Daily maintenance

　　(1) Inspection before departure

　　A. Check whether the diesel and engine oil are sufficient and whether there is any leakage;

　　Check the working conditions of the engine and other instruments;

　　C. Check the status of each operating mechanism, tire, light, horn, and wiper;

　　Check whether the cooling liquid of the cooling system is sufficient and whether there is leakage;

　　Check whether the engine, transmission, clutch and corresponding operating mechanism are working properly;

　　F. Check the brake system components and pipelines for air leaks.

　　(2) Inspection items on the way

　　Pay attention to the state of the workpieces of each meter and indicator;

　　Check whether the temperature of the engine, transmission and other systems is normal;

　　C. Check tire pressure.

　　(3) Maintenance after parking

　　A. Turn off the main power switch;

　　Clean up the water and dirt in each air tank;

　　C. Add engine oil, fuel oil and lubricating oil, and lubricate each lubrication point as required;

　　Check the tire air pressure and make up air to make it reach the prescribed air pressure;

　　Clean the fuel filter, oil filter and air filter as needed;

　　Keep the product clean, especially remove the dust on the cylinder fins, oil radiator and intercooler;

　　G. The supporting and connecting bolts can be tightened as required;

　　H. Eliminate faults found during driving and prepare for the next trip.

　　I. Check whether the hinged and connected parts of the carriage and the frame are worn or deformed, check the shaft sleeve and fill with grease.

　　J.Check whether the frame is seriously deformed, whether the connecting bolts are loose, and if necessary, repair or tighten them.

　　K.Check the frame main beam and beam for open welding and cracks. If there is, it should be repaired and welded in time.

　　L. Add coolant as needed.

　　(3) Maintenance and maintenance of the vehicle

　　Daily routine maintenance is generally performed once a day and night, and its contents include:

　　Clean the interior and chassis of the vehicle and check for missing parts;

　　Check whether the operating mechanism is working properly;

　　Check whether the operating mechanisms such as meters, wipers, horns, driving and parking brakes, and steering gears are normal;

　　Check the oil level of the oil in the engine oil pan and the oil level should not be lower than the middle position of the two scales of the oil dipstick;

　　Drain the water in the fuel tank once a day and check whether the air vents are clear;

　　Check the fuel capacity and add fuel once per shift to keep the fuel tank with sufficient fuel;

　　Check the cooling water level.

　　Routine maintenance within 400 hours: It is divided into four gears: 50 h, 100 h, 200 h, and 400 h.

　　C. Preventive maintenance (also called compulsory maintenance):

　　Its maintenance is in the range from 800 h to 6000 h, and it can be divided into five gears of 800 h, 1500 h, 3000 h, 4500 h, and 6000 h. After 8000 h, the vehicle is overhauled.

　　Emergency maintenance:

　　Maintenance and repairs performed when a temporary failure occurs.

　　Contents of regular maintenance

　　(1) Routine maintenance within 50 hours:

　　Grease after every 50 hours of driving;

　　Check and clean the air filter;

　　Check the accumulation in the gas cylinder;

　　Check the liquid level of the battery electrolyte. Zh

　　Check and tighten the nuts of the thrust rod bolts.

　　(2) Routine maintenance within 100 hours:

　　Check the oil level of the power steering oil tank, and supplement it when it is insufficient;

　　Check the oil level of the transmission, if necessary, make up as required;

　　Check the oil level of the main reducer and wheel reducer in the middle and rear axles, and make up when it is insufficient;

　　Inspect and tighten the nuts of the "U" bolts of the front and rear suspension;

　　Check the tire pressure to make it meet the requirements;

　　Inspect the tires and rims for damage.

　　(3) Routine maintenance after 200 hours of driving:

　　Replace the engine oil filter element;

　　Change the engine oil;

　　Cleaning the fuel filter;

　　Tightening the rim bolts

　　Inspect and tighten the nuts of the "U" bolts of the front and rear suspension;

　　During the road test, check the steering horizontal and straight tie rods, and eliminate the possible gap between the steering arm and the ball pin. Zh

　　Remove the cover of the limit valve, clean the dust on the surface of the valve body with compressed air, and press the valve stem back and forth several times to ensure that there is no jamming.

　　(4) Routine maintenance after 400 hours of driving:

　　Replacing the outer filter element of the air cleaner;

　　Replacing the fuel filter element;

　　Change the steering hydraulic oil and clean the filter element in the steering oil tank;

　　Fasten the flange bolts of the drive shaft;

　　Check and calibrate the toe, which should be 0 ～ 3 mm;

　　Check and tighten the front and rear suspension bolts;

　　Check the clearance between the exhaust valve and the rocker arm according to the requirements of the engine manual;

　　Tighten the bolts and nuts of the steering horizontal and straight tie rods;

　　Check and eliminate the possible gaps between the horizontal and straight steering rods;

　　Grease the hub bearings.

　　(5) Routine maintenance after 800 hours of driving:

　　Clean the engine radiator scale;

　　Lubricate the bearings and bushings of the engine starter;

　　Replace the filter element of the air filter;

　　Clean the oil filter of the lifting mechanism with gasoline;

　　Replace the main reducer and lubricating oil for wheel deceleration;

　　Change the transmission lubricant;

　　Inspect and tighten the bolts and nuts of the steering gear;

　　Conduct a comprehensive inspection of electrical equipment.

　　(6) Routine maintenance after 1500 hours of driving:

　　Adjust high-pressure pumps, nozzles, and valves;

　　Clean the fuel tank and check the fuel supply pipeline;

　　Fasten the engine connection bolts, intake and exhaust manifolds, throttle levers;

　　Check the clearance between the spline and the sleeve of the drive shaft, and tighten the flange bolts;

　　Check the transmission suspension mechanism, tighten the bolts and adjust the shift mechanism;

　　Check the front wheel alignment and the horizontal and straight tie rod pins.

　　(7) Routine maintenance after 3000 hours of driving:

　　Comprehensively correct the steering horizontal and straight tie rods

　　Overhauling the airway system;

　　Tyre replacement or tyre replacement;

　　Check the air compressor, replace the rubber pads and hoses;

　　Adjust the high-pressure pump and adjust the valve;

　　Check the belts of fans and generators;

　　Inspecting the cylinder head and grinding the valve;

　　Check the water pipe of the water tank

　　Check the maximum and minimum speeds of the engine;

　　Check the clutch friction plate and adjust the clutch operating mechanism.

　　(8) Routine maintenance after 4500 hours of driving:

　　High-pressure hose of the power steering device;

　　Lift the oil cylinder, distribution valve, power output device, and replace the high-pressure hose and lifting oil;

　　Open the gearbox cover, check the shift fork, gear and fork bracket, and replace it if damaged;

　　Spherical bearing of thrust rod

　　Hose on pneumatic circuit of pneumatic device.

　　(9) Routine maintenance after 6000 hours of driving:

　　Engine supercharger

　　The compression pressure of each cylinder of the engine;

　　Working conditions of the thermostat of the cooling system;

　　Clutch assembly

　　Check the front axle and fill the hub with grease;

　　Rear axle differential

　　Generator and starter motor.

　　(10) The vehicle is overhauled after 8000 hours of driving.

　　Requirements for use of diesel engine oil

　　The correct selection of diesel engine oil is of great significance for ensuring the performance and life of the diesel engine. To sum up, the main functions of engine oil in diesel engines are lubrication, cooling, cleaning, vibration reduction and sealing. On diesel engines equipped with HVT and STC, the oil also has the function of hydraulic transmission. The performance of engine oil can be reflected by the main inspection indicators of engine oil. These indicators mainly include viscosity, pour point, oxidation stability, acidity and alkalinity (TAN and TBN).

　　1.Selection of viscosity grade

　　In the SAE standard, the viscosity of engine oil is divided into single-stage and multi-stage. The use of multi-grade oil can reduce the formation of deposits, improve the engine's performance under low temperature conditions, and improve the durability of the engine by ensuring lubrication under high temperature conditions. Mining Dump Truck Engine Co., Ltd. recommends using SAE 15W / 40 under normal ambient temperature operating conditions (temperatures above -15 ° C). Practice has proved that the use of multi-grade oil at low engine load can greatly reduce fuel consumption compared to single-grade oil.

　　Multi-grade motor oil with lower viscosity can be used in lower temperature climate conditions, but as long as the ambient temperature rises, 15W / 40 motor oil is used. The comparison table of engine oil viscosity and ambient temperature can be found in the user manual of each oil company.

　　For engines that operate at an ambient temperature that remains constant below -25 ° C, we recommend the use of API grade III synthetic engine oils. Above this temperature, mineral-based multi-grade lubricants are recommended. 0W / 30 synthetic motor oil that meets API class III can be used in operating conditions where the ambient temperature never exceeds 0 ° C. OW / 30 oils cannot provide the same fuel dilution protection as higher-grade multi-grade oils. Using 0W / 30 oil under high load conditions may cause severe cylinder wear.

　　Mining Dump Truck Engine Co., Ltd. does not recommend the use of single-grade oil. Where it is really impossible to purchase multi-grade oil, single-grade oil can be used instead. However, the use of single-stage oil will make the engine's lubrication worse at the beginning of startup and low load, fuel consumption will increase, or the viscosity will be too small and the lubrication will deteriorate at high load.

　　When using single-grade oil, you must ensure that the oil operates within the ambient temperature ranges listed in Table 1.           

Table 1 Ambient temperature range for single-stage oil operation

　　It is not recommended to use special “run-in” oil on new or overhauled mining dump truck engines.

　　2. Explanation of quality level

　　Mining Dump Truck Engine Co., Ltd. recommends the use of oil that meets the American Petroleum Institute (API) performance level CF-4 or higher. If CF-4 grade oil cannot be purchased, CD-grade oil is allowed for engines without EFI and non-emission requirements, but the oil change period should be shortened as required; oils below CD-grade must not be used.

　　The oil performance of the American Petroleum Institute (API) is divided into two series: the letter "C" indicates that the performance of the oil meets the requirements of the engine manufacturer; the letter S indicates that the performance of the oil meets the requirements of the automobile manufacturer. The following is a brief description of the oil performance levels beginning with the letter "C":

　　CA: Suitable for light-load diesel engines. For naturally aspirated diesel engines, bearing quality and piston ring deposit formation can be reduced if high-quality fuel is used.

　　CB: Suitable for normal load diesel engines. It can prevent bearing erosion and reduce the production of sediments for naturally aspirated diesel engines burning high sulfur fuel.

　　CC: Suitable for medium and high load diesel engines. For low-pressure diesel engines, it has the effect of preventing the formation of high-temperature deposits and bearing corrosion; in gasoline engines, it also has the effect of preventing rust and low-temperature deposits.

　　CD: Suitable for high-load diesel engines. It is suitable for high-speed, high-charged engines, has strong adaptability to fuel specifications, and has the functions of effective anticorrosion and reducing sediment. Low-strength engines in the NH and K series engines produced by Mining Dump Truck Engine Co., Ltd. can use this grade of oil.

　　CE: It is suitable for high-speed and high-load turbo diesel engines. Its basic performance is similar to that of the CD-level, but it is necessary to test the performance of the NTC-400 engine for dump trucks. This is a transition performance level.

　　CF: It is mainly suitable for indirect injection diesel engines, not for diesel engines produced by Mining Dump Truck Engine Co., Ltd.

　　CF-4: Suitable for high-performance, high-load diesel engines, especially for heavy vehicles driving on highways. It can effectively improve oil consumption and control piston ring carbon deposits.

　　It is recommended that this grade of oil is suitable for all non-electric injection engines produced by Mining Dump Truck Engine Co., Ltd. EFI engines are required to use API grade CG-4 engine oil. At the same time, they must use low sulfur fuel that meets environmental protection standards.

　　In summary, Mining Dump Truck Engine Co., Ltd. recommends the use of engine oils that meet the following API levels:

　　①CD——Use conditionally;

　　CF-4——Recommended for most engines;

　　③CG4——for EFI engine.

　　3. Synthetic motor oil

　　Synthetic motor oil is designed for use in extreme environmental conditions where the ambient temperature can be as low as -45 ° C. Under these extreme conditions, petroleum-based engine oils do not work well on diesel engines. Mining Dump Truck Engine Co., Ltd. recommends using synthetic or partially synthetic motor oils when the ambient temperature is kept constant below -25 ° C. All motor oils must meet API classification level III and SAE viscosity grades.

　　Synthetic or partially synthetic motor oil must not be used for running-in of new or overhauled engines. Use standard petroleum-based high-quality 15W / 40 motor oil within the first oil change cycle. When using synthetic or partially synthetic motor oils, the same oil change interval as that of petroleum-based motor oils is recommended.

　　4. Oil change period

　　Mining Dump Truck Engine Co., Ltd. formulates technical specifications for oil replacement based on oil pollution. Maintaining the correct oil and filter replacement cycle is an important factor in ensuring the normal operation of an engine.

　　The oil will be contaminated during use, and the main additives in the oil will be gradually exhausted. But as long as these additives work properly, the oil will protect the engine well. Between the oil and filter change intervals, it is normal for the oil to become contaminated. The degree of pollution depends mainly on the operating conditions of the engine, the number of hours or kilometers of oil used, the amount of fuel consumed, and the amount of newly added oil. Extending the oil and filter replacement intervals will reduce engine life due to corrosion, carbon deposits, and poor wear. The user should reasonably determine the oil change period according to the engine usage. Here are several methods to determine the engine oil change period when the engine and engine oil are used normally:

　　(1) Physical and chemical inspection method

　　The engine oil will continuously degrade during the process. When it deteriorates to a certain degree, it will not meet the lubrication requirements of the engine. When any index of the operating engine oil decays to the standard in Table 2, the new engine oil should be replaced.

　　(2) Load rate method

　　It is typically applicable to M11 vehicle engines. The oil change period can be determined according to fuel consumption, vehicle maintenance quality, idle time and fuel type.

　　(3) chart method

　　For NH, K6 and KV engines, the longest engine oil change interval can be determined according to the "oil change interval graph" in the maintenance manual. If the above-mentioned methods are not used to determine the oil change interval of the engine, then the maximum oil change interval of the engine cannot exceed 250h or 6 months (250h or 12 months for power generation engines).

　　When changing the oil, the full-flow oil filter and the bypass filter must be replaced at the same time.