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Operating manual
Operation manual of 10X8 Carrier
Company Introduction
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
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
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.
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
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.
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
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
Open pipe shape, crises-cross shaft free joint type with needle bearing, totally 6 pieces.
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.
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
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.
Steering device, brake pedal, accelerator pedal, down hill reducer pedal, vehicle lights
3-3 adjust shaft of air collecting door, shift shaft (not indicated in the
picture)
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.
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.
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.
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.
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.
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
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
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
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
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
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
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.
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.
接油罐
接动力缸后腔
接油泵
Fig. 5-2
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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.
1. Air supply
Air compressor air dryer air reservoir ball valve air filter anti-coagulator
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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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
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
7. Appendix drawing
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