XDR80T Tri-Axle Rigid Mining Truck Operation and Maintenance Manual

XDR80T Tri-axle Rigid Mining Truck Operation and Maintenance Manual
XDR80T
XUZHOU XUGONG MINING MACHINERY CO .,LTD.

Preface
This manual provides rules and guides for safe and efficient operation of this machine. to read through
and understand this manual, learn to correctly operate, maintain and repair your machine; pay attention to
safety informations & safety signs and be sure that you understand related safety requirements.
Always follow all the notices specified in this manual during operation, repair and maintenance and bear
in mind that all the accidents are caused by failing to follow basic safety rules in terms of operations and
maintenance.
This symbol refers to safety warnings and shows important safety information.
The moment you catch the sight of this symbol, please keep alert about potential dangers, read through the
information below this symbol, and inform related operating stuff immediately.
Please keep this manual inside the cab, leaving access to all staff for them to make periodical references.
You can contact Xugong Excavator Machinery Company Limited or authorized dealers for request of a
new manual once your manual is lost or defaced.
This manual should be considered as an integral part to this machine. As a seller, you must attach this
manual to this machine.
This machine are designed to work in following conditions:
Ambient temperature: -30℃ ～ 40℃ (For environments below -15° C, you need to choose a low
temperature startup configuration )
Altitude: 0 m - 2000 m
When the machine is used beyond the above conditions, please contact with Xuzhou Xugong Mining
Machinery Co., Ltd. or its dealers.
Xuzhou Xugong Mining Machinery Co., Ltd. cannot predict all possible and potential dangerous
situations in operation and maintenance, so safety information in this manual and on the machine does not
include all possible safety measures. If methods or actions not specifically recommended or allowed in the
manual are used, you have the responsibility to take necessary measures to guarantee the safety.
Never conduct out-of-range operations and applications under no circumstances.
Important: If this manual is not compliant with your machine, please contact your boss, Xuzhou
Xugong Mining Machinery Co., Ltd., or its authorized dealer to obtain a correct safety manual.
Store and read it carefully.
All the materials, signs and specifications of this manual are the latest ones before publication.
The contents are subject to change without prior notice
DMOMZH80TA-01
III Preface
Machine Number
Please correctly record all numbers for future maintenance. This information is also required by the
dealer. If this manual is on the machine, please place the machine number part in a safe area for filing in
order to search the machine after the manual is lost.
Numbers listed are unique identification numbers (serial numbers) of each machine and hydraulic parts;
please fill these identification numbers in corresponding areas for quick finding when they are required.
Machine
Model:
Product ID code:
Figure-1
Engine
Model: ___________________
Number of manufacturing:
__________________
Figure-2
V Machine Number
Table of contents
Preface ............................................................................................................................III
Machine Number.............................................................................................................V
1 Safety .......................................................................................................................... 1-1
1.1 Safety Information .............................................................................................. 1-1
1.2 Safety Signs ........................................................................................................ 1-3
1.3 Safety Equipment ............................................................................................. 1-10
1.4 Safety Rules ...................................................................................................... 1-12
1.5 Safe Operation .................................................................................................. 1-18
1.6 Safety Maintenance Instructions ...................................................................... 1-28
1.7 Notes on Tires................................................................................................... 1-40
1.8 Accessories Installation and Other Safety Instructions .................................... 1-42
2 System Components and Functions......................................................................... 2-1
2.1 Vechicle assmbly drawing .................................................................................. 2-1
2.2 Operation Unit Layout........................................................................................ 2-2
2.3 Display................................................................................................................ 2-3
2.4 Bus Keyboard Switch ....................................................................................... 2-14
2.5 Handles and Pedals ........................................................................................... 2-16
2.6 Cigarette Lighter (installed on some models)................................................... 2-22
2.7 Horn .................................................................................................................. 2-23
2.8 Steering Wheel ................................................................................................. 2-23
2.9 Radio................................................................................................................. 2-24
2.10 Combination switch ........................................................................................ 2-28
2.11 Power supply switch ....................................................................................... 2-30
2.12 Clothes-hook................................................................................................... 2-31
2.13 Air Conditioning and Control Devices ........................................................... 2-32
2.14 Door and Windows of Driver’s Cab ............................................................ 2-38
2.15 Door Lock....................................................................................................... 2-39
2.16 Safety Support ................................................................................................ 2-39
3 Operation ................................................................................................................... 3-1
3.1 General Principle ................................................................................................ 3-1
3.2 New Machine Running-in and Operating Instructions....................................... 3-2
3.3 Pre-boarding Preparation and Inspection............................................................ 3-3
3.4 Preparation and Checking After Getting on the Machine .................................. 3-4
Table of Contents I
3.5 Running Operations ............................................................................................ 3-5

3.6 Machine Operations.......................................................................................... 3-25
4 Maintenance and Warranty of Main Assemblies................................................... 4-1
4.2 Suspension system .............................................................................................. 4-2
4.3 Engine ................................................................................................................. 4-9
4.3.1 Materials and maintenance interval ............................................................. 4-9
4.3.2 Maintenance instructionsOperation description ........................................ 4-12
4.3.3 Common faults and solutions .................................................................... 4-16
4.3.4 Maintenance............................................................................................... 4-22
4.3.5 Other descriptions - fuel liquid heater operation manual (for
option) ...................................................................................................... 4-28
4.4 Transmission..................................................................................................... 4-32
4.5 Hydraulic Retarder(option)............................................................................... 4-34
4.6 CLUTCH .......................................................................................................... 4-39
4.7 Transmission shaft ............................................................................................ 4-43
4.8 Front axle .......................................................................................................... 4-45
4.9 Intermediate and Rear Axles ............................................................................ 4-48
4.10 Braking system ............................................................................................... 4-53
4.11 Lifting System ................................................................................................ 4-57
4.12 Steering System .............................................................................................. 4-64
4.13 Electric system................................................................................................ 4-69
4.14 Air Conditioning System ................................................................................ 4-71
4.15 Centralized Lubrication System ................................................................... 4-108
5 Maintenance and Lubrication.................................................................................. 5-1
5.2 Maintenance........................................................................................................ 5-2
5.3 Recommended fuel, coolant and lubricant ......................................................... 5-7
5.4 Regular spot inspection and maintenance schedule table................................. 5-10
6 Transport, Storage and Protection .......................................................................... 6-1
6.1 Transport............................................................................................................. 6-1
6.2 Daily and short-term storage and protection ...................................................... 6-2
6.3 Long-term storage............................................................................................... 6-3
7 Major Components and Specifications ................................................................... 7-1
7.1 Constitution ........................................................................................................ 7-1
7.2 Technical Specifications ..................................................................................... 7-2
II Table of Contents
8 Appendix .................................................................................................................... 8-1

8.1 Electrical Schematic Drawings........................................................................... 8-1
8.2 Hydraulic Principle Diagram.............................................................................. 8-2
Table of Contents III

Chapter 1 Safety
1.1 Safety Information

To help you use this machine safely, this manual explains safety warnings and labels fixed on this machine
to provide instructions on related potential risks and methods of preventing these risks.
Users and after-sales service personnel must know all kinds of warning signs on the machine well before
you operate and maintain the machine, strictly comply with safety rules and suggestions in this manual,
and actively take safety prevention measures and countermeasures to minimize risks of casualties, ma-
chine damage caused by improper maintenance, or unsafe factors caused by improper maintenance.
1. Signal language
It is used to inform you of potential dangers that may lead to personal injury or equipment dam-
age. It is used to indicate the potential danger levels together with the symbol text.
Danger
It is used to indicate a risk that will lead to death or serious injury, if not avoided.
Warning
It is used to indicate a potential risk that may lead to death or serious injury if not
avoided.
Caution It is used to indicate a potential risk that may lead to light or medium injury, if not
avoided.
"Caution" can also be used to remind people of unsafe operations that may cause personal injury, and
machine and environment damage.
2. Safety information examples of using signal language
No overloading! Overloading or rough loading will seriously affect service life of parts and the
machine.
3. Other signal language

In addition to information mentioned above, the following signal terms indicate items to be observed
for machine protection or provide information that is useful for you.
Note: This is used to indicate measures to be taken for preventing shortening of the machine service
life.
Remarks: This provides you usefaul information.
4. Safety signs
Safety signs are fixed on the machine to inform on-site operator or maintenance worker of potential
dangers during operation and maintenance.
Safety 1-1
Both "text safety sign" and "graphic safety sign" are used on this machine to indicate safety measures.
Example of a text safety sign
Warning
Key switch
Please carefully read t he operat or’ s
manual and decorat ion manual before
you operate t he t ruck.
XCMGB001
Figure1-1
Graphic safety sign
A graphic safety sign shows a dan-

WARNING
ger level equivalent to signal terms by
Never stand on the platform
image, It can help the operator or the when the machine travels.
maintenance person to know the risk
type and degree.
Figure1-2
Xuzhou Xugong Mining Machinery Co., Ltd. cannot predict all possible and potential dangerous situa-
tions in operation and maintenance. Therefore, safety information in this manual and on the machine does
not include all possible safety measures.
If actions not recommended or allowed in this manual are taken, necessary measures shall be taken to en-
sure the crane safety.
Never conduct out-of-range operations and applications under no circumstances.
1-2 Safety
1.2 Safety Signs

This machine uses the following warning signs and safety signs:
• Fully understand correct locations and content of the signs.
• To ensure that signs are read, the signs must be placed at correct locations and kept clean. Do not use or-
ganic solution or gasoline to clean the signs. Otherwise, paint on the signs will peel off.
• In addition to warning signs and safety signs, other signs should be treated in the same way.
• Signs being damaged, lost or cannot be read normally must be replaced with new ones.
Locations of Safety Signs
1 2 3
4
Side of the left Side of the left Both sides of the

superstructure handle battery box left reservoir
5 6
7
Upper of the Suspension cylinder Upper of the hydraulic

lifting cylinder surface oil tank
10 14
8 9 11 12 13
Side of the left Driver's cab control console Driver's cab

superstructure handle front windscreen
Figure 1-3
Safety 1-3
Safety Signs
1. Safety ladder warning
Warning
Safety ladder: Take care when
you get on/off the driver’s cab!
A7017
Figure1-4
2. Accumulator charging hazard
Danger
Only dry nitrogen can be filled.
Oxygen is prohibited because it
may cause explosion. See the
operating manual for correct
inflation procedures.
A7015
Figure1-5
1-4 Safety
3. Accumulator high-voltage warning
Danger
High voltage. Release gas and
fluid pressure in the accumulator
before you maintain the machine.
See the operating manual for
correct maintenance procedures.
A7016
Figure1-6
4. Parking position warning
Warning
When the container is lifted,
ensure that the truck is parked
on a flat ground. Parking on
a slope is prohibited.
A7011
Figure1-7
Safety 1-5
5. Danger of suspension maintenance
Danger
High-pressure cylinder filled with dry nitrogen
High voltage risks. Please do not remove plug,

pressure tap and charging valve or any metal
part before pressure in the oil cylinder is
released, preventing metal parts from flying
out of oil cylinder violently and casualties.
Please connect the inflation tool to the
inflation valve to fully release the cylinder
pressure.
The cylinder can be filled with only dry
nitrogen. Professional inflation tools shall be
used and operation specifications shall be
followed.
A8001
Figure1-8
6. Hydraulic oil filling warning
Warning
Before you fill oil, you need to
lower the truck body, turn off
the key switch, and shut down
the engine.
A2012
Figure1-9
1-6 Safety
7. Container extrusion warning
Warning
After the container is lifted and
before the safety device is
installed, do not work under
the container, preventing
extrusion.
A7011
Figure1-10
8. Safety sign for anti-explosion
329900205
Figure1-11
9. Safety sign for scalding prevention
Figure1-12
Safety 1-7
10.Read safety signs illustrated in the oper-

ation and maintenance manual.
329900207
Figure1-13
11.Lifting handle notice
Note
When the truck is running, the
container lifting handle shall be
placed in the “HOLD”
position.
Figure1-14
12.Park brake warning
Warning
Please apply parking brake
before you leave the truck.
A2023
Figure1-15
1-8 Safety
13.Emergency exit safety sign
Emergency
exit
329900209
Figure1-16
Safety 1-9
1.3 Safety Equipment

Uniform and Protective Articles
• Fix long hair, loose clothes or jewelry, in

case they get caught on a control lever or
protrusions, which may cause personal
injury or casualty.
• Don't wear oil-stained clothes, which
may easily catch fire.
• Take precautions according to the nature
of work, such as wearing safety helmet,
protective shoes, thick gloves, reflective
vest, gas-defense mask, safety eye gog- Figure1-17
gles, ear plug and safety belt, etc. Check
all the protective articles for omission
before work, and check each article
whether they are in good conditions or
not; remember to use them each time.
• The waste gas exhausted from an engine may cause disease or death. Make sure a well-functioning ven-
tilating device is applied before operating this machine in a closed area.
• Don’t apply a tool of inadequate strength to repair the equipment; otherwise, it may break or slip,
cause accidents or can’t meet installation requirement.
• Don't wear loose clothes or jewelry, which may get caught on operative equipment or a protrusive part
of the equipment.
• Operators must be concentrated on operation, don’t listen to the radio or music while working.
• When using a walkie-talkie, better stabilize the talk-back equipment, and try not to accept commands
through an earphone.
1-10 Safety
Safety Equipment
To protect you and people around you, you should know what safety devices your truck has. Please ensure
that all equipment is fixed in place and under working condition:
For example:
• FOPS
• seat belt
• Headlamp
• Horn
• Fender board
• Baffle
• Reversing buzzer
• Reflector Figure1-18
• Fire extinguisher
Make sure all shields and covers are in their proper

positions. Damaged shield and cover must be
repaired immediately.
Know how to use safety devices and correctly use
them.
Do not remove the cab guard railing without
permission (except for machine maintenance).
Extinguisher and First-aid Kit
To prevent fire disasters or injury accidents, the following cautions must be observed:
• Configure with the first aid case and fire

extinguisher nearby.
• Read carefully and understand instruc-
tions attached to the fire extinguisher
and use the fire extinguisher correctly.
• Inspect and maintain the fire extin-
guisher regularly to ensure that it can be
Figure1-19
used at any time.
• Inspect the first-aid case regularly and
add fire fighting powder if necessary.
Safety 1-11
• Develop emergency countermeasures to

fires and accidents.
1.4 Safety Rules

Carefully read this manual and the information in relation to safety signs affixed to this machine; keep the
signs intact; if lost or damaged, replace it immediately. Please contact authorized dealers or Xuzhou Xu-
gong Mining Machinery Co., Ltd for any questions.
• Only a certified, qualified experienced operator can control this equipment. Only operators who meet
the above conditions can check and maintain the machine.
• Obey safety regulations, notices and instructions when operating or maintaining the machine.
• Patients and drunks are not allowed to operate or maintain this machine, for they may cause damage to
themselves or others.
• When collaborating with other operators or site commanders, ensure everyone is clear about gesture
signals.
• Ensure all handrails, pedals, engine hood and covers are well-installed; if damaged, place repair
immediately.
• Understand using methods of all the safety parts, such as lock lever and seat belt and correctly operate
them.
• Don't randomly disassemble safety parts, the operator should keep them in good conditions instead.
• Incorrect use of safety parts will cause severe personal injury or casualty.
Noise protection
• Being in big noise for a long time may

result in the injury or loss of your
hearing.
• Wear proper hearing protectors like ear
cap or earplug to prevent harmful or un-
comfortable big noise.
Figure1-20
Window glass for the driver’s cab
1-12 Safety
If window glass in the driver’s cab is damaged or broken, dust in the air and surrounding noise will affect
the driver's health. Therefore, once the window glass is damaged, you need to stop the machine and re-
place the glass immediately.
Safety in Construction Site
Before any operation, you shall know and get familiar with the construction site:
• Conditions of transport roads

• Direction of transport roads
• Whether culverts, obstacles, sewage and
ice exist
• Whether traffic congestion exists
• Whether dense dust, smoke and fog exist
• Check rock strata and conditions around
the construction site and determine the
safest operation method. Do not work in
Figure1-21
areas with a danger of collapse or falling
stones.
• Conduct necessary inspection to prevent
any unauthorized person from entering
the work area.
• Check the shape and conditions of bot-

Danger
tom rock, depth and speed of water flow
before you start working across shallow
water, working in it or working on un-
consolidated ground.
• Design and lay roads on the construction
site to allow the machine passing by
safely.
• If a vehicle must drive through a strip Figure1-22
material pile, it is necessary to select a

good angle, go through by one wheel
first, and then go through slowly.
• Before you drive a truck to enter a build-
ing, it is necessary to know the passage
size to prevent damage or crash to the
door top, doorway, corridor, as well as
Safety 1-13
bearing limit of ground and ramp that

where vehicle passes through.
Working on Unconsolidated Ground
• Do not drive on unconsolidated ground or operate the machine near projection near overhanging rock
and deep channel, Under the action of machine weight and vibration, soil on the embankment or beside
the excavated ditch will become soft, leading to a landslide risk. Before an operation, you shall ensure
soil texture safety to prevent the machine from rolling or falling. Remember that soil in these places will
become soft after heavy rain, blasting or earthquake.
• Under the action of machine weight and vibration, soil on the embankment or beside the excavated
ditch will become soft, leading to a landslide risk. Before operating the machine, you should confirm
the soil safety to prevent from machine rolling over or falling.
Never approach high voltage cables
• Never walk or operate the machine near the cables for an electric shock risk, which will cause equip-
ment damage or casualty accidents. bserve with the following rules when working on the work site near
cables:
• Before you start work near site with cables, inform the local electric power company of work to be car-
ried out and negotiate safety construction measures with the company.
• The machine may suffer from electric shock when the machine stands too close to cables, causing seri-
ous burns or even death. A safe distance must be kept between the machine and the cables (as shown in
the table below).
• If the machine is too close to the cables, a signal man is required for guidance.
• When the machine works near the high voltage cables, anyone is not allowed to be close to the
machine.
• If the machine is too close to or touches the cables, the driver should not leave the cab until outage is
confirmed to prevent from electric shock. Additionally, no one is allowed to get close to the machine.
• In order to prevent accidents, wear the rubber shoes and rubber gloves, Place a layer of rubber cushion
on the seat; the exposed body part shall not be in contact with the lower vehicle body.
Cable Voltage Safe Distance

100V-200V ＞ 2 m (7ft)
6,600V ＞ 2 m (7ft)
22,000V ＞ 3m (10ft)
66,000V ＞ 4m (14ft)
154,000V ＞ 5m (17ft)
1-14 Safety
Cable Voltage Safe Distance

187,000V ＞ 6m (20ft)
275,000V ＞ 7m (23ft)
500,000V ＞ 11m (36ft)
Cautions for Ventilation
If it is necessary to start the engine or deal

with the fuel oil, cleaning oil or paint in the
closed area, open the doors and windows to
ensure good ventilation for exhaust gas’
fatal fatality.
Figure1-23
Emergency Exit of Driver's Cab
• You can use the safety hammer to break the window glass as an emergency exit if the cab door cannot
be opened for some reasons.
• During the escape process, you can first remove glass fragments from the window frame and pay atten-
tion not to be scratched by the glass. Do not get slipped due to shattered glass.
Ensuring Good Visibility
Rearview mirrors are equipped for this machine to improve the sight line. Even though, a driver on the
seat cannot see some places and shall pay attention during operations.
Machine damage or severe personal injuries may be caused if the operator is not clear of the construction
site or barriers within the area around the machine during operations with bad sight. Observe with the fol-
lowing terms strictly during operations with bad sight:
• Check the rearview mirrors before starting work every day. Remove dirt and adjust the visual field to
ensure a good sight.
• Turn on working lamps and head lamps when you work in a dark place. If necessary, set , and set auxili-
ary lighting in the working area.
• If visuality cannot be guaranteed, operations should be stopped and the machine can be parked along
the roads in bad weathers, such as fog, snow, rain or sand days.
Safety 1-15
• When the machine works at the road side or on the unconsolidated ground, you need to set signs. If the
sight is poor, a signal man is required. The operator shall pay special attention to signs and follow the
signal man’s instructions.
• The signal shall be given by one signal man only.
• Before operations, ensure all of the workers understand all of the signals and gestures.
Prevention of Asbestos Dust Hazards
Inhaling of asbestos dust in the air will lead to the lung cancer. Personnel that dismantle or handle industri-
al waste may breathe asbestos. The following rules shall be followed:
• During cleaning, spray some water to reduce the dust but compressed air cannot be used.
• If there is asbestos dust in the air, operate the machine in the upwind position and all of the operators
should use the dust filtering masks.
• During operation, other personnel are not allowed to close to the machine.
• Workplace regulations, speculations, and environmental standards should be complied with.
This machine does not contain the asbestos, but the counterfeit parts contain the asbestos possibly.
Therefore, it is necessary to use genuine XCMG Mining Machinery parts, because breathing too
much asbestos may lead to injury of lungs or death.
Prevent scolding
Hot coolant
• To avoid hot coolant or steam from

spraying and causing burning, wait until
the liquid is completely cooled before
you check or discharge the coolant.
• Before the engine is cooled, do not open
the radiator cap. Before the engine is
cooled, do not open the radiator cap. The
radiator cover shall be screwed off Figure1-24
slowly though the coolant has been
cooled to release pressure inside the ra-
diator, preventing severe burn.
Hot oil
1-16 Safety
• To prevent hot oil from scalding, wait

the oil is completely cooled before you
inspect or discharge the oil. Even though
the oil is cooled, you shall slowly crew
off the cover or plug screw to release the
internal pressure.
Figure1-25
Safety 1-17
1.5 Safe Operation

Start the engine
Getting on the Machine Safely
When you get on/off the machine:
• Always face the machine and keep

three-point contact with the machine
(one hand and both feet or both hands
and one foot).
• It is prohibited to jump on and off from
the machine, or climb up or down the
machine when the machine travels.
• Do not use any control mechanism as a
handrail.
Figure1-26
• Keep the cab, hanging ladder and hand-
rails clean. Oil, grease, ice and snow in
these places may lead to the driver’s
slipping and falling. The driver should
clean mud on his safety boots before get-
ting on the vehicle.
Adjusting the Seat
Improper seat positions may cause operator

fatigue and operation errors. Every time
when the operator is changed, the seat
should be adjusted again. When the opera-
tor leans against the back of seat, he should
be able to push the pedal to the bottom and
operate the operating lever correctly. If he
cannot, he can move the seat forward and
Figure1-27
backward and make a second adjustment.
1-18 Safety
Fastening the seat belt well
• If the machine turns over, the operator

may be hurt or ejected off the cab, or
bore down by the tipping machine, caus-
ing serious injury or death accidents.
Carefully check the safe belt, belt
buckle, and fixed part before you operate
the machine. If there’s any loss or
Figure1-28
abrade, you should replace the seat belt
or other parts before operation.
• Ensure that you sit on the seat with the
seat belt fastened to prevent accidents
when operating the machine.
• It is suggested to replace the seat belt
every three years, regardless of its use
condition.
Inspection before starting the engine
Conduct the following inspections before starting the engine:

• Wipe off dirt on the window surface to ensure a favorable sight.
• Wipe off dirt on the head lamp and working lamp and check whether the lamps work normally.
• Check the liquid level of the coolant, the fuel level, and the engine oil level.
• Check whether the air filter is blocked and whether the circuit is damaged.
• Check whether there is sludge or dirt around moving parts of the accelerator pedal or the brake pedal;
check whether the pedal works properly;
• The operator’s seat is adjusted to a position easy for operation and check whether the seat belt or the
attaching clamp is damaged or worn.
• Check whether the instrument works properly, whether the reflector height is proper, whether the shift
handle is idle, and whether the lifting handle is in the HOLD position.
• Adjust rear view mirror to an angle where the condition behind the vehicle can be seen from the seat.
• Check whether there are people or obstacles on, under, or around the machine. If yes, report an alarm to
ensure that they can evacuate to a safe area.
• Check whether the parking brake handle is in the PARKING position.
Safety 1-19
Precautions for Starting the Engine
• Ensure that there are no people on, under

or around the machine and beep the horn Correct
to remind people around the machine of

keeps away from the machine.
• You can only start and operate the ma-
chine on the seat.
• In addition to the operator, only one per-
son can stay on the machine and on the
front passenger's seat.
• Do not start the engine in a manner
Figure1-29
which can lead starting motor short cir-
cuit, because it is not only dangerous,
but can also damage the device.
Starting the Engine in Cold Regions
• Complete preheating is required. If the machine is not well preheated before you operate the handle, the
machine will work slowly, leading to accidents.
• If the battery acid is frozen, do not charge the battery or start the engine with a different power supply.
This may lead to battery ignition or explosion.
• Before charging or starting the engine with a different power supply, you should first dissolve the bat-
tery acid and check freezing and leakage of the battery acid.
Starting the Engine Using Auxiliary Cables
When you start the engine by connecting auxiliary cables, be sure to operate the machine according to in-
structions in the operation manual. Improper operation will lead to battery explosion or machine out of
control, resulting in casualties.
It is prohibited to start the machine with auxiliary cables without permission. If necessary, please contact
XCMG or its authorized agent.
1-20 Safety
• When auxiliary cables are used for en-

gine starting, two people are required
(one sits in the operator's seat and the
other operates the battery).
• Before the engine is started with auxili-
ary cables, you must wear goggles and
rubber gloves.
• When a normal machine is connected to
a faulty machine with auxiliary cables, Figure1-30
the normal machine should be with the
same battery voltage as the faulty ma-
chine. These two machines are not al-
lowed to be contacted.
• When auxiliary cables are connected,
key switches of the normal machine and
the faulty machine should be turned to
"OFF". Otherwise, the machine may
move when the power is turned on, lead-
ing to dangers.
• When auxiliary cables are connected, the

positive pole (+) must be connected first.
• When auxiliary cables are dismantled,
the grounding or negative (-) cable
(grounding side) should be disconnected
first.
• When auxiliary cables are dismantled,
do not allow auxiliary cable clamps con-
tact each other, nor allow cable clamps
contact with the machine.
Figure1-31
• Ether cold starting liquid is highly flam-
mable and explosive. Read instructions
on the ether container before use.
• Do not use ether if the engine is
equipped with an ignition plug preheater
or other forms of preheaters.
Safety 1-21
After Starting the Engine
Keep the engine idle for 3-5 minutes after you start the engine, observe the pressure gauge, instrument and
alarm lamp, confirm that they are in good operation, and readings are within the normal working range.
Operation
Inspection Before Operations
• Check at the place without obstacle and operate slowly. Nobody can be close to the machine while
checking.
• Always fasten the seat belt.
• Check whether operations on the instrument and equipment are normal, and whether the steering, lift-
ing, and brake systems work normally.
• Check whether the machine sound, vibration, heating, smell or the instrument are normal, and whether
engine oil or fuel oil has leakage.
• If there are any abnormal conditions, stop using the machine and repair the machine at once.
Observe and carefully listen to whether there is abnormal noise in the machine. If there is any fault
or exception, stop the machine immediately. Before a further operation, please resolve the fault
immediately and report to the superior.
1-22 Safety
Cautions Before Operations
To prevent serious injury or death, please pay attention to the following items before you move the
machine:
• Recheck and confirm that there are no people and obstacles around the site before you drive the
machine.
• Honk the horn to warn people nearby before you drive the machine.
• The driver must sit on the main seat when operating the machine.
• If an extra person is allowed on the machine, he/she can only sit on the front passenger's seat.
• Check whether the reversing bleeper works normally.
• Close the door and window of the driver's cab and check whether the door is locked.
• A ground signal man must be set in places with poor visions.
Cautions During Driving
• The load of the dump compartment is not allowed to exceed the maximum payload.
• It is not allowed to turn the key switch to OFF. If you shut down the engine during driving, the steering
mechanism works hard, which is dangerous.
• Lower the dump compartment, turn the lifting handle to the FLOAT position, and then drive the
machine.
• At the entrance, exit and potholes, the empty vehicle must give way to heavy vehicles.
• To prevent accidents caused by collision with other objects, you should operate the machine at a safe
operating speed, especially in places with limited space, such as doors or places with other machines.
• On rough roads, you should drive the machine at low speed and avoid direction changing.
• Without permission, vehicles cannot pass through any unauthorized section. Sufficient safety work
should be made for passing through when being permitted. Make sure the road ahead is clear before ve-
hicles enter the road.
• During driving or operating, always keep a safe distance between the machine and people, buildings,
and other machines to prevent collision.
• Before going through a bridge or a building, check whether the bridge or the building is firm enough to
support the machine weight first.
• Height limits are set for work in tunnels, buildings, under bridges or other similar places, so you should
operate the machine slowly, take care, and do not allow the machine or the dump compartment to touch
anything.
• Long-time continuous driving at a high speed will cause tire overheating, abnormal increase of tire in-
flation pressure, resulting in tire blowout. Tire explosion is destructive and may cause death.
• Before long-time continuous driving, please contact XCMG or its authorized agent.
Safety 1-23
Cautions for Driving on Slopes
To prevent the machine from turning over or sliding to one side, always obey the following issues:
• Slow down using the brake when you drive sown the slope. Do not turn the steering wheel suddenly.
• Drive the machine at a low speed when being on grass and slippery road. Even on very small slopes,
the machine can slip.
• To stop the machine on a slope, you should fully step on the brake pedal, stop the machine with the help
of the park brake, and shut down the engine.
• Do not shift the gear nor engage the transmission neutral gear when driving downhill.
Cautions for Lifting the Compartment
• Check whether there are people or ob-

stacles behind the machine before
unloading.
• Park the machine in a correct position
and recheck whether there are people or
obstacles behind the machine.
• Send out specified signals and operate
the dump compartment slowly.
• If necessary, block the wheels using a
stopper or specify a signalman. Figure1-32
• Do not perform dumping operation on
slopes. The machine stability on slopes
become poor and there is a risk of
tipping.
• Do not drive when a compartment is
lifted.
• During loading operations, the driver
cannot leave the seat and other people
cannot get on or off the machine.
Cautions for Snowy and Frozen Ground
• Roads covered by snow or ice are slippery, so take care to drive or operate the machine. Do not operate
the handle suddenly. A very small slope can make the machine to slip, so be careful when working on a
slope.
• Temperature rising will make the frozen ground to be unconsolidated, resulting machine tipping over.
1-24 Safety
• The machine may tip over or be buried in the snow if it enters deep snow, so take care not to leave the
road shoulders. Otherwise, the machine may fall into the snow.
• Install a tire chain when driving the machine on roads covered by snow.
• Do not stop the machine suddenly through the service brake when driving on a snow covered road. You
can engage a low gear and stop the machine through the engine and double braking (step on the brake
pedal for several times).
• Do not dump materials that are frozen in the compartment. Otherwise, the machine may tip over.
Machine Parking
• Select a parking lot.

• Park the vehicle on a solid and flat ground.
• Select an area without falling rocks, landslides and other hazards for machine parking. If the terrain is
low, park the machine in a place without flooding hazards.
• Do not stop the machine on the construction road. If you really need to stop the machine at these places,
you must use flags during the day and signal lamps at night to remind other personnel and vehicles ac-
cording to the local rules.
• If the machine must be parked on a slope, place a stopper under wheels to prevent the machine from
moving.
Shutting Down the Machine
For detailed procedures of stopping the machine, refer to the operation and maintenance manual. The gen-
eral stopping procedures are as follows:
• The parking handle stays in the "PARK" position;
• The transmission is engaged in the neutral position;
• The lifting handle stays in the “HOLD” position;
• Keep the machine in idle running for 3-5 minutes until the engine is cooled.
• Turn the steering wheel left and right to release pressure in the accumulator;
• Turn the key switch to the “LOCK” position and stop the engine;
• Take down the key;
• Close windows, skylights and cab doors;
• Lock all overhaul doors and boxes.
• When you get off the machine, keep three points in contact with the machine, as well as face it. Do not
jump off the machine.
• When you leave the machine, pay attention to slippery walkways and ladders.
Battery
Safety 1-25
Prevention of the danger caused by battery

The battery acid includes sulfuric acid, so the inflammable and explosive hydrogen is generated. Wrong
operations may lead to injury or fire. Therefore, the following cautions must be observed:
• It is prohibited to smoke or use open fire

near the battery.
• Turn the key switch to OFF before you
operate the battery.
• When the battery is operated, goggles
and rubber sleeves should be worn.
Figure1-33
• The battery’s electrolyte is highly corrosive. If clothes and your skin are splashed with electrolyte,
flush it with a large amount of clean water immediately. If the electrolyte splashes into eyes, flush your
eyes with a large amount of clean water immediately and see a doctor, because there is a risk of
blindness.
To prevent battery explosion, observe the following cautions during operation:
• Do not allow tools and other metal objects to contact with each other between battery terminals; do not
put tools and other metal objects near the battery.
• Shut down the engine before working on the battery.
• In the process of disconnecting the battery, first disconnect the negative (-) terminal (ground side), then
the positive (+) terminal; in the process of connecting battery, first connect the positive (+) terminal,
then connect the negative (-) terminal (ground side). Make sure that all terminals are firmly connected.
• In the process of charging the battery, if the battery temperature exceeds 45 °C, stop charging until the
battery temperature drops to the room temperature, and then reduce the charging current by half for con-
tinuous charging.
• In the process of charging, if acid spraying at the battery vent, stop the charging immediately.
• It is strictly prohibited to smoke and introduce a kindling material.
• Stop the charging when the electric eye displays in green (indicating that the battery is fully charged).
1-26 Safety
Traction
Safety rules on traction
• Improper operation or selection of un-

qualified wire rope will cause serious ac-
A
cidents when the equipment is damaged
B
by towing:
• Don’t attempt to tow a machine on a C
slope.
• Wear protective gloves and safety helmet
when you use a wire rope.
Figure1-34
• Check whether the strength for the wire
rope can bear the weight of the towed
machine.
• Do not use wire ropes with broken strand
(A), reduced diameter (B) and twisted
ones (C), which can be disconnected
during towing.
• In the process of towing, do not stand
between the towing machine and the
towed one.
• Operate the machine slowly and be care-
ful not to suddenly load the wire rope.
Safety 1-27
1.6 Safety Maintenance Instructions

Warning labels
• Before you maintain the machine, please

hang a sign of "Do Not Operate" or simi-
lar warning sign on the shifting handle in
the cab to warn other people that the ma-
chine is under maintenance.
• If necessary, attach additional warning
signs around the machine.
• During the maintenance, serious acci-
dents will be caused if someone starts
the engine, contacts with or operates the
slow running handle or lifting handle.
Figure1-35
No operating!
When not this sign is not in use, please keep it in the
tool box.
If there is no tool box, keep it in the operation
manual bag.
Work Site Preparation
• Select a clean and flat place with enough space, sufficient light, and good ventilation for maintenance.
• Clean the working floor, wipe off fuel oil, lubricating oil and water, and lay sand or other adsorption
materials on slippery floors.
• Do not leave the hammer or other tools in the work area.
• If the work area is not clean and tidy, persons may stumble, slip or drop, and be injured.
Cautions Before Repair and Maintenance
For prevention of accident:

• Understand the maintenance regulations before operating the machine.
• Keep the work area clean and dry.
• Do not spray water or steam in the cab.
1-28 Safety
• Do not fill lubricating oil and maintain the machine when the machine moves.
• Do not contact the removable parts with your hands, feet or clothes.
Self Preparation
Only approved personnel can maintain or repair the machine, and an observer can be arranged if
necessary.
• Wear protective clothing and safety

shoes as required.
Figure1-36
• Wear rubber apron and rubber gloves

when contacting with corrosive materi-
als. Wear safety gloves when handling
wood materials, wire ropes or sharp
edged metals.
Figure1-37
• Wear protective masks when you dis-

mantle spring or elastic parts or add acid
to battery. Wear safety helmet and gog-
gles when you weld or cut parts with a
welding gun.
• Do not perform grinding, flame cutting Figure1-38
or welding operations without respirators
and ventilation. If welding is required on
this machine, know correct operating
procedures by referring to relevant
manuals.
Shutting Down the Engine Before Maintenance
Safety 1-29
• Park the machine on a solid, flat ground.

• Select a place with no falling rock, col-
lapse or low-lying flood risks.
• Lower the dump truck body, turn the lift-
ing handle to the HOLD position, and
then shut down the engine. Figure1-39
• Place the park brake handle to the
PARKING position and block the wheels
to prevent the machine from moving.
Maintenance When the Engine Works
To prevent damage, maintenance should not be carried out when the engine runs. If the maintenance must
be carried out when the engine runs, at least two maintenance persons are required and the following rules
need to be obeyed:
• One person must sit in the operation seat

and be ready to shut off the engine. Both
persons should be in contact.
• Place the lifting handle in the HOLD po-
sitionand the parking handle in the
PARKING position.
• When operations are performed near the
fan, fan belt or other rotating parts, the
operator must pay special attention to
prevent the belt from being coiled. Figure1-40
• Never insert tools or other objects into
the fan or the fan belt. Otherwise, the
parts will break or fly out.
• It is prohibited to touch any handle. If an
operating lever must be contacted, the
operator needs to send signals to other
persons to warn them to move to a safe
place.
Suitable tools
1-30 Safety
Correctly use proper tools. Using damaged,

low-quality, defective, and temporary tools
or incorrect use of tools will lead to serious
accidents.
Figure1-41
Suspended Cylinder Handling
The suspended cylinder and battery has high-pressure nitrogen. Wrong handling of them may lead to seri-
ous injuries. To prevent injuries, the following rules should be obeyed:
• Do not move or dismantle the air cylinder.
• Do not take it near or to the fire.
• Do not drill, weld or work on it using a cutter.
• Do not hit it with a hammer or roll it.
• Please consult Xuzhou Xugong Mining Machinery Co., Ltd. or its authorized agent for cylinder air in-
flation and deflation.
Work Under the Vehicle
• Pads and frames that are strong enough

to support the machine weight should be
used to support the machine if people
need to work under the machine.
Figure1-42
Safety 1-31
• When the dump truck body is lifted for Driving direction

inspection, the lifting handle should be Maintain
placed in the HOLD position. Then fix

the safety device.
Lifting
Lowering
Figure1-43
Working in a Noisy Environment
• When the engine is maintained in a long-time noisy environment, earshields or earplugs are required.
• If the noise of the machine is too loud, temporary or permanent hearing problems can be caused.
Cautions for Using Compressed Air
• When an air compressor is used for cleaning, flying particles may cause equipment damage or personal
injury.
• When you clean the parts or radiator with an air compressor, wear the safety goggles, dust mask, gloves
and other protective articles.
1-32 Safety
Cautions for Using the Hammer
When you knock on hard metal parts, such

as pins, blades or bearings with a hammer,
flying parts and metal fragments will cause
personal injury. Therefore, it is necessary
to wear goggles and gloves, and ensure that
no one is around.
Figure1-44
Welding work
• In the process of welding, fire, gas or electric shock may occur. Therefore, only qualified welders with
appropriate equipment can carry out welding operations. Unqualified personnel are strictly prohibited
to carry out welding operations.
Cautions for High Pressure Oil
The internal part of the hydraulic system always has pressure. Never forget to check whether there is pres-
sure remaining in hydraulic oil pipeline before checking or replacing pipelines. The residual pressure in-
side oil pipeline may cause severe accident, therefore, do as follows:
• Release system pressure before you maintain the hydraulic system:
1. Unscrew the butterfly nut on the breather valve, press the exhaust button, and release internal pres-
sure of the hydraulic oil tank.
2. Release pressure of the accumulator. After the engine is shut down, turn the steering wheel left and
right for several times to release pressure of the steering accumulator. Step on the foot pedal for sev-
eral times to release pressure of the brake accumulator. Step on the foot pedal for several times to re-
lease pressure of the brake accumulator.
• Open fire is not allowed around the hydraulic system and splashed hydraulic oil should be removed
immediately.
Safety 1-33
• Diesel or pressurized hydraulic oil can

penetrate the skin or eyes, causing seri-
ous injury, blindness or death. It is diffi-
cult to determine whether pressurized
hydraulic oil is leaked. A piece of card-
board or wood chip is needed for finding
the leakage. It is not allowed to contact
with the leaked liquid directly, so you
Figure1-45
need to wear a mask or safety goggles to
protect your eyes. If any liquid pene-
trates your skin, flush your skin with a
large amount of clean water and see a
doctor as soon as possible.
• When the engine runs, high pressure will
be generated in the fuel pipeline. You
can check or maintain the fuel pipeline
system only after the engine is shut
down for 30s and the internal pressure
drops.
1-34 Safety
Safety Operation Relating High-pressure Hose
If the high-pressure hose has oil leakage, it will cause operating trouble and even fire. If the bolt on the
hose is found to be loosened, stop operations and screw up/down the bolts to the specified tightening tor-
que. If there is any damage to the hose, stop the operation immediately, and contact Xuzhou Xugong Min-
ing Machinery Co., Ltd. or its authorized agent.
The hose needs to be replaced in time if the following problems are found:
• Damage or leakage of hydraulic pipe connection
• Cladding frayed or disconnected, or strengthening layer wire exposed.
• Cladding expands in some places.
• Impurities inside cladding
• Movable parts distorted or crushed.
Care for Hot Cooling System
When the engine gets hot, pressure in the

refrigeration system increases. Stop the en-
gine to allow the system’s cooling before
you remove the radiator cap. You can re-
move the radiator cap only after the coolant
has cooled down.
Figure1-46
Contact with hot, high-pressure coolant can cause

serious injury.
Safety 1-35
Air Conditioning Maintenance
Stay away from the source of ignition when you maintain the air conditioning system.
• Correctly use the refrigerant when you

maintain the air-conditioning system by
referring to the instructions on the refrig-
erant container. Refrigerant R134a can-
not be replaced by other ones.
Otherwise, the air conditioning system
will be damaged.
Figure1-47
• If the air conditioner refrigerant gets into
the eyes, it may cause blindness; if the
refrigerant comes into contact with skin,
Refrigerant R134a is non-toxic gas at room
it can cause frostbite.
temperature and will change into highly toxic gas
• Use the recovery and circulation system when encountering a fire source.
and do not discharge the refrigerant di-
rectly into the atmosphere.
Cautions for High Voltage
• High voltage will occur inside the fuel

injection terminal and the engine con-
troller when the engine is working or just
stopped. Therefore, there is a risk of
electric shock. Please do not touch the
fuel injector or the engine controller.
• Please contact Xuzhou Xugong Mining
Machinery Co., Ltd. or its authorized Figure1-48
agent if you must contact with the injec-

tor terminal or the engine controller.
1-36 Safety
Accumulator
The accumulator is filled with high pressure nitrogen. Improper operation of the accumulator may cause
explosion and serious accidents. Therefore, the following notes must be kept to:
• Do not disassemble the accumulator.

• The accumulator cannot be close to the
fire source or be exposed to the flame.
• Do not perform drilling, welding and gas
cutting operations on the accumulator.
• Do not crash or roll the accumulator. No
impact is allowed on the accumulator.
• When the reservoir is handled, you must Figure1-49
release the gas. Please contact Xuzhou
Xugong Mining Machinery Co., Ltd. Or
its authorized agent for this operation.
Prevention of Fire and Explosion Hazards
• Stop the engine and turn off the electrical equipment before you refuel oil tank. Pay special attention
when you refuel the hot engine and prevent any sparks around the grounded nozzle.
• Handle all solvents and dry chemicals in a well ventilated environment according to steps indicated on
the container.
• Remove all dust and residues from the machine. Do not palce greasy rags or other combustible materi-
als on the machine.
• Please use non-flammable solvents other than gasoline, diesel or other combustible materials to clean
the parts.
• Store flammable liquids and materials in suitable containers according to safety regulations.
• Check whether fire extinguishers, fire extinguishing systems and fire detectors (if equipped) are ready.
Do not smoke when you handle fuel or maintain the fuel system, because oil and gas in the empty
fuel tank can be exploded easily. Do not perform cutting and welding operations on the pipeline,
fuel tank, or containers with fuel. Otherwise, fire, explosion, or casualties may be caused.
Periodic replacement of safety-critical parts
• To operate the machine safely in the long run, hoses, seat belts and other components related to safety
must be replaced regularly;
Safety 1-37
• Component materials may change when specified time is exceeded. Excessive use will cause wear and
damage. It is difficult to decide how long these components can be used according to visual inspection
or touch, so faults or serious injuries will occur. Therefore, they should be replaced regularly.
• If there are any defects in safety parts, replace or repair it even it has not reached the allotted time.
Carrying Out Maintenance
• In the process of repairing the machine, check all parts and replace worn, broken and damaged parts.
Excessively worn and damaged parts will become invalid when the machine is operated, causing casual-
ties. Replace damaged or unconfirmed signal marks.
• Tighten all fasteners and joints according to the specified torque.
• Install all fenders, covers and shields after maintenance. Replace or repair damaged fenders. Only hy-
draulic oil filling system agreed or recommended by Xuzhou Xugong Mining Machinery Co., Ltd. can
be used.
• Start the engine and check for leakage (hydraulic system). Operate all control devices to ensure that the
machine functions properly. Conduct a test if necessary. Shut down the machine and check your work
(for missing of cotter pins, washers, nuts, etc.) after the test and recheck all hydraulic oil levels before
you operate the machine the next time.
Correct Disposal of Waste
Improper disposal of waste will harm the environment and ecology. Consult with the local recycle center
or Xuzhou Xugong Mining Machinery Co., Ltd. for waste recycling or disposal methods.
• Potential hazardous wastes in equipment

of Xuzhou Xugong Mining Machinery
Co., Ltd. include hydraulic oil, fuel oil,
coolant, refrigerant, filter, battery, etc.
• Use a leak proof container to discharge
liquid and do not use the food or drink
container, because this will lead to mis-
taken drinking. Figure1-50
1-38 Safety
• Do not pour liquid waste on the ground,

the sewer, or any headwaters.
• Air conditioner refrigerant leakage will
damage the earth's atmospheric layer, so
you need to recover or regenerate air
conditioning refrigerant according to rel-
Figure1-51
evant regulations.
Safety 1-39
1.7 Notes on Tires

Tire Handling
Casualty accidents will be caused by burst and disintegrating of wheels and rims or any of them. The fol-
lowing rules shall be obeys to keep safety:
• Deflate the tires completely when you

Wrong Result
repair the tire and rim part. Special
equipment and technology are required
for maintenance, disassembly, repair and
assembly of tires and rims.
• Never perform welding or ignition oper-
ations near tires.
Figure1-52
• Do not damage lips of tires when lifting
or handling the tires to prevent air
leakage.
• Never throw or roll rim parts, or allow
them to fall down to prevent deformation
or damage.
• Never mix rim parts from different
manufactures.
• Use special tires and inflate them with
specified pressure at the place away Figure1-53
from the busy work site.
• Place the tire in a safety protection frame
before inflation. If no tire protection
frame or the tire is installed on the ve-
hicle, use safety chains or wire ropes to
tie the tire and rim assembly up.
• Do not stand in front of an installed tire
when it is inflated. A long hose with a
clip shall be used and the tire shall be in- Figure1-54
flated by standing at the side. To prevent
over inflation, use a gas-pressure meter
to measure the pressure time and time
again when the tire is inflated using the
air pump.
1-40 Safety
• Keep away from heated tires and enter At least 15 m At least 460m
corrugated area as shown in the figure.
• Abnormal tire pressure drop indicates
that the tire has leakage, so it must be
repaired.
• Tire pressure increase is normal in the
vehicle driving process. It is not neces-
sary to take decompression measures,
Figure1-55
and you can slow down or stop the ve-
hicle to allow the tire to cool down.
• Ensure that the torque value for wheel
fixing nut reaches the recommended val-
ue in the instruction manual provided by
the manufacturer (700 - 800N.m for
XDE80T).
Cautions for Storing Tires
• Tires for construction machinery are

very heavy. If the tires are going to over-
turn, do not try to stop them and leave as Stopper
soon as possible. Ensure that the lifting
device can bear this weight during the
lifting operation.
• In general situation, tires cannot be 60°-70°
stored in the warehouse without permis- Figure1-56
sion. If being stored in the open air, the
tires should be covered with canvas to
avoid sun exposure and rainwater.
• Tires should be kept away from heat sources, and should not be placed with oil, inflammable and chem-
ical corrosive substances.
• Tires should be firmly blocked instead of standing on the ground horizontally. Anyone who touches
them should not allow them to roll or overturn.
• Do not place the tire by side, because this operation will lead to tire deformation or damaged.
Safety 1-41
1.8 Accessories Installation and Other Safety Instructions

1. When optional parts or accessories are installed, please contact the dealer of Xuzhou Xugong Mining
Machinery Co., Ltd. in advance.
2. Any injuries, accidents or product faults caused by using accessories or parts without approval from
Xuzhou Xugong Mining Machinery Co., Ltd. are unrelated with this company.
3. When installing and using the accessories, combine operating accessories according to the instruction
manual about the accessories and the general instruction about the accessories in this manual.
4. The working device may bump the cab or other parts of the machine if combined with a different op-
tional part; before using an unfamiliar working device, be sure to inspect if it interferes with the ma-
chine and be cautious with the operation.
Unapproved Modification
Any modification without approval from Xugong Mining Machinery Co., Ltd. is possible to cause danger.
Therefore, before the modification, please contact the dealer of Xuzhou Xugong Mining Machinery Co.,
Ltd.
Xuzhou Xugong Mining Machinery Co., Ltd. will not be liable for any injury, accident or product failure
caused by modification performed without its authorization.Xuzhou Xugong Excavator Co., Ltd bears no
responsibility for any injury, accidents or product failure caused by unauthorized modification.
1-42 Safety
Chapter 2 System Components and Functions
2.1 Vechicle assmbly drawing
3 2
4
Figure 2-1
1. Carriage 2. Rear axle 3.Intermediate axles 4. Front axle
System Components and Functions 2-1

2.2 Operation Unit Layout

The main control devices in the driver’s cab are located on the cab floor, instrument panel and the main
console. Additional control devices can be installed in other parts of the cab. When supplemental instruc-
tion or control information is needed, check the decoration manual.
2 3 4 10
18 5
8 7
20
17
19
9
16
12
11
13
15
14
19
Figure 2-2 Driver’s cab and instrument desk arrangement
1. Instrument 2. Face blowing airinlet 3. Combination instrument

4. Radio 5. Combination key 6. Air-conditioning controller
7. Steering Wheel 8. Combination switch 9. Accelerator pedal
10. Defrost air vent 11. Gear handle 12. Ashtray

13. Lifting pneumatic 14. Parking Switch 15. Seats
2-2 System Components and Functions

16. Brake pedal control valve 17. Clutch pedal 18. Cigar Lighter
19. Folding seat 20. Safety hammer
2.3 Display
F H
7 bar 高压过滤器堵塞报警 10.5 v WIF
P
2
1 X 1000 rpm
F
3
M
0 65km/h
R
6.0 bar 1 D 2 4.5 bar
99999
. 6h t CDO 96536 km
E L
FUEL GAUGE COOLANT TEMP
F1 F2 F3 F4
Figure 2-3
Main screen
After the mining truck is powered and the ignition switch is turned on, the vehicle-mounted computer dis-
play will enter the display main interface, which shows vehicle-related information, as shown in the
figure.
7 bar 10.5 v
2
1 X 1000 rpm
F
3
M
0 65km/h
R
6.0 bar 1
D 2 4.5 bar
99999
. 6h t CDO 96536 km
Figure 2-4
The main interface has instrument display, oil pressure, brake circuit pressure, system voltage, mileage
and other function options in the function part.

The instrument panel in the main interface shows the vehicle speed, gear, fuel level and all warning indica-
tor lamps.
Fog Marker Right

Left Low Engine yellow
lamp lamp turning
turning beam warning
F H
Oil pressure
Parking brake 7 bar 10.5 v WIF Moisture in fuel warning
P
Charging indication
Low coolant liquid warning
Return oil filter clogged F Engine water temperature/steering

warning/fuel level
pressure early-warning
M
Exhaust brake Air filter blockage alarm
R
High-pressure filter 6.0 bar 1 Braking primary circuit pressure
Braking secondary 4.5 bar
High steering oil
clogged warning 2
temperature warning
circuit pressure
99999
. 6h
E CDO 96536 km
L
Engine hours Driving mileage
Figure 2-5
Braking indicator lamp 2

1 High beam
X 1000 rpm
Front shaft brake disc alarm F
3 Engine red lamp warning
Middle shaft brake disc alarm M
0 65km/h Differential lock
Rear shaft brake disc alarm R
D
Figure 2-6
Descriptions of icons
Name Symbol Description
Parking indicator lamp P This lamp turns on when parking is applied.
High beam indicator lamp This lamp turns on when the high beam starts to work.
Low beam indicator lamp This lamp turns on when the low beam starts to work.
Fog lamp indicator lamp This lamp turns on when the fog lamp starts to work.
This lamp turns on when the marker lamp starts to

Marker lamp indicator lamp work.Marker lamp:It turns on when the marker lamp
works.
It indicates the situation that the AC alternator charges
the battery. This lamp turns on when charging is
Charging indicator lamp
insufficient. Left steering indicator lamp This lamp
turns on when charging is insufficient.
This lamp turns on when the left steering indicator
Left steering indicator lamp
lamp works.


This lamp turns on when the left steering indicator
Right indicator lamp
lamp starts to work.
It displays the current oil
It displays the current oil pressure in real time.
pressure
Engine water temperature
It displays engine water temperature in time.
display
Braking primary circuit pressure and
Brake circuit pressure 1 brakingsecondary circuit pressure are shown at the
upper and lower sides, respectively.
Return oil filter clogged This lamp turns on when the high-pressure filter is
warning blocked.
This lamp turns on when the differential lock is

Differential lock lamp
unlocked.
Steering pressure alarm

This lamp turns on when the steering pressure is low.
lamp
Fuel level display It displays the vehicle fuel residue in time.
High-pressure filter clogged This lamp turns on when the high-pressure filter is
lamp blocked.
Low coolant level alarm This lamp turns on when the coolant is lower than
lamp thespecified value.
High steering oil It turns on when the steering oil temperature is higher
temperature alarm lamp than the set value.
Moisture in fuel alarm lamp WIF It turns on certain water enters the fuel.
Air filter blockage warning

This lamp turns on when the air filter is blocked.
lamp
Engine warning indicator When the engine has an alarm, this lamp turns on.
lamp (yellow) Immediate troubleshooting is required.
when this lamp turns on, the engine has a shutdown
Engine stop indicator lamp
fault. You are suggested to stop the engine as soon as
(red)
possible to resolve the fault.
When exhaust brake is engaged, this lamp will turn
Exhaust brake indicatorlamp
on.
When the front axle brake disc alarms, this lamp turns
Front axle brake disc alarm
on and an “F” will be added aside.


Intermediate axle brake disc When intermediate axle brake disc alarms, this lamp
alarm turns on and an “M” will be added aside
When rear axle brake disc alarms, this lamp turns on
Rear axle brake disc alarm
and an “R” will be added aside
Braking indicator lamp When the vehicle is braking, this lamp will turn on.

Instrument Display
Main menu interface
Enter the main menu interface, and you can set up instrument, system information, controller I/O state,
and engine fault code.
Main Menu
Instrument setting
System information
I/O Controller I/O port state
Engine fault code
ok
Figure 2-7
Instrument setting interface
Enter the instrument setting interface to set the backlight, language, instrument information, controller in-
formation, and administrator.
Instrument Setting
Back light setting
Language settin
Instrument information
Controller information
1/2
ok
Figure 2-8

Instrument Setting
Administrator setting
2/2
ok
Figure 2-9
Back light setting
Click the back light setting icon to enter the back light setting interface. You can set the brightness of the
back light in the back light setting interface.
Backlight Setting
45%
ok
Figure 2-10

Language setting
In the language setting interface, you can select Chinese, English and Russian.
Language Setting
Chinese
Figure 2-11
Instrument information display
Enter the instrument parameter interface by clicking the instrument information display icon. The instru-
ment display interface includes instrument mode, code number, software version and other information.
Instrument Information
Instrument model:
Instrument number:
Software version:
ok
Figure 2-12

Controller information interface
Enter the controller information interface by clicking the controller information icon. Controller version
information is displayed on controller information interface.
Controller Information
Version information: D80A_000
ok
Figure 2-13
Administrator setting interface
Press keys corresponding to the administer settings,which can do the video settings.
Administrator Setting
Video setting
ok
Figure 2-14

System information interface
Enter the system information interface by clicking the corresponding icon. The system information inter-
face displays power system information, hydraulic system information, and GPS status information.
System Information
Power system information
Hydraulic system information
GPS status information
ok
Figure 2-15
Power System Information Display
Enter the power system information interface by clicking the corresponding icon. The system information
interface displays oil pressure, engine coolant temperature, speed, and oil level in the tank, etc.
Power System Information
Oil pressure ℃
Engine coolant temperature ℃
Speed r/min
Oil level in the tank %
ok
Figure 2-16

Hydraulic system information display
Enter the hydraulic system information interface by clicking the corresponding icon. The hydraulic system
information interface displays steering pressure and steering oil temperature and so on.
Hydraulic System Information
Steering pressure bar

Steering oil temperature ℃
ok
Figure 2-17
GPS status information display
Enter the GPS parameter interface by clicking the GPS status information icon. GPS display interface con-
tains positioning status and equipment status, etc.
GPS status information
Positioning status: longitude and latitude:E122.12，N60.30

Elevation:1200.6m
Number of satellites:6
Equipment status: GPS power supply:Normal

GPS antenna: Normal
SIM card: Fault
ok
Figure 2-18

Controller I/O port state interface
Enter the controller I/O port parameter interface by clicking the corresponding icon. The controller I/O
port parameter interface contains the reverse gear switch, neutral switch, parking brake switch, high-pres-
sure filter blockage switch, return oil filter blockage switch, and interaxial differential lock, etc.
Controller I/O
Reverse gear switch

Neutral gear switch
Parking brake switch
High-pressure filter blockage switch
Return oil filter blockage switch
Inter-axle differential lock
1/4
ok
Figure 2-19
Engine fault code
Enter the engine fault code parameter interface by clicking the corresponding icon. Refer to the figure for
engine related fault codes.
Fault code
Figure 2-20

2.4 Bus Keyboard Switch

Bus keyboard
Figure 2-21
Functions
Key Function Operating Instructions Corresponding Indicator
Press front head lamp switch
When front head lamp is
Front head lamp once to activate it; press it again
activated, the indicator lamp
control for deactivation; implement the
above the key turns on.
control circularly.
Press the fog lamp switch once
When front head lamp is
to activate it; press it again for
Fog lamp control activated, the indicator lamp
deactivation;
implement the control circularly.
Press marker lamp switch once
When marker lamp is activated,
Marker lamp to activate it; press it again for
the indicator lamp above the key
control deactivation; implement the
turns on.
control circularly.
Press rear lamp switch once to
When rear lamp is activated, the
activate it; press it again for
R Rear lamp control indicator lamp above the key
deactivation; implement the
turns on.
control circularly.
Press roof alarm lamp switch
When roof alarm lamp is
once to activate it; press it again
Roof alarm lamp activated, the indicator lamp
for deactivation; implement the
control circularly.

Key Function Operating Instructions Corresponding Indicator

Press exhaust brake switch once
When exhaust brake switch is
Exhaust brake to activate it; press it again
activated, the indicator lamp
control circularly.
Press differential lock switch
When differential lock is
Differential lock once to activate it; press it again
X activated, the indicator lamp
control circularly.
Press the emergency signal lamp
switch once to activate it; press When emergency signal lamp is
Emergency signal
it again activated, the indicator lamp
lamp control
for deactivation; implement the above the key turns on.
control circularly.
Press engine diagnosis request
When engine diagnosis request
Engine diagnosis switch once to activate it; press
is activated, the indicator lamp
request control it again for deactivation;
Press engine diagnosis request
When engine diagnosis request
Transmission switch once to activate it; press
is activated, the indicator lamp
retarder control it again for deactivation;

2.5 Handles and Pedals
2 3 4 10
18 5
8 7
20
17
19
9
16
12
11
13
15
14
19
Figure 2-22
9. Accelerator pedal 11. Gearshift handle 13. Lifting handle

14. Parking handle 16. Brake pedal 17. Clutch pedal

Lifting handle
Located at driver’s right side, the lifting handle is designed to lift and lower truck body. There are three
operating positions on this handle, which are arranged from front to rear:
Driving direction
Maintain
Lifting
Lowering
Figure 2-23
Lifting control handle switch
The truck body can be lifted by pulling the

handle backward; by pull the handle to
neutral position lifting function will be
stopped.
Figure2-24 Lift (rear)

Maintain switch
Pull level to neutral position and truck

body will achieve maintain function - stay-
ing unchanged at current position.
To realize normal drive, lifting handle

should be pulled to this position.
Figure2-25 Maintain (middle)
Lowering switch
Lifting control handle is located at the left

side of driver's seat.
Pull the handle forward and truck

body will realize the lowering function by
gravity.
Figure2-26 Fall (front)

Gearshift handle
This vehicle carries a manual transmission box, which requires operation of gearshift handle to select a
proper position in order to ensure normal vehicle operation. Control handle is located at the right side of
driver's hand.
Forward
direction
Figure 2-27
Refer to following table for maximum gradeability and maximum travel speed for each gear.
Gear Max. grade ability (%) Max. travel speed (km/h)

1 30 4.0
2 20.4 5.5
3 13.4 8.0
4 9.6 10.8
5 6.2 15.5
6 3.8 22.6
7 2.1 32.8
8 1.1 45

Accelerator pedal
An electric signal in proportion with foot

pedal angle is offered to engine fuel system
by accelerator pedal.
Note: Electronic-controlled engine

doesn’t respond to any angle of acceler-
ator pedal before engine is heated up to
normal working condition. Ensure that
your foot is away from the accelerator
pedal when starting the engine.
Figure2-28
Clutch pedal
When clutch pedal is depressed, drive-cyl-

inder push rod will move piston forward,
and brake fluid will flow along oil pipeline
and enter hydraulic control chamber of
clutch booster cylinder; the brake fluid, on
one hand, acts on the piston as working
pressure; on the other hand, serves as con-
trol pressure that regulates the pressure of
booster cylinder air chamber. When com-
pressed air enters booster cylinder air
chamber and produces air power, the pneu-
matic power will push piston, move boos-
ter- cylinder push rod, and rotate rocker
arm, and a further reaction will result - re-
Figure2-29
lease fork will bring release bearing to
make backward movement, and disengage
the clutch.

Service brake pedal
Slow down or stop the vehicle by stepping

on the service brake pedal installed on the
cab floor with your right foot according to
the speed, load and road conditions. Re-
lease the pedal after the vehicle slows
down. When parking is required, step on
the pedal once until the vehicle stops sta-
bly. Do not repeatedly step on the pedal.
Figure2-30
Hand brake valve (parking brake)
Hand brake valve is located on the right

side of seat. (In the figure, brake valve han-
dle is engaged at “Parking” position)
Only when parking brake signal lamp turns
off, air pressure exceeds 0.55Mpa and
parking brake is completely released, can
Parking
P
Driving
the vehicle start running.
Figure2-31
Never start the vehicle before parking brake signal

lamp turns off!

Brake with transmission hydraulic retarder(optional)
This vehicle carries a transmission retarding device, mainly applied to travel on downslope with heavyload
or frequent downslope travel. With this device, the driver can reduce service brake application frequency.
Please use it together with engine exhaust brake.
Its control switch is located on driving handle beneath steering wheel, on the right-hand direction. the re-
tarder handle obtains a different retarding capacity when positioned from rear to front. The retarder will
close when the handle is pulled to the end; pull it forward to gradually increase the retarding capacity;
when it’s pulled to the forefront position, the retarder will come in the maximum working condition, ac-
cordingly, the retarding capacity becomes the strongest.
Figure 2-32
2.6 Cigarette Lighter (installed on some models)

The cigarette lighter is used to light
cigarettes.
Press the cigarette lighter and pull out

the cover after several seconds when the
cigarette lighter pops up to the initial
position.
Cigar lighter socket also serves as a

power source for an electric appliance not Figure2-33
more than 240W (24V×10A).
Note: The voltage for the cigarette

lighter is 24V.

2.7 Horn
When the steering column middle horn but-
ton is pressed, the horn makes a sound.
Figure2-34
2.8 Steering Wheel

The steering wheel’s position can be adjusted as required for operation convenience. During adjustment,
the adjusting lock should be pulled out to slope the steering wheel upwards and downwards. After the ad-
justment, the adjusting lock should be pushed back.
Hydraulic power of the steering system is provided by the continuously-running pump and accumulator,
which helps maintain a continuous hydraulic power source for steering cylinder operation.
2 1
Figure 2-35 Steering wheel
1.Steering Wheel 2. Combination switch
Turn the steering wheel to move the front wheels according to the steering direction and steering radius.
The steering speed of the front wheels should be in direct proportion to the steering wheel speed. When

the steering wheel stops turning, the front wheels should stop turning and stay in the original position.
When the steering wheel turns reversely, the front wheels are straightened or continue to turn reversely.
2.9 Radio
Panel introduction
MIC
MIN VOL MAX TD-650 MP3 RECEIVER
AND
LOU
LOUD
AS AUX
MOD PS
PUSH /II INT RPT RDM D-DN D-UP

SEL/MENU PWR CLK 1 2 3 4 5 6
Figure 2-36
1. PWR: Startup & shutdown

2. BND: Band selection
3. LOU/ loudness control, hang up.

4. 1//▷ /ll， 2/INT， 3/RPT， 4/RDM， 5/D-DN， 6/D-LP： radio adjusting/storing key and MP3 play-
ing function key
5. AS/PS: automatically preset radio/music
6. MOD: mode selection.
7. ︽︾: Manual/automatic scan key; select the previous/next track, fast forward/fast reverse key
8. Knob: volume/time adjustment; system bass, treble, balance; sound effect setting key, answer key.
9. MOD: Make a short press to turn from USB/SD into FM; press again to shift between FM1/FM2/FM3;
make a long press to automatically scan stations and save.
10.CLK: Clock display/setting
Operation description
1. Mode conversion key

Press “PWK” to turn this product to operative mode. Press “MOD” button to shift among each
mode.If the USB flash disc is connected, it will go straight to next mode. This product has following
modes: RADIO, BT PLAY (Bluetooth), USB and AUX IN (external audio input) mode.
1) Radio setting: press PWR key to power up this device; after that, press BND button to select from
FM1, FM2, FM3, AM1 and AM2.
Make a short press on “︽” button or “︾” button to start auto scan. Make a long press on
“︽” button or “︾” button for over 2s to start manual scan. Make a long press on “AS/PS”
(over 2 s) to automatically preset radio stations. Make a long press on any of the “1”......“6” but-
ton for over 2 s, the current radio station will be preset into corresponding button.

2. MP3 (USB/SD/MMC) play
1) In radio mode, insert USB/SD and system will automatically shift to USB/SD play mode.
Make a short press on︽︾to play the previous/next track in USB/SD;
Make a long press on ︽︾to fast backward/forward the current track.
When system is playing tracks in USB/SD, the corresponding USB/SD icon will flash.
2) In MP3 play mode: Play/pause, browse, repeat, random, -10/+10 to select songs.
◆1//▷/ll： play/pause control key;
◆2/INT： Preview Play/Scan Play;
◆3/RPT： Repeat/Play All control key;
◆4/RDM： Random/Play All control key;
◆5/D-DN： Minus 10 Tracks track selection control key;
◆6/6/D-LP： Plus 10 Tracks song selection control key; counterclockwise turn the knob to decrease
current volume; clockwise turn the knob to increase current volume; (volume level: 0-32).
3. Clock Setting
1) Clock setting operation is in Radio/MP3 Play mode:/MP3
2) Make a short press on MUTE/CLK key, shift Mute Switch;
3) Make a long press on this key and the clock will display; repeat this operation and you can turn the
knob counterclockwise/clockwise to adjust the value of hour; make another long press and you can
turn the knob counterclockwise/clockwise to adjust the value of minute. After five consecutive
jumps, the system will automatically exit Clock Setting.
Note: After clock setting is completed, as long as BAT (yellow line) power is not interrupted,
the clock will constantly cycle.
4. Sound Effect Setting
1) setting operation is in Radio/MP3 Play mode; make a short press on the knob, BS 0/TE 0/BL 0/EQOF
will appear in order;
2) After BS O appears (bass), turn the knob counterclockwise/clockwise to select the desired bass value
(-7~7);
3) After TE O appears (treble), turn the knob counterclockwise/clockwise to select the desired treble
value (-7~7);
4) After BL O appears (balance), turn the knob counterclockwise/clockwise to select the balance value
(-7~7) of left and right speakers;
5) Only after EQOF appears, turn the knob counterclockwise/clockwise to produce JAZZ/POP/ROCK/
CLASSIC/FLAT/EQOF (sound effect off) sound effects. When electronic sound effect is activated, it
will be impossible to manually set BS and TE value.
5. Bluetooth setting

Activate Bluetooth and search new “device”; when system gets contact with the cellphone, system
will prompt a message for you to confirm whether to connect the device; you may choose “Yes” to
allow the connection; after the connection succeeds, “ ” will appear on system LCD display,.
showing successful connection. Once the Bluetooth match succeeds, if the system is not in BT PLAY
mode, you may press “MOD” button to shift to BT PLAY mode.
Technical Specifications
General characteristics
• FM
Frequency Range 87.5MHz —108 MHz Distortion (1mV input) ≤2
Channel search
100KHz（ 0.1MHZ）
step-length
Channel locking
23～8dB
sensitivity
Signal to Noise Ra-
≥48dB
tio (SNR)SNR
• MP3
Frequency
0Hz —20KHz
response
Signal to Noise Ra-
60 dB
tio (SNR)SNR
• AM
Frequency Range 522~1620KHz
Channel locking
36±10
sensitivity
Signal to Noise Ra-
≥43dB
tio (SNR)SNR
The cellphone can be charged with USB data wire (function selectable: none\5V 0.5A\5V 2A).
Note: It’ s recommended not to charge for too long, as this device doesn't have a cell saturation
detection function, there might be a hidden risk of damaging the cell.
Cautions:
• To avoid traffic accident, please adjust volume to a proper level.
• In hot or cold climate, please keep this device indoor. Ideal temperature can ensure that this device has
good performances.

• After being wet by water, this device will be easily damaged. Do not spray water onto this device when
this truck is washed.
• When this device is with long high-power output, its casing temperature will largely increase. This is
normal. Do not touch heated objects in case of being scalded.
• Except professional maintenance staff, no one shall tear warranty strip seal and open this device for pri-
vate adjustment or repair; otherwise, you will lose warranty service.
Feature introduction
TD-650 is a knob type car audio system. It’s integrated with following functions: FM, AM tuning, Blue-
tooth, MP3 (USD/SD), clock, sound effect adjustment, external audio input and loudness, etc.
1. System configuration: digital tuning radio, USB/SD-MP3 player, electronic clock display.
2. Frequency modulation function: support FM (87.5 MHz ~ 108 MHz), AM (522 KHz ~1620 KHz) and
24 stock radio stations.
3. AUX function: play MP3 files from USB flash disc/SD card, and input external audio like cellphone
and MP3.
4. Sound effect function: support POP/ROCK/Classic/FLAT sound effects.
5. Bluetooth function: make phone calls or answer the call with Bluetooth headset and play music.
Before you installing and dismantling the audio, please turn off the power supply of the vehicle.
Please maintain the vehicle without power supply to avoid unnecessary loss.
When the vehicle is powered, please do not open the shell at will, preventing damage to the
machine caused by high voltage in the machine.
For your safety, please keep the volume within a range where you can hear traffic signals (horn,
siren).

2.10 Combination switch
Figure 2-37
The combined switch is used for starting the steering lamp and windshield wiper, and selecting the high
beam/low beam headlamp.
Move the handle upwards to send signals of

steer forwards. An indicator lamp to the
right of the instrument board will be lit to
indicate the selected direction.
Move the handle downwards to send signals

of steer backwards. An indicator lamp to
the left of the instrument board will be lit
to indicate the selected direction.
After the vehicle is steered, the steering signal cannot be automatically canceled. The steering
signal lever must be manually pulled to meso-position.

Headlamp high beam operation
Move the handle upwards to change the

headlamp to the high beam mode. When
the high beam mode is selected, the high
beam indicator on the instrument will turn
on. Move the handle upwards again to
change the high beam mode to the low
Figure2-38
beam mode.
Wiper operation
The wiper is operated based on a 24V elec-

tric motor. The combination switch in-
stalled on the steering column can turn the
wiper speed to speed or high speed.
Figure2-39
Washer operation
The washer installed under the instrument panel in the cab has a plastic storage tank equipped with a 24V
electric pump.
The washer is under control of a combination switch installed on the steering column assembly. When the
switch is turned on, the washing liquid is drawn through the outlet hose and supplied for injectors located
in each wiper arm.
Maintenance
If the washer needs to be maintained, check the coarse strainer for opening difficulty and hoses for dam-
age. Check the voltage from the control switch to the pump. If the pump fails to be operated, a new pump
assembly is required for replacement.
Note: The pump can only be replaced as an assembly and cannot be repaired.

2.11 Power supply switch

Main power switch
Power master switch is located on the exterior wall of battery box, which is mounted on framework longi-
tudinal beam.
Main power supply switch: Main power supply switch:

ON - horizontal position OFF - vertical position
Figure 2-40
If this vehicle will be out of service for a long term, please turn off power master switch, so as to
avoid occurrence of accident. When engine stops and key switch is at LOCK position, power
master switch can be closed.
Key switch
Key switch is designed to start and shutdown the engine.

“LOCK” position:
Insert key switch and turn it in this position. When key switch is turned to this position, all electric circuits
are cut off and engine is off.
ACC”position:
When key switch is turned to this position, all electric circuits are connected with power.
“ON” position:
When key switch is turned to this position, all electric circuits are connected with power.
When engine is on, key switch is also in this position.
“START” position:

This position is to start the engine. Keep the key in this position when you are about to start the engine.
Release the key switch when engine is starting up, at this moment key switch will return to “ON”
position.
Steering position Usage Remarks
The vehicle is The key can be

1(LOCK) powered off. pulled out at
this time.
Electric equipment
2(ACC) is connected when
the truck stops.
3(ON) Traveling
Automatic reset
4(START) Starting the engine
to the ON gear.
Figure 2-41
2.12 Clothes-hook
The hook can be used to hang up a single
cloth, which cannot be heavier than 2 kg.
Figure2-42

2.13 Air Conditioning and Control Devices

Operation description
Hot weather
1. Close the heating valve.
2. Switch on refrigeration function.
3. When starting, firstly keep fresh air switch off for 10-20 minutes to fast cool down temperature.
4. Adjust the air flow to the maximum.
5. When indoor temperature is desired, turn on fresh air switch.
Weather with appropriate temperatures
1. Turn off the cooling and heating switches.
2. Turn on the fresh air switch.
3. Adjust the air flow to a suitable degree.
Cold weather
1. Close refrigeration function.
2. Turn on heating water valve.
3. When starting, firstly keep fresh air switch off 10-20 minutes for to temperature to fast rise.
Control panel
Figure 2-43
1. Air Volume Adjustment button(Left) 2. Temperature Adjustment button(Right)
Air conditioner switch:turns on/off the air-conditioning system.

Temperature adjusting switch: adjusts and sets the temperature.
Air volume adjusting switch: adjusts the air volume.

Maintenance and Service
1. Maintenance Guide
1) The basic work of regular maintenance like strainer cleaning, inspection of compressor belt tension
etc., can be fulfilled by the driver. But, the job like the refrigerant refilling and circuit maintenance
etc., can be done only by the qualified technician. To ensure smooth maintenance, use of appropriate
tools is absolutely necessary.
2) Once the system is opened or there is a leakage, the desiccators must be replaced.
3) The air conditioning system is very sensible to the dust, dirt and moisture. In installation and mainte-
nance, special cares must be taken to prevent the system from contamination.
4) Do not open the joint cover of pipeline and compressor. Dirt and moisture are very harmful to the per-
formance of air conditioning and the first cause of the compressor damage. The most compressor fail-
ing to be compensated is because of the contamination of system.
5) In installation and maintenance of air conditioning system, new or clean parts must be used. Before
refilling the refrigerant, the vacuum pumping is required for at least 45 min. The pointer of low pres-
sure gauge should indicate the mercury column below 750 mm, where the moisture in the system will
be eliminated.
6) Before performing the circuit maintenance, be sure that the line insulation is in good condition and
the PS safely controlled.
2. Maintenance Guidance
Regular preventive maintenance plays a key role in ensuring good and lasting operation of the air condi-
tioning system.
3. Troubleshooting reference
1) Common trouble shooting

Is the clutch powered after the air conditioning system is turned on?
Note:
• Observe the compressor’s clutch center to check whether the clutch rotates with the belt pulley. If
the clutch does not rotate, check the clutch power supply. If the clutch is not powered:
• Check the power supply fuse in the air conditioning system.
• If the fuse is in good condition, check the power supply for pressure protection. Under normal cir-
cumstances, pressure-protection is long-term powered. If the pressure protection inlet is powered
and the outlet is not, the system may lack refrigerant and require maintenance and refrigerant
supplement.
• If the pressure protection inlet is not powered:

• Check the temperature controller: If the temperature controller inlet is powered while the outlet is
not, the evaporator temperature is not low, and the surface temperature controller fails, replace the
temperature controller.
• If the temperature controller inlet is not powered:
• Check power supply in and out of the air volume switch: If the air volume switch has power in and
no power out, replace the air volume switch. If the air volume switch inlet is not powered, check
the fuse again.
Does the belt has noise?
• Belt looseness or wear will whistle. If you hear this sound, adjust belt tightness or replace the belt.
Is there any noise around the compressor?
• Check whether parts around the compressor and compressor frame are loose, and tighten them if
necessary. Is there any noise from the compressor?
• Suction and exhaust valve or internal damage may be the cause of the noise.
• In a place with oil stain, the noise may be caused by refrigerant leakage. Check whether there is
leakage using a tester. Replace parts if necessary, and carefully check the compression seal gasket,
seal ring and shaft seal.
Check the hot water valve for internal leakage.
• Check whether the heat exchanger and the hot water pipe connecting with heat exchanger are hot.
If yes, the water valve has leakage.
2) Minor failure
3) Check system pressure to see whether there is oil contamination near pipe joints and around the
compressor.
Table 2-1 Air conditioning repair
Task Procedure Corrective measures

Operate the air conditioning system for a
Weekly maintenance few minutes to ensure relevant compo-
nents’ good lubrication.
Check the return air filter screen for dust Clean or replace the filter
and blockage. screen.
If necessary, adjust belt tight-
Monthly maintenance Check the compressor belt’s condition.
ness or replace the belt.
Clean the parts using water or
Check the condenser dust.
compressed air.
Check pipelines for wear or check the
Semi-annual Conduct leakage tests and re-
joints for leakage. Oil stains indicate
maintenance place pipelines if necessary.
leakage.

Table 2-1 Air conditioning repair(continued)
Task Procedure Corrective measures

Bubbles indicate refrigerant is
When the air conditioning system works,
lacked, so refrigerant filling is
check the liquid mirror.
required.
Check whether the hot water pipes are If there is wear, replace hot
worn and are well connected. water pipes.
Table 2-2 Air Conditioning Troubleshooting
Problem Possible Cause Inspection Measure

Check the fuse/line,
1. Blown fuse, line dis-
motor grounding condi- Replace the fuse or
connection, and joint
tion, and the connector line.
poor contact
contact condition.
The fan motor does not
Check the motor line
work. 2. Motor fault Replace the motor.
resistance.
Check power supply in
3. Air volume switch Replace the air volume
and out of the air vol-
fault switch.
ume switch.
Remove the blockage.
Remove the stopper
Check the dust on the
1. Evaporator air inlet and clean the evapora-
The fan works nor- air inlet and fins of the
blockage tor and the return air fil-
mally, but the air vol- evaporator.
ter screen using air or
ume is insufficient.
water.
2. The evaporator is Temperature controller Replace the tempera-
frozen. fault ture controller.
Check the belt vibration
1. Belt looseness Adjust the tension.
The compressor does or jump.
not work or works Check whether the
2. The compressor is Replace the
abnormally. compressor is locked or
damaged internally. compressor.
the belt is broken.

Table 2-3 Compressor Working Pressure
When the compressor works at a speed of 3300 rpm and the ambient temperature is 30-38℃, nor-
mal pressure at the suction side and exhaust side of the compressor is as follows:
High pressure side: 14-21 bar
Low pressure side: 1-2.5 bar
As an empirical law, pressure at the high side is usually 8 times greater than that at the low side.
Pressure at the low 1. Too large expansion The pipeline at suction Replace the expansion
pressure side is too valve opening side is frosted. valve.
high. When the pres-
After the clutch is en-
sure at the high side is
gaged, pressure at the Replace the
too high, the pressure at 2. Compressor fault
high is equal to that at compressor.
the low side is also too
the low side.
high.
The pressure at the high
Repair leakage points
1. The refrigerant is side is low and the
and refill the
insufficient. liquid mirror has air
refrigerant.
bubble.
The inlet of the expan-
2. The expansion valve sion valve is frosted. Clean or replace the ex-
is blocked or turned off. Water or other sundries pansion valve.
Pressure at the low side are possible causes.
is too low. There is frost in the
3. Blockage between pipeline between the Clean the system with
dryer and expansion dryer and expansion nitrogen or replace the
valve valve, which may cause pipeline
negative pressure.
Adjust the probe posi-
4. Temperature control- The evaporator is
tion or replace the tem-
ler fault frozen.
perature controller.
1. The condenser has Condenser fins are pol-
Clean condenser fins.
poor heat dissipation. luted or blocked.
High side pressure is When the ambient tem-
Recover redundant re-
too high. perature is of 30-38℃,
2. Excessive refrigerant frigerant and adjust it to
high side pressure is
the proper amount.
greater than 23 bar.

Table 2-3 Compressor Working Pressure(continued)
When the compressor works at a speed of 3300 rpm and the ambient temperature is 30-38℃, nor-
mal pressure at the suction side and exhaust side of the compressor is as follows:
Remove refrigerant oil
from the compressor
and condenser, refill the
High side pressure is
3. Excessive condenser oil, and observe the oil
too high.
volume from the com-
pressor. Replace the
dryer.
High pressure at both Empty the system. Re-
4. Air enters into the
high and low pressure fill refrigerant after
system.
sides vacuumization.
Empty the system. Re-
5. Blockage in the con- High side pressure is
place the faulty parts.
denser, dryer or high- high and low side pres-
Refill refrigerant after
pressure side pipeline sure is low.
vacuumization.
Find out the leakage
Low side pressure is 1. The refrigerant is low. There are bubbles
point. Refill refrigerant
too low. insufficient. in the liquid mirror of
after vacuumization.
the dryer.
1. The clutch is not Refer to the basic trou-
engaged. bleshooting section.
System pressure is
consistent. 2. The compressor does Replace the
consistent with the low
not work. compressor.
side pressure.

2.14 Door and Windows of Driver’s Cab

Opening the Door and Windows of the Driver’s Cab
1. Press the lock catch before you opening

the door and window of the driver’s
cab.
2. Move the front window back and (or)

move the rear window forward.
Door and window lock catch
Figure2-44
Closing the Door and Windows of the Driver’s Cab
1. Move the front window forward and (or) move the rear window back.
2. Ensure that the lock catch is completely locked after the window and door are closed.
Cab Emergency Exit
If the door cannot be opened in an emer-

gency circumstance, you can take down the
safety hammer to break the front wind-
shield for escape.
Don’t use the safety hammer under

any other circumstances.
Figure2-45

2.15 Door Lock
• The machine should be stopped on a flat

ground before you release the door lock.
• Do not release the door lock when the
truck is on a slope. The door may be
closed suddenly, causing injuries. 2
• Before you release the door lock, do not

extend your body or hands outside the
1
machine, and do not put your hands on
the door frame. The door may be closed
suddenly, causing injuries.
• Push the cab door to lock it on the lock
Figure2-46
post when you close the door.
2.16 Safety Support

Safety support is located on the rear part of framework (left side or rear).
• When truck body is at “non-lift state”, safety support is in “flat placement state” (that's non-work-
ing state).
• The safety support is designed to lift truck body up 22° for inspection or repair; as long as lifting switch
is kept at maintain position, the safety support will prevent truck body from accidental fall (rotate safety
support to the shown angle of the figure, and it will comes into working state).
Figure 2-47

Figure 2-48
Figure 2-49
Figure 2-50

Chapter 3 Operation
3.1 General Principle

This machine can only be operated by those qualified, experienced operator with mining truck operating
certificate, who is allowed to inspect and maintain this machine. Operation notices:
• Read carefully and master this manual before this machine is started and operated for the 1st time.
• As an important part of the equipment, this manual should be placed accessible for the convenience of
timely replacement or supplement when it is lost, damaged or unable to read.
• Careful check should be done before this machine is started. This machine can be used and operated-
strictly according to the safety procedure.
• Don’t directly run the engine at high speed when at low temperatures. If hydraulic oil temperature is
below 25°C, preheating operation should be done so that the oil temperature can be raised to the re-
quired one for the operation.
• Long-acting anti-rust antifreeze has been added into water radiator before delivery; if the machine will
be left unused for a long period, drain out the antifreeze so as to prevent corrosion.
• When in winter, winter type lubricating oil and diesel should be used for a diesel engine. Both oil type
and details about engine cold start are specified in this manual and diesel engine instructions.
• When a refill is needed for the loss of hydraulic oil, make sure to use the identified clean hydraulic oil.
Oil of different brand is forbidden.
• Pay attention to the cleanliness of hydraulic oil at any time. If it is aging, deteriorated or not clean
enough, be sure to replace it at once with the new oil. Normally, hydraulic oil should be replaced after
the running-in period.
• The key parts of hydraulic system have been sealed by lead. During the warrant period, the seal can’t
be opened privately by the customer, or it won’t be guaranteed.
• Before the delivery, the machine has been checked and adjusted strictly. But proper running-in must be-
gone through using the machine, so that all parts can run in very well and the life span of the machine
can be lengthen.
Scopes of application
Altitude: 0 m - 2000 m
Ambient temperature: -25℃~40℃。
Operation 3-1
3.2 New Machine Running-in and Operating Instructions

Note: Machines of Xuzhou Xugong Mining Machinery Co., Ltd. have been thoroughly adjusted and
tested before delivery. However, full load operation before running-in will seriously affect machine
performance and shorten the machine’s service life.
Always perform machine running-in during first 100 hours when the machine is operated (as indicated by
the hour meter).
Ensure that you fully understand information in this manual and pay attention to the following issues dur-
ing machine running-in:
• Keep the machine in idle running for 3-5 minutes after the engine is started. During this period, do not
engage a gear or step on the accelerator pedal, and then slowly adjust the accelerator to 1500 rpm until
the water temperature reaches about 60°C.
• Avoid high-speed operations under heavy load.
• Avoid sudden start, sudden acceleration, unnecessary sudden stop and sudden change of direction after
the engine is started.
3-2 Operation
3.3 Pre-boarding Preparation and Inspection

Following the safety regulation
• Read carefully and abide by all the

safety signs as well as all the safety-re-
lated information in this book.
• If necessary, please install, maintain or
replace safety signs.
• If safety signs or this manual are lost or
damaged, please order the new ones
from appointed dealer of Xuzhou Xu- Figure3-1
gong Mining Machinery Co., Ltd. in the
same way of purchasing other parts (type
and delivery number of the machine
must be written clearly).
• Learn to correctly safely operate this ma-
chine and ensure only well-trained staff
are qualified to operate maintain this
machine.
• While carrying out the operation and
maintenance, all the safety rules, warn-
ings and requirements must be strictly
followed.
• Keep the machine under proper working conditions. Any modification unapproved may spoil the func-
tion or safety of the machine; even shorten its life span.
• Safety indications are the basic regulation for the safe of the machine. However, they won’t invol-
veyou into any kind of danger that you may run into. If there is some question, please report to your
higher-up at first before operating or maintaining this machine.
• You can’t operate this machine in the case of bad health, weariness due to the medicine or unease in
the environment, which will reduce your response towards the contingency and lead to the accident
• While working with other driver or traffic keeper on the spot, it is necessary to ensure the hand language
and working environment are familiar to all the personnel.
• Please pay attention to all the factors affecting safety at any time.
Operation 3-3
3.4 Preparation and Checking After Getting on the Machine

Adjust Operator’s Seat
Sitting on an improperly-mounted seat, the operator will soon feel fatigued and cause misoperation.
• Every time when the operator is

changed, the seat should be adjusted
again.
• When the operator leans against the back
of seat, he should be able to push the
pedal to the bottom and operate the oper-
ating lever correctly; if he cannot, he can
move the seat up and down, to and for,
and make a second adjustment.
Figure3-2
Fastening the seat belt well
• If the machine turns over, the operator may be hurt or ejected off the cab, or bore down by the tipping
machine, causing serious injury or death accidents. Carefully check the safe belt, belt buckle, and fixed
part before you operate the machine. If there’s any loss or abrade, you should replace the seat belt or
other parts before operation.
• Ensure that you sit on the seat with the seat belt fastened to prevent accidents when operating the
machine.
• It is suggested to replace the seat belt every three years, regardless of its use condition.
3-4 Operation
3.5 Running Operations

Before Starting the Engine
Patrol Inspections
Before starting the engine, you should patrol around and under the machine to see whether there are loose
bolts and nuts, and oil, fuel and coolant leakage, and check the hydraulic system.
Check whether wires near high-temperature positions are loose, and whether there is clearance and dust
accumulation.
Before you start the engine every day, the following inspections and cleaning work should be carried out:
1. Check whether the truck body, frame, tires, oil cylinders, connecting rods and hoses have fracture, ex-
cessive wear and excessive clearance problems. If there are any abnormal conditions, repair or replace
the device.
2. Clean dirt and debris around the engine, battery and radiator. Check whether dirt and dust are around
the engine, radiator and intercooler. Check whether inflammables (dry leaves, twigs, etc.) are around
batteries, engine silencers, turbochargers, and other hot parts. Remove dirt or inflammables (if there
are).
The warning sign is hung on the handle.

Remove inflammables around batteries, engine silencers, turbochargers, and other hot parts.
Otherwise, fire may be caused.
Fuel or oil leakage can cause the machine to be on fire.
In case of any fault, contact XCMG or its authorized agent.
3. Check the engine surroundings for coolant and oil leakage. If any abnormal condition is found, repair
the part.
4. Check the transmission, differential case, wheel rim, steering/lifting oil tank, hose and joint for oil leak-
age. If any abnormal condition is found, repair the part with oil leakage.
5. Check air filter mounting bolts for looseness. Tighten loose bolts (if there are).
6. Check the truck body base rubber for cracks, embedded external materials or bolt looseness.
7. Check the handrail for damage and the bolts for looseness. Repair damaged parts and tighten the loos-
ened bolts (if there are).
8. Check the instrument for damage, lamps on the instrument for damage, bolts on the instrument for
looseness. If any abnormal condition is found, replace the parts, remove dust on the surface and tighten
the loose bolts.
9. Check the rearview mirrors and other mirrors for damage. Replace damaged mirrors (if there are). Re-
move dust from mirror surfaces and adjust angles so that you can see the rear area when sitting on the
driver's seat.
Operation 3-5
10.Check the seat belt and fixing suspension clasp.

• Check whether bolts used for installing the suspension clasp to the machine are loose. Tighten loose
bolts.
• Replace the seat belt if the belt has been used for a long time or external damage or visible wear, such
as suspension clasp breakage or deformation is identified.
11.Check the tire.
Tire side
Tire bead
Figure 3-3
If the tires used are worn or damaged, they can blow out and cause serious injury or death.
To ensure safety, do not use the following tires.
Wear:
• Tire thread groove is less than 7% of that of new tire (pattern bottom contains wear
indication)
• Tires with excessively uneven wear or stepped wear
• Damage
• Tires with streak flaws or cracks in rubber due to wear
• Tires with cutting or pulling marks
• Tires with peeling (separated) surface
• Tires with damaged tire beads
• Tires with exposed inner tube or being improperly repaired
• Deteriorated, deformed or abnormally damaged unusable tires
12.Check the rim.
3-6 Operation
Check wheel rim (wheel) for deformation, wear or cracks.

Pay special attention to each side of wheel rim, have a thorough check of locking collar, wheel
rim snap ring.
Inspection Before Startup
Check items in this section before you start the engine every day:
Check coolant level, and add coolant.
1. Check coolant in the expansion tank (1), the water level should be at the neck at the lowest part of the
fill port (3).
2. If the water level is below the liquid level window (4), remove the water tank cover (2), refill engine
coolant to the neck at the lowest part of the filler (3), and then tighten the water tank cover (2).
3. If more coolant is added than usual, check relevant parts for leakage.
4. If the coolant level in the expansion tank is above the neck at the lowest part of the fill port (3), you
need to remove the water tank cover (2) and check antifreeze in the expansion tank for any other liquid.
If there is no other liquid, drain the antifreeze to make its level at the neck at the lowest part of the fill
port (3); if there is other liquid, check other parts for leakage.
1 2 3 4 1 2 3 4
Auxiliary water tank integration Independent auxiliary water tank（optional）
Figure 3-4
Operation 3-7
When you check the coolant, you must check the expansion tank after the engine is cooled.
Once the engine is shut down, the coolant is in high temperature and the cooling system is with
high pressure. A burning risk is caused when you remove the expansion tank cover to check the
coolant. The expansion tank cover can be removed only after the engine is cooled and pressure is
released through slowly rotating the cover.
Check pressure difference indicator alarm indication
On instrument board, you may check whether air filter pressure-difference indicator alarm lamp turns on
or not. If it turns on, clean or replace air filter element.
Air filter blockage alarm lamp This lamp turns on when

the air filter is blocked.
Main filter
element Safety filter element
Safety filter element
Main filter
element
Standard configuration (desert filter) Optional（oil bath filtration）
Figure 3-5
Check the oil level in the engine sump and refill oil.
1. Check the oil level with the dipstick (1).
2
2. Take out the dipstick (1) and wipe it with
a cloth. 1
3. Insert the dipstick (1) into the filler pipe

(2) fully, and then take it out again.
Make the oil level gage indicator to face
the engine when dipstick is inserted. 3
4. The oil level should be between H and I Figure3-6

of the dipstick (1). If the oil level is be-
low L, fill oil to the engine through the
oil filler (3).
3-8 Operation
5. If the oil level is above H, remove the

drain plug (4) to drain excess engine oil
and then check the oil level again.
6. If the oil level is appropriate, insert the

oil dipstick and tighten it.
Figure3-7
Notes:
• When you check the oil level after the engine starts to work, at least 15 min is required from en-
gine stopping to inspection.
• If the machine stays with an angle, level the machine before inspection.
• It is forbidden to run the engine when the oil level is at the "L" (low oil level) position or above
the "H" (high oil level) position, because this operation may cause engine performance declining
or engine damage.
Figure 3-8
Check the transmission oil level and refill the oil.
Transmission oil level check is used to determine whether the started transmission has enough oil for safe
starting.
Oil level must be inspected on a regular basis. Park the crane on a level ground when checking the level of
transmission oil and refill oil. The hot oil's volume will expand. In order to get exact measurement, do not
Operation 3-9
check the oil level as soon as the vehicle stops. Check oil level when oil is still and cools down. Remove
observation-hole bolt (1) and look at the hole horizontally. If the oil surface can be seen, the oil amount is
enough. If not, please add oil.
Too much oil Too little oil Proper oil

1
Figure 3-9
3-10 Operation
Check the drive axle oil level and add oil if necessary
1. Park the vehicle on the flat ground and 1
ensure that the wheel rim oil port （1）

stays in a level condition.
2. Remove observation-hole bolt (2) and

look at the hole horizontally. If the oil
surface can be seen, the oil amount is
2
enough. If not, please add oil.
Figure3-10
Check the oil level of the hydraulic oil tank and refill the oil.
Check oil levels of the steering oil tank and lifting oil tank and refill oil if oil levels are below the upper
oil levels.
1
1
1.Transparene
liquid level gauge
Figure 3-11
Check the fuel tank level, refuel the tank, and drain water using the oil-water separator.
When the engine runs, refuel the fuel tank is prohibited.
1. Check the fuel indicator (1) on instrument board; if fuel is insufficient, add some.
2. Remove fuel tank cover (2) and add fuel into filling port (3); observe fuel indicator while adding fuel in
case of overflow.
3. Recap fuel tank (2) after filling up the tank.
4. Inspect oil water separator (4). If it contains water, open the water drain valve (5) on the bottom, so as
to discharge water or impurities. When clean fuel flows out, screw down water drain valve (5).
Operation 3-11
1 F H
7 bar 高压过滤器堵塞报警 10.5 v WIF
P
2
1 X 1000 rpm
F
3
M
0 65km/h
R
6.0 bar 1 D 2 4.5 bar
99999
. 6h t CDO 96536 km
E L
FUEL GAUGE COOLANT TEMP
F1 F2 F3 F4
Figure 3-12
2 3 4
Figure 3-13
3-12 Operation
Check indicator lamps, warning lamps, switches and instruments.
Before you start the engine, turn the key

switch to the ON position and check all
monitors for faults.
The instrument won’ t work if they

are in fault, please contact Xuzhou Xugong
Mining Machinery Co., Ltd. or its author-
ized dealer for troubleshooting.
Figure3-14
Check the braking effect.
Check the brake performance of service brake and transmission hydraulic retarder.
Please contact the dealer of Xuzhou Xugong Mining Machinery Co., Ltd. for the handling of any abnor-
mal condition.
Check the accumulator nitrogen pressure
Method of checking the nitrogen pressure:
Before starting the vehicle, connect

pressure testing equipment to inflation
valve port (1) of accumulator, take the
pressure reading and check if related re- 1
quirement is met (9MPa).
If any abnormal condition is found, Figure3-15

please contact Xuzhou Xugong Mining
Machinery Co., Ltd. or its authorized
agent.
Insufficient accumulator inflation pressure will lead
to steering difficulty, and serious accidents or injury
may be caused.
Check the hydraulic system for leakage and hoses for wear.
Operation 3-13
Check the hydraulic system and parts for leakage and hoses for wear or damage.
Check whether the reversing alarm works normally.
• Turn the key switch to the ON position.

• Put the shift handle into the R (reverse) position and confirm that the reversing alarm works.
Check electric wires
• Check whether the fuse for damage, capacity for error, and electric wire for disconnection or short cir-
cuit. Check terminals for looseness and tighten loose parts.
• Check battery wires, starting motor and generator carefully.
• Check whether there are inflammables around the battery and remove the inflammables.
• If any anomaly has been found, please contact Xuzhou Xugong Mining Machinery Co., Ltd. or its au-
thorized dealer.
If a fuse blows frequently or the wire has short circuit trace, Investigate the cause and repair it
immediately, or contact any authorized dealer of Xuzhou Xugong Mining Machinery Co., Ltd.
Keep the battery top surface clean and check the air vents on the battery cover. If air vents are
blocked by dirt or dust, wash the battery cover and clean the air vents.
Check and tighten the rim nuts.
• Check the rim nuts (1) for looseness and

tighten it (if there are loose nuts). Tight-
ening torque: 700 N•m - 800 N•m
(71.4kgf•m - 81.6kgf•m, 515.9lbft -
589.6lbft).
• After the tire is replaced, tighten the nuts
and tighten rim clamp nuts after the Figure3-16
truck drives for 5-6 km.
• Check the bolt and rim clamp for cracks.
Replace if there are.
Check the tire inflation pressure.
• Before you start the machine, tires are cold. Use a tire pressure gauge to measure the inflation pressure.
• Check the tire and rim for damage and wear.
• Check rim bolts for looseness.
3-14 Operation
The following table shows proper inflation pressure.
Tire Specifications Inflation Pressure

16.00R25 1.2MPa
Adjustment Before Operations
Driver's seat adjustment
The operator’s seat has a completely adjustable buffer drive system, which is comfortable and conven-
ient for operation.
Safety Prompt: be sure to only adjust the seat after the truck grinds to a halt; otherwise, dangers
will result.
Make an adjustment.
The following adjustments must be made in the operator's seat.
1. Horizontal adjustment: Pull the handle forward to move the seat back and forth to a proper position.
Release the handle to lock the position.
2. Seat height adjustment: after connected with power, press or pull suspension adjustment handle, and
you will adjust seat height and suspension hardness through air inflating or discharging mechanism.
3. Pull the handle to adjust the backrest to the required position.
4. Headrest adjustment: Press the handle, and adjust the headrest to a desired position.
5. Safety belt (on the left of seat)
The seat belt cannot be twisted when being fastened; ensure that the seat belt buckle is correctly inserted
into the buckle; the seat belt strap should be close to the body; you can unfasten the seat belt by pulling
the belt buckle from the release buckle.
3
2
1
Figure 3-17
Operation 3-15
1. Horizontal adjustment handle 2. Height adjustment valve 3. Seat cushion

4. Backrest angle adjustment handle 5. Safety belt 6. Headrest
Seat parameters
1. Horizontal adjustment function: seat front-rear adjustment amount 240mm (+135mm, -105mm); adjust-
ment grade: 15mm for each tap position
2. Weight adjustment: 50-130kg
3. Mechanical vibration reduction: adjusting range: 100mm
4. Height adjustment function: 100mm
5. Headrest adjustment function: adjustment stroke 60mm (20mm x 3)
6. Overall dimensions (L x H x W) 550 x 981 x 520mm
7. Seat cushion height (working state) 380, seat cushion width 520, seat cushion depth 460
8. Backrest: Height 600 Width 520 Angle adjusting range 60°
9. Connection dimension (left/right x front/rear) 260 x 330
Adjust steering wheel inclination angle
the steering wheel is able to be adjusted

forward, backward, upward and downward.
Rotate the lever counter-clockwise (1) to
adjust steering wheel forward and back-
ward; when steering wheel is properly
1 2
positioned, clockwise rotate the lever (1) to
secure the steering gear firmly; counter-
clockwise rotate the lever (2) to adjust the
steering wheel upward and downward,
when it’s positioned in place, secure
steering gear firmly by rotating the lever
(2) clockwise.
Figure3-18
Adjusting amount: Front/rear: 5° /5°
Up/down: +25mm
Adjust the view mirror
Before working, be sure to adjust mirror position and angle; if not correctly adjusted, the mirror will not
guarantee a good vision, and may get damaged or injure others. Keep mirror surface clean and clear.
3-16 Operation
REARIVEW
Adjust installation of left and right

rearview mirrors, so the situation in the left
rear of the machine can be seen.
Refer to right figure, turn the rearview

mirror and while doing so, take it as final
adjustment standard that the truck side
view shall enter the mirror.
Figure3-19
Ground view mirror
Install the ground view mirror so as to

observe vehicle left front zone and front
zone. As shown in the figure, you may ad-
just connecting rod and the angle of ground
Lower mirror
view mirror to obtain the best view.
Figure3-20
Operations Before Starting the Engine
Operation 3-17
2 3 4 10
18 5
8 7
20
17
19
9
16
12
11
13
15
14
19
Figure 3-21
Before starting the engine, make sure gear shift handle is engaged in neutral position; besides,
parking brake switch is at parking position.
Before standing up from the driver’ seat, you shall pull the gear shift handle at neutral position
and pull the parking brake switch at parking position
1. Make sure that parking brake handle (14) has been engaged at “parking position” .
Parking
P
Driving
Figure 3-22
2. Make sure gear shift handle (11) is at “neutral position” .
3-18 Operation
Figure 3-23
3. Make sure lifting handle (13) is at “maintain position” .
Driving direction
Maintain
Lifting
Lowering
Figure 3-24
Operation 3-19
4. Ensure that transmission retarder switch is at “close position” (this operation applies for the vehicle
that has a hydraulic retarder).
Figure 3-25
5. The key switch (8) is turned to the ON position and confirm that machine instrument has no abnormal
condition.
Figure 3-26
Start the engine
Preheating Operations
Do not start the operation immediately after the engine is started. First, carry out the following operations
and inspections:
1. Keep the engine idling for 3-5 minutes (as a preheating operation) after the engine is started.
2. After a preheating operation, check whether the machine monitor works normally.
If any abnormal condition is identified, carry out maintenance or repair.
Check the engine water temperature. If the water temperature is lower than 50°C, keep high idle speed
running for 5 minutes.
3. Check whether there is any abnormal condition in steering operations, lamp flickering, horn sound, ex-
haust color, and noise or vibration.
If any abnormal condition is identified, repair the machine.
When steering oil temperature is low, the steering operation will be a little difficult. Therefore, you need
to reduce steering operations when adjusting driving.
3-20 Operation
Do not accelerate the engine suddenly until preheating is complete.

Do not run the engine at low idle or high idle speed for more than 10 minutes.
If acceleration is required, gradually accelerate the engine to a medium speed.
Normal Startup
The driver should sit on the seat before the engine is started. Do not attempt to start the engine
short circuit. If so, serious injury or fire will be caused. Before you start the engine, you need to
confirm that there are no people or obstacles around the site, and then honk the horn for three
times. Exhaust gas is toxic. Special attention shall be paid to ensure good ventilation when you start
the engine. It is forbidden to start the engine in a closed space.
2 3 4 10
18 5
8 7
20
17
19
9
16
12
11
13
15
14
19
Figure 3-27
Note:
• Do not suddenly accelerate the engine before you complete a preheating operation.
• Single engine starting cannot lasts for more than 30s.
• If the engine fails to be started, you need to wait at least 2 minutes before the next starting.
Operation 3-21
1. Turn the key in the key switch to the

START position to start the engine.
2. After the engine is started, release the

key in the switch to allow the key return-
ing to the ON position.
Figure3-28
Starting the Engine in Winter
The driver should sit on the seat before starting the engine. Do not attempt to start the engine short
circuit. If so, serious injury or fire will be caused. Before you start the engine, you need to confirm
that there are no people or obstacles around the site, and then honk the horn for three times.
Auxiliary primer fluid is prohibited because it will cause explosion.
Exhaust gas is toxic. Special attention shall be paid to ensure good ventilation when you start the
engine. It is forbidden to start the engine in a closed space.
Note:
• Do not suddenly accelerate the engine before you complete a preheating operation.
• Single engine starting cannot lasts for more than 30s.
• If the engine fails to be started, you need to wait at least 2 minutes before the next starting.
1. You had better to park the machine in the workshop for storage if the engine does not run in winter.
2. Determine whether preheating is required according to the engine body.
3. If temperature of the engine body is below -4 °C, the engine body needs to be heated (by cold start sys-
tem and fuel heating).
4. Start the engine only after the engine body temperature is above - 4 °C.
5. Turn the key in the key switch to the START position to start the engine.
6. After the engine is started, release the key in the key switch. The key will automatically return to the
ON position.
3-22 Operation
Shutting Off the Engine
If the engine stops suddenly before being cooled, a risk of shortening the service life of engine parts
will be caused. Therefore, sudden engine stop is prohibited except in an emergency.
Keep the machine idling for 5 minutes before the engine stops, cooling the engine gradually.
1. Move the shift handle to the NEUTRAL position and then press the parking brake switch to apply park-
ing brake.
2. Lower the dump truck body and place the lifting handle in the hold position.
3. Run the engine with a low idle speed for about3 -5 minutes to slowly cool it down.
4. Turn the key in the key switch to the ACC position to stop the engine. Remove the key from the key
switch.
Inspections After Shutting Down the Engine
1. Patrol the machine, check whether the dump truck body, frame and pipeline are in good condition, and
whether there is oil or water leakage.
2. Refill the fuel.
3. Check for paper and debris near the engine, and remove the paper and debris to prevent fire hazard.
4. Remove dirt on the frame.
Double-cavity tank selection(optional)
Return valve Oil suction valve

operating handle operating handle
Auxiliary
oil tank Main oil tank
Figure 3-29
Operation 3-23
Starting phase
Change oil suction valve control handle and oil return valve control handle to auxiliary tank direction; at
this moment, low brand diesel in auxiliary tank will be used to ensure a successful engine start.
Normal running phase
When vehicle has been started for a period of time, 0# diesel in main tank has been heated up; at this time,
oil suction valve control handle and oil return valve control handle will change to main tank direction. Ve-
hicle enters into normal running state.
First change oil return valve control handle to main tank direction; be careful with this operation
for prevent of main tank fuel from entering auxiliary tank.
Pre-shutdown phase
Before stopping the vehicle: first, change oil suction valve control handle and oil return valve control han-
dle to auxiliary tank direction; and then, keep the vehicle running for several minutes before stopping it.
Change oil suction valve control handle to auxiliary tank direction, run the vehicle for 3-4 minutes;
and then change oil return valve to auxiliary tank direction; be careful with this operation for
prevent of main tank fuel from entering auxiliary tank.
3-24 Operation
3.6 Machine Operations

Moving the Machine Forward
Before you move the machine, make sure the site around the machine is safe and then honk the
horn before you start the engine.
No one is allowed to approach the machine.
Remove all obstructions from the machine runway.
Pay special attention to invisible places behind the machine when you move the machine
backward.
2 3 4 10
18 5
8 7
20
17
19
9
16
12
11
13
15
14
19
Figure 3-30
1. Confirm that there is no alarm signal displayed on the machine monitor.

2. Fasten the seat belt.
3. Make sure lifting handle (13) is at “maintain position” and PTO indicator lamp is off.indicator lamp
of the truck turns off.
4. Completely depress service brake pedal, and lift up parking brake handle (14) to release the brake.
Operation 3-25
Parking
P
Driving
Figure 3-31
5. Make sure parking brake has been released and pull gear shift handle (11) to a desired position.
6. Step on the accelerator pedal (9) to move the machine.
Be sure gear shift handle is secured firmly

The accelerator pedal shall be released together with clutch operations before the gear is switched
from gear I to another gear.
Moving the Machine Backward
Before moving forward and backward, ensure that the new driving direction is safe. There are
invisible places behind the machine, so you should pay special attention when moving the machine
backward.
Stop the machine completely before you shift between directions of forward and backward.
Place the shift handle (11) into the R (reverse) position, and gradually step on the accelerator pedal (9) to
reverse the machine.
When truck body is being lifted, the truck shall not move backward. Lower the truck body down
and pull gear shift handle to R position.
Completely halt the vehicle in the middle of operating vehicle forward or backward switches. Run
the engine with a low idle speed.
Do not step on the accelerator pedal after you move the shift handle.
Do not operate the shift handle when you step on the accelerator pedal. Otherwise, a big impact
will be caused and the service life of the machine will be reduced.
3-26 Operation
Stopping the Machine
Park the truck in spacious space and prevent sudden stop.

The brake will be overheated and shortened in its service life, if the service brake is used
repeatedly or kept stepped for a long time.
Machine stopping through parking brake may damage the brake.
Normal stop
2 3 4 10
18 5
8 7
20
17
19
9
16
12
11
13
15
14
19
Figure 3-32
Release the accelerator pedal (9) and step on the service brake pedal (16) to stop the machine.
Operation 3-27
Emergency Stop
If service brake is faulty, do as follows.
Immediately place a backstop under tires when you stop the machine.
At the moment of emergency stop, the parking brake disc is in high temperature. Therefore, before
you repair or maintain the machine, wait for that the machine is cooled. Consult with Xuzhou
Xugong Mining Machinery Co., Ltd. or any authorized dealer for repair and adjustment.
1. Open retarder control switch (19) and commence the retarding process.
Figure 3-33
2. If retarder fails to supply sufficient braking force, depress driving brake pedal (16) to stop the vehicle.
3. When you’re about to stop, press parking brake switch (14) to halt the vehicle.
Parking
P
Driving
Figure 3-34
3-28 Operation
4. If the machine is emergently stopped, immediately place the backstops under the tires, and then find out
the cause and repair the machine on site.
Figure 3-35
Gear Shifting
This vehicle carries a manual transmission, so the operator is required to depress the clutch pedal for gear
shifting. After cutting off the power connection between engine and transmission, follow gear signs to
shift gears one by one. Up-shifting operation doesn’t allow “Jump Gear” operation. Prohibit coasting
at neutral position.
As Fastre 8DS240A transmission doesn’t have a synchronizer, gears 1-7 as well as reverse-gear meshing
sets are located on the second shaft through involute spline sliding sleeve and power is transferred through
the engagement between meshing-set male spline and gear female spline. Gear 8 is firmly fixed on second
axle through involute spline tooth seat cover. Involute sliding sleeve is on tooth seat involute male spline,
and its power is transferred through the meshing of male spline, gear tooth seat and gear male spline. Spe-
cific to mining truck operation mode, the transmission has a quite large speed ratio range between both
ends. The speed ratio at the overgear is 0.75, so the speed ratio range between the direct gear and the over-
gear is large. The overgear is recommended in truck transportation and transmission. It is relatively diffi-
cult to select the overgear
According to the mining truck’s working condition, speed ratio ranges at both ends of the transmission
are large and the middle speed ratio range is even. The speed ratio at the overgear is 0.71, so the speed ra-
tio range between the direct gear and the overgear is large. The overgear is recommended in truck trans-
portation and transmission. It is relatively difficult to select the overgear.
• Anti-out-of-gear mechanism
Operation 3-29
To prevent spontaneous out-of-gear of the

transmission during operation, sliding Synchronizer
Pa
sleeves of all 8DS240A forward and re- sliding sleeve
verse gears are designed with mechanisms

of preventing spontaneous out-of-gear. The
principle of this mechanism is to produce
an axial force that prevents out-of-gear us-
ing a reverse bevel gear. At the end of the
Tapered
external spline tooth of the sliding sleeve, tooth ring
there are reverse tapered teeth. The gear in-
Figure3-36
ternal spline tooth, meshed with the exter-
nal spline tooth, is also correspondingly
inserted with an reverse tapered teeth.
When the torque is transmitted, an axial
force Pa is generated along the axial direc-
tion due to existence of the inverted taper
angle, preventing automatic separation of
the sliding sleeve from the tapered tooth
ring.
3-30 Operation
• Control mechanism
8DS240A transmission uses the telecontrol
7 5 3 1
form and is equipped with interlock and
Front
self-locking mechanisms. Gears on the cab Empty
control lever are as shown in the figure.

8 6 4 2 R
Figure3-37
Retardation operation(option)
If a transmission retarder has been installed, its control switch is located on the lower driving lever of
steering wheel at right side.
Retarder operation
When vehicle is about to walk along a slope, the operator should firstly apply the brake
and reduce the speed to a proper level. To start driving downhill, operator should release foot pedal and
close throttle, hold down the lower part of transmission retarder switch to activate transmission retarder
Apply service brake to reduce speed if it runs too fast. Downshift the pre-set gear to a lower level so as to
safely drive on downhill.
Main brake operation
If main brake has been long applied, brake

disc may become heated. Due to “heat
fading”, braking performance will largely
reduce. For this reason, the operator should
avoid long-term use of service brake in
case of accident.
2 1
Figure3-38
Operation 3-31
Machine Steering
The steering wheel’s position can be adjusted as required for operation convenience. During adjustment,
the adjusting lock should be pulled out to slope the steering wheel upwards and downwards. After the ad-
justment, the adjusting lock should be pushed back.
Hydraulic power of the steering system is provided by the continuously-running pump and accumulator,
which helps maintain a continuous hydraulic power source for steering cylinder operation.
To steer the machine while driving, turn the steering wheel to the steering direction. When the machine
drives around a curve, you should release the accelerator pedal to shift to a low gear before the machine
enters the curve, and then step on the accelerator pedal to drive around the curve. Driving around the curve
with a high speed is not allowed.
If the machine steers at a high speed or on a slope, there is a risk of tipping over. Therefore,
steering is not allowed in this condition.
Loading Operation
When large wheel loaders or excavators are used to load big stones, parts of the truck body will be dam-
aged if stones are loaded to the dump truck body directly. To prevent damage to the truck body, you can
load sand or soil before loading big stones to reduce the impact on the truck body.
Note:
1. After parking the vehicle on a working site, during loading process, gear lever shall be kept at
neutral position while parking lever shall be kept at “PARKING” position so as to ensure a stable
braking force. Before starting the vehicle, the operator should pull up the lever to release the ve-
hicle from “PARKING” position.
2. During loading, ensure that the ground where the truck is parked be firm and reliable to prevent
tires from falling into the ground.
3. Load materials into the truck evenly and be sure not to load too much materials.
Dump Operation
When the dump truck is loaded, dump operations should be performed according to the signal sent
by the signalman.
When large rocks are being tipped over, you should slowly operate the dump truck body.
Loading is not allowed when the dump truck is lifted.
Step 1: Engage the power take-off (PTO).
3-32 Operation
1. When truck comes to a halt, pull out

handbrake and apply the parking brake.
Place the transmission to the neural
position.
2. Turn the PTO switch to the position

shown in the figure（Figure 3– 39） ,
Figure 3–39step on the clutch and wait
for about 2 seconds.
Figure3-39 HOLD (PTO Off)
3. Turn the PTO switch to the position

shown in the figure（Figure 4–34），
Figure 3– 40when indicator lamp turns
on, slowly ease the clutch, and then PTO
engagement is completed.
Do not drive the vehicle when the PTO is engaged.
Operation 3-33
Step 2: Pneumatic control valve lifting
1. Pull pneumatic control valve operation

lever to lifting position （Figure 4–
35）， Figure 3– 41and cylinder tube
extends to lift cargo compartment.
Figure3-41 (Lifting )

lever to neutral position （Figure 4–
33） , Figure 3– 40and lifting process
stops, cargo compartment comes to a
halt.
Figure3-42 (Lowering)
Step 3: Pneumatic control valve lowering operation (including PTO removing)
1. Step on the clutch for 5s during the lowering operation.

2. Move the operating lever to the lowering position. Note: For this pneumatic control valve, lowering
movement is linked with PTO switch disengaging movement, which means, when you pull operation
lever to lowering position（Figure 4–36） ,Figure 3–42PTO switch also returns to “off” position
（Figure 4–36） ,Figure 3–42and cargo compartment begins lowering. Check whether the indicator
lamp turns off and slowly release the clutch. The lowering operation is completed.
3. About 1 minutes after the truck body is completely lowered, move the pneumatic control valve from the
lowering position to the neutral position. This ensures that cylinders at each stage are retracted back into
the base barrel.
3-34 Operation
Operation of removing the PTO*.
1. Pull pneumatic control valve operation lever to neutral position, and press clutch.
2. Pull PTO switch to “off” position （Figure 4–33）Figure 3–39so as to ease PTO. Check whether
the indicator lamp turns off and slowly release the clutch. The PTO disconnection is complete.
*As an independent action, this operation is unrelated with cylinder lifting.
In order to ensure the stability of lifting, the engine speed should be controlled within 1000rpm at the be-
ginning and end of lifting.
Cautions for operation:
• When driving in rainy or snowy days, or on muddy or unconsolidated ground, you should confirm the
machine loading conditions and pay special attention to prevent tires from slipping or rotating and fall-
ing into the ground.
• When the machine is running while the engine stops, stop the machine immediately. Then move the
shift handle to neutral and start the engine again.
• Even loading is required. It should be prevented to load too much materials in the front part of the truck
body.
• When driving on a slippery road, shift the transmission to a lower gear to prevent rear wheels from
being locked.
• When the machine drives through a water pit, water will splash into the front brake to greatly reduce
the braking force. Therefore, take great care when you drive the machine in such areas. If water splashes
into the brake, the brake can be engaged for several times during driving. Therefore, friction heat be-
tween the caliper and the brake disc can remove water stains.
Parking
Prevent the machine from stopping suddenly.

Park the machine on a solid, flat ground. Do not place the machine on a slope. If the machine must
be parked on a slope, stop the wheels to prevent the machine from moving.
If the shift handle is moved by mistake, the machine will move suddenly, resulting in serious
accidents. Before leaving the driver’s cab, the driver should press the parking brake switch to
apply the parking brake.
To prevent damage to the parking brake, you can use the parking brake function only when
parking the truck.
1. Release the accelerator pedal and step on the service brake pedal to stop the machine.
2. Move the shift handle to the NEUTRAL position and then pull the parking brake handle to apply park-
ing brake.
Operation 3-35
Inspection on the Machine after Daily Work
Check the engine water temperature, engine oil pressure and fuel level through the instrument. Don’t
abruptly stop the engine if it’s overheated; before stopping, run the engine at a moderate speed and grad-
ually cool down the engine.
Lock the cab doors after leaving the vehicle.
Tire Handling
Tire Pressure
Factory air pressure of XDR80T light-duty mining truck is 0.65 ~ 0.7 Mpa. The tire pressure should be
readjusted according to the specific situation in the mining area after the truck arrives at the mining area.
It is recommended that the air pressure be not more than 1.2MPa. Before being inflated, the tires should
be cooled first. Check the tire, steel ring, inflating valve, etc. The tires should be placed in safety cages
when being inflated, preventing injuries due to blowout of tire.
Cautions for tire inflation:
• Check whether there are foreign matters hanging in the tire tread and groove. If yes, remove them;
• Check the tread pattern depth. If the depth is less than 5mm, the tire must be replaced! When a tire is
measured, at least six points shall be measured along the tire circumference;
• Check the tire crown and sidewall for cutting, delaminating and chunking. If tire crown or sidewall de-
laminating is greater than 30 cm, tire shoulder chunking is greater than 200 cm,2,or the cut is deeper
than 200cm, the tire can be regarded as scrap tire and should be replaced in time.
Cautions for Tire Use
• Avoid sudden starting or braking during driving and slow down when the truck makes a turn;
• Avoid overloading or uneven loading, which will cause excessive wheel load on one side;
• Avoid driving on a road shouder when the truck drives in a loading zone or on a carrying road. Try to
prevent sharp rocks and bumps on the road from scratching and impacting damaged tires;
• The driver shall regularly check the tires and check whether the tires and rims are abnormally damaged;
• To prolong tires’ service life, tire rotation should be carried out according to the specified tire rotation
method every 4000-5000km.
Tire Transposition and Maintenance
Every 5000km of maintenance, tire rotation should be carried out according to regulations. Tire rotation
principles are as follows:
• The difference between outer diameters of both tires in the rear axle cannot be greater than 12 mm, and
the tire with a smaller outer diameter shall be installed inside;
3-36 Operation
• Front wheels should be equipped with balanced tires with less wear and in the same model (the tread
pattern is more than 20 mm);
• New tires must be used in pairs;
• On the same shaft, tires of the same size and tread pattern must be installed. Otherwise, braking devia-
tion, body swing and steering out of control will be caused;
• Check hub bolts and wheel nuts for scratches. To ensure safety, if threads of one bolt are damaged, re-
place the bolts in pairs, because the partner bolt may be damaged;
• Check the wheel rim’s contact surface and mounting hole, and replace the rim in time in case of defor-
mation or damage;
• Check the wheel rim and replace it if there is any crack.
Tire rotation sequence diagram:
1 2 5 4 7 10 9 8 6 3 2 1
3 4 5 6 3 10 7 1 4 8 9 5 10 6 3 7 8 1 2 9 6 5 4 3
7 8 9 10 9 8 3 8 3 1 2 6 2 5 4 1 4 7 10 5 10 9 8 7
Once Twice Three times Four times Five times
Figure 3-43
4 5 10 7 8 9 6 3 1 2
1 7 10 2 5 9 8 4 7 3 6 10 9 2 1 8 3 4 5 6
8 3 6 9 6 2 1 3 1 4 5 2 5 10 7 4 7 8 9 10
Six times Seven times Eight times Nine times Ten times
Figure 3-44
Tire Replacement
Cautions:
• Pay attention not to damage bolts on the wheel when you replace a wheel;
• The fitting surface of the drum brake and rim cannot be pasted with paint, grease and other dirt;
• The wheel nut’s pressing surface should be clean without dirt or oil stain;
Operation 3-37
• Before you install the wheels, you shall first clean the outer circles matching with the wheel locating
hole and wheel side reducer housing and apply a little grease to them;
• Threads of all wheel nuts should be right ones. Install the wheel, tighten the nuts by the angle crossing
sequence while the wheel is hung,
• lay down the wheel, and tighten the nuts using a moment of 700-800 Nm.
• Each time after the tire is reinstalled, the tire nuts must be tightened again after the truck drives for 5-
6km.
Clutch Operations
Step on the clutch pedal when the truck is started, and then engage the gear.
• Gear 1 must be used for full load starting!
• During shifting, you must pull the shift lever smoothly until it is fully engaged.
• The truck cannot be parked with a high gear.
• The reversing gear can be engaged only when the truck is stopped.
In the process of using the truck, check the oil level of the clutch oil tank in the front of the cab every day
to ensure that the oil level is between the MIN line and the MAX line. The clutch control system uses
DOT4 brake fluid. Brake fluid of the same specification and from the same manufacturer shall be used for
filling. Mixing of fluid is strictly prohibited. Before you operate the clutch, exhaust gas in the pipeline and
the clutch power cylinder.
Figure 3-45
Use of Brake
Diagram for common clutch trouble shooting:
The vehicle adopts a travel-parking integrated brake, 1 for left, right and front axle, and 4 for intermediate
and rear axle. Each brake is connected with a brake chamber. Air pressure, as the power source for service
3-38 Operation
brake, exert service brake on the push rod of brake air chamber. Triggering the spring to provide parking
brake, and air pressure is thus released.
Compared with drum brake, the disc brake has such features: less heat fading, faster response, larger brak-
ing torque and stronger adaptability. However, confined to a small heat capacity, if continuously applied
during a heavy-loaded long-distance downslope operation, it can easily get heated and cause brake friction
plate and brake disc to abnormally wear, the latter may even crack. For this reason, to give full play to disc
brake, engine exhaust brake or hydraulic retarder (if equipped) shall be the prioritized braking choice for a
heavy duty downslope operation.
When a parking brake fails to be released due to a brake chamber fault, to solve this problem, you may
counterclockwise loosen the nut on the rear of faulty brake chamber, retract the long screw rod by around
60mm, and then the problem is solved (if chamber port 12 is not blocked, you are suggested to firstly
block wheels, and then release handbrake to do it, because such a way is not only easier but also won’ t
damage screw thread). After replacement of a brake chamber, when air enters parking brake cavity (under
release of handbrake), you may screw the long screw rod into chamber rear, and when it clings to the end,
set a tightening torque of 40Nm.
Parking air intake 12 Driving air intake 11
Screw
Figure 3-46
Differential Lock Operation
The drive axle is equipped with an inter-axle differential lock. When wheels slide or fall in mud pits, the
differential lock can help improve the truck trafficability. Only when vehicle is at stopped state can the dif-
ferential lock be engaged; to engage it, be sure to firstly disengage the clutch and be sure that engine is at
idle or neutral state. When differential lock has been engaged, the vehicle must be operated to travel at a
speed equivalent to walking, and shall be limited to 5km/h.
Disengage differential lock： release throttle, depress clutch pedal and then press rocker witch to reposi-
tion it. The differential lock will disengage after the switch indicator lamp is off.
Operation 3-39
To use a differential lock, you need to first step on the clutch, and then press the differential lock
switch.
After getting out of trouble, you need to disengage the differential lock immediately. You need to
first step on the clutch first and then press the differential lock switch.
Determining and Maintaining the Driving Road
Driving road determination plays an important role in ensuring safety and reducing cycle time. To ensure
safe operations, do as follows.
Determining the Driving Road
• Make the driving road as a one-way road as far as possible.

• Keeping one-way traffic free is important. The road should be wide enough to ensure that the vehicle in
the opposite direction can pass through smoothly. If sufficient width cannot be ensured, a transition
point should be set along the road.
• Set up mirrors on bends with poor visibility.
• Set a signal board for warning at least 1.5m away from the road edge if the road edge is not solid and
may collapse.
• It is very important to set up vertical lamps or reflectors to ensure road trafficability at night.
• Keep the slope within 10% (about 6°) as much as possible. In case of a braking failure, the emergency
escape point shall be set on the downhill slope.
• Select a straight road as much as possible. Especially when the machine runs at high speed in the middle
of a bend, the bending radius should be as large as possible.
• Small S-shaped bends are particularly dangerous, so such bends should be avoided. The curve radius
should be at least 17-18m.
• The curve radius should be as large as possible.
• The width of the curved part should be greater than that of the straight part.
• The outside of the curve should be slightly higher than the inside.
• Pay special attention to the firmness of the curve outer edge.
• The road should not be passed through by other roads and a dedicated lane should be provided.
Maintaining the Driving Road
• To ensure road traffic safety, the following work must be carried out according to road conditions.
• Remove road conditions such as uneven road surface, left/right inclination, and road edge falling. Estab-
lish solid passages to remove obstacles, such as stones, branches, etc.
• Maintain the roads using bulldozers or graders frequently.
3-40 Operation
• Spray the road frequently to prevent dust from raising and reducing the visibility.
Transport
Cautions During Transportation
The machine should be disassembled for transport. Please contact Xugong Mining Machinery Co., Ltd. Or
an authorized agent of Xugong Mining Machinery Co., Ltd. when transporting the machine.
Transportation Procedures
According to the basic rules, the machine should be transported on a trailer.

Determine the trailer specifications based on weight and dimensions provided in “Specifications”.
Method of Fixing the Machine
After the machine is loaded at the designated position, fix it according to the following steps.
1. Pull down the parking brake handle to apply the parking brake.
2. To prevent the machine from moving while being transported, insert backstops into each tire and fix the
machine reliably in place with the chain or wire rope.
Note: The machine must be firmly secured to ensure that it does not slide to one side.
Method of Lifting the Machine
The machine should be lifted according to the following procedures at a port or in other places:
The operator who conducts hoisting operation with a crane shall be well-trained for qualification.
Ensure that No one is within the vehicle before lift.
Ensure that the steel rope has sufficient lifting capacity and strength.
Keep the vehicle horizontal during hoisting.
When about to conduct hoisting operation, press parking brake switch to stop the vehicle.
Personnel is prohibited to enter into machine-hoisting area during the operation.
Only the machine with a hoisting mark can conduct lifting operation.
Before lifting, please consult with Xugong Mining Machinery Co. Ltd. or any authorized agent by Xugong
Mining Machinery Co. Ltd. for repair and adjustment.
When lifting, stop the machine on a solid flat ground and obey the following steps:
1. Start the engine and place the lifting handle in the holding position.
2. Stop the engine, apply the parking brake, and confirm that the site around the machine is safe.
3. Select the wire rope, label, stay bar and other equipment that match with the machine weight, and install
the wire rope to the lifting position.
Operation 3-41
4. Install a protective stopper at the contact point between the lifting equipment and the vehicle body to
prevent damage to the main equipment.
5. Stop lifting when the machine is off the ground (lifting for 10-20cm), carefully check the machine for
and check whether the wire rope is loose, and then slowly continue the lifting operation.
Operations in Winter
Cautions for Low Temperature
If the temperature is too low, the engine will be difficult to start and the coolant will be frozen. Therefore,
do as follows.
Fuel Oil and Lubricating Oil
Fuel and oil recommended by XCMG should be used for all parts.
Coolant
Antifreeze is poisonous. Be careful not to splash it into your eyes or touch your skin. If it has been
splashed into your eyes or on your skin, flush your eyes or skin with plenty of water and see a
doctor immediately.
Please contact the sewage treatment department for changing the antifreeze or dealing with
coolant containing antifreeze discharged from the radiator. Antifreeze is toxic. Do not allow it to
flow into the sewer or spill it on the ground.
Antifreeze is flammable, so do not bring it near open fire. Do not smoke when handling antifreeze.
Note:
• Try to use the brand antifreeze recommended by Xugong Mining Machinery Co., Ltd. or use antifreeze
of the same specification.
• Methanol, ethanol or propanol based antifreeze is prohibited.
• Leak preventive is absolutely prevented. It cannot be used alone nor mixed with antifreeze.
• Do not mix antifreezing solution of one brand with that of another brand.
See details for changing the coolant and mixing the antifreeze in "cleaning the inside of the cooling
system".
3-42 Operation
Battery
Batteries can produce flammable gases, so open flames or sparks cannot be brought near the
batteries.
The battery acid is very corrosive. If it splashes into your eyes or on your skin, flush your eyes or
your skin with plenty of clean water immediately and see a doctor.
The battery acid can dissolve the paint. If it splashes on a vehicle body, flush the vehicle with water
immediately.
If the battery acid is frozen, do not charge the battery or start the engine with a different power
supply. There is a risk of explosion.
The battery acid is toxic. Do not allow it to flow into the sewer or spill it on the ground.
Battery capacity declines as ambient temperature drops. Battery electrolyte may have freezed if battery
charge rate is found decline. Try to make the charging rate to approach 100% and keep the battery isolated
from the low temperature, so the machine can be started easily the next morning.
Measure the specific gravity of battery acid and calculate the charging rate based on the following table:
Charging Rate Battery Acid Temperature (°C)

% 20℃ 0℃ -10℃ -20℃
100 1.28 1.29 1.30 1.31
90 1.26 1.27 1.28 1.29
80 1.24 1.25 1.26 1.27
75 1.23 1.24 1.25 1.26
Do not leave the battery in a low-temperature environment for a long time to prevent machine starting
difficulty.
As the battery capacity will decrease in low temperature, cover the battery, or remove the battery from the
machine, store it in a warm place, and install the battery when the machine is used again.
Cautions after Completion
To prevent mud, water, etc. from freezing and prevent the machine from starting difficulty the next morn-
ing, the following regulations should be obeyed at all times:
• Mud and water on the truck body must be completely removed. This prevents damage to the seal due to
mud or dirt entering the sealing surface together with frozen water drops.
• The machine should be parked on a solid and dry ground.
• Park the machine on a wood board if possible.
• A wood board can help to prevent the crawler from being frozen into the soil, so the machine can be
driven away the next morning.
Operation 3-43
• Turn on the drain valve to drain water accumulated in the oil-water separator to prevent the part from
being frozen.
• In a low-temperature environment, the battery capacity drops obviously, so cover the battery or remove
it from the machine, keep it in a warm place, and install it again the next morning.
After Winter
When the weather warms up, you should operate the machine using the following methods:
• Fuel and oil recommended by XCMG should be used for all parts according to the weather conditions.
Safe Operation Procedures Against Fire
Fire Caused by Fuel Oil Or Engine Oil
Fuel oil, engine oil, antifreeze and glass cement are all special inflammables. In order to avoid fire, the fol-
lowing regulations shall be observed:
• Engine oil or fuel oil shall be kept in a

designated place and people are not al-
lowed to be close to them without
permission.
• Do not smoke or use any open fire near
the fuel oil or engine oil.
• Check whether the pipe fixation clamp is Figure3-47
lost or loosened, whether the hose is
twisted, whether the hose and pipeline
have mutual friction, whether the oil
cooler is damaged, whether the flange
bolt for the oil cooler is loosened to pre-
vent oil leakage. Tighten, repair or re-
place any lost, loosened or damaged
fixing clamp, pipeline, hose, oil cooler
and its flange bolt.
3-44 Operation
• Store or fill oil in places with good

ventilation.
• Turn off the engine before refueling.
• The operator shall stay around the ve-
hicle during oiling or re-filling fuel tank.
• Prevent the fuel oil from overflowing to Figure3-48
the overheat surface or the parts of the
electric system.
DANGER
• Wipe away the overflowed fuel or en-
gine oil after oiling or re-filling fuel.
• Put the duster cloth sticking with oil or GAS
other flammable materials into the safe
vessel to ensure safety in the work place.
• Tighten the fuel oil and machine oil tank Figure3-49
caps firmly.
• Use inflammable engine oil to flush
parts with the engine oil, . Diesel and
gasoline are not recommended for their
inflammability.
• Transfer all the flammable materials to
the safe places before grinding or
welding.
• Do not weld or use the cutting torch to
cut the pipe with flammable liquid.
Fire Caused by Accumulation of Flammable Materials
• Remove dry blades, wood chips, paper scraps, dust and other accumulated flammable materials accu-
mulated or stuck in the engine, exhaust pipe, muffler, battery, hoods or frame at any time to prevent
fire.
Fire Caused by Electrical Wires
• Short circuit of the electric system may cause fire.

• Keep wire joints clean and tight.
• Check cables and wires for looseness and damage every day and check terminal covers for missing or
damage.
Operation 3-45
• If the cable or wire is loosened or damaged, tighten the loosened joint or wire clamp, and repair or re-
place the damaged wire.
Fire Caused by Hydraulic Pipeline
• Check whether all hoses, clamps, fenders and gaskets are fixed in place.
• If they are loosened, they will vibrate during operation and rub with other parts, resulting in hose dam-
age, high-pressure oil splashing, fire hazard or personal injury.
Fire Caused by Lighting Equipment
• Use lighting equipment with function of explosion-proof when check fuel, engine oil, battery acid , and
coolant. If these devices are not used, explosion hazards and serious injury may be caused.
• Comply with relevant rules in this manual when you use the electric source for lighting.
Actions in Case of Fire
If there is a fire, leave the machine soon according to the following requirements:
• Turn the key switch to OFF and shut down the engine.
• Use handrails and ladders to leave the machine.
3-46 Operation
Chapter 4 Maintenance and Warranty of Main Assemblies
Only those trained and qualified can repair and maintain this machine.
Read carefully the related content in this book before any maintenance.
If a diesel engine is running indoors, ensure the space is well-ventilated.
For the details of diesel engine, see OPERATING MANUAL OF DIESEL ENGINE, which is
included in the documents along with the mining truck.
• While carrying out maintenance or repair for this machine, the related record should be made
and saved.
• For the mining truck, it is important to maintain and ensure its normal function.
• The machine should be kept clean so that any failure such as leakage, looseness of screw or con-
nection will be spotted.
• Be sure to protect the environment! Don’t pollute the environment with oil liquids and other
harmful pollutants.
• The content of this chapter includes items related to regular check, maintenance and repair. The
operator of mining truck should carry out these items according to the regulation.
Special lubricants should be used if the excavator works in extremely hot or cold weather, please
contact XCMG authorized dealers.
If the requirement about special lubricants can’t be satisfied, please contact XCMG authorized
dealers.
Maintenance and Warranty of Main Assemblies 4-1

4.2 Suspension system

Materials and maintenance interval
Maintenance
interval
Nor-
First Applied
Part mal Target
No. Description Unit Qty main- environ-
Number main- part
ten- ment
ten-
ance
ance
（h）
（h）
Front
Autran 4 10_bluk
1 822538783 L 6000 suspen
hydraulic oil
sion
Intermedi
CAT hydraulic oil
ate and
addictive (1U-
2 822538163 KG 0.5 20000 Rear
9891One kilogram
suspen
pack)
sion
Maintenance instructions
1. To ensure that the hydro-pneumatic spring can be normally used both in summer and winter, nitrogen
adjustment and supplement is allowed during season changes.
2. The seal should be reliable and oil leakage is prohibited during the service life.
3. It adapts to various environmental conditions. The hydro-pneumatic spring should not be stuck due to
corrosion, silt and other reasons during the service life.
Air Check for Hydro-pneumatic Suspension
1. The lightly-loaded truck is parked on a flat road.

2. Remove dirt outside the oil gas hydro-pneumatic spring inflation valve, and remove the protective cover
of the inflation valve.
3. Before check, the tool ejector pin should be completely pushed out. After the inflation valve is con-
nected, slowly push in the ejector pin using handle 2 of the air check connector at the tool end. When
pressure gauge 3 indicates a value, continue to rotate handle 2 for half a turn. After the pressure value is
recorded, anticlockwise rotate handle 2 for half a turn, push out the inflation valve element, remove the
air check tool, and the air check process is ended.
4-2 Maintenance and Warranty of Main Assemblies

3
2
Figure 4-1 Air check tool
1. Rotary joint 2. Air checking joint handle

3. Pressure gauge 4. Deflating handle
Air Inflation for Hydro-pneumatic Suspension
1. The lightly-loaded truck is parked on a flat road.

2. Remove dirt outside the oil gas hydro-pneumatic spring inflation valve, and remove the protective cap
of the inflation valve.
3. Connect nut 4 at one end of the air inflation tool equipped with the pressure gauge to the nitrogen cylin-
der, and rotating joint 1 at the other end to the hydro-pneumatic spring inflation valve to be inflated.
4. Before inflation, the tool ejector pin should be completely pushed out. After the inflation valve is con-
nected, slowly push in the ejector pin using handle 2 of the inflation connector at the tool end. When
pressure gauge 3 indicates a value, continue to rotate handle 2 for half a turn. Open the nitrogen cylinder
valve element for inflation until nitrogen pressure is slightly higher than the specified value - 0.5MPa,
and then close the nitrogen cylinder and keep it for 10s until the pressure becomes stable. Rotate defla-
tion handle 5 on the pressure gage base until rated pressure is reached after deflation, and then anti-
clockwise rotate air inflation connector handle 2 to push out the inflation valve element. Then, remove
the air inflation tool and the air inflation tool is ended.

3
2
1 4
Figure 4-2 Air inflation tool
1. Rotary joint 2. Inflatable joint handle 3. Pressure gauge
4. Nut 5. Deflating handle

Oil Filling for Hydro-pneumatic Suspension
1. Before oiling, inspect and make sure all

oil fluids have been carefully filtered
and are up to standards Autran 4 10_bluk
hydraulic oil is applied to of hydro-pneu- P
P
matic suspension of this vehicle. Oil that
does not meet the requirements is pro-
hibited. Otherwise, suspension perform-
ance and service life will be affected.
2. Park the no-load vehicle on flat ground

firstly; before oiling front suspension, be Figure4-3
sure to open inflation valve P1 to ex-
haust air of the spring; when piston rod
falls to the lowest, close the inflation
valve, and then open inflation valve P1
and vent hole P2 simultaneously, fill oil
through P1; 15 minutes later, fill oil till
it overflows, and then recap P1 and P2;
3. In order to refill rear suspension, reser-

voir must be firstly inflated, balanced
suspension pipeline be secondly in-
stalled; single side middle-rear wheels
175cm
must be lifted off ground by a machine,
piston rod dimensions shown in the fig-
ure must be 175 ±3mm, or the summed
dimension of middle rear piston rods Figure4-4
must be 350 ±6mm. After all the condi-

tions are met, you may open oil inflation
valve of middle rear suspension cylinder,
add hydraulic oil through a higher filler
port till the lower port overflows; install
oiling valve and continue with oil filling
till the higher port overflows; wait 15
minutes and add some oil till it over-
flows, and then install the oiling valve.
4. Refill the cylinder through manual pump

or oiling machine.

Hydro-pneumatic Suspension Storage and Transportation
1. During transportation, the hydro-pneumatic spring cannot fall or collide with other objects.
2. During transportation, any hydro-pneumatic spring part cannot contact with corrosive substances such
as acid and alkali.
3. The warehouse with products stored should be clean and dry with good natural ventilation, and stable
temperature and humidity. It is not allowed to place products outside the warehouse.
4. If products are stored in the manufacturer for more than 3 months, 5% of each batch should be checked
for corrosion before product delivery. If no corrosion is identified, these products can be stored continu-
ously. If corrosion is identified, this batch of products should be repaired.
5. After long-term storage, check the appearance of hydro-pneumatic spring, and remove dust and rust on
its surface. Check nitrogen pressure in the hydro-pneumatic spring, and replenish nitrogen if necessary.

Common faults and solutions
Fault Cause Remedy

Inflate and fill the hydro-
1) The truck jumps violently. Too much air or oil pneumatic suspension as
required.
Find out the cause, replace parts,
2) The truck leans when being
Oil or air leakage refill and inflate the hydro-
empty.
pneumatic suspension.
3) Regular air inflation is The inflation valve is loosened Tighten, repair or replace the
required. or has leakage. inflation valve.
4) Oil leakage occurs between
Replace with a new oil seal,
the cylinder sleeve and the The oil seal is damaged or the
repair the barrel, and supplement
barrel or oil filling is regularly barrel surface is strained.
oil.
required.
Check whether the pre-inflation
pressure change of the spring
exceeds ±0.3MPa using the air
checking tool. If there is air
1. The pre- inflation pressure of
shortage and pressure shortage is
5) The hydro-pneumatic the hydro-pneumatic spring
less than or equal to 0.5MPa,
spring’s vibration attenuation decreases.
supplement air pressure to the
deteriorates. 2. A large amount of oil is in the
rated value. Unscrew the oil
ring cavity of outer cylinder.
filling port of the ring cavity,
check whether there is a large
amount of oil leakage, and drain
the oil if necessary.
Maintenance
Periodic maintenance involves the following procedures:

1. Check whether the cleaning device is worn, damaged, or has oil or air leakage. Special attention should
be paid to the exposed part of the piston rob and the air inflation valve. Repair or replace parts as
required.
2. Check whether all components are damaged or loosened. Repair or replace relevant parts if looseness,
defectiveness, or fracture is identified.
3. Check whether oil leakage is identified outside the suspension. If yes, repair or replace relevant parts as
required, and refill oil. The following phenomena indicate that the suspension needs to be maintained
inside.

1) Oil leakage is identified around the suspension.
2) Air column height changes frequently and nitrogen refilling is required.
Other notes:
1. When you’ re not sure whether pres-

sure is in a suspension, you must not re-
move suspension-cylinder pipe and
hose; when the system is under pressure,
do not remove hydraulic parts;
2. It’ s forbidden to use a hammer to open

or close air cylinder valve and inflation
tool;
3. Do not disassemble the suspension cylin-

der; If replacement is necessary, the air
pressure in the parts to be replaced must Figure4-5
be reduced to atmospheric pressure with
an inflatable tool.
4. When removing and installing inflation

valve, pay attention not to damage O
ring (refer to the right figure).

4.3 Engine
4.3.1 Materials and maintenance interval
Donaldson desert filter maintenance schedule

Filter element maintenance (Donaldson desert filter)
Maintenance
interval
Fir- Nor-
Tar-
Part st mal
NO. Description Unit Qty Target part get
Number mai- main-
part
nte- ten-
nan- ance
ce （h）
K6000-1012240B Engine oil
1 800162638 EA 2 500
oil filter filter element
K6200-1105140 Fuel filter
2 800162637 filter element EA 1 500 element (fine
component filter)
K6200- Fuel filter En-
3 800162635 1105350KS1 filter EA 1 500 element gine
element component (coarse filter)
Oil water
K6505-1105350
separator
4 800160016 diesel oil prefilter EA 1 500
filter element
part
(long)
P781098 main air
5 800105256 EA 1 500 Air filter En-
filter element
gine
P781102 air
air
6 800105257 security filter EA 1 1000 Air filter
filter
element
Note:
1. First maintenance must be executed;
2. 500h is equivalent to 7,000 km; 1,000h is equivalent to 12,000 km; 1,500h is equivalent to 17,000
km; 2,000h is equivalent to 22,000 km.

Oil liquid maintenance schedule
Filter element maintenance (oil bath filter)

Maintenance
interval
Fir- Nor-
Tar-
Part st mal
No. Description Unit Qty Target part get
Number mai- main-
part
nte- ten-
nan- ance
ce （h）
K6000-1012240B Engine oil
1 800162638 EA 2 500
oil filter filter element
K6200-1105140 Fuel filter
2 800162637 filter element EA 1 500 element (fine
component filter)
K6200- Fuel filter En-
3 800162635 1105350KS1 filter EA 1 500 element gine
element component (coarse filter)
Oil water
K6505-1105350
separator
4 800160016 diesel oil prefilter EA 1 500
filter element
part
(long)
3560 Safety filter
Oil bath filter
5 800165081 element (oil bath EA 1 500 En-
(option)
filter is for option) gine
3560-1 Main filter air
Oil bath filter
6 800165080 element (oil bath EA 1 500 filter
(option)
filter is for option)
Note:

Oil liquid maintenance details:

Mainte-
nance
interval
Fi-
rst Nor-
Part Target Applied en-
No. Description Unit Qty m- mal
Number part vironment
ai- main-
nt- ten-
en- ance
an- （h）
ce
CH-4 15W/40
Above -10
822502276 Engine oil (Shell L
°C
209L)
1 32 500 Engine
CH-4 10W/30
822502277 Engine oil (Shell L -25℃~30℃
209L)
Delo ELC-55/45
Delo long-acting
2 822933579 heavy-duty L 76 20000 Radiator
antifreeze/coolant
(-45°C Caltex IBC)
Note:

4.3.2 Maintenance instructionsOperation description
Replace engine oil and oil filter element
1. Extract oil plug (2) from oil pan and drain oil (when engine is hot). Check whether the engine oil color
is normal and whether there are foreign matters during oil discharging, so as to find out hidden troubles.
2. After draining out used oil, recap oil plug. Use a special spanner to replace filter element (1); refill en-
gine till oil level reaches the upper limit of oil dipstick.
3. To prevent engine starting without lubricating oil, you should use the exhaust brake or rotate the start
button when the high-pressure oil pump is in the fuel cut-off position. Keep the engine idling for a
while, restart the engine again and keep it work at a low speed. Check the engine oil filter for no-leak-
age. Stop the truck for 5 minutes. Check and fill the oil to upper limit of the dipstick.
H
OK
1 2 Oil dipstick
Figure 4-6
Replace fuel filter and oil water separator element
1. Regularly inspect the lower liquid level

of oil water separator (4); if oil is in a
high level, you may loosen the lower
liquid drain valve till fuel flows out;
after that, tighten up liquid drain valve.
2. Place a container under fuel fine filter

(3) diesel coarse filter (5) and oil water
separator (4), use a special spanner to re-
move the outer casing and then take 3
down the element. Figure4-7
3. Install a new filter element and then rein-

stall the casing.

4. During the installation, the tightening

should ensure that the sealing surface
must touch the one of seat, and then
manually tighten 1/2 - 3/4 turns. Observe
the specified tightening angle. Overtight-
ening may damage the seal and cause
fuel leak; under-tightening may cause oil 4 5
to leak from clearance. Figure4-8
Air Filter Maintenance
1. Inspect intake air resistance. Only when intake air resistance reaches the maximum, or when air filter
meets the regular maintenance schedule, is it necessary to replace filter element.
2. Shut engine, remove main filter element (2), clean dust valve (5), and then open air filter end cover (4).
The main filter element on axial seal is tightly installed on outlet pipe, so it might be a little bit difficult
to take it down. Replace the dust valve (5) when it has a crack, gets damaged or lost; if it is intact, it on-
ly needs cleaning.
3. Visually inspect the safety filter element (3). Be sure not to take it down for inspection, unless it has
been damaged and you’ ve prepared a spare part to replace it. Normally, it is time to replace the safety
filter element (3) after three main filter elements have been replaced; a clean wet cloth should be used
to clean the interior of outlet pipe before replacement and sealing surface inspected for damage. Try to
avoid exposing engine outlet – air filter outlet; if a proper safety filter element is unavailable for re-
placement, please cover that outlet.
4. Inspect whether conspicuous dust has been left on the clean side of the old filter element; eliminate any
hidden fault before installing a new filter element.
5. Inspect whether new filter element is intact and pay special attention to sealing face and the clean side
in case of installing a damaged element. Do not wipe the sealing face, because a layer of lubricating
agent has been applied on Donaldson filter element before ex-factory in order to guarantee customers
easier installation.
6. If a new filter element (3) has been installed lately, you may inspect if it has been mounted correctly be-
fore installing main filter element (2); after that, push the edge of filter element with hand and carefully
install the main filter element (2). Ensure that the main filter element has been completely installed into
the casing (1). Don’ t utilize the pressure of end cover (4) to push the main filter (2), otherwise, casing
(1) and buckle will be damaged and you will lose warranty; if you fail to install end cover (1) in place
due to filter element, you can take down the end cover, and continue to pushing into main filter element
(2) and install it in place.
7. If a rain cap or pre-filter is equipped, please also inspect both of them; if damaged, the service life of
compressed air filter may be shortened.

8. Inspect whether alarm indicator lamp (6) has been repositioned; inspect all fasteners, including hoop,
clip, nut and the connection; inspect pipeline for defects and repair it if needed; any kind of leakage will
result in dust directly entering engine.
9. Remove lower-end dust collection plate, take out filter element, and lightly knock at the end face of tire
so as to shake off dust. Blow the filter element from inside to outside along the cross direction of the ob-
lique angle using dry compressed air with pressure of no more than 0.49 MPa. A hair brush can also be
used to slightly brush the polluted surface to remove the dust and dirt on the filter element.
5 4 3 2 1
Figure 4-9
Maintain oil-bath type air filter (for option)
1. No oil has been injected to a new vehicle before delivery;

2. Add engine oil before putting the truck into operation, oil type must be in line with engine, or viscosity
must be of a similar level;
3. Make sure the adding amount of oil won’t exceed the specified level (a mark exists on the outside of
oil pan), and not exceed oil baffle plate. Oil amount: 3L;
Figure 4-10
4. Daily inspect whether the steel clip in connection of the casing and oil pan is loose;

Figure 4-11
5. Shake oil pan, if oil barely flows, it suggests that it is time to clean coarse filter element assembly and
replace oil;
In normal working conditions, it can serve for 80-120 hours.
In extremely harsh conditions, see to it to daily inspect, clean and replace oil.
Oil change
Clean the
filter screen
Figure 4-12

4.3.3 Common faults and solutions
Engine Basic Parameters
Model YC6K480-GT30
Supplier Yuchai Engine
Type Six-cylinder, four-stroke, supercharging intercooling,
Cylinder diameter x
129Mm×155 mm
stroke
Total displacement 12.155L
Compression ratio 16.5:1
Rated power/RPM 353kW/1900 rpm
Max. torque/RPM 2200N·m/1100-1500 rpm
The engine fails to start
Fault Cause Troubleshooting

Check the starting system. The starting speed should not be
The starter speed is too low.
lower than 110 r/min.
Check the oil supply pipe joint for looseness. Unscrew the
The oil supply system has air. bleeder screw on the fuel filter assembly and send fuel through
the manual pump until there is no bubble.
The fuel line is blocked. Check whether the oil supply line is unobstructed.
The fuel filter is blocked. Replace the spin-on element of the fuel filter assembly.
The fuel delivery pump does not or Check the oil inlet pipe for leakage and
fitfully supply oil. check the fuel delivery pump for trouble.
There is less fuel injected or no fuel
1. Check the fuel injector atomization.
injected. Or, the injection pressure is
2. Check whether the controller is energized.
low.
Starting system failure
The electric wire is incorrectly or
Check whether the connection is correct and reliable.
poorly connected.
The battery is in low power. Charge the battery.
The starter carbon brush is in poor Repair or replace the electric brush, clean the commutator
contact with the commutator. surface with wood flask paper, and blow it clean.
The compression pressure is
Replace the piston ring and the cylinder liner (as appropriate).
insufficient.

Check the valve clearance, valve spring, valve guide pipe and
The piston ring is excessively worn
valve seat for sealing. If the sealing is not in good condition,
and the valve leaks.
grind the valve seat.
The connector of fuel cut-off
solenoid valve is loose or dirty, or Tighten, clean or replace the connector.
corroded.
Incorrect assembly timing Check/adjust the timing.
Insufficient Engine Power

Check the air filter and intake pipe. Clean or replace the air
Air inlet blocked
filter element.
Check valve timing and adjust it if necessary; clean the exhaust
High exhaust back pressure
pipe.
Pressure of the pressurization system
Check and eliminate leakage at the pipeline and joint.
is insufficient.
Abnormal supercharger operation:
The flow pathway is polluted,blocked Clean or replace the compressor casing and turbine casing.
or damaged
Bearing failure; Replace the pipes.
The turbine and gas compressor has
carbon deposition and fatlute on the Clean the turbine and gas compressor.
back.
The intercooler is damaged or has air
Repair or replace the intercooler.
leakage.
Check the oil pipe and joint for sealing and check the fuel filter
The fuel pipeline is blocked or has oil
for blockage.
leakage.
Replace the spin-on filter.
The sensor is damaged. Check and replace the valve guide pipe.
The booster compensation pipe is
Replace the pipes.
damaged.
Incorrect valve timing Check and adjust valve timing and valve clearance.
Tighten cylinder cover bolts or replace the cylinder gasket
Air leakage of cylinder gasket
according to the specified procedure.
The valve is not well sealed. Grind, or replace and regrind the valve.


The engine is overheated or the Check and repair the radiator and temperature controller .
coolant temperature is too high. Check the tension of fan belt.
Serious piston ring wear or breakage Replace the piston.
Abnormal Noise When the Engine Works

Check whether the assembly timing is correct.
① Abnormal sound in the cylinder
Check and adjust valve timing.
② An impact sound can be heard at the crankcase Dismantle and check the bearing shell, replace it
due to serious wear of connecting rod bearing shell if necessary, and maintain specified reasonable
and main bearing shell. clearance.
Check connecting bolts and damage to them, and
③ The absorber is damaged and does not work.
replace them if necessary.
④ The transmission gear is worn with excessive

Check clearance in circular tooth and replace the
gap. An impact sound can be heard at the housing
gear according to the wear condition.
for timing gear.
Replace the piston, repair the cylinder sleeve
⑤ An impact sound can be heard at the cylinder
according to the wear condition, and pay attention
wall due to excessive clearance between the piston
to maintain clearance between the cylinders.
⑥ The supercharger bearing is damaged, and

Replace the supercharger assembly.
rotating parts collide with the housing.
⑦ A large sound occurs on the cylinder cover due

Adjust the valve clearance.
to excessive clearance.
Remove carbon deposition and dirt from the
⑧ Supercharger surge compressor passage and exhaust passage. The
operation altitude is too high.
Black Exhaust Gas
Air inlet blocked Check the air filter and air inlet pipe and clean them.
Poor quality fuel Replace it with specified fuel.
Poor fuel injector atomization Inspect, repair or replace the fuel injector.
Pressure of the pressurization
Check and eliminate leakage at the pipeline and joint.
system is insufficient.


The supercharger works
Check and replace the supercharger.
abnormally.
The intercooler is damaged or
Repair or replace the intercooler.
has air leakage.
White/Blue Exhaust Gas
① Poor quality fuel with too much

Replace the fuel.
moisture.
② Excessively low Check the thermolator working temperature and replace the
coolant temperature thermolator if necessary.
③ Incorrect gas distribution or oil

Perform check and adjustment by special personnel.
supply timing.
④ Low compression pressure and

Check or replace the piston ring and cylinder gasket.
incomplete combustion
⑤ The piston ring is installed in an

incorrect direction, so the opening is Perform check and reassembly.
not staggered.
⑥ Long-term low load operation. Appropriate working speed and load should be used.
⑦ Supercharger seal ring wear. Check and replace the bearing shell.
⑧ Supercharger thrust bearing wear Check and replace the bearing shell.
⑨ The supercharger oil return pipe is

Clean and repair the oil return pipe.
blocked.

Abnormal Lubricating Oil Pressure
1. Low lubricating oil pressure
① Lubricating oil becomes thin or

the lubricating oil you used is Select lubricating oil as specified.
improper.
② The lubricating oil pump rotor is

worn or the assembly clearance is Replace the lubricating oil pump.
excessive.
③ The lubricating oil filter is
Replace the spin-on filter element.
blocked.
④ The pressure regulating valve of
Repair the valve.
the lubricating oil filter fails.
⑤ The lubricating oil pump gear is

Replace the pipes.
damaged or worn.
⑥ The inlet pipe of lubricating oil

Repair and replace the pipe.
pump has leakage.
⑦ Bolts for fixing lubricating oil

Tighten the bolts to a specified torque.
pump inlet pipe are loose.
⑧ Excessive bearing clearance Check and replace the bearing shell.
2. 2. High lubricating oil pressure

Select lubricating oil of the specified brand. Drive the
Low temperature leads to higher
machine at a low speed after the engine is started, and check
lubricating oil viscosity.
the oil after the temperatures is normal.
Overflow valve blockage Check and clean the valve.
3. High consumption of lubricating oil and large consumption
① The external lubricating oil

Check and repair the pipeline.
pipeline has leakage.
② Heavy engine load Reduce the load.
③ Improper brand of lubricating oil Select lubricating oil as specified.

④ The piston ring is blocked or

Check, repair and replace (if necessary) the piston ring.
seriously worn.
Replace with a piston ring of a larger size or repair sleeve
⑤ Serious cylinder bore wear
after boring the cylinder.
⑥ The valve guide pipe is

excessively worn, so the valve stem Check and replace the valve guide pipe.
seal fails.
High Outlet Water Temperature
① Insufficient coolant with a mall

Check whether coolant is sufficient. If not, refill it.
flow.
② The belt is too loose. Adjust it.
③ The water pump has leakage. Repair the pump in time.
④ The thermostat is damaged or fails. Check and replace the cylinder gasket.
Check whether the actual temperature is consistent with the
⑤ The water-thermometer is damaged
temperature indicated by the gauge; if not, replace the sensor
and water temperature sensor fails.
plug or the water-thermometer.
⑥ Cylinder gasket Check and replace the cylinder gasket.
⑦ Matching problem between the

Match them again according to the requirements.
water tank and fan
Supercharger Common Troubles and Troubleshooting

Check the pipeline between the air filter and the compressor,
① The air inlet system is
pipeline the compressor outlet and inlet pipe, and the inlet pipe for
blocked.
blockage. Clean them up.
Check the pipeline between the air filter and the compressor,
pipeline the compressor outlet and inlet pipe, and the joint between
② Air inlet leakage
intake pipe and engine for leakage. Tighten fastening bolts, and
replace the gasket and other parts.
③ The exhaust system is

Repair it or replace relevant parts.
blocked.


Check joints between the exhaust pipe and engine, turbine inlet and
exhaust pipe, turbine housing and intermediate housing, and turbine
④ Exhaust leakage
outlet and exhaust pipe for leakage. If there is leakage, replace the
sealing gasket and tighten fastening bolts.
⑤ The compressor rotor collides

with the compressor housing and Replace the assembly.
turbine housing.
⑥ Oil leakage in the oil inlet and

Replace the pipes.
return pipes
Engine Automatic Flameout
① The fuel is used up. Check and fill fuel. Exhaust air in the oil circuit.
Check and clean the oil circuit, exhaust air in the oil
② The oil circuit is blocked or plenty of
circuit, find out the cause of air intake and remove the
air enters the oil circuit.
trouble.
If the engine stops suddenly while the water temperature is
③ The engine oil circuit is blocked, normal, this may be the cause. You should dismantle the
which causes the bearing liner burnout. oil sump for inspection and maintenance, and replace
corresponding damaged parts.
Allow the engine to cool down by itself (cold water filling
④ Engine overheating cylinder pulling is or flushing is prohibited) first, try to turn the crankshaft,
generally caused by water shortage or and then try start the engine if there is no stagnation. If the
high water temperature crankshaft cannot be turned, internal check is required.
Repair and replace damaged parts.
4.3.4 Maintenance
Engine view
The following figure contains engine related components, interface positions and specifications, and is
used to guide connections in engine testing and installation. The figure shows a general situation. Actual
layout will be slightly different due to the actual situation.

Fuel return High pressure

Oil water
Fuel filter Fuel inlet port oil pipe Tanker cap Left rear lug
separator filter
Air hater
Exhaust gas outlet
of supercharger
Oil pump
Oil Scale
High pressure
fuel pump
Starter
Oil drain port
Figure 4-13 Fuel pump side view
Supercharger Engine water inlet Engine steam

Right rear lug compressor main pipe Right front lug
outlet
Supercharger Engine water outlet
Supercharger Drain pipe

air inlet
Water temperature sensor
Air compressor Thermostat cover plate
Waterproof plug II
Oil cooler
Water pump
inlet pipe
Warm air intake
Waterproof
plug I
Oil temperature and Egine oil filter
pressure sensor
Figure 4-14 Exhaust side view

Oil water
separator filter
Water
pump Engine air inlet
Generator
Generator belt
Fan belt Absorber
Figure 4-15 Front end view
Steering
pump
Flywheel
housing
Flywheel
Figure 4-16 Rear end view
Engine cleaning
1. Solvents and acid wash

Several types of solvents and acid wash can be used to clean engine parts. Any special cleaning fluid is
not recommended by the engine manufacture. Following the instruction book of the cleaning fluid is
OK. Experience shows that when the cleaning liquid is heated to 90 - 95°C, the best cleaning effect can
be obtained. The cleaning cabinet can mix and filter the cleaning liquid according to a fixed proportion,
greatly improving the cleaning effect. Before you put parts into the cleaning cabinet, remove all the gas-
kets, O-rings, sludge, carbon deposits, etc. with a wire brush or blade.

Do not damage any surface that is connected with the gasket.
Acid can damage the engine, so always prepare a box of soda water as neutralizer.
After pickling, you should rinse all parts with hot water, dry them thoroughly with compressed air, and
blow out residual water from all screw holes and oil passages.
If cleaned parts are not used immediately, apply proper amount of anti-rust oil to them. Before these
parts are installed on the engine, anti-rust oil must be removed.
2. Steam cleaning
Steam cleaning can remove dirt in all forms and dirt can pollute the cleaning cabinet.
To prevent injury of high pressure and high temperature to human, protection suit must be
worn.
Do not use steam to clean the following parts: 1. electrical components, 2. circuit, 3. oil atomizer, 4. fuel
injection pump, 5. belt and hose and 6. bearing.
3. Engine repair requirements
1) Correctly use tools and equipment.
2) A clean environment should be provided and specified cleaning requirements must be observed. Parts
must be clean. Pollution can cause early wearing.
3) Replace all parts or assemblies that do not meet requirements due to damage.
4) Use genuine engine parts and assemblies.
5) Carrying out specified disassembly and assembly procedures can prevent damage to parts.
Overview of Engine Disassembly and Reassembly
1. Engine disassembly
1) Before removing the oil pipe, water pipe, air pipe and pipeline that connect the chassis with the en-
gine, hang labels on them to indicate their positions to prevent wrong reassembly.
2) Remove the battery cable.
3) Drain the engine coolant (ensure that the pressure cap can be removed and the switch can be opened
only after the coolant temperature is lower than 50 °C).
4) Drain the oil.

5) Remove harness and cables that connect the engine on the chassis.
6) Remove air inlet and exhaust pipes (air filter to supercharger pipe, supercharger to intercooler pipe,
intercooler to engine air inlet pipe, and supercharger to muffler pipe).
7) Remove pipes related to the cooling system (water tank to water pump pipe, AdBlue nozzle cooling
pipe, heating return pipe, urea tank heating pipe, and engine steam removal pipe; engine water outlet
to water tank pipe, heating water intake pipe).
8) Remove the oil inlet and return pipe.
9) Remove fixing bolts of the oil scale sleeve on the water tank.
10)Remove the air compressor intake/exhaust pipe.
11)Remove the steering pump’s oil inlet pipe, oil return pipe and oil overflow pipe.
12)Remove all engine-driven accessories on the chassis (rear PTO, propeller shaft, air conditioning
compressor belt, etc.).
13)Remove all accessories on the chassis that affect engine lifting.
14)Remove fixing bolts of upper suspended engine.
15)Lift the engine using the truck hook block (transmission - lifting).
16)Remove the engine’s front and rear engine mount brackets, install the engine supporting feet, and
place the engine on the ground stably.
17)Cover all engine openings to prevent dust and debris from entering the engine.
2. Engine assembly inspection

Before the engine is lifted, you need to:
1) Check whether all rubber cushions are cracked or damaged.
2) Check whether all fixed machine legs are cracked or whether mounting screw holes of flywheel hous-
ing and machine legs are damaged.
3. Engine reassembly
1) Lift the engine using the truck hook block (transmission - lifting), installed the suspended support,
and tighten bolts according the specified torques.
2) Lift the engine assembly on the chassis, install the mount bracket in an aligned way, and tighten the
assembling bolts according to the specified torque.
3) Install all removed accessories of the engine and chassis. All previously dismantled oil pipes, water
pipes, air pipes and pipelines should be installed to their original positions according to label instruc-
tions, to ensure that they are correctly arranged and fixed, preventing collision, interference and dam-
age and ensuring that the joints are tight and reliable.

4) Fill oil as required.
5) Fill coolant as required. Ensure that air in the cooling system can be discharged smoothly, refilling
time is normal, and the filling amount meets requirements.
6) Unscrew the bleeder plug on the fuel-water separator and press the hand pump for drainage until the
filter is filled with fuel.
7) Make the final inspection to ensure all pipes, wires, joints and components are installed and tightened
correctly.
4. Engine start and pilot run
1) Start the engine.

Note: The starter cannot work for more than 30 seconds. After the starter stops working, wait
for 2 minutes before starting.
2) Run the engine at a low idling speed for 2 to 3 minutes.
3) Observe the oil pressure gauge and check whether the oil pressure can meet the requirements.
4) Shut down the engine, wait for 5 to 7 minutes until the oil flows back to the oil sump, recheck the oil
and coolant level, and continue to fill oil to the specified level if necessary.
5) Run the engine at a speed of 1000 rpm for 8 to 10 minutes. Check whether the engine works nor-
mally, whether there is abnormal noise, and there is any leakage.
5. Engine flywheel casing bolting requirement
1. Tighten up double-end studs and nuts 12 1

that connect flywheel casing
11 2
See the right diagram for process: 1-7-6-

12-3-9-10- 4-2-5-8-11. 10 3
2. Apply thread locker on double-end

9 4
studs.
3. Pre-tighten first; refer to tightening se-

8 5
quence; tightening torque: 65N.m± 6.
7 6
4. If double-end studs and buts are dam- Figure4-17
aged or broken during detachment,
please replace them immediately; after
they have been detached for 3 times,
please replace all the them.

Qty for single

No. Code Specification/Name Remarks
unit
1 860170856 Q129B1040TF6/01 Stud 12
Q32010T13F6(P=1.25)/01 Hexagon nut
2 860170857 12
with flange M10×1.25
3 860170855 K6000-1002265/04 Gasket 12
4.3.5 Other descriptions - fuel liquid heater operation manual (for option)
Switch panel
Indicators are divided into power indicator lamp (green) and state indicator lamp (red); state indicator
lamp indicates heater working state and fault code.
Switch on
Press switch and it turns on (gear 1 is for only water circuit; gear 2 is heater operation switch)
1. When heater starts working, power indicator lamp (green) turns on and it starts self-inspecting.
2. If self-inspecting shows no fault, and heater starts working in a normal way, the state indicator lamp
(red) will turn on.
3. If state indicator lamp (red) starts flashing, it means a fault has occurred; refer to the cause in detailed
fault code table.
Switch off
Close switch and it turns off.

Power indicator lamp (green) goes off, solenoid valve is shutdown, fuel supply is suspended and heater
stops combustion. Heater main motor drives combustion-supporting wind wheel to continue operation,
cooling down the heater; at this moment, the state indicator lamp (red) won’ t immediately go off, it will
keep lighting up for 3 minutes for heater to cool down and main motor to stop.
When state indicator lamp (red) is on, it is forbidden to shut vehicle power switch (key switch and
power master switch); otherwise, heat won't dissipate and will cause fault or fire accident.
Fuel liquid heater fault and repair(option)
Control circuit has multiple fault identification functions, and continuously monitors heater working state
(including battery pressure, combustion state). When a fault occurs, heater state indicator lamp (red) will
start flashing according to binary coding, giving fault type information. 5 flashes is taken as one group,

and it flashes in long and in short; a long flash lasts for 1s, represented by 1; a short flash lasts for 0.2s,
represented by 0; the interval is 0.5s within each group; a 3s interval follows each flash group; the flashing
can indicate multiple fault state; see the table for fault code.
Fault code (indicator lamp flashes as per binary coding, indicating a indicator lamp fault. 5
flashes is taken as one group, and it flashes in long and in short; a long flash lasts for 1s, repre-
sented by 1;a short flash lasts for 0.2s, represented by 0; the interval is 0.5s within each group and
a 3s interval follows each flash group).
Fault
Fault type Fault code Cause Troubleshooting
description
Combustion Combustion sensor

Replace combustion sensor or
FAULT00 00000 sensor break resistance value is
control box
circuit too large
Inspect motor, water pump,
Load short Load current is too
FAULT01 00001 ignition plug and solenoid
circuit large
pump for current
Test voltage; if it is high,
Switch-on
Power voltage inspect generator voltage
FAULT02 00010 checking voltage is
is too high regulator; if voltage is not high,
too high
replace control box
Test voltage, if low, inspect
The heater terminal
Power voltage generator output voltage and
FAULT03 00011 voltage is too low
is too low line voltage drop; if voltage is
for 10 seconds
not low, replace control box.
Combustion Combustion sensor Inspect the line for short
FAULT04 00100 sensor short resistance value is circuit, replace combustion
circuit too small sensor or control board
Overheated Overheated sensor Replace overheated sensor,
FAULT05 00101 sensor break resistance value is check wiring or replace control
circuit too large box
Overheated Overheated sensor
Replace overheated sensor or
FAULT06 00110 sensor short resistance value is
control box
circuit too small
Solenoid pump Solenoid pump Replace solenoid pump or
FAULT08 01000
over current over current control box
Water
Water temperature
temperature Replace water temperature
FAULT11 01011 sensor resistance
sensor short sensor or control box
value is too small
circuit

Fault
description
Water
Water temperature
temperature Replace water temperature
FAULT12 01100 sensor resistance
sensor break sensor or control box
value is too large
circuit
If heater works well, inspect
combustion sensor wiring;
Heater ignition Heater ignition
FAULT13 01101 replace combustion sensor or
failure failure
control box; if not well, inspect
heater oil line
Lack of fuel, add fuel; oil line
air leakage; tighten oil
Combustion Combustion stops
FAULT14 01110 line;combustion sensor short
stops after work
circuit, replace combustion
sensor or control box.
Ignition plug
Ignition plug Replace ignition plug and
FAULT18 10010 resistance value is
break circuit tighten wire
too large
Inspect ignition plug wire and
Ignition plug Ignition plug over replace ignition plug or control
FAULT19 10011
over current current box
Inspect main motor wiring,

Main motor blocks extract connector and directly
Motor over or try if main motor rotates; if it
FAULT21 10101
current internal short the rotating speed is low,
circuit of motor replace main motor; otherwise,
replace control box.
Water pump is
Inspect water pump motor,
Water pump blocked or
FAULT22 10110 replace water pump or control
over current Motor internal
box
short circuit
Air pressure is Oil pressure sensor
FAULT25 11001 Replace control box
over low is damaged

Fault
description
Air pressure is Oil pressure sensor
FAULT26 11010 Replace control box
over high is damaged
Heater air inlet and Inspect heater inlet and outlet
Heater is
FAULT27 11011 outlet line is air volume, and installation
overheated
blocked correctness
The main motor
does not turn after Inspect main motor wiring,
Test shows being energized, extract connector and directly
motor no or the controller is try if main motor rotates; if it
FAULT29 11101
rotation not placed doesn’ t rotate, replace main
movement properly, or the fan motor; otherwise, replace
is too far from the control box.
controlle
Inspect heater water system,
Heater water loop
Heater works open valve, fill in antifreeze;
FAULT30 11110 is poor or lack of
dry open heater vent plug to release
antifreeze
air
Feedback
Control wire
FAULT32 signal not
harness has a fault
detected

4.4 Transmission
Maintenance
interval
Ap-
Nor-
First plied
Part mal Target
No. Description Unit Qty main- envi-
Number main- part
ten- ron-
ten-
ance ment
ance
（h）
（h）
Trans
GL-5 80W/90 gear oil
9 822502286 L 13.5 500 mis
(Shell 209L)
sion
Maintenance instructionsOperation description
Proper lubrication is an important step in transmission maintenance procedures. transmission relies on

gear rotation splash lubrication. To ensure correct and reasonable lubrication, the following conditions
should be met:
1. Maintain the set oil level;
2. Inspect regularly;
3. Repair and maintain the gearbox in strict accordance with the maintenance time interval;
4. Use the correct grade and type of lubricating oil.
Draining the Oil
It is very important to drain oil when the transmission is hot! The magnetic drain plug should be removed
in the process of draining the oil. After the oil is drained, the drain plug should be cleaned before being
reinstalled.
Oil adding

Correct oil level Wrong oil level
Figure 4-18 Transmission oil level
• Before oil drain, clean the periphery of the oil drain plug of the gearbox, screw out the oil drain plug,
and refuel the gearbox to the specified oil level (flush with the bottom plane of the oil drain hole of the
gearbox).
• Transmission installation angle and ground slope affect the oil volume that is actually filled, so ensure
that the truck is parked on a flat road before oil filling.
• Do not overfill the oil until it is above the specified oil level. Otherwise, oil leakage at the front bearing
cover and transmission shift cover will be caused.
• After lubricating oil is filled, tighten the filling plug to the specified torque of 47 ~ 68 NM.
Filler screw plug
Figure 4-19 Transmission refuel bolt

4.5 Hydraulic Retarder(option)

Oil liquid maintenance
Maintenance
interval
Nor- Applied
Serial Part First mal Target envi-
Description Unit Qty
No. Number mainte- main- part ron-
nance ten- ment
（h） ance
（h）
CH-4 15W/40 Engine oil Above -10
822502276 L
(Shell 209L) °C
1 32 500 Engine
CH-4 10W/30 Engine oil -25℃~3
822502277 L
(Shell 209L) 0℃
Delo ELC-55/45 Delo long-

acting heavy-duty
2 822933579 L 76 20000 Radiator
antifreeze/coolant (-45°C
Caltex IBC)
DOT4/HZY4 Motor vehicle Clutch/

3 822538184 EA 1 2000
brake fluid (800G) brake fluid
Autran 4 10_bluk hydraulic

Hydraulic
4 822538783 oil（ Steering 59L/ KG 179 2000
Oil Tank
Lifting120L）
No. 2 Extreme pressure
lithium lubricating grease（ Above

822537653 KG
175kg/barrel International 32℃
standard barrel diameter） Centralized
5 6 70
No. 1 Extreme pressure lubrication -32℃~3
822502580 KG
lithium lubricating grease 2℃
Extreme pressure lithium Below

822502607 KG
lubricating grease (No.00) -32°C
Wheel
reductor
GL-5 80W/90 gear oil (Shell -25℃~
6 822502286 L 18 1000 2000 gear box
209L) +40℃
(4.5L for a
single box)


Maintenance
interval
Nor- Applied
Serial Part First mal Target envi-
Description Unit Qty
No. Number mainte- main- part ron-
nance ten- ment
（h） ance
（h）
Intermedi
ate axle
GL-5 80W/90 gear oil (Shell
7 822502286 L 20 1000 2000 casing
209L)
(main
retarder)
Rear axle
GL-5 80W/90 gear oil (Shell casing
8 822502286 L 20 1000 2000
209L) (main
reducer)
GL-5 80W/90 gear oil (Shell Transmis

9 822502286 L 13.5 500
209L) sion
CAT hydraulic oil addictive
10 822538163 (1U-9891One kilogram KG 0.5 20000 Suspension
pack)
Instructions
Retarder rotation control mechanism
To meet requirements of mining truck transport and site transfer, this transmission overgear speed ratio is
0.71. This transmission has adopted a retarder rotation control mechanism to prevent overspeed rotation
and delayed heat dissipation that cause retarder early damage (when engine rotation speed exceeds
1780rpm, retarder input speed exceeds rated value of 5000 rpm). Normally, overgear is applied in truck
transport or site transfer operations; be sure to disengage retarder.
Refer to the right figure for retarder rotation control mechanism. Transmission delivery state is shown in
the figure. Engage shifting fork towards front, location screw plug 3 mates with shifting fork upper hole b,
sliding sleeve 3 and retarder are disengaged by the engagement tooth of driven wheel 1, retarder is set on
output shaft by driven wheel 1, and retarder moves freely. When vehicle approaches a mining site, the op-
erator shall barely or not use overgear; in heavy load condition, retarder shall work well; on this occasion,
hex screw plug 6 and shifting fork shaft lock-down screw 3 shall be screwed off; take a M10 long bolt

(length >45mm), screw it into the end-face hole c of shifting fork 5 from the hole of hex screw 6; pull bolt
head backward, when sliding sleeve 2 meshes with retarder driven gear 1, maintenance staff should screw
in shifting fork shaft lock-down screw 3, and then screw 3 and shifting fork shaft hole a will mate; sliding
sleeve will mesh with driven wheel 1, and then driven wheel starts rotating with output shaft 7; when ve-
hicle is started, retarder will work once switched on.
On truck transport or site transfer occasions, be sure to disengage retarder again.
4 5a 3 bc 6
1
2 7
Figure 4-20
ydraulic retarder operation instructions
When shifting to manual operation, 5 gear switches will be used: “constant speed gear” gear 1 and 4
braking gears: gear 2-5.
A Retarder gear switch (a special

A
mounting position).
0 Retarder gear shifting switch B

0
1 Constant speed gear 1
2
2 Brake gear 1 3
4
5
3 Brake gear 2
Figure4-21
4 Brake gear 3
5 Brake gear 4

Constant gear usage
① Adjust vehicle speed

0
1
② Activate “constant speed” function 1
3
2
4
under a specific speed. The retarder can, 5
within its max. braking torque, ensure ve-

0
hicle to run at a constant speed. If the ve- 1
2
hicle has been at “constant speed” , but 2
3
4
the driver needs to set a re-adjusted con- 5
stant speed for downslope travel, the driver

0
should simply pull gear lever to “gear 0” 1
2
firstly, and then pull it to “constant speed 3
3
4
gear” gear 1. If “constant speed” func- 5
tion has been activated but truck speed still Figure4-22

increases due to a steep downslope or over-
weighted truck loads, the driver shall use
service brake to assist retarder for speed
regulation. If lever is not at “constant
speed gear” , auto regulation function will
immediately shut down. When “constant
speed gear” is in service, if retarder be-
comes overheated (working indicator lamp
starts flashing), it will automatically reduce
torque or quit. If you want to realize “con-
stant speed” function again, you’ re re-
quired to shift to “constant speed
gear”manually after working indicator
lamp stops flashing.
③Quit “constant speed gear” .
Brake gears usage
Gear 2-5 are brake gears, and braking torque increases accordingly by degrees; you can select a proper
and reasonable brake gear according to vehicle weight, braking distance and slope gradient. Pull retarder
gear switches one by one (don’ t attempt to skip switches) so as to obtain corresponding braking torque!
To reduce the applied braking torque, you don’ t need to pull retarder lever switch to low gears by de-
grees, you are allowed to skip gears. After braking comes to an end, please pull retarder lever switch to
“gear 0” .

Gear indicator lamp working situations
1. If ambient temperature is low, when truck is started and the retarder is initially activated, truck may re-
sult in a delayed braking performance.
2. Hydraulic retarder converts kinetic energy of whole truck into heat, which is then taken away by engine
circulating antifreeze. When engine antifreeze temperature and retarder oil temperature exceed setting
values, retarder will alarm the driver to slowly quit the brake. To better perform hydraulic retarder's
function, in practice, the driver should combine vehicle weight, slope gradient, slope distance and other
factors into the consideration of a properly and reasonably determined downhill travel speed and engine
rotation speed, so as to keep retarder working without quit and not give an alarm; to be specific, when
truck weight is heavy and slope is steep and long, the driver should increase engine speed in order to
travel down a slope at a low constant speed.
3. No matter retarder lever is pulled to any gear, transmission must maintain at a proper forwarding gear
(do not confine with a retarder when coasting), so that engine cooling system takes away braking heat
(when truck travels at a constant speed, engine speed shall not lower than 1600 rpm, however, the driver
must pay attention to avoid engine racing out of control). Apply retarder in a proper situation, which
means when there is snow, ice or a large amount of clogged water on the road, prohibit using retarder.
When truck travels without load, in order to reasonably use the retarder, the driver must pull retarder
lever by degrees and avoid jerking the brake, which may affect travel safety. When a towing vehicle
travels at a sharp-turn mode, the retarder shall not be used. Retarder shall not serve as a parking brake.
To better retarder performance and increase its service life, engine cooling medium must be antifreeze.
Retarder immersion depth shall not exceed its bottom. During operation and repair, it’ s strictly forbid-
den to stamp/crack control valve and heat exchanger assembly.
Hydraulic retarder oil and change cycle
Hydraulic retarder working medium: when environment temperature is above -10 °C, the suitable oil is
10W40 gasoline engine oil; when environment temperature is below -10 °C, the suitable oil is 0W40 or
5W40 gasoline engine oil; oil performance grade is API SL and above, semi-synthetic oil or fully syn-
thetic oil.
Hydraulic retarder oil change cycle:Hydraulic Retarder
Open oiling screw plug, add an amount of 6.5L oil initially for FH240 hydraulic retarder. After the first
fill, in order to change oil, firstly open oil drain plug to exhaust used oil, and then add an amount of 6.5L
new oil. Use a dipstick to measure oil adding amount, firstly place the oiling screw plug (with dipstick) in
filler port without tightening it, and then take out the oiling plug dipstick to inspect whether oil has
reached 6.5L marker.
Tightening torque for oiling screw plug, oil-pan drain plug and heat exchanger drain plug is respectively
15-25Nm, 25-35Nm and 25-35Nm.
Oil change cycle is 70,000 km.
Note: when the covered distance is below this mileage, change oil at least once a year.

Filler screw plug
Drain screw
plug
Figure 4-23
4.6 CLUTCH
Maintenance
interval
Nor- Applied
First
Serial Part mal Target envi-
Description Unit Qty main-
No. Number main- part ron-
ten-
ten- ment
ance
ance
（h）
（h）
DOT4/HZY4 Motor Clutch
1 822538184 vehicle brake fluid EA 1 2000 master
(800G) cylinder
The factory standard of XDR80T is ceramic clutch, fiction disc and pressure plate are made of ceramic
material; when the clutch is faulty, replace friction disc and pressure plate altogether. It’ s forbidden to
replace ceramic fiction disc with organic disc; otherwise, clutch friction disc will only serve a short life
span. The push rod of clutch booster cylinder shall be used together with clutch assembly as a set; it’ s
forbidden to privately change it with another brand of clutch assembly, because a push rod of improper
length may cause accelerated clutch damage.

The pressure 1) The friction disc and pressure 1) Replace

plate plate are seriously worn. 2) Measure the spring force.
pressing 2) The pressure spring is broken Replace the spring if the spring
force is or the spring coefficient is force does not meet the
reduced. reduced. requirements.
1) The friction disc’s surface is
stained with oil.
1) find out the source and clean
Clutch Slip 2) The friction disc is seriously
The friction the oil stain.
burnt.
disc’s 2) Replace
3) The friction disc rivet is
friction 3) Replace
exposed.
coefficient is 4) Replace
4) The friction disc material is
reduced. 5) Finish the surface or replace
not suitable.
the damaged parts.
5) The flywheel and pressure
plate are ablated or deformed.
1) The oil cylinder and air 1) Repair or replace the oil
Operation cylinder are damaged. cylinder or air cylinder.
difficulty 2) The oil circuit and pneumatic 2) Check the pipes and then seal
circuit has leakage or air intake. them.
Excessive
pedal free The adjusting nut is loose. Tighten the nut.
The clutch is
stroke
not completely
Height of
separated. Adjust the height to make the
release levers Improper adjustment
deviation to be within 0.2mm.
is not equal.

Instructions
Clutch operating system
Clutch booster cylinder adopts gas and liquid hybrid power, requiring 7 bar air pressure and 1 MPa hy-
draulic pressure. Hydraulic power is offered by foot pedal, requiring 100N stamping force; clutch liquid is
DOT4 brake fluid, which, when used for a long term, may easily absorb water; the recommended change
cycle is 2,000 hours or 40,000 km, residual liquid must be completely drained before replacement.
Air in pipelines and the clutch booster cylinder should be completely drained when the oil is replaced.
Otherwise, if the clutch cannot move when you step on it, the booster cylinder push rod’s effective stroke
will be shortened. Therefore, the clutch cannot be separated completely, leading to difficulty in gear shift-
ing and abnormal clutch wear! The specific exhaust steps are as follows: firstly, release the booster cylin-
der deflation valve, fill D0T4brake fluid into the reservoir, step on the clutch pedal while replenish the
brake fluid until it overflows from the deflation valve, and then tighten the deflation valve. Quickly step
on the clutch pedal for several times and keep on it, release the booster cylinder deflation valve until no
air escapes, and tighten the deflation valve. Repeat the above steps for 2-3 times to exhaust all the air.
DOT brake fluid is corrosive. During exhaust operation, prevent brake fluid from being splashed on per-
sonnel and the vehicle paint surface. You are suggested to exhaust every 500 hours or 10000 km.
Special instructions for ceramic clutch
There is a large difference in the application between a clutch made of ceramic and organic materials.
Rotation speed of a clutch made of organic materials shall not be too high. Do not press the clutch pedal
for too long. While, before applying a ceramic clutch, the driver should firstly increase vehicle speed, and
then stabilize throttle and speed, and shall not reduce speed; besides, clutch pedal should be pressed
longer.
Clutch debugging
Inspect for adjusting the gap between push rod and piston of clutch main pump: to adjust the gap, firstly
lightly push the pedal with hand, when you develop a feeling that the push rod has clung to piston, you
may start adjusting the height of stop bolt, ensuring a clearance of 0.5mm~1mm left between push rod and
piston; after that, tighten up the nut. The clearance between the two shall not exceed 1mm; otherwise, the
effective stroke of clutch main pump will be decreased.
Other instructions
1. During air exhausting procedure, pay attention to tightening up air release valve before easing foot ped-
al, in case of taking in air; when easing the pedal, be sure to ease it to the max. height, so that brake fluid
of liquid storage tank can replenish hydraulic cavity of clutch main pump.
2. The working medium of hydraulic system must meet the requirement of brake fluid DOT3 and DOT4.

3. Brake fluid replacement. Residual liquid must be drained out of hydraulic system before new brake flu-
id of designated brand and of the same batch to be filled in; do not mix different fluids.
4. DOT brake fluid is corrosive, during air exhausting procedure, it shall not spill on persons and vehicle
painted surface.

4.7 Transmission shaft

Maintenance
interval
Nor-
First Applied
Serial Part mal
Description Unit Qty main- Target part environ-
No. Number main-
ten- ment
ten-
ance
ance
（h）
（h）
No. 2 Extreme
pressure lithium
lubricating
grease（ 175kg/ Propeller shaft
1 822537653 KG 0.5 200
barrel grease fittings
International
standard barrel
diameter）
As an important part for power transmission in the automotive transmission, the propeller shaft transfers
engine power to wheels together with the transmission and drive axle, enabling the vehicle to generate the
driving force.
The propeller shaft system has precise dynamic balance. Therefore, if it needs to be disassembled, all its
parts should be marked, so they can be reassembled to the original positions.


1) The propeller shaft is bent and deformed.
1) Re-inspect the dynamic balance
2) Universal joint forks at both ends of the propeller
after cold pressing correction.
Propeller shaft shaft have incorrect relative positions.
2) Recondition the assembly.
jitter 3） The cross bearing of universal joint and spline
3) Replace
of transmission shaft are seriously worn.
4) Rebalance.
4) The dynamic balance sheet falls off.
1) The propeller shaft is bent and deformed. 1) Re-inspect the dynamic balance
The propeller
2) Universal joint cross shaft and needle bearing are after cold pressing correction.
shaft has
seriously worn. 2) Replace the universal joint.
abnormal sound.
3) Propeller shaft spline looses. 3) Replace
Instructions
The dynamic balance and extendibility of a propeller shaft play a significant role on the life span of entire
drive system. If the dynamic balance of a propeller shaft is ineffective, it will cause transmission and axle
flange to abnormally joggle, further damaging the internal bearing and gear; a propeller shaft with poor
extendibility will leave transmission and axle flange under rather large axial force, causing transmission
casing crack, spoiling engagement gear pad, cracking engine housing and bringing damage to axle inpu-
tend bearing, etc. Therefore, regular inspection and maintenance is of vital importance to propeller shaft;
once an anomaly has been defected, repair or replace the propeller shaft immediately.
Note: Each propeller shaft has four grease fittings, and both of propeller shaft itself and universal
joint require grease lubrication.

4.8 Front axle

Maintenance
interval
Ap-
Nor-
plied
Serial Part First mal
Description Unit Qty Target part envi-
No. Number mainte- main-
ron-
nance ten-
ment
（h） ance
（h）
No. 2 Extreme
pressure lithium
lubricating
Inside of front
1 822537653 grease（ 175kg/ KG 1.5 200 500
axle hub
barrel International
standard barrel
diameter）
The front axle (non-driven steering axle) consists of knuckle, hub, etc. There is a large amount of lubricat-
ing grease sealed in wheel hub of front axle; if you need to maintain it, just open the end cover and replen-
ish some.
Inspection of steering knuckle
Check whether the steering knuckle has crack at the root and whether the shaft neck is worn. If there is
crack, replace the steering knuckle. Otherwise, serious accident may be caused.
Connection between wheel rim and axle
The specification of rim nut is m24, and the tightening torque is 700 ~ 800 N.m. Rim nuts must be tight-
ened in groups, symmetrically and evenly. In normal use, frequently check the nuts for looseness, identify
the looseness in time and tightened the nuts in time. When the spherical rim nut is used, check whether the
nut spherical surface matches the rim spherical socket, and compact the nut to ensure reliable connection.
Lubrication

Type of lubricating oil: GB5671 general lithium grease or GB7324 2# general lithium grease.
Oil filling position and oil volume
As shown in the figure, fill 2# lithium grease into the inner cavity of the hub, and the oil filled should be
2/3 of the inner cavity.
1 2 3 4 6 7 5 8 9 10
11
12
23 22 21 20 19 18 17 14 13
15 16
Figure 4-24 Front axle assembly exploded view
Adjustment method of hub bearing clearance
As shown in breakdown drawing of front axle, tighten the nut with a tightening torque of 800N. M. At the
same time, rotate the hub until it cannot be rotated; then unscrew the nut until a 120-140 N tangential force
is applied to the bolt hole of the hub, and the hub can just rotate freely, and then lock the nut.
Fault Cause Troubleshooting Method

Bearing failure Replace the piston.
Improper bearing clearance See adjustment method of hub bearing
The hub is
Excessive or less lubricating grease clearance
overheated.
Use of excessively old bearing for Make an adjustment.
external ring Repair or place the hub.
Serious overload Loading as rated capacity

The bearing is adjusted to excessively Make an adjustment.
The bearing is loose or tight. Make an adjustment.
damaged early. Being improperly connected and Clean the hub and replace the
installed lubricating grease.
Dirt in the hub Replace the piston.


Poor quality bearing
Excessively high impact load Courteous driving
The wheel rim nut The nut is not tightened as specified. Adjust the tightening torque to 700-
is damaged. Being improperly connected and 800 N.m.
installed Reinstall the nut.
Serious overload
Loading as rated capacity
The brake disc is Frequent braking
overloaded. Foreign matters between brake disc
Clean the foreign matters.
and friction disc
The brake does not Rectangular seal ring damage Replace the piston.
return to its original Braking liquid dirt Clean the brake the replace the oil.
position. Piston corrosion Replace the piston.

4.9 Intermediate and Rear Axles

Maintenance
interval
Nor-
Seri- First Applied
Part mal
al Description Unit Qty main- Target part environ-
Number main-
No. ten- ment
ten-
ance
ance
（h）
（h）
GL-5 80W/90 Wheel reductor
1 822502286 gear oil (Shell L 8 250 1000 gear box (4.5L
209L) for a single box)
GL-5 80W/90
Intermediate 25℃~
2 822502286 gear oil (Shell L 42 250 1000
axle casing +40℃
209L)
GL-5 80W/90
3 822502286 gear oil (Shell L 35 250 1000 Rear axle casing
209L)
Basic requirements
1. Clean oil, dirt and dust frequently, especially keep the ventilation plug open. Check tightening of all
parts, especially the main reducer, rim brake and rim bolt, etc., and tighten them in time if they are
loose.
2. Often check the oil leakage in various parts, and repair and eliminate it in time. Check the lubricating
oil level in the main reducer and rim assembly, and fill lubricating oil in time to reach the required oil
level to ensure normal operation.
3. The gap between the friction plate and the inner round surface of the brake drum is generally 0.25 ~ 0.5
mm, which can be completed by the adjustment mechanism on the brake arm.
4. The friction disc surface of the brake should be free of oil stain and foreign matters to ensure normal
braking.
Connection between wheel rim and axle

The specification of rim nut is m24x1.5, and the tightening torque is 700 ~ 800 N.m. Rim nuts must be
tightened in groups, symmetrically and evenly. In normal use, frequently check the nuts for looseness,
identify the looseness in time and tightened the nuts in time. When the spherical rim nut is used, check
whether the nut spherical surface matches the rim spherical socket, and compact the nut to ensure reliable
connection.
Lubrication
1. Types of lubricating oil GL-4 85W/90 gear oil

2. Refueling position
Place the axle in its working installation position, and then fill oil from the plug hole.
As shown in the figure, the oil filling positions of the middle and rear axles are both located at the plug
holes on the axle package assembly.
Oil drain hole Oil injection

hole
Oil level hole
Figure 4-25 Oil filling positions of the middle and rear axles
Position the axle to its working installation position, and then refuel from the plug hole. Wheel reductor
lubricating points are the screw plugs on wheel assemblies. There are two points on wheel reductor, 1 is
drain port and 2 is filling port.

Figure 4-26 Oil filling positions of the middle and rear axle rim reducers
3. Oil adding amount

Axle assembly oil amount: oil adding amount is determined on the basis of axle oil level. Oil level for
axle package and reductor: 10~15mm to the lower edge of horizontal-state screw plug thread.
To add a fixed amount of oil: add 42L 80W/90 gear oil for main retarder of intermediate axle casing;
38L 80W/90 gear oil for main retarder of rear axle casing; 4.5L 80W/90 gear oil for single-sided wheel
reductor.
4. Oil Level Inspection
When the oil level is checked, the axle should be placed at its working installation position, and the in-
spection can be made at least 15 minutes after oil filling.
Replace the oil.
After the initial 250 working hours, the first oil replacement shall begin; after that, regular replacement
shall start at an interval of 1,000 working hours. Generally, the oil level should be checked once every
500 hours.

Bearing failure
Replace the piston.
Improper bearing clearance
The hub is Make an adjustment.
Excessive or less lubricating grease
overheated. Make an adjustment.
Use of excessively old bearing for
Repair or place the hub.
external ring
Serious overload Loading as rated capacity

The bearing is adjusted to excessively Make an adjustment.
The bearing is loose or tight. Make an adjustment.
damaged early. Being improperly connected and Clean the hub and replace the
installed lubricating grease.
Dirt in the hub Replace the piston.


Poor quality bearing
Excessively high impact load Courteous driving
The wheel rim nut The nut is not tightened as specified. Adjust the tightening torque to 700-
is damaged. Being improperly connected and 800 N.m.
installed Reinstall the nut.
Serious overload
Loading as rated capacity
The brake disc is Frequent braking
overloaded. Foreign matters between brake disc
Clean the foreign matters.
and friction disc
The brake does not Rectangular seal ring damage Replace the piston.
return to its original Braking liquid dirt Clean the brake the replace the oil.
position. Piston corrosion Replace the piston.
Instructions
Use of differential lock
The differential lock is a mechanism that ensures driving wheels can run synchronously. When a vehicle
drives on complicated road and one wheel slips, the differential lock can ensure that other wheels can still
play the driving force.
When a vehicle drives on a road with good condition, the differential lock should be disabled. Interaxial
differential lock 3 is required when truck travels on a muddy or poor road, and it is a rocker switch lock lo-
cated in the cab. The driver must firstly release clutch before engaging differential lock.
Cautions for using the differential lock
The clutch must be disengaged first before the differential lock is engaged. When the truck stops or runs at
a walking speed, a rocker switch is used to control the differential lock. After the differential lock is en-
gaged, the indicator lamp turns on.
After the vehicle passes the poor road, the inter-axle differential lock should be disengaged. If the indica-
tor lamp is still on, stop the vehicle and find out the cause until it is confirmed that the differential lock
has been disengaged before driving.
To ensure good passage capacity of the vehicle, the inter-axle differential lock should be regularly checked
for engagement performance. The specific method is to carry out secondary maintenance and comprehen-
sive inspection every 2000 h or 10000 km.
Maintenance

1. When the main reducer is disassembled or reassembled, contact engagement between the main drive
gears should be checked by coloring, and the inspection area should be close to the small end in the gear
length direction. Perform adjustment to make the engagement mark to be equal to or greater then 1/2 of
gear length and be in the middle of the gear height. For detailed requirements, See the figure for specific
requirementsFigure 4–27.
Driven spiral
Position of contact mark
bevel gear on passive gear surface
Gear moving
Adjustment method
direction
Active surface Precursor Back up
Close the passive gear to the driving

gear, and move the driving gear
outward if the backlash is too small
Driven surface
Move the passive gear away from the
Driving spiral driving gear, and if the backlash is too
bevel gear large, move the driving gear inward.
Active
surface Close the driving gear to the driven
gear. If the backlash is too small,
move the driven gear outward
Move the driving gear away from the

driving gear, and if the backlash is too
Driven large, move the passive gear inward
surface
Figure 4-27 Gear engagement and contact condition and adjustment methods
2. The anti-loose form applied in wheel reductor is “nut + locking plate + anti-nut”. To adjust it, firstly
set an 800 N.m tightening torque on No. 20 lock nut while rotating wheel hub; and use a copper bar to
axially shake the hub in place; then unscrew locknut 20 by 1/6~1/8 turns, install thrust washer 19, and
then tighten locknut 18 with a tightening torque of 800 N.m.
When a tangential force of 120-140 N is applied to the rim bolt, the hub just can rotate freely. Align the
locking nut hole with the thrust washer hole. Screw lock bolt 17 into the lock bolt 18 to make the bolt
head to be inserted into the thrust washer hole. If these bolts do not match, you can change the loosening
angle of the internal lock nut 20 to perform adjustment.
3. When needle rollers in the planetary gear of the rim reducer are replaced, all needle rollers must be se-
lected in groups, making inner diameter deviation in the same group to be no more than 0.005 mm; the
cylindricity of the needle roller is 0.003 mm; the radial clearance between the needle roller, the plane-
tary gear inner hole, and the planetary shaft is 0.015-0.030 mm.
4. During maintenance, parts originally coated with sealant should be cleaned with solvent. After the sol-
vent is dried, apply LOCTITE 598 sealant with thickness of 1mm; the bolts should also be cleaned.
After the solvent is dried, apply LOCTITE 262 stop adhesive to the thread end, and tighten the bolt ac-
cording to the required tightening torque.
5. All seals must be replaced once being removed and can not be reused.
6. The brake friction disc should be replaced when being less than 2 mm to the groove due to wear.

4.10 Braking system

1. Braking noise and vibration
Cause Solutions:
Installation of dis brake and related parts fails to
Refer to assembly manual and re-install them
meet requirement
Brake disc has cracks or grooves Replace or repair the brake disc.
Brake disc movement fails to satisfy related
Replace or repair the brake disc.
requirements
Friction-plate pressure spring has been
Replace the friction disc compressed spring.
permanently deformed
Detach friction plate and slurcock; clean both
Friction plate fails to freely slide on frame
and frame
The friction plate in use is not the one designated
Replace it according to manufacturer
by manufacturer
2. Braking deflection
Cause Solutions:
One side of friction plate has worn out Replace the friction disc.
Abnormal gap between friction plate and brake Start initial gap adjustment and function
disc inspection
and frame
The friction plate in use is not the one designated
Replace it according to manufacturer
by manufacturer
Air release plug of brake chamber is not removed Remove the brake chamber’s relief plug.
Rotating shaft assembly loses efficacy Inspect rotating shaft function
3. Brake dawdles or cannot be completely released
Cause Solutions:
After brake release, brake chamber still has
Inspect relay valve and quick release valve
compressed air
Abnormal gap between friction plate and brake
Start initial gap adjustment
disc
and frame
Cause Solutions:
Brake caliper sliding function anomaly Replace guide sleeve or bushing
Abnormal gap between hub bearing Adjust hub gap
4. No braking force or poor braking performance
Cause Solutions:
Friction disc worn-out Replace the friction disc.
Check whether clearance between the friction
Adjust the gap
disc and the brake disc is excessive.
Fast brake disc abrasion Replace or repair the brake disc.
Abnormal pressure in brake chamber Inspect air circuit for leakage
Rotating shaft assembly loses efficacy Inspect rotating shaft function
5. Braking smoke
Cause Solutions:
Semi-axis oil seal damage Replace semi-axis oil seal
Narrow gap between friction plate and brake disc Start initial gap adjustment
Excessive oil in axle casing Adjust oil level for axle casing
Brake dawdles and causes abnormally high Inspect brake repositioning and sliding
temperature performances
Wait about 2 minutes after the truck is started and drive the truck after the air pressure turns
stable. Otherwise, abnormal wear of the parking brake friction disc can be easily caused! As
service brake is disc type, continuous heavy-loaded downhill travel will overheat the brake and
make it red, even lose the efficacy of brake seals; so, service brake shall serve as parking brake as
recommended, and shall not be long used; engine exhaust brake and hydraulic retarder are
prioritized for heavy-duty downhill operation.
Instructions
The braking system of XDR80T tri-axle rigid mining truck is composed of service brake (foot brake),
emergency brake, parking brake (hand brake) and auxiliary brake (engine exhaust brake, in-cylinder brake
and hydraulic retarder, which is for option).

Service brake
Service brake is a running-parking integrated pneumatic disk brake in a floating structure whose friction
plate gap is under automatic adjustment. Running-brake force and parking brake force are supplied under
the action of double-cavity spring brake chamber.
Brake: when a braking movement is requested, chamber ejector rod starts pushing pressure arm to rotate.
The pressure arm, while rotating and outputting braking displacement, it also realizes braking force rein-
forcement; and then it transfers braking displacement and reinforced braking force to standard seat. And
then standard seat passes both to screw rod, and the rod is driven to push ejector plate to move the inner
friction plate, eliminating the gap between friction plate and brake disc; in the meantime, reactive force
will move brake caliper inward, bringing outer friction plate to mate with brake disc; thus, both the inner
and outer friction plates will close up the brake disc and a braking force will result.
Brake reposition: an eased brake pedal will cause the release of chamber pressure; under the function of
return spring, standard seat will bring screw rod to its original position. This process will guarantee a cer-
tain gap between brake disc and friction plate.
Brake clearance auto compensation: to guarantee a clearance between friction plate and brake fluid, a
mechanism has been applied in the brake to automatically adjust friction plate abrasion clearance. Clear-
ance adjustment mechanism works at every cycle of brake, the trigger is located on pressure arm. When
the clearance exceeds setting value, by rotating screw thread pair, adjustment mechanism will compensate
the clearance. The normal clearance is 0.6～1.0mm; if it’ s narrower than the setting value, braking zone
will be overheated; while a wider clearance will result in insufficient braking torque or brake failure.
A good braking performance is of great significance to traveling and parking safety; the operator should
regularly observe brake in-service condition. Key points: 1. friction plate and brake disc abrasion situation.
When the abrasion has reached the specified min. value (the highest allowable abrasion is 8mm, the ex-
treme is 2mm), friction plate or brake disc must be replaced without delay; 2. The clearance between fric-
tion plate and brake disc. When the clearance exceeds specified value, the truck must receive
maintenance.
To maintain the brake, operator should park the truck on flat ground, block wheels; or place the truck on a
working platform.
1. Ensure the truck won’ t move during maintenance; don’ t engage the brake when replacing
friction plate
2. Don’ t clean brake with compressed air or other equivalent high-pressure devices in case of cas-
ing damage.
3. To prevent injury, collaborators are required for brake detachment and maintenance operation;
4. After installing new friction plates, the driver shall avoid engaging emergency brake and longdis-
tance brake in the first 50,000 km mileage, in case brake gets overheated.
5. Use recommended repair kit and apply specified setting torque on bolts and nuts.

Friction plate usage requirements

1. When friction plate is ablated, worn, cracked or oil-stained, it must be replaced unhesitatingly.
2. Replace friction plate and pressure spring at the same time.
3. Friction plates of the same truck must be replaced altogether.
Auxiliary Brake
The auxiliary brake of XDR80T tri-axle rigid mining truck is engine exhaust brake, which reduces travel
speed by engine and supporting devices, mainly used applied in heavy-duty long-distance downhill
situations.
The exhaust brake works based on the engine speed, so when the exhaust brake works, it is strictly
prohibited to engage the neutral gear and to shift gears by disengaging the clutch. Otherwise, the
exhaust brake fails, resulting in engine flameout, galloping, no steering, and driving accidents! The
exhaust brake works only when the engine speed is greater than 1000 rpm.
Operation method of engine exhaust brake: Turn on the exhaust brake’s rocker switch when truck
drives down the slope. When the engine speed is greater than 1000 rpm and brake is required, you need to
release the accelerator pedal. Then, the exhaust brake solenoid valve supplies air for the exhaust brake cyl-
inder to turn off the exhaust brake butterfly bamper, realizing exhaust brake. If truck speed is too high, the
driver should stamp service brake, let main brake system work; at this time, engine exhaust brake system
continues working till truck speed reduces to a safe range before foot pedal is eased.
The entire brake system takes air as power source, so a guarantee of stable air pressure is the first
and foremost thing to braking safety, which calls for daily inspection of air circuit for leakage. Air
compressor outlet air temperature is high, so condensed water will generate inside pipeline, and
the air contains corrosive gasoline, which will bring damage to air valve and threaten braking
safety; operator must manually open water drain valve to exhaust water out of air storage
cylinders (all 8 cylinders must be opened). It’ s more necessary in cold weather than in winter!
The drier cylinder of air drier must be replaced at least once semi-annually; otherwise, drying and
filtration performance will largely deceases and affect braking performance!
Brake disc and friction plate maintenance standard
Friction plate initial thickness: 30 mm; min. thickness: 11 mm; min. liner thickness: 2 mm; max. uneven
abrasion amount: 1 mm; brake disc initial thickness: 45 mm; thickness limit: 37 mm; max. axial jump:0.15
mm; max. thickness difference: 1 mm; max. surface crack: less than 75% of brake disc opening; max. dent
depth: 0.5 mm.

4.11 Lifting System

Maintenance
interval
Nor-
First Applied
Serial Part mal
No. Number main-
ten- ment
ten-
ance
ance
（h）
（h）
D802.063.18 Lift
803277418 return oil filter Pcs
1 element 1 1000 Lifting oil tank
All
08102117 Air
803277637 Pcs seasons
filter element
Autran 4 10_bluk
2 822538783 L 120 3000 Lifting System
hydraulic oil
XDR80T light-duty mining truck uses full-hydraulic steering and pneumatic hydraulic lifting. Fill 59 L oil
to the steering oil tank and 120L to the lifting oil tank till the visible window.
Visual window
Steering tank
Lift the oil tank
Figure 4-28

Figure 4-29
Lifting tank filter element positions: 1. return oil filter element; 2. air filter element
Details about maintenance and point inspection are as follows:
Maintenance Maintenance Frequency

Type
Content Part Daily Weekly Semiannually
Check the lifting
Air pipe valve for damage
and leakage.
Check the limit

valve for normal
Pneumatic con- Limiting valve
Gener- operation, damage
trol system
al and leakage.
main- Check the limit
ten- valve for normal
Air control valve
ance operation, damage
and leakage.
Check the oil

Hydraulic cylinder for work, Clean the oil
All
System damage and cylinder.
leakage.

Maintenance Maintenance Frequency

Type
Content Part Daily Weekly Semiannually
Oil pump Check the oil port.
Check the lifting

Hydraulic oil pipe valve for damage
and leakage.
Check the lifting

Lifting valve valve for damage
and leakage.
Check the oil level

Oil level
and fill the oil.
Check the filter
Return filter Replace the return
element for
element filter element.
sundries.
Check the filter
Replace the air
Air filter element element for
filter element.
Oil tank contamination.
assembly Check the hydraulic Replace the
Oil tank assembly
oil level. hydraulic oil.
Clean the oil tank

Oil tank assembly
inside.
Check whether the
nut and bolt meet
Nut and bolt
the requirement
(torque).
General introduction
Before adding hydraulic oil in tank, clean oil filter in case of contaminating oil. If hydraulic oil level ex-
ceeds the max. marker of oil level indicator, tank oil will overflow. If the dumper truck won't be used for a
long time, please lubricate all rotary points regularly for anti-rust purpose.
It’ s dangerous to maintaining the vehicle by standing too close to or on driving parts.
If cargo compartment should be lifted for maintenance, please make sure it has been firmly
supported.
It’ s life-threatening to work under a not firmly supported cargo compartment.

Hydraulic oil
In order to prevent hydraulic system from damage, the hydraulic oil we recommend is Castrol Autran
410. You may also use other hydraulic oils of the same level that come from a different supplier.
Post-accident treatment
Inspect hydraulic system for damage (pay attention to inlet pipe, hydraulic oil tank and connection be-
tween oil pump and PTO). Inspect the connection of all air circuits and oil lines for damage or leakage. If
there is any problem, please do not lift the cargo compartment before XCMG service staff come.
Maintenance
For safety concern, except from observance of maintenance schedule, visual inspection and walk-around
inspection can also help find hidden troubles at earlier stage, save maintenance cost and reduce shutdown
time. Positions for inspection:
1. Wheel - inspect whether tire manufacturer is in line with requirements, whether nuts have been tight-
ened up (knock with a spanner and hear the sound: nut should sound heavy and dull). Check if tires are
stuck by foreign objects, rotating tire may help eject such objects out.
2. Chassis and fittings - inspect the overall condition for crack and abrasion, check the mating operation of
some devices (like oil cylinder) and rotary points as well as mounting points.
3. Air line brake and hydraulic system - inspect pressure and oil level, hear if there is air leaking sound;
observe the truck and ground, and check if hydraulic oil is oozing, leaking or flowing on the ground.

Fault Cause Solutions:
The PTO is not engaged. Engage the PTO.
There is no oil in the tank. Fill oil into the tank.
The ball valve at the bottom of oil
tank is not turned on. The oil suction Turn on the ball valve.
The oil cylinder is not pipe is blocked.
lifted when the pneu- Low air pressure/blocked pneumatic
Increase the air pressure drive.
matic control valve is in and oil circuit
the UP position. The limit valve does not work and
Contact Xugong Mining Machinery
the oil cylinder is connected to a
customer service center or dealer
wrong valve port.
The detachable coupling is not well
Tighten the coupling.
connected.
Lifting valve failure Lifting valve damaged

Fault Cause Solutions:

Check the air pressure (minimum
Excessively low air pressure
The cylinder is lifted 6bar, 87psi).
too slowly. The gear pump is damaged. Contact Xugong Mining Machinery
Overflow valve damage customer service center or dealer
Oil level in the tank is excessively
Fill oil into the tank.
low.
Cylinder lifting is not
stable. The hydraulic oil is mixed with air.
The gear pump is damaged.
Oil level in the tank is excessively
Fill oil into the tank.
low.
The hydraulic oil circulates using the
Manually remove or redistribute the
The oil cylinder cannot relief valve (overload or uneven
load.
be fully lifted. load).
Overflow valve damage
Overload Remove partial load.
The compartment falls
The check valve at the lifting value Contact Xugong Mining Machinery
when you step on the
does not work (fixed). customer service center or dealer
clutch.
When the pneumatic
The air pipe bends at the lifting
control valve is in the Contact the service station or HYVA
valve and the pneumatic control
"DOWN" position, the dealer.
valve.
cylinder is lifted.
The return filter element is blocked. Replace the return filter element.
The lowering speed is adjusted to an
excessively low or high value.
The oil cylinder falls
The limit valve does not work. Contact Xugong Mining Machinery
too slowly or fast.
The pneumatic control valve does customer service center or dealer
not work.
The oil is too thick.
The air pipe leaks.
The pneumatic control The pneumatic control valve is Contact Xugong Mining Machinery
valve fails suddenly. blocked by dust. customer service center or dealer
The limit valve does not work.

XDR80T Tri-Axle Rigid Dumper Truck Cargo Compartment Lifting Instructions
Cargo compartment lifting procedure
Step 1: Engage the power take-off (PTO).
1. After the vehicle stops, pull the parking

brake or apply the parking brake.
Place the transmission to the neural

position.

lever to neutral position （Figure 4–
30）
3. Step on the clutch and wait for about 2

seconds.
Turn the PTO switch to the position shown

in the Figure 4– 31when indicator lamp
turns on, slowly ease the clutch, and then
PTO engagement is completed.
Figure4-31 PTO on
Do not drive the vehicle when the PTO is engaged.
Step 2: Pneumatic control valve lifting


lever to lifting position ， Figure 4–
32and cylinder tube extends to lift cargo
compartment.

lever to neutral position （Figure 4–30)
and lifting process stops, cargo compart-
ment comes to a halt.
Figure4-32 lift
Step 3: Pneumatic control valve lowering operation (including PTO removing)
1. Step on the clutch for 5s during the low-

ering operation.
2. Move the operating lever to the lowering

position. Note: For this pneumatic con-
trol valve, lowering movement is linked
with PTO switch disengaging move-
ment, which means, when you pull oper-
ation lever to lowering position , Figure
4–33PTO switch also returns to “off”
position , Figure 4– 33and cargo com-
partment begins lowering. Check Figure4-33 decline
whether the indicator lamp turns off and
slowly release the clutch. The lowering
operation is completed.
3. About 2 minutes after the truck body is

completely lowered, move the pneu-
matic control valve from the lowering
position to the neutral position. This en-
sures that cylinders at each stage are re-
tracted back into the base barrel.
Operation of removing the PTO*.

1. Pull pneumatic control valve operation lever to neutral position, and press clutch.
2. Pull PTO switch to “off” position Figure 4–30so as to ease PTO. Check whether the indicator lamp
turns off and slowly release the clutch. The PTO disconnection is complete.
*As an independent action, this operation is unrelated with cylinder lifting.
4.12 Steering System

Maintenance
interval
Nor-
First Applied
Serial Part mal
No. Number main-
ten- ment
ten-
ance
ance
（h）
（h）
XCMG80A03-
813406753 GYL-01007 filter Pcs
element
1 1 250 1000 Steering oil tank
EF-089N-100A All
803277666 Steering return oil Pcs seasons
filter element
Autran 4 10_bluk
2 822538783 L 59 3000 Steering System
hydraulic oil

Figure 4-34
Replace high-pressure filter element
1. Clockwise turn the hexagon nut as shown in Figure 2 with a tool, remove casing 1 and expose filter ele-
ment 3.
2. Clockwise turn filter element 3 by 1/4 circle, and remove the filter element from the buckle.
3. Install a new filter element, counterclockwise turn it by 1/4 circle. Fix filter element on the buckle.
Note: Do not damage the O ring on casing 1 during installation.

Steering oil cylinder spare part replacement
Figure 4-35
Steering cylinder filter element positions: 1. Return oil filter element; 2. air filter element
Pay attention to the difference between the type of return filter element and that of steering cylinder.

Steering system fault diagnosis
Fault Cause Inspect and troubleshoot
Steering linkages of front axle is
Adjust or replace damaged part.
worn or damaged
Add a proper amount of oil into
Steering oil level is low steering cylinder and brake control
cylinder.
Steering is inflexible or
Lubricate each points with correct
difficult, steering Lack of lubrication
oils at specified intervals.
pressure wont’ alarm
Steering cylinder is damaged Replace steering cylinder.
Inflate all tyres according to
Incorrect tire inflation
specified pressure.
Front suspension cylinder lacks in Repair front suspension cylinder as
pressure per requirements.


The filter of steering oil cylinder has
Replace oil filter.
been polluted
Steering cylinder pipeline has been Repair or replace damaged hose or
damaged joint
Adjust steering valve group pressure
Steering valve pressure is to 18Mpa; if impossible, replace
insufficient steering valve or corresponding
insert pin.
Symptoms: after adjustment,
Steering is inflexible or
steering valve pressure still cannot
difficult, steering pres-
rise, after engine has run for 10
sure gives alarm
minutes, oil pump casing
Steering pump insufficient pressure
temperature exceeds ≥100 °C; from
these symptoms we can conclude
that steering pump is damaged.
Replace steering cylinder.
Steering pump is out of order Repair or replace steering cylinder.
Replace damaged hoses; inspect
steering cylinder and brake control
Steering system hydraulic pipe is
cylinder for oil level; add oil if
damaged
needed; meanwhile, inspect steering
system for pollution.
No steering movement Steering valve failure Repair or replace steering valve.
Drain all hydraulic oil out of
steering system, thoroughly rinse it
Steering system is completely and clean it; check all valves,
polluted. cylinders and oil tanks; install new
filters and add new hydraulic oil;
frequently inspect filters.
If after engine has run for 10
minutes, oil pump casing
Steering oil temperature temperature exceeds ≥100 °C, it
Steering pump is damaged.
warning can be considered that steering
pump is damaged. Replace steering
pump.


Symptoms: check steering pressure
on control board, when turning
steering wheel, the pressure is about
Steering valve insert pin is damaged 18.5Mpa (normally it fluctuates at
16-18.5Mpa), and oil temperature
exceeds ≥90 °C. Replace steering
valve or valve insert pin.
Reversed steering Incorrect connection of hydraulic Re-connect pipelines according to

direction pipeline hydraulic principle scheme.

4.13 Electric system

If electric device is damp or wire cladding is damaged, short circuit and machine failure will result.
Don’ t spray cab interior with water. Don’ t let water enter electric components when washing the
machine.
Trouble Content Fault Analysis Measure

Lead wire is disconnected Inspect and repair
Engine rotation speed is Sensor internal fault Replace

irregular and fluctuates Lead short circuit (ground fault) Inspect and repair
Controller internal fault Replace

Vehicle power cannot
Power relay fault Replace
be interrupted
Lead short circuit fault (ground
No device works Inspect and repair
fault)
Fuse fault Replace
Combination instrument Lead disconnection fault Inspect and repair

screen is black Lead short circuit (ground fault) Inspect and repair
Display screen fault Replace
Resistor fault Replace
Combination instrument Lead disconnection fault Inspect and repair

no display Lead short circuit (ground fault) Inspect and repair
Display screen or controller failure Replace
Coolant temperature sensor failure Replace
Inaccurate display of
Lead disconnection fault Inspect and repair
engine coolant
Lead short circuit (ground fault) Inspect and repair
temperature
Lead wire is short circuit to 24V Inspect and repair
Fuel level sensor fault Replace
Fuel level is incorrectly Lead disconnection fault Inspect and repair

displayed Lead short circuit (ground fault) Inspect and repair
Lead wire is short circuit to 24V Inspect and repair

Trouble Content Fault Analysis Measure

Wiper motor internal failure Repair or replace
Wiper does not work Lead disconnection fault Inspect and repair
Lead short circuit (ground fault) Inspect and repair
Power failure Repair or replace
Steering pressure is Signal wire break circuit fault Inspect and repair
inaccurately displayed Signal wire short circuit fault Inspect and repair
Sensor fault Replace
Power failure Repair or replace
Steering oil temperature Signal wire break circuit fault Inspect and repair
is incorrectly displayed Signal wire short circuit fault Inspect and repair
Sensor fault Replace
Instructions
Battery usage:
1. When vehicle is in storage period, inspect and charge all the batteries every two months in summer and
every three months in winter; add distilled water as needed.
2. Weekly inspect batteries when vehicle is in service.
3. When the truck is temporarily not in use for more than 2 weeks, the batteries should be charged before
and after being stopped.
4. Battery liquid level shall exceed polar plate and partition plate. Electrolyte is easy to be consumed in
summer. When the electrolyte is excessively reduced, check whether the battery is overcharged. When
the electrolyte is insufficient, distilled water should be filled. Dilute sulphuric acid is forbidden.
5. Remove terminal rust and apply anti-rust oil.
Maintenance
Battery maintenance:
1. To prevent short circuit, when removing (or installing) battery wire, the ground wire must be firstly re-
moved (or installed).
2. Keep the battery upper part and related connecting wires clean and dry.
3. Do not break the batteries when the batteries are transported.
4. Metal tools cannot be placed on batteries when the truck is maintained.
5. Battery electrodes cannot be incorrectly connected. Otherwise, relevant connecting wires and electrical
equipment will be burnt out.
6. The battery connecting line should be reliably connected with the battery terminal.

7. If the truck is not used for a long time, the battery should be removed from the truck and placed in a
cool and ventilated place.
Other instructions
1. Do not install any electric component except the ones specified by Xuzhou Xugong Mining Machinery
Co., Ltd.
2. External solenoid interference will cause control system failure. Before installing a radio receiver or
other wireless devices, please contact Xuzhou Xugong Mining Machinery Co., Ltd. or its authorized
dealer.
3. When installing an electric device, do not connect it with any special power adapter
4. Do not connect any optional power source with fuse, starter switch or power relay
4.14 Air Conditioning System

Maintenance
interval Ap-
First plied
Serial Part Normal Target
Description Unit Qty main- envi-
No. Number mainte- part
ten- ron-
nance
ance ment
（h）
（h）
Air
XCMG15-22R- 062
1 803593078 EA 1 500 conditioning -
Fresh air filter net
indoor unit
Jin leng refrigerant Air
2 822537615 R134A（ 0.3KG/ EA 4 1000 Conditioning
bottle System
Maintenance Guide
1. The basic work of regular maintenance like filter screen cleaning, inspection of compressor belt tension
etc., can be fulfilled by the driver.
2. Check and clean the a/c condenser. Keep the fins clean without contaminants. Clean the fins with cool
water or compressed air. Never use hot water or hot vapor.

3. Check the refrigeration dose of the refrigeration system, that is, observe the observation window of the
reservoir. Under normal conditions, there are no bubbles in the observation window, and there are a
small amount of bubbles when the engine speed changes.
4. Check drive belt of the compressor for tension.
5. Check hoses and their connection.
6. Check power connection of cooling system in order to make sure that there is no open circuit and short
circuit.
7. Do not open the joint cover of pipeline and compressor. Dirt and moisture are very harmful to the per-
formance of air conditioning and the first cause of the compressor damage. The most compressor failing
to be compensated is because of the contamination of system.
8. In installation and maintenance of air conditioning system, new or clean parts must be used. Before add-
ing the refrigerant, the vacuum pumping is required for at least 45 min. The pointer of low pressure
gauge should indicate the mercury column below 750 mm, where the moisture in the system will be
eliminated.
9. Before performing the circuit maintenance, be sure that the line insulation is in good condition and the
PS safely controlled.

Maintenance Guidance
Regular preventive maintenance plays a key role in ensuring good and lasting operation of the air condi-
tioning system.
Task Corrective measures

Weekly maintenance
Operate the air conditioning system for a few minutes
to ensure relevant components’ good lubrication.
Monthly maintenance
Check the return air filter screen for dust and
Check the return air filter screen for dust and blockage.
blockage.
If necessary, adjust belt tightness or replace
Check the compressor belt’s condition.
the belt.
Clean the parts using water or compressed
Check the condenser dust.
air.
Semi-annual maintenance
Check pipelines for wear or check the joints for Conduct leakage tests and replace pipelines
leakage. Oil stains indicate leakage. if necessary.
When the air conditioning system works, check the Bubbles indicate refrigerant is lacked, so
liquid mirror. refrigerant filling is required.
Check whether the hot water pipes are worn and are
If there is wear, replace hot water pipes.
well connected.
1. Is the clutch powered?

When the fan works normally, observe the compressor’s clutch center to check whether the clutch ro-
tates with the belt pulley. If the clutch does not rotate, the clutch is not powered.
2. Is the pressure-protection inlet powered?
Under normal circumstances, pressure-protection is long-term powered. If the pressure-protection inlet
is powered, refrigerant is lacked or pressure-protection is damaged. At this time, a manifold manometer
is required to check the system pressure. If the pressure is lower than 0.2 M, the refrigerant is lacked.
The leakage position should be found and resolved, and then refrigerant is filled. If the pressure is high-
er than 0.2 M, pressure-protection is damaged. Therefore, pressure-protection should be replaced. Vac-
uumization and refrigerant filling are performed. If the pressure-protection inlet is not powered, the
component switch is damaged and the pressure switch needs to be replaced.
3. Does the belt has noise?
Belt looseness or wear will whistle. If you hear this sound, adjust belt tightness or replace the belt.

4. Is there any noise around the compressor?

Check whether parts around the compressor and compressor frame are loose, and tighten them if
necessary.
5. Is there any noise from the compressor?
Suction and exhaust valve or internal damage may be the cause of the noise.
6. Is there any oil stain around the pipe joints and the compressor?
In a place with oil stain, the noise may be caused by refrigerant oil brought by refrigerant leakage.
Check whether there is leakage using a tester. Replace parts if necessary, and carefully check the com-
pression seal gasket, seal ring and shaft seal.
7. Check the hot water valve for internal leakage.
Check whether the heat exchanger and the hot water pipe connecting with heat exchanger are hot. If
yes, the water valve has leakage.
Minor failure
The fan motor does not work.
Possible Cause Inspection Measure

1. Blown fuse, line Check the fuse/line, motor grounding
disconnection, and joint poor condition, and the connector contact Replace the fuse or line.
contact condition.
Check the motor's power supply and Replace the resistor or the
2. Motor fault
resistor. motor.
Check the control panel’s power Replace the control panel if
Control panel fault
supply in and out. necessary.
The fan works normally, but the air volume is insufficient.

Remove the stopper and clean
Check the dust on the air inlet
1. Evaporator air inlet blockage the evaporator and the return air
and fins of the evaporator.
filter screen using air or water.
Replace the temperature
2. The evaporator is frozen. Temperature controller fault
controller.
The compressor does not work or works abnormally.

Check the belt vibration or
1. Belt looseness Adjust the tension.
jump.
2. The compressor is damaged Check whether the compressor
Replace the compressor.
internally. is locked or the belt is broken.
Check system pressure to shoot the truck.
When the compressor works at a speed of 3300 rpm and the ambient temperature is 30-38 ° C, normal
pressure at the suction side and exhaust side of the compressor is as follows:

Pressure at the low pressure side is too high.
When the pressure at the high side is too high, the pressure at the low side is also too high.
1. Too large expansion valve The pipeline at suction side is
Replace the expansion valve.
opening frosted.
After the clutch is engaged,
2. Compressor fault pressure at the high is equal to Replace the compressor.
that at the low side.
Pressure at the low side is too low.
The pressure at the high side is
Repair leakage points and refill
1. Insufficient refrigerant low and the liquid mirror has air
the refrigerant.
bubble.
The inlet of the expansion valve
2. The expansion valve is Clean or replace the expansion
is frosted. Water or other
blocked or turned off. valve.
sundries are possible causes.
There is frost in the pipeline
3. Blockage between dryer and between the dryer and expansion Clean the system with nitrogen
expansion valve valve, which may cause negative or replace the pipeline
pressure.
Adjust the probe position or
4. Temperature controller fault The evaporator is frozen. replace the temperature
controller.
High side pressure is too high.
1. The condenser has poor heat Condenser fins are polluted or
Clean condenser fins.
dissipation. blocked.
When the ambient temperature Recover redundant refrigerant
2. Excessive refrigerant is of 30-38°C, high side pressure and adjust it to the proper
is greater than 23 bar. amount.
Remove refrigerant oil from the
3. Excessive condenser High side pressure is too high. compressor and condenser, refill
the oil, and replace the dryer.


High side pressure and low side Empty the system. Refill
4. Air enters into the system.
pressure are both high. refrigerant after vacuumization.
5. Blockage in the condenser, Empty the system. Replace the
High side pressure is high and
dryer or high-pressure side faulty parts. Refill refrigerant
low side pressure is low.
pipeline after vacuumization.
Low side pressure is too low.
High side pressure is low. There
Find out the leakage point. Refill
1. Insufficient refrigerant are bubbles in the liquid mirror
refrigerant after vacuumization.
of the dryer.
System pressure is consistent.
Refer to the basic
1. The clutch is not engaged.
troubleshooting section.
2. The compressor piston is High side pressure is consistent
Replace the compressor.
damaged. with the low side pressure.
Instructions
Hot weather
1. Close the heating valve.
2. Switch on refrigeration function.
3. When starting, firstly keep fresh air switch off for 10-20 minutes to fast cool down temperature.
Weather with appropriate temperatures
1. Turn off the cooling and heating switches.
2. Turn on the fresh air switch.
3. Adjust the air flow to a suitable degree.
Cold weather
1. Close refrigeration function.
2. Turn on heating water valve.
3. When starting, firstly keep fresh air switch off 10-20 minutes for to temperature to fast rise.
Maintenance
Assembling Tools and Equipment

Recycling/recirculating device
Whenever removing refrigerant from system, be sure to follow Figure 4–36and go through collection and
recirculation procedure. This procedure is in line with new principles regarding retreated refrigerant. Col-
lected refrigerant will be recirculated in order to remove contaminants. Treated refrigerant can be used in
the same machine or vehicle group.
In order to achieve this, recycling/recirculating device will repeatedly separate oil from refrigerant and re-
peatedly filter the latter so as to remove moisture, acidness and particulates.
Note: for reuse of refrigerant, it must be recycled in a clean way in order to guarantee purity.
A device that can only remove or draw refrigerant is also necessary. Draw the used refrigerant. It is also
used to maintain refrigerant that were collected from air conditioning system.
During maintenance, it’ s forbidden to directly exhaust refrigerant into atmosphere.
High side
hose (red)
Low side
Quick joint hose (blue)
Figure 4-36 Recycling/recirculating device
Mixed use of different types of refrigerant will damage the device. A special recycling/recirculating
device must work on only one type of refrigerant. Mixed use is prohibited; otherwise, the device
will be damaged, even cause personal injury. Refrigerant recycling treatment must be done by a
special company qualified by local law.
Before refrigerant treatment, please test refrigerant type with a special testing device, and figure out if oth-
er types of refrigerant has been mixed. If the refrigerant type is incorrect or it is polluted, please change it
with a correct type.

Refrigerant recycling/recirculating device must comply with the standards stipulated by the laws and regu-
lations of the user's country. It’ s strictly forbidden to use a device that does not comply with the stand-
ards stipulated by the laws and regulations of the user's country. Even if some specific details may change,
the basic working principles of all machines are the same.
Leak detector
Electronic detector Figure 4–37is very accurate and safe. It is a portable device with flexible probe that
detects refrigerant leak. Even an extremely tiny amount of leak can be detected and reported by a buzzer,
warning device or lamp. Some leak detectors only apply to just one type of refrigerant. Be sure that the
leak detector in use is applicable to system refrigerant.
OFF OAL DPR

BAT BRING
Figure 4-37 Classic electronic leak detector
Manifold pressure gage
A classic manifold pressure gage (Figure 4– 38) has two screw type manual valves that control pipeline
connected to the system, two pressure gages and three hoses. With pressure gage we can take the reading
of system pressure or vacuum. Manifold and hoses are used to enter air conditioner, remove air and mois-
ture, add or remove system refrigerant. There is a shutoff valve about 30 cm (12 inches) to the end of hose
that can be used to minimize the loss.
R-134a pressure gage has a blue hose (with black stripe on it) at low pressure side, a red hose (with black
stripe on it) at high pressure side, and a yellow hose (with black stripe on it) used for hose of maintenance
(center). These hoses are fastened on pressure gage with a 1/2 inches ACME internal thread nut. A special
quick dis-connector is normally in connection with the shutoff valve of hoses at high and low pressure
side. Free end of central hose contains a 1/2 in. ACME internal thread nut and a shutoff device within 30
cm (12inches) to the end of hose. These special hoses and joints are designed to minimize the loss of re-
frigerant and prevent from adding incorrect refrigerant into system.

If it’ s needed to replace old hoses with new ones, new hoses must be in consistent with standards
and suitable for R-134a refrigerant.
Low pressure gauge

(vacuum pressure gauge) High pressure gauge
30 60 200 300
90
0
10 100 400
120
20
30 150 0 500
Low side seat LOW

PRESSURE
MIGH
PRESSURE
High side seat
Manual Manual
valve valve
Low side Maintenance High
port port side port
Figure 4-38 Manifold pressure gage
Low pressure side pressure gage

Low pressure side pressure gage shows the readings of vacuum and pressure. Vacuum side of scale mark
has been calibrated to 0-76.2 cm Hg (0-30in.Hg). Pressure side of scale mark has been calibrated to 1034
kPa (150psi).
When air conditioner is in service, do not open the manual valve at high pressure side. The high
pressure may damage container and cause personal injury.
High pressure side pressure gage

High pressure side pressure gage is designed to only test compressor outlet pressure. The scale mark has
been calibrated to 0-3447 kPa (0-500psi).
Installation of manifold pressure gage
Before maintaining air conditioning system, you’ re recommended to take a visual inspection onto en-
gine and air conditioning system components. Pay special attention to belt, hose, pipes and all connected
components, as well as radiator cover and fan clutch. Inspect condenser and radiator for blockage or possi-
ble contamination. Minimum the possibility of component failure.

Shut down the engine. When engine is running, do not connect or maintain the device.
1. Ensure that all manifold valves are always closed since the beginning (clockwise turn them to shut).
2. Check whether the hoses on manifold are in tight connection.
3. Position maintenance hose joints at low pressure and high pressure sides, and remove their protective
caps.
4. Use two maintenance hoses to accurately connect manifold to the standby valve on compressor,(Figure
4–39)At this time, do not open the standby valve.
Figure 4-39 Maintenance hose connection
No matter what kind of pressure gage it is, connection procedure is all the same. No matter it is a recycling
device or a single pressure gage, the connection is all the same. The next procedure differs with the type
of device. If a recycling/recirculating device has been applied, then the entire maintenance can be com-
pleted. If only one group of pressure gage has been applied, the maintenance will be confined to adding re-
frigerant or observing pressure.
Exhaust air out of maintenance hose
The purpose of this procedure is to remove air out of hoses before commencing system test. According to
environmental regulations, all maintenance hose should contain a shutoff valve 30 cm (12in.) to hose end.
These valves guarantee that only a tiny amount of refrigerant will be exhausted into atmosphere. R-134a
pressure gage has a combined quick dis-connector and shutoff valve at high pressure and low pressure
side. Central hose also needs a valve.
It’ s better for the initial cleaning to be done before being connected to recycling or recirculating device.
When central hose has been connected with recycling device, after connecting maintenance hose with high

and low pressure sides of the system, we can start cleaning process. Manifold valve and standby valve will
be closed. After being activated, the vacuum pump will draw all air and moisture out of central hose. This
process only takes several minutes. Hose is the only zone to be placed into vacuum and it is actually not a
long-lasting process. Close the valves and ensure hoses are cleaned. Now it is the safety time for other
manifold valves to be opened.
Air conditioning system is a closed loop, so two standby valves have been mounted on compressor (Fig-
ure 4–40) to conduct diagnostic test, refill system and draw air. Use manifold pressure gage to connect
proper hoses with compressor standby valve, so as to make the work easy.
The new, special and maintenance hose joint (Figure 4–41) has been designated to use for R-134a system.
The purpose is to avoid accidental mix of R-12 system refrigerant and lubricant. System maintenance port
is quick dis-connector type, without external screw thread. It contains a Schrader type valve. Joint diame-
ter at low pressure side is smaller than the one at high pressure side.
High pressure
side standby
Low pressure L valve
H
side standby
valve
Figure 4-40 Compressor standby valve
2 3
1
Figure 4-41 Maintenance hose joint
1. Standby valve 2. Quick connector 3. Maintenance hose connection
Vacuum pump
Vacuum pump (Figure 4–42) is intended to draw out all refrigerant, air and moisture from system. This
function is realized by reducing system pressure to a point when water turns into vapor (boiling) and draw-
ing (pumping out) all air and refrigerant from system.

Figure 4-42 Vacuum pump
System performance test
• Conduct this test in order to establish conditions of all system components. During the test, observe fol-
lowing conditions: put a fan in front of condenser to simulate normal ram air flow and stabilize the
system.
• Install temperature gage into an evaporator vent that’ s the closest to air conditioner.
• Start engine and run it at a speed of 1000 rpm.
• Estimate the reading taken from pressure gage and check if it matches with the reading taken in ambient
temperature.
• Set air conditioning system into max. refrigeration speed and max. blower speed.
• Shut all windows and cab door.
• Start to feel the hose and components of high pressure side. All of these components should be very
hot. Inspect whether outlet temperature and inlet temperature of condenser are even. If the outlet tem-
perature is cooler than inlet temperature, it means there is no blockage.
Put hands on hose and components of high pressure side and be extremely careful. In most cases,
these components may be very hot.
• Feel the hose and components of low pressure side. They should be cold. Inspect the connection near
expansion valve. Inlet should be hot while outlet should be cold.
• Wait for at least 10 minutes for system to stabilize, and then observe pressure gauge reading. Compare
the reading with technical specifications in table 1.
Note: In very damp conditions the pressure may be slightly higher and in extremely dry condi-
tions the pressure may be a little bit lower.
• Inspect the cold air venting hole of driver’ s cab. Outlet air temperature will be 16-22°C (30-40°F)
lower than ambient temperature.

If pressure and temperature are not within specified ranges, it means the system is faulty. Refer to prelimi-
nary inspection at the end of this chapter for a poor system performance diagnostic techniques.
Table 4-1 Nominal R-134a pressure range
Ambient temperature Pressure at high pressure side Pressure at low pressure side
21°C（70°F） 820 - 1300 kPa (120 - 190 psi) 70 - 138 kPa (10 - 20 psi)
27°C（80°F） 950 - 1450 kPa (140 - 210 psi) 70 - 173 kPa (10 - 25 psi)
32°C（90°F） 1175 - 1650 kPa (170 - 240 psi) 105 - 210 kPa (15 - 30 psi)
38°C（100°F） 1300 - 1850 kPa (190 - 270 psi) 105 - 210 kPa (15 - 30 psi)
43°C（110°F） 1450 - 2055 kPa (210 - 300 psi) 105 - 210 kPa (15 - 30 psi)
Note: All the pressures in this table are for reference only. Weight is the absolute method to determine
how much refrigerant to fill in.
System oil
R-134a air conditioning system requires Poly Alkylene Glycol (PAG) oil. This is the only oil recom-
mended for this system.

PAG oil treatment and repeated use
• Just like all other chemicals, try to avoid contact with skin and do not take it in.
• PAG oil cannot be re-used. PAG oil, taken from no matter a new or old machine, must be stored in a
well labeled container and sealed according to local regulations. PAG oil is an environment pollutant,
and must be recycled according to local regulations after use.
• After maintenance or replacement, immediately seal all PAG oil related pipes and PAG oil tank. PAG
oil has strong water absorption, if moisture has been absorbed by air conditioning system, component
may be damaged, which will affect the normal operation of overall vehicle. If PAG oil storage tank
takes in moisture, oil purity will be influenced, and the rest of oil will be wasted.
Oil amount
Make sure air conditioning system contains a proper amount of lubricating oil. Otherwise, compressor will
be damaged. If lubricating oil is lower (or higher) than the specified amount, compressor will be damaged.
A low amount of lubricating oil will cause excessive abrasion to moving parts. An excessive amount of lu-
bricating oil will result in compressor stagnation. When refrigerant starts to gasify, lubricating oil won't be
compressed, causing system pressure to increase, and exceed specified value, bringing damage to internal
parts.
Inspect system oil
When system is disconnected for inspection, see to it to replace liquid storage dryer and gas-liquid
separator (if equipped).
1. Remove compressor from the truck. With the compressor placed horizontally, extract drain screw plug
and use a container (with clear scale mark) to collect oil. Shake compressor and rotate the shaft so as to
drain oil.
In no case shall a/c compressor be vertically placed on clutch assembly. Otherwise, compressor
clutch will be damaged and an early fault of compressor will result.
2. Inspect oil for any impurity or particulate. If particulate has been found, investigate the cause and main-
tain it. Before repair, be sure to rinse the system. Refer to “Wash the System” . If no particulate has
been found, take the next step.
3. Put an amount of 205 ml PAG oil into compressor oil pan. Add oil through drain hole and then install
drain screw plug. Add a specified amount of oil so as to ensure the best system performance. Excessive
oil will result in reduced cooling efficiency. Insufficient oil will lead to a compressor fault.

4. Refer to “Oil Replacement Reference Table” for oil amount of each component. Add oil into the inlet
of drier or gas-liquid separator.
As another oiling method, oil can be injected into system when needed.
5. Connect all hoses and components of the system. Before re-assembly, lubricate O ring with refrigerant
oil.
Before installing a new compressor, be sure that oil has been completely drained out. Add an
amount of 205 ml new PAG oil into compressor. If compressor oil amount has not been adjusted,
system may have contained an excessive amount of oil, which will result in poor system
performance. Besides, a new liquid storage drier and gas-liquid separator (if equipped) must be
installed and an amount of 205 ml oil must be added to either of them.
6. Exhaust the system. Refer to “Exhaust the System” in the end of this chapter.
Table 4-2 Oil Replacement Reference Table
Component Oil adding amount

Condenser 30 ml
Evaporator 40 ml
Hose 70 ml
Refrigerant
Recirculated refrigerant
Collect refrigerant from truck air conditioning system with a refrigerant recycling device. When refriger-
ant is being filtered by a refrigerant recycling device that complies with standards (such as SAE J2099 or
the standard in the country or region where the user's located), the refrigerant is thus cleaned by this de-
vice. Filter can remove refrigerant impurities that only influence air conditioning system performance.
Therefore, the refrigerant the re-circulates in the truck can be re-used in that truck only.
Regenerated refrigerant
Regenerated refrigerant has received more thorough filtration and has reached the same purity level as
new refrigerant. For this reason, regenerated refrigerant can be re-used into all systems, not only truck sys-
tem. Regeneration device is very expensive, so it is rare to see one in a maintenance shop and not com-
monly owned by users. It can only be seen in a special air conditioner maintenance shop.

To fill up the system, be sure to use new, recirculated or regenerated refrigerant. Failing to observe
this suggestion may lead to early component abrasion, damage and a poor cooling performance.
Refrigerant amount
Refrigerant filling amount: about 900 g. If system is not filled up with sufficient refrigerant, cooling per-
formance will reduce. If system is filled up with excessive refrigerant, when working under high pressure,
system component may get damaged. Adding an excessive amount of refrigerant into air conditioning sys-
tem will not help increase cooling performance.
If a doubt raises that refrigerant hasn’ t been added as specified, be sure to recover system refrigerant
and add a specified amount in it. This is not simply a recommended procedure, it is also a guarantee of a
normal cooling performance and a regularly long life span of components. Use a sight glass to determine
if a correct amount of refrigerant has been added.
If the sight glass in R-134a system is unclear, it may indicate that the system is in lack of
refrigerant. However, sight glass shall not be taken as a metering tool. A weighing machine/scale
must be used to guarantee a proper amount of refrigerant to add. If conditions permit, use a
recycling device or regenerating device to completely collect refrigerant before adding a specified
amount.
R-134a refrigerant packing specifications
• One-off iron tank: 300g/pc; 30 pcs/box;

• One-off steel cylinder: 13.6kg/pc;
• Re-usable steel cylinder (recyclable steel cylinder): 400kg/pc; 800kg/pc.
Refrigerant R-134a steel cylinder is a pressurized container, should be stored in a cool, dry and
ventilated place away from fire, heat source, straight sunlight, and handled with care in case of
damaging the cylinder fittings and valve.
System leak test
Refrigerant leak is the most common fault in the use of air conditioner. his fault will cause cooling anom-
aly or cooling failure, the major cause is internal component damage. The leaking point may be at follow-
ing positions:

• First, traces of leaked refrigerant oil appear around compressor shaft. If the system has been out of serv-
ice for a period of time (winter), shaft seal may become dry and show slight leakage. Centrifugal force
generated by spinning of clutch belt pulley can also lead to this fault. When system starts working and
moisturizes the seal, the leak may stop. Such a leak can be located by visual inspection or perceived by
finger circling around the shaft. R-134a is colorless and odorless, so won't leave traces of leak, but
shows strong affinity to refrigerant lubricating oil.
• The second zone is hose joint and easily worn sections of pipes. Visual inspection and physical detec-
tion are needed on screw joint and where gaskets are used. Check for condensation by moving a finger
along the bottom of condenser and evaporator, especially near the drain hole, and this will help quickly
know evaporator state. Any new trace of leak found here clearly indicates a leak.
Normally, a 50% fill can easily find most leaks. If the system is empty, then connect manifold pressure
gage with the system and add an amount of at least 900g refrigerant into system.
When engine is running, be careful with leak detection. When in natural state, refrigerant is
harmless and colorless gas, but when it contacts open flame, it produces toxic smoke (phosgene)
that will cause severe injury and death.
Note: Refrigerant density is larger than air, so it leaks downward. Place a sensing hose or detective
probe beneath the lower surface of all components to detect leak.
Refrigerant leak will cause environment pollution, prolong downtime and affect truck utilization rate. Fol-
lowing are several detection methods.
1. Electronic leakage detector
Move a detective probe towards any possible leaking source. When the probe detects a leak, it will
alarm. When the tensity of leakage changes, alarm sound and frequency will also change.
2. Soap water detection
Apply soap water on components. Bubbling points are leaking points. After positioning leaking points,
be sure to repair or replace related parts.
3. Fluorescence detection
When exposed under ultraviolet/blue-ray leak detection lamp, fluorescent leak detecting agent will glow
bright yellow and green light. This principle is used in leak detection of various liquids. First of all, add
an amount of proportionally mixed fluorescent leak detecting agent into system; secondly, run the sys-
tem for 20 minutes; thirdly, wear a pair of special glasses while shining system exterior using a detec-
tive light; finally, leaking position will turn into yellow fluorescence.
Fluorescence detection can accurately and clearly expose a leak, which will be straight observed; be-
sides, it is foolproof, portable and low cost.

Hose length will influence refrigerant capacity. When replacing a hose, if possible, be sure to install
a new one of the same length. Before assembling the system, be sure to inspect compressor oil level
and add oil according to “Oil Replacement Reference Table”.
Refrigerant recycling and recirculation
Exhaust the previously recycled oil
1. Pull recycling device switch and controller switch to OFF

2. Insert recycling device plug into correct power source.
3. Drain the recycled oil through a marked drain valve on front side of the machine.
4. Pull controller knob to ON. Low pressure gage will show rise.
5. When the reading rises, immediately turn the gauge to OFF and wait for pressure to stabilize. If pressure
fail to rise to 34-69kPa (5-10psi), turn the controller switch to ON and OFF again.
6. When pressure reaches 34-69kPa (5-10psi), open oil drain valve, collect oil with a container and dispose
of it as per local regulation.
The oil has absorbed impurities during circulation, so do not re-use it.
Carry out recycling
1. Make sure the device in service is the one that matches with the refrigerant that you intend to maintain
the truck with.
Each set of recycling device matches with one kind of refrigerant, so do not mistake them;
otherwise, system component will be damaged.
2. Inspect oil level through sight glass. If it has been drained, the level on sight glass will be zero.
3. Before recycling, be sure to inspect refrigerant level, and make sure there is enough space.
4. Before connecting to air conditioning system, ensure all shutoff valves have been shut.
5. Connect a proper hose with the to-be-recycled system.
6. Start recycling procedure according to manufacturer instructions.
7. Pump the system till vacuum exists in air conditioning system.
8. When system pressure has reached 0 kPa (0psi), if it takes a long time for the pressure to steadily fall
vacuum, then close the manifold valve and inspect system pressure. If it rises to 0 kPa (0psi) and then
stops, it may indicate a huge leak.

9. Before recycling device stops, be sure to inspect system pressure. 5 minutes later, system pressure shall
not exceed 0. If the rise continues, then re-start it and begin recycling procedure again. This cycling will
continue till system exhausts refrigerant.
10.Inspect oil level through sight glass and determine how much oil to substitute with. The amount of oil
lost during recycling must be added into system.
11.Put a “Recycled” (red) magnetic label on steel cylinder, which will reduce the possibility of filling
system with polluted refrigerant. Take a record of the amount of recycled refrigerant.
Carry out recycling procedures
The refrigerant stored in cylinder must receive a recycling procedure before reuse. Recycling or cleaning
mode is a continuous recycling design, it can quickly clean refrigerant. Refer to manufacturer’ s instruc-
tions for this procedure.
Vacuumize and refill air conditioning system
If air conditioner components have been repaired, or replacement parts have been installed, or air condi-
tioning system has been re-assembled, be sure to vaccumize the system. This vacuumization will remove
air and moisture out of system. After vacuumization, you may add new refrigerant into the system.
In order to maximize the vacuumization and remove as much air and damp moisture as possible,
be sure to adopt Repeated Vacuumization Method, that's, to vacuumize the system for over 30
minutes after the first vacuumization.
Repair the system
Maintenance and repair procedure for air conditioning system is the same as other trucks. Air conditioning
system components are made of soft materials (copper, aluminum and bronze, etc). Sticking to following
procedure will help increase work efficiency, reduce unnecessary replacement, lower maintenance cost
and use cost.
Completely collect refrigerant oil before maintaining air conditioning system. Do not apply any
grease or sealant to air condition connections. (Refrigerant and lubricating oil are environment
pollutants, shall not be exhausted directly into air.)
Note: To prevent air, moisture or chippings from entering an open system, be sure to put on a cover
or plug to the openings of pipeline, joint, component and grease container. Keep all connections,
caps and plugs clean.

Do not expose air conditioner components, hoses and oils to atmosphere. Keep all openings sealed
and plugged until mounting components are ready for installation and system is ready for
vacuumization and refilling materials. PAG oil and liquid storage drier/gas-liquid separator drying
agent can absorb moisture. Keeping system components open to atmosphere will let moisture
invade system, bringing damage to components and causing system failure.
Flush the system
If any kind of impurities are found in hoses, components or oils, the entire system must be flushed with
water. Major components (like compressor) are extremely easily to be affected by impurities; if system is
contaminated, it must be replaced. If system is contaminated, evaporator and condenser should also be re-
placed. Evaporator and condenser are multi-path devices, cannot be cleaned by flushing.
Chippings can only be removed with methods recognized and refrigerant compulsive demanded by
SAE and/or IMACA. Other methods may cause harm to environment and air conditioner
components.
(Flushing methods, and applied refrigerant must comply to laws and regulations of country
(region) where user's located)
1. Completely collect refrigerant and lubricating oil as specified.

2. Inspect all other components (like condenser, evaporator, hoses and pipe joints). If any of these items is
damaged or heavily polluted, replace it.
3. If any of these items is damaged or heavily polluted, replace it. The cleaning agent applied must comply
to local standards. Prohibit using unqualified expired cleaning agent.
4. After flushing, blow the system with dry air for 5-10 minutes.
5. After removing all impurities out of expansion valve, the valve is then ready for re-installation. If im-
purities fail to be washed away, be sure to install a new expansion valve.
6. Replace a new compressor.
7. Add oil into air conditioning system as per “Inspect System Oil” .

Replace components
Hose and joint
If a damaged hose needs to be changed, be sure to replace a new one of the same type. Sometimes hoses
or joints might have been blocked or fastened in case of being damaged by vibration, inspect them and be
sure they have been firmly fixed there.
For normal truck operation, you’ re recommended to use XCMG genuine spare parts.
Pipeline
Be sure to use two spanners to disconnect or connect air conditioner pipe joints (connected to metal pipes).
Copper pipe and aluminum pipe are extremely easily twisted or broken. If collars or clamps have been ap-
plied to pipes to prevent vibration, be sure they are fixed firmly in place.
Expansion valve?
When taking down expansion valve from the system, be sure to firstly remove thermal insulation, sec-
ondly clean this area and thirdly disconnect pipes from liquid storage condenser. Remove capillary tube
and exterior balance pipe (if equipped). Remove expansion valve from evaporator inlet. To the expansion
valve, the only parts that can be maintained or replaced is filter net. If the filter net works well, then the
valve shall be replaced. If capillary tube and balance pipe have served, then fix them on a clean surface
and replace or install thermal insulation.
Compressor.
Compressor may develop a failure due to shaft seal leak (no refrigerant in system), oil distribution disc
failure, bearing failure or their internal parts failure, or other problems regarding high/low pressure, heat,
deficient lubrication. Ensure compressor has been firmly installed, clutch belt and drive belt pulley have
been aligned.
Use a stethoscope to hear if there is noise inside compressor.
Before installing a new compressor, be sure that oil has been completely drained out. Add an
amount of 205 ml new PAG oil into compressor. If compressor oil amount has not been adjusted,
there might be an excessive amount of oil within system, which will result in poor performance.

In no case shall a/c compressor be vertically placed on clutch assembly. Otherwise, compressor
clutch will be damaged and early fault will result in compressor.
CLUTCH
Clutch failure includes electric fault, clutch belt bearing fault, clutch disc abrasion or bulge, lose of clutch
disc elastic force. The clutch can be replaced with a new part, component or an entire assembly. If the
clutch shows traces of overheated damage, replace the entire clutch.
The quick way to inspect lead or clutch coil failure is to use a fuse lead to connect to the coil. Following
this procedure can help bypass clutch electric circuit control device.
When air conditioning system is off or clutch is not engaged, a noisy bearing implies a belt pulley bearing
fault. An early developed bearing fault might result from misalignment between clutch and drive belt
pulley.
Sometimes, in order to guarantee a better installation of clutch, a washer or might be needed, or the mount-
ing hole of compressor bracket must be enlarged.
If clutch fails to engage or clutch disc slips after energized, excessive abrasion of clutch disc may be ow-
ing to the friction on belt pulley. Too small or too large clearance between clutch disc and belt pulley, or
lose of elastic force are possible causes. The ideal clearance between belt pulley and clutch disc is 1.02
±0.043 mm (0.023~0.057in.). If the clearance is too wide, when clutch coil is energized, the magnetic field
it has built might be not strong enough to draw clutch disc back and lock on belt pulley.
Maintenance staff may mistake some faults and jump to a conclusion that the compressor is
broken down due to internal stagnation and scrap it. Before scrapping it, please check whether
compressor clutch works well. The normal service life of a compressor is two times of its clutch.
Note: Do not mistake clutch coil fault as compressor stagnation. If clutch coil is short-circuited, aged
and has too large resistance value, coil will cause clutch slip due to deficient electromagnetic force.
Maintenance staff must test the coil in case of scrapping it due to mis-diagnosis.
Remove clutch coil terminal, test coil resistance with a multimeter and compare it with standards; if the
value exceeds standard range, the coil must be replaced:
12.0±0.37Ω@20°C（ 68°F）
16.1±0.62Ω@116°C（ 240°F）
20°C is a typical temperature which was taken after engine has been stopped for over 4 hours, before truck
was started in a summer morning. 116°C is the working temperature when engine runs in hot weather. For
a temperature value that ranges between the above-stated temperature values, its resistance rises and drops
with the change of temperature.
Maintain compressor clutch

Use a proper tool to remove and replace clutch component. During maintenance, be sure to use a
special tool to reduce the possibility of causing damage to components and parts. Do not hit or
knock on clutch disc, hub assembly or pin shaft. Hit or knock may cause damage to compressor.
1. Remove belt guard plate from front side of compressor.

2. Remove drive belt from compressorbelt pulley（ 1，Figure 4–43 ）
3 4
1 2
Figure 4-43
1. Belt pulley 2. Clutch hub / drive plate shaft 3. Axle 4. Lock nut
3. Remove lock nut（ 1， Figure 4–44） with a thin-walled sleeveor an equivalent tool. When removing
the lock nut, be sure to use a clutch hub disassembling tool (2) and a spanner wrench or equivalent tool
to fix the hub (3). After removal, replace it with a new lock nut.
1 3
Figure 4-44
1. Thin-walled sleeve 2. Clutch hub disassembling tool 3. Clutch hub
4. Screw clutch disc and hub assembly disassembling tool（ 2， Figure 4–45）in the hub of clutch as-
sembly (1). Use a spanner to hold the object still, tighten up central screw so as to extract clutch disc
and hub assembly

Figure 4-45
1. Clutch assembly 2. Clutch disc and hub assembly disassembling tool
5. Remove the key from slot（Figure 4–46）
1 2
Figure 4-46
1. Key 2. Key slot on shaft
1 2
Figure 4-47
1. Clutch hub 2. Belt pulley

6. Inspect the friction surface of clutch hub and that of belt pulley. Scratches that appear on the surfaces
are considered normal. Do not replace the above-said part because of this defect.
Inspect the steel friction surface on clutch and make sure it has never been damaged in
overheated situations. Inspect parts in the adjacent area of clutch and check if they have been
damaged due to overheat.
If there are prominent overheat traces, the compressor might be replaced. Overheat may cause
leakage and component damage.

Disassembly of pulley
1. Remove belt pulley locating ring from belt pulley assembly with locating ring pliers （Figure 4–48）
3 2
1
Figure 4-48
1. Belt pulley assembly 2. Belt pulley locating ring 3. Locating ring pliers
2. First remove sleeve retainer from compressor and second remove the sleeve.
3. As shown in the figure, install belt pulley extractor（ 1， Figure 4–49）and extractor guide rod on
compressor. If it adopts a multi-groove belt pulley, then install extractor leg on extractor to substitute
standard leg. Extend extractor leg to the rear of belt pulley. Do not use belt groove to extract belt pulley
from compressor.
1 2
Figure 4-49
1. Belt pulley extractor 2. Belt pulley assembly 3. Extractor guide rod
4. Cling to compressor shaft, tighten up the central screw on extractor so as to remove belt pulley.
5. Clean belt pulley and its bearing with cleaning agent. Inspect the assembly for damage. Inspect the bear-
ing for dents, excessive looseness, noise and lubricant leak. If above issues are found, be sure to change
the assembly.
6. Inspect clutch coil
Inspect clutch coil resistance with multimeter. Resistance ranges as below:
12.0±0.37Ω@ 20°C（ 68°F）

16.1±0.62Ω@ 116°C（ 240°F）

The clutch may have a problem if coil resistance exceeds the range. Replace clutch coil without delay.
Installation of pulley
1. Place belt pulley assembly on compressor and locate it. Use a bearing installer（ 1，Figure 4–50 ）
multipurpose lever (2) and a hammer to slightly knock belt pulley into compressor and keep knocking it
till it comes in place. During installation, installing tool should only act on bearing inner ring, because
once bearing outer ring carries load, bearing will be damaged.
2 1
Figure 4-50
1. Bearing installer 2. Multipurpose lever
2. Make sure belt pulley can normally rotate. If belt pulley fails to rotate normally, please remove belt pul-
ley according to “Remove belt pulley” and inspect if it has been damaged. If it has, please immedi-
ately change it till it can normally rotate.
3. Install belt pulley locating ring in place.
4. Install sleeve on compressor. Install sleeve retainer.
Install clutch assembly.
1. Insert the key into key slot of clutch hub. Extend the key 4.5 mm (0.18in.) off hub edge and use petrole-
um butter to hold its position.
2. Put clutch assembly on compressor and position it in place. Align key with the slot of shaft.
3. Install drive disc installer（ 1，Figure 4–51）on compressor shaft. Set collar (2) must be placed under
the nut of tool.

1 2
Figure 4-51
1. Drive disc installer 2. Set collar
4. Use drive disc installer (1) to press clutch into compressor. Keep pushing and pressing clutch disc till a
2 mm (0.079 in.) clearance forms between clutch friction surface and belt pulley friction surface.
Note: The external thread of installer is left-rotated.
5. Install lock nut （ 4， Figure 4–43）and tighten it in place. The clearance measurement taken present-
ly should be 1.02 ± 0.043mm (0.040±0.017 in.) If the clearance falls into the range of technical specifi-
cations, then the key has been correctly installed.
6. Install belt pulley on compressor. Ensure the belt has proper tension. Refer to belt tension table on en-
gine manual for the technical specifications .
7. After re-assembly, run the engine at highest idling speed, and run air conditioner under the max. load
condition, so as to grind clutch mating surfaces. Turn air conditioner switch on and off at a one-second
interval, again and again, for at least 15 times.
Install air conditioner pipeline
According to operation standard, it’ s required to inspect the dimension, joint type and joint plug
of air conditioner pipeline.
1. Apply refrigerant oil: extract plug from one end of pipeline, inspect if it contains an O ring; if it does,
check O ring specification. If it is correct, apply a layer of refrigerant oil on O ring to increase smooth-
ness for easier installation. See Figure 4–52

Figure 4-52
2. Pipe joint should be vertical with compressor joint; put pipe joint completely into the concave side of
corresponding joint, and observe if O ring is exposed part or has a side cut. See Figure 4–53、Figure
4–54
Figure 4-53
Figure 4-54
3. Rotate pipe joint nut manually by 3/4 turns, and then tighten it up with a spanner. See Figure 4–55、
Figure 4–56

Figure 4-55
Figure 4-56

4. After installation, check if plug has been inserted, also check the arrangement and angle of pipeline. If
everything is correct, make a permanent label with a red marker pen. See Figure 4–57
Figure 4-57
System vacuumization
Air conditioning system must be completely vacuumized in following situations: after initial installation,
after component replacement (system interruption) or a large amount of refrigerant leak that has been
found. The entire system must be pumped into vacuum (take away system moisture with a vacuum pump).
After the pumping, add refrigerant and lubricating oil in the system.
The working principle of vacuum pump taking in moisture is that: firstly turn air conditioning system a
vacuum environment; secondly moisture will boil and gasify under vacuum environment; thirdly vacuum
pump will vacuumize the system.
The lower air pressure is, the lower boiling point it is. So it will take about one hour for vacuum pump to
take in all moisture contained in the system.
It’ s forbidden to substitute vacuum pump with air conditioner compressor, because it will bring
damage to compressor.

Figure 4-58 Vacuum pump connection
Please follow the procedure below to completely pump the air conditioner out of moisture.
1. Connect the high and low pressure hoses of manifold pressure gage respectively to the high and low
pressure joint of compressor, and then connect the central hose of manifold pressure gage with vacuum
pump.
2. Open the high, low pressure manual valves on manifold pressure gauge, start the vacuum pump, observe
the two pressure gages. Vacuumize system till the pressure falls in the range of 98.7-99.99 kPa.
3. Close the high, low pressure manual valves on manifold pressure gage, observe pressure gage and check
if pressure rises. If pressure rises, it indicates a leak. Inspect the leak and repair it. If pressure gage
pointer keeps still, then open the high, low pressure manual valves, start vacuum pump and keep it
working for 45 minutes so as to stabilize vacuum pressure gage pointer.
4. Close high, low pressure manual valves.
5. Turn off vacuum pump.Vacuum pump（Figure 4–58）
Note: In normal conditions, 45 minutes is enough for vacuum pump to gasify system moisture
and pump it out. If it has been checked that there is no leakage in the system, but pressure gage
reading still increases after 45 minutes, then increase pumping time so as to ensure that all mois-
ture to be cleared.
Note: Refer to the table below for the optimum vacuum technical parameters on all kinds of
altitudes.
Table 4-3 Vacuum pressure reference table
Altitude Optimum vacuum

0m 760 mm Hg
305m 735 mm Hg
610m 707 mm Hg
914m 681 mm Hg

Table 4-3 Vacuum pressure reference table(continued)
Altitude Optimum vacuum

1219m 656 mm Hg
1524m 633 mm Hg
1829m 608 mm Hg
2134m 585 mm Hg
2438m 564 mm Hg
2743m 542 mm Hg
Note: The table specifies the optimum vacuum pressure parameters on typical altitudes.
Refill refrigerant
Figure 4-59 Refill refrigerant
The correct way of adding refrigerant into R134a system is to firstly collect all refrigerant from system.
Put refrigerant on a weighing machine to ensure a correct amount of refrigerant to be added into system.
Most of recycling devices contain a weighing machine, which is very convenient to add a correct amount
of refrigerant (adding amount is about 900 g). On some kind of devices, during refrigerant refilling, the lu-
bricant needed can also be injected meanwhile. Only after making sure that the cooling system is all right
by pressure building and leak inspection, can refrigerant be added in system. This process is Freon Filling.
There are two Freon Filling methods: gas state filling and liquid state filling. We normally take the gas
state filling method and we do not recommend the latter. Never fill in liquid state refrigerant from low
pressure end, because liquid Freon will cause liquid impact to the running compressor and may damage it.
Before starting engine (let compressor work), please close the high-pressure filling valve on pressure
gage.
Vaccumize the system before adding refrigerant.

Connect the high and low pressure hoses of manifold pressure gauge respectively to the high and low pres-
sure joint of compressor, and then connect the central hose of manifold pressure gage with refrigerant
cylinder.
1. Fill liquid refrigerant both from high, low pressure ends: (Liquid State Freon Filling)
1) After cooling system has been vacuumized, remove the yellow hose of gage base out of vacuum
pump, and then tightly connect it with the adapter of refrigerant cylinder.
Open the angle valve of refrigerant cylinder, loosen adapter screw thread of the yellow hose, and then
exhaust the pipe air with a little amount of gas state refrigerant.
At this time, engine is in off state! Air conditioner does not work.
2) After that, open the two valves of gage base, and fill refrigerant into the air conditioning system from
both high and low pressure sides, until two pressure gage pointers show balance. Due to the differ-
ence of environment temperature, generally, the balanced pressure in air conditioning system is 0.4-
0.6 MPa (pressure gage reading) .
If it’ s necessary to warm Freon cylinder, be sure to immerse it in warm water whose
temperature shall not exceed 50 °C; otherwise, over-high temperature will cause Freon
cylinder to explode, leading to injuries and deaths.
2. Add gas state refrigerant from low pressure side: (Gas State Freon Filling)
Start engine and adjust compressor speed to 1800-2000 rpm. Open all knobs of air conditioner to the
max. position. Keep air conditioner stay in compulsory refrigerating working state.
At this moment, high pressure valve of high and low pressure gage base is at closed state! Open
the low pressure valve and let gas state refrigerant enter system. Erect Freon cylinder vertically,
do not place it upside down. Otherwise, when air conditioner starts running, liquid state
refrigerant will enter compressor inlet cavity and cause liquid impact.
Observe refrigerant filling amount
When adding refrigerant, keep observing sight glass Figure 4–60. When white bubbles seen from sight
glass gradually decreases till only a little amount is left, it indicates refrigerant filling is enough and refill-
ing process should stop.

Figure 4-60 Drier sight glass
Refrigerant amount estimation
Estimate according to Figure 4–61whether the refrigerant amount is proper or not.

Bubbles: it is gas - liquid mixed state.
Transparent: when all refrigerant is liquid, it shows transparent.
Turbid: when refrigerant lubricant separates from refrigerant, it shows a thin layer of milk white.
Turbid with bubbles: when gas state refrigerant mixes with the separated oil, it shows a thin layer of milk
white.
Conditions: when ambient temperature is 30-35 °C; compressor speed is 1800-2000 rpm.
(After ON) (About one minute)
Moderate
Overcharge
Insufficient
Figure 4-61 Refrigerant amount estimation
Air conditioning system tightening torque

It’ s very important to set correct tightening torque to each connection of air conditioner. If not,
poor connection will lead to leak.
Refer to following table for tightening torque:

Table 4-4 Air conditioning system tightening torque
Tightening torque （ N﹒ Re-check torque （ N﹒

Part and component
M） M）
Bolt that fixes air conditioner
26 24-28
compressor to bracket
Nuts that fix air conditioner and blower
6 5-8
casing into front wall plate
Air conditioner maintenance valve
38 28-49
(pipe type connection)
Clutch fixing nut 37 34-39
Cylinder head socket cap screw 33 30-34
Joints of inlet and outlet hoses 27 24-30
Oil filler plug 33 30-34
Connector from expansion valve to
24 22-26
evaporator
Connector from evaporator hose to
14 12-16
liquid storage drier
Other instructions
Compared with construction vehicles, mining trucks have some different characteristics: vibration and im-
pact due to design differences, change of operators and different climate conditions, etc. Generally speak-
ing, non-road equipment and devices have particularities, so the air conditioning system of common
trucks or road construction trucks cannot satisfy the operating requirements of mining trucks.
The sealing performance, insulating performance and thermal insulation performance of driver’ s cab
play a significant role on the air conditioning system. It’ s recommended to shut all venting holes under
very damp conditions, including booster system inlets.
It’ s of great significance to keep system and components clean. If dust and oil sludge enter condenser,
evaporator and air filter, air conditioner refrigerating performance will be reduced.
Compressor, condenser, evaporator, hoses and hose joints must be kept clean and firmly fixed, and won’
t loosen or fall during truck operation, so as to keep air conditioning system work well.

The cost of component failure (causing vehicle downtime) is far more expensive than that of preventive
maintenance, please regularly inspect air conditioning system with reference to operation and maintenance
manual. (clean and inspect belt tension, as well as electrical component operation.)

4.15 Centralized Lubrication System

Centralized lubrication alarm

Automatic lubrication system
Maintenance
interval
Nor-
First Applied
Part mal Target
No. Description Unit Qty main- environ-
Number main- part
ten- ment
ten-
ance
ance
（h）
（h）
No. 1 Extreme
822502580 pressure lithium KG -32℃~32℃
Central-
lubricating grease
1 5 70 ized lubri-
Extreme pressure
cation Below
822502607 lithium lubricating KG
-32°C
grease (No.00)
2 801142183 Grease filter Pcs 1 2500 SHEET
1. Correct wire electrical devices as per power input wiring diagram, and add a sufficient amount of grease
(suit ambient temperature) (Do not pour grease in an off tank), pump some times till oil comes, and then
connect pipeline.
2. Be sure to use clean, pollution-free grease whose viscosity is within the specified range.
3. Never arbitrarily disassemble the pump body, so as to avoid air entry.
4. Keep sufficient grease in the lubricant vessel, but not full. Grease shall not lower than the lowest oil lev-
el. Refill grease at a slow and even speed.
5. In extremely cold regions, in order to guarantee lubricating effect, it is allowed to add a proper amount
of hydraulic oil into lubricating pump.

Common faults
Phenomenon Cause Troubleshooting

Inspect the power supply,
1. The motor does not turn
inspect the motor
Re-wiring according to wiring
No oil comes from oil outlet 2. Motor reversing
requirements
3. There is air at the bottom of Be careful not to mix in air

the oil tank when refueling
Inspect and troubleshoot oil
1. Oil leakage at pipe joints
leakage
Stress can't be builted up 2. Pump body damage Contact our company
3. Dirty grease causes pump
Replace with clean grease
body to be stuck
Instructions
Brief introduction of the system
J00097-95 Grease lubrication system is applicable to XDR80T system mining trucks. 24VDC voltage
grease pump drives 3 groups of MVB type progressive distributors to add grease into each point of mining
truck. Grease pump has three outlets, and a built-in attribute controller whose setting mode is d1, lubricat-
ing time is 160s at an interval of 40 minutes.
Scope of Applications: Mining truck customized grease lubrication system
System technique application parameter
Grease pump cylinder

6L
volume
Oiling range NLGI 000#～2# (refer to maintenance notes for details)
Max. system working
25MPa
pressure
Pump outlet flow rate 5.5ml/min/ each outlet
Number of lubricating point 45
Lubrication points Lubrication point screw thread M10X1 (internal screw thread)
System operating
-40℃~70℃
temperature
Grease pump input voltage 24VDC

Progressive distributor MVB type

Grease filling port 1. Straight-through quick filling port 2. Standard straight-through oil
specification cup
Grease outlet specification M10X1 (inner) -￠ 6 pipe F hole (3 outlets)
Level of protection IP65

System working principle
1. Pump system schematic diagram
Figure 4-62
In this system, built-in electric motor of grease pump drives piston to make reciprocating motion, caus-
ing pump grease to enter into main pipeline, and enabling MVB progressive distributor piston to make
progressive reciprocating motion, so as to lubricate moving parts. Electric grease pump adopts filtration
grease filling, which is done through two different greasing nozzle connection types. Electric grease
pump has a built-in digital display controller, with it the operator can set a reasonable lubrication
interval.
2. Grease pump safety valve

1 4
2 5
3 6
Figure 4-63
Safety valve opening pressure is 25 Mpa (already set in factory). Adjustment screw rod 1 presses steel
ball 6 by spring 3 pressure rod 2. When lubrication system has a fault due to blockage, and when pres-
sure rises to 25 Mpa, pressure oil will push steel ball through a small hole on the bottom of valve body
5, making pressure rod 2 to move upward, and grease will overflow from the middle hole of adjustment
screw rod 1, so as to protect grease pump from being damaged. The function of nut 4 is to lock adjust-
ment screw rod 1. Do not privately adjust safety valve in case of damaging the entire lubrication
system.
Note: safety valve code number: 48007 (including articulated body)
Grease pump dimensions are shown in following figure: Welding points are shown in following
figure:

2-φ9
186
Mounting hole
162
352
518
MAX264
Oil outlet (oil outlet 3)
M10x1 (inner)
- φ 6 pipe f hole
Oil filling
port 2
(external)
MAX272
Power
input port
Figure 4-64
Installation and debugging
1. Inject clean grease into lubrication pump, do not exceed the height line. Do not exceed high level
marker. Otherwise excess grease will be wasted and oil reservoir will be partly damaged.
2. Lubricating grease usage requirement:
1) When ambient temperature is below 0 °C, use NLGI000#~NLGI00# low temperature grease
2) When ambient temperature is between 0 °C- 25 °C, use NLGI00#~NLGI1# grease.
3) When ambient temperature is above 25 °C, use NLGI0#~NLGI2# grease.
4) For a new truck in running-in period, use NLGI00# grease.
3. The system must be installed in a conspicuous position and convenient for inspection and repair.
4. Be sure to clean all the oil lines of the lubrication system and dry them with high pressure air.
5. Power input end wiring diagram
DIN plug on pump DEUTSCH type

public connector
2 1 Brown
1 External power supply
3 (DEUTSCH type bus
2 Blue 2 connector)
1
Figure 4-65
Operating instructions of program controller
1. Panel display description:

There is a four-digital tube on the display panel, showing system working status and programming.
Three LEDs are used to separately indicate Power source (Green), Pump running (Red) and Alarm for
low grease level (Yellow).
Power indicator IMTERNATIONAL

lamp
POWER
Operation
indicator lamp RUN
Alarm
ALARM
indicator lamp
Control panel
Figure 4-66
2. Control panel key function description
Key description
Used for the conversion of programming

S steps and program browsing
Used for storing and starting

R programming data
Used to move the flashing (cursor) bit

of the digital tube in the setting state
Used to change the data of nixie tube

flashing bit in the setting state
Figure 4-67

3. Operation flowchart
Setting mode: "S" + "R" Browse mode: "S"
Control mode 1~ 4
1 2 3 4
Operation
Alarm time “S” Loop count “S” Pulse period “S”
time "S"
1~999“S” 1~999
（second） 1~999
（ times ) 1~99
1: second “S” “S” Pulse opening “S”
time
2: minute “S”
3: hour 1~99（second）
Intermittent time Pulse opening “S”
time
1~9999
“S” 1~99（second） “S”
1: second
2: minute
3: hour “R” “S”
Return
Operate
Figure 4-68
Operation flowchart (note: X: 0-9)

4. Operation Instruction:
• Power connection: when power resumes, the controller continues to execute the previous work and
display previous status; to reset settings, please press Next Step.
• Parameter setting:
1) Press the keys "S" and the "R" to enter the setting mode at the same time, and the next cursor
flashes in this mode;
2) Change the desired data according to the function prompts by using keys “ ” and“
”.
3) After a setting is completed, press key "S" to enter next setting item. ( same way to modify
parameters)
– Operation and stop: after completing all the settings, press “R” to save up the already set pa-
rameters and start the lubricating pump. No matter what kind of working status the controller is
in, you may press “R” to re-start the controller, and it will work according to the newly saved
parameters; for example, when pre-filling grease to system pipeline, you may press “R” and
“S” simultaneously to stop the running pump motor.

– Program browse: no matter what status the controller is currently in, you may press “S” to
browse all the parameters that have been saved up, and your operation won’ t affect the status.
Stop pressing the key and wait a little while, it will automatically return to the previous status.
– Alarm: no matter what kind of warning status the controller is currently in, the internal faulty re-
lay will respond and the controller stops output.
Control mode description: User can initially choose the corresponding control mode according
to configured lubrication system. Only when you’ re very familiar with lubrication system
working process or when you’ re under the guide of professional staff, can you select a differ-
ent control mode.
– Time mode (d=1)： this mode can only be used in SLR system and PRG system.
Lubrication system goes into a periodical cycle according to the oil supply time (1-999 second/
minute/hour) and intermittent time (1-999 second/minute/hour) pre-set in controller.
– Pressure mode (d=2)：

This mode is mainly used in PDI system
Lubrication system oil supply process is under the control of the pressure switch installed on lu-
brication pump or system. The whole course, from when lubrication pump is started, system
pressure rises to rated value, till pressure switch is pushed to act, must be controlled within a
pre-set period of time and completed before a warning is given. When pressure switch closes,
controller will flash 4 times, which means to delay 4s (the default value is 4s, ensuring pressure
to build at pipe end), and then stop the pump to complete oil supply. After that, system enters in-
to intermittent time keeping. Otherwise, when an oil supply failure occurs (leak, blockage and
pump damage, etc), extending the time it takes for system to build pressure, and when pressure
building course reaches the pre-set warning time, system will give out an oil supply failure
warning signal, digital display is “EEPP” (in this status, you need to firstly press “R” to re-
lease alarm before entering setting status to alter parameters). Warning time setting depends on
the actual situation (pipe length, oil supply amount), normally, it is 4-8s longer than the time the
system takes for pressure switch to make normal actions. Wind power PDI system operation
time has been adjusted to the max. 999s, intermittent time has been set by manufacturer.
– Count mode (d=3)

This mode can only be used in PRG system
In lubrication system, the whole oil supply process is under the control of circulation switch in-
stalled on oil distributor. When lubrication pump starts operating according to the cycle time
pre-setting on controller, if the system works well, oil distributor outlet starts supplying oil as in-
tended. When one oil supply cycle is completed, cycling switch will generate signal once and
controller counts once. When oil supply cycling time reaches the pre-set value of controller, the
controller will stop outputting, and system enters into intermittent time counting. Once lubrica-
tion system has a fault (blockage, leakage or pump damage, etc), and due to this fault, any of

cycling switch action time is extended and reaches controller pre-set warning time (5 minutes by
default), controller sends out an oil supply fault warning signal, digital tube shows a flashing
value, which is the current value.
– Pulse mode (d=4):

This mode is mainly used in PUILES system.
Under this mode, lubrication pump works in pulse (non-continuous) mode. For example, pneu-
matic plunger type and solenoid plunger type lubrication pump. Plunger makes reciprocating
motion under pulse on/off time control of air source solenoid valve or drive electromagnet
power supply
For XDR80T series mining truck, lubrication system control mode is d1!
Maintenance
1. MVB distributor maintenance instruction. When oil distributor won’ t feed oil, please firstly inspect
rule out lubrication point blockage phenomenon. You can remove lubrication point adapter, and observe
whether the running oil distributor is injecting oil or not. If oil distributor is outputting oil, you may re-
move and clean it. Anomalies, like distributor plunger blockage problem, will be eliminated by adopting
this method.
1) Clear that oil distributor plunger matches with valve body, so plunger pair cannot be exchanged.
Please well label detached parts.
2) Remove screw plugs from both sides of valve body, and then take out the plunger carefully, clean the
plunger and valve body with kerosene. After cleaning, use clean high-pressure air to blow each hole
of valve body. Apply a little amount of clean lubricating oil on plunger to ensure plunger can
smoothly slide into the cylindrical hole of valve body. Re-install each screw plug according to tight-
ening torque technical requirements.
3) After re-installing oil distributors, use manual pump or high-pressure greasing gun to test the installa-
tion. If plungers work well, install oil distributors to their original positions.

Oil inlet
Oil outlet
A A
A A
A A
A A
A A
A A
A A
A A
A-A
Screw plug O-ring Screw plug
Plunger
Figure 4-69
2. Maintain plunger pump pair: when pump no more outputs oil or pump pressure drops to zero, firstly, re-
move oil outlet assembly; secondly, unscrew 8 with a small flat-head wrench; thirdly, take out 4, 5, 6
and 7 with tweezers; fourthly, remove 1 and 2; finally, clean plunger and pump body of 3 with kerosene.
After cleaning, reinstall in sequence. If the fault cannot be eliminated, please replace the piston pump
assembly with a new one.
1 2 3 4 5 6 7 8
G1/4
M22X1.5
(19.2)
Figure 4-70
3. Plunger pair
1. Supporting pad 2. Pump spring 4. Valve element
assembly
5. Gasket 6. Spring base 7. Valve spring 8. Adjustment seat
Plunger pump component code number: 22480

Dispersed manual lubrication
Manually lubricate the 8 lubrication points on drive shaft, and check oil storage conditions of all the points
daily; add oil when necessary. Use a manual grease gun or pneumatic grease pump to add grease.
Figure 4-71


Chapter 5 Maintenance and Lubrication
Only those trained and qualified can repair and maintain this machine.
Read carefully the related content in this book before any maintenance.
If a diesel engine is running indoors, ensure the space is well-ventilated.
For the details of diesel engine, see OPERATING MANUAL OF DIESEL ENGINE, which is
included in the documents along with the mining truck.
• While carrying out maintenance or repair for this machine, the related record should be made
and saved.
• For the mining truck, it is important to maintain and ensure its normal function.
• The machine should be kept clean so that any failure such as leakage, looseness of screw or con-
nection will be spotted.
• Be sure to protect the environment! Don’t pollute the environment with oil liquids and other
harmful pollutants.
• The content of this chapter includes items related to regular check, maintenance and repair. The
operator of mining truck should carry out these items according to the regulation.
Special lubricants should be used if the excavator works in extremely hot or cold weather, please
contact XCMG authorized dealers.
If the requirement about special lubricants can’t be satisfied, please contact XCMG authorized
dealers.
Maintenance and Lubrication 5-1

5.2 Maintenance
Maintenance Detail
Donaldson desert filter maintenance schedule

Maintenance
interval
Nor-
Part First mal Target
NO. Description Unit Qty Target part
Number mainte- main- part
nance ten-
（h） ance
（h）
K6000-1012240B oil Engine oil
1 800162638 EA 2 500
filter filter element
Fuel filter
K6200-1105140 filter
2 800162637 EA 1 500 element (fine
element component
filter)
K6200-1105350KS1 Fuel filter Engine

3 800162635 filter element EA 1 500 element
component (coarse filter)
K6505-1105350 Oil water

4 800160016 diesel oil prefilter EA 1 500 separator filter
part element (long)
P781098 main air

5 800105256 EA 1 500 Air filter Engine
filter element
air
P781102 air security
6 800105257 EA 1 1000 Air filter filter
filter element
Steer-
HCG300FCN4Z Steering high-
7 803277506 EA 1 1000 ing
filter element pressure filter
system
Fuel tank filter, Hy-

08102117 Air filter one for each draulic
8 803277637 EA 2 1000
element tank (big and Oil
small) Tank
5-2 Maintenance and Lubrication


Maintenance
interval
Nor-
NO. Description Unit Qty Target part
nance ten-
（h） ance
（h）
D802.063.18 Lift Lift return oil

9 803277418 return oil filter EA 1 1000 filter element
element (big tank)
Steering return
EF-089N-100A
oil filter
10 803277666 Steering return oil EA 1 1000
element (small
filter element
tank)
Note:

Oil liquid maintenance schedule

Maintenance
interval
Nor-
No. Description Unit Qty Target part
nance ten-
（h） ance
（h）
K6000-1012240B oil Engine oil
1 800162638 EA 2 500
filter filter element
Fuel filter
K6200-1105140 filter
2 800162637 EA 1 500 element (fine
element component
filter)
K6200-1105350KS1 Fuel filter Engine

3 800162635 filter element EA 1 500 element
component (coarse filter)
K6505-1105350 Oil water

4 800160016 diesel oil prefilter EA 1 500 separator filter
part element (long)
3560 Safety filter

Oil bath filter
5 800165081 element (oil bath EA 1 500
(option) Engine
air
3560-1 Main filter
Oil bath filter filter
6 800165080 element (oil bath EA 1 500
(option)
Steer-
HCG300FCN4Z Steering high-
7 803277506 EA 1 1000 ing
filter element pressure filter
system
Fuel tank filter,

08102117 Air filter one for each
8 803277637 EA 2 1000 Hy-
element tank (big and
draulic
small)
Oil
D802.063.18 Lift Lift return oil
Tank
9 803277418 return oil filter EA 1 1000 filter element
element (big tank)


Maintenance
interval
Nor-
No. Description Unit Qty Target part
nance ten-
（h） ance
（h）
Steering return
EF-089N-100A
oil filter
10 803277666 Steering return oil EA 1 1000
element (small
filter element
tank)
Note:

Oil liquid maintenance details:

Maintenance
interval
Ap-
Nor-
plied
Part First mal
No. Description Unit Qty Target part envi-
Number mainte- main-
ron-
nance ten-
ment
（h） ance
（h）
CH-4 15W/40 Engine Above
822502276 L
oil (Shell 209L) -10 °C
1 32 500 Engine
CH-4 10W/30 Engine -25℃~
822502277 L
oil (Shell 209L) 30℃
Delo ELC-55/45
Delo long-acting
2 822933579 heavy-duty L 76 20000 Radiator
antifreeze/coolant
(-45°C Caltex IBC)
DOT4/HZY4 Motor
Clutch/brake
3 822538184 vehicle brake fluid EA 1 2000
fluid
(800G)
Autran 4 10_bluk
hydraulic oil（ Hydraulic Oil
4 822538783 KG 179 2000
Steering 59L/ Tank
Lifting120L）
No. 2 Extreme
pressure lithium
lubricating grease（ Above
822537653 KG
175kg/barrel 32℃
International standard
barrel diameter） Centralized
5 6 70
No. 1 Extreme lubrication
-32℃~
822502580 pressure lithium KG
32℃
lubricating grease
Extreme pressure
Below
822502607 lithium lubricating KG
-32°C
grease (No.00)


Maintenance
interval
Ap-
Nor-
plied
Part First mal
No. Description Unit Qty Target part envi-
Number mainte- main-
ron-
nance ten-
ment
（h） ance
（h）
Wheel reductor
GL-5 80W/90 gear gear box (4.5L
6 822502286 L 18 1000 2000
oil (Shell 209L) for a single
box)
Intermediate
GL-5 80W/90 gear
7 822502286 L 20 1000 2000 axle casing 25℃~
oil (Shell 209L)
(main retarder) +40℃
Rear axle
GL-5 80W/90 gear
8 822502286 L 20 1000 2000 casing (main
oil (Shell 209L)
reducer)
GL-5 80W/90 gear

9 822502286 L 13.5 500 Transmission
oil (Shell 209L)
CAT hydraulic oil

addictive (1U-
10 822538163 KG 0.5 20000 Suspension
9891One kilogram
pack)
Note:
5.3 Recommended fuel, coolant and lubricant
• In order to keep your machine in the best state for a long term, it is essential to observe oil instructions
in this manual. Otherwise, engine, drive system, cooling system and other components will be over
abraded, and their service life span will be shortened.
• Oil addictive that is accessible from the market may be good to machine, and might also bring damage
to machine. XCMG mining truck shall not use any addictive.

• Specified oil amount refers to the total oil volume of tank and pipeline; replenishing oil amount refers
to the amount of oil that should be added into system during inspection and maintenance.
• When temperature is below 0 °C (32℉ ), in order to start engine, be use to use multi-grade oil as recom-
mended, even if daylight temperature is rather high.
• Use recommended oil according to ambient temperature specified in the table below.
When sulfur content is below 0.5%, replace oil according to the required maintenance interval specified in
this manual. When sulfur content is above 0.5%, please refer to following table:
Engine oil pan oil replacement cycleEngine

Sulfur content of fuel oil
sump
Above 1.0% 1/4 standard cycle

0.5-1.0% 1/2 standard cycle
Oil material selection

Ambient Quality stand-
Greasing points Name Oil/viscosity grade
temperature: ard level
Above -10 °C SAE 15W/40 API
OIL SUMP Engine oil -25℃~30℃ SAE 10W/30 CH-4,
-30℃~-30℃ SAE 5W/30 CI-4
Above 8℃ 5#
Above 4℃ 0#
Sulphur content
E- Above -5℃ -10# GB 252
Fuel tank Light diesel oil shall not exceed
ng- Above -14℃ -20# GB 20891
0.035%
ine Above -29℃ -35#
Above -44℃ -50#
Above -15℃ -25# Anti-freezing
Anti-freeze Above -25℃ -35# agent, must be
Radiator
solution mixed with
Above -30℃ -40#
water
TRANSMISSION Above +40℃ SAE 85W/140
Differential -25℃~+40℃ SAE 80W/90
Gear oil API GL-5
Main reducing gear
Below -25℃ SAE 75W/90
Wheel reducer
Anti-wear
Hydraulic Oil Tank hydraulic
-10℃~+40℃ 46
suspension cylinder oilHYDRAUL
IC OIL

Ambient Quality stand-

Greasing points Name Oil/viscosity grade
temperature: ard level
Multi-purpose Above -40℃ ISO VG460 NLGI SAE 1
extreme pres-
sure lithium lu-
Front hub bearing bricating grease
STEERING (without mo-
COLUMN lybdenum),
Above -30℃ NLGI SAE 2
Propeller shaft yoke melting point:
head bearing 190 °C (com-
posite lithium
synthetic
grease)
Multi-purpose With or without molybdenum

Above 32℃ N LGI 2
extreme content
pressure With or without molybdenum
Centralized lubrica- -32℃~32℃ N LGI 1
lithium content
tion and other lubri-
lubricating
cating positions Consult with
grease With or without molybdenum
Below -32°C local grease
(composite content
suppliers
lithium grease)
Temperature conversion table
Centigrade -32 -30 -27 -25 -20 -18 -15 -10 0 10 15 25 32 35 38 45 93 190-32 -30 -27 -25 -20 -18 -15
°C -10 0 10 15 25 32 35 38 45 93 190
Fahrenheit -26 -22 -17 -13 -4 0 5 14 32 50 59 77 90 95 100 113 200 374-32 -30 -27 -25 -20 -18 -15
℉ -10 0 10 15 25 32 35 38 45 93 190
Note 1: When ambient temperature is continuously higher or lower than the listed ambient temper-
ature, please consult grease manufacturer for oil viscosity.
Note 2: Engine company only recommends engine oils that comply with API level, and won’ t rec-
ommend any other oils. Multi-grade viscosity oils used under various ambient temperatures as
specified are recommended.
Note 3: When working under the lowest temperature, if without correct preheating or heating pro-
cedure, transmission service life will be reduced; if an auxiliary heating device is available, please
heat up the oil to the lowest temperature limit. If without an oil heating device, operate engine throt-
tle to a certain degree, heat up oil by pulling transmission to neutral position.

5.4 Regular spot inspection and maintenance schedule table

Maintenance level
First
mai-
First 50h Every Every Every
Main- nte-
3030 routine 500h 1000h 2000h
ten- nanc-
Operation content
ance e
items Mai-
Main- Main- Main-
30h in- Inspec- nte-
ten- ten- ten-
spection tion nanc-
ance ance ance
e
Replace engine oil ● ● ● ●
Replace engine oil filter When replacing engine oil
Inspect and adjust valve clearance ● ● ● ● ●

Replace fuel filter element ● ● ● ●
Clean fuel rough filter element or
● ● ● ●
replace the element
Check coolant volume and fill it up ● ● ● ● ● ●

Replace coolant Replace once every 12,000 hours or two years
Fasten cooling pipe clamps ● ●

Fasten intake air hose and flange
● ● ● ● ● ●
connector
Engine
Inspect air filter maintenance
● ● ● ● ●
indicator lamp
Clean the dust collecting cup of the

● ● ● ● ●
air filter
Clean the main element of the air
Clean it after electronic pressure difference alarm gives a warning
filter
Replace air filter main element ● ● ● ●
Replace the safety element of the air
● ●
filter
Check the booster bearing clearance ●
Electrical element and electric con-
Inspect it every 250 hours750h inspection
trol system wire
Trans-
mis- Check transmission oil level ● ●
sion
Maintenance level
First
mai-
Main- nte-
3030 routine 500h 1000h 2000h
ten- nanc-
Operation content
ance e
items Mai-
Main- Main- Main-
ten- ten- ten-
spection tion nanc-
ance ance ance
e
Replace transmission oil (at least
● ● ● ●
once per year)
Replace transmission ventilation

● ● ●
device
Check and adjust tapered roller
Front At first inspection and 500h maintenance
bearing clearance
axle
Replace hub grease ● ●
Check the lubricant levels of final
● ●
reduction drive and wheel reductor
Mid-
Inspect axle difference At first inspection and 500h maintenance
dle
Replace transmission oil for final
axle
reduction drive and wheel reductor ●
(at least once per year)
Check the lubricant levels of final

● ●
reduction drive and wheel reductor
Replace transmission oil for final
Rear reduction drive and wheel reductor ●
axle (at least once per year)
Clean ventilation device ● ● ● ●

Check and adjust hub roller bearing
At first inspection and 500h maintenance
clearance
Trans- Re-tighten the drive shaft bolts Every 100 hours
mis-
Visually check propeller shaft
sion Every 100 hours
connection and wear
shaft
Driv- Check the movement of the wiper ● ● ● ● ● ●
er's Re-tighten driver’ s cab cushion
● ● ● ●
cab lock nut

Maintenance level
First
mai-
Main- nte-
3030 routine 500h 1000h 2000h
ten- nanc-
Operation content
ance e
items Mai-
Main- Main- Main-
ten- ten- ten-
spection tion nanc-
ance ance ance
e
Re-tighten engine radiator grille ● ● ● ● ●
Inspect framework for cracks ● ● ● ● ● ●
Inspect wheel nut tightening
Chas- ● ● ● ● ● ●
conditions
sis
Check battery fixation ● ● ● ●
Check fuel tank fixation ● ● ● ●
Drain off the water in the air
● ● ● ● ● ●
reservoir
Check the sealing of air pressure
● ● ● ● ●
system
Check the thickness of brake shoe

friction disc, and adjust brake ● ● ● ●
clearance.
Clean wheel brakes ● ● ●
Check the easy-worn positions of
● ● ● ● ●
hoses and brake circuit
Brak- Check the function of brake
● ● ● ● ●
ing chamber
system Check foot brake pedal, handbrake
and exhaust brake efficiency ● ● ● ● ● ●
(inspect at commissioning period)
Check retarder system: indicator

lamps work well, connectors are
Take an inspection before travel
fastened, and appearance looks
clean
Inspect retarder oil seal, bearing
lubrication, hand control switch
Once a month
function, relay wiring and contact
state

Maintenance level
First
mai-
Main- nte-
3030 routine 500h 1000h 2000h
ten- nanc-
Operation content
ance e
items Mai-
Main- Main- Main-
ten- ten- ten-
spection tion nanc-
ance ance ance
e
Check electric system working
condition (signal light, head light,
● ● ● ● ● ●
wiper, heater and ventilation device,
etc.)
Check the liquid level and specific

Elec-
gravity of battery electrolyte and the
tric
voltage of each battery unit ● ● ● ● ●
system
Check the fixing of battery terminal
and apply grease to the electrode
Check the fixing of battery terminal

● ● ● ● ●
and apply grease to the electrode
Check the function of tachometer ● ● ● ● ● ●

Replace steering hydraulic oil
●
(20000~25000km)
Check and adjust the location of

● ●
front wheels
Steer- Check function of steering system ● ●
ing Check steering rod clearance ● ● ● ●
system Check steering rod bolt, joint and
● ●
fasteners
Replace steering high-pressure filter ● ● ●
Replace Steering return oil filter
● ● ●
element
Lifting Inspect vehicle oil pipe for abrasion Once a daily

Sys- Inspect hydraulic tank oil and level
Once a daily
tem gauge.

Maintenance level
First
mai-
Main- nte-
3030 routine 500h 1000h 2000h
ten- nanc-
Operation content
ance e
items Mai-
Main- Main- Main-
ten- ten- ten-
spection tion nanc-
ance ance ance
e
Check whether oil cylinder bracket
and top big nut are loose, and check Once a daily
cylinder bracket clearance
Lift the cylinder under no-load

condition and check if the cylinder Once a daily
tilts
Check whether bracket bolts of oil
Once a week
tank and pump are loose
Check if limit valve works well Once a week

Replace lift return-oil filter element
● ●
and air filter element
Inspect lifting angle ● ● ● ● ●
Inspect air circuit sealing
● ● ● ● ●
performance
Replace hydraulic oil ●

Short-distance trial run (including
● ● ● ● ●
Over- braking test )
all ve- Visually inspect leak conditions ● ● ● ● ● ●

hicle Inspect and tighten connections of
● ● ● ● ● ●
cargo compartment
Water pump ● ● ● ● ● ●
Clutch pedal shaft ● ● ● ● ● ●
Clutch release bearing ● ● ● ● ● ●
Lubri-
Clutch shifting fork shaft ● ● ● ● ● ●
cation
Universal joint ● ● ● ● ● ●
Steering main pin and front shaft ● ● ● ● ●
Suspension pin Every 10 hours

Maintenance level
First
mai-
Main- nte-
3030 routine 500h 1000h 2000h
ten- nanc-
Operation content
ance e
items Mai-
Main- Main- Main-
ten- ten- ten-
spection tion nanc-
ance ance ance
e
Stay rod pin Every 10 hours
Absorber lower bracket ● ● ● ● ● ●

Transmission controller ● ● ● ● ●
Cab door hinge ● ● ● ● ● ●
Apply anti-rust re-treatment to driv-
Every 12 months
er’ s cab according schedule


Chapter 6 Transport, Storage and Protection
6.1 Transport
The machine should be disassembled for transport. Please contact Xugong Mining Machinery Co., Ltd. Or
an authorized agent of it when transporting the machine.
Loading and Unloading
When loading and unloading the machine, incorrect operation will cause the machine to tip over and fall,
so the following matters should be paid attention to:
• Loading and unloading can only be carried out on solid and flat ground.
• Keep a safe distance from roads and cliff edges.
• Keep spectators away.
• Use a ramp with enough strength to ensure that its width, length and thickness can provide a safe load-
ing and unloading slope (≤15 °).
• Ensure that the ramp is clean, free of grease, oil, water and loose materials on the surface, and clean dirt
on the machine aisle. Please pay attention to the slippery slope surface for loading and unloading in
rainy and snowy weather.
• Run the engine at a low speed to drive the machine to work slowly.
• The machine’s center of gravity at the connection between the ramp and the trailer will suddenly
change and it is easy for the machine to lose balance, so it is necessary to drive slowly across this part.
• Do not correct the driving direction on the ramp. If necessary, drive the machine off from the ramp, cor-
rect the direction, and then drive into the ramp.
• When loading and unloading the machine on the embankment or platform, ensure that the embankment
or platform has sufficient width, strength and slope.
• After the machine is loaded, lock the driver’ cab door. Otherwise, the door may suddenly open during
transportation.
• Secure the machine with chains and blocks.
Vehicle transportation
Place the machine on a trailer and pay attention to the following issues:
• Understand total length, width and height of vehicle for transportation and the machine. Prevent contact
with obstacles in high places and narrow passages.
• Check whether the building is firm enough to support the weight capacity first when passing bridges or
buildings at special ports. Please obey traffic laws and regulations, and commands of the traffic police
when driving the machine on roads.
Transport, Storage and Protection 6-1

6.2 Daily and short-term storage and protection
• Inspect the machine, repair abraded and damaged parts; if necessary, install new parts.
• Clean air filter element.
• If possible, retract all hydraulic cylinders; if impossible, apply grease on exposed hydraulic cylinder
rod.
• Lubricate all the lubricating positions.
• Place the crawler on long and firm cushion blocks.
• Clean the machine.
• When the battery is fully charged, remove the battery and store it in a dry and safe place. If not re-
moved, separate the battery negative cable connection from the (-) terminal. If it’s not necessary to re-
move the battery, disconnect the negative pole from terminal (-).
• Add anti-rust agent to engine coolant. In winter, you need to use the anti-freezing agent or drain the
coolant off. If the cooling system is emptied, be sure to hang a nameplate “No Water of Radiator” in
conspicuous position.
• Loosen the belts of alternator and cooling fan.
• Paint where necessary to avoid rusting.
• Store the machine in a dry and safe place. If it is stored outdoors, cover it with a waterproof cover; If
the machine is parked outdoors, the exhaust port should be covered.
6-2 Transport, Storage and Protection

6.3 Long-term storage

Before Storage
When the machine is stored for a long time (more than one month), take the following measures:
• Clean and dry the machine, and put tit in a dry building instead of outdoors. When you have to put it
outside, park the machine on a flat ground and cover it with a cover cloth.
• Before the machine is stored, you should fill the fuel to prevent moisture accumulation.
• Replace and fill lubricating oil.
• Apply a thin layer of grease on the metal surface of the hydraulic cylinder’s piston rod.
• Remove the battery’s negative terminal wiring and cover the battery. Or remove the battery from the
machine and store it separately.
• Turn on the parking brake.
• Adjust inflation pressure of each tire to make the inflation pressure to be within the specified range for
this type of tire.
• Put the shift handle in N (neutral) position and turn the key switch to the OFF position.
• To prevent corrosion, always use high-quality coolant of recommended brand to fill the cooling system.
During Storage
If rust prevention must be done for a machine that is parked indoor, the doors and windows must
be opened, in order to prevent personnel from gas poisoning.
• Start the engine once a month and drive the machine for a short distance to cover the moving parts and
components with a new layer of oil film and charge the battery at the same time.
• Before you operate the working device, wipe off lubricating grease on the hydraulic piston rod.
After Storage
Note: If there is no monthly rust prevention operation when the machine is stored, please contact
the after-sales personnel of Xugong Mining Machinery in the mine.
When using the machine after long-term storage, do as follows before use.
• Wipe off grease on the piston rod of the hydraulic cylinder.
• Fill oil and apply grease to all lubricating points.
• When the machine is stored for a long time, moisture in the air will be mixed into the oil. Therefore,
you need to check oil before and after starting the engine. If there is moisture in the oil, replace all oil.
Cautions Before Driving after Long-term Storage
Transport, Storage and Protection 6-3

• Check positions of all oil and water before driving the machine.
• When driving the machine that has been stored for a long-term time, you need to drive at a speed of 10-
15km/h (6.2- 9.3MPH) for 5 minutes or run the machine for 1 km, and then change to normal driving.
6-4 Transport, Storage and Protection

Chapter 7 Major Components and Specifications
7.1 Constitution
XCMG XDR80T tri-axle rigid dump truck is a tri-axle rigid dump truck used in small and medium-sized
open-pit mines (with an annual output of 300,000-4 million tons) or small and medium-sized water con-
servancy projects, with a total servicing weight of about 34tons.
The truck is composed of the following assembles and systems:
• Power system: consists of the diesel engine, fuel oil/lubricating oil system, cooling system, air intake
system and the exhaust system, and provides power for the whole truck.
• Driving system: consists of front/rear suspension, transmission, front, middle and rear axle, propeller
shaft, brake device, wheel, centralized lubrication system, etc.
• Hydraulic system: consists of the lifting system and steering system. Each of them uses a hydraulic oil
tank and is powered by a gear pump.
• Cab and structural parts: including frame, cargo compartment and other structural parts, automatic
weighing system (optional), centralized fire extinguishing system (optional), etc.
XDR80T
Figure 7-1
Major Components and Specifications 7-1

7.2 Technical Specifications

General introduction
XDR80T Three-axle rigid mining truck is globally the first to have adopted the technical advantage of a
rigid dumper. Based on the advantageous technologies, having borrowed the design concept of wide-body
trucks, it has defined the technical development of an economic mining truck of next generation. Its com-
prehensive cost is low and design service life is 6-8 years. It is as highly reliable as a classic mining truck,
and its sales price is slightly higher than a wide-body dumper, but far more lower than a classic dumper. It
is featured in strong driving performance, small turning radius and superior grade ability, and has strong
adaptability to muddy, rocky and narrow working conditions.
Equipment Highlights and Characteristics
1. Enhanced reliability
1) It has adopted a fully hydropneumatic suspension instead of the traditional flat leaf spring structure.
Front axle is Macpherson independent suspension, which has excellent vibration reduction and buf-
fering reservoir that largely improved framework load-bearing force and increased frame service life.
Framework torsion and deformation problem has been reduced and the service life of engine and
transmission has been prolonged, which reduces maintenance cost. Overall machine vibration has
been greatly reduced, so as to ensure more comfortable driving experience. The bottleneck problem
of frequent breakage of front suspension leaf spring has been eliminated forever, so as to ensure a
high attendance rate.
2) Compared with riveted wide-body framework, it is more adaptable to off-road mining working envi-
ronments and shows an advanced design idea and high reliability.
2. Increased safety
1) A fully hydraulic steering design idea borrowed from traditional mining trucks has been adopted to
make steering movement more energy-saving and safer, and has solved a long-lasting industrial prob-
lem of heavy mechanical steering operation of a heavy truck, and reduced driver’ s intensity of
labor.
2) The adoption of emergency steering device has helped prevent a certain of accidents: without this de-
vice, when a vehicle loses power it can only resort to emergency braking but cannot steer, which will
cause accidents.
3) Pneumatic caliper disc brake system has stable braking performance, which is safe and reliable, and a
simple structure that is convenient for maintenance.
4) The hydraulic retarder offers a safer braking performance, and friction plate has a longer life span.
With the hydraulic retarder, the problem of largely decreased braking force of a heavy-loaded truck
7-2 Major Components and Specifications

under downhill traveling circumstance due to heat fading phenomenon is solved, and overall vehicle
braking force manual safety has been guaranteed. With this retarder, customers will never have to
add an additional brake spraying device, which will increase operation cost.
3. Promoted comfort
The all new cab has a good looking appearance and an upgraded interior trim set, has eliminated the old
downscale design of the current industry, the entire design looks better and more eye striking. The exte-
rior appearance is fully mould pressing, offers a wider view. An all-round upgraded cab sealing per-
formance brings in better dust-proof and sound insulation effect. Instrument board, central console and
man-machine interaction interface brings more friendly operation experience. The adoption of LCD
brings intelligence to a new level. Cellphone, walkie-talkie slot and cup holder manifest more thought-
ful details
Product key configuration
Component Manufacturer State

Engine Yuchai Engine China
Power
Air filter Donaldson, America China
assembly
WATER BOX XCMG China
CLUTCH Fast Eaton China
Transmission Transmission Fastgear China
system Drive axle XCMG China
Wheel reducer XCMG China
Steering gear pump XCMG China
Lifting gear pump XCMG China
Hydraulic Accumulator HYDAC China
System Steering cylinder XCMG China
Lifting cylinder XCMG China
Steering valve Parker China
Electric Main controller XCMG China
system Liquid crystal instrument XCMG China
Driver's cab XCMG China
Driver's cab
Heater and air conditioner XCMG China
Front suspension cylinder XCMG China
Suspension
Rear suspension cylinder XCMG China
Automatic lu-
Automatic lubrication
brication BIJUR China
system
system

1. Engine
Manufacturer: Yuchai Engine
Type: Type: YC6K480-GT30
Rated power: 353kW/1900r/min;
Max. torque: 2200Nm/1100~1500r/min;
Type: straight line, water-cooler, four-stroke, charge air cooling system, electric controlled high-pres-
sure common rail
Emission standard: stage III, GB20891-2014
Option: Yuchai YC6K520-GT30
2. CLUTCH
Manufacturer: Fast EatonFast Eaton
Type: 430 dry type diaphragm ceramic spring clutch
3. Transmission
Manufacturer: Shaanxi Fastgear
Type: 8DS240A
8-Gear double intermediate axles, non-synchronizer transmission, 8 forwarding gears and 1 reverse
gear. A transmission that’ s dedicatedly customized to adapt to open pit mine conditions, suitable for
working in low-speed large-torque state, which shows super strong load bearing capacity
4. Axles
Divided type front axle. Front hub is made of quality iron casting, steering knuckle is premium steel
casting, strong and durable.
Intermediate and rear axle casings are made of high strength alloy steel, and key seams have 100% re-
ceived ultrasonic flaw detection. knuckle bearing is in connection with framework, which ensures rear
axle casing has enough rotation freedom relative to framework, and guarantees a longer life span of
both. A lateral connecting rod offers spacing for rear axle, and features in simple structure and is main-
tenance friendly.
5. Vehicle frame
Framework is made of a pair of balanced longitudinal beams and transverse beams at let and right,
which form into an enclosed structure. Longitudinal beam is box-like cross section structure and trans-
verse beam is torsion resistance structure that eliminates stress-raising source of bending and cracking.
Framework strength has been upgraded, because it is made of high quality low-alloy high-strength steel.
Key seams have 100% received ultrasonic flaw detection.
A detachable upper gantry beam is convenient for hoisting engine.
It has adopted computer aided design and received finite element analysis.
6. Cargo compartment
Cargo compartment bottom plate and rear damper plate are made of high-strength anti-wear steel which
as a long life span; with such a lightweight design, it can maximize its loading value.
A sloping plate design idea has been borrowed to strengthen the transition between bottom plate and
side board, so loading materials will be smoothly dumped.
A safety pin has been added in lifting mechanism, guarantees the safety of maintenance staff.

7. Suspension System
XDR80T tri-axle rigid mining truck is armed with Macpherson independent suspension, left-right sym-
metric, guarantees reliable wheel positioning and stable comfortable driving experience. Hydro pneu-
matic suspension is articulated with front and rear axles through knuckle bearing and framework;
exposed part of piston rod is covered by a telescoping jacket; it is able to adapt to changes of load and
road condition, can quickly absorb impact and weaken vibration, ensure smooth a smooth travel.
Front suspension: Macpherson independent suspension, hydro pneumatic suspension cylinder
Rear suspension: four-bar linkage and anti-roll bar structure, hydro pneumatic suspension cylinder, dou-
ble air chamber reservoir, whose frequency changes a little when vehicle is fully loaded, ensures com-
fortable driving experience.
8. Steering system
Fully hydraulic steering is characterized by stable steering operation and highly accurate response. It
contains an emergency steering function that is powered by reservoir and is a guarantee of driving
safety.
Divided steering trapezium, is more in line with Ackermann steering geometry when in large rotation,
and reduces tire wear.
9. BRAKING
Overall truck is equipped with a running-parking integrated pneumatic disk brake system.
10.lift
Lifting system is an imported mature mechanism, cargo compartment lifting operation is done through
a lifting valve group that controls telescoping type multi-section cylinder.
11.Tire
The truck carries large-diameter tires, with large off-ground clearance, it obtains a good passing ability;
tire has basically no overload and a durable life.
Tire:16 R25 Full steel radial type
Rim: 11.25/2.0
12.Driver's cab
Cab has a wide space and a wide view. It has a complete set of devices: displaying meters, alarm, light-
ing, control switches and radio, etc. Driver’ s seat is adjustable, air suspending shock reduction type.
The cab also has an electric windshield wiper, washer, thickened glass and air conditioner. Vehicle trav-
el data and fault alarm items show on touchscreen LCD and controllable instruments. The base plate is
made of thickened steel plate and plastic sponge combination. It is soundproofing, and also offers pro-
tection to driver from tire explosion.
13.Power system
Engine has advanced technologies, is highly efficient and energy saving.
Three-level desert filters and two types of oil filters are for option.
Exhaust system pipe is a shorter and upgraded design, with a little exhaust back pressure.
Radiator, which is customized for mining operation, has strong anti-vibration performance and friendly
maintenance; inlet fan brings a large volume of air with low power consumption; overall vehicle has
strong heat load capacity

Fuel is supplied in a three level filtration system, which can fully protect the engine and high-pressure
common rail injection system.
14.Lighting system
All lamps are LED, the system is composed of head beam, steering lamp, clearance lamp, parking lamp,
reversing lamp and maintenance lamp, etc.
Lighting lamp and alarming lamp are reasonably arranged so as to meet various requirements under
changing weather.
Control and working voltage is DC 24V.
15.Automatic lubrication system
Automatic lubrication system regularly lubricate each component, which reduces the cost and time of
maintenance.
16.Safety Devices
Driver's cab is equipped with three-point-type seat belt, escape hammer and evacuation window. Be-
sides, the overall truck has emergency steering device, anti-skid walking platform, standard guardrail
and reverse warning, etc.
17.Others
Humanized handrail design is for ease of getting on/off the truck.
Flip engine hood offers easy access to inspection.
Reasonably designed mudguard can efficiently prevent muddy water from splashing on chassis
accessories.
18.Accompanying spare parts and tools
A set of supplied tools and easily damaged parts for maintenance purpose.
19.Colors
Main color:engineering yellow
Product Main Technical Specifications
Classes Item Unit Parameter

Full length of the whole machine mm 9308
Full width of the whole machine mm 4578
Dimension Full height of whole machine mm 3918/4345
parameter Wheel Wheel base mm 3800+1750
center
Front wheel mm 3094
distance
Rear wheel mm 2984
Weight Overall vehicle weight Kg 110000
parameter Rated loading capacity Kg 72000
Empty vehicle weight Kg 34000

Classes Item Unit Parameter

Front axle % 33
No load
Mass Rear axle % 67
distribution Front axle % 20
Full load
Rear axle % 80
Engine model / YC6K480-GT30
Engine rated power kW/r/min 353/1900
Dynamic
Engine maximum torque Nm/r/min 2200/1100~1500
parameters
Driving form / 6×4
Tire / 16.00R25
Maximum driving speed km/h 45
Driving Min. turning diameter m 22
parameters Max. grade ability % 30
Min. off-ground clearance mm 440
Working Loading height mm 3592/4332
parameter Lifting time S 28
Fuel tank L 650
Hydraulic Oil Tank L 121+59
Maintenance
Cooling System L 72.5
amount
Engine oil L 32
Gear oil L 105
Compartment
2:1 Heaped capacity m3 30-50
capacity

A
B
C
D
E
Figure 7-2
A:4578 B:3700 C:2022.5 D:2984 E:3950.5

H
Figure 7-3
F:4020 G:440 H:3094
O
R
I
Q
J
50.0°
P
K
L M N
Figure 7-4
I:4345 J:1699 K:514 L:1766 M:3800

N:1750 O:9308 P:534 Q:3518 R:8809


Chapter 8 Appendix
8.1 Electrical Schematic Drawings
Figure 8-1
Appendix 8-1
8.2 Hydraulic Principle Diagram
Figure 8-2
8-2 Appendix
Xuzhou Xugong Mining Machinery Co., Ltd
Address: No. 169 Heping Street, Xuzhou city, Jiangsu, China
Unified national customer service hotline: 400–110–9999
Service Tel: 400-110-9999 0516-83113333
Fax: 86-0516-83113222
Post Code: 221004
Website: Http://www.xcmg.com
Edition No.: Nov, 2021
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XDR80T Tri-axle Rigid Mining Truck Operation and Maintenance Manual

XUZHOU XUGONG MINING MACHINERY CO .,LTD.

3.5 Running Operations ............................................................................................ 3-5

8 Appendix .................................................................................................................... 8-1

Table of Contents III

1.1 Safety Information

3. Other signal language

Example of a text safety sign

Graphic safety sign

A graphic safety sign shows a dan-

1.2 Safety Signs

Side of the left Side of the left Both sides of the

Upper of the Suspension cylinder Upper of the hydraulic

Side of the left Driver's cab control console Driver's cab

1. Safety ladder warning

2. Accumulator charging hazard

3. Accumulator high-voltage warning

4. Parking position warning

5. Danger of suspension maintenance

High voltage risks. Please do not remove plug,

6. Hydraulic oil filling warning

7. Container extrusion warning

8. Safety sign for anti-explosion

9. Safety sign for scalding prevention

10.Read safety signs illustrated in the oper-

11.Lifting handle notice

12.Park brake warning

13.Emergency exit safety sign

1.3 Safety Equipment

• Fix long hair, loose clothes or jewelry, in

Make sure all shields and covers are in their proper

Extinguisher and First-aid Kit

• Configure with the first aid case and fire

• Develop emergency countermeasures to

1.4 Safety Rules

• Being in big noise for a long time may

Window glass for the driver’s cab

Safety in Construction Site

• Conditions of transport roads

• Check the shape and conditions of bot-

material pile, it is necessary to select a

bearing limit of ground and ramp that

Working on Unconsolidated Ground

Never approach high voltage cables

Cable Voltage Safe Distance

Cable Voltage Safe Distance

Cautions for Ventilation

If it is necessary to start the engine or deal

Emergency Exit of Driver's Cab

Ensuring Good Visibility

• To avoid hot coolant or steam from

• To prevent hot oil from scalding, wait

1.5 Safe Operation

Getting on the Machine Safely

When you get on/off the machine:

• Always face the machine and keep

Adjusting the Seat

Improper seat positions may cause operator

Fastening the seat belt well

• If the machine turns over, the operator

Inspection before starting the engine

Conduct the following inspections before starting the engine:

Precautions for Starting the Engine