have been done fore the vehicle leaves the factory. In order to avoid accidents during transportation, necessary check-ups should be done before use. Check-up contents are as followings: 1. Check and fasten each bolt, nut and lockpin. 2. Check engine, transmission case, rear axle, dynamic turning system, lifting system fuel level, capacity and fuel quality, refuel or replace if necessary. Check the above assembly pipeline connection. 3. Check if the tyre pressure is within the specification, which is front and rear tyre pressure 650 ±50kpa 4. Check accumulator fluid level, it should be 6-10mm higher than the clapboard. 5. Check electrolyte proportion, it should be 1.29 when the temperature is 15ºC. For each 10ºC increase/decrease, the proportion will increase/decrease by 0.007 respectively. Add or adjust fluid if necessary. Check if the connection between lead and electric bottle is tightened, and if the electricity circuitry is working. 6. Check engine, starting device, voltage adjustor etc. 7. Check elasticity of fans or generator’s belt. When slightly depressed, the belt should sink about 10mm. 8. Check for each connectors of engine cooling system. Check if fuel supply system is working when the engine starts. 9. Check brake efficiency, i.e. brake distance, to see if there is any deflection or stagnancy. Also check any leakage in the pipelines. If there are any faults, troubleshoot the cause and solve them immediately. 10. After the vehicle starts, check if the turning system is working and if the drive panel and signals are working.
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Operatio n Manual of Dump Truck BJZ3364 2.3 NEW VEHICLE RUN IN AND MAINTENANCE 2.3.1 Significance Of New Vehicle Run New vehicle’s lifespan, extension of interval of heavy repair and working reliability and economically depends largely on this new vehicle run at the beginning and the maintenance quality. Although new vehicles or vehicles which just completed their heavy repair have done vehicle run before leaving the factory, the surface of accessories is still rough. The shape of accessories after machining, coordination and clearance between each part still have some deviation. When the vehicle is operating, due to the friction the temperature will rise. Because the clearance between each part is small, the lubricants cannot easily reach those parts, hence resulting in bad lubrication and worsening the wear and tear. Therefore, new vehicle run in is necessary, otherwise over friction can occur in the parts if new vehicles are immediately put into full load travel after leaving the factory. The thermal expansion will result in biting of the parts and abnormal wear and tear. Vehicle’s lifespan will be largely reduced. Hence it is important to carry out the new vehicle run in to maintain a normal working condition to prolong the lifespan. New vehicles or those which have just completed the heavy repair have the running regulation. For mine use vehicle, BJZ3364 Dump Truck, the continuous travel time is 150 hours in the run. There are specific regulation for the use and maintenance of the vehicle during the run. 2.3.2 Regulati ons During New Vehicl e Run A. Red uc e The L oad Mass Always reduce the load during the run. Add load as recommended below Run time First 50 hours First 51-100 hours Load No load 10000kg Run time First 101-150 hours First 150 hours onwards Load 15000kg 20000kg If the load is too heavy, the engine and chassis have to bear with too much pressure and will affect the lubrication, thus the load will directly affect the accessories’ lifespan, Break in quality will not be guaranteed. Gear Transmission 1st 2 nd 3 rd 4 th 5 th 6th Case type Normal gear 4.2-4.3 6.5-6.7 9.9-10.2 15.4-15.8 23.7-24.4 30.9-31.8 Overdrive 4.8-4.9 7.5-7.7 11.8-12.1 19-19.6 30.9-31.8 40.6-41.8 gear ______________________________________________________________________ Page - 17 - of 178
Operatio n Manual of Dump Truck BJZ3364 B. Control lin g The Speed Carry out the run with a reduced speed, no high speed travel is allowed. The maximum speed for each gear is stated as below. Gear Transmission 1st Case type Normal gear 4.2-4.3 Overdrive 4.8-4.9 gear
2 nd 6.5-6.7 7.5-7.7
3 rd
4 th
5 th
6th
9.9-10.2 15.4-15.8 23.7-24.4 30.9-31.8 11.8-12.1 19-19.6 30.9-31.8 40.6-41.8
NOTE: 1) Unit is km/hour 2) Engine tur ning speed is no faster th an 1700-1750turns /min C. Regulati ons On Drivi ng Durin g The Run 1. Do not step on the pedal too fiercely when start. Strictly control the acceleration pedal to prevent engine run up. 2. After start, maintain middle speed (1200-1400turns/min) to slowly heat up the engine. When the water temperature reaches 70ºC, fuel pressure is not lower than 350kpa, brake pressure in not lower than 450kpa, ampere meter pointer indicates at charge position, the vehicle can be started. 3. Use 1st gear to start the vehicle, maintain the steadiness and reduce the impact on brake system. 4. Choose the road surface properly, avoid travelling on a bad road surface. Adjust the gear level according to the road surface condition. Do not exceed the regulated speed. When changing gear from high speed to low, “two feet clutch” method should be used. 5. Avoid max speed run for engine. Avoid long time travel with low speed and high acceleration to prevent deposit of charcoal in the cylinder. 6. Jumping of gear is prohibited when climbing up. Choose appropriate gear when downgrading. Strictly prohibit overspeeding operation of engine. 7. Avoid sudden brake or long time brake. When at heavy load, apply intermittent pressure to the brake pedal over a distance before stop line. 8. Replace lubricants in the run according to the regulation. ______________________________________________________________________ Page - 18 - of 178
Operatio n Manual of Dump Truck BJZ3364 9. In the first 30-40km traveling, check the transmission case, front and rear hub (shaft stub), main reducer, rear tyre planetary reducer, turning device, transmission shaft, if there is overheating at lifting pump or noise and any other abnormal phenomenon. If there is, find out the reason and do the necessary troubleshooting. 10. Please follow the above regulations during the run. In the following 400km, please use the vehicle carefully to avoid long time high speed operation of the engine.
2.3.3 Maintenance During The Run Maintenance during the run consists of 3 parts: Before, during and after the run. A. B efo re The Run Please refer to 2.2 “NEW VEHICLE CHECK UP”. B. During The Run Maintenance during the run is carried out in the first 50 hours. Its purpose is to carry out a timely maintenance for the parts which has begun to undergo some technical changes, and ensure the smooth run for the next stage. Main contents for the maintenance are as follows: 1. Clean engine lubrication, replace lubricants and filter core of primary and secondary filter. 2. Lubricate each lubricating point. Details please refer to 03 “Lubrication” table 3 3. Clean the filter core of the air filter. Clean the seeper and feculence in the reservoir tank. 4. Check the efficiency of the brake device, the sealing condition of between connection points and brake pipelines. Adjust and fasten accordingly. 5. Check and tighten cylinder cover and bolts pipelines of air entering and exhausting pump. 6. Fasten the transmission case and bolts of its kickstand. 7. Fasten the flange bolts of front and rear transmission shaft. 8. Fasten the bolts of rear axle shell and main reducer shell, and the nuts of drive pinion bearing shell fixed on the main reducer shell. 9. Fasten the nuts of the hub on the tyres. 10. Fasten the nuts of U type bolt on front and rear suspension shelf. 11. Check the steering drag link and steering tie rod of front tyre, especially the possible clearance between the turning arm, sphere-pin and lever. Fasten any bolts and nuts.
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Operatio n Manual of Dump Truck BJZ3364 C. Af ter Th e Run A maintenance is necessary when the run is finished. Check and verify the connection points of the parts, fasten and adjust them if necessary. After the run the vehicle can therefore start its normal operation. Main contents for maintenance after the run: 1.
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, filt er 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 engine’s iron cast cylinder shell, first warm-up, then check the tightness of air cylinder shell’s 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 assembly’s 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.
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Operatio n Manual of Dump Truck BJZ3364 2.4 REGULATIONS ON NORMAL DRIVING OPERATION A. Bef or e Dri vi ng Daily maintenance is necessary for driving. Please refer to “Daily Maintenance” in 2-5. B. Vehicle Starting 1. Step down the clutch pedal, switch the gear to neutral. 2. Turn the key to ignition to start the engine. Beware that the interval between each ignition should be 20-30 seconds. Strictly prohibit continuous starting to avoid wasting electric power of accumulator. 3. Use antifreeze when temperature is 0ºC or below 0ºC. 4. Strictly prohibit head on starting. When the tow truck launches, use a rigid connecting rod. 5. Slowly heat up the engine after starting. When the water temperature raises about 70ºC, and machine oil pressure and brake pressure is normal, amperemeter pointer points to charging position and indicators on the panels are all working, then start driving. 6. Pull down the parking brake handle to release the arrester. 7. Start the full load vehicle with 1st gear, no load with 2 nd gear. C. During Traveling 1. Keep engine’s water temperature at 75-90ºC, machine oil pressure at 350-490kpa, brake pressure at 450-750kpa. 2. Switch gear according to the road condition. To prevent damage to the parts and engine, do not jump gear or long time travel with low speed gear 3. Use “two feet clutch” method when switch gear. Strictly prohibit jump gear. 4. If encounter obstacles, release the accelerograph first then brake. Never use arrester and accelerograph at the same time. 5. This vehicle uses hydraulic power turning device, so sliding with engine off is strictly prohibited. This is to prevent hydraulic power assistant to lose its function and result in malfunction of turning device. 6. When climbing down a considerably long slope, make use of engine to brake, adjust appropriate gear accordingly, at the same time use feet control brake to control the speed, avoid overspeed operation of the engine. Strictly prohibit climbing down with neutral gear. 7. Use parking brake when parking on the slope. If it is an upgrade, the transmission case should be at 1st gear, if downgrade, then use reverse gear. 8. Distance between two traveling vehicle is 30m for downgrade and 15-20m for upgrade. 9. No overtaking in one-direction traveling road. ______________________________________________________________________ Page - 21 - of 178
Operatio n Manual of Dump Truck BJZ3364 D. Parking 1. Release the accelerator, step on the clutch pedal to switch the gearlever to neutral, slowly step the brake pedal till the vehicle stops. 2. After the vehicle stops, push up the parking brake handle. If the parking brake functions, the relative indicator will be on in the panel. 3. When parking, if the parking time is short (5-8min), engine may not be off, to prevent wastage of electricity when start again. If parking time is long, then switch off the engine, otherwise long idling time will lead to incomplete combustion to produce accumulating charcoal and diluted lubricants. 4. Unless in the situation of flying car, must not use “emergency choke” to switch off the engine. 5. Before off the engine, the engine should be idling running for 3-5min to let lubricants and cooling fluid to cool down firebox bearing and shaft and thus cool down the engine. This is especially important for worm wheel pressure engine. 6. Pull up the off engine switch, close the starting switch, pull out the key and switch off the power circuit. 7. In winter, often replace the cooling fluid in the engine. 8. When parking for a long time, the vehicle should be placed in a horizontal parking place, with support of stow-wood to lift up the vehicle from ground. E. Liftin g of carriage 1. Accurately switch the gearlever to neutral. 2. Step the clutch pedal till the end, switch on the lifting function, put the lifting control handle to “lift” position, and then slowly release the clutch. 3. Step on the gas to accelerate the engine, gradually lift the carriage and dump the load. 4. During the dumping put the lifting control handle to “dump” position to let the carriage automatically get back to its original position. 5. When the carriage if fully lowered down, step the clutch pedal, switch off the lifting function to disconnect the power output. 6. No moving of the vehicle if the carriage is not completely lowered down. F. Regulations on use in winter 1. In winter, use special fuel and lubricants (for winter use) for engine and chassis assembly. Details please refer to 03 “Lubrication”. 2. Daily release the fuel tank’s sewerage. 3. When retrieving the vehicle, open all the water releasing taps of the engine to release all the cooling fluid. 4. Use a warm cylinder to start in winter. Warm-up the engine to 50 ºC (fill in hot water into the cooling system), idling running should be no less than 5min, do not fill in cooling fluid after start to prevent cracking in the cylinder. ______________________________________________________________________ Page - 22 - of 178
Operatio n Manual of Dump Truck BJZ3364 5. Gradually heat up the engine till 75 ºC, then start the vehicle. 6. When parking outdoor with temperature -30 ºC and below, disassemble the storage battery and put it in a warm place. 2.5 MAINTENANCE Maintenance of the vehicle is closely related to the environment and the condition of the vehicle. We will classify the working condition into 3 categories: good, moderate and bad (refer to the table below). Working condition Road condition: Road foundation Slope Turn Speed Distance traveled Environment: Dust level Corrosive matters Basicity Temperature Daily working time Load Water, fuel quality Lifting times Dumping manner Driver’s experience Organization
Good
Moderate
Bad
Hard, smooth Smooth Large Middle >3miles
Soft, up and down <8% Large Middle 1-3miles
Too soft, slippery >8% Small High <1mile
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. Dut y Vi si t Main tenance 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
Operatio n Manual of Dump Truck BJZ3364 B. Preventi ve Maint enance Preventive maintenance is also called forced maintenance. It is done from 800 to 6000 hours. It is divided into intervals of 800, 1500, 3000, 4500, 6000 hours. After 8000 hours the vehicle needs to send for heavy repair. C. Emergency Maintenance Maintenance for emergency cases. 2.5.1 Daily Check s Contents: 1. Clean the insides of vehicle and chassis, check if there is any loss of the parts. 2. Check the working conditions of lights, panel, water scrape device, horn, working and parking brake, turning system and other control systems 3. Check the fuel level of engine fuel and chassis machine oil. The fuel level should not be lower than the middle position of two dipstick scale. 4. Discharge the fuel tank ponding daily. Check the smoothness of the venthole. 5. Check fuel capacity. Add fuel at every shift. Keep sufficient fuel in the tank for better cooling of the pump nozzle. 6. Check water level of the cooling fluid. It should be lower than expansion case shell by 30-50mm. Avoid using alkaline liquid. 7. Check the indicator of air filter, when it shows red signal, clean or replace filter core. 2.5.2 Maintenance Within 50 Hours A. Ap pl y L ub ri cants Once Ever y 50 Hour s. Refer to “Lubrication” (table 3) for the parts to be lubricated. B. Parts That Need To Be Maintained After Every 50 Hours Travel. 1. Check and clean air filter. Use 680kpa compressed air to blow it. 2. Check if there is any deposit in the reservoir tank, for example, water and feculence. 3. Check the electrolyte level of the storage battery, it should be 6-10mm higher than the block board. C. Parts That Need To Be Maint ained Aft er Every 100 Hours Travel 1. Check the fuel level of power turning system’s fuel tank. Refill if insufficient. 2. Check the fuel level of transmission case. Refill if insufficient, 3. Check rear axle’s main reducer shell and fuel level of rear tyre planetary reducer. Refill if insufficient.
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Operatio n Manual of Dump Truck BJZ3364 4.Check front and rear tyre pressure. It should be 650±50kpa. 5.Check if there is any damage on front and rear tyre and hub. D. Parts That Need To Be Maint ained Aft er Every 200 Hours Travel 1.Replace the filter core of engine machine oil filter. 2.Replace engine machine oil. 3.Clean fuel filter. 4.Fasten nuts of hub fixed on the tyre. 5.Check and fasten the U type bolts and nuts of front and rear suspension shell. E. Parts That Need To Be Maint ained Aft er Every 400 Hours Travel 1. Replace external filter core of air filter. 2. Replace filter core of fuel filter. 3. Replace the hydraulic fuel of power turning system and filter core of filter. 4. Fasten flange bolts of front and rear transmission shaft. 5. Check and adjust the toe to be 5-7mm. 6. Check and fasten bolts of front and rear suspension shelf. 7. Check the clearance between exhaust valve and rocker. Carry out the check-up according to the instructions in the engine manual. 8. Fasten the bolts of main reducer shell and rear axle shell. 9. Fasten the nuts of steering drag link and steering tie rod. 10. Check and eliminate any possible clearance between steering drag link and steering tie rod. 11. Lubricates the hub of front and rear tyre. 2.5.3 Prevent ive Maint enance A.Par ts That Need To Be Mai nt ained A ft er Ev ery 800 Hour s Tr avel 1. Clean the furring in engine radiator. 2. Lubricate the bearing and lining of engine starter. 3. Replace the inner filter core of air filter. 4. Use gasoline to clean the fuel filter of lifting system 5. Replace the lubricants of rear axle’s main reducer and rear tyre’s planetary reducer. 6. Replace the lubricants of transmission case. 7. Check and fasten the bolts and nuts of redirector. 8. Adjust the clutch. 9. Check and adjust the clearance between steering stub seat and front axle head. 10. Adjust the arrester. 11. Completely check the wiring.
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Operatio n Manual of Dump Truck BJZ3364 B.Parts that n eed to be maintained after every 1500 hours travel. 1. Adjust pump nozzle and valve. 2. Clean the fuel tank and check the fuel supplier pipeline. 3. Fasten engine’s kickstand, air entering and exhausting pipelines, accelerograph lever and bolts of emergency engine off device. 4. Check the clearance between transmission shaft spline and cover, fasten the flange bolts. 5. Check transmission case’s suspension shelf, fasten the bolts and adjust the gear switching system. 6. Check the position of front rear, steering drag link and steering tie rod. 7. Check front tyre’s positioning device, adjust the hydraulic positioning valve of turning device if necessary. 8. Clean steel plate’s spring and apply lead lubricants between the reeds, fasten the bolts.
C.Parts That Need To Be Maintai ned Af ter Every 3000 Hour s Travel 1. Completely adjust turing steering drag link and steering tie rod. 2. Examine and repair the gas system. 3. Tyre transposition of replacing tyre (refer to Figure 11).
Figure 11 - Tyre Transpo sit ion 4. Check the air compressor, replace rubber gasket and tube. 5. Replace pump nozzle, and just valve. 6. Replace fan and engine’s belts. 7. Clean the cylinder shell, rub the valve. 8. Replace water tank’s tube. 9. Check the max and min turning speed of the engine. 10. Replace clutch friction disk and adjust clutch control system. 11. Replace the rubber supporting of shock absorber.
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Operatio n Manual of Dump Truck BJZ3364 D.Parts That Need To Be Maintained After Every 4500 Hours Travel 1. Replace the high pressure tube of the power turning device. 2. Check the lifting fuel cylinder, distribution valve and power take-off, replace high pressure tube and lifting fuel. 3. Open the transmission case’s cover, check the shift fork, gear wheel and fork kickstand, replace if there is any damage on the parts. 4. Check and repair shock absorber and replace its oil. 5. Check and repair or replace front steel plate spring lining, front and rear steel board spring lining or any other lining. 6. Check the sphere surface bearing of rear suspension shelf thrust lever. 7. Replace the gas pipeline tube of gas device.
E.Parts That Need To Be Maintained After Every 6000 Hours Travel 1. Check supercharger of diesel engine. 2. Check compressed pressure of each engine cylinder. 3. Check working condition of cooling system thermostat. 4. Check clutch assembly. 5. Check and repair front axle. 6. Check and repair rear axle differential. 7. Check and repair engine and starting motor. F. Heavy Repair After 8000 Hour s Travel
2.5.4 Notices For Maintenance A. Basic Req ui rem ent For Ac ces so ri es, Par ts A nd As sem bl y 1. Clean the accessories, parts and assembly when necessary. Clean and rub-up using compressed air. 2. No scratch, burr or damage on the surface of accessories and parts. Do not whack machining surface using steel hammer. If need to whack machining surface, use a wooden, rubber and soft alloy hammer. 3. Refit the scratches if the repair does not affect cooperation dimension. B. Bearing Assembly 1. Bearing should remain intact till assembly. After check-up, dip into gasoline or coal oil to wash and dry. 2. When pressing bearing, do not let bearing ball or pole transfer external force, slowly apply force on the outer circle of bearing. 3. Carry out the check and adjustment of bearing only after bearing bolts are fastened.
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Operatio n Manual of Dump Truck BJZ3364 C. Rubber Oil Seal Assembly 1. Oil seal should be clean, no scratch on working blade and surface. Therefore, check carefully for the working surface before putting the flange mandrel and seat ring into the oil seal, check if there is any burr, sharp angle, sharp side (including the assembling tools used) or any other scratch. Apply engine lubricants on the oil seal pressure surface. At the same time, apply butter on the working blade and surface. If it is a double blade oil seal, apply 1/2 butter on the double blade mouth. 2. During pressing, apply force uniformly on oil seal till the end. Avoid askew or overexert to damage oil seal. Do not use hammer or other tools to directly whack on oil seal surface. 3. During assembly, beware of oil seal spring (drop or missing). It is better to dip oil seal into grease for 4-8 minutes before assembly. 4. During spray-painting and gelatinizing, do not wet the oil seal surface.
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 Connecti on 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.
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Operatio n Manual of Dump Truc k BJ Z3364
Chapter 3 Lubrication Lubricating the vehicle correctly can greatly reduce the wear and tear of the parts and vehicle’s 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
1
Fuel tank
2
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
6
6
6
10
10
17
Specification
Interval (hours)
Replacement period
Summer:#0,#10 diesel oil Winter: #-10. #-35 diesel oil Whole year use 15W/40CD diesel oil
Daily
Every 1500 hours Every 200 hours
Daily
10
Drinking water or water without basicity Winter: add antifreeze Summer: #46 engineered hydraulic oil Winter: #32 engineered hydraulic oil #22 synthesized gear oil
Daily
Every 800 hours
Every 100
Every 400 hours
Every 100
Every 800 hours Every 800 hours
17
17
#22 synthesized gear oil
Every 100
14
14
14
#22 synthesized gear oil
Every 100
95
95
95
1.2
1.2
1.2
Summer: #46 engineered hydraulic oil Winter: #32 engineered hydraulic oil Specified spindle oil Standard: SY1206-74
Every 800 hours Every 4500 hours Every 4500 hours
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Operatio n Manual of Dump Truc k BJ Z3364 Table 2 Time table for washing and replacing filter core of filter Part of filter
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
1
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
1
Wash
Table 3 Lubricating location and timing #
Location
# points
Lubricant specification
Every 50 hours
1
Fan belt shaft Accelerator pedal shaft
1
√
Cab door ream shaft Clutch and brake pedal shaft Clutch fork shaft
2
#3 lithium SY1412-75 #1 or #2 calcium sodium SY1403-77 Same as above
3
Same as above
√
3
Same as above
Clutch main detached shaft Steering tie rod and steering drag link reamer Front transmiss ion shaft and gimbal
2 3
#2 lithium SY1412-75
4
#1 or #3 calcium sodium SY1043-77
√
3
Same as above
√
2
3
4
5
6
7
8
1
Every 100 hours
Every 200 hours
Every 400 hours
Every 800 hours
Every 1500 hours
√
√
√ √
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Operatio n Manual of Dump Truc k BJ Z3364 #
Location
# points
Lubricant specification
Every 50 hours
9
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
2
Same as above
√
4
Same as above
√
2
Same as above
√
2
Same as above
√
4
Same as above
√
4
Same as above
√
4
Same as above
√
2
Same as above
√
4
Same as above
√
2
Same as above
√
4
Same as above
√
2
Same as above
√
2
#2 lithium SY1412-75
√
2
#1 or #3 calcium sodium SY1403-77
√
Engine bearing
1
#10 machine oil GB443-64
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Every 100 hours
Every 200 hours
Every 400 hours
Every 800 hours
Every 1500 hours
√
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Operatio n Manual of Dump Truc k BJ Z3364 #
Location
24
Steel plate spring
25
Front rear brake room Accumul ator polar stack
26
# points
4
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
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Operatio n Manual of Dump Truc k BJ Z3364
Figure 12 - Lubric ating Lo cation Sketch Map
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Operatio n Manual of Dump Truc k BJ Z3364
Chapter 4 Clutch 4.1 SUMMARY AND TECHNICAL DATA 4.1.1Techni cal 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 4.2.1Clut ch Func tio n Clutch is a composing part of vehicle transmission system, transmission system connects to engine through clutch. Clutch’s 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 Struct ure 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. Clutch’s 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 t wo 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. Clutch’s 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
Operatio n Manual of Dump Truc k BJ Z3364 Orientation sleeve uses 4 bolts to assemble on the clutch shell. Separating bearing cover is positioned on the sleeve and is forward/backward movable.
Figure 13 - Doubl e Blade Dry Fric tio n Clutc h Sketch Map 1 Initiative platen 2 Middle platen 3 Driven plate assembly 4 Separating lever 5 Compressed spring 6 Flywheel 7 Clutch shell 8 Regulating nut
9 Separating bearing 10 Clutch shaft 11 Separating fork 12 Oil nozzle 13 Clutch shell 14 Vitta assembly 15 Ventilation window lid
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Operatio n Manual of Dump Truc k BJ Z3364 4.3.2 Working Princi ple A. Jo in in g Co nd it io n When pedal is not stepped down, it is in a freedom condition. Under the effect of compressed spring (5), platen (1) and middle platen (2) and flywheel clamp driven plate and make clutch into a joint condition. Power of engine is transfer through platen, middle platen, driven plate assembly and transmission shaft to transmission shaft #1. B. Separation Condition When pedal is stepped down, separating fork (11) moves separating sleeve through rocker and lever, separating bearing (9) is moved forward to drive separating lever (4) and compressed spring (5), platen (1) and middle platen (2) and driven plate assembly (3) is moved backward, at this moment clutch is separated and cut power transfer of engine. 4.4 CLUTCH USAGE AND MAINTENANCE 1. In order to ensure clutch’s performance and lifespan, do not overexert on the pedal. 2. Inject #2 hammer base grease into clutch’s 5 lubricating nozzle on schedule. Refer to Figure 14 for clutch’s nozzle position.
Figure 14 - Clut ch Nozzle Posit ion Sketch Map
Please refer to table for each nozzle’s lubricating interval. ______________________________________________________________________ Page - 36 - of 178
Operatio n Manual of Dump Truc k BJ Z3364 Serial number 12
14
1 2 3
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
Interval Every 50 hours
Every 100 hours
Every 200 hours
4.5 CLUTCH REGULATION AND AB RASION LIMIT 4.5.1 Clutc h Regulati on A. Since clutch is often used, driven plate friction lining piece will become worn and thin. Under the effect of compressed spring, platen and middle platen and driven plate are moved forward, separating lever’s small end is moved backward, so that to keep complete joint of clutch. If there is no certain clearance in between separating lever’s small end bearing, separating lever’s small end cannot move backward and will affect the complete joint of clutch. This will also lead to skidding. Therefore in order to ensure clutch in a normal joint condition, certain clearance must be kept between separating lever’s small end and separating bearing. This clearance is 3mm.
B. How To Adjust 3mm Clearance 1. Clutch pedal path required for eliminating 3mm clearance is called clutch pedal freedom path. Adjust clutch pedal freedom path to ensure 3mm clearance. On the other hand, clutch pedal freedom path is controlled by the length of the lever, therefore, 3mm clearance is obtained by adjusting the length of clutch lever. 2. Before replacing friction flake, due to wearing and tearing of friction lining flake, separating lever’s small end is moved backward. When 3mm clearance cannot be obtained by adjusting the length of clutch lever, can adjust the nuts of separating lever to make 3 separating lever’s small end in the same plane, the difference in height (oriented at the same plane) between each other can be +0.15 − 0.10
.
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Operatio n Manual of Dump Truc k BJ Z3364 3. When replacing new friction flake, re-adjust separating lever’s small end to the same plane as flywheel, 89.7mm. Refer to Figure 13. C. Regulation On Clutch Pedal Freedom Path By loosening the nuts of clutch lever and changing the length of clutch lever to adjust pedal freedom path. Its freedom path should be 25-34mm. D. Separating bearing’s separating path must be 12.7mm.
4.5.2 Clutch’s Abrasion Limit 1. Replace with new friction flake when friction flake’s lining flake is torn till the same level of rivet head. 2. Replace with new clutch platen when platen’s friction surface is burnt or torn and its warping over 0.38mm. 3. Extent of each surface repair by abrading on clutch’s middle platen cannot exceed 0.38mm, total abrading cannot exceed 0.76mm. 4. After abrasion, the circularity of 3 copper tube on clutch’s fork shaft cannot exceed 0.5mm, otherwise replace it.
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Operatio n Manual of Dump Truc k BJ Z3364 4.6 CLUTCH BREAKDOWN ANA LYSIS AND TROBL ESHOOTING
Problem Skidding of clutch Phenomenon: when need to speed up, its speed does not increase as engine turning speed increases
Clutch separation is not complete. Phenomenon: noise can be heard from gear when step clutch pedal to end, shift gear
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. Clutch’s 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 lever’s small end in the same plane, difference in level is 0.15 mm 0.10 +
−
3. Driven plate is warp 4. Middle platen is out of shape
Noise form clutch. Phenomenon: abnormal noise can be heard form clutch
5. Wear and tear in separating shaft sleeve or stick onto position sleeve 1. Wear and tear and collision of accessories due to long time use 2. Lack of grease on separating bearing or separating fork shaft 3. Wear and tear of driven plate spline and spline shaft, not working normally
Adjust or replace Abrading. If after abrading the dimension differs too much, replace Replace
Disassemble clutch to check, replace when necessary Add grease
If spline cooperated clearance exceeds 0.35mm, carry out a heavy repair
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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 shaft’s angle and improve the transmission efficiency, incline the transmission assembly by 2º8’ 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 Technic al Data Technical data Standard mode Model BJC-154-100 Max allowable 980.6 Nm torque input 2300rpm Max allowable rotation speed 154mm input 1005mm*390mm*550mm Transmission About 324kg center distance Outline dimension Transmission weight 1 2 3 4 5 Each gear gear Speed 7.42 4.73 3.12 2.0 1.3 Speed ratio ratio
Overdrive mode BJC6-154-115 1127.7Nm 2300rpm 154mm 1005mm*390mm*550mm About 324kg
6
R
1
2
3
4
5
6
R
1.0
6.84
6.44
4.1
2.62
4.62
4.0
0.76
5.92
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Figure 15 - Transmi ssio n Device Assembly Sketch Map 1 Hexagon head bolt 2 Rear support subassembly 3 Rear shockproof subassembly 4 Rear suspension subassembly 5 I type hexagon nut 6 gear oil pump control pump 7 Transmission assemble 8 Front bracket beam assembly 9 Hexagon head bolt 10 I type hexagon nut
11 Front support sub-assembly 12 I type hexagon nut 13 Spring gasket 14 Small hexagon head bolt 15 Control pipe sub-assembly 16 Spring gasket 17 Small hexagon head bolt 18 Small hexagon head bolt 19 Spring gasket 20 I type hexagon nut 21 Gear shifting box subassembly
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Operatio n Manual of Dump Truc k BJ Z3364 5.2 TRANSMISSION FUNCTION A. Main Fun ct ion Of Transm is si on 1. Change torque and rotation speed transmitted from engine to vehicle drive bridge to satisfy vehicle’s traction and rotation speed for starting, accelerating and climbing. 2. Change the rotation direction of engine’s power transmission to enable the vehicle to rum reversely. 3. Enable the separ ation of engine and the vehicle transmission system when the engine is still on. 4. Transmission with power take-off can output engine power. 5.3 TRANSMISSION STRUCTURE AND WORKING PRINCIPLE 5.3.1 Structure Introduction We can see from the transmission assembly transverse section plane map Figure 16, the transmission consists of 3 parts: drive gear, control mechanism and basic accessories. The function of drive gear is to adjust speed ration and rotation direction and it is 3-axis: axis 1, axis 2 and middle axis. Control mechanism is located under transmission upper shell. I t uses moving gear shifting fork axis to control gear shifting fork and move t he teeth cover on axis 2 to implement gear shifting. Basic accessories are: shell body, front shell, rear shell and upper shell. They are the framework of transmission and provide support to drive gear and control mechanism, fulfill the lubrication and sealing of all accessories. 1. Drive gear consists of axis one 2, axis two 11, middle axis 29. Axis one is equipped with detachable one uranium bevel wheel 5, in order to lubricate axis one front shell’s 42308 bearing, front shell 3’s inner open has oil path, axis one is equipped with oil blocking ring 4, shell body 28’s front end is equipped with oil collector 6, axis one flange plate 1 axis is equipped with SG60x90x12 framework type rubber oil seal. Axis two’s two ends are equipped with 192314 bearing to enhance rigidity. There is no axis-direction clearance in teeth hub, rolling neilsbed, blocking gasket and bearing. Each gear from driven gear’s connecting teeth is claw teeth. One side’s obliquity is 2.5° so that it is not easy to jump gear. Axis two fifth gear teeth ring is looping type to provide condition for changing speed ratio and gears. Axis two’s reverse gear 20 is sliding rolling inner clenching. Gear speed of odograph is changeable and this is done by changing the driven gear 25 of odograph and eccentricity stopper’s angel. Middle axis, except that 1st and 2nd gear and reverse gear are made into one body as middle axis, the rest are all looping for easy change of gears. ______________________________________________________________________ Page - 42 - of 178
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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 two’s 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 39’s 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 4 th 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 transmission’s 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 fr om 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
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Figure 16 - Standard Transmi ssio n Transverse Secti on 1 Axis one flange 17 1st and 2 nd gear’s gear 2 Axis one 18 Gear rolling neilsbed 3 Transmission front shell 19 Axis two 1st gear’s gear 4 Oil blocking ring 20 Axis two reverse gear’s gear 5 Axis one gear 21 Transmission rear shell 6 Oil collector 22 Odograph driving gear 7 Transmission upper shell 23 Axis two flange 8 Gear shifting fork axis 24 Axis two flange nut 9 Gear shifting control axis dialing head 25 Odograph driven gear th 10 Axis two 5 gear’s gear 26 Oil pump connecting axis 11 Axis two 27 Oil pump connecting axis mesh cover th 12 Axis two 4 gear’s gear 28 Transmission shell body rd th 13 3 and 4 gear gear 29 Middle axis 14 Oil feed plug 30 Middle axis 3rd gear’s gear 15 Axis two 3rdgear’s gear 31 Oil drain plug nd 16 Axis two 2 gear’s gear 32 Middle axis 4 th gear’s gear ______________________________________________________________________ Page - 44 - of 178
Operatio n Manual of Dump Truc k BJ Z3364 33 Middle axis bearing cover 34 Middle axis 5thgear’s gear 35 Middle axis transmission gear 36 Gear shifting control axis arm 37 Gear shifting control axis 38 Gear shifting control axis seat 39 Dialing fork mechanism support 40 5th and 6 thgear’s gear shifting fork 41 Gear sensor 42 Reverse gear limit spring
43 Ventilating cap 44 Reverse gear limit tube 45 Reverse gear bearing’s blocking cover 46 Reverse gear’s gear 47 Reverse gear’s gear blocking cover 48 Reverse gear axle 49 Oil meter plug
5.3.2 Work ing Princi ple The working principles of transmission are mainly shown in the power output path of each gear. Different transmission paths will satisfy different speed ratio and hence change the torque and rotation speed for the driving wheel input. When clutch is stepped, control the gear shifting handle; slide the gear cover of axis two forward or backward through distant lever and control mechanism. When idling axis two’s driven gear and axis two’s gear are meshed together, power is transmitted through axis one and middle axis’ gear to axis two and then exported. Below is transmission path for each gear and speed ratio:
th
th
5 6 Gear Teeth Cov er
st
nd
rd th 3 4 Gear Teeth Co ver 1 2 Gear Teeth Cov er
Ax is Two
Ax is One Ax is Two Fl ang e
Lifting Oil Pump Connecting Axis
Ax is One Fl ang e Power Output Mess Cover Middle Axis
Figure 17 - Transmi ssio n Neutral Gear Posi tio n ______________________________________________________________________ Page - 45 - of 178
Operatio n Manual of Dump Truc k BJ Z3364 Neutral gear position is a position when each gear ’s teeth cover is at the middle position. Although axis one and middle axis’ gears are rotating in mesh, the power cannot be export from axis two. When in neutral gear position, middle axis power can be transmitted to lifting oil pump connecting axis by power output mesh cover, lifting dialing fork axis and gear oil pump control pump, and then the lifting pump will start to work. During the normal travel, power output mesh cover must be put in each gear’s position. Below shows a teeth number of transmission gear in each gear. There are two types: standard transmission gear teeth number, overdrive transmission gear teeth number (with bracket).
Figur e 18 - 1st Gear Positi on 1stg ear position: axis two’s 1 sta nd 2 ndg ear teeth cover move backward, so that axis two’s nd 2 g ear driven gear Z=38’s joint teeth is in mesh with 1 st and 2 ndg ear teeth hub. Power is exported through axis two. Its transmission ratio is 43/21*38/11=7.42 (41/22*38/11=6.44).
Figur e 19 - 2nd Gear Positi on 2nd gear position: axis two’s 1 st and 2 nd gear teeth cover move forward, so that axis two’s 2ndg ear driven gear Z=33’s joint teeth is in mesh with 1 st and 2 ndg ear teeth hub. Power is exported through axis two. Its transmission ratio is 43/20*33/15=4.73 (41/22*33/15=4.1). ______________________________________________________________________ Page - 46 - of 178
Operatio n Manual of Dump Truc k BJ Z3364
Figure 20 - 3rd Gear Positio n 3rdg ear position: axis two’s 3 rda nd 4 thg ear teeth cover move backward, so that axis two’s rd 3 g ear driven gear Z=29 (or 28)’s joint teeth is in mesh with axis two 3 rda nd 4 thg ear teeth hub. Power is exported through axis two. Its transmission ratio is 43/20*29/20=3.12 (41/22*28/20=2.62).
Figur e 21 - 4th Gear Positio n 4thg ear position: axis two’s 3 rda nd 4 thg ear teeth cover move forward, so that axis two’s 4 th gear driven gear Z=28 (or 27)’s joint teeth is in mesh with 3rda nd 4 thg ear teeth hub. Power is exported through axis two. Its transmission ratio is 43/20*28/30=2.0 (41/22*27/31=1.62).
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Figure 22 - 5th Gear Positi on (or 6th Gear Positio n) 5thg ear position: axis two’s 5 tha nd 6 thg ear teeth cover move backward, so that axis two’s th 5 gear driven gear Z=23’s joint teeth is in mesh with axis two 5 th and 6 th gear teeth hub. Power is exported through axis two. Its transmission ratio is 43/20*23/38=1.3 (41/22*21/51=0.76) (for overdrive transmission, use 6th gear position).
Ax is One and Two are j oi ned as o ne b od y
Figur e 23 - 6th Gear Positio n (or 5th Gear Positi on) 6thg ear position: axis two’s 5 tha nd 6 thg ear teeth cover move forward, so that axis two and axis one are joined together and power is exported through axis two. Due to the joining of axis one and two, its speed ration is 1 (5thg ear position for overdrive transmission).
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Figure 24 - Reverse Gear Position Reverse gear position: axis two’s reverse gear’s gear moves backward, so that axis two’s reverse gear’s gear Z=35 is in mesh with reverse gear Z=21, and reverse gear interpose gear is always in mesh with middle axis 1st gear’s gear Z=11. Due to addition of interpose gear, the direction of power output from axis two is in reverse rotation. Its transmission ratio is 3/20*21/11*35/21=6.84(4/22*21/11*35/91=5.92). From the changing of speed ratio we realize that the larger the speed ratio, the lower the drop of engine transmission gear traction wheel’s rotation speed, and larger the increase of torque. Therefore when vehicle is climbing the slope with heavy load, the driver usually uses low gears to increase traction of driving wheel. When traveling on the flat road, use high gears, so that engine operates with lower rotation speed and fuel can be saved. Take note that torque from engine is amplified through transmission, however, due to consume of mechanical transmission, there is slight loss in power output.
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Operatio n Manual of Dump Truc k BJ Z3364 5.4 TRANSMISSION OPERATION AND LUBRICATION MAINTENANCE 5.4.1 Operatio n Transmission is an important assembly in vehicle transmission system. It directly affects the performance of vehicle. From past experiences if we want the vehicle to operate normally, an important issue is how to correctly operate the transmission. In order to optimize the performance of transmission, please take note of the followings: 1. Usually use 2ndg ear to start. In difficulties are encountered when using 2 ndg ear, try st nd to use two feet clutch, or first use 1 g ear to start, then change to 2 g ear. Use gear rd by force may cause damage to control mechanism. Must not use 3 gear to start. 2. When switching gear, follow the operational sequences. Must not jump gear because this may cause serious clashes between teeth cover and axis two driven gear’s joint teeth and lead to damage of joint teeth side surface. 3. When lifting, first put the gear shifting handle to neutral gear position, step the clutch and after a while press the lifting electromagnetic valve button. This is to prevent that after ventilation of lifting oil pump control pump, middle axis power is still not cut off and power output mesh cover is not positioned on middle axis joint teeth and this result in clashes between them. 4. If difficulty is encountered when engaging gear or noise is heard during traveling, first check the joints of clutch and transmission control mechanism. If there is no problem, then open the transmission upper shell and check. Must not carry on the operation when the vehicle if faulty. 5. Regularly check the temperature of transmission, especially the temperature rise of front and rear shell bearing. Under normal condition the highest temperature allowed for transmission is 85 ºC. 5.4.2 Lub ric ation Maint enance Lubrication is often ignored by people. In fact it is very important for the lifespan of transmission. If gears and bearing which are often rotating work without lubricants, they will be soon heated up and abraded and even burnt. To prevent this, refer to the followings: 1. For every 100 hour travel, check transmission oil level height once. When opening oil meter plug, if the lowest point of oil meter cannot touch the oil surface, please open transmission shell fuel intake plug to fill in the fuel. The highest point of oil surface is the lower edge of oil meter plug hole. 2. After that, for every 80 hours travel, change the lubricants in transmission. Release the oil completely when it is still hot, as well as clean the iron powder on the magnetic core. 3. When changing oil, check if there is any leakage at the oil seal edge, each joint plane and oil plug. There should not be any leakage for lubrication maintenance. #22 synthesized gear oil can be used both in winter and in summer. ______________________________________________________________________ Page - 50 - of 178
Operatio n Manual of Dump Truc k BJ Z3364 4. There are many steps in transmission control system and it is very often used, so that it will easily become loosed and worn. Check regularly and often apply butter to gear shifting subassembly, single ball universal axis subassembly, adjusting lever subassembly rotating auxiliary position. It is better to wash them as well.
5.5 TRANSMISSION B REAKDOWN ANALYSIS AND TROUBLESHOOTING Transmission may be broken down due to random causes. Most of time it is due to lack of maintenance, bad product quality, quality during assembling and adjustment. Once there is malfunction, find out the causes and solve accordingly. A. Dif fi cu lt y In Gear En gag in g, Or Noi se 1. Clutch is not completely separated. 2. Fork lift mutual and self lock system get stuck. Space lock pin head’s shape is distorted. Burrs in fork lift. 3. Distortion or burrs in teeth cover or gear’s joint teeth side surface so that meshing is impossible. 4. Compression spring inside fork lift self lock is ruptured or distorted. 5. Supporting points of joints in control lever system becomes loose or damaged. B. Gear Cannot Be Released Af ter Engaging. Or Vehicle Does Not Move After Handle Is Moved 1. After the control axis dial head is torn, when shifting gear the head is emerged and causes failure in the conductor groove. 2. 949/22K bearing falls off and deflects control axis. Dial head cannot be restored to its original position. 3. Gear shifting fork or conductor’s positioning stop screw become loose or fall off. 4. Gear shifting fork of control axis’s dial head is broken. C. Sudden Rise Of Oil Level In Transmission And Spillover Through Ventilating Cap 1. Lifting oil pump bearing ring is off groove or broken, and leading to damage of high pressure oil seal ring, resulting in oil entering transmission rear shell. 2. Lifting oil pump two ends bearings are not on the same center, gears in oil pump sweep the boring and damage the high pressure oil seal ring, resulting in oil entering transmission rear shell.
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Operatio Operatio n Manual of Dump Truc k BJ Z336 Z3364 4 D. Noise is heard when engaging gear gear or driv ing 1. Gear shifting fork and axis two teeth hub are not face to face and this leads to clashes between teeth cover and joint teeth. 2. Since axis two moves in a large area, fork lift and gear shift fork are immobile, this relatively makes teeth cover and joint teeth to move and this movement causes the noise from clashes between joint teeth t eeth and teeth cover. 3. Adjusting bracket of axis two blocking cover front end is smashed or falls off, causing a larger axis-direction clearance in axis two. Movement of axis two is equivalent to shifting gear. 4. Fork lift of fork axis is deflected, or gear shifting fork is largely distorted during use, causing gear shifting fork two support feed and axis two not vertical to each other, resulting in deflection of following teeth cover. Noise is caused due to impact. 5. The coordination between gear shifting fork axis and hole is too vast, when use positioning stop screw to tighten, gear shifting fork will be deflected and leads to deflection of teeth cover. 6. Dial fork system support tighten screw becomes loose, causing the position changed in fork lift, and it is equivalent to the position change in gear shifting fork. E. Twist Off Of Transmission Lifti ng Dial Fork. 1. Due to improper operation when lifting, turn on the lifting electromagnetic valve button without stepping clutch, after lifting oil pump control pump is ventilated, middle axis power is not cut off, thus power output mesh cover cannot be engaged on middle axis joint teeth and result in impact on joint teeth side surface. Sometime it is mistaken that the journey of lifting oil pump control pump is not long enough, and adjust the fork shape nut or weld a nut on adjusting control pump, causing the journey of control pump journey too long, and twisting off the dial fork from the root. 2. Dial fork axis and control pump are not put in their initial position when assembling. Power output mesh cover axis-direction moving distance and control pump journey are not matching. Dial fork axis is often tweaked. 3. Power output mesh cover is distorted during thermal treatment, diameter-direction is deflected. It is too tight to mesh when middle axis is rotating. The maximum force applied by control pump after ventilation is 2
2
2
P=π/4×d ×7.5kgN/cm ×9.8 (P=π/4×4 ×9.8×7.5 920N), at this time dial fork axis root root maximum maximum torque torque M=P×O.0 M=P×O.075=92 75=920×O.0 0×O.075 75 69 Nm, it is is too large large a torque for dial fork axis root and therefore twist-off happens.
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Operatio Operatio n Manual of Dump Truc k BJ Z336 Z3364 4 4. Dial fork axis oil pump joint dial block is too often used and it goes out of teeth joint cover groove. Although there is still journey after control pump ventilation, the teeth joint cover cannot move in axis-direction and cannot lift either. 5.6 TRANSMISSION’S ASSEMBLY / DISASSEMBLY TECHNICAL REQUIREMENT In order to maintain transmission well, assembly/disassembly technical requirements should be mastered. Correct operation and troubleshoot are based on understanding these requirements. Here we will introduce the specified requirements for assembly/disassembly. This illustration will be shown with figures for a better understanding.
5.6. 5.6.1 1 Notes On Assembl y / Disassembl y A. Specific tool must be used for assembly/disassembly of transmission, so that the process will be easier, as well as maintain the precision of the parts. B. Wash all the accessories with diesel oil before assembly. Keep the transmission shell body clean. At the same time check if there is scratch or burrs on the machining surface of accessories. C. After transmission is disassembled, it should undergo run-in inspection before putting into use. Items checked in run-in inspection are below: 1.Each gear run-in time Rotation speed 500rpm 1400rpm 1800rpm 2300rpm Total
Run-in time 8 min 16 min 11 min 7 min 42 min
Each gear run-in time distribution 1st 2 nd 3 rd 4 th 5 th 3min 3min 2min 2min 2min 2min 2min 3min 2min 3min 3min 2min 2min 5min 5min 6min 7min 8min
6 th
7 th
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 ºC. 4. Transmission appearance appearance should be clean. There should not be any leakage l eakage at each connecting plane, oil seal edge and oil plug.
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Operatio Operatio n Manual of Dump Truc k BJ Z336 Z3364 4 D. Due to large impact on transmission during work, when assembling fasten bolt, tighten the bolt according to screw down moment. Bolt with lead thread lock wire must be locked well so that it will not loose. Below is transmission fasten bolt screw down moment and their position: Fasten parts name and position Axis two bearing shell fasten bolt
Specification M14×120
Screw down moment 137-167Nm
Front shell compression bolt
M12×50 M12×55
59Nm
Front shell & shell body combination M18×100 bolt
196Nm
Shell body & rear shell combination M10×30 bolt
39Nm
Rear shell fixed lifting pump bolt
59Nm
M12×45
Rear upper & lower shelf and rear M16×70 shell fixed bolt
147Nm
Upper shell circumjacent fasten bolt
40Nm
M10×65 M10×110
Upper shell fixed control axis support M8×25 bolt
30Nm
Dial fork support and shell body M10×30 combination bolt
40Nm
Gear shifting fork positioning stop bolt M10×18
30Nm
Conductor move-up bolt
30Nm
M10×15
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Operatio n Manual of Dump Truc k BJ Z3364 5.6.2 Transmi ssio n Sub-assembl y Assembl y / Disassembl y Techni cal Requirements Instructions with bracket are data for overdrive transmission. Instructions without bracket are data for standard transmission.
Output End
m m 5 . 0 o T 4 . 0 +
Input End
Figure 25 - Midd le Axis Sub-assembly -0.125
1. Nominal common line dimension 91.5-0.210 /7 -0.11
2. Nominal common line dimension 66.01-0.175/5 -0.11
3. Nominal common line dimension 70.88-0.175/5
-0.11
( 91.36-0.175/7 ) -0.125
( 71.08-0.210 /6 ) -0.11
( 70.95-0.175/6 )
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Operatio n Manual of Dump Truc k BJ Z3364 -0.11
4. Nominal common line dimension 47.95-0.175/3
-0.11
( 48.10-0.175/3 )
-0.09
5. Nominal common line dimension 48.33-0.148/3 -0.087
6. Nominal common line dimension 48.83-0.145 /3 7. 92312 bearing 8. Middle axis assembly inside the shell should have 0.4-0.5 mm clearance in axis-direction, adjust using rear shell inner adjusting gasket. It is used mainly to solve the problem of expansion and contraction of middle axis due to thermal expansion, prevent damage of rear shell and bearing. 9. Non-straight tolerance of middle axis here: maximum curving degree measured should not exceed 0.15mm. 10. 92215 bearing. 11. Loose 3rd 4 th 5 th 6 th gear’s gear on middle axis should not have clearance in axis-direction. Use this adjusting gasket to adjust (must not use soft steel gasket or copper gasket). It is done to enhance middle axis anti-bending intensity and prevent overheat and jumping of 92215 bearing. 12. 92312 bearing.
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42208 Bearin g
4 To 4.5mm
Figure 26 - Reverse Gear Axis Sub-assembly -0.125
1. Nominal common line dimension 46.7-0.190 /3. 2. 42208 bearing. 3. No clearance is allowed for other parts on axis. Use this gasket to adjust. 4. Reverse gear bearing blocking cover is closely attached to inner circle of two bearings to maintain 0.2-0.3 mm axis-direction clearance in reverse gear’s gear. However, no clearance is allowed in other parts on axis. This is done so to prevent friction between bearing bead side surface and rolling path, reduce heat produced.
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Output End
o T o T
7 . 1 < t o N
o T
Input End
Figure 27 - Axi s Two Sub-assembly 1. 9349/47K bearing 2. 92314 bearing ______________________________________________________________________ Page - 58 - of 178
Operatio Operatio n Manual of Dump Truc k BJ Z336 Z3364 4 3. Rolling needle ring’s each each side is installed with 43 6.1×8 rolling needles. needles. Must not be less than that, or else rolling needle will be slanted and cannot rotate, heat will be produced. Each group of rolling needles’ diameter tolerance is 0.005 so that the difference between diameters is small enough for self rotation. 4. Joint teeth’s side face meshing clearance should should be less than 0.6 mm and when teeth width abrasion length exceed 20% of whole length, replace it. 5. Each gear gear rolling needle needle ring nominal diameter isΦ77.8-0.032 -0.012
6. 9242/100 rolling needle bearing. 7. 9243/100 rolling needle bearing. 8. 192314 bearing’s bearing’s axis-direction windage windage should not exceed 0.22mm. If exceeding exceeding too much, axis two will jump in axis-direction. 9. Axis two loose teeth hub and rolling neilsbed should not have axis-direction clearance, but leave 0.1-0.2mm clearance in front of blocking cover, use gasket to adjust. The existence of this clearance is to prevent heating of bearing if 192314 bearing axis-direction clearance is gone. Take note: when axis two flange nut is compressed, axis-direction thrust produced is transmitted to axis two itself through half circle collar, and this has nothing to do with the 0.1-0.2mm clearance in front of blocking cover. 10. M48×1.5 flange nut tighten torque is 392-785Nm. 11. Gasket slice used for adjusting axis-direction clearance (must not use soft steel gasket or copper gasket instead) to prevent crush or distortion during power transmission. 12. Axis two assembly should not move around inside body shell, use rear shell stopping jaw inner adjusting gasket slice to adjust. It is better to have 0.05mm surplus when two sides stick together. If axis two moves around too much, I will crack rear shell and cause oil leakage and clashes between teeth cover and each gear’s joint teeth side surfaces. Axis tow bearing cover’s bolt will become loose and axis two will start jumping. -0.142
13. Nominal common line dimension 83.46-0.227 /5 14. Each gear’s gear nominal aperture Φ90+0.35 -0.142
15. Nominal common line dimension 85.24-0.229 /5 -0.125
16. Nominal common line dimension 85.29-0.210 /5 ________________________ _______________________________________ ______________________________ ___________________________ ________________ ___ Page - 59 - of 178
Operatio Operatio n Manual of Dump Truc k BJ Z336 Z3364 4 -0.11
17. Nominal common line dimension 65.48-0.175/4 -0.11
18. Nominal common line dimension 55.97-0.175/4 -0.09
19. Nominal common line dimension 52.86-0.148/4
-0.11
(65.55-0.175/1) -0.11
(55.89-0.175/4) -0.09
(32.3-0.148/3)
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 two’s front end and shell body’s power input end to be 79.12-81.33. With 392-785 Nm torque, tighten the flange nuts and release two M14×2 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 withΦ3 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
22. Shell body nominal apertureΦ150-0.03
Figure 28 - Axis Two Sub-assembl Sub-assembl y C-C Secti Secti on
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Operatio Operatio n Manual of Dump Truc k BJ Z336 Z3364 4
To
Not < 1.7 To
Figure 29 - Axis One Sub-assembl Sub-assembl y 1. SG60x90x12 framework type assembly/disassembly.
oil seal.
Replace the oil
seal for
every
2. 42308 bearing. 3. Axis one assembly assembly should not move around around inside the front shell, adjust using front shell stopping jaw. 0.05mm surplus is best when two planes stick together. If axis one moves around too much it will crack the front shell and cause oil leakage. -0.09
4. Nominal common line dimension dimension 49.99-0.148/4 -0.09
50.13-0.148/4 5. Minimum distance between between axis one joint teeth teeth end surface and and axis two 5th gear teeth hub end surface is 1.7mm. 6. 92314 bearing. 7. Oil blocking ring is installed installed inside front end to raise raise oil level and lubricate lubricate 42308 bearing. 8. M33x15 axis one one flange lock nut nut tighten torque is 343 Nm, then tighten tighten spherical cylindrical bolt. ________________________ _______________________________________ ______________________________ ___________________________ ________________ ___ Page - 61 - of 178
Operatio n Manual of Dump Truc k BJ Z3364
Figure 30 - Rear Shell Sub-assembly 1. Odograph gear central distance is adjustable and it is adjusted by left-right off-center plug. Its speed ratio range is adjustable. For this vehicle the speed ratio is 1:3.3. 2. SG85x110x12 framework type oil seal. Replace the oil seal for every assembly/disassembly. 3. 208 bearing. 4. The direction of oil pump joint axis’ mesh cover must not be mistaken, otherwise because L journey is guaranteed; dial fork axis will r upture due to tweaking of root part.
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Operatio n Manual of Dump Truc k BJ Z3364
A-A Sec ti on
Figure 31 - Gear Shifti ng Syst em Sub-assembl y 1. 5tha nd 6 thg ear’s gear shifting fork will determine the position of axis two 5 th and 6 th gear teeth cover. Use movable dial fork system support to adjust 5 th and 6 th gear teeth cover to make it the same distance with adjacent two gear joint teeth end surface. Fasten the bolts on dial fork system support girder. The other gears’ teeth covers should have the same distance with adjacent two gear joint teeth end surface, they are adjusted by each gear’s gear shifting fork positioning stop bolt. Here must use positioning stop bolt to adjust, otherwise there may be clashes between teeth cover and adjacent two gear joint teeth. 2. Gear shifting fork axis’ camber must not exceed 0.1mm. 3. There should not be any looseness between gear shifting fork and fork axis, otherwise when top bolt is screwed down, gear shifting fork will be deflected, and fork root will be abraded. If damage is too serious it will affect teeth cover’s movement and gear engaging. 4. Gear shifting fork end surface’s abrasion should not exceed 1mm. ______________________________________________________________________ Page - 63 - of 178
Operatio n Manual of Dump Truc k BJ Z3364 5. Groove which consists of 1st 2 nd 3 rd 4 thg ear conductor, reverse gear conductor and th th 5 6 gear is required to have its inner edge uniformly aligned, aperture between each other must be kept at 2;3;2mm. Its tolerance should not be larger than 0.5mm; else the control axis dial head can be mounted in between when choosing gear. 6. Take note of 3rd 4 thg ear conductor’s stop bolts. When they are tightened, they must th th not touch 5 6 gear’s gear shifting fork. 7. Coordination clearance between steel ball and socket inner lock pin is usually around 0.12-0.24. This clearance must not exceed 0.48mm after abrasion. 8. Φ9 steel ball and space lock pin installed in the middle of dial fork system support and gear shifting axis are required to be flexible, otherwise gear shifting is impossible (must not use welding rod or lead wire to replace the space lock pin). 9. During maintenance, check if there is abrasion or distortion of gear shifting fork axis. Take note that when repairing, do not deepen ball socket, just rasp the rim. 10. Stop bolt of each gear shifting fork and conductor must not become loose when screw in, and anti-looseness device must be well installed to prevent unlocking and dropping.
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Operatio n Manual of Dump Truc k BJ Z3364
Figure 32 - Upper Shell Sub-assembl y 1. Ventilating cap must not be jammed; otherwise there will be leakage on oil seal edge. 2. Make sure that the distance between 949/22k bearing end surface and gasket slice end surface is 15mm, otherwise bearing will be scratched when gear shifting control axis moves. 3. 949/22k bearing. 4. Gear shifting control axis dial head should coincide with gear shifting control axis arm center line so that the forward and backward moving distances of gear shifting handle are the same and it will not touch driver’s seat. 5. 949/22k bearing. 6. Please refer to the name plate speed ratio to identify to type of transmission (standard or overdrive).
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Operatio n Manual of Dump Truc k BJ Z3364
Furcation Nut
Figure 33 - Contr ol Pump Sub-assembly 1. Under normal condition this nut should be tightened to root of wire knot to guarantee 29mm journey. Due to vibration and inner spring pressure effect, unlocking may occur and 29mm journey will be changed. It will in turn leads to oil pump connecting dial block’s abrasion and running out of mesh cover groove. 2. After inflation of control pump, mesh cover cannot be mounted on it. Do not adjust by changing the length of furcation nut because it does not change 29mm journey, instead it will only causes dial block’s abrasion.
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Operatio n Manual of Dump Truc k BJ Z3364
Control Pump As sem bl y
Dial Fork Axis Arm
Dial Fork Axis
Dial Block Mesh Cover
Figure 34 - Lifti ng Pump Contr ol Mechanism 1. Initial position is required when dial fork axis, dial fork axis arm and control pump are assembled together, such that the clearance between dial block and mesh cover’s each edge of two sides is 0.25mm, otherwise due to the spring effect in the control pump, dial block will touch one side and cause abrasion. There will even be noise if the situation is very serious. 2. Micro regulation can be implemented for furcation nut so that the initial position requirement can be fulfilled. 3. 208 bearing. ______________________________________________________________________ Page - 67 - of 178
Operatio n Manual of Dump Truc k BJ Z3364
Chapter 6 Transmis sion Shaft 6.1 SUMMARY AND TECHNICAL DATA 6.1.1 Technical Data 6.1.1.1 Middl e Transmi ssio n Shaft Belt Gimb al Assembl y Sustain working torque Spline specification Gimbal cross axis assembly dimension Installation dimension Maximum stretching length Maximum shortening length
- 1020Nm - 10-50×38×6 - Φ5O×135 - 447.7mm - 20.5mm - 20.5mm
6.1.1.2 Rear Ax is Transmi ssio n Shaft Belt Gimb al Assembl y Sustain working torque Spline specification Gimbal cross axis assembly dimension Installation dimension Maximum stretching length Maximum shortening length
- 6570Nm - 16-60×74×5 - Φ89×10 - 1046mm - +43mm - -55mm
6.2 TRANSMISSION SHAFT FUNCTION The function of transmission shaft is to connect parts with non-homocentric and transmit power. Usually the connection between each part is not on the same straight line; instead it changes position accordingly during operation. Transmission shaft is to transmit torque, meanwhile it solves the problem of each joint part not homocentric and the distance between them is constantly changing. Hence, it is necessary to make transmission shaft flexible. When relative contraposition happens between two parts (engine and transmission or transmission and rear axis), they can still rotate.
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Operatio n Manual of Dump Truc k BJ Z3364 6.3 TRANSMISSION SHAFT STRUCTURE AND WORKING PRINCIPLE 6.3.1 Middle Transmi ssio n Shaft Belt Gim bal Assembl y Middle transmission shaft belt gimbal assembly consists of middle transmission shaft tube fork assembly, gimbal projecting edge fork and gimbal cross axis belt bearing assembly. Refer to Figure 35 for its configuration. It connects clutch and transmission and axis angle is 2.09°
Figure 35 - Middl e Transmis sion Shaft 1 Middle transmission shaft 2 Middle transmission shaft tube fork assembly 3 Middle transmission shaft gimbal protruding edge fork 4 Gimbal cross axis belt bearing assembly 5 Gimbal bearing cover board 6 Gimbal bearing cover board bolt lock 7 Hexagonal head bolt 8 Gimbal tube fork oil seal gasket ring 9 Gimbal tube fork oil seal 10 Gimbal tube fork oil seal 11 Balance slice
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Operatio n Manual of Dump Truc k BJ Z3364 6.3.2 Rear Axis Transmissi on Shaft Belt Gimbal Assembl y Refer to Figure 36 for its configuration. It connects transmission and rear axis. Its axis angle is 3.07 º.
Figure 36 - Rear Axi s Transmi ssi on 1 Rear axis transmission shaft 2 Rear axis transmission shaft tube fork assembly 3 Rear axis transmission shaft gimbal protruding edge 4 Gimbal cross axis belt bearing assembly 5 Gimbal bearing cover board 6 Gimbal bearing cover board bolt lock 7 Hexagonal head bolt 8 Gimbal tube fork oil seal gasket ring 9 Gimbal tube fork oil seal 10 Gimbal tube fork oil seal cover 11 Balance slice This vehicle is assembled with two gimbals in series. When assembling, make the 1 st gimbal’s driven fork and the 2ndg imbal’s driving fork on the same plane, meanwhile make 2 gimbals’ joint axis angle same, so that output axis’ rotation speed is equal to input axis’ rotation speed, as shown in Figure 37.
Figure 37 - Transmi ssio n Princi ple ______________________________________________________________________ Page - 70 - of 178
Operatio n Manual of Dump Truc k BJ Z3364 6.4 TRANSMISSION SHAFT ASSEMBLY AND OPERATION In order to ensure normal working of transmission shaft and lengthen its lifespan, take notes of the following points during assembly: A. In order to ensure that transmission shaft input’s rotation speed is the same as output rotation speed, transmission’s two ends’ gimbal forks should be on the same plane, meanwhile in order to maintain the accurate dynamic balance of transmission shaft, tube fork and splines axis are marked by arrow, when assembling must aim at the arrow. B. Causes of breakdown of transmission shaft dynamic balance: 1. Axis tube curving rolling needle bearing cover becomes loose or transmission’s two ends gimbal forks are not on the same plane. Must repair it, otherwise it will shake vigorously, affect the whole transmission system and damage accelerating parts. 2. Balance slice falls off during operation due to loose welding of balance slice. C. Middle transmission shaft tube fork should be installed on the side of clutch. Rear transmission shaft tube fork should be installed on the side of transmission. This is to ensure that the tube fork jaw inclines downwards to prevent water or dust from coming in.
6.5 TRANSMISSION SHAFT MAINTENANCE
6.5.1Lubrication Serial number 1 2 3
Lubrication location
Interval
Middle transmission shaft tube fork oil injector Rear axis transmission shaft tube fork oil injector Gimbal cross axis oil injector
Every 50 hours Note: do not add too much butter
6.5.2 Check-up After the first 50 hours, check if joint flange’s fixed bolt is loose for every 400 hours.
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Operatio n Manual of Dump Truc k BJ Z3364 6.6 TRANSMISSION SHAFT BREAK DOWN ANALYSIS AND TROUBLESHOOTING
Malfunctions Joint plane abrased
Causes Loose bolts, surface phase movement
Transformation of transmission shaft tube
Occasional external causes or irregular movement of transmission system 1. Transmission shaft loses balance 2. Bad lubrication on bearing, oil injector jammed 3. Clearance between bearing two end surface does not meet requirement. Too tight, heat produced when rotating and abrasion of rolling needle and bearing Oil seal is not tight enough and water with impurities comes in or lack of lubrication grease 1. Abrasion of bearing or crack of rolling needle 2. Clearance between spline axis and tube fork is too large 3. Parts lose balance
Cross axis and bearing abrasion
Gimbal cover fork gets stuck
Transmission shaft vibration is too noisy
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
Oxidation of spline groove. Replace oil seal, filing with sand paper Replace bearing Replace the abrading parts
Find the balance
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Operatio n Manual of Dump Truc k BJ Z3364
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.
Figure 38 - Rear Axis Confi gurati on ______________________________________________________________________ Page - 73 - of 178
Operatio n Manual of Dump Truc k BJ Z3364 1. Rear axis main reducer is level two transmission. Level one is arc spiral cone gear with transmission ratio 1.38. Level two is cylindrical bevel wheel with transmission ration 3. Main reducer’s total transmission ratio is 4.14. 2. Rear axis differential is straight teeth cone gear with 4 planetary gears. Planetary gear and half axis gear’s stop working surface must be installed with wearable gasket slice. Cross axis is separating type. 3. Rear wheel planetary reducer is straight teeth planetary gear transmission device. It is installed inside wheel hub. Planetary system gear’s transmission ratio is 3.33. 4. Half axis is fully floating type. Two ends are separately connected to half axis gear and sun gear using involute spline. 5. Rear axis shell is steel casting. Axis shell two ends are located using stop jaw, half axis tube is installed into axis shell stop jaw and fastened using bolts. Rear axis total transmission ratio is 4.14×3.33=13.78.
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.
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Operatio n Manual of Dump Truc k BJ Z3364 7.3 REAR AXIS ASSEMBLY AND REGULATION 7.3.1 Main Reducer As sembly A nd Regulati on Main reducer configuration. As shown in Figure 39.
Figure 39 - Main Reducer Confi gurati on 1. Cone driving and driven gears installed in main reducer are pre-matched and pre-labeled, they are not separately exchangeable. In order to adjust cone driving gear bearing shell’s 7618 and 7614 two bearings’ elasticity so that the two bearings can bear with the load together, a proper adjusting gasket slice installed in front bearing inner ring and cone driving gear protruding shoulder end surface should be chosen. Firstly measure the dimension A according to Figure 40, dimension B from Figure 41 and dimension C from Figure 42, then refer to Figure 43, follow the equation X=A-B-C to get the adjusting gasket slice’s thickness. The thinnest gasket slice has thickness 0.05, so after calculating the axis-direction allowable clearance should be less than 0.05. Gasket slice’s thickness can be 0.05, 0.10, 0.30 and 0.50. Fasten the groove nuts with joint axis and 686-883 Nm torque. Compaction force should not be transmitted to bearing beads. Cone driving gear should be agile and rotation torque should not bigger than 7 Nm (oil seal friction torque is not counted and no axis-direction jump when manually pushing). ______________________________________________________________________ Page - 75 - of 178
Operatio n Manual of Dump Truc k BJ Z3364
Figure 40
Figure 41
Figure 42
Figure 43 - Cone Drivi ng Gear Bearing Shell As sembly 2. After the adjustment of cone driving gear bearing shell assembly is finished, in order to satisfy the requirement for clearance of cone driving and driven gear contacting area and teeth side, when installing cone driven gear and driving cylindrical bevel wheel into main reducer shell, no axis-direction clearance is allowed in between the two. Refer to Figure 39. Axis two ends 7613 and 7618 bearing’s elasticity is decided by choosing appropriate adjusting gasket slice thickness from two groups, and separately installed into reducer outer shell’s left and r ight cover. Inside each group there should be at least one slice with thickness 0.05 and 0.1mm, the rest should follow the requirements. Usually first align with cone driving and driven gear back cone surface, i.e. the cone distance joints of two cone gears coincide at a point, then adjust accordingly. ______________________________________________________________________ Page - 76 - of 178
Operatio n Manual of Dump Truc k BJ Z3364 After the adjustment of the bearing, when singly rotating cone driven gear, the rotation torque should not be larger than 7 Nm. When measuring power torque, bearing should be lubricated, and measure only after gear rotates continuously in one direction no less than 5 rounds. 3. Adjustment of cone driving and driven gear contacting area and teeth side’s clearance. Apply a layer of red lead oil on cone driven gear’s teeth surface, and rotate when no load in two directions. Greason type: required to control the driven gear convexity contacting print within the teeth central area (lean to small end), with distance 2-7 mm to small end. Contacting area dimension is usually 1/2-5/8 of teeth height and teeth length. Non-working surface should be controlled within teeth’s central area. Cone driven gear’s correct contacting situation is shown in Figure 44.
Teeth side c learance adjus tment ______________________________________________________________________ Page - 77 - of 178
Operatio n Manual of Dump Truc k BJ Z3364
2 - 7mm
0.8 ~ 1.6mm
Figure 44 - Cone Driven Gear Contact Fig A: contacting area condition of adjustment of driven cone gear during assembly. Fig B: contacting area changing condition of driven cone gear under load condition. Cone driving and driven gear mesh teeth side clearance is 0.25-0.35mm. This is under the consideration of oil saving and prevention of dead bite of mesh gear when thermal expansion. It is required to measure 3-4 different positions within one week. When incorrect contracting area and teeth side clearance are found during installation of driving and driven cone gear, adjust according to the methods shown in Figure 44. ( Figure 44 shows driven large gear contacting surface). Adjusting formula: larger follow in, small follow out, head main in, root main out. Driving cone gear’s front and rear direction adjustment is done by adjusting gasket slice on cone driving gear bearing shell assembly and main reducer shell contacting stop jaw circle. Driven cone gear’s left and right adjustment is done by two groups of gasket slices on main reducer shell left and right shell (inside and below). Under normal situation: the gasket reduced from one side is just the gasket added on the other side. Do not add or reduce gasket slices so that the axis-direction clearances of two end bearings remain constant.
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Operatio n Manual of Dump Truc k BJ Z3364 7.3.2 Diff erential Assembly And Adj ustm ent Differential’s configuration is shown in Figure 45.
Figure 45 - Differential configuration 1 Hexagonal groove nut 2 Uncork pin 3 Hole bolt 4 7521 cone roller bearing 5 Adjusting nut 6 Cylindrical pin
7 Rear axis differential shell 8 Planetary gear gasket slice 9 Half axis gear and planetary gear 10 Half axis gear gasket slice 11 Cross axis 12 Driven cylindrical bevel wheel
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 gear’s rotation to complete the speed difference effect when turning.
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Operatio n Manual of Dump Truc k BJ Z3364 1. When assembling and adjusting differential, assemble the rear axis differential shell according to the labels and assemble in pairs. Do not change them at will. In order to ensure the correct installation distance of gear and correct mesh and teeth side clearance to be 0.2-0.4mm, it is required to label and choose in groups: half axis gear (two); half axis gear gasket slice (two); planetary gear (four); planetary gear gasket slice (four), as one group. Outer gasket slice has one plane with oil groove for better lubrication. When assembling differential shell, it is required to match the correct label and the relative position should not be changed. When it is fastened with cylindrical driven bevel wheel, be ware of tighten torque of hexagonal groove nut to be 137-167 Nm, and with uncork pin. Hence due to the large transmission power, here is easily to become loose. Make sure that the differential shell two end axis path 7521 bearing should be on the same axis as cylindrical driven bevel wheel mesh node circle. Maximum concentricity tolerance is 0.05mm. In order to take care of the different axial, when two half axis are assembled, a 0.42-0.5mm axis direction clearance is designed when half axis gear axis diameter matches the differential shell hole diameter, so that half axis can automatically float and find the aixiality, and guarantee the agile rotation and easy differential. Differential assembly should be able to turn easily manually. The turning should not be tight or get stuck. 2. When differential assembly is installed into main reducer, use adjusting differential bearing’s adjusting nut to adjust driven cylindrical bevel wheel’s teeth and driving cylindrical bevel gear’s teeth so that their locations can align. Refer to Figure 46 below.
Figure 46 - Cylindr ical B evel Wheel Teeth Ali gnment When the above locations are adjusted properly, lock the adjusting nut tight and fasten the nut using stop wrench.
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Operatio n Manual of Dump Truc k BJ Z3364 7.3.3 Rear Wheel Planetary Reducer’s As sembly A nd Ad just ment Rear wheel planetary reducer is straight teeth planetary gear transmission device and is installed inside the wheel hub. Refer to Figure 38. Sun gear is fastened on the half axis by spline which meshes with 4 planetary gears. Inner gear is fastened on half axis tube by connecting inner gear shell. Planetary gear seat is fastened on rear wheel hub using double head bolt. When sun gear rotates, planetary rotates immediately around sun gear. Planetary gear’s rotation again will lead to the rotation of planetary gear seat through planetary gear axis. The rotation of planetary gear seat is just the rotation of wheel. 1. Rear wheel planetary reducer’s inner gear is fastened on half axis tube through inner gear shell and four C16×50 flat key. 2. Four C16×50 flat keys inlayed on half axis tube and inner gear shell inner hole key groove should have tight conjugation and should not have looseness, otherwise force is not evenly distributed when transmitting power. 3. When assembling rear wheel planetary reducer inner gear, check the radial runout tolerance of inner gear, usually it should not exceed 0.22mm. If inner gear radial runout is too much, it will affect four planetary gear’s power distribution, causing early stage damage of planetary roller needle. 4. The adjustment of clearance between half axis stop push bolt and half axis end surface: screw down half axis stop push bolt and make it touch half axis end surface till cannot screw down further, then withdraw the half axis stop push bolt by one buckle, and tighten using nut. The axis direction clearance between half axis end surface and half axis stop push bolt is 1.5mm.
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Operatio n Manual of Dump Truc k BJ Z3364 7.4 REAR AXIS BREAK DOWN ANALYSIS AND TROUBLESHOOTING Malfunction Constant noise
Causes 1. Abrasion of bearing 2. Bad lubrication
Discontinuous noise
Periodic noise
When accelerating or decelerating silvery knock can be heard
3. Abrasion of gear teeth 4. Driving and driven gear mesh position and clearance not suitable 1. Wheel bearing clearance too large 2. Improper cylindrical gear installation 3. Cone gear bearing clearance too large 4. Wheel imbalance or improper assembly 1. Differential gets stuck 2. Abrasion of planetary gear and half axis gear teeth 3. Differential parts coordinating clearance too large 1. Improper adjustment of rear wheel planetary reducer 2. Coordinating clearance too large
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
7.5 REAR AXIS MAINTENANCE 1. After run-in period, replace the lubricants for every 800 hours travel. Oil brand is #22 synthesize gear oil. When replacing lubricants, oil should be discharged when it is still hot, and clean the scrap iron on permanent magnet of oil discharge plug. After new vehicle’s run-in, when replacing oil for the first time, dilute machine oil should be added in after deposed oil is discharged (better use #5 high speed machine oil – SYB1101-62), the amount added in should be about 2/3 of main reducer’s capacity. Lift up rear wheels, start the engine and run for about 5 minutes, discharge the cleaning machine oil, and then add in #22 synthesize gear oil. 2. Check the volume of lubricants for every 100 hours travel. 3. When adding oil, use oil level indicator to control the oil level of main reducer. When adding oil for wheel hub, open the screw plug 5. Add oil till it overflows. 4. Check the tightness of bolt regularly. 5. Wash and replace oil for wheel hub bearing for every 40 hours travel. If there is oil leakage, first check oil seal. If oil seal is fine, t hen check if ventilating cap is stuck. ______________________________________________________________________ Page - 82 - of 178
Operatio n Manual of Dump Truc k BJ Z3364
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 7º30’. Configuration is guaranteed and cannot be adjusted. 2. Knuckle pin back inclination 0º. Position is guaranteed by steel board spring installation and cannot be adjusted. 3. Front wheel extroversion 0 º, 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.
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Operatio n Manual of Dump Truc k BJ Z3364 8.3 FRONT AXLE ASSEMBLY AND REGULATION A. The axis-direction clearance between knuckle seat and front axis head is adjusted by knuckle upper gasket slice 16, the maximum clearance is 0.2mm. B. Adjustment of front wheel toe: 1. Adjust the wheel toe when there is no load. 2. Vehicle should be parked on flat road and positioned as if it travels in a straight line. 3. Wheel pressure is 650 kpa. 4. Use a ruler with scales to contact the front wheel outer rim, the contact point is in front of wheel rim and on the horizontal central line. Mark with chalk. 5. Put the ruler on the back of wheel, lift up front axis, rotate the left and right wheel to the same direction by 180 º. Make the chalk marker at the same height as wheel in front and lower down the wheel. 6. The length measured at the back of wheel minuses the length measured in front of wheel and we get front wheel toe. It should be 1-3mm. 7. If requirements are not met, adjust the transverse puller’s length.
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Operatio n Manual of Dump Truc k BJ Z3364
Figure 47 - Front Wheel Configu ration 1 Front axis tube 2 Turning transverse puller assembly 3 Front axis spring support 4 Turning straight puller assembly 5 Turning straight puller arm 6 Brake bracket 7 Knuckle pin 8 Knuckle lock bolt 9 Knuckle seat 10 Knuckle axis
11 Brake firm 12 Wheel 13 Front wheel hub 14 Knuckle axis lock tight nut 15 Front wheel hub cover 16 Knuckle upper gasket slice 17 Knuckle arm 18 Front axis head 19 Front thrust pole pin axis cover
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Operatio n Manual of Dump Truc k BJ Z3364 8.4 FRONT AXLE B REAKDOWN ANALYSIS AND TROUBLESHOOTING Malfunction Swing of front wheel
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 tyre’s 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
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Operatio n Manual of Dump Truc k BJ Z3364 8.5 FRONT AXLE MAINTENANCE A. Often check the clearance between knuckle seat and front axis head. If the clearance if larger than 0.2mm, adjust till it is within 0.1mm. B. Often check the ball pin of transverse and straight puller, it should be turned arduously by manual and no lag. Take note that it must not be too loose. C. After run-in and 400 hours travel, wash the wheel hub bearing and replace new #2 lithium base lubricating grease. Apply the lubricating grease periodically onto the grease jaw. D. After 400 hours travel, must re-tighten all the joint parts.
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Operatio n Manual of Dump Truc k BJ Z3364
Chapter 9 Steering Syst em 9.1 SUMMARY AND TECHNICAL DATA
Droop arm angle # circles of steering wheel # circles of steering wheel after adjustment Steering machine transmission ratio When traveling on a straight line Maximum output torque of steering arm
: 90° : 5.82 : 4.875 : 23.27 : 9635Nm (14Mpa)
9.1.1Steering System Summary During traveling, vehicle needs to change its direction very often. Steering is done by deflecting some certain angle of steering wheel (front wheel) on the ground. Steering system is controlled by the driver. It is a system which makes steering wheel (front wheel) deflects. This vehicle has hydraulic pressure power assistance, so that labor intensity of driver is greatly reduced and maneuverability of vehicle is greatly enhanced. When using power steering, the push of front wheel steering mainly depends on hydraulic pressure. The whole steering procedure (including steering direction and steering angle) much obey the driver’s operation. This power steering can satisfy the following requirements: 1. When it is not steering, it can automatically keep the front wheel in the middle position and maintain the straight line travel of vehicle. 2. When steering, front wheel steering angle should be proportional to steering wheel’s steering angle, the direction should be consistent as steering wheel. 3. Steering should be sensitive, short period of time for action lag, maximum steering angle should be done within 2-3 seconds (equivalent to turning the steering wheel for 2-3 rounds). 4. Light and handy steering, but also have the road feeling. When driver controls the vehicle to do steering, he should depend not only on the eyesight, but also the condition of road resistance so that it will react to the steering wheel. Make sure that the driver has a feel of the road inside his mind. 5. Prevent reverse impact. During the travel if front wheel clashes with barriers, the impact transmitted to steering wheel should be as small as possible. 6. Ensure that the control valve can be automatically back to its right position and prevent wheels from vibrating. 7. Good following actions. 8. Safe and reliable. When power steering is not functioning, steering can also be done by manpower through mechanical system. ______________________________________________________________________ Page - 88 - of 178
Operatio n Manual of Dump Truc k BJ Z3364 9.1.2Steering Structure
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 system’s 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 Oil Can
Oil Return Pipe
Oil Input High Pressure Pipe
Oil Pressure Pipe
Steering
Steering Pump
Figure 48 - Steering
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Operatio n Manual of Dump Truc k BJ Z3364 9.2 WORKING PRINCIPLE 9.2.1 Middle Posit ion When vehicle is traveling on a straight line (steering wheel is still), hydraulic oil from oil pump enters the oil enter gate and passed through the pre-opening clearance of steering valve. Because at the moment the steering valve is still, steering device’s two working cavities will have the same oil pressure and no assistant power will be produced. Hydraulic oil goes back to oil tank through oil returns gate. 9.2.2 Steering Process When turning the steering plate, the pre-opening clearance between valve core and steering screw is changed, so that oil pressure difference corresponding to steering resistance is produced between two working cavities. This oil pressure difference functions on steering nut (piston) and pushes steering nut (piston) to overcome steering resistance and results in displacement, and brings along the arm axis to achieve power assistance steering. 9.2.3 Positi on Return Process When steering is done, force on steering plate disappears. Under the effect of power steering device inner tweak pole and front wheel auto-return position torque, the oil pressure difference between steering device’s two working oil cavity is eliminated. Wheel will be then on the straight line travel position till it goes back to the vehicle straight line travel position.
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Operatio n Manual of Dump Truc k BJ Z3364
To Upper Oil Tank 去往上油缸
From Lower Oil Tank 来自下油缸
Input 输 入Axis, 轴逆时 针旋转 An ti -Clo ck wi se Rot ati on
Left 左 Rotation 转向
Middle Position 中间位 置
To Upper Oil 去 往下油缸 Tank
From Lower Oil 来自上油缸 Tank
Input Axis, 输入轴 顺 时Clockwise 针旋转 Rotation
高压油 High Pressure Oil 低 压Pressure 油 Low Oil
Right Rotation 右转 向
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Operatio n Manual of Dump Truc k BJ Z3364 9.2.4 Road Feel Effect
“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 device’s 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.
9.3 POWER STEERING PUMP Power steering pump uses American Vickers company V20F series single line balance constant current and pressure lamina pump. The model details are below: Serial number: V20F 1P 6P 38C 6H 11 Explanation:
Lamina Pump
Manufacturer Design Serial Number
Serial Label Embeded Flux Control And Overflow Valve
Overflow Valve – Default Value 2000psi
2 Bolt Flange Throttl e Hole Number Flux 6-6USgpm
Oil Inlet Dimensi on ¼ NPT Screw Thread
Oil Exit And Ent er On The Same Side
Rated Flux – USgpm Oil Outlet Dimensio n ¾ -16 Straight Screw Thread Overflow Outlet Dimensio n 1/2’’ NPT Screw Thread
Ax is Bo dy Is Sp li ne Ax is Connection
Note: In the serial number, the second part of number is the pump’s flux and pressure.
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Operatio n Manual of Dump Truc k BJ Z3364 9.4 STRUCTURE AND WORKING PRINCIPLE V2OF series single line balance constant current and pressure lamina pump has the capability of maintaining the pressure balance on pump axis sides. For every one rotation of pump axis, pump will suck oil twice, the compress oil twice. There is special whole constant current and pressure valve in pump cover, so that within the rotation speed of engine, the flux of pump can be maintained at a certain value to prevent too high pressure. Pump consists of entrance body, exit cover and pump core. Pump core consists of a stator with inner ellipse curve, a rotor with lamina groove and 12 lamina. Rotor connects to rotor axis through spline. Pump core nip is installed in between pump body and pump cover. Ball bearing and axis cover are installed onto pump body and pressure plate separately to support pump’s rotor axis and locate the rotor axis’ rotor into stator. When pump axis is driven by engine, the rotor and lamina make the oil flow along stator’s inner ellipse curve and oil flow is produced. Oil enters the pump core through pump entrance, and is discharged by pump cover exit through pressure plate. 9.4.1Pump’s Working Princi ple A. Pu mp co re Refer to Figure 49. Pump axis is connected to engine, leads rotor to rotate within stator. Centrifugal force is produced from this rotation, so that lamina will slide along stator’s inner ellipse curve. The diameter-direction movement of rotor’s rotation and lamina will lead to lamina’s cubage increase when lamina pass through curvilinear entrance, thus results in vacuum and make oil enter the cavity under the atmospheric pressure.
Stator
Oil Inlet
Rotation Direction
Oil Outlet
Rotation Direction Lamina
Oil Outlet
Oil Outlet
Rotator Oil Inlet
Driving Axis
Oil Inlet
Figure 49 – Power Steering Pump ______________________________________________________________________ Page - 93 - of 178
Operatio n Manual of Dump Truc k BJ Z3364
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 lamina’s operation it will always cling to the curve surface to ensure good sealing. B. Fluid Forc e Balance As shown in Figure 49, stator’s 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
Ac ti on Pos it io n
Ax is
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.
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Operatio n Manual of Dump Truc k BJ Z3364 D. Constant Current An d Pressur e Valve The working principle of constant current and pressure valve is shown in Figure 51. Figure 51 is whole constant current and pressure valve installed on pump cover, and is used for restrict pump’s maximum flux and maximum system pressure. 1. Figure 51A shows the situation when pump constant current and pressure valve is not functioning, all the oil from pump will flow into steering machine. Large spring cavity is connected to pressure exit through damp hole, the oil pressure of cavity and spring force is slightly larger than the oil pressure of slide valve on the other side. When slide valve is closed, pump oil discharge and side open hole are sealed by slide valve sealing surface. 2.
Figure 51B shows the condition when flooding is functioning. When pump’s flux is larger than assured value of measuring hole, the height of measuring hole front and rear pressure cover will increase along with the increase of flux. When flux exceeds the limit of measuring hole, the pressure difference will push slide valve to overcome the spring force and open up the slide valve. Extra oil will flow to side open hole through the clearance from opening slide valve.
3. Figure 51C shows the maximum pressure when system pressure exceeds constant current and pressure valve’s limit. At this moment the valve needle for stabilizing pressure will be open. The oil from large spring cavity will flow to side open hole through the clearance from opening valve needle. The sudden pressure decrease in this cavity will lead to increase in pressure difference between slide valve right and left sides. This pressure difference will push the slide valve to the left hand side and compress the large spring and open the slide valve. The oil from right side of slide valve will flow to side open hole through the clearance from opening slide valve.
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Operatio n Manual of Dump Truc k BJ Z3364
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Operatio n Manual of Dump Truc k BJ Z3364 9.4.2 Use And Maint enance Noti ce 1. Pump must rotate according to the direction pointed by arrow casting on the stator. If want to change the rotation direction, must rotate the stator reversely. Refer to Figure 52. Must not rotate at will, else it will get stuck. From Cover Side
Right Hand Rotation
Left Hand Rotation
Figure 52 2. 3. 4. 5. 6.
When pump is operating, eliminate the air in the system. Oil used in pump must be the oil stated in whole vehicle instruction. The oil added to the system must be filtered using 200-eye wire netting. Replace the oil regularly. Wash the oilcan. Replace the filter core at any moment. Check the oilcan’s oil level regularly, renew if insufficient.
9.4.3 Assembly An d Disassembl y Lamina pump disassembly is shown in Fig 09-12. Take note of the following points: 1. Usually the seal ring and oil seal should not be used again after assembly/disassembly. If still want to use them, they must not be mangled during assembly/disassembly. Must not wash any rubber part in gasoline or diesel oil, else the rubber will metamorphose. 2. Do not scrap the machining surface of parts, must keep them clean. 3. During disassembly remember the relative position of pump cover exit and pump body entrance. Must not mistake the position. Assemble according to the model and specified alphabets, the explanation of alphabets are shown in Fig09-13. 4. When installing pump axis oil seal, take note that the hoped spring should face the pump core (see Fig 09-14). 5. When lamina goes into rotor groove, be ware that lamina’s round side should face stator’s inner curve. 6. Test the assembled/disassemble pump on the platform. First turn the pump axis manually. This is to check if the pump is flexible. Then test with recommended rotation speed and pressure. During the test, check if there is oil leakage or air suck. ______________________________________________________________________ Page - 97 - of 178
Operatio n Manual of Dump Truc k BJ Z3364
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w e i V n o i t c e S
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g n i r p S
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g n i r p S m a J
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t e l t u O l i O e r u s s e r P
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Operatio n Manual of Dump Truc k BJ Z3364 A – opposite the oil inlet B – from oil inlet anti-clockwise 90 º C – on the side of oil inlet D – from oil inlet clockwise 90 º
Hooped Spring
Cover
Exit Reference Standard
Pump Body (Oil Inlet Reference)
Figure 54
Ax is Oil Seal (Spring Faces Inner Pump Cover)
Figure 55
9.4.4 Malfunction Analysis And Troubleshooting Malfunction Possible causes Troubleshoot No oil comes out Mistake in pump Immediately change driving direction to from pump driving direction prevent pump getting stuck, Fig 09-11 shows the right position of two rotation direction ring Joint axis or pump Disassemble pump, check pump axis and axis cut pump core to see if there is damage, replace when necessary Oilcan oil exit get Check if there is dust or dirt in the filter core, stuck wash if necessary Oil too sticky cannot Change the oil throughout and replace the renew appropriate and filtered new oil Slide valve or safety When disassemble pump, wash the valve in valve needle get detergents. Put valve back to valve cover, stuck check if it gets stuck, use sandpaper to rub off the granule on the surface, do not make valve cylinder rim round or rub the cover inner hole, clean all parts and reassemble the oil pump Rotor lamina get Disassemble the pump and check for dirts stuck into groove and metal crumbs, wash the parts throughout, replace the broken parts, wash the system if necessary and change the oil Oil pressure no System pressure Use manometer to adjust sufficient valve (safety valve) it too low Pump’s flux is lost 1 some valve get stuck and are always open, oil flows freely to oilcan 2 Oil entrance pipe of pressure pipe crack ______________________________________________________________________ Page - 99 - of 178
Operatio n Manual of Dump Truc k BJ Z3364 Noise pump
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 oilcan’s 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
9.5 OPERATIONAL AND REGULATION NOTICE A. St eeri ng Wheel Freep lay Check In order to make steering wheel sensitive and flexible, when just start turning the steering wheel, swing the steering droop arm to deflect the steering wheel. However, due to the assembling clearance between steering device and steering transmission mechanism, steering wheel has to empty-turn to a certain angel first, this is called the steering wheel freeplay. Proper steering wheel freedom journey is useful in relaxing the bounce-back, make the driving gentle so the driver will not be over nervous, but the freeplay should not be too large (refer to Figure 56).
Figur e 56 - Steerin g Wheel Freeplay Check According to the regulation, when BJZ3364 self dump truck travels in a straight line, steering wheel’s free steering momentum (i.e. freedom journey) to the left or right should not be larger than 20 degree (or equivalent to turning for 80mm on the steering wheel), if it exceeds this value then check and adjust. ______________________________________________________________________ Page - 100 - of 178
Operatio n Manual of Dump Truc k BJ Z3364 B. Check s teering Joint’s Reliability Steering will shake due to looseness of joint bolts on steering machine support. Screw down steering machine support and vehicle frame’s joint bolt and steering machine and its support’s joint bolt. Bolt’s diameter is M20: the screw down torque of steering machine fixed on support is 441 Nm, and screw down torque of steering support fixed on the vehicle frame is 294 Nm. Must not use usual linked wrench or uncork wrench to fasten, must use specific sleeve wrench connecting to long pole to fasten (best to use torque force wrench). C. Strict ly Prohibit “ Dead Wheel” When steering machine is in its limit position or front wheel meets hard obstacles, strictly prohibit turning the steering wheel by force, i.e. do not let steer wheel become “dead wheel”. Must turn during traveling. D.Beware Of Mixin g Air Int o Oil If oil mixes with air, steering wheel will shake. Shaking of steering wheel means when steering wheel is not given a steering instruction, it will suddenly shake randomly. This natural shaking is unpredictable, and this malfunction is commonly called “steering wheel hits hand”. It is a special malfunction of power steering. This malfunction is dangerous, when it gets serious it will injure the arm or wrist. Check immediately and do the necessary troubleshooting.Due to the low condensability of oil, it usually can be ignored, but condensability of air is larger and it is about one thousand times of oil, hence even there is a small amount of air in the oil, it will have large influence. Under the impact of pressure oil, air will soon be smashed into numerous air bubbles and mix into the oil (when low pressure they will automatically be separated out). Oil with air bubbles is very unstable, it becomes something similar to volatile “elastomer”, sometimes it compresses and sometimes it expands, causing the change in cubage of oilcan piston’s two sides, i.e. the position of piston is constantly changing. Hence, it will lead to the swing of steering wheel thread bar connecting piston and slide valve and steering wheel. This random and sudden impact of swing is steering wheel shake, or commonly known as “steering wheel hits hand”. It is relatively simple to solve this problem: find out where the air suck happens and causes of it and get rid of them. If this malfunction happens, stop the vehicle and do the troubleshoot. ______________________________________________________________________ Page - 101 - of 178
Operatio n Manual of Dump Truc k BJ Z3364 Check mainly the following parts: 1. Any damage in oil pump oil seal. Replace if there is. 2. Any looseness or loose seal or damage in oil suck pipe’s two connecting ends. 3. Oil level in the oil tank is too low. Renew it. Usually the oil level should be about 20 mm below the oil tank’s top. 4. Oil suck pipe gets stuck, causing partial vacuum increase, increasing the possibility of air suck. E. Righ tly Judg e Steering Turning Standard (Li ght Or Heavy) For this type of power steering, when difficulties are met in steering, it is not right to generally say the steering is light or heavy. This is because it is different from mechanical steering. In order to judge and eliminate the failure, two guild lines should be reflected for judging the power steering: one is if there is difficulty in steering (whether the force applied onto the steering wheel is light or heavy), another one is the possible gyration speed when steer wheel is turning (speed of turning the steering wheel). Both situations are possible to happen, i.e. it can be “slow turning is light, fast turning is heavy” or “both slow and fast turnings are heavy”. The causes for these two situations are different but mainly because of leakage of power steering oil pump’s oil pressure and flux and steering machine. For a good steering machine, within 5 seconds the steering wheel can be turned from left to right or right to left, rotation is about 4.875 rounds. When traveling on a flat road, the normal turning force applied on steering wheel (not including sharp turn) is about 49 N. F. Stri ctl y Prohi bit Engine Flameout Or Slide With Neutr al Gear This is because hydraulic power steering is used. It prevents malfunction of hydraulic power and danger when steering. G. Operation A nd Adj ustm ent Of Steerin g In order to maintain safe and reliable working of steering machine, driver should fully understand the structure and principle of steering machine, how to use and maintain. 1. This whole power steering machine uses normal current structure. It relies on vehicle engine driving oil pump. Therefore, the vehicle must not slide with engine flameout, otherwise the driver will not get used to the heavy steering due to engine flameout. 2. If the steering system fails due to malfunction of oil pump and oil path, the steering machine can be treated as mechanical steering machine, force steering till vehicle reaches maintenance station. But do not force steering for a long time. Do not overload the vehicle. 3. Make sure the inside of power steering system is clean. When renewing oil, do not use unclean container to fill the oil. When disassembling and checking, do not put the parts at will. Do not allow any sundries go into the system during assembly. System’s working oil level should not be lower than the standard. ______________________________________________________________________ Page - 102 - of 178
Operatio n Manual of Dump Truc k BJ Z3364 4. Must not disassemble the control valve of steering machine at will. 5. When assembling steering droop arm, keep the wheel just. Align the droop arm’s reticle with swing arm output end surface’s reticle. When vehicle travels in a straight line, if freedom clearance of steering wheel is too large or too small, check steering knuckle and puller system 6. During the steering, steering wheel is allowed to be turned to its limit position but do not do this for a long time, else the oil pump’s lifespan will be affected. 7. The connection of power steering machine’s oil entrance and exit must not be mistaken. Follow the arrow on steering machine front cover to connect the pipes. Oil entrance is oil pump’s high pressure oil, oil exit is oil returning can’s low pressure. 8. Replace the oil when new steering machine has done its 5000km run-in or every 20000km travel after that. Meanwhile replace oilcan’s filter core. Filter core’s precision must not be lower than 30μm. Check the oil level in the can regularly during use. If there is any metamorphose or too many impurities. If any bad condition is found, renew or replace. H.Replace (Renew) Oil Procedure 1. Lift up the front axis, or disassemble the straight puller from droop arm 2. Open oilcan cover, and open steering machine oil discharging bolt or release steering machine’s oil exit. Turn the steering wheel in repeat till two ends limit position, release the resid in oil pump and oilcan. When necessary, engine can be operated in idling mode, and turn the steering wheel to left and right till limit position for a few times, stop when no more oil flowing out form oil gate. 3. Screw down steering machine oil discharging bolt or close steering machine oil exit well. 4. Take off oilcan’s filter core, put it back after washing it clean. Renew the oilcan with clean hydraulic oil. 5. Run the engine in idling mode, turn the steering wheel to the left and right to limit position for a few times, meanwhile renew the oilcan till the oil level in oilcan does not decrease and not bubble is produced. 6. Renew the oil till the oil level in the oilcan reaches the mark. 7. Screw down oilcan’s upper cover. I. Oil for power steering machin e: (recomm endation) Shanghai refinery, Lanzhou refinery #8 hydraulic t ransmission oil. Oil must be clean. J. Use of steering oi l pump: choose the steering oil pum p reasonably according to vehicle’s performance requirements and power steering machine basic parameters. K. When assembli ng dr oop arm, make the wheel just and align w ith the marking lin e on steerin g arm axis. ______________________________________________________________________ Page - 103 - of 178
Operatio n Manual of Dump Truc k BJ Z3364 9.6 BREAKDOWN ANALYSIS AND TROUBL ESHOOTING Malfunction Causes Both left 1. Oil lack in hydraulic system. and right steering 2. Air in hydraulic system. are heavy 3. 4. 5. 6.
Different weight when turning left and right When fast steering, steering wheel’s 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 piston’s 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 piston’s 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.
1. Lag in steering oil pump 1. floating copper cover, not always closely stick to wheel end surface. 2. Dirt in steering machine 2. piston sealing ring.
3. Steering machine thread pole’s push bearing broken. 4. Hydraulic oil too dirty. 5. Knuckle pin bearing broken. 6. Air in hydraulic system
Check the oil pump.
3.
Check where it lags, lift the front axis, turn the direction machine, if diesel engine does not start, direction machine can rotate freely, else oil pump has problem. Change the bearing.
4. 5. 6.
Change oil. Replace bearing. Exhaust.
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Operatio n Manual of Dump Truc k BJ Z3364 Deflection in running
1. Lag in steering axis.
2. Bubble in oil, direction is unstable. 3. One front wheel gets stuck (brake does not return position). 4. Unequal looseness between two wheel bearings (one too loose, one too tight). 5. Pressure in left and right tyre does not meet requirement (difference too large). Shaking 1. Incomplete air exhaust in hydraulic system. 2. Lack of oil in oilcan, air is sucked into oil pump. 3. Bad oil path seal, air is sucked. Oil leakge 1. Oil leakage due to broken oil in stearing seal. machine 2. Oil leakage in O type seal ring. 3. Oil leakage or breaking of oil pipe. 4. Oil leakage on oil pipe head joint. 5. Insufficient oil mucosity. 6. Looseness in steering machine hydraulic parts joint surface. Abnormal 1. Folding in hydraulic pipe oil noise when pipe. steering 2. Unstable oil pump discharge. 3. Lack of oil in oilcan. 4. Problem on vehicle chassis.
1. Check the lagging parts, check if there is diameter-direction chop force on input axis. 2. Check and eliminate. 3. Check and repair the brake.
4. Check and adjust.
5. Charge.
1. Exhaust. 2. Renew oil, exhaust. 3. Check oil path and sealing. 1. Check and replace oil seal. 2. Check and replace O type ring. 3. Check or replace oil pipe. 4. Check oil leakage parts. 5. Use oil reasonably. 6. Check and tighten.
1. Check oil path, replace oil pipe. 2. Replace oil pump. 3. Renew oil. 4. Check steering pole, puller system.
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Operatio n Manual of Dump Truc k BJ Z3364
Chapter 10 Braking Device 10.1 Brake Sys tem 10.1.1 Summary Braking device is used to control vehicle’s 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 vehicle’s 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 vehicle’s brake is air driven. It is characterized by the air reservoir through each foot brake system’s 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 vehicle’s lifting and electrical control air horn. 10.1.2 Brake System Working Princi ple 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-pump’s 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 panel’s low pressure indicator. ______________________________________________________________________ Page - 106 - of 178
Operatio n Manual of Dump Truc k BJ Z3364 When air pressure is lower than 450Kpa, red indicator lights up and no traveling is allowed.
10.1.3 Brakin g System Main Components And Working Princi ple
e l p i c n i r P g n i k r o W e c i v e D g n i k a r B – 7 5 e r u g i F
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Operatio n Manual of Dump Truc k BJ Z3364 1 Handle braking valve 2 Foot brake valve 3 Braking pedal 4 Manometer 5 Electrical controlled air horn 6 Electromagnetic valve 7 Lifting control valve 8 Pressure adjustment valve 9 Air compressor 10 Front braking sub-pump
11 Double connecting single direction valve 12 4-loop protecting valve 13 Air desiccator 14 Lifting position limit valve 15 Wet air storing valve 16 Rear air storing valve 17 Front air storing valve 18 Quick release valve 19 Rear braking sub-pump 20 Water discharging valve
10.1.4 Maintenance In Braking System 1. During the use, if oil and water separate, too much diesel oil in air reservoir or pipe path, check for the reason of jumping oil in air compressor, and repair the worn parts. 2. Water discharging valve on the bottom of air reservoir should regularly discharge the seeper. This should be done daily if it is in deep winter. If the seeper has become ice, use a rag dipped into warm water to heat and melt the ice. Strictly prohibit firing. 3. For every 800 hours traveling, clean the front and rear braking room. After cleaning, apply the lubricating grease on the vat wall. Carry out some gas seal test before assembly. 4. System’s air pressure should be kept at normal readings. Before the traveling, the pressure should not be lower than 450 Kpa, else vehicle should not be started. During the normal traveling the pressure should be kept at 750 Kpa. 5. Apply lubricating grease regularly on brake feet support pin or brake camshaft lining.
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Operatio n Manual of Dump Truc k BJ Z3364 10.1.5Brakin g System Malfu ncti on And Troub leshoot ing Malfunction Powerless brake
Brake feet does not return position
Deflection brake
in
Causes 1. Insufficient system pressure. 2. Bad adjustment of brake feet. 3. Abrasion or crack of friction slice. 4. Transformation or scratch of brake drum. 5. Lubricating grease goes into brake drum. 6. Air leakage or breaking of brake chamber. 1. Brake cam axis diameter direction clearance is too small or cam axis is rusty, bad lubrication. 2. Brake feet support pin or pin hole is rusty or bad lubrication. 3. Brake feet retracting spring wears out or damaged. 4. Lag in brake chamber piston and piston pole. 5. Brake chamber and pipe air circulation is bad, gets stuck. 6. Lag in the joint of brake chamber and swing arm. 1. Oil remain on a side of wheel brake feet slice and brake drum. 2. Air leakage of one side of brake chamber and pipe. 3. Unequal adjusting clearance between left and right brake feet friction slice and brake drum or bad contact. 4. Different degree of tightness between left and right 4 wheel hub bearings, difference is large.
Troubleshoot 1. Check air path and all joints. 2. Re-adjust. 3. Replace new friction slice. 4. Repair and rub brake drum. 5. Eliminate oil leakage and wash the brake. 6. Check and repair brake chamber. 1. Eliminate the rust and re-lubricate.
2. Same as above. 3. Replace new spring. 4. Eliminate the lag. 5. Check and eliminate the jam. 6. Eliminate the lag. 1. Eliminate the oil remains.
2. Eliminate the leakage. 3. Re-adjust or repair brake feet friction slice.
4. Re-adjust.
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Operatio n Manual of Dump Truc k BJ Z3364 10.2 Air Compr essor 10.2.1Structure
Figure 58 - (AWC-10) Cummi ns Ai r Comp ressor (Sing le Cylind er) 1 Cooling fluid 2 Unload valve 3 Air adjusting device tie-in
4 Air entrance 5 Air entering valve 6 Air discharge valve
10.2.2Working Princi ple Ai r ent eri ng When piston moves downwards, partial vacuum appears in air cylinder, air is sucked into air compressor through engine air entering branch pipe or air compressor’s 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).
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Operatio n Manual of Dump Truc k BJ Z3364 Unloading When air reservoir’s pressure is under some scheduled pressure, air pressure goes into unloading machine cap’s upper part through a pressure adjusting device. This pressure forces unloading cap downwards and keep air entering valve open (when no pump air circulation). 10.2.3 Maint enance Of Air Compressor 1. When air compressor is working normally, very few machining oil goes into the compressed air. If large amount of machining oil is often discharged from double-entry brake distribution valve’s dirt discharging valve, it means the piston ring may be broken or wrong assembly of ring gate uncork. Repair accordingly. 2. Check if it is smooth in air compressor’s oil pipe and water pipe, if it is tight in air discharging pipe’s tie-in. 3. Observe if the engine is too hot after it starts, if there is knocking sound in air cylinder’s piston and piston pin, if there is abnormal noise, find out the cause and repair. 4. After every 1000-1500 traveling, disassemble the air compressor’s cylinder cover and wash it carefully. Check the coordination condition of air entering valve’s pistons, if there is serious abrasion must replace them.
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Operatio n Manual of Dump Truc k BJ Z3364 10.2.4 Air Compressor Malfuncti on An alysis And Troubleshooting Malfunction Cause Troubleshoot Insufficient 1. Filter shared with engine is 1. Use water with washing power pressure, low too dirty and gets stuck. to wash and dry. efficiency 2. Abrasion or scratch of air 2. Open cylinder cover, clean entering valve, bad sealing carefully, smoothen the parts of condition. abrasion, if too serious the replace. 3. Clearance between piston 3. Clean the dirt and smoothen the and air cylinder wall is too cylinder body. large or serious abrasion of piston ring. 4. Bad seal in air cylinder cover 4. Replace with new parts. and air cylinder body. 5. Air leakage in air 5. Disassemble from air discharging tie-in and joint compressor and do welding or pipe. replacement with new parts. Oil jump in air 1. Air ring and oil ring gates are 1. Check and change gate compressor on the same line. position. 2. Serious abrasion of piston 2. Clean and check the opening ring, scratch of cylinder body clearance of piston ring in or ring lost. cylinder, and transformation of cylinder body, replace with new parts. 3. Filter gets stuck or 3. Disassemble, clean, penetrate machining oil return oil pipe through. gets stuck. Machining oil is sucked upwards, curve axis tank oil level is too high. Abnormal 1. Serious abrasion in air 1. Replace if abrasion is too noise in air compressor each moving serious. compressor part, coordinating clearance too large. 2. Fasten bolt or clearance 2. Fasten the joint bolt or check between air compressor and joint axis device’s coordinating engine axis joint device too clearance. large. Abnormal 1. Unloading valve spring 1. Replace. working of broken or transformed. unloading 2. Unloading valve gets stuck 2. Smoothen or replace new valve valve or inflexible. body. 3. Air leakage in sealing ring 3. Replace the sealing gasket and and pipe. pipe.
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Operatio Operatio n Manual of Dump Truc k BJ Z336 Z3364 4 10.3 4-Loop Protection Valve
Figure 59 - 4-Loop 4-Loop Prot ection Valve Worki Worki ng Prin cipl e
A. Techni Tech ni cal Data Medium Used temperature range Working pressure Weight
: air : -40ºC to +90ºC : maximum 1Mpa : 1.2 kg
B.Use It is used in multi-loop air brake system. When one of the l oop fails, the others can still be charged by this valve and air supply is not affected. C. Working pri ncip le (Figur (Figur e 59) 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 1’s 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 2’s opening pressure, pressure will then leak through the broken 21 loop, but the rest loops are still working with normal pressure.
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Operatio Operatio n Manual of Dump Truc k BJ Z336 Z3364 4 10.4 10.4 Cart Cartwh wh eel Brake Chamber A.Techni A.Tech ni cal Data Piston diameter Piston journey Working pressure
: 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 10.4.1 .1 Assembl y Of Front Brake Chamber 1. Before assembly, assembly, all the parts parts should be cleaned, cleaned, there should not be any dust, crumbs crumbs or burrs. No scratch should be found on the working surface. 2. Fasten all the firmware, firmware, apply a little seal glue glue on pipe tie-in. Run Run the sealing test test after assembly. 3. When assembling assembling piston and sealing sealing ring, apply some lubricant lithium MoS2 grease grease or industrial Vaseline on the working surface. 4. Assemble the piston piston assembly’s assembly’s each part of (17)(15)(14)(13)(16)(4)(6)(7) (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 amount of grease on air cylinder cylinder (15) working surface. surface. When assembling 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 sealin sealing g of screw down tie-in (18). (18). Finally get into pin axis (8) and put on gasket ring and opening pin (9). 7. After assembly, assembly, 50 kpa of compressed air should be filled into brake brake chamber. chamber. At this moment the piston should be above to push out rapidly with 74mm journey, journey, and return to its original position under the effect of position returning spring after unloading.
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Operatio Operatio n Manual of Dump Truc k BJ Z336 Z3364 4
Figure 60 - Wheel Front Chamber 1 Air entering tie-in 2 Air cylinder body 3 Sealing ring 4 Piston
5 Piston pole 6 Position returning spring 7 Dustproof cover 8 Joint fork
Figure 61 - Front B rake Chamber Chamber Parts
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Operatio n Manual of Dump Truc k BJ Z3364 10.4.2 Front Br ake Chamber Malfunct ion Analys is And Troublesho oti ng Malfunction Causes Troubleshoot Insufficient or no brake 1. Sealing ring turns over or 1. Replace sealing ring force in brake chamber cracked. and smoothen cylinder. 2. Pipe gets stuck or tie-in’s 2. Wash the pipe, apply sealing fails some sealing glue on the tie-in. Slow position returning 1. Four holes on dustproof 1. Check air hole, repair of brake chamber piston cover (4) or spring seat (13) piston pole and spring get stuck, piston pole is not seat. flexible 10.4.3 Rear Br ake Chamber A.Techni cal Data Working brake: Epithelial effective diameter Piston’s working journey Working pressure
: 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.
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Operatio n Manual of Dump Truc k BJ Z3364
Disconnect Handle Brake
Figure 62 - Brake Chamber Durin g Normal Run 3. Working brake: brake chamber’s working brake is film mode. Air with different pressure comes from foot brake valve, causes the motion of taper film and pushes the piston. At the same time it pushes the swing arm and makes camshaft rotate, it opens the brake feet and produces braking effect. See Figure 63. Take note that the whole braking chamber is separated into two parts, handle brake must not interrupt normal working brake. 4. Handle brake: by moving the handle brake control valve handle in the chamber, the compressed air is discharged into the atmosphere from the quick release valve in rear vehicle frame. It pushes the piston under the effect of spring and thus achieve parking brake. See Figure 64. 5. Release of handle brake: it is done by turning handle brake cylinder’s rear part’s adjusting bolt. See Figure 65. This is to move the vehicle when engine fails and does not supply compressed air.
Working Brake Position
Disconnect Handle Brake
Figure 63 Chamber In Worki ng B rake ______________________________________________________________________ Page - 117 - of 178
Operatio n Manual of Dump Truc k BJ Z3364
Handle Brake Position
Fast Release Valve Air Circ ulating Handle Brake
Figure 64 - Chamber In Parkin g B rake
Released Handle Travel Position
Brake
Figure 65 - Chamber In Released Brake By Manual
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Operatio n Manual of Dump Truc k BJ Z3364 10.4.4 Rear Brake Chamber Assembly And Requirements 1. Wash all the parts before assembly. There should not be any oil dirt. Especially on the cylinder working surface, there should not be any scratch on it. 2. The seal on the pipe tie-in and sealing gasket should be reliable. It is allowed to apply a small amount of sealing glue at the sealing parts. 3. Before assembly, check the sealing ring and film carefully. The shape of edge and working surface must be correct, they must be also clean, no crack or lack of flesh. 4. Apply some grease on the handle brake’s piston and cylinder body and piston pole’s working surface during assembly. 5. Follow the procedure below during assembly. See Figure 66 for each part. First assemble the handle brake cylinder: Small piston (31), opening block ring (35), brake chamber piston (2), sealing frame and two O shape ring (34), hole-used block ring (33), sealing ring (1) and felt ring (3) are assembled into big and small piston body assembly. Install the big and small piston body assembly into air cylinder (25), then revise and push downwards to make small piston insert into cylinder body lower end’s sealing ring. 6. Install two support gasket slices (4) on big piston’s upper cover, and install a drum shape spring (5) in between them. 7. Put the above assemblies and brake chamber rear cover (6) on the pressure machine frame. See Fig 10-4-8. Take note that an emery cloth should be put on the pressing head and rear cover’s upper end to prevent side sliding. Then turn on oil pressing machine till rear cover (6) is in touch with cylinder (25). Install the spring ring (7) till it fully goes into the groove, then release oil pressing machine and get it off from the workbench. 8. Screw the brake releasing bolt (10) into it, meanwhile install gasket slice (29) and bolt (22) on the lower end of small piston. Fill in 450 kpa compressed air to loosen the brake releasing bolt. Install nylon gasket (8) and round nut (9). The screw down torque should not be lower than 98 Nm. 9. Check if there is any air leakage in the gasket slice (29) and nylon gasket (8). Working chamber’s assembly can only be carried out when the above requirements are fulfilled. 10. When assembling working brake chamber, first install the fixed board (19) onto brake chamber front end (18), and make it firm. Then install flat gasket (17), spring gasket ring (16) and nut (15). Do not screw down too tight. 11. Install the retracting spring (28) onto push pole (20), and then cover the push pole (20) with working brake chamber front cover (18).
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Operatio n Manual of Dump Truc k BJ Z3364
Figure 66 - Rear Brake Chamber Parts 1 Large sealing ring 2 Piston body 3 Felt ring 4 Gasket slice 5 Drum shape spring 6 Hold-use block ring 7 Gasket 8 Round nut 9 Adjusting bolt 10 Cap cover 11 Opening pin 12 Flat gasket 13 Pin axis
14 Nut 15 Spring gasket ring 16 Flat gasket 17 Front cover 18 Fixed board 19 Push pole 20 Skin bowl 21 Bolt 22 Nut 23 Bolt 24 Cylinder body 25 Joint fork 26 Nut
27 Retracting spring 28 Gasket ring 29 Small sealing ring 30 Small piston 31 Collar clamp 32 Hole-use blocking ring 33 Sealing framework 34Block ring
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Operatio n Manual of Dump Truc k BJ Z3364 12. Put the skin bowl (21) in between handle brake cylinder and working brake chamber front cover. Install the collar clamp (32) and screw down the fi xed bolt (24). When screwing down, use a wooden hammer to knock the collar clamp (32) surrounding lightly to make it into the right position. Then screw down two fixed bolts (24), the torque is 49 Nm. 13. Under a 750 kpa pressure, charge the brake chamber. Check the sealing condition of collar clamp (32). 14. After the whole assembly, install the joint fork (26) and nut (27) for the last check. 15. Testing requirements for whole vehicle check: when filling 50 kpa compressed air into the working brake chamber, piston should be quickly pushed with 62mm journey. After discharging the air it should immediately return its position. When filling 450 kpa compressed air into handle brake cylinder, handle brake should be immediately released. 16. Adjustment of handle brake should be done during assembly. Fill the compressed air into handle brake chamber, turning the brake releasing bolt (10) and push the front push pole (20) all the way till the end. Finally cover the brake chamber cap cover (11).
Figure 67 - Rear Br ake Assembl y
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Operatio n Manual of Dump Truc k BJ Z3364 10.4.5 Malfunction Analysis And Troubleshooting Malfunction Causes Troubleshoot Working brake is 1. Air leakage in cylinder’s 1. Check and replace the always in working sealing parts and small big and small piston state piston. sealing ring. 2. Air leakage in cylinder rear 2. Check and replace the part’a adjusting bolt. small piston’s O shape ring. Air leakage in 1. Looseness of collar clamp, 1. Re-screw down collar working brake uneven tightness of the clamp bolt with torque chamber surrounding, air leakage 29Nm. from collar clamp. 2. Crack in skin film. 2. Replace with new skin bowl. Handle brake fails 1. Damage or transformation 1. Replace with new drum Insufficient force of drum shape spring. shape spring. 2. Jam or incomplete air 2. Check and wash the circulation of air pipe pipe.
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Operatio n Manual of Dump Truc k BJ Z3364 10.5 Cartwheel Arrester A.Techni cal Data Brake drum diameter Friction slice width
: 462mm : 180mm
Friction area
: 1584mm
Friction slice dimension (length×width×height) Friciont slice’s frictional index (with temperature 350oC)
: 220×180×15mm
2
: 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 princi ple 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
Operatio n Manual of Dump Truc k BJ Z3364 1 Brake drum 2 Support pin 3 Brake feet 4 Retracting spring 5 Retracting spring pin 6 Camshaft
7 Adjusting spline cover 8 Adjusting bolt 9 Idler wheel 10 Nut 11 Adjusting arm
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.
Figure 69 - Front A rrester
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Operatio n Manual of Dump Truc k BJ Z3364 10.5.1Assembl y Of Front Wheel Ar rester 1. Wash all the parts before assembly. No burrs, no flying edge, especially no scratch or oil dirt on the friction slice and brake drum’s working surface. 2. Carry out the drill of friction slice (1) and brake feet only on the specific machine. When use rivet (3) for riveting, it should be done from one end to the other, or from middle to the two ends, so that there will not be any clearance. When riveting, its rivet head should touch the fiction slick hole bottom part closely, and lower than half of the thickness of friction slice. In order ensure good contact between friction slice and brake drum, carry out the outer circle grinding on specific machine. See Figure 70.
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 knife’s 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
Operatio n Manual of Dump Truc k BJ Z3364 9. For brake feet assembly, use the specific machine to check the clearance between friction slice and brake drum, it should be 0.65mm at cam and 0.35mm at support pin. The upper and lower feet should be consistent. 10. Finally install two oil nozzles (23) on the two support pin (7) and apply some grease. 10.5.2Assembl y Of Rear Wheel Arr ester 1. The riveting of rear wheel arrester friction slice and brake feet, lining and idler wheel’s assembly are basically the same as front wheel arrester. We will not repeat here. 2. Install the camshaft seat (9) on rear axis, get into bolt (10) gasket ring (11) and finally screw down the bolt, screw down torque is 44 Nm. Apply some loose proof potion on this bolt.
Figure 71 - Rear Wheel Arrester KD 3. Press the two camshaft cover (7) (8) into camshaft seat (9) two ends, do not scratch the working surface of cover when assembly, apply some grease. 4. Insert the spline cover (18), install adjusting bolt (19) and nut (20) into brake arm (21). Then together put them on camshaft spline. Beware of proper position of brake arm upper end and brake chamber support. Finally install the axis-use block ring (22) and meanwhile carry out the check just as the arrester. 5. Finally install the rear brake drum (23) on rear wheel hub, put on stop gasket ring (24), screw down 8 fixed bolts (25). Beware of the symmetry when screwing, screw down torque is 275-314 Nm, move the stop gasket slice and install it on the rear axis, at the same time install the oil nuzzle (26), apply some grease. 10.5.3Adj ustm ent Of A rrester There is abrasion of arrester’s friction slice along with the vehicle operation, so must adjust regularly. When the thickness of friction slice is smaller than 9mm (minimum limit), replace it. ______________________________________________________________________ Page - 126 - of 178
Operatio n Manual of Dump Truc k BJ Z3364 Adjustment procedure: firstly release lock tight nut, screw the adjusting bolt till it touches closely. The reversely screw the nut till friction is eliminated, and screw down the lock tight nut. If all the bolts are screwed down, but still need to adjust, then must disassemble the spring block ring and swing arm, and put the adjusting cover on spline axis the move it by one tooth. 10.5.4Malfu ncti on Analysi s And Trou bleshoo t Malfunction Weak brake
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.
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Operatio n Manual of Dump Truc k BJ Z3364 10.6 Air Reservoir A. Techni qu e Data Model
: three unattached air reservoir
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.
C. Structu re And Working Principle The air reservoirs are two in parallel. See Figure 72. Used working pressure is 750 Kpa, their capacity is about 60 L. A block board is welded in the upper air reservoir (1), divide the reservoir into 5L and 55L. Hence the air reservoir are divided into three separate parts: regenerating air reservoir (1), front brake chamber air reservoir (4) and rear brake chamber air reservoir (5). Water discharging valve (6) is installed on the bottom of each air reservoir. It is used for discharging the oil water. When using, just press its valve pole.
Figure 72 - Air Reservoir 1 Regenerating air reservoir 2 Middle block board 3 Tie-in seat
4 Front air reservoir 5 Rear air reservoir 6 Water discharging valve
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Operatio n Manual of Dump Truc k BJ Z3364 10.6.1 Main Malfu ncti on A nd Maint enance Usually there is no malfunction of air reservoir. The possible causes of malfunction may be due to damage in retracting spring or rubber seal ring gets old and transformed, disassemble and check, replace the spring and seal ring. See Figure 73. In order to reduce the deposit water and rust of water discharging valve, need to discharge water regularly.
Figure 73 - Air Reservoir Water Discharge Valve
10.7 Hand Brake Valve A.Techni qu e Param eter Model Valve’s venthole diameter Working pressure
: two position three connecting valve : 8mm : 750 kpa
B.Use Handle brake device is vehicle’s 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 panel’s 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 cab’s instrument panel. Handle has only two brake position, right is driving position.
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Figure 74 - Handle Brake Valve Principle 1 Air reservoir 2 Handle brake valve
3 Quick release valve 4 Rear brake sub-pump
C. Working Princi ple The compressed air from rear air reservoir (1) is connected to handle brake control valve’s air entrance through pipe. The compressed air goes into air exit through seal ring A’s 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 A’s 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 chamber’s 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.
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Operatio n Manual of Dump Truc k BJ Z3364 10.7.1 Malfu nct ion Analys is And Troublesho ot Fig Handle position
Airflow pathway
Handle position
Airflow pathway
Causes Troubleshoot 1. When handle in this 1. Repair this valve’s position, if valve B’s seal seal ring and valve ring and seat’s 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 valve’s 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 A’s 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
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Operatio n Manual of Dump Truc k BJ Z3364 10.8 Quick Release Valve A. Us e Quick release valve directly connects to rear brake chamber, its function is to stop the brake and rapidly discharge the compressed air from air chamber into atmosphere. To Atmos phere
To Brake Chamber
To Brake Chamber
Ai r So ur ce
Figure 75 - Quick Release Valve 1 Valve 2 Retracting spring 3 Valve B.Working Principle The structure of this valve is shown in Figure 75. The air source shown in figure comes from foot brake valve’s compressed air. The rest three holes are labeled i n the figure. When compressed air comes in from air source, when valve (3) moves, it closes the air discharging hole connecting the atmosphere, meanwhile connects air source entrance and each air chamber, passes through pipe airflow to each brake chamber. When there is no compressed air in air source entrance, under the effect of retracting spring (2), valve (3) closes the air source, opens the air discharge hole, the compressed air from each brake chamber goes to atmosphere through pipe and air discharging hole. 10.8.1 Malfu nct ion And Troubl eshooti ng The main malfunction is valve (3) rubber seal valve’s damage or retracting spring (2) fails. In general, repair by washing the valve and replace the broken parts. ______________________________________________________________________ Page - 132 - of 178
Operatio n Manual of Dump Truc k BJ Z3364 10.9 Foot Brake Valve
A.Techni qu e Data Medium Temperature range for use Working pressure
: air : -40ºC +80ºC : maximum 1 Mpa
Relative over pressure between #1 loop and #2 loop
: ∆P=30
+10 − 20
Kpa
B. Use To fulfill flexible control in double loop main brake system’s 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
Operatio n Manual of Dump Truc k BJ Z3364 10.10 Pipelin e And Tie-In A.Us e Pipeline and tie-in are the devices for transmitting liquid. If need to connect one pipeline to another or to a valve, GB3733.1-3765-83 and Q640 rotating pipe tie-in are required. Mainly use ferrule fitting tie-in. The quality of these pipelines and tie-in directly affect the performance of whole system. Must emphasize this point during operation. B. Pipeline Basic Specifications And Ap plications Specification 14x1 10x1 6x1
Example on parts used in this vehicle 1 Working brake pipeline 2 Air reservoir joint pipeline 1 Assistant gas device’s main pipeline 2 Handle brake pipeline 1 Lifting system gas control pipeline 2 Gas horn and manometer pipeline 3 Cab’s instrument panel control pipeline
C. Ferru le Fittin g Tie-In Structu re And Sealing Pri ncip le 1. Structure Although there are many kinds of ferrule fitting tie-in, the structure is simple. It consists of tie-in body, ferrule fitting and compressed nut. See Figure 76.
Heightened Belt
Figure 76 - Ferru le Fitti ng Tie-In 1 Tie-in body 2 Ferrule fitting 3 Compressed nut 4 Pipeline The important part is ferrule fitting (2). Its surface must have sufficient rigidity and rigid layer depth, edge must be sharp, and the core should have certain plasticity to ensure good transformation ability. The edge should not be cracked or become dull due to pipeline’s cut-in.
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Operatio n Manual of Dump Truc k BJ Z3364 2. Sealing principle The ferrule fitting provides the main sealing function. It is under the effect of compressed nut R force’s axis-direction sub-force Fx and moves along the tie-in inner cone surface in axis-direction (see Figure 77), meanwhile the edge is under the effect of reverse force R’s axis-direction sub-force Fg and it shrinks and eliminates the clearance between ferrule fitting and pipeline, makes the edge cuts into the pipeline. In order to control the cutting depth, according to the theory, after compression it just needs to rotate 1
1
1 rounds. The theoretical cutting depth is
～
3
about 0.25-0.5mm. However, during the assembly the ferrule fitting will hump up and pipe will shrink, so the practical cutting depth is smaller than the theoretical value. Part of this cutting pipe will form ring sealing area which if fully air proof. The humping and transforming of ferrule fitting also help to prevent the compressed nut become loose.
Figure 77 - Sealin g Princ ipl e 10.10.1 Assembly not ice 1. Wash all the pipes and tie-ins before assembly. Keep them clean. 2. The pipelines for assembly must be cut using cutting wheel (Figure 78), and use the triangle knife to remove the burrs on the inner rim of pipe (Figure 79). Blow off the cutting crumbs.
Figure 78
Figure 79
3. The compressed nut put on the pipe end’s ferrule fitting must be just align when installing on tie-in (Figure 80), apply a little machine oil. ______________________________________________________________________ Page - 135 - of 178
Operatio n Manual of Dump Truc k BJ Z3364
Marking Line On Nut Helps The Task Mentioned Above
Figure 80
t n i o P p o t S
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 pipeline’s tie-in, beware of the assembly order. Assemble the aluminum made parts first, then the steel made parts, to prevent damage on screw thread.
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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. Vehicle’s 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 point’s 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 spring’s 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.
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Figure 82 1 Front thrust pole 2 Front spring front suspend ear 3 Pin 4 Front main spring 5 Front spring pressing board
6 Front rubber auxiliary spring 7 Tube shock absorber 8 Front axis 9 Vehicle frame 10 Front spring rear suspend ear
11.2 Rear Susp ension
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.
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Operatio n Manual of Dump Truc k BJ Z3364 Vehicle Frame
Rear Axl e Casing
Figure 83 1 Front support 2 Thrust pole 3 Main spring
4 Main spring pressing board 5 Rubber auxiliary spring 6 Rear support
11.3 Assembl y / Disassembly Notic e 1. When steel board spring bears with loads and transforms, relative sliding happens in between the slices to absorb the shock. Clean the slices before assembly, apply graphite grease and list it as a maintenance item, for normal use and lifespan lengthening. During the use do not only care about replacing the broken slice, also wash and apply grease, otherwise it will causes steel board spring to self-friction, increases the frictional force between the slices and reduce the capability of shock absorption. The wheel will have to bear with more impact and pass to the vehicle frame, and this will affect the lifespan of the vehicle. When assembling/disassembling the steel board spring, must not use steel made hammer to knock. 2. Rubber auxiliary spring: it is a substantial rubber part and is used to protect the main spring. It has small initial rigidity and larger terminal rigidity, so that when road condition is bad, it will effectively protect the main spring.
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Operatio n Manual of Dump Truc k BJ Z3364 11.4 Breakdown Analysis And Troubleshooting Malfunction Steel board spring is too hard
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 absorber’s capability weakens. 5. Wheel gets stuck
Noise in suspension
1. Lack of lubricants in between spring slices. 2. Looseness of mounting bolt. 3. Abrasion of shock absorber pin 4. Shock absorber external pipe broken due to impact, friction between external pipe and inner pipe
2. Disassemble the shock absorber and check, replace when necessary 3. Check the brake feet’s adjustment. 1. Disassemble the spring, add lubricants. 2. Screw down the nut according to the regulated torque. 3. Replace the shock absorber’s pin. 4. Repair steel tube of shock absorber, replace the shock absorber if necessary.
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Operatio n Manual of Dump Truc k BJ Z3364
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 t wo 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.
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Operatio n Manual of Dump Truc k BJ Z3364 12.3 Assembl y Notice 1. When assembling wheel, beware of the air nuzzle position. Front wheel air nuzzle should face inside, namely left wheel faces right, right wheel faces left. Rear wheel is double tyre, outer wheel faces outside, inner wheel faces inside. Thus i t is convenient to charge the tyre, front wheel air nuzzle faces inside to prevent scratch. 2. When assembly tyre’s shoe, inner tube and lining, should keep it dry and clean. Inner tube should be assembled into shoe with slight charge in the inner tube. Before assembly, spread a small amount of talcum powder on the shoe. When assembling, make sure the relative position of shoe, inner tube and lining is right. No folding or deflection. There should not be any crimple and crack of lining. Tyre with the same pattern should be installed for each vehicle. After assembly, charge the tyre according to the requirements. 3. The assembly of front and rear wheel hub: lift the front axis and rear axis, screw down bearing’s lock tight nut till it cannot be screwed further, at the same time turn the wheel to positive and negative two directions so the bearing roller will correctly sit on the inner and outer ring’s cone surface. The wheel hub should be able to rotate freely and not obvious swing. When wheel rotates, it should be quite. The slight resistance is even within one rotation. If the bearing is too tight, it will be overheated during traveling, causing damage of bearing. If the bearing is too loose, the impact during traveling will also damage the bearing. So must be very careful when adjusting wheel hub bearing. 12.4 Cartw heel Use And Maintenance 1. Keep the tyre under normal pressure. The most common cause of breaking tyre is improper pressure charge. If tyre pressure is insufficient, tyre will transform to a larger extend, this does not only increase tyre’s inner stress, it will also increase its temperature, reducing its lifespan.
Insufficient pressure % Lifespan reduced %
% lifespan reduced due to insufficient tyre pressure 10 20 30 40 5
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.
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Operatio n Manual of Dump Truc k BJ Z3364 2. Prevent overload. The damage brought by overload is similar to that of by low pressure. But for overload the stress is even larger, the tyre temperature is higher, so the wearing is more serious. 3. Prevent contact with oil substances, especially do not park the vehicle at where the machining oil, gasoline and butter is, else the rubber will deteroprate or transform. 4. Beware of maintenance of traveling road surface. The quality of road surface will greatly affect the tyre’s lifespan. The abrasion of tyre will increase if the road surface becomes rougher. So do the maintenance and make sure the road surface is flat. 5. Carefully drive the vehicle. The endurance of tyre also depends on the driving skill to a large extend. Incorrect or careless driving will dramatically reduce the tyre travel journey. Sudden start, sudden brake, sudden turn or collision with obstacles should all be prevented. 6. Beware of storage. When storing the tyre, prevent high temperature, direct sunshine or getting wet, prevent contact with acid, alkali, salt, oil or any organic solvent. Prevent drench or dunking into water. Storeroom’s temperature should be kept at -15ºC to +30ºC, relative humidity should be around 50-80%. Must not put the tyre near to heat radiation device.
12.5 Breakdown Analysis And Troubleshooting
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)
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Operatio n Manual of Dump Truc k BJ Z3364
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
: 8335 kpa : (1000rpm) 215L/min : 95 L : not more than 20 seconds : not more than 20 seconds
Maximum working temperature
: 10OºC
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 t o its original position by its own weight.
13.3 Assembly An d Working Principle Hydraulic dump mechanism is required to be convenient and flexible, safe and reliable, and can ensure carriage lifting, stop while lifting, descending, stop while descending and lifting safety automatic limit position. Hydraulic dump mechanism consists of oil pump, lifting cylinder, distribution valve, oil tank and oil pipe. See Figure 85. Oil pump is driven by gear box power obtaining device to produce hydraulic pressure oil with certain pressure and flux for lifting cylinder to use. Lifting cylinder is connected to vehicle case. The pressure oil goes into lifting cylinder, and lifting cylinder will produce push force sufficient to lift the carriage. Distribution valve is controlled by pressure control. Distribution valve is a combinational hydraulic pressure valve, it has the function of safe overflow protection, changing oil flow direction, opening and closing oil path and preventing oil from lifting can flows reversely into oil pump.
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Figure 85 - Hydraulic Dump Mechanism System
13.4 Lift Pump 13.4.1 Structu re And Workin g Princ ipl e Lifting system uses gear oil pump. Figure 86 shows a double connecting parallel gear oil pump. Its structure is simple, double metal abrasion endurance gasket slice is installed on gear end surface. It has a long lifespan and not broken easily. So, even though this kind of oil pump’s gear end surface clearance is irreversible, it can work steadily for a long time, and maintenance and repair are also relatively convenient.
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Figure 86 - Liftin g Oil Pump Section 1 Joint cover 2 Oil seal 3 Pump shell 4 Sealing ring 5 Pump shell 6 Gear 7 Abrasion endurance gasket slice
8 Bearing 9 Pump shell 10 Axis 11 Bolt 12 Oil seal 13 Main axis
Oil pump’s 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
Figure 87 - Oil Pump Worki ng Princ ipl e ______________________________________________________________________ Page - 146 - of 178
Operatio n Manual of Dump Truc k BJ Z3364 13.4.2 Assembl y / Disassembl y Noti ce And Technical Requir ements
Figure 88 - Lifti ng Oil Pump Secti on 1. Do not damage oil pump and the sealing rings, especially do not put oil seal and rubber sealing ring into gasoline or diesel oil for cleaning, otherwise the rubber will metamorphose. 2. Do not injury the working surface and keep it clean. 3. Do not mix gear (9), (33) and abrasion reduction gasket slice (8). Separate them during assembly/disassembly. If mistaken, axis-direction clearance will change. Must not install the gasket slice in wrong direction. 4. Install the rollers fully. Do not skip any of them. Replace if roller gets seriously burnt. 5. Keep the gear end surface smooth. Use blade ruler to check, it is best if there is not light penetration. Repair or replace if the abrasion is too serious. 6. Gear end surface abrasion reduce gasket slice is a main part to keep the capability of oil pump, but it is also easily broken. If the abrasion of surface is too serious, replace it. 7. When assembling, especially repairing or after changing the parts, must check and adjust the axis-direction clearance for assembly. It must not exceed 0.06mm, otherwise it will increase the leakage, oil pump capability will not meet the requirement. But the end surface clearance should not be small than 0.01mm, otherwise there will be lag when operating.
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Operatio n Manual of Dump Truc k BJ Z3364 8. Check and test after assembly. 1. Oil pump can be rotated by manual, the rotation should be flexible, there should not be any lag. 2. View from the axis end, test with rotation in anti-clockwise direction, under the pressure of 8335 kpa, oil pump cubage efficiency should not be lower than 85%. 3. Check when under the effect of oil pressure, the sealing condition of oil pump, especially see if there is oil leakage at axis end high pressure oil seal (28). If oil leaks, replace the oil seal.
13.5 Lift ing Vat Lifting vat (lifting cylinder) has the function of lifting the carriage, and dump the cargo from the carriage. Lifting cylinder’s two ends: one is fixed on the vehicle frame, the other is fixed on the bottom of carriage. See Figure 89.
Figure 89 - Lifting Cyli nder Secti on
13.5.1 Work ing Princi ple Lifting pump is a three level flex type. See Figure 90. When lifting, under the effect of lifting oil pump pressure oil, the outer cylinder tube of lifting cylinder is lifted first. When outer cylinder tube finishes lifting, then level 2, level 3 cylinder tube will be lifted in turn. This lifting cylinder is a single direction type. It has only one oil entering gate. Descending of carriage is not done by high pressure oil effect, it is done by opening distribution valve oil circulating path, carriage will descend under the effect of its own weight.
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Figure 90 - Lifting Cyli nder Secti on 1 Upper suspend ear 2 Sealing ring 3 Elastic lock ring 4 Level 1 cylinder tube 5 Level 2 cylinder tube 6 Level 3 cylinder tube 7 Column stuck pole
8 Sealing ring 9 Copper cover 10 Sealing ring 11 Felt ring 12 Lower suspend ear 13 Joint bearing
13.5.2 Assembl y / Disassembl y Noti ce And Technical Requir ements 1. Check if there is any scratch or serious abrasion or any other defect on the part surface. Especially check the cylinder tube outer surface of level 1, 2 and 3. 2. Check if there is serious abrasion on the copper cover. If the abrasion is too serious, replace it. 3. Disassemble the lifting cylinder once, replace all the O shape sealing ring. 4. Strictly prohibit using gasoline or diesel oil to wash rubber sealing ring.
13.6 Dist rib uti on Valve The function of distribution valve is to change the oil flow direction, lift or lower down the carriage based on the requirements. The driver controls the distribution valve by moving lifting electromagnetic gas moving control valve. Figure 91 shows the distribution valve section.
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Operatio n Manual of Dump Truc k BJ Z3364
Figure 91 - Distri buti on Valve KD 13.6.1 Worki ng Princi ple Distribution valve is pole sliding type, it uses compressed air to control the action of valve pole. Pressure limit safety spring device and a stop return valve are installed on distribution valve. The former is used to protect hydraulic system’s safety. The latter is used to prevent oil in the hydraulic cylinder flows reversely into the pump. The carriage can be stopped at any position while lifting or descending. See Figure 92. When lifting, oil from oil pump will flow into oil cavity A through stop return valve 2, as shown form the solid line arrow, through the oil pipe joint into lifting cylinder. When lifting is done, position limit steel wire will pull the main valve pole. If at this moment the oil pump is still operating and transmitting oil, t he oil will flow into oilcan by changing its path to cavity B. When descending, move the lifting electromagnetic gas moving control valve handle in the cab, so that it is at “descending” position (at this moment the compressed air goes into oil returning valve pole gas chamber), as shown in I-1, oil returning valve pole is pressed down, cavity A and B are in connection, oil from oilcan will flow back through oil returning pump. Carriage will descend under the effect of its own weight.
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Operatio n Manual of Dump Truc k BJ Z3364
From Oil Pump
Oil Inflow Path Oil Return Path Oil Return
Figure 92 - Dist rib uti on Valve Section 1 Main vale pole piston 2 Stop return valve 3 Steel ball 4 Main valve pole 5 Safety valve spring 6 Oil returning valve pole 7 Oil returning valve piston C Main valve pole control gas chamber D Oil returning valve pole control gas chamber
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Operatio n Manual of Dump Truc k BJ Z3364 13.6.2 Assembly / Disassembl y Notic e And Technic al Requir ement 1. The coordinating clearance between valve pole and valve poles is better kept within 0.008-0.012mm, the maximum is 0.025mm. Otherwise there will be serious leakage. 2. After disassembly, replace all the O shape rubber sealing rings. 3. The pressure of safety valve spring is limited within 8335 kpa. Under any circumstances it must not exceed 9806 kpa or higher. Otherwise the whole hydraulic mechanism will be damaged. 4. Strictly prohibit using loose fibrous cotton thread or cloth to wipe the parts, otherwise there will be lag in the coordinating plane. 5. Strictly prohibit using gasoline or diesel oil to clean rubber sealing parts to prevent metamorphoses.
13.7 Limit Valve Position limit valve is an air distributor. It is control by a steel thread connecting to the carriage. It is used to prevent over lifting of the carriage. When carriage is lifted to its limit position, the oil going into hydraulic cylinder will be cut. See Figure 93 for its structure KD.
Figure 93 - Positi on Li mit Valve KD It consists of iron casting shell (5) and valve pole (3). Valve pole has an open hole, the steel thread passed through this hole and connects the carriage. The steel thread is fastened under the valve pole using one pressing board ( 2) and two bolts (1). See Figure 93. 13.7.1 Work ing Princi ple Usually the limit valve will not be in the working state. See Figure 94. the compressed air from air reservoir passes through hole (1) but hole (1) and (2) are not in connection, so it does not work. When carriage reaches its lifting limit, the steel thread will pull the valve pole and overcome the spring (7) force, then move it to the right (Figure 95). ______________________________________________________________________ Page - 152 - of 178
Operatio n Manual of Dump Truc k BJ Z3364 Thus the sealing ring (3) on the right will be moved to right hand side of hole (2), make hole (1) and (2) in connection. The compressed air from air reservoir will passed through hole (2) and goes into distribution valve main valve pole control gas chamber (Figure 92-C) to push main valve pole, lifting will then be stopped. 13.7.2 Assembl y / Disassembl y Noti ce And Technical Requir ement 1. Strictly prohibit using gasoline or diesel oil to wash rubber sealing parts. 2. Beware of dirt entering the coordinating plane. 3. When assembling, apply a layer of lubricants on valve and valve pole coordinating plane.
Figure 94 - Limi t Valve Not In Work ing State 1 Air entering hole 2 Air exit hole 3 Sealing ring 4 Felt ring 5 Steel thread fasten bolt 6 Pressing board
7 Spring 8 Elastic block ring 9 Dust proof cover 10 Valve pole 11 Valve 12 Air returning hole
Figure 95 - Limi t Valve In Worki ng State 1 Air entering hole
2 Air exit hole
12 Air returning hole
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Operatio n Manual of Dump Truc k BJ Z3364 13.8 Operation On Lift System 13.8.1 Operation Procedure The control of oil pump is electromagnetic stretch type. By the carriage dump button switch on the instrument panel, control the electromagnetic gas moving valve to make electromagnetic gas moving valve ventilates. Control power obtain device’s combinational gay cylinder, gas cylinder piston will then push power obtain device swing arm to make oil pump driving axis engages gear. The dump procedure is: firstly step down the clutch, move the gearlever to neutral position, then connect the lifting electromagnetic valve switch. At this moment, the compressed air from air reservoir will make oil pump gear engages gear through power obtain device combinational gas cylinder. Oil pump starts rotating, and now can lift the carriage. 1. Lifting: put the lifting gas moving control valve handle into “lifting” position, at this moment the gas valve closes, gas path is closed. Distribution valve main valve pole (A, B) are in their original position as shown in Figure 96. The output high pressure oil from oil pump will be transmitted to lifting cylinder’s oil entering pipe through distribution valve (See the flow oil lifting oil shown in Figure 96), then input into lifting cylinder. Under the effect of oil pressure the lifting cylinder will slowly move up the lift the carriage. When carriage dumps to its limit angle, limit steel thread B (Figure 97) will be pulled tightly and move the limit valve pole to the right, see Figure 95. At this moment limit valve will be open, compressed air goes into hydraulic distribution valve’s main valve pole control chamber through pipe hole 1 and 2, push main valve pole, and then close lifting cylinder oil entering pipe. Lifting will stop automatically. If the oil pump keeps rotating, then the output oil from oil pump will flow back to oilcan through distribution valve. 2. Descending: first cut off the lifting electromagnetic switch to make oil pump gear move away from power obtain device combinational cover. Oil pump is not working at the moment. Then put the lifting control handle to “descending” position, and gas valve opens, and connects the compressed air to control distribution valve loop valve pole. At this moment the oil from hydraulic cylinder will flow into oilcan through oil returning pipe. Carriage will descend under the effect of its own weight. 3. Stop while lifting: follow the “lifting” procedure, stop the oil pump operation midway, at this moment under the effect of distribution valve high pressure oil entrance stop r eturn valve, the oil in oil cavity will not flow back to oil pump. The oil in hydraulic cylinder will support the carriage and make it stop.
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Operatio n Manual of Dump Truc k BJ Z3364 4. Stop while descending: follow the “descending” procedure. When the carriage descends to any position, close the lifting gas moving control valve (put the lifting handle to “lifting” position), then make the distribution valve cuts the oil in lifting cylinder and not letting it back to oilcan through oil pipe, then the carriage can be stopped. Lifting Stop Lowering
r e d n i l y C g n i t f i L o T
k n a T l i O o T n r u t e R
Stop & Descend
Lift
From Lifting Oil Pump
Figure 96 - Liftin g Distri but ion Valve
Connect To Handle Gas Control (Always Open) To Air Reservoi r Tube
Open Air Path Close Air Path
Figure 97 - Lifting Control System 1 Oil pump 5 Distribution valve 9 Oil tank
2 Elbow 3 Tie-in 6 Limit valve 7 Lifting cylinder 10 Oil return pipe 11 High pressure oil pipe
4 High pressure oil exit pipe 8 Cushion device 12 Limit steel thread
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Operatio n Manual of Dump Truc k BJ Z3364 13.8.2 Operation An d Adj ustm ent Notic e 1. Oil pump gear engagement and distribution valve’s gas path control pressure should be higher than 450 kpa. 2. When lifting is done, during the traveling, strictly prohibit closing the lifting electromagnetic valve switch, strictly prohibit putting the lifting control handle to lifting position, otherwise the oil pump will operate for a long time or carriage will be lifted, causing accidents. 3. Check the steel thread, make sure it does not tangle the other parts, otherwise the cushion spring will be damaged, causing accidents. 4. Check if the steel thread is loose. Especially take note of the adjustment of steel thread installed on A segment (Figure 97). Make sure it is not too tight. It should have looseness with 10-14mm. Usually this segment of steel thread will not function unless gas path fails (limit valve is not functioning), then through this segment of steel thread the distribution valve main valve pole will be pulled and hydraulic pressure cylinder oil path will be closed, and let the carriage limits its position for the safety purpose. 5. One easy wat to check lifting limit angle (45º±2°) is after the carriage is lifted up, the distance between the rear two cushion rubber blocks and vehicle frame rear rim inclined surface should be about 50mm. See Figure 98. 6. The most important point of hydraulic system is that the oil must be clean, during the assembly/disassembly must not knock, move at will or scratch the précised parts. 7. Do not adjust distribution valve’s safety valve spring at will, otherwise the parts will be broken due to pressure overload. 8. When repairing, strictly prohibit supporting the carriage on the soft ground. This method is very unreliable, and it may cause deflection of carriage and lag in oil cylinder.
Carriage
Distribution Valve Limit Valve
Vehicle Frame
Figure 98 - Check Lifti ng Li mit Angl e
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Operatio n Manual of Dump Truc k BJ Z3364 13.9 Malfunct ion Analysis A nd Troubleshooting Malfunction Cannot lift
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 . Replace with new parts 5. Disassemble, wash or replace the O shape ring
6. Repair and eliminate the lagging parts 7. Lag in distribution valve or 7. Check and repair the safety valve fails distribution valve 8. Oil pump fails 8. Check and repair the oil pump Carriage 1. Abrasion of side board of lifting 1. Repair oil pump lifting too oil pump gear, the efficiency of slow oil pump is reduced, flux is greatly reduced 2. Lag in oilcan 2. Check and eliminate the lag 3. Limit valve fails, hydraulic 3. Check and repair the limit valve control valve main valve partially open, insufficient flux into oilcan 4. Oil pump oil suck pipe gets . Clean the filter stuck Does not 1. Hydraulic control valve’s single 1. Disassemble, clean stop after direction valve gets stuck, bad lifting sealing 2. Main valve pole and oil return 2. Abrasion is too serious, replace valve pole’s sealing is bad 3. Oil leakage in oilcan and valve 3. Check and eliminate and oil pipe Carriage 1. Insufficient pressure, cannot 1. Check gas path and pressure cannot push hydraulic control valve descend loop valve pole 2. Oilcan gets stuck or 2. Check and repair coordination is too tight 3. Oil return valve gets stuck 3. Check oil return valve ______________________________________________________________________ Page - 157 - of 178
Operatio n Manual of Dump Truc k BJ Z3364 Carriage 1. Insufficient pressure (lower 1. Check the gas path descend too than 441 kpa), lifting hydraulic slow control valve oil return valve pole is not fully open 2. Oilcan gets stuck or 2. Check oilcan coordination too tight 3. Oil return pipe or valve partially 3. Check oil return pipe and valve gets stuck
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Operatio n Manual of Dump Truc k BJ Z3364
Chapter 14 Vehicle Frame, Carriage, Cab And Dri ver 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 240×l30×l2mm. 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. Frame’s 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 Carri age 14.2.1 Carriage Structu re And Funct ion 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 8º30´´ so that it will prevent sliding of ores from the motherboard.
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Operatio n Manual of Dump Truc k BJ Z3364 The motherboard uses 15MnMoVNRe adjusting high strength steel plate. Its abrasion resistance is 4-5 times compared to 16Mn steel plate. The side board and front board are both welded using 8mm thick 16Mn steel plate.
Figure 99 - Connecti on Of Carri age, Lift ing Cyli nder, Skip B ucket Axi s & Scratch Slate 1 Bolt 2 Flat gasket ring 3 Block cover 4 Glue gasket 5 Spring gasket ring 6 Nut 7 Bolt 8 Position locating plate 9 Nut 10 Oiling nuzzle 11 Upper pin 12 Dust proof cover 13 Elastic block ring 14 Active joint 15 Hydraulic lifting cylinder 16 Bolt 17 Elastic gasket ring 18 Pin lock slice 19 Elastic block ring 20 Dustproof cover 21 Elastic block ring 22 Active joint
23 Oiling nuzzle 24 Dustproof cover 25 Bolt 26 Shock absorbing glue gasket 27 Spring gasket ring 28 Nut 29 Pin 30 Glue gasket ring 31 Flat gasket ring 32 Uncork pin 33 Dial rock pole 34 Bolt 35 Spring gasket ring 36 Cover board 37 Lining 38 Bracket 39 Bolt 40 Nut 41 Adjusting gasket ring 42 Shock absorbing gasket ring 43 Bolt 44 Carriage pin axis
45 Support seat 46 Nut
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Operatio n Manual of Dump Truc k BJ Z3364 There is a protection plate in front of carriage. Its function is to protect the cab from occasional dropping of rock and earth. The exhaust gas from diesel engine can go to carriage’s exhaust gas intake gate, passes through motherboard and front abdomen board and left and right abdomen board, and finally it is discharged through the holes on left and right side plate. This is namely exhaust gas warm-up device. It is used to prevent freezing of carriage when operating in winter. There are two types of carriage heights. One is the usual carriage and i s used for carrying cargos like iron ore. The other is with additional height and is used for carrying cargos like magnesium ore and limestone. Carriage skip bucket (Figure 99) is fixed on two girders by upper support seat. Left and right lifting cylinder’s upper pivot lifts up the carriage through lifting upper seat, and self dump can be fulfilled. Three cushion rubber gaskets are installed on the bottom of two girders to amortize the impact between carriage and vehicle frame. Two cushion gaskets are installed on the back of carriage skip bucket axis and it will amortize when carriage is lifted up. A scratch slate is installed onto left and right of carriage rear bottom. It will automatically get rid of the rocks and mud in between rear wheel’s two tyres. A position locating bracket is installed on the left and right outer side of girder. It can prevent carriage from swinging left and right.
14.2.2 Note When Using The Carri age 1. Make full use of safety lock. Safety lock is installed on the back of motherboard bottom. When lifting the carriage and repairing the transmission, must take off the joint lock axis from safety lock and put the joint plate into frame’s traction pin seat. This is for safety purpose. When reparation is done, must restore the position of joint pin axis and joint plate. Otherwise the safety lock will be pressed and transformed when skipping the carriage in the future. 2. When disassembling the carriage, first take off the skip bucket pin from lifting cylinder, then put the lifting cylinder on the rear tyre upside-down, finally take off the nut of carriage skip bucket axis seat. 3. When sending the vehicle for repair, must check if the lifting position limit valve is safe and reliable so that the bolt from skip bucket seat will not be snapped when lifting the carriage.
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Operatio n Manual of Dump Truc k BJ Z3364 14.3 Cab Cab assembly consists of floor assembly (2) and engine cover assembly (11). Accumulator and air filter are installed on the right side of floor assembly. A small ladder is fixed on the left side for the driver to climb up. Four walls of the cab are all install with glass windows for better sight view. Left and right windows can be opened the moved. Heatproof and shockproof dope is applied on can’s head cover assembly and right side board, the right side board is also on the left side on engine cover assembly, so it is also called left detachable cover assembly. Front glass window (17) has electric wiper (14). There is a large tool box at the back of driver seat. When installing air conditioning device, this tool box will be removed. The fixing device (1) between cab and vehicle frame has 4 elastic bearing covered by rubber and metal. If there is damage on elastic ring, the vibration of cab will become serious and this will make driver tired more easily. Replace with new elastic bearing assembly for safety and comfort.
Figure 100 ______________________________________________________________________ Page - 162 - of 178
Operatio n Manual of Dump Truc k BJ Z3364 Cab is single sided left positioned. It is a whole metal structure. Cab f rame is welded using square steel tube and has more intensity compared with the old one. 1 Fixing device assembly 2 Floor assembly 3 Front window assembly 4 Front fence assembly 5 Side fence assembly 6 Rear fence assembly 7 Head cover assembly 8 Cab door assembly 9 Mirror assembly 10 Radiator cover assembly 11 Engine cover assembly 12 Front wing plate assembly
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.
14.4 Driver Seat
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
Operatio n Manual of Dump Truc k BJ Z3364 2. The elasticity of seat can be adjusted according to the weight of driver. How to adjust: push the pallet on the handle (1) inwards, the push up the handle to increase elasticity. When push the pallet outwards then push down the handle (1), the elasticity will decrease. The elasticity is suitable when suddenly sit on the seat, the compressing distance of the side plate should not exceed 10mm. 3. How to adjust backrest: use both hands to lift up the backrest so that the flashboard tine is facing one of the grooves of bolt shell, then insert the seat. B. When adjusting the handle (1), must not continuously move the handle without limit, especially when reducing the elasticity, the handle has to be pushed outwards. When the seat elasticity is suitable, stop pushing the handle. Otherwise the pin on the bolt may be broken and the adjusting screw pole will fall off. The seat can no more be l ifted and shock absorber will also be easily damaged. C. Apply lubricants regularly on the sliding path and roller.
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Operatio n Manual of Dump Truc k BJ Z3364
Chapter 15 Electric al 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 accumulator’s electric energy to drive the diesel engine’s rotation. 15.1.1 Work ing Princi ple 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 machine’s meshing pinion in mesh with flywheel t eeth ring. At the same time the connect-brake touch point (6) is closed. ______________________________________________________________________ Page - 165 - of 178
Operatio n Manual of Dump Truc k BJ Z3364 Thus, the accumulator will start to supply electricity to armature winding (5) and field inductance (4) in series, and the starting machine will start rotating. The meshing of meshed pinion and flywheel teeth ring will drive t he diesel engine to rotate. On the diesel engines starts, switch the key to position (1), the connection “BAT” and “ST” circuit will then be cut off. The magnetic force produce by pull in winding (3) will be demagnetized. Under the effect of position returning spring, the meshed pinion returns to its position, meanwhile the connect-brake touch point (6) will be open, the accumulator stops supplying electricity to the starting machine, the starting machine will stop rotating. The electricity of electric device is supplied by two 12V accumulators. Two accumulators are in series, cathode is connected to iron, so the output voltage is 24V. Its function is to supply electricity to starting machine when starting the engine. When engine is overloading, it will help the engine to supply electricity. When the electric pressure of engine is higher than the accumulator, it can store the surplus electric energy, i.e. charge.
Figure 102 - Starting Circui t 1 Starting switch is at position I 4 Field inductance 2 Starting button switch 5 Armature winding 3 Pull in winding in connection with mesh 6 Starting machine connect-brake touch point pinion 15.1.2 Accum ulator 1. Accumulator model and specification Model: 6-Q-195 type Specification: rating voltage 12V. Rating capacity 195 Amp*hour for 20 hours discharge rate. Starting discharge current is 585Amp.
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Operatio n Manual of Dump Truc k BJ Z3364 2. Maintenance of accumulator Carry out the maintenance regularly. This is necessary for the efficiency and lifespan of accumulator. 1. Observe for any electrolyte leakage from accumulator outer shell. 2. Check if the assembly of accumulator on the vehicle, lead tie-in and connection of electric pilot is tight. 3. Clean the dust on accumulator cover often, wipe off the electrolyte on the cover, free the liquid renew cover’s gas block hole, clean oxide on electric pilot and wire tie-in, wash them, apply Vaseline to prevent erosion. 4. Check and adjust the proportion of electrolyte and liquid level. The liquid level can be measured using glass tube. Electrolyte liquid level should be 10-15mm higher than the pole plate. If electrolyte is insufficient, add in distilled water. Do not add in dilute sulphuric acid unless the decrease in liquid level is caused by spill of electrolyte. 5. Check the discharge extent of accumulator, if it exceeds the regulated valve then charge. The charging condition of accumulator can be obtained from measuring the electrolyte proportion. Electrolyte proportion is measured using proportion meter. Take note that when measuring the proportion, also measure the temperature of the electrolyte. Compare the measured proportion with temperature with table 15-1 and convert to proportion under l5ºC. For example, electrolyte temperature is 30ºC and measured proportion is 1.28, converted to 15ºC proportion is 1.28+0.01=1.29. Table 15-1 Electrolyte proportion under conversion of 15ºC correction Measured +45 +30 +15 0 -15 -30 -45 temperatur e Correction proportion reading
of 0.02 meter’s
0
0
-0.01
-0.02
-0.03
0.04
For every 0.01 reduction in proportion, it is equivalent to accumulator discharing %6. If t he 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
Operatio n Manual of Dump Truc k BJ Z3364 3. Refer to table 15-2 for accumulator’s malfunction, causes and troubleshoot. 15.1.3 Starti ng Machi ne The function of starting machine is to drive crank shaft’s rotation when diesel engine starts. This vehicle used 40MT24V starting machine produced by DeIco-Remy. It is fixed on the diesel machine flywheel outer shell using three bolts. The electromagnet 7 used for controlling mesh pinion’s meshing mechanism and closing starting machine connect-brake touch pint is fixed on the starting machine stator shell using 4 bolts. 1.
Working principle Starting machine has 4 poles, field inductance in series, and uses accumulator for electricity supply. When starting switch is in position II and starting button switch is pressed, the electricity gets connected. Magnetic force is then produced in pull in winding active iron core. It drives the pinion through double shoulder pole, make driving pinion in mesh with flywheel ring. At this moment the connection pole (14) closes (Figure 103), starting machine will drive diesel engine to rotate. Magnetic connection is produced by passing the electricity through starting machine’s field inductance. Electricity also passes through armature winding and produce rotating distance. This rotating distance drives the rotor. Due to the mesh of upper gear and flywheel teeth ring, the rotor will drive diesel engine’s flywheel to rotate. Once the diesel engine starts, starting switch returns to its original position. Power source is cut off, pull in winding is demagnetized. Under the effect of position returning spring, the double shoulder pole will make mesh pinion go back to its position. Meanwhile, the connection pole (14) is cut off, no electricity in starting engine and rotation stops. After diesel engine starts, driving pinion and flywheel teeth ring immediately fall off each other so that the starting machine will not be damaged.
Table 15-2 Malfunction Causes Troubleshoot Accumulator 1. No electricity in 1. Charge does not accumulator supply 2. Looseness of connection 2. Fix the connection pole, if eroded electricity pole then replace 3.
Bad grounding
3. Clean the grounding and fix the grounding
4.
Electrolyte liquid level too low
4. Add distilled water
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Operatio n Manual of Dump Truc k BJ Z3364 5.
Pole damaged or short circuit
5. Use charging machine to check, use low current to charge, if within some time the electricity overflows then replace the accumulator 6. Eliminate the short circuit
6.
Cannot charge the accumulator
Short circuit in electric device, make the accumulator discharge 1. Looseness of connection pole
1. Fix the connection pole, if eroded then replace
2.
2.
Bad grounding
3.
Electrolyte liquid level too low 4. Pole damaged or short circuit
5.
Short circuit in electric device, make the accumulator discharge 6. Generator does not charge
Too much expand of distilled water
7. 1´2´ fuse gets burnt 1. Short circuit in electr ic device causing temperature rise in accumulator 2. Accumulator case damaged
Clean the grounding and fix the grounding 3. Add distilled water 4.
Use charging machine to check, use low current to charge, if within some time the electricity overflows then replace the accumulator 5. Eliminate the short circuit
6.
Check the generator
7. 1.
Replace the fuse Eliminate the shor t circuit
2.
Replace the accumulator
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Operatio n Manual of Dump Truc k BJ Z3364
Figure 103 - Starting Machi ne Circuit Princi ple 1 Driving pinion 2 Position returning spring 3 Double shoulder pole 4 Active iron core 5 Positioning winding 6 Pull in winding 7 Connection pole 8 Starting button switch 9 Starting switch 10 Fuse
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.
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Operatio n Manual of Dump Truc k BJ Z3364 3. Malfunction, Causes And Troubleshooting Malfunction Driving pinion does not mesh
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 pinion’s teeth or teeth ring Long charging of pull in winding 4. Check starting switch’s joint
15.1.4 Starting Electromagnetic Valve The function of starting electromagnetic valve (Figure 104) is to supply electricity for engine when starting. When need to start the starting machine, start switch is turned in position II, press the starting button switch, connect the power source, the electricity passes electromagnetic valve’s small connection pole (1), reaches the cathode, makes electromagnet produce suction to suck the valve to connect connection pole (2) and (3). The electricity supplied by accumulator passes through connection pole (2) (3) and flows into starting machine’s positioning winding and pull in winding, makes the starting machine start working. Once the diesel engine starts, starting switch returns to its original position, pinion power source is cut, electromagnet suction force disappears, valve returns its position under the effect of spring. Connection pole (2) (3) get disconnected, starting electromagnetic valve finishes working. ______________________________________________________________________ Page - 171 - of 178
Operatio n Manual of Dump Truc k BJ Z3364
Figure 104 - Starting Electromagnetic Valve Switch 1 Connection pole 5 Electromagnet 2 Connection pole 6 Valve 3 Connection pole 7 Spring 4 Pinion By using starting electromagnetic valve, we can prevent burning of starting machine joint caused by large current. This burning will cause pull in winding long time electrified and driving pinion and flywheel teeth ring will not get disconnected. 15.1.5 Starting Switch The function of starting switch is to connect and disconnect starting machine circuit. It can also cut the circuit for illuminating and other electric devices then vehicle does not start. Starting switch has 3 positions (Figure 105).
Figure 105 - Starting Switch Position 0: when vehicle is not starting, all touch points open Position I: electrify all the electric devices except for starting machine pull in winding Position II: electrify all the devices, field inductance of starting machine pull in winding Starting switch is fixed on the instrument panel using loop nut. ______________________________________________________________________ Page - 172 - of 178
Operatio n Manual of Dump Truc k BJ Z3364 The starting switch uses two series. One is on ignition switch, the other is on starting button. The purpose is to prevent operational mistake. Only when two switches close simultaneously it will work. The causes of malfunction and troubleshoot: Malfunction Causes Starting switch cannot Disconnection in touch close the circuit point and connection pole Starting switch cannot Inner touch points are open the circuit welded together
Troubleshoot Connect them, fix the touch point Replace switch
the
starting
15.2 Electr ical Generating Device The function of this device is to convert the mechanical energy into generator’s electric energy, for charging accumulator, fulfilling the requirements of electric device. The current during normal traveling of vehicle is partially absorbed by accumulator and partially used by electric devices. If the device works normally it will output a maximum 28V voltage, the minimum voltage should be equal to the voltage of accumulator. The generator used for this vehicle is self commuted. It has inner touch point free pressure adjusting generator. This kind of whole generator has good voltage adjusting precision, endurance and shockproof. On the other hand, the generator and pressure adjusting device are assembled together so there is no external wire, thus relatively there is less malfunction. In the whole assembly, the only part in motion is rotor. Its one end is fixed on generator’s driving end by roller bearing, the other end is fixed on generator’s rectifying end by roller bearing. Magnetic wire, stator wire and 6 rectifying diode and adjusting device circuit sub-assembly are all fixed. Fan is installed on the driving end for cooling purpose. There is a large lubricant reservoir for good lubrication. Only one live wire is needed to connect the generator and accumulator. “R” output tie-in is used by some communicating devices. Meanwhile it can be used for magnetism charge after generator is disassembled and repaired.
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Operatio n Manual of Dump Truc k BJ Z3364 (28V DC, Max 2A Curr ent) Supply Magnetic Charge Indication
Grounding
Current
Or
Electrical Switch
14V Direct Current Electrical Pressure Max 2A Current Provides Rotational Speed Signal Or Change Indication
e c n a t c u d n I d l e i F
e c i v e D g n i t s u j d A
Ar mat ur e Winding
Grounding
Figure 106 - Generator Circui t Prin cipl e
15.2.1 Work ing Princi ple 1. R(W) end commutes through one of the 4,5,6 silicon pipe, forms half wave commuting voltage with ground. So its output signal is 14V DC pulse voltage (maximum load cannot exceed 2A). R(W) end is used to connect rev meter. 2. B+ end commutes in full wave through4,5,6 and 7,8,9 silicon pipe. It passes through filter wave capacitor C and outputs 28V DC current. When electric switch K is closed, it charges the accumulator or supplies electricity for it. 3. D+ end commutes in full wave through 1,2,3 and 4,5,6 silicon pipe and outputs 20V DC voltage (maximum load is 2A). D+ end is used to connect charge indicator and supply generator’s self-excitation current.
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Operatio n Manual of Dump Truc k BJ Z3364 15.2.2 Malfunct ions , Causes And Trou bleshoo tin g Malfunction Causes Insufficient electricity in 1. Accumulator fails accumulator 2. Circuit loose
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
15.2.3 Generator m aint enance Since AC current generator is different from DC current generator, take note of the following points during use: 1. No short circuit of cathode and anode of generate and accumulator, otherwise commuting components will be burnt. 2. Switch on the power switch when vehicle stops driving, cut off the circuit, otherwise accumulator will keep discharging into field inductance and burn it. 3. After accumulator is fully charged, charging current will automatically decrease. When engine operates with middle speed, the charging current is small or zero, this does not mean the charging system has malfunction. Because when there is sufficient electricity in accumulator and engine and voltage adjusting device are all normal, it is just the accumulator is fully charged. If the ampere meter points to discharge direction, it shows that there is malfunction in engine.
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Operatio n Manual of Dump Truc k BJ Z3364 15.3 Illu minati on Device 15.3.1 Summary Illumination device is used for: 1. Indicate vehicle width (width indicator) 2. Indicate turning direction (turning indicator) or brake (stoplight) 3. Light up front and rear of vehicle (headlight, dipped headlight and back working light) Illumination device consists of: 2 headlights 2 back working lights 2 front small lights (indicate width and turning) 2 back combinational lights (indicate width, turning and brake) 1 top light 1 socket for manual working light 2 front foglights 15.3.2 Malfunct ion, Causes And Trou bleshoo tin g Malfunction Causes One or some illumination 1. Broken fuse device do not light up 2. Broken light socket wire 3. Broken light 4. Circuit short or open
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.
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Operatio n Manual of Dump Truc k BJ Z3364 2. Working principle When there is short circuit, the current increases and exceeds the rating melt current of fuse, and fuse melts. Hence the circuit with fuse will be cut off.
Serial # 1 2 3 4 5
Capacity 50A 30A 6A 6A 6A
6 6A 7 6A 8 6A Note: before melting point.
Circui ts pr otected by fuses (BJZ3364) Circuit under protection
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 sensor ’s 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 t he cause according to “electric circuit principle” and do the troubleshooting. ______________________________________________________________________ Page - 177 - of 178
