Page 1 Operation and Maintenance Manual MT86H Off‐Highway Dump Truck WARNING Before operation maintenance, drivers and service personnel shall always read and get understanding of the manual. Otherwise, fatal accident may occur. This manual shall be kept properly for future reference by the personnel concerned.
Page 2 Tel: 86‐0531‐81663345 Technical service: 86‐0531‐81666372 Fax: 86‐0531‐81666853 Accessory sales: 86‐0531‐67605016 Web: www.lgmg.com.cn ...
Page 3 MT86H Operation and Maintenance Manual Contents Foreword ........................IV Chapter I Safety ......................1 1.1 Basic precautions ....................3 1.2 Operation precautions..................4 1.3 Other precautions ....................5 1.4 Notices&signs and their pasting positions ............6 ...
Page 4 MT86H Operation and Maintenance Manual 3.8 Operation at low temperature environment ............. 49 3.9 Wheel replacement and tire pressure .............. 51 3.10 Running-in of new vehicle ................53 Chapter IV Operation and Maintenance of Main Assemblies ......55 ...
Page 5 MT86H Operation and Maintenance Manual 6.4 Principle of hydraulic system ................ 156 6.5 Schematic diagram of electrical system ............157 III ...
Page 6 Thanks for choosing mining dump trucks manufactured by Lingong Group Jinan Heavy Machinery CO., LTD., Ltd. This manual describes the mechanism, driving and operating, maintenance and adjustment, technical parameters and service/adjustment data of the MT86H series mining dump trucks. Maximizing the profits from your Off-Highway Dump Truck is our common goal, which is to a large extent dependent on your familiarity with the truck and a careful and thorough maintenance.
Page 7 MT86H Operation and Maintenance Manual △ WARNING ● Only the specially trained personnel with corresponding qualifications are allowed to operate and maintain the truck. ● Incorrect operation, maintenance and repair are dangerous, and may lead to personal injury.
Page 8 MT86H Operation and Maintenance Manual Safety Attentions Operators should understand and follow prevailing national and local safety regulations. In case of no relevant national or local regulation, safety attentions in this manual will be applicable. Most accidents are caused by failure of following regulations on machine operation and maintenance. To avoid accident, please read, understand and follow all warning requirement and notes in the manual and on the machine before operation and maintenance. Details of safety measures are explained in Chapter I "Safety". Since it is unable to predict all possible dangers, therefore, safety explanation in the manual and on the machine may not include all safety precautions. In case of using steps and operation in this ...
Page 9 MT86H Operation and Maintenance Manual Chapter I Safety 1 ...
Page 10 MT86H Operation and Maintenance Manual 2 ...
Page 11 MT86H Operation and Maintenance Manual 1.1 Basic precautions The off-highway dump truck described here is a kind of mining engineering machinery, which has quite different structure and working properties compared to ordinary vehicles; therefore, the safety precautions and operation Fig.
Page 12 MT86H Operation and Maintenance Manual the hand brake, lower down the cargo body, shut down the engine and remove the key. 5) Do not place the inflammables and explosives near the hot parts like turbocharger, exhaust pipe, muffler and radiator for fear of fire or other accidents.
Page 13 MT86H Operation and Maintenance Manual △ ! When driving the truck under full load on a slope: ● Do not brake the truck abruptly when driving downhill; ● Never disengage the clutch or coast Fig. 1-7 the truck at neutral gear when driving downhill;...
Page 14 MT86H Operation and Maintenance Manual 4) Repair and replacement of tyre shall be done by the specialized personnel as it is highly risky. 5) Be careful when doing welding around the tyre, to avoid accidents due to tyre explosion.
Page 15 MT86H Operation and Maintenance Manual 2) Hydraulic oil mark: at hydraulic oil tank. 3) Fuel tank filling notice and sign: at fuel tank. 4) Lifting notice & sign: at the underpart of the hydro-cylinder support. 5) “No treading” sign: on battery box and fuel tank.
Page 16 MT86H Operation and Maintenance Manual 6) “High temperature” sign: near the muffler. 7) “Working safety” signs: at front end and in the middle of the cargo body. 8) Buffer tank operation Caution: beside the buffer tank.
Page 17 MT86H Operation and Maintenance Manual 11) Travelling Caution:（1）：at the front part windshield. 12) Travelling Caution:（2）：at the front part windshield. 13) hydro-cylinder notice：at the right front side of the seat in cab. 14) Parking brake handle valve notice：at the left front part of the Parking brake handle valve.
Page 18 MT86H Operation and Maintenance Manual 10 ...
Page 19 MT86H Operation and Maintenance Manual Chapter II Product Introduction 11 ...
Page 20 MT86H Operation and Maintenance Manual 12 ...
Page 21 MT86H Operation and Maintenance Manual 2.1 Outline and component name 1 2 3 4 5 6 7 ...
Page 22 MT86H Operation and Maintenance Manual 2.3 Application As an off‐highway dump truck featuring open cargo body, this machinery is suitable for loading/unloading and transportation of earth‐stones and minerals at ports, docks and various engineering sites, but in no case shall it be used for works and operations on road,loading/unloading or transportation of combustibles and explosives, and operations under ground or in environments containing explosive medias. △ ! WARNING： ● The truck is an off-road dump truck and should not be used on the road. ● When using the truck, please load the truck strictly in accordance with the standard load limited by the truck.
Page 23 MT86H Operation and Maintenance Manual 2.5.2 Main dimensions Items Parameters Items Parameters 2792 (front axle) 3800 (Front‐middle) Track width (mm) Wheelbase (mm) 2526 (rear axle) 1500 (Middle‐rear) Departure angle Approach angle (°) 30 40 (°) Min. ground ≥315 No. of axles 3 clearance (mm) 2.5.3 Engine Items Parameters Items Parameters Inline, DI, water‐cooled, Type No. of cylinders 6 supercharged and inter‐cooled ...
Page 24 MT86H Operation and Maintenance Manual Items Parameters/contents Total decelerate ratio 12.87 Wheel rim spec. 10.0/2.0‐25 Wheel Tire spec. 14.00R25 Tire pressure (MPa) 0.85 Brake pressure (MPa) 0.85 Brake system main brake Pneumatic, dual‐circuit Brake system Brake system auxiliary brake Engine exhaust emission brake Brake system parking brake Spring brake & emergency brake NOTE: All wheel rims shall be subject to the same specification. The tire pressure value indicated in the table is factory air pressure (no load), and the actual air pressure shall be adjusted according to “Comparison table of speed, load and air pressure” in 3.9. 2.5.5 Steering system Items Parameters/contents Type hydraulic steering Max. turning angle 38° Safety valve I/A Steering pump ...
Page 25 MT86H Operation and Maintenance Manual Chapter III Operation 17 ...
Page 26 MT86H Operation and Maintenance Manual 18 ...
Page 27 MT86H Operation and Maintenance Manual 3.1 Door operation △ ! WARNING: Do not drive unless all doors are properly closed! 3.1.1 Use door switch outside Door opening: When the door is unlocked, lift Fig.3-1 the handle and pull it outward (as shown in Fig.
Page 28 MT86H Operation and Maintenance Manual always make sure that the window and door are closed and the door is locked. Please keep valuables with you, rather than leave it behind in the cab. 20 ...
Page 29 MT86H Operation and Maintenance Manual 3.2 Cab interior device 3.2.1 Instrument cluster 2 4 7 8 9 3 Fig.3-4 1. Mileage & travel time display screen 2. Engine tachometer 3. Alarm indication mark 4. Oil pressure gauge 5. Voltmeter 6. Barometer of brake circuit 1 7. Barometer of brake circuit 2 8. Fuel gauge ...
Page 30 MT86H Operation and Maintenance Manual 3.2.3 Alarm indicators S/N Description Color S/N Description Color Width lamp on Parking indicator Red Green indicator Low gear indicator Green High beam indicator Blue (reserved) High gear indicator Low oil pressure alarm Green Red (reserved) indicator Forward gear indicator Inter‐wheel differential Green Green ...
Page 31 MT86H Operation and Maintenance Manual 3.2.4 Summary of rocker switch marks and function description (The key switch will be ineffective when it is set to gear 1, unless otherwise specified.) 3‐7 S/N Name Condition Function Remarks When the switch is turned to gear 2 and Clearance lamp ON / 3, the instrument lighting actuation will 1 headlamp OFF be effective; and high beam inching will be ineffective. 1 Lamp switch Clearance lamp and 0 ...
Page 32 MT86H Operation and Maintenance Manual S/N Name Condition Function Remarks Electric horn Press down horn on the steering wheel, 0 Horn selected and it will work. 8 change‐over Press down horn on the steering wheel, switch 1 Air horn selected and it will work. 0 OFF Inter‐axle differential solenoid valve Inter‐axle actuated; when inter‐axle differential 9 differential 1 ON switch is set to proper position, the switch corresponding indicator lamp on the instrument will be on. 0 ...
Page 33 MT86H Operation and Maintenance Manual 3.2.5 Power switch 1) Main power switch The main power switch is located outside the battery compartment of frame side rail. △ ! CAUTION: If a vehicle will not be driven for a long time, please turn off Fig 3‐8 ...
Page 34 MT86H Operation and Maintenance Manual lamp; and horizontally move it backward to turn on the left turn signal lamp. When the key switch is set to position 3, move the handle to turn on the turn signal lamp, and then a prompt will be heard; when the key switch is set to position 1 and 2, move the handle to turn on the turn signal lamp, and then a prompt ...
Page 35 MT86H Operation and Maintenance Manual Press and hold the windshield washer button, and the water jet on wiper blade will inject glass cleaner, and meanwhile, the wiper will automatically start working at low gear; water injection will be stopped after the release.
Page 36 MT86H Operation and Maintenance Manual switch, to use the electrically controlled air horn. Fog lamp 3) Fog lamp operation Press down the front fog lamp switch to power on the front fog lamp. Pull the switch, and then Fig 3-16 the fog lamp will be off.
Page 37 MT86H Operation and Maintenance Manual required angle and release the handle to lock the backrest. Range：0～60mm。 2) Horizontal adjustment: pull handle 2 upward to move the seat forward and backward to the required position, and release the handle to 4 ...
Page 38 MT86H Operation and Maintenance Manual backrest, do not lean back too much in case of hidden danger caused by triggering rear window. 3.2.9 Transmission gearshift lever The gearshift lever is installed on the engine hooding. In this way, the disturbance of cab...
Page 39 MT86H Operation and Maintenance Manual Fastening: Hold the latch of seat belt, wrap the seat belt around the shoulder and insert the latch into the striker until a click is heard. Unfastening: Press down the red button on the...
Page 40 MT86H Operation and Maintenance Manual △ ! CAUTION: While closing the cover, do not apply too much force and make sure that nobody stays within the travel range of cover in case of pinch. 3.3.2 Left/right rearview mirrors They are as shown in Fig. 3-26.
Page 41 MT86H Operation and Maintenance Manual rearview mirror is at the bend of the bracket. 2) Tighten the fixing bolts of the rearview mirror to be reliable without looseness. 3) When fine-tunning the rear-view mirror, press it upwards, downwards, leftwards and rightwards.
Page 42 MT86H Operation and Maintenance Manual corre-sponding rocker switch inside, and can be turned on or off at the same time. 3.3.4 Expansion tank The expansion tank is located at the rear left side of cab (as shown in Fig. 3-28).The...
Page 43 MT86H Operation and Maintenance Manual 3.4.3 Check suspension system Check if the mechanical lock operates properly. To prevent the mechanical lock from being released by vibration of the truck, weld a pin to the rear suspension, and then insert the pin from the rear suspension when the mechanical lock is latched.
Page 44 MT86H Operation and Maintenance Manual in the figure, insert the ripping bar and swing it up and down so as to complete tiltingoperation; during tiltingoperation, the position of manual reversion handle shall not be changed. 3) Turn the cab back: pull the manual reversion ...
Page 45 MT86H Operation and Maintenance Manual 4) Operate the pump to tilt up the cab to return is back to the original place, check, and top 5) Finally, screw in the oil plug. △ ! WARNING: The oiling and bleeding of tilting system are not allowed unless the cab is restored.
Page 46 MT86H Operation and Maintenance Manual fault! 3.6.1 Preparation The preparations before driving mainly include: routine inspection before every driving, engine start and flameout. 1) Turn on the main power switch (as shown in Fig. 3-35) to power on the truck.
Page 47 MT86H Operation and Maintenance Manual washer fluid instead of ordinary water or other washing liquid. c. Check fuel: Open the filler cap, insert the dip stick until the fuel tank bottom and make it lean against the upper edge of filler to the extent that the immersed end of dip stick is vertical to the tank bottom.
Page 48 MT86H Operation and Maintenance Manual e. Check engine oil: Measure the engine oil MAX MIN level before startup. If it has been started, do not measure the engine oil level until 15 minutes after stalling. Fig 3‐40 Oil dipstick scale Pull out the dip stick to clean it with cloth, and then insert it back into original position.
Page 49 MT86H Operation and Maintenance Manual 6) Check the lubricant, coolant and air duct for leakage. 7) Check engine air intake system. a. Check the primary filter inlet for blockage by foreign matters to avoid too much negative pressure present in the air intake system; for...
Page 50 MT86H Operation and Maintenance Manual 3.6.2 Engine start 1) Turn on the main power switch and turn the key switch to ON position, getting ready to start the engine. △ ! CAUTION: When the vehicle is running, do not turn off the key switch.
Page 51 MT86H Operation and Maintenance Manual interval between two successive start-ups shall be no less than 60 s. However, if it is not possible to start up for three successive times, stop it until any fault has been identified and cleared.
Page 52 MT86H Operation and Maintenance Manual started, immediately shut down the engine for overhaul. 4) Operation of supercharger The supercharger is installed at the rear upper end of engine, consisting of turbine assembly and pump impeller assembly. The exhaust gas...
Page 53 MT86H Operation and Maintenance Manual of supercharger. b. To shut down the engine, always run it at idle speed for 2-3 min, and shut it down after the supercharger slows down. Pay special attention not to depressing the accelerator forcibly before the engine stops.
Page 54 MT86H Operation and Maintenance Manual will be cut off for exhaust braking. The engine may be overheated after it runs overloaded, and in this case, the engine should be shut down after running at idle speed for 2-3 min.
Page 55 MT86H Operation and Maintenance Manual The drive axle of MT86 mining dump truck is equipped with bogie differential lock. When the wheel slips or gets stuck in the mud, the bogie differential lock can lock the bogie differential between the intermediate axle and the rear axle, thus increasing the vehicle trafficability.
Page 56 MT86H Operation and Maintenance Manual 3.7.4 PTO operation △ ! CAUTION: PTO can be used only on the engine-out condition! It is not allowed to use the PTO in the low or reverse gear. This manual only gives introduction to PTO engagement and disengagement.
Page 57 MT86H Operation and Maintenance Manual takeoff switch automatically opens and returns. Operation temperature environment 3.8.1 Engine cooling system The long-life antifreeze and anticorrosion coolant applied by the engine cooling system Fig 3-52 Air dryer can be kept unfrozen above -35℃. If the vehicle has to work in the environment below -35℃, the coolant concentration should be...
Page 58 MT86H Operation and Maintenance Manual condition.Under normal condition, the service life of desiccant in the air dryer is half a year. If any oil-water mixture is drained from air reservoir, air dryer is ineffective and the desiccant should be replaced immediately.
Page 59 MT86H Operation and Maintenance Manual 3.8.4 Startup system Start the engine with an auxiliary startup device under low temperature. Make the electronic heating flange operate with a relay so as to start the engine successfully under -30　C. 3.8.5 Park In case of cold climate, do not park until...
Page 60 MT86H Operation and Maintenance Manual 2) The fitting surface of brake drum and wheel rim shall be free from paint, grease or other contaminants. 3) The seal face of wheel nuts shall be kept clean without contaminants or oil stain.
Page 61 MT86H Operation and Maintenance Manual 3.10 Running‐in of new vehicle The running-in mileage is 1,500-2,500 km as specified. Before running-in, do routine inspection to ensure that the vehicle is kept in normal working condition. Precautions for running-in: 1) Do not speed up immediately after the engine gets started.
Page 62 MT86H Operation and Maintenance Manual wheel hub and brake drum. In case of overheating, find out the cause, and adjust and repair in time. 7) The vehicle must experience a run-in of 1,500km. it might be put into use after the brake interval is readjusted and the fasteners (except gelatinizes bolts) are rechecked.
Page 63 MT86H Operation and Maintenance Manual Chapter IV Operation and Maintenance of Main Assemblies 55 ...
Page 64 MT86H Operation and Maintenance Manual 56 ...
Page 65 4.1.1 Operation and maintenance of engine See Operation and Maintenance Manual of WD12 Series Diesel Engine for details 4.1.2 Change of engine oil,filter,prefilter During operation of MT86H, it is necessary to Fig 4‐1 1. Drain plug periodically replace engine oil, filter and pre-filter as appropriate to keep the engine Oil dipstick ...
Page 66 MT86H Operation and Maintenance Manual eliminate timely the fault potential if any. b) After the oil has been drained off, remove the foreign materials from the drain plug that then should be screwed on. c) Replace with a new oil filter element, and ...
Page 67 MT86H Operation and Maintenance Manual fit a new filter, clean up the fitting surface first, fill the filter full with clean media to be filtered, lubricate the rubber seal ring with little clean media to be filtered, then...
Page 68 MT86H Operation and Maintenance Manual loose. 6) Check the oil pressure and water temperature of the diesel engine. 7) Check if the exhaust temperature, color, sound and vibration are normal, and the speed is stable. Refer to "Periodic Inspection and Technical Maintenance of Diesel Engine"...
Page 69 MT86H Operation and Maintenance Manual 1 4.2.1 Cyclonic prefilter 3 The cyclonic prefilter is maintenance-free and is removed for inspection only when there is 2 abnormal noise, and if necessary, the rotator should be replaced. Fig 4‐7 4.2.2 Coarse filter 1.Cyclonic prefilter 2. Coarse filter 3.Fine filter...
Page 70 MT86H Operation and Maintenance Manual 4.2.3 Fine filter The fine filter is composed of the main filter element and the safety filter element. The main filter should be maintained when the indicator alarms or every 200-250 working hours. The safety filter element is only used as second protection and may not be cleaned.
Page 71 MT86H Operation and Maintenance Manual ① The main filter has been damaged; ② After the indicator is cleaned and installed, it still alarms: ③ The main filter element has been cleaned for 5 times. △ ! CAUTION: The safety filter element cannot be cleaned, and should be replaced together with the outer filter element.
Page 72 MT86H Operation and Maintenance Manual backward, finally to release the clutch successfully. The clutch drive cylinder, clutch fluid reservoir and clutch pedal assembly etc. are arranged to the front wall of the cab, with the drive cylinder connected to the clutch booster...
Page 73 MT86H Operation and Maintenance Manual assembly on the spline shaft (with a tool used for positioning the clutch driven disc to be installed), with the fly wheel central hole aligned. Assemble any two holes of the clutch pressure plate assembly to the two studs on the...
Page 74 MT86H Operation and Maintenance Manual While adjusting, push the pedal gently by hand until you feel the drive cylinder push rod against the piston, adjust the height of stop bolt to ensure a clearance between the push rod and piston of 0.5 mm~1 mm, and then tighten the...
Page 75 MT86H Operation and Maintenance Manual 4.3.4 Precautions 1) Remember to release the pedal after the bleed valve is tightened during air discharge in order to avoid air suction, and allow the Fig 4‐9 Brake fluid pedal to rise up to the maximum height, so that the brake fluid in the fluid reservoir is added into the drive cylinder hydraulic cavity.
Page 76 MT86H Operation and Maintenance Manual 4.3.5Common faults and troubleshooting Faults Causes Solutions The transmission is misaligned at re‐assembly; Align the driven disc assembly carefully, and Clutch return The hub is mounted on the align the clutch with an analog spindle; difficulty causes input shaft, and the driven Do not push the transmission forcibly, but rotate shift difficulty ...
Page 77 MT86H Operation and Maintenance Manual Fault Causes Solutions The cap assembly drops Do not use the cover assembly that has ever Shift is difficult during assembly so that the dropped; or is unavailable return spring is twisted; Check the return spring carefully before ...
Page 78 MT86H Operation and Maintenance Manual Fault Causes Solutions The positioning element has The clutch been damaged; Check the fork and guide sleeve, and replace it if generates noise, Mechanical operation errors any abnormal wear sign; and the pedal is during the clutch assembling Make sure the parts are lubricated; loose result in damage to the Check the clutch cable carefully locating plate The audible harsh noise occurs when the clutch ...
Page 79 MT86H Operation and Maintenance Manual Fault Causes Solutions The truck is operated rudely; The clutch is operated too frequently; The driver always puts his Check the release bearing sleeve systematically; The clutch slips foot on the pedal; Educate the driver The release bearing is stuck with the sleeve of the input shaft Checks the sealing ring of the engine and the ...
Page 80 MT86H Operation and Maintenance Manual Fault Causes Solutions Since the self‐regulator is worn to the limit, the release Periodically check the state of the self‐regulator bearing has no sufficient and the preload of the release bearing, and backward travel after the push the fork of the clutch in reverse; driven disc assembly has Check the adjustment allowance, and the ...
Page 81 MT86H Operation and Maintenance Manual Fault Causes Solutions When replacing the clutch, pay special attention to the condition and lubrication of the fork. In The travel of the release case of any irregular mark or unsmooth Gear generates bearing is insufficient, movement, replace the parts; friction sound causing the clutch being ...
Page 82 MT86H Operation and Maintenance Manual Operation maintenance transmission 4.4.1 Main performance parameters The MT86 mining dump truck is applied with the countershaft and single case structure, which is designed with seven forward gears and one reverse gear without synchronizers. The ...
Page 83 MT86H Operation and Maintenance Manual addition, the output shaft gear is radially floating on the output shaft to make the gear engaged with the countershaft gear properly and distribute the load as equal as possible. Since the output shaft gear floats on the...
Page 84 MT86H Operation and Maintenance Manual The power transmission route is shown in the figure (left). 4.4.3 Transmission structural parts 1）Installation and adjustment of flexible shaft control system The 7DS200 transmission is remotely operated. The flexible shaft operating system is installed and regulated as follows: a.
Page 85 MT86H Operation and Maintenance Manual transmission end to see if it meets the requirement. And if not, adjust the connecting length of flexible shaft ball joint with pull rod thread so as to adjust the installation dimension of the flexible shaft.
Page 86 MT86H Operation and Maintenance Manual output rotatory direction and the engine running direction are consistent. The POT connects the transmission inner cavity, so it is unnecessary to add lubricating oil. The MT86 mining dump truck is applied with the QH70 power takeoff.
Page 87 MT86H Operation and Maintenance Manual the sight glass of the housing side and add oil until it spills out of the mouth. The reference oil capacity of the 7DS200K transmission is 23 L. c. Oil level inspection The oil level should be inspected periodically, always with the truck parked on a level road.
Page 88 MT86H Operation and Maintenance Manual the lubricating oil for its level and leakage after 10,000 km, replenish when necessary and clean the strainer. If the limited period (mileage) of the mandatory maintenance is exceeded, change the lubricating oil after driving for 25,000 km.
Page 89 MT86H Operation and Maintenance Manual lack of lubrication. To avoid such phenomena, notice that: never step on the clutch pedal to allow the truck skidding at natural. To drag the truck, either pull out the axle shaft or release the drive shaft, or drag with the driving wheel off the ground.
Page 90 MT86H Operation and Maintenance Manual ●Before starting, in the case that the truck air pressure does not reach to a correct level, never let the parking brake lever go to do gearshift; ●While the transmission is set at neutral，never slide downhill;...
Page 91 MT86H Operation and Maintenance Manual differential and inter-wheel differential as well as bogie differential lock. An evolvent S-shaped cam drum brake and external respiration piston spring brake chamber are adopted. 4.5.2 Operation and maintenance of front axle ...
Page 92 MT86H Operation and Maintenance Manual other dirt; apply grease, oil, or other thread paste to the threads of the wheel bolts and wheel nuts before installation. ① Clean the matching surface between the brake drum and the rim, the outer circle...
Page 93 MT86H Operation and Maintenance Manual mm, and the clearance between the upper and lower drums and shoes shall not be greater than 0.3 mm; ● The axle friction plate must be accessories from Lingong Group Jinan Heavy Machinery Co., Ltd.
Page 94 MT86H Operation and Maintenance Manual before 5,000 kilometers (or within 1 month). The first maintenance items are listed as follows: ① Refill grease to the grease nozzle of the master pin, the camshaft support and the regulating arm as required. If it is difficult to refill grease, check it immediately and stop operating;...
Page 95 MT86H Operation and Maintenance Manual and maintenance, stop the engine, park the truck on flat road, apply the parking brake, and set wedges on both wheels of any axle to avoid safety accidents. 4.5.3 Operation and maintenance of drive ...
Page 96 MT86H Operation and Maintenance Manual lock is latched to avoid internal gear damage. When the differential lock between axles is latched, the truck shall not run for a long time on undulate road. The differential lock shall be released in time after the truck has passed ...
Page 97 MT86H Operation and Maintenance Manual 5,000km, check the thickness of the brake shoe friction plate, which shall not to be less than 8mm. The inspection period thereafter may be shortened as appropriate to avoid other serious faults due to excessive wear of the friction plate;...
Page 98 MT86H Operation and Maintenance Manual to ensure that they rotate flexibly; ⑤ Refill grease to the grease nozzle of the axle every 15 days (as shown in figure). If it is difficult to refill grease, check it immediately and stop operating.
Page 99 MT86H Operation and Maintenance Manual maintenance. The periodic maintenance items are listed as follows: ① Repeat the first maintenance items; ② Replace the hub bearing grease of the front axle assembly; ③ Lubricate the brake shoe pin and the brake Fig. 4‐26 Intermediate Axle Part...
Page 100 MT86H Operation and Maintenance Manual Operation maintenance suspension system △ ! Warning: It is necessary to replace the thrust rod repair kit after the truck has run for 4 months, (20,000km). The Fig4‐27 Front suspension system user will bear consequences of vehicle 1. Front push rod 2. Front bearing of the leaf spring...
Page 101 MT86H Operation and Maintenance Manual 1. Re-tighten the thrust rod bolts/front and rear leaf spring bolts periodically at the interval specified in "5.2 MT86 mining dump truck compulsory maintenance details". If the engine has operated for 30 hours during the truck shipment...
Page 102 MT86H Operation and Maintenance Manual shock absorber, stop block and front push-rod, Failure Analysis of Shock Absorber 1) Specifications of fasteners MT86H Failure mode Analysis and solution Application Tightening Refill appropriate Specification torque (Nm) grease and then Front spring proceed with M24 750±50 U‐bolt and nut operation. ...
Page 103 MT86H Operation and Maintenance Manual above fasteners. 2) Description of front leaf spring MT86H: 13 pieces in total, in which four main leaves, reinforced parallel semiellipse front leaf spring. The leaf spring configuration for each model has already been justified by vehicle ...
Page 104 MT86H Operation and Maintenance Manual such as tie rod ball; f. If suspension components are damaged and loose, such as wear resisting washer between lifting lug and leaf spring eye or bracket; g. If front axle and wheel alignment is correct;...
Page 105 MT86H Operation and Maintenance Manual accelerate break of leaf spring plate. e.If the wear extent of the wear block exceeds 50% total thickness or it fall off, replace it immediately; otherwise, the leaf spring seat will be damaged, thus influencing the service life of the seat;...
Page 106 2) Description of rear leaf spring broken cover. Assemble it according to the above MT86H: 15 pieces in total, in which five main procedures. Replace the whole set of pieces, reinforced parallel semiellipse leaf bearing and adjust the bearing clearance to prevent bearing from breaking again due to Crack in local stress of bearing bearing caused by axial ...
Page 107 MT86H Operation and Maintenance Manual spring. Fault mode Solutions The leaf spring configuration for each model Replace the sealing ring. For specific procedures, Oil leakage has already been justified by vehicle refer to paragraph a. due to sealing Removal, installation and performance test. Modification without ring failure adjustment of balance approval may lead to major fault and loss.
Page 108 MT86H Operation and Maintenance Manual of the screw, and separate them from the balance shaft. The sketch map is as shown in the left figure. ③ Take the rubber bearing out of the balance shaft casing from the two ends.
Page 109 MT86H Operation and Maintenance Manual if the end face of the bearing block cling to the end face of the balance shaft through the upper and lower measuring holes, if the depth at the two measuring holes are the same and if the depth meets or is close to the theoretic depth (The theoretic depth is 35±0.1 mm).
Page 110 MT86H Operation and Maintenance Manual △ CAUTION: Do not change the number of leaf springs or replace them with ones of different thickness without approval. What is more important, do not modify the suspension structure without authorization! Do not use unaccepted components by our company such as push rod, slide plate seat and guide plate.
Page 111 MT86H Operation and Maintenance Manual Operation maintenance steering system The steering system consists of a steering control system and a hydraulic power steering system. The steering system consists of a steering wheel, a steering column, a steering drive axle, a pilot valve, a vane pump, a hydraulic oil, a steering gear, an oil pipe, a steel pipe, a steering cylinder, etc., as shown in left Figure 4‐33. In order to adapt to harsh operating ...
Page 112 MT86H Operation and Maintenance Manual operating position, and tighten the adjusting handle . 4.7.2 Hydraulic power steering system Full-hydraulic steering gear, pilot valve, hydraulic oil pump, hydraulic oil tank, steering cylinder, hydraulic pipeline, etc. The steering cylinder is φ70. 1) Full-hydraulic steering system construction (as shown in Figure 4-33) 2) Full-hydraulic steering system principle The steering pump is a vane pump.
Page 113 MT86H Operation and Maintenance Manual the pilot valve rod operate. When the pilot valve P opening is connected with CF opening, the high-pressure oil flows to the steering gear, passes through the valve element passage in the steering gear, to the steering gear L opening or R opening, and to the steering cylinder.
Page 114 MT86H Operation and Maintenance Manual steering cylinder). L opening is connected with the rod cavity of the left steering cylinder (the rodless cavity of the right steering). The steering gear T opening is connected with the oil return opening of the hydraulic oil tank.
Page 115 MT86H Operation and Maintenance Manual and turn steering wheel left and right to limit positions for several times to discharge oil from the oil tank, booster pump, steering gear and booster cylinder; ④ Retighten the oil return pipe (note that it...
Page 116 MT86H Operation and Maintenance Manual for maintenance. 4) Important connected positions and tightening torque requirements. Torque No. of Name Spec. ( Nm) places Steering wheel M22*1.5 580±58 1 fixing nut Steering gear M10*35 48±4 4 fixing bolt Booster cylinder M16×45 220±22 6 bracket bolt Drag link lock M12×1.5 85±8 2 ...
Page 117 MT86H Operation and Maintenance Manual 5) Common fault causes and troubleshooting methods Common faults Causes Troubleshooting methods 1. Oil in oil tank is insufficient 1. Check oil level of oil tank and refill 2. Air invades into oil passage it as specified 3. Filter or oil passage is blocked 2. Exhaust and check oil level and 4. Oil pump pressure is insufficient tightness of pipeline connectors 5. Inner leakage of steering gear is 3. Clean filter or dredge or replace ...
Page 118 MT86H Operation and Maintenance Manual Common faults Causes Troubleshooting methods 1. Oil pipe is bent 1. Clean or replace it High oil temperature 2. Oil passage is blocked 2. Dredge oil passage 1. Steering shaft has jammed 1. Check jamming position and 2. Steering valve is asymmetric check if input axle is subjected to 3. Flow of oil pump is excessive radial shear 4. Oil is too dirty and steering valve 2. Regulate or replace valve cannot return immediately assembly Run‐off 5. Wear or pressure of tires on both 3. Regulate or replace oil pump sides differs greatly 4. Clean and change oil 6. Bubbles exist in oil and direction 5. Replace tire or inflate is unstable 6. Check and exhaust air 7. One front wheel (braking 7. Maintain brake ...
Page 119 MT86H Operation and Maintenance Manual 4.8 Operation and maintenance of brake system 4.8.1 Composition of brake system The brake system of MT86 mining dump truck mainly consists of two-circuit service brake (foot brake), auxiliary brake (engine exhaust Fig 4‐38 brake) and emergency/parking brake (hand 1.
Page 120 MT86H Operation and Maintenance Manual pressure falls by 0.05 Mpa at most or in 30 min, it falls by 0.01 Mpa at most. △ ! CAUTION: Do not adjust the release pressure of pressure regulating valve without approval.
Page 121 MT86H Operation and Maintenance Manual and the clutch is released, the auxiliary brake will not work. When the speed of engine is lower than 1,100 r/min, the auxiliary brake will not work. The exhaust braking efficiency is higher at low gears.
Page 122 MT86H Operation and Maintenance Manual If braking is activated automatically due to leakage from air pipe connected to the spring brake chamber, it is only needed to unscrew the bolt at the rear end of spring brake chamber to release position, and the braking will thus be released (see the figure left).
Page 123 MT86H Operation and Maintenance Manual 4.8.4 Quick joint The pipes of the vehicle are mainly equipped with Jietong quick joints so as to make the tightness of brake system better. △ ! CAUTION: The removal of pipe joint without using special tools may lead to...
Page 124 MT86H Operation and Maintenance Manual checked. 1) Check method: For the truck equipped with an air dryer, regularly check accumulated water in the air reservoir (recommended monthly). When accumulated water is found in the air reservoir furthest from the dryer, it indicates that the desiccant has failed, and the drying cylinder should be replaced.
Page 125 MT86H Operation and Maintenance Manual subject to Max. temperature of 130℃ for 1 h. 4.8.8 Braking operation To stop the vehicle, follow the steps below: 1) When the vehicle is running, first release the accelerator pedal to reduce vehicle speed.
Page 126 MT86H Operation and Maintenance Manual will significantly affect brake effect. 4) It is not recommended to use the emergency brake under non-emergency conditions. Especially when running on a wet and slippery road, the vehicle may be at a risk of side slide if the emergency brake is applied.
Page 127 MT86H Operation and Maintenance Manual speed before shutting it off; otherwise it may lead to faults such as cylinder scoring and supercharger damage. 2) After the engine shuts down, disconnect all switches, and at last disconnect the master power switch on the body of battery box.
Page 128 MT86H Operation and Maintenance Manual 4.8.10 Driving on slopes 1) When driving downhill, effectively utilize the engine exhaust brake and eddy current retarder to keep the vehicle speed within a safe range. 2) When vehicle runs at low gear or goes downhill, the speed of engine should not exceed the Max.
Page 129 MT86H Operation and Maintenance Manual 4.8.11 Driving on icy road 1) When driving on icy road, please use tire chains. 2) Always drive at low speed, and avoid sudden acceleration. 3) Avoid sudden braking and sharp turning, otherwise the vehicle may be subject to side slide and drifting, which will cause accidents.
Page 130 MT86H Operation and Maintenance Manual lamps of vehicles running in front. 2) In case of heavy fog, stop driving, park the vehicle at a safe area, and meanwhile turn on the hazard warning switch to make the left and right turning lamps flash simultaneously.
Page 131 MT86H Operation and Maintenance Manual 4.8.14 Brake line troubleshooting No. Causes Root causes Troubleshooting methods Start the truck without stalling until the barometer indicates 0.85 MPa, make it stall for 10 minutes. If the pressure drops by more than 0.15MPa, the pipeline may System pressure is leak or the air chamber may be damaged. insufficient Check the pipeline and the air chamber. If the pressure reaches up to 0.85 M,Pa (due to accuracy of barometer), the air dryer Service brake and the four‐circuit protection valve may force is have failed. Replace them. 1 insufficient or When air exists in the brake valve inlet, brake cannot be depress the brake valve. If no air is applied Brake valve is out of work exhausted from the air outlet, replace the brake valve. If there is no problem with the above ...
Page 132 MT86H Operation and Maintenance Manual No. Causes Root causes Troubleshooting methods If there is no problem with the above valves, depress the brake pedal. If the Parking brake Relay valve is out of work brake air chamber 11 opening is smooth 2 can not be Brake air chamber is but the brake air chamber push rod release damaged cannot be pushed out, replace the brake air chamber. Start the truck without stalling until the barometer indicates 0.85 MPa, make it stall for 10 minutes. If the pressure drops Horn does not by more than 0.15MPa, the pipeline may work and ...
Page 133 MT86H Operation and Maintenance Manual 4.9 Operation and maintenance of A/C 4.9.1 General The A/C system consists of radiator, compressor, integrated condenser, evaporator and fan which are connected as a closed system with pipes. The radiator utilizes the engine circulating water as heat source, the compressor is driven by the engine belt, the ...
Page 134 MT86H Operation and Maintenance Manual Refrigeration: after the refrigerant enters the pipeline of the refrigeration system, it is pressurized by the compressor into refrigerant gas of high-temperature and high-pressure, and then into liquid state (actually a vapor-liquid mixture) after being cooled through the condenser.
Page 135 MT86H Operation and Maintenance Manual desirable inside temperature. Setting range: LO, 18℃-29℃ and HI. Generally, temperature 5 set within 22℃-26℃ is appropriate. If you want that it is cooler inside, set the 1 4 temperature at LO. If you want that it is warmer 2 ...
Page 136 MT86H Operation and Maintenance Manual 3) Night vision function Switch on clearance lamp power, the key symbols and other symbols are displayed synchronously. 4) Air outlet mode selection By pressing the air outlet mode selection key and defrosting selection key, 4 air outlet modes can be selected, which are head blow, feet blow, feet blow &...
Page 137 MT86H Operation and Maintenance Manual or display screen damage. 4) The refrigerant filler is on compressor and pipes. In case of insufficient refrigerant or poor refrigeration, please contact professional personnel to supplement refrigerant. When refrigerant is insufficient, white foam can be seen through the observation window on the upper part of pipe.
Page 138 MT86H Operation and Maintenance Manual 4.9.4 Service and maintenance Maintenance interval Maintenance items Description Weekly Monthly Bimonthly Quarterly Yearly Check the amount of Amount of ＋ refrigerant through refrigerant observation window. Check leakage with Refrigerant ＋ halogen leak leakage detector. Check hose for ＋ cracking and ...
Page 139 MT86H Operation and Maintenance Manual Maintenance Maintenance interval Description items Weekly Monthly Bimonthly Quarterly Yearly Check clip plug for ＋＋ Connector looseness. Thermistor Check if it works ＋ switch normally. Electrical Check if it meets Magnetic ＋ element ...
Page 140 MT86H Operation and Maintenance Manual S/N Symptom Probable causes Solutions The sensing bulb of expansion Tighten the sensing bulb clamp. valve is loose. There is excessive refrigerant. Discharge the extra. High air return 4 pressure The compressor leaf is damaged. Replace the leaf. The compressor cylinder gasket Replace the cylinder gasket. leaks. The drive belt is damaged. Replace the belt. The clutch conductor is Replace the conductor. damaged. Compressor does The compressor piston is 5 Replace the compressor. not work. damaged. The thermostatic switch is in Replace the thermostatic switch. failure. The clutch coil is damaged. ...
Page 141 MT86H Operation and Maintenance Manual S/N Symptom Probable causes Solutions The conductor is loose or in Do troubleshooting. short circuit. The rotor shaft is bending. Replace it. 10 Fan rotates slowly. The controller resistor is burnt Replace the resistor. out. The voltage is insufficient. Check the alternator. Check the fixing screw of blade. Tighten the screw. Joint leaks. Repair or replace it. 11 Hose or joint leaks. Hose leaks. Replace the hose. 133 ...
Page 142 MT86H Operation and Maintenance Manual 134 ...
Page 143 MT86H Operation and Maintenance Manual Chapter V Maintenance 135 ...
Page 144 MT86H Operation and Maintenance Manual 136 ...
Page 145 ! CAUTION: Users should carry out the initial inspection immediately after delivery of the truck provided that the engine has worked for 30 h or more on the way of shipment. 5.2 Details on mandatory maintenance of MT86H mining off-highway off-highway dump truck Period ...
Page 146 MT86H Operation and Maintenance Manual Period Material code Material name Specification Unit Qty Remarks Rear axle unilateral wheel 500h 5301000007 Gear oil SAE85W/90GL‐5 L 36.6 reducer 6.3L （7000 km） Rear axle main drive:24L 4110000001390 Oil filter 612630010239 Piece 2 5301000010 Diesel engine oil CF‐4 15W/40 L 27 Weichai ...
Page 147 MT86H Operation and Maintenance Manual △ ! CAUTION: ● The oil acts as the primary medium to absorb the dust and other particles when the oil-bath is working, so the clean waste engine oil or gear oil can be applied.
Page 148 MT86H Operation and Maintenance Manual No mineral oil can be used. Use alcohol or one piece of clean cloth to wipe impurities. c. Rust protection After cleaning all the waste oil and grease on the part surface, smear one layer of clean oil on the surface to prevent rust. 2) Inspection Before cleaning parts, use prepared measuring instrument or tools to inspect. Determine whether the parts are suitable for reuse according to specified maintenance standards. Damaged parts require maintenance or replacement. If one piece of matched part is severely damaged, and its ...
Page 149 MT86H Operation and Maintenance Manual Maintenance level nd rd Item Description Initial Routine class class inspection inspection maintenance classmaintenance classmaintenance maintenance Tighten air intake pipeline hoses ● ● ● ● ● ● and flange connecting pieces Check air filter maintenance ● ● ● ● ...
Page 150 MT86H Operation and Maintenance Manual Maintenance level nd rd Item Description Initial Routine class class inspection inspection maintenance classmaintenance classmaintenance maintenance Check and adjust clearances of taper roller Whenever doing the 1 class inspection and the 2 class maintenance bearing for wheel Front axle hub Replace grease ● ● for wheel hub ...
Page 151 MT86H Operation and Maintenance Manual Maintenance level nd rd Item Description Initial Routine class class inspection inspection maintenance classmaintenance classmaintenance maintenance Re‐tighten propeller shaft Once every 100 hours bolts Propeller Visually inspect shaft connection and Once every 100 hours wearing of propeller shafts Check actions of ● ● ● ● ● ...
Page 152 MT86H Operation and Maintenance Manual Maintenance level nd rd Item Description Initial Routine class class inspection inspection maintenance classmaintenance classmaintenance maintenance Check fixation of Chassis ● ● ● ● fuel tanks Drain air ● ● ● ● ● ● reservoir ...
Page 153 MT86H Operation and Maintenance Manual Maintenance level nd rd Item Description Initial Routine class class inspection inspection maintenance classmaintenance classmaintenance maintenance Check retarder system, in which indicator shall operate properly, connecting pieces Check before each trip are connected firmly, and appearance is clean Check clearance between retarder Once every months rotor and stator Brake system Check retarder oil seal, bearing ...
Page 154 MT86H Operation and Maintenance Manual Maintenance level nd rd Item Description Routine class class Initial inspection inspection maintenance classmaintenance classmaintenance maintenance Check fixation of battery wiring terminals and ● ● ● ● ● apply grease to electrodes Electrical system Check correctness of speed displayed ● ● ...
Page 155 MT86H Operation and Maintenance Manual Maintenance level nd rd Item Description Routine class class Initial inspection inspection maintenance classmaintenance classmaintenance maintenance Check for inclination of oil cylinder when Once every day lifting it without load Check for looseness of bracket bolts of Once every week oil tank and oil pump Check if limit Lifting valve operates Once every week system properly ...
Page 156 MT86H Operation and Maintenance Manual Maintenance level nd rd Item Description Routine class class Initial inspection inspection maintenance classmaintenance classmaintenance maintenance Clutch release ● ● ● ● ● ● bearing Clutch fork shaft ● ● ● ● ● ● Universal joint ● ● ...
Page 157 MT86H Operation and Maintenance Manual 5.3.3 Selection of oil products Recommended types and Type Amount Part standards Ambient temp.≥‐15° CF‐4 15W/40 Engine oil 27L Weichai engine Ambient temp.＜‐15°CF‐4 15W/40 Heavy‐duty vehicle gear oil (GL‐5) Central axle: 45.6L 85W‐90 Rear axle: 36.6L Axle main drive, bogie Gear oil differential housing, final Ambient temp.≥‐15° Heavy‐duty drive and transmission vehicle gear oil (GL‐5) 85W‐140 Transmission:23L Ambient temp.≥‐26° Heavy‐duty vehicle gear oil (GL‐5) 80W‐140 L‐HM46 hydraulic oil GB11118.1 135L Hydraulic oil tank Hydraulic L‐HM32 hydraulic oil GB11118.1 oil ...
Page 158 MT86H Operation and Maintenance Manual 5.3.4 Reference table of oil products in China and abroad 1) Engine oil Grade of Grade of similar foreign brand oil (ranked as per US SAE) domestic oil CALTEX SHELL MOBIL ESSO Diesel engine oil RotellaSX 40; MobilDelvacSuper 130 Essolube XT‐3; CD or higher Rotella TX 40, 20W/40; (SAE15W‐40) (‐15°C～ CALTEX Delo Essolube XT‐2 15W‐40 GB11122 Rotella DX 40 50°C) Gold MobilDelvacSuper 130 Multigrade Diesel engine oil Rotella SX30, 10W/30; (SAE10W‐30) 15W‐40 CD or higher Rotella TX30; Essolube XT‐5 (‐20°C‐40°C); Delvac 1# 5W‐30 GB11122 ...
Page 159 MT86H Operation and Maintenance Manual 5.4 Lubrication of chassis 1. Lubrication requirements Note: The contents shown in this lubrication scutcheon are the data under normal working conditions and temperature. Customers can make adjustments according to difference of working conditions and temperatures. 2. List of categories of lubricant 151 ...
Page 160 MT86H Operation and Maintenance Manual 3. Lubrication diagram 152 ...
Page 161 MT86H Operation and Maintenance Manual Chapter VI Annex 153 ...
Page 162 MT86H Operation and Maintenance Manual 6.1 List of bulbs Name Type Power Qty. Headlamp (high/low) H4 24V70W/75W 70W/75W 2 Front fog lamp H3 24V70W 70W 2 Side turn signal lamp 24V1W 1W 2 Front turn signal lamp 24V1W 1W 2 Height lamp 24V0.4W 0.4W 3 Front working lamp and rear ...
Page 163 MT86H Operation and Maintenance Manual 6.3 Schematic diagram of brake 155 ...
Page 164 MT86H Operation and Maintenance Manual 6.4 Principle of hydraulic system Engine Take power device 156 ...
Page 165 6.5 Schematic diagram of electrical system 157 ...

LGMG MT86H Operation And Maintenance Manual

Foreword

Chapter I Safety

Chapter II Product Introduction

Chapter III Operation

Chapter IV Operation and Maintenance of Main Assemblies

Chapter V Maintenance

Chapter VI Annex

Quick Links

Troubleshooting

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Summary of Contents for LGMG MT86H

Table of Contents