10×8 Carrier

Operating manual
Operation manual of 10X8 Carrier

Company Introduction

RG PETRO-MACHINERY (GROUP) CO. LTD is one of the largest manufacturers of

petroleum drilling equipment in China. It is a stock company, reorganized from Nanyang
petroleum machinery plant (former No.2 Petroleum Machinery Manufacturing Plant of
National Petroleum Industrial Ministry of China). As a former national technical equipment
production base, authorized by former national economic and commercial committee of
China, RG PETRO-MACHINERY (GROUP) CO. LTD has become a company for national
new product trial production of China, light-duty drilling rigs production base of SINOPEC
and top 50 high growing and high-tech enterprise in Henan Province.
RG PETRO-MACHINERY (GROUP) CO. LTD, possesses postdoctor scientific and
research center, carriagestic petroleum drilling equipment, Tools standardization technical
committee truck-mounted equipment standardization department, Henan province
petroleum engineering and technological research center, technical center, information
center and quality inspection center at provincial level… research institution, has possessed
16 production branch plants for forging, metal machining, heat treatment, steel-structure
manufacturing, general assembly, painting and new product trial production, and over sixty
thousand square meters comprehensive testing sites for drilling rigs as well as have special
purpose railway to factory. Possess Nanyang Huamei petroleum equipment CO., LTD.
Nanyang Xincheng aerial equipment CO., LTD… Sino-American joint ventures and Nanshi
Litian transmission CO., LTD. Nanyang RG vehicle manufacturing CO., LTD. RG(Luoyang)
petroleum equipment CO., LTD.…. holding companies.
RG PETRO-MACHINERY (GROUP) CO. LTD has established a complete quality
assurance system and HSE system. It is one of the first companies that got the certification
of ISO9001 /2000 in the industry of China and now its products are licensed with API spec
8A, 8C, 11E, 4F, 7K, 16C and pass the “3C” compulsory certification of China.
The products includes：
² 1000M－4000M truck-mounted drilling rig
² 1000M－7000M Skid-mounted drilling rig
² 1000M－4000M Trailer-mounted drilling rig
² 35T－225T Onshore workover rig
² 60T－225T Offshore workover rig

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Operation manual of 10X8 Carrier
² 4000M－7500M Oilwell logging equipment
² 50T－70T Heavy-duty trailer
² Top drive drilling units
² Petroleum special vehicles
² Wellhead tools
Firmly holding the principle of “Customer First”, RG PETRO-MACHINERY (GROUP)
CO. LTD has established a professional service organization in all the carriagestic major
oilfields and in Canada and Russia and to provide all-around after-sales services ranging
from equipment installation, debugging, maintenance, training to spare parts supply. The
products of RG PETRO-MACHINERY (GROUP) CO. LTD is in great demand in all the
oilfields of China and have been exported to move than 30 countries and regions across the
world such as, America, Canada, Mexico, Venezuela ,Russia, Britain, Hungary, Switzerland,
Turkmenistan, Kazakhstan, Uzbekistan, Egypt, Sudan, Nigeria , Saudi Arabia , Iraq , Oman,
Iran, India, Indonesia and Thailand. RG PETRO-MACHINERY (GROUP) CO. LTD
warmly welcomes customers home and abroad for contact and cooperation to create a
shining success for all!
RG PETRO-MACHINERY (GROUP) CO.LTD will be your cordial friend and ideal
partner forever!

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Operation manual of 10X8 Carrier

Preface
RG Petro-Machinery (Group) Co., LTD thanks very much for you choosing the drilling
and workover rigs which are designed and manufactured by us.

This manual is specified for using XJ100 workover rig. This model is one-engine 10X8

carrier vehicle.

Before using the vehicle, please read this use’s manual carefully. Since the technology

of the product is keeping updated, there may be inconsistency between the contents in this

manual and the practical product. If this is the case, final reference shall be subject to the

practical product. It is not the aim of this manual to provide a standard process for operation.

Every user shall be responsible to establish suitable criterions according to the local HSE

and the local condition.

As the structure of the carrier is very complex, this manual can’t cover everything. If

the user meets the situation not mentioned in this manual, please inform the technical

service department of our company at once, and we will provide technical support or

dispatch personal for after-sale service.

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Operation manual of 10X8 Carrier

Important safety statement

Any operation, management, maintenance and repair personnel of the product must
know very well of the relative content of the instruction and abide by the regulation related
to operation, management, maintenance and repair, especially for the content such as safety
warning and attention given by this instruction, as well as common-sense safety regulations
and matters needing attention prompted by national law, regulation, industrial regulation, so
as to avoid human injury and damage of the equipment.
The instruction could not list all safety warning information in details, so any method I
is selected for operation, it must be ensured that it will neither endanger the human safety
nor damage the equipment.
Correct maintenance is the key factor for safe and reliable operation of the product.
The maintenance personnel shall maintain the equipment according to the method
introduced in the instruction manual.
The correct repair of the product and replacement of the components manufactured by
origin factory are key factors for safe and reliable operation of the equipment. The user must
maintain and replace the component within the scope authorized by the manufacturer.
When the user has special requirement for the product, the configuration of the product
may differ from the instruction manual, and the actual configuration of the product shall
govern.

Please read carefully when the instruction manual uses the following title and mark!

Warning: Used for the situation where incorrect operation procedures and
methods may lead to human injuries.

Caution: Used for the situation where there may be human injuries and damage of
equipment if the operation procedure and method is not observed strictly.

Note: Used for the situation where there is need for attention or independent
explanation.

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Operation manual of 10X8 Carrier

Special Hint

Regardless of in the manufacture, the driving and the work process, the tight situation for
transmission bolt, axle bolt, and tire bolt of this equipment is main factors of affecting
security of the equipment .Reminds the user checking bolts before starting and using the
equipment and forbid bolts appear loose, fracture, distortion. The related requirements are the
following table:
No. Item Tighten torque Remark
1 transmission shaft bolt M10X1 25Kg.m
2 Axle hanging leaf spring bolt 42～48Kg.m
3 Tie Ma Qiao tire bolt 55～60Kg.m Different axle choose
Suo Ma Qiao tire bolt 75Kg.m different type

1. Note：The inspection in this content doesn’t stand for that the inspection for other

items in other manual and instructions can be avoided.

2. Lubrication is the key point which could assure all equipment operating normally

and extend its operational life span, special notice should be noted by the user that the clean

lubricating oil and grease should be charged or changed according to the schedule time and

stated trademark.

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Operation manual of 10X8 Carrier

Contents
1. Main technical specification ------------------------------------------------------------------ 1
2. Structure and specification of main components------------------------------------------- 1
2.1 Engine and transmission ---------------------------------------------------------------------- 1
2.2 Transmission shaft ----------------------------------------------------------------------------- 1
2.3 Vehicle axle -------------------------------------------------------------------------------------- 1
2.4 Carrier frame ----------------------------------------------------------------------------------- 2
2.5 Suspension --------------------------------------------------------------------------------------- 2
2.6 Wheels and tires -------------------------------------------------------------------------------- 2
2.7 Steering system---------------------------------------------------------------------------------- 2
2.8 Brake system ------------------------------------------------------------------------------------ 3
2.9 Electric system ---------------------------------------------------------------------------------- 3
2.10 Cab ---------------------------------------------------------------------------------------------- 4
3. Control devices and instruments in the cab------------------------------------------------- 4
3.1 The cab has the following switches and instruments (see Fig 3-1) --------------------- 4
3.2The cab has the following manipulators (see Fig 3-2) ------------------------------------ 5
3.3 Capacity data ----------------------------------------------------------------------------------- 6
4. Driving and operation--------------------------------------------------------------------------- 7
4.1 Breaking in for new vehicle------------------------------------------------------------------- 7
4.2 Preparation before vehicle running --------------------------------------------------------- 8
4.3 The starting operation of the vehicle-------------------------------------------------------- 8
4.4 Cautions in driving----------------------------------------------------------------------------- 9
4.5 Stop ----------------------------------------------------------------------------------------------10
4.6 When the carrier is used in winter --------------------------------------------------------- 11
4.7 Grease lubrication points in the vehicle ---------------------------------------------------- 2
4.8 Examination and replacement of oil in the vehicle --------------------------------------14
4.9 Main adjustment points of the vehicle-----------------------------------------------------14
4.10 Keeping into and out of storage of the vehicle ------------------------------------------15
5. Maintenance of main component ------------------------------------------------------------17
5.1 Transmission shaft ----------------------------------------------------------------------------17
5.2 axles ----------------------------------------------------------------------------------------------17
5.3suspensions --------------------------------------------------------------------------------------18
5.4 steering system ---------------------------------------------------------------------------------19
5.5 air system ---------------------------------------------------------------------------------------24
5.6 electrical system -------------------------------------------------------------------------------26
6. Attached tools------------------------------------------------------------------------------------27
7. Attached drawing -------------------------------------------------------------------------------28

Attached with < Operation manual of axles>

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Operation manual of 10X8 Carrier

1. Main technical specification

Description 10×8 F Carrier
Driving type 10×8
Chassis weight in working order 21.5
Maximum overall weight specified by the manufacturer 54t
Axle load (full loaded):
First Axle 11t/ second Axle 11t/ third Axle 13t/ fourth Axle 13t / fifth Axle 11t

Size (Length×Width×Height) mm
Chassis 13110×2850×2780
Complete Rig 18800×2850×4300
Axle distance 1350+4685+1300+1350
Wheel distance 2295mm
Minimum ground clearance 311mm
Minimum turning diameter 33m
Approach/departure angle 26°/17°
Limited speed 45km/h(Only V gear is allowed)
Braking distance (30km/h) ≤15m
Maximum climbing distance (torque converter efficiency 70%) 26%
Continuous running distance (full loaded) 350km
Oil consumption per hundred km 90L/100km

2. Structure and specification of main components

2.1 Engine and transmission
The engine and transmission box will be chosen by user, and the related technical
parameters will be settled by user also, all these will not be illuminated in this instruction.
2.2 Transmission shaft

Open pipe shape, crises-cross shaft free joint type with needle bearing, totally 6 pieces.

2.3 Vehicle axle

First axle is the steering drive axle, single reduction final drive with wheel reducer. The

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Operation manual of 10X8 Carrier

speed ratio is 2.25×3.378=7.826. Rzeppa constant velocity universal joint.

Second axle is the steering driving axle
Third axle is saddle-shaped pneumatic suspension driven axle
Fourth and fifth axles are the tandem driving axle, single reduction final drive with
wheel reducer. The speed ratio is 2.25×3.378=7.826. Equipped with inter-wheel and
inter-bridge differential and pneumatic lock-up (without lock-up air circuit).

2.4 Carrier frame

I-shape beam welded by steel plate
The size of cross section is shown in Fig 2-1

2.5 Suspension
First and second axles employ the spring steel plate balancing suspension.
Third axles employ the air spring suspension.
Fourth and Fifth axles employ rigid balance girder suspension.

2.6 Wheels and tires

The 4 wheels of the front axle are single tired, with one spare tire.
Tire: 18-22.5 tubeless tires, cross-country tread pattern, air pressure 0.70MPa, load
capacity 50kN.
Wheel rim: 14-2.5 wheel rim
wheel setting angle: kin pin sidewise inclination 5°,caster 1.2°，camber 1°，
First axle toein 0~5mm，second axle toein 4~9mm，third axle toein 6~12mm。
The 6 wheels of the rear axle are double tired, with one spare tire.
Wheel type 12-20，air pressure 0. 6MPa, load capacity 32.5kN, wheel rim type:
8.5V/20。

2.7 Steering system

Type: steering through the front two axles, hydraulic driving.
Steering linkage: tandem drag link

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Operation manual of 10X8 Carrier

Steering hydraulic system: equipped with steering pump, follow-up valve, excess flow
valve and two servo cylinders. The flow control valve is fixed inside the pump (some
models do not have the flow control valve). Pump flow is 13G/min，working oil pressure is
13MPa. The working principle is shown in Fig 2-2.
Steering device: screw-nut circulating ball, single-pin type crank, semi-integral,
average transmission ratio: 33.4

液 压 油 箱 回 油 单 向 阀 方 向 机 随 动 阀

截 止 阀

出 油 滤 芯

转 向 油 泵
转 向 油 缸
溢 流 阀

Fig.2-2 Steering oil circuit illustration

图中文字 CHARACTER IN THE FIG ：

液压油箱 hydraulic oil tank 截止阀 stopping valve 出油滤芯 outlet filter element 转
向油泵 steering oil pump 溢流阀 excess flow valve 转向油缸 steering oil cylinder
回油单向阀 oil returning one-way valve 方向机随动阀 steering device follow-up valve

2.8 Brake system

Main brake system: single-circuit foot-control pneumatic brake, impact on all five
axles, working pressure 0.8MPa.
Stopping brake: hand-control airless spring brake, impact on the third, fourth and fifth
axles.
Emergency brake: the stopping brake also works as emergency brake.

2.9 Electric system

24V single-wire minus earth

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Operation manual of 10X8 Carrier

Lighting: head light, front small light, fog light, rear light, side light, cab top light,
instrument light, variant indicate light, alarming light.
Electric horn D34DG-24
Inserted fuse box, BX-502 type.

2.10 Cab
Single cab, oil drop prevented brim, door glass able to move up and down, seats able to
be adjusted back and forth, up and down, equipped with air collector, sun visor, safety belt,
fire extinguisher.

3. Control devices and instruments in the cab

3.1 The cab has the following switches and instruments (Fig 3-1)
Rapid start switch, wiper switch, wheel differential lock-up switch, engine stopping
switch, stopping brake switch, front fog light switch, back fog light switch, top light switch,
instrument light switch, engine start-up switch, stopping brake switch, preheater switch.
Engine oil pressure gauge, engine water thermometer, torque converter oil pressure
gauge, speedometer, air pressure gauge.
Left-turn indicate light, right-turn indicate light, no charge indicate light (optional), low
air pressure indicate light (optional), torque converter oil temperature warning light, log
light indicator, close light indicator, far light indicator.

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Operation manual of 10X8 Carrier

Fig 3-1 Instrument panel in the cab

3.2The cab has the following manipulators (Fig 3-2)

Steering device, brake pedal, accelerator pedal, down hill reducer pedal, vehicle lights

combination switch, seat adjustment.

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 Operation manual of 10X8 Carrier

3-3 adjust shaft of air collecting door, shift shaft (not indicated in the
picture)

3.3 Capacity data

Components Capacity （L） Oil type
fuel box 420 0#、10# light diesel oil
First, second, third, fifth, axles inter-axle differential 31 85W90 high loaded vehicle gear oil
axle package 11.5l, wheel brim 31 （GL-5）
steering device 2.5 N68 anti-wear thickening hydraulic oil
hydraulic oil tank 600 N68 anti-wear thickening hydraulic oil

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 Operation manual of 10X8 Carrier
storage battery battery sulfuric acid
anti-coagulate device necessary absolute alcohol
atomized lubricator necessary mechanical oil or N22 hydraulic oil

Note: the oil types in the table are for reference only, and the user shall choose according to the
practical environment and situation. The amount of added oil shall be based on the dipstick or other
observable oil level marks.

4. Driving and operation

4.1 Breaking in for new vehicle
The breaking in distance shall be 1500 km, with limited chassis speed 35 km/hour
Sudden acceleration is forbidden in the breaking in period. And try to avoid emergency
braking and long-time braking.
1) In breaking in period, maintenance shall be carried on three times:
Maintenance before breaking in:
Examine and fix all the outside screw, nut, and pins
Examine all the oil surfaces
Examine the air pressure of tires, the discharge condition, electrolyte proportion, and liquid
level of the storage battery,
2) Maintenance during the breaking in period, after running for 500km.
Replace the lubricate oil and filter element
Lubricate all the lubrication points of the vehicle
Examine the performance of the brake system and the sealing condition of circuits
Tighten the cylinder cover, vent-pipe screws, tire nuts, U-shaped screws, transmission shaft
nuts, etc. And it should be noticed that after first running for 40 km, one should first
examine that if any parts is heating or making noise.
3) Maintenance after breaking in, according to the requirements of second level
maintenance of vehicle.
4.2 Preparation before vehicle running
Maintenance before running
Examine the levels of four liquids: the liquid level in the radiator, the oil level in the engine,

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Operation manual of 10X8 Carrier

the oil level in the torque converter, the liquid level in the storage level.
Fix the nuts of the tires, and examine the air pressure
Examine if all the drag drafts in the steering system have been fixed tight
Examine if all the drag drafts and rockers in the brake system have been fixed tight
Examine if all the bolts in the suspension assembly have been fixed tight
4.3 The starting operation of the vehicle
1） All the gearing handle on and under the vehicle shall be shift to the “run” operation.
2） The lock-up switch of the torque converter (HOKE valve) shall be set to "run” position
3） The shift shaft shall be set to “free” position
4） The inter-axle and inter-wheel differential lock-up switch shall be set to “disjoint”
position
5） The main oil pump shall be set to “disjoint” position
6） The belt of the steering oil pump shall be installed properly, and the pump is working
normally.
7） Make sure the air suspension pressure adjustment is set to 0.42Mpa
8） Examine the locking condition of the derrick, and examine that if there is a still object
which may affect the normal operation of the vehicle.
After the above 8 steps of examinations, the vehicle can be started.
9）Open the electric general switch, and connect to the power source.
10) Pull the “Rapid Start” shaft. If there is air pressure, press down the “Rapid Start”
pneumatic control valve.
11) Start the engine, if it can not get running in 30 minutes, stop it and wait for 2 minutes
and start it again.
12) Observe the oil pressure gauge of the engine immediately after it get started. If it can not
get to the normal value in 15 seconds, Stop the engine immediately!!! And observe the oil
pressure gauge of the torque converter, If the value is not in the normal range, or keep
obviously fluctuating, then examine the oil level in the torque converter.
13) Keep idling till the water temperature and the air pressure of the engine get to normal
values.
14) Examine the value of the air suspension pressure gauge.

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Operation manual of 10X8 Carrier

15) Draw out the stopping brake switch (after the air pressure get to 0.6Mpa)
16) Accelerate the vehicle slowly to run it up, usually on second shift.
17) Refer to the user's manual of the engine for instructions for running in winter
4.4 Cautions in driving
1) Keep examine all the instruments when driving, especially the water thermometer, the oil
pressure gauge of the engine, the current meter, the air pressure gauge, etc.
2) The vehicle employs power steering, so sliding with the engine stopped or the torque
converter shifted to free is strictly forbidden!!!
3) Before the vehicle is shifted from higher gear to lower gear, the accelerator shall first be
reduced and make the vehicle slow down to speed of lower gear. Before the vehicle is
shifted from lower gear to higher gear, the accelerator shall first be raised up and make the
vehicle faster. Forcible shifting is forbidden!!!
4) Only on a muddy ground can the front driving and inter-axle, inter-wheel differential lock
is used. When the inter-axle, inter-wheel differential locks are used, steering is not allowed.
When the front driving is used, high–speed running is not allowed and steering shall try to
be avoided. When the vehicle is trapped in the muddy ground, one should first try
connecting the inter-axle differential lock, then the inter-wheel differential lock, and finally
try connecting the front driving.
After the vehicle get to the normal ground, the front driving should be disconnected, and the
differential lock shall also be disconnected.
After running for every 5000 km or one month, one should examine if the differential lock
can be operated precisely.
5) Before shifted to reverse gear, the vehicle should be stopped first. Reverse gearing when
the vehicle is moving forward is forbidden.
6) Hydraulic reducer can be used when vehicle is going down hill. In order to improve the
efficiency, the vehicle can first be downshifted. If only partial reducing effect is needed, the
reducer can be partly fueled. (Controlling through the reducer pedal). Accelerator is not
allowed to be raised when the reducer is used.
7) After the vehicle goes through the water, it shall be tested on braking immediately in
order to extrude the water in the braking hub.

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 Operation manual of 10X8 Carrier

Note:
1. Rapid braking is not allowed on too wet ground, to prevent the vehicle from deviating or turning round.
2. Use the light and sound warning devices properly according to the local regulations of the transportation
department.
3. Use the seat belt and comply with the local transportation rules.

4.5 Stop
1）Pull the shift handle to the free gear, and make the vehicle slow down and stop.
2) Let the engine idling for 2 minutes to let it cool down. And then step on the gas for 2-3
seconds to make all parts get enough oil, then stop the engine.
3) Set the stopping brake switch to “OFF” position
4) Cut the general power switch
5) If stopping the vehicle for a long time or on a slope, one should use a piece of wood
beam or iron beam to stick the vehicle tight.
6) For laying aside of the vehicle for more than one month, please refer to section 4.11 for
instruction.

Note: 1. if stopping the vehicle on the road at night or due to some failure, one should press down the
warning light switch, and place suitable warning sign to the direction of other vehicles. (The warning sign is
prepared by the user.)
2. Do not run or stop on muddy and soft road ground or road surface. Especially do not stop the vehicle on
the soft road side in case that the vehicle will be trapped in or turned over due to the large self weight.

7) Maintenance after running

Discharge the water of all the air reservoirs.
Examine the air filter differential indicator, if the red get outside, clean the dust.

Note: After the vehicle is stopped running, one should use the stopping brake to stop the vehicle
timely, to prevent the vehicle from moving by accidental reason.
In the first month of running, the main engine should be kept running for about 20 minutes every time.
Only if both the main engine and auxiliary engine are in good condition for use, can the advantage of
double-engine vehicle be revealed.

4.6．Use in winter
An air temperature under 5℃ indicates, the vehicle is working in winter.

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 Operation manual of 10X8 Carrier

When the air temperature becomes 0℃, alcohol can be added into the anti-coagulator.
Examine the working condition of the preheater, and add gas into the little gas tank.
According to requirements, the engine, transmission box, torque converter, and the
driving axles shall be fueled with winter-use fuel, lubrication oil, and cooling liquid.
Keep the storage battery warm. If there is no heat preservation device for the storage
battery, it should be taken to the hothouse for storage after the vehicle stops running.
Before and after running everyday, the water in all the air reservoirs should be
discharged.
Clean the agglomeration staff in the fuel tank once every week
Clean the coarse filter once every week.
The brake air chamber, brake adjust arm and the cam shaft may be eroded by snow and
mud due to the relatively low position, so they should be cleaned and lubricated regularly.
When the vehicle is running on snow or muddy ground, especially when there are
many slopes, the wheels of the back axles may be equipped with tire chain (prepared by the
user).
4.7 Grease lubrication points in the vehicle

Assembly part points Examine Maintenance

period
period
Dividing device Drop box 3 3# lithium lubricate grease every day every week
sliding fork of 8 3# lithium lubricate grease every day every week
transmission shaft
transmission shaft
bridge piece of 2 3# lithium lubricate grease every day every week
transmission shaft
needle bearing of 16 3# lithium lubricate grease every day every week
transmission shaft
Steering main pin 12 3# lithium lubricate grease Every week Every month
Steering vertical 3 3# lithium lubricate grease Every week Every month
tension bar ball
steering wring
Steering cross bar 4 3# lithium lubricate grease Every week Every month
ball wring

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 Operation manual of 10X8 Carrier
Vertical tension 1 3# lithium lubricate grease Every week Every month
bar criss-cross
shaft

assembly part points Examine maintenance

period period
steering device transmission 2 3# lithium lubricate grease every week Overhaul period
shaft and bearing
steering device spline shaft 1 3# lithium lubricate grease every week Overhaul period
steering device gimbal 1 3# lithium lubricate grease every week Every month
Steering oil cylinder wrist 2 3# lithium lubricate grease every week Every month
steering oil tank ball wring 2 every week Every month
steering pump base 2 3# lithium lubricate grease every day every week
Steering
front axle iron plate spring 4 graphite lubricate grease Every three month
back axle iron plate spring 2 graphite lubricate grease Every three month
front axle iron plate spring 4 3# lithium lubricate grease every week Every month
central bearing pin
back axle balance girder 4 3# lithium lubricate grease every week Every month
side pin
back axle iron plate ear pin 2 every week Every month
Suspension back axle iron plate spring 2 3# lithium lubricate grease every week Every month
central bearing pin
back axle distance rod 4 3# lithium lubricate grease every week Every month
Third axles axle head 2 3# lithium lubricate grease every week Every 3 month

brake front axle brake arm worm 4 3# lithium lubricate grease every week Every month
wheel
system back axle brake arm worm 6 3# lithium lubricate grease every week Every month
wheel
back axle brake arm 6 3# lithium lubricate grease every week Every month
supporter

4.8 Examination and replacement of oil in the vehicle

Part Examine period Oil replace period
First, second, third, fourth, examine the temperature of the axle heads, and six month
and fifth axles. axle package every work shift
steering device ----- six month
hydraulic oil tank examine the oil level every work shift six month

anti-coagulator add when needed

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 Operation manual of 10X8 Carrier
atomized lubricator All the time add all the time
vibration isolator When necessary six month

Note: 1. the above examine and oil replace periods should be decided according to the working condition. If
working condition changes, then the periods may be extended or reduced.
2. every work shift: every 8-hour or 12-hour work shift when drilling
3. every day: for drilling, means every working hour, that is, every shift

4.9 Main adjustment points of the vehicle

part adjustment Examination and
adjustment period
down-hill reducer cylinder be able to complete the full stroke of the reducer shaft two months
Connecting cylinder be able to cut off the self protection device two months
Differential lock-up one month
lock up and disconnect normally
cylinder
one month
Shift handle exact gearing, and reliable positioning
one month
Air suspension pressure air pressure stick to the defined value stably

part adjustment Examination and adjustment period

steering over flow valve oil stick to the defined value stably one month
Six months
toein meet requirement
Six months
wheel distance meet requirement
Six months
axle wheel hub distance According to the requirements of axles.
Note: The above adjustment parts shall also be paid attention to in usual time. If any problem rises, adjustment
should be performed. Nevertheless, adjustment shall be carried out at least once in every examination and adjust
period.
4.10 Keeping into and out of storage of the vehicle
1. Following processes should be done when keeping the vehicle for storage for more
than one month:
1) Try to keep it in dry, well-ventilated indoor parking lot. If not, all the doors and
window shall be closed.
2) Dismantle the battery jar and deliver to the special keeping department. If not, it

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Operation manual of 10X8 Carrier

should be examined once every month.

3) Cut off the power general switch
4) Discharge the coagulated staff in the air reservoir.
5) Examine the condition of the protection layer on the surface of the outside parts, and
the erosion condition of the surfaces. If necessary, process it with lacquer or oil package.
6) Examine the outside appearance of the vehicle once every month. Rusted parts shall
be taken on antirust process and protection measure. If some components are damaged by
accident reason, the reason should be found. After the situation is clear, proper repair shall
be taken.
For storage in winter one may refer to the section 4.6.
Preparation for running after storage of long time shall be taken according to the
related part in this section.
2. If the vehicle is not planning for use for more than 6 months, it should be sealed up
for keeping.
1) When washing the car, please note that different detergent and watching manners
should be performed to different parts.
2) Examine the lacquer layer condition of the vehicle frame and the chassis.
Supplement the lacquer if necessary. Paste oil to protect the chrome plate surface. Paste oil to
protect the surface without covering layer.
3) Place the vehicle on the dry and well-ventilated parking lot, and fill the lubrication
oil at every lubrication points described in Section 4.8.
4) Discharge the diesel oil, add 10% antirust oil and then add the diesel oil again to fill
the oil tank.
5) Brace the axles (or brace the vehicle by hydraulic supporter after if move into the
parking lot). Reduce the air pressure of the tires to 50-100Kpa. Cover the tires to prevent sun
light and/or damp
6) Dismantle the storage battery and keep it in special storage room.
7) Hang a plate on the steering wheel. On the plate written:” Before running, discharge
the antirust oil in the engine, hydraulic transmission box, and axles, and fill with required
oil”

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The effect period for above storage is 6 months for wet and warm area.
3. Backing to use of the vehicle
1) Take off the cover on the tires, and charge to specified air pressure. Remove the
supporting staff of the vehicle (It is also proper to charge the air with the self air source and
remove the hydraulic supporter after the engine can be used).
2) Discharge the added antirust in the components. Fill with required oil, and examine
the oil level.
3) Remove the cover of all the air vents. Install the air filter element and triangle belts.
Install the storage battery. Examine the electric circuits and all the electric elements.
4) Use the manual oil pump to discharge the air in the fuel circuit.
4. Test on road
After every maintenance or long time storage, the vehicle shall be tested running on
road for 10-15 km. Test shall be carried on the road with relatively few vehicles and in good
condition.
1) Before test running, examine and prepare operations described in Section 4.2 and
4.3 shall be taken first.
2) Examine after start-up:
3) Brake performance: brake distance and stability. Adjust again if necessary.
4) Steering performance: the amount of steering force. Is there block and vibration
situation.
5) Speed variation performance: the condition of gear shifting. Is there tripping,
out-of-gear, or gear struck environments.
6) Are all the lights, sounds, indicating lights, and instrument indicators are working
normally. Are the sounds of engine, torque converter, axles normal?
7) Oil, air, and water leakage phenomenon.
8) After the original problems are solved, will they occur again?
5. Maintenance of main components.
5.1 Transmission shaft
There are 6 transmission shafts in the chassis. All are open pipe type, with extending part.
5.1.1 Lubrication and maintenance

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1) Fill the grease after running 2500 km. When fill through the grease mouth, rapidly
press the grease gun, in order to make the four bearings equally lubricated.
2) Examine the tightness of the gimbal cover and the flange bolts after running 2500
km.
3) Examine the axial and radial clearance of the gimbal after running 2500 km. And
make sure it is not more than 0.10mm. And the spline gear clearance no more than 0.25mm.
4) When installing again, the transmission shaft and the gimbal fork shall be on the
same plane. The arrowheads on the transmission shaft and the extending fork should point
to each other. And then fill with the grease.

5.2 Axle
For steering driving axle please refer to Steering Driving Axle User’s Manual.
For steering follow-up axle please refer to Steering follow-up Axle User’s Manual.
For Air Suspension follow-up axle please refer to Air Suspension follow-up Axle User’s
Manual.
For tandem driving axle please refer to Tandem Driving Axle User’s Manual.

Note: If dismantle and replace the tire, please fix the bolts according to the specified torque
(55kN.m-60kN.m) for tire bolts. And after running 0 km, 50 km, 150 km, examine the torque and fix again.

5.3 Suspension
1）Suspension of the two front axles
Parallel sliding-plate, Leaf-spring, balance suspension. Four adjustable support beams.
Examine the tightness of the bolts on all support beams and the U-shaped bolts on leaf
spring after running 2500 km. Examine the distance between first and second axles
(1350±3mm). But the error of the left and right side distance of axles (distance between axle
heads) can not exceed 2mm. Examine the toein (following the Section 2-7). Fill the grease
according to Section 4-8. Examine the oil levels of the four hydraulic vibration reducer
every 2500 km.
2）Suspension of the two back axles
Rigid balance girder suspension. Two support beam.
Examine the tightness of the bolts on all support beams, the center bearing bolts, and

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the bolts on the side covers after running 2500 km. Examine that if the center support
aligning bearing and the support beam side rubber bearing are loose. Fill the grease
according to Section 4-8.
3）Air suspension
The third axle is air suspended, which has relatively low rigidity, So it can protect the
axles from overloaded on uneven ground.
The air circuit is shown in Fig. 5-1.
The air suspension pressure regulating valve help maintain the pressure at 0.42MPa.
When the air suspension axle gets over the boss, the regulating valve will discharge the air
automatically, In order to prevent the pressure from getting up to 0.6MPa. In this way, the
axle will be not overloaded. If the dynamic air pressure is too high, please examine the
regulating valve.
If by any chance, the air chamber breaks, and the downward pressure is below
0.42MPa, then the protection valve will automatically cut off the air circuit, and prevent the
main air circuit in braking system, and ensure it above the safety braking pressure.

70PSI
75PSI

（图中文字 letters in the fig：）

气囊：air bag 滤清防护阀 filter protection valve 调压阀 pressure regulating valve
气悬挂管线：Gas suspension pipe line
Air suspension axle has limit block and iron chain to limit the stroke distance of the air
chamber
Before using, the air suspension shall be set to 0.42MPa, all the bolts shall be fixed

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tight, and the handle should be removed. When the vehicle is started (that is, all the handles
on and under the vehicle are set to “Run” position), the air chamber will charge
automatically. At this time, make sure that the working pressure of the pressure regulator is
set to proper value, or the air chamber may break.

5.4 Steering system

1）FDZ125D type steering device
The structure is shown in Fig. 5-2
For working principle, please refer to Fig. 5-3: a, b, c.
a. If the steering wheel does not move, the distributing valve is set to middle position,
and the pressure oil goes back to oil tank directly. The inlet and outlet of the pressure oil
tank are disconnected. The wheels keep running straight forward.
b. If the steering wheel is turned left. Because of the inertia, the rocker 11 connected
with the wheel and the steering nut 10 does not move at this moment. The steering wheel
makes the worm rod rotate. Compared to the still nut 10, the worm rod is turning right, and
makes the valve core 6 move right. The pressure oil is connected with the right chamber of
the oil tank, while the left chamber is connected with the oil returning circuit. Then the
pressure oil pushes the wheel to rotate, and the rocker 11 (together with nut 10) moves left,
and make the worm axis and the valve core move left until get back to middle position. And
new balance relation with the steering wheel establishes. And the wheels remain certain
turning angle.
When the turning angle of the steering wheel increases, the turning angle of the wheels
increase accordingly, and new balance establishes.
When the steering wheel is turned right, the process is just opposite to the above
process.
c. Situation when the steering force is lost. In this situation, the left inlet of the one-way
valve 3 becomes low-pressure area. When manual force turns the steering wheel, the oil in
the servo cylinder will be pushed by manual force to the oil returning circuit, and open the
one-way valve to make it enter the inlet. Thus the left and right chamber of the servo
cylinder is connected, and the steering resistance is reduced.

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Note: The chassis uses steering by the three front axles, and the steering resistance is large. Once the
force steering is lost, actually manual force can not complete steering. At this time, the vehicle shall be
stopped at once.

2）Steering pump
The steering pump is gear pump, with discharge capacity of 13G/min, maximum
rotation of 2400r/min，and rating pressure of 13MPa. The steering pump is drove by the
engine flywheel through belt. When drilling, the belt can be disconnected by manual.

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Fig. 5-2 FDZ125D Power steering device schematic illustration

1．Device shell 2. Circulating iron ball 3. Steering nut 4. Steering worm 5. Middle flange 6. Stop bearing 7. Distributing valve
concave ball backing 8. Distributing valve protruding ball backing 9. Distributing valve shell 10. Distributing valve 11. Passive gear shell 12.
Distributing valve fixed nut 13. Fixed nut stopping backing 14. Distributing valve stopping nut 15. Spline shaft 16. Pressing screw plug

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接油罐

接动力缸后腔
接油泵

Fig. 5-2

接油罐：Connected to the oil tank

接油泵：Connected to the oil pump

接动力缸前腔 connected to the front cavity of power cylinder

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Power steering oil way sketch map

a. Keep the steering not move b. Move the steering wheel c. steering pump disabled & steering forced
1.steering oil tank 2.steering oil pump 3.one- way vale 4.steering wheel 5.shell of distribution vale
6. distribution vale 7.four-position device 8 steering screw rod 9.steering rocker arm shaft
10.steering nut 11.rocker arm

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3）Steering cylinder
Cylinder diameter is φ70mm. Stroke is 310mm. there are joint bearings on both sides
of the cylinder. After the cylinder or the circuit is disconnected, the steering wheel shall be
push to the left and right limits, in order the discharge the air through the vents. If not, there
may be vibration when steering. Note that the steering wheel can be held to the limits for
more than 5 seconds, or the oil pump will be over heated.

4）Excess flow valve

When the steering wheel is put to limit, the pressure should be 100MPa. If not, adjust
the valve.

5.5 Air circuit system

1. Air supply

Air compressor air dryer air reservoir ball valve air filter anti-coagulator

Pressure valve←→ safety valve

The air compressor is supplied and installed by the user.
The top section of the air compressor is communicated with alcohol anti-coagulator,
alcohol will be added when temperature is below 0℃ degree.

Warning: alcohol can not be added when the air compressor is running. Before adding the
alcohol, make sure there is no air pressure in the air circuit.

When the compressed air goes into the dryer, there will be a kind of chemical inside
the dryer, which can absorb the water and the impurity and put them on the bottom of the
dryer. When the air compressor offloaded, the pressure regulator will send pressure signal to
the dryer. The discharge valve will be opened. And the water and the impurity will be
discharged. Normally, when the air compressor is running for 90 seconds, it should
discharge for 30 seconds. If the discharge time is too short, the water may accumulate inside.
There is DC heater inside the dryer, and the temperature sensor switch will automatically
cut off when the temperature is 7℃.
The air reservoir capacity is 0.3m3. The specified pressure of the safety valve on the air
reservoir is 1.1MPa（160PSI）. There is water discharge valve on the bottom, which will

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discharge water once everyday.

2. Air filter
The working pressure of the air filter is 1MPa（150PSI）. The maximum working
temperature is 52℃. There is a discharge valves on the bottom. The valve can be manually
discharged or auto discharged. For manually discharged one, it shall be discharged
periodically. When the filter is repaired, the air inlet shall be closed, and reduce the pressure
in the circuit and the container to zero. Plastic container can only be washed by warn water.
Other parts can be washed by warn water or soap water. Blow to the filter element in the
opposite direction to the air current. Clean off the impurity on the surface. Use clean and dry
compressed air to blow the parts and the inside holes in the shell.

3. Anti-coagulator
When the air temperature is below 0℃, fill with alcohol, in order to prevent the pipe
lines or containers form freezing.

4. Dual-lock valve
It includes two 2-position-3-way Control Valves, which are separately connected to the
pulling handle on and under the vehicle, and on the front axles. The function is: when two
back axles are working, only chassis circuit has air pressure. When both the two back axles
and the front axles are disconnected at the same time, only the winch has air pressure. In this
way, false operation can be avoided.
5. Brake circuit
The main air goes to the front axle brake air chamber through the brake pedal valve,
and serves as a control signal to open the consistently closed relay valve . The main air is
sent to the back axle brake air chamber through the relay vlave. This structure is able to
synchronize the front brake and the back brake.
There are two-level air chambers in third, fourth and fifth axles. The upper chamber
has a reinforced spring. When the vehicle is running, the main air is sent out through the
stopping brake valve, and serves as a control signal to open the relay valve, the air pass
through the relay valve and is sent to the lower chamber. Thus the brake is released.
When braking, the main air is sent to the upper chamber through the relay valve, and it
counteracts with the air from the lower chamber. Then the reinforced spring will serve to

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brake.
If the vehicle is stopped, then the valve is closed, and the air in the lower chamber is
discharged through the rapid discharge valve, stopping brake is accomplished.
If there is failure in the main air circuit, the two-level air chamber will serve to brake.
And if one wants to starts the vehicle again, he/she may remove the screw on the brake air
chamber and discharge the air, and then the brake is released.
The structure and adjustment of the brake air chamber is described in the Axle
Introduction.
If failure of certain vehicle part occurs, and the vehicle has to be drawn, one shall try to
ensure that the drawing is performed when the engine is running.

Note: 10X8 carrier vehicle employs power steering and pneumatic braking. Drawing the
vehicle without steering and braking will be much dangerous. Only emergent short-distance
drawing is allowed, at the speed no more than 4km/h. And the operation should be much careful,
and prepare well for any possible accident

5.6 Electric equipment

The circuit of the vehicle is 24V, minus earth, and one wire type. The preheater is 12V.
the electric power is supplied by from the battery jar.
The storage battery is 24V supplied by the user.
The general switch of power supply controls power of the vehicle.
All the lights are control by combined switch control. The combined switch consists of
the turning switch, light switch, rain-wiper switch and the horn button.
The turning switch: consists of left, middle, and right gears, to control the left and right
turning light and the turning indicating light.
Rain-wiper switch consists of two gears of fast and slow
The light switch: consists of four gears: free gear, gear 1 (open the rear signal light and
front and back small lights), gear 2 (open the rear signal light, back small light and the low
beam), gear 3 (open the rear signal light, back small light and the high beam)

6. Accessory tools

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item name amount note
1 Grease gun 2 200g
2 2P hammer 2
3 8P hammer 2
4 monkey wrench 2 8″
5 monkey wrench 2 12″
6 Open end wrench（5.5-55mm） 2 set 9 pieces/set
7 Box wrench（5.5-55mm） 2 set 6 pieces /set
8 pincers 2 8″
9 screwdriver 2 8″
10 screwdriver 2 4″
11 24V work lamp 2
12 Philips driver 2 10″
13 saw 2
14 Oil press gun 2
15 Torque spanner 2 30kg
16 Wire stripper 2
17 Pipe tongs 2 12”, 24” one piece
18 Allen wrench 2 set 8 pieces /set
19 Socket wrench 2 set 17 pieces /set
20 Chain spanner 2
21 30T hydraulic jack 2
22 Tire spanner 2
23 Charge pipes and pressure gauge 20m

24 Limit block 2
25 Tire oil wrench 1

26 tire pry rod 2 Self-made

27 English system tools for the
engine include:
28 allen wrench 1/2 ″3/3″ 3/4″ 1
29 Socket wrench 1/4 ~15/16″ 18
30 Open end chain spanner 3/8″~1″ 11

Other tools are in the main frame tool kit.

7. Appendix drawing

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Electric schematic diagram

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