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LGMG MT86 Operation And Maintenance Manual

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Operation and Maintenance Manual
MT86
Off-Highway Dump Truck
△
!
WARNING
Before
operation
and
maintenance,
the
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.
LINGONG GROUP JINAN HEAVY MACHINERY CO., LTD

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Summary of Contents for LGMG MT86

  • Page 1 Operation and Maintenance Manual MT86 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 MT86 Off-Highway Dump Truck Operation and Maintenance Manual 880*1230 mm sextodecimo 8 printed sheet 2st edition and printed for the first time in April 2018 LINGONG GROUP JINAN HEAVY MACHINERY CO., LTD Add: F12,Building 3 LushangGuoao Plaza, 9777 Jingshi Road,Lixia District,Jinan, Shandong,...

  • Page 3: Table Of Contents

    MT86 Operation and Maintenance Manual Contents Contents ..................................I Foreword ................................... I Safety Attentions..............................II Chapter I Safety ............................... 1 1.1 Basic precautions ..............................3 1.2 Operation precautions ............................3 1.3 Other precautions ..............................4 1.4 Notices&signs and their pasting positions ......................5 Chapter II Product Introduction..........................
  • Page 4 Chapter V Maintenance ............................133 5.1 Mileage for routine inspection & maintenance interval ................135 5.2 Details on mandatory maintenance of MT86 mining dump truck ............135 5.3 Key points of maintenance ........................136 5.4 Lubrication of chassis ..........................148 Chapter VI Annex ...............................

  • Page 5: Foreword

    For the latest information on the dump truck or in case of any doubts about this manual, please consult LGMG. This manual is applicable for MT86 series Off-Highway Dump Truck (standard configuration). Users shall be in strict accordance with the mileage or time interval in the maintenance schedule to do maintenance to the assembly and the dump truck.

  • Page 6: Safety Attentions

    MT86 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.

  • Page 7: Chapter I Safety

    MT86 Operation and Maintenance Manual Chapter I Safety...
  • Page 8 MT86 Operation and Maintenance Manual...

  • Page 9: Basic Precautions

    MT86 Operation and Maintenance Manual 1.1 Basic precautions The 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 instructions involved herein this manual shall be followed prior to the operation.

  • Page 10: Other Precautions

    1.3 Other precautions 1) Unauthorized modification is not allowed. Any modification without permission from LGMG may lead to an accident, and users shall contact with the Marketing Dept. of LGMG previously. LGMG assumes no liability for the casualties and damages incurred therefrom.

  • Page 11: Notices&Signs And Their Pasting Positions

    MT86 Operation and Maintenance Manual beneath, the stay bar of the cargo body should be set to a safe position for support, and restore the stay bar once the repair is finished. 3) Always inspect the tire from the side and never stay before or behind the rotating tire.
  • Page 12 MT86 Operation and Maintenance Manual 2) Hydraulic oil mark: at hydraulic oil tank. Fig.1-11 3) Fuel tank filling notice and sign: at fuel tank. Fig.1-12 4) Lifting notice & sign: at the underpart of the Fig.1-13 hydro-cylinder support. 5) ―No treading‖ sign: on battery box and fuel tank.
  • Page 13 MT86 Operation and Maintenance Manual Fig.1-15 7) ―Working safety‖ signs: at front end and in the middle of the cargo body. Fig.1-16 8) Buffer tank operation Caution: beside the buffer tank. Fig.1-17 9) Air reservoir Caution: at the external wall of the air reservoir.
  • Page 14 MT86 Operation and Maintenance Manual 14) Parking brake handle valve notice：at the left front part of the Parking brake handle valve. Fig.1-21 15) storage battery burst-no fireworks notice：at the left part of the battery case. Fig.1-22 16）pay attention to the work device logo: the rear door of the container.

  • Page 15: Chapter Ii Product Introduction

    MT86 Operation and Maintenance Manual Chapter II Product Introduction...
  • Page 16 MT86 Operation and Maintenance Manual...

  • Page 17: Outline And Component Name

    MT86 Operation and Maintenance Manual 2.1 Outline and component name 1. Cab 2. Front alxe 3.Cargo 4. Middle axle 5.Rear axle 2.2 Outline dimension...

  • Page 18: Application

    MT86 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.

  • Page 19: Vehicle Parameters

    MT86 Operation and Maintenance Manual 2.5 Vehicle parameters 2.5.1 Vehicle performance parameter Whole machine parameter Items Parameters Items Parameters Max. total mass (kg) 86000 Overall dimension（mm） 9070× 3450× 3960 Max. gradeability (%) Max. vehicle speed（km/h） Volume of cargo body ≤22 —...
  • Page 20 MT86 Operation and Maintenance Manual 2.5.4 Transmission system Items Parameters/contents Planetary Type Go 1 gears 4.40 Go 2 gears 2.33 Transmission Go 3 gears 1.53 FC6A250PR Go 4 gears 1.00 Go 5 gears 0.72 Go 6 gears 0.61 Reverse gear R 3.97...
  • Page 21 MT86 Operation and Maintenance Manual 2.5.5 Steering system Items Parameters/contents Type hydraulic steering Max. turning angle 38° Safety valve Steering pump Vane pump: displacement40ml/r Min. turning diameter (m) System working pressure (Mpa) 2.5.6 Working device Items Parameters/contents Type pneumatic control...
  • Page 22 MT86 Operation and Maintenance Manual...

  • Page 23: Chapter Iii Operation

    MT86 Operation and Maintenance Manual Chapter III Operation...
  • Page 24 MT86 Operation and Maintenance Manual...

  • Page 25: Door Operation

    MT86 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 the handle and pull it outward (as shown in Fig. 3-1) Fig.3-1...

  • Page 26: Cab Interior Device

    MT86 Operation and Maintenance Manual 3.2 Cab interior device 3.2.1 Instrument cluster 1. Coolant thermometer 2. Engine tachometer 3. Fuel gauge 4. Alarm indication mark 5. Barometer of brake circuit 1 6. LCD 7. Barometer of brake circuit 2 8. Voltmeter 9. Speedometer 10.
  • Page 27 MT86 Operation and Maintenance Manual 3.2.3 Alarm indicators Description Color Description Color Parking indicator Width lamp on indicator Green Low gear indicator Green High beam indicator Blue (reserved) High gear indicator Low oil pressure alarm Green (reserved) indicator Forward gear indicator...
  • Page 28 MT86 Operation and Maintenance Manual 3.2.4 Summary of rocker switch marks and function description Fig.3-7 NAME state function remake When the switch is turned to gear 2 and 3, the instrument Clearance lamp ON / lighting actuation will be effective; and high beam inching will headlamp OFF be ineffective.
  • Page 29 MT86 Operation and Maintenance Manual state Name Function Remarks Rear working lamp OFF Rear working lamp switch Rear working lamp ON The side working lamp is also controlled by this switch. Inter-axle Inter-axle differential solenoid valve actuated; when inter-axle differential switch differential switch is set to proper position, the corresponding indicator lamp on the instrument will be on.
  • Page 30 MT86 Operation and Maintenance Manual 3.2.5 Power switch 1) Main power switch The main power switch is located outside the Fig.3-8 Main power switch battery compartment of frame side rail. △ CAUTION: If a vehicle will not be driven for a long time, please turn off the main power switch for the avoidance of accident.
  • Page 31 MT86 Operation and Maintenance Manual Horizontally move the combination switch handle forward to turn on the right turn signal 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;...
  • Page 32 MT86 Operation and Maintenance Manual △ CAUTION: Always fill the washer via the filler port with the specialized glass cleaner instead of plain water or other cleaning agent for windshield Hazard warning switch washing. Fig.3-14 Electronic control gas horn button 3.2.7 Commonly-used switch operation...
  • Page 33 MT86 Operation and Maintenance Manual will be off. 4) Interior lighting Items Parameters After the battery box switch is turned on and the Seat width 510mm interior ceiling lamp switch is pushed to one side (both Seat height 855mm the right and left are ok), the interior lighting lamp will be Height on and off (as shown in left figure).
  • Page 34 MT86 Operation and Maintenance Manual 3) Front height adjustment: move handle upward gently to exert to or relieve from the front end of cushion upwards or downwards an appropriate force to lower (lift) it to the required position, and release the handle to lock.
  • Page 35 MT86 Operation and Maintenance Manual spring brake will get completely loosened, and the vehicle can get started. △ WARNING: Before the parking brake signal lamp is off, never start the vehicle! Fig.3-21 Safety belt 3.2.11 Other interior devices 1) Seat belt...

  • Page 36: Cab Exterior Devices

    MT86 Operation and Maintenance Manual 3.3 Cab exterior devices 3.3.1 Radiator cover Open radiator cover: rotate the two knobs as shown in Figure 3-25. Fig.3-25 Close radiator cover: pull down the radiator cover and rotate the knob in reverse. △...

  • Page 37: Cab Suspension

    MT86 Operation and Maintenance Manual 3.3.4 Expansion tank The expansion tank is located at the rear left side of cab Fig.3-28 Expansion tank (as shown in Fig. 3-28). 3.4 Cab suspension 3.4.1 Front suspension Fig.3-29 The cab front suspension is applied with the rotating suspension axle together with rubber shock absorber.
  • Page 38 MT86 Operation and Maintenance Manual 3.5.2 Cab tilting operation △ ! WARNING: During the whole process of tilting, personnel are strictly prohibited to enter the cab, and personnel without fixed duties are strictly prohibited to stay around the cab. Fig.3-31 1.

  • Page 39: Preparation Before Driving

    MT86 Operation and Maintenance Manual to the original place, check, and top up. 5) Finally, screw in the oil plug. △ WARNING: The oiling and bleeding of tilting system are not allowed unless the cab is restored. The low temperature and wear-resistant hydraulic oil of 0.5 L L-HV32 GB11118.1 shall be applied.
  • Page 40 MT86 Operation and Maintenance Manual level of hydraulic oil shall be between 1/4 of the level meter and MAX. If the oil level is higher than MAX, drain oil; if it is lower than 1/4 of the level meter, refill it to the standard level.
  • Page 41 MT86 Operation and Maintenance Manual Pull out the dip stick to clean it with cloth, and then insert it back into original position. Pull it out to check the oil trace again. The upper end of the oil trace shall be between MAX and MIN. If it is higher than MAX, drain oil.
  • Page 42 MT86 Operation and Maintenance Manual normal alarming. If the air filter is blocked, this alarm indicator shall be on. At this time, always check the metal and paper filter element for blockage, and service or replace it in time. d. The oil bath type air filter should not be over oiled.
  • Page 43 MT86 Operation and Maintenance Manual NEUTRAL position. Turn the key switch to START to start the engine. △ CAUTION: If the engine cannot get started successfully for the first time, set the key switch to ACC, and start the engine again. The time for...
  • Page 44 MT86 Operation and Maintenance Manual reading after the engine is 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 discharged by the Fig.3-47...

  • Page 45: Start-Up And Gearshift

    MT86 Operation and Maintenance Manual speed due to its inertia, thus resulting in quick burnout of rotor shaft, bearing and sealing ring because of oil shortage. c. Before starting the engine which has been withdrawn out of service for a long time, always...
  • Page 46 6900 3.7.3 Differential lock machinery 6750 The drive axle of MT86 mining dump truck is 36 level 6700 equipped with bogie differential lock. When the 6650 wheel slips or gets stuck in the mud, the bogie...

  • Page 47: Operation At Low Temperature Environment

    MT86 Operation and Maintenance Manual Operation temperature environment 3.8.1 Engine cooling system The long-life antifreeze and anticorrosion coolant applied by the engine cooling system can be kept unfrozen above -35C. If the vehicle has to work in the environment below -35C, the coolant concentration should be increased appropriately.
  • Page 48 MT86 Operation and Maintenance Manual 3.8.3 Battery The battery applied is maintenance-free. If the vehicle will not be used for a long time and the temperature is low, you had better remove the battery and place it in a warm room.

  • Page 49: Wheel Replacement And Tire Pressure

    * Specified torque of wheel nuts: Use a 36 mm hexagon socket to tighten MT86 wheel rim bolt to a torque of 700 - 800 Nm. 7) Each time when a tire is refitted, always tighten the wheel nuts again after the vehicle travels 50 km.
  • Page 50 MT86 Operation and Maintenance Manual that the vehicle is kept in normal working condition. Precautions for running-in: 1) Do not speed up immediately after the engine gets started. Only when the coolant temperature reaches normal range can the engine speed be increased.

  • Page 51: Chapter Iv Operation And Maintenance Of Main Assemblies

    MT86 Operation and Maintenance Manual Chapter IV Operation and Maintenance of Main Assemblies...
  • Page 52 MT86 Operation and Maintenance Manual...

  • Page 53: Operation And Maintenance Of Engine

    See Operation and Maintenance Manual of WP12 Series Diesel Engine for details 4.1.2 Change of engine oil filter prefilter During operation of MT86, it is necessary to periodically replace engine oil, filter and pre-filter Fig 4-1 1. Drain plug as appropriate to keep the engine operating properly.
  • Page 54 1. Fuel coarse filter 2. Fuel fine filter be replaced in strict accordance with the period specified in ―Mandatory Maintenance of 5.2 MT86 mining dump truck‖; while over the limited period (mileage) of the mandatory maintenance, the replacement is required every 5000 Km (200h).
  • Page 55 MT86 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 install the filter by hand and screw it for 3/4 circle after the sealing surface bonds with fitting surface.
  • Page 56 Maintenance of Diesel Engine" section of Operation and Maintenance Instruction of WP12 Engine for details. 4.1.4 Maintenance MT86 engine shall be inspected and maintained at interval specified in ―5.1 Interval Mileage of Routine Inspection and Maintenance‖. Refer to "Periodic Inspection and Technical Maintenance of Diesel Engine"...

  • Page 57: Operation And Maintenance Of Intake System

    MT86 Operation and Maintenance Manual 4.2 Operation and maintenance of intake system The working component of the intake system is the three-stage desert filter, which consists of the cyclonic prefilter, coarse filter and fine filter. 4.2.1 Cyclonic prefilter The cyclonic prefilter is maintenance-free and is...
  • Page 58 MT86 Operation and Maintenance Manual or damage. 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 （2000km）.
  • Page 59 MT86 Operation and Maintenance Manual 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 60: Transmission Use And Maintenance

    MT86 Operation and Maintenance Manual 4.3Transmission use and maintenance The vehicle uses FC6A250PRT automatic transmission vehicle. The transmission has the following advantages: Assembly of the overall torsional shock absorber torque converter, starting smoothly, no clutch wear. Optimized shift procedures and speed ratio, smooth shift torque control, protection of the engine and transmission Fig.4-10...
  • Page 61 MT86 Operation and Maintenance Manual oil level sensor; Shifters: panel and handle type shifters; Solenoid valve: with a retarder for a total of seven solenoid valves,1 control torque converter latch, 5 control transmission shift, the remaining one control the retarder work;...
  • Page 62 MT86 Operation and Maintenance Manual greater torque will release the lockout clutch, to achieve twist, torque conditions generally work in the 1 block, 2 block part of the area and reverse gear. 4.3.3Planetary gear set The planetary gear set is located at the rear end of the torque converter and provides six forward gears and one reverse gear.
  • Page 63 MT86 Operation and Maintenance Manual rotor and the output shaft, thereby slowing down the vehicle. The retarder is used as an auxiliary braking system, and the brake torque can be controlled continuously or continuously. Control method In the horizontal direction before and after the handle can choose a different retarder stalls, a total of one neutral, H gear for the exhaust brake gear and three control files.
  • Page 64 MT86 Operation and Maintenance Manual Automatic transmission with a lock-up clutch, you can in the 2 block part of the region, 3 to 6 block to achieve torque converter latch to reduce the heat generated by the torque converter. Under normal operating conditions, the...
  • Page 65 MT86 Operation and Maintenance Manual Hose movement or wear g）If the transmisssion is hit or damaged and breather plug is blocked or dirt accumulated, remove all dirt. After the inspection is completed, report any maintenance needs to the maintenance location to ensure that all maintenance is completed.
  • Page 66 MT86 Operation and Maintenance Manual handle, 3 driver buttons, a two-digit display and an LED indicator. N button (N activates the transmission neutral, pressing this button will change the transmission to neutral); D button (D to activate the transmission forward gear, press this button will change the transmission to the forward 1 block or 2 block);...
  • Page 67 MT86 Operation and Maintenance Manual from N to any range or between D and R stops. N block (neutral) Description: When starting the engine, check the vehicle accessory and for a longer period of idle operation (more than 5 minutes), please use the N block.
  • Page 68 MT86 Operation and Maintenance Manual display shows the highest gear available for the transmission, and the right side shows the current gear position of the transmission. The transmission has 6 forward gears. R block (reverse gear) Description: Before switching from...
  • Page 69 MT86 Operation and Maintenance Manual Driving speed is too high Programmable parameter effects Neutral shift suppression By the parking brake into the neutral Direction suppression Automatic gearshift to meet the switching and speed requirements, the transmission will be normal shift. In some...
  • Page 70 MT86 Operation and Maintenance Manual minute timer. If the correct conditions for starting the oil level check are not reached, the range selector keypad will use the gear display to display one of the following items. The display shows only two characters at a time.
  • Page 71 MT86 Operation and Maintenance Manual OL-HI- The Oil level is higher XX OL-OK The oil level is right △ Note: The manual dip gauge measurement should be compared with the electronic oil level display readings regularly to ensure that the results provided by the two methods are comparable.
  • Page 72 MT86 Operation and Maintenance Manual the specified limits after the retarder is combined, the retarder will continue to work to help the vehicle decelerate; The retarder can operate for about 1 second before it can feel the retarder function. The driver should anticipate this delay to avoid unnecessary use of the brakes;...
  • Page 73 MT86 Operation and Maintenance Manual speed. To use the engine anti-drag brake control speed, you need to choose a lower gear, you can make the engine to produce greater braking force. When the vehicle load is large, the ramp is steep when the vehicle...
  • Page 74 MT86 Operation and Maintenance Manual such a road, please close the retarder, Reduce the speed and choose a lower gear before losing the adhesion. In the acceleration or deceleration should be as slow as possible to prevent the wheel slip or out of control.
  • Page 75 MT86 Operation and Maintenance Manual 7)Parking brake The parking brake system prevents the vehicle from moving after the engine is turned off. When the driver leaves the cab and the engine is in operation, the transmission must be placed in neutral N and the parking brake must be fully functional.
  • Page 76 MT86 Operation and Maintenance Manual △ CAUTION: Be sure to place the transmission in neutral before closing the engine. Maintenance and maintenance Periodic inspection Regular inspection for automatic transmission Fig.4-16 is very important, you can find possible problems in 1. Magnetic filter cover...
  • Page 77 MT86 Operation and Maintenance Manual requirements of the OEM and the engine manufacturer to ensure that the cooling system provides adequate cooling capacity. If the abnormal situation is found in the inspection, the relevant maintenance management personnel shall be notified in time and handled in a timely manner.
  • Page 78 MT86 Operation and Maintenance Manual Transmission oil dipstick is located on the right side of the transmission, the end of the dipstick marked with oil level cold, hot mark line, to meet the oil level test conditions, screw out the dipstick...
  • Page 79 MT86 Operation and Maintenance Manual detection. The appropriate oil level line is between the lowest oil level and the highest hot oil level. If the oil level is lower than the minimum oil level, need to increase the oil to the hot minimum oil level above;...
  • Page 80 MT86 Operation and Maintenance Manual △ Note: If the user needs to replace the oil, you need to first remove the oil in the transmission, including tubing and oil cooler in the oil. Replace the transmission oil (1) Remove the drain plug from the bottom of the transmission so that the transmission oil is discharged into the appropriate container;...
  • Page 81 MT86 Operation and Maintenance Manual oil into the container. Replace the drain plug with a tightening torque of 18 ± 3.5 N • m; Remove the transmission oil filter housing. Discard the filter used in the shell. Remove the filter when there will be residual oil discharge, the oil discharged into the container;...
  • Page 82 MT86 Operation and Maintenance Manual particle debris. Excessive debris indicates a potential failure. If you find large particles, please consult the relevant manufacturers, for further analysis and guidance; △ Note: the magnet is easy to brittle, do not drop the magnet or with any hard objects percussion.
  • Page 83 MT86 Operation and Maintenance Manual Serial Maintenan Maintenance Remarks number ce items content 1. Check the Maintenance Transmissi oil level of the amount on oil 2. Replace the of 23L Oil filter replace Magnetic clean filter Transmissi on oil sampling...

  • Page 84: Operation And Maintenance Of Front Axle

    4.4.1 The front steer axle and intermediate and rear drive axles The front axle of the MT86 mining dump truck is a two stage drive axle with ―central 1st stage reducer & wheel planetary reducer‖, and equipped with casting axle housing, bogie differential and inter-wheel differential as well as bogie Fig.4-19 Front alxe...
  • Page 85 MT86 Operation and Maintenance Manual the rim, the outer circle surface between the rim positioning hole and the wheel rim reduction shell, and the seal surface of the wheel nut; ② Do not damage threads of the wheel bolts, and apply grease, oil, or other thread paste to the threads of the wheel bolts and wheel nuts before installation;...
  • Page 86 MT86 Operation and Maintenance Manual and regulate immediately; ④ Check if the regulating arm and the camshaft are jammed. If so, refill grease immediately to ensure that they rotate flexibly; Refill grease to the grease nozzle of the master pin, the camshaft support and the regulating arm every 15 days.
  • Page 87 MT86 Operation and Maintenance Manual km or 1 year after the first maintenance. The periodic maintenance items are listed as follows: Repeat the first maintenance items; Lubricate the brake shoe pin and the brake roller; Check the friction plate wear degree. The thickness of the friction plate shall not be less than 8mm.
  • Page 88 MT86 Operation and Maintenance Manual c. Precautions for differential lock operation: The truck shall be stopped or running at low speed (less than 10 km/h) when the differential lock is latched to avoid internal gear damage. When the differential lock between axles is latched, the truck Intermediate Axle Part Fig.4-28...
  • Page 89 MT86 Operation and Maintenance Manual ② The clearance between the brake shoe and the brake drum shall be kept between 0.7 and 1.2 mm, and the clearance between the upper and lower drums and shoes shall not be greater than 0.3 mm;...
  • Page 90 MT86 Operation and Maintenance Manual of the middle rear axle Periodic maintenance: The periodic maintenance shall be carried out every 10000km or 1 year after the first maintenance. The periodic maintenance items are listed as follows: ① Repeat the first maintenance items;...

  • Page 91: Operation And Maintenance Of Suspension System

    MT86 Operation and Maintenance Manual 4.6 Operation and maintenance of suspension system △ ! Warning: It is necessary to replace the thrust rod repair kit after the truck has run for 4 months, Fig4-27 (20,000km). The user will bear Front suspension system consequences of vehicle failures due to 1.
  • Page 92 MT86 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 process, the...
  • Page 93 MT86 Operation and Maintenance Manual shock absorber, stop block and front push-rod, Failure Analysis of Shock Absorber 1) Specifications of fasteners Failure mode Analysis and solution MT86 Application Refill appropriate grease and Tightening Specification then proceed with operation. torque (Nm)
  • Page 94 MT86 Operation and Maintenance Manual above fasteners. 2) Description of front leaf spring MT86: 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 performance test.
  • Page 95 MT86 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 96 MT86 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 97 2) Description of rear leaf spring MT86: 15 pieces in total, in which five main 3. Remove the bush, bearing inner race and pieces, reinforced parallel semiellipse leaf shaft sealing ring, and take out the bearing spring.
  • Page 98 MT86 Operation and Maintenance Manual a. Removal, installation and adjustment of balance suspension assembly Specific procedures are shown left. △ ! CAUTION: When press machine is not 5. Install the shaft seal ring, bearing inner race, bush, available, after bearing outer ring and dust cover and assembled shaft housing in turn.
  • Page 99 MT86 Operation and Maintenance Manual degradation occurs, replace the oil seal. ● Check bearing for crack or damage; Malfunction table of rear suspension ● Parts within repair or wear limit should Fault mode Solutions be replaced before reaching the limit.
  • Page 100 MT86 Operation and Maintenance Manual components by our company such as push Malfunction table of rear suspension rod, slide plate seat and guide plate. Fault mode Solutions The modified or replaced parts may not Replace the balance shaft Break in balance shaft...
  • Page 101 MT86 Operation and Maintenance Manual 5,000km, check all bolts of balance suspension assembly once, and fill the system with GL-5 85W/90 heavy duty gear oil from the oil filler on balance shaft housing. Do such maintenance every 5,000km thereafter. In...
  • Page 102 MT86 Operation and Maintenance Manual requirements above, under heavy load carrying conditions, it may lead to balance shaft housing deformation which will cause sealing ring failure, a clearance between balance shaft housing cover and balance shaft housing, and extending of bolt. When it is...
  • Page 103 MT86 Operation and Maintenance Manual a. Do maintenance on balance suspension assembly in strict accordance with the routine maintenance rules in the chapter of Service and Maintenance. b. If oil leakage occurs at the seal joint of balance shaft housing cover and balance shaft...
  • Page 104 MT86 Operation and Maintenance Manual paragraph of service and maintenance, when the vehicle is in heavy load carrying condition, the dry friction of bearing will generate overburning which finally may lead to bearing to get broken. b. If the bearing clearance is not adjusted...
  • Page 105 MT86 Operation and Maintenance Manual 6) Solutions for bracket cracks and break a. Replace the overall balance shaft, see the figure left. b. Where it is available, it is needed to conduct assembly of parts. Please perform in accordance with the following procedures: ①...
  • Page 106 MT86 Operation and Maintenance Manual burr, oil dirt, etc. ● After applying accelerant, do assembly and arrangement quickly; otherwise the retaining compound will cure soon and it will bring difficulty to assembly work. If only retaining compound is applies and accelerant is...
  • Page 107 MT86 Operation and Maintenance Manual size of each mounting hole. 4.6.4 Regulation method of outer side and side stop of portal frame Guide 1) Check the side limit wear extent (guide cover cover plate thickness); replace the side stop plate if the wear extent is >...

  • Page 108: Operation And Maintenance Of Steering System

    MT86 Operation and Maintenance Manual 4.7 Operation and maintenance of 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...
  • Page 109 MT86 Operation and Maintenance Manual the steering drive shaft is subjected to great impact, and energy is absorbed by the deformation of the steering column or the dislocation of the steering drive shaft. Steering control system is of continuous and adjustable type.
  • Page 110 MT86 Operation and Maintenance Manual a pressure signal to the pilot valve Ls opening to enable 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 111 MT86 Operation and Maintenance Manual clean the oil tank and periphery to prevent dirt contamination. During inspection, pay attention to the scale on the oil level gauge. When engine is running, the hydraulic oil level is even with the central scale of oil level gauge; when engine does not work, the hydraulic oil level will be a little higher than the central scale.
  • Page 112 MT86 Operation and Maintenance Manual change. ⑤ When the oil filter is filled with hydraulic oil, run the engine at idle speed, turn the steering wheel left and right for several times, and at the same time, keep supplementing oil till the oil level does not lower and is within the range and no bubble appears.
  • Page 113 MT86 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 2. Air invades into oil passage refill it as specified 3.
  • Page 114 MT86 Operation and Maintenance Manual Common faults Causes Troubleshooting methods blocked 4. Regulate or replace steering valve 4. Steering valve is jammed 5. Adjust clearance 5. Steering gear is too tight 6. Check and adjust it 6. Connection is loose 1.
  • Page 115 MT86 Operation and Maintenance Manual Common faults Causes Troubleshooting methods 7. One front wheel (braking 7. Maintain brake non-return) is blocked 1. Air invades into oil passage 2. Oil level of oil tank is too low, and oil pump sucks air 1.

  • Page 116: Operation And Maintenance Of Brake System

    MT86 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 brake) and emergency/parking brake Fig.4-43 (hand brake).
  • Page 117 MT86 Operation and Maintenance Manual function of engine exhaust brake. After you press the exhaust brake switch, the running vehicle can utilize the energy from engine for auxiliary brake. When driving down a long slope, be sure to use the exhaust brake.
  • Page 118 MT86 Operation and Maintenance Manual brake system is above 0.55 Mpa and the parking brake indicator goes out can spring braking be released. Apply: Pull the handle. At the same time, the parking brake indicator on instrument panel will light up.
  • Page 119 MT86 Operation and Maintenance Manual loaded vehicle on a slope. Therefore, when parking the vehicle on a slope, wedge the wheels for safety. 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.
  • Page 120 MT86 Operation and Maintenance Manual 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 121 MT86 Operation and Maintenance Manual To stop the vehicle, follow the steps below: 1) When the vehicle is running, first release the accelerator pedal to reduce vehicle speed. 2) When the vehicle approaches the stopping position, slightly depress the brake pedal to stop the vehicle slowly.
  • Page 122 MT86 Operation and Maintenance Manual running on a wet and slippery road, the vehicle may be at a risk of side slide if the emergency brake is applied. 5) After the vehicle cleaning or vehicle passing over deep puddle, water may enter the brake drum, which will reduce the braking effect of the vehicle.
  • Page 123 MT86 Operation and Maintenance Manual △ ! Warning: ● Avoid parking the vehicle on a steep slope. If there is no alternative, besides applying parking brake, choke the wheels with wooden wedge. In addition, engage the transmission in 1st gear when...
  • Page 124 MT86 Operation and Maintenance Manual use tachometer to inspect and view the speed of engine. 5) To reduce wear and heat caused by braking, before travelling down a steep or long slope, first reduce vehicle speed, and then select a lower gear.
  • Page 125 MT86 Operation and Maintenance Manual 3) Avoid sudden braking and sharp turning, otherwise the vehicle may be subject to side slide and drifting, which will cause accidents. 4.7.13 Driving on foggy days 1) Turn on fog lamps, drive it at a low speed, and pay attention to road markings and tail lamps of vehicles running in front.
  • Page 126 MT86 Operation and Maintenance Manual 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 leak or the air System pressure is insuffici chamber may be damaged.
  • Page 127 MT86 Operation and Maintenance Manual When air exists in the relay valve inlet (1 Relay valve is out of work opening) and the brake valve relay valve (4) but (2), replace the relay valve. Brake air chamber is damaged If there is no problem with the above valves, depress the brake pedal.
  • Page 128 MT86 Operation and Maintenance Manual...

  • Page 129: Operation And Maintenance Of A/C

    MT86 Operation and Maintenance Manual 4.9 Operation and maintenance of 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...
  • Page 130 MT86 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 131 MT86 Operation and Maintenance Manual desirable inside temperature. Setting range: LO, 18℃-29℃ and HI. Generally, temperature set within 22℃-26℃ is appropriate. If you want that it is cooler inside, set the temperature at LO. If you want that it is warmer inside, set the temperature at HI.
  • Page 132 MT86 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 133 MT86 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 134 MT86 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. Refrigerant Check leakage with halogen ＋ leakage leak detector.
  • Page 135 MT86 Operation and Maintenance Manual Maintenance interval Maintenance Description items Weekly Monthly Bimonthly Quarterly Yearly Check clip plug for ＋ ＋ Connector looseness. Thermistor ＋ Check if it works normally. Electrical switch element Check if it meets specified ＋ Magnetic clutch requirements.
  • Page 136 MT86 Operation and Maintenance Manual Symptom Probable causes Solutions The sensing bulb of expansion valve is Tighten the sensing bulb clamp. loose. There is excessive refrigerant. Discharge the extra. High air return pressure The compressor leaf is damaged. Replace the leaf.
  • Page 137 MT86 Operation and Maintenance Manual Symptom Probable causes Solutions The conductor is loose or in short circuit. Do troubleshooting. The rotor shaft is bending. Replace it. Fan rotates slowly. The controller resistor is burnt out. Replace the resistor. The voltage is insufficient.
  • Page 138 MT86 Operation and Maintenance Manual...

  • Page 139: Chapter V Maintenance

    MT86 Operation and Maintenance Manual Chapter V Maintenance...
  • Page 140 MT86 Operation and Maintenance Manual...

  • Page 141: Mileage For Routine Inspection & Maintenance Interval

    ! 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 MT86 mining dump truck Period...

  • Page 142: Key Points Of Maintenance

    MT86 Operation and Maintenance Manual Period Material code Material name Specification Unit Remarks 5301000045 Diesel engine oil CH-4 15W/40 4110001117322 Fuel Coarse Filter Element 1000424916 Piece 4110001595001 Fuel Coarse Filter Element 1000495963 Piece 4190001637 Fuel oil filter 1000422382 Piece 4190001633...
  • Page 143 MT86 Operation and Maintenance Manual 1) Check the hand brake and the foot brake. 2) Check working conditions of the illumination system, instrument signal system and various indicators (oil pressure, air reservoir pressure, air filter maintenance indicator and charge indicator).
  • Page 144 MT86 Operation and Maintenance Manual prescribed limits, replace this part or the matched part as required. In the perspective of preventive maintenance, some parts under repair or within wear limits should be replaced before they exceed the limits. All the parts should be carefully inspected by visual observation or infrared inspection. If the following anomalies are found by visual observation, this part can be repaired or replaced as required.
  • Page 145 MT86 Operation and Maintenance Manual Maintenance level Item Description Initial Routine class class inspection inspection maintenance classmaintenance classmaintenance maintenance Clean main filter element of air Once every 250 hours filter Replace safety filter element of Whenever replacing the main filter element...
  • Page 146 MT86 Operation and Maintenance Manual Maintenance level Item Description Initial Routine class class inspection inspection maintenance classmaintenance classmaintenance maintenance differential Replace lubricating oil for ● main reducer and wheel reducer (at least every year) Check oil levels ● of main reducer...
  • Page 147 MT86 Operation and Maintenance Manual Maintenance level Item Description Initial Routine class class inspection inspection maintenance classmaintenance classmaintenance maintenance cab tilting manual oil pump Check adjustment ● ● ● ● ● ● of lifting cylinder Check fixation of ● ●...
  • Page 148 MT86 Operation and Maintenance Manual Maintenance level Item Description Initial Routine class class inspection inspection maintenance classmaintenance classmaintenance maintenance be easily scratched. Check functions ● ● ● ● ● of brake chamber Check performance of foot brake, hand ● ●...
  • Page 149 MT86 Operation and Maintenance Manual Maintenance level Item Description Initial Routine class class inspection inspection maintenance classmaintenance classmaintenance maintenance headlamp, height lamp, wiper, HVAC and air breather) Check liquid level and gravity of battery electrolyte ● ● ● ● ●...
  • Page 150 MT86 Operation and Maintenance Manual Maintenance level Item Description Initial Routine class class inspection inspection maintenance classmaintenance classmaintenance maintenance hydraulic oil tank Lifting system and level meter Check for looseness of oil cylinder bracket and top big nut, Once every day...
  • Page 151 MT86 Operation and Maintenance Manual Maintenance level Item Description Initial Routine class class inspection inspection maintenance classmaintenance classmaintenance maintenance Check fixation of carriages and ● ● ● ● ● ● tighten them when necessary ● ● ● ● ● ●...
  • Page 152 MT86 Operation and Maintenance Manual 5.3.4 Selection of oil products Type Recommended types and standards Amount Part — MC11-13 Engine oil Central axle: 33.6 L Heavy-duty vehicle gear oil (GL-5) 85W-90 Axle main drive, bogie differential Rear axle: 29.6L Gear oil housing, final drive and transmission —...
  • Page 153 MT86 Operation and Maintenance Manual 3) Gear oil (drive axle oil) Grade of similar foreign brand oil (ranked as per US API, GL-5) Grade of domestic CALTEX FUCHS MOBIL ESSO SHELL Heavy-duty vehicle gear CALTEX Mobil gear Spirax EP Super extreme Titan Gear HD80W-90(-20°...

  • Page 154: Lubrication Of Chassis

    MT86 Operation and Maintenance Manual 5.4 Lubrication of chassis 1. Lubrication requirements 2. List of categories of lubricant...
  • Page 155 MT86 Operation and Maintenance Manual 3. Lubrication diagram...
  • Page 156 MT86 Operation and Maintenance Manual...

  • Page 157: Chapter Vi Annex

    MT86 Operation and Maintenance Manual Chapter VI Annex...
  • Page 158 MT86 Operation and Maintenance Manual...

  • Page 159: Schematic Diagram Of Brake

    MT86 Operation and Maintenance Manual 6.1 Schematic diagram of brake 6.4 Principle of hydraulic system...

  • Page 160: Hydraulic System Schematic Diagram

    MT86 Operation and Maintenance Manual 6.2Hydraulic system schematic diagram Take Engine Power drivce...

  • Page 161: Engine Diagnostic Code

    MT86 Operation and Maintenance Manual 6.3 Engine Diagnostic Code Index DFC Name Index DFC Name DFC_ECRVlvSCBat DFC_InjVlvCyl2BNoLoad 1414 DFC_ECRVlvSCGnd DFC_InjVlvCyl2ERR 1414 DFC_ECRVlvOpenLoad DFC_InjVlvCyl2MNoLoad 1414 DFC_AccPedBrkPlaus DFC_InjVlvCyl2SCB 1414 DFC_AFSSRCRawMax DFC_InjVlvCyl2SCG 1414 DFC_AFSSRCRawMin DFC_InjVlvCyl2SCL 1414 DFC_AirHtStickOn 2898 DFC_InjVlvCyl3AHSSCBat 1415 DFC_APP12Plaus 520252 DFC_InjVlvCyl3AHSSCGnd...
  • Page 162 MT86 Operation and Maintenance Manual Index DFC Name Index DFC Name DFC_CSLpCDSCBat DFC_InjVlvCyl5SCL 1417 DFC_CSLpCDSCGnd DFC_InjVlvCyl6AHSSCBat 1418 DFC_CTSCDNpl DFC_InjVlvCyl6AHSSCGnd 1418 DFC_CTSCDOvrTemp DFC_InjVlvCyl6ALSSCBat 1418 DFC_CTSCDSRCMax DFC_InjVlvCyl6ALSSCGnd 1418 DFC_CTSCDSRCMin DFC_InjVlvCyl6BNoLoad 1418 DFC_ECBtCDPlausLock 520203 DFC_InjVlvCyl6ERR 1418 DFC_EngMBackUpLimp 4203 DFC_InjVlvCyl6MNoLoad 1418 DFC_EngMCaS1NoSig 4201 DFC_InjVlvCyl6SCB...
  • Page 163 MT86 Operation and Maintenance Manual Index DFC Name Index DFC Name DFC_FlIncPSCBat DFC_OPSCDSRCMax DFC_FlIncPSCGnd DFC_OPSCDSRCMin DFC_FlSysWtDet 520264 DFC_OTSCD1Npl DFC_FrmMngAPPMaxErr 522064 DFC_OTSCDSRCMax DFC_FrmMngCM1DLC 522056 DFC_OTSCDSRCMin DFC_FrmMngCM1TO 522056 DFC_OTSCDSRCNpl DFC_FrmMngDashDsplDLC 522052 DFC_PCVOL 1443 DFC_FrmMngDashDsplTO 522052 DFC_PCVSCB 1443 DFC_FrmMngDEC1DLC 522062 DFC_PCVSCG 1443 DFC_FrmMngDEC1TO...
  • Page 164 MT86 Operation and Maintenance Manual Index DFC Name Index DFC Name DFC_FrmMngTSC1DRDLC 522038 DFC_stAirFltFoul DFC_FrmMngTSC1DRTO 522038 DFC_stFuelFoul 520289 DFC_FrmMngTSC1PEDLC 522039 DFC_STGPRSLCKMOD1 522014 DFC_FrmMngTSC1PETO 522039 DFC_STGPRSLCKMOD2 522014 DFC_FrmMngTSC1TEDLC 522040 DFC_stOil DFC_FrmMngTSC1TETO 522040 DFC_stOilFlt DFC_FrmMngTSC1TRDLC 522041 DFC_StrtCDLSSCBat 1675 DFC_FrmMngTSC1TRTO 522041 DFC_StrtCDLSSCGnd 1675...
  • Page 165 MT86 Operation and Maintenance Manual Index DFC Name Index DFC Name DFC_InjVlvCyl1SCL 1413 DFC_RmtAccPedBrkPlaus 520277 DFC_InjVlvCyl2AHSSCBat 1414 DFC_ComGPSKeyErr 520218 DFC_InjVlvCyl2AHSSCGnd 1414 DFC_ComGPSMsgTo 520218 DFC_InjVlvCyl2ALSSCBat 1414 DFC_ComT50StMaxErr 14161 DFC_InjVlvCyl2ALSSCGnd 1414 DFC_ComGPSDrvCyclIdle 520218...

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