目 录

Table of Contents

一、产品系列说明

I. DESCRIPTION OF PRODUCT SERIES

二、产品使用指南

II. GUIDE FOR PRODUCT OPERATION

三、产品常见故障检查与处理办法

III. CHECK AND HANDLING METHODS FOR COMMON PRODUCT TROUBLES

1 匠心品质 创富万家
 一、产品系列说明

I. Description of Product Series

本说明书适用于矩形箱前顶自卸、瓦楞箱前顶自卸、U 型箱前顶自卸、矿用前顶自卸、渣土前

顶自卸等系列车型。
The instruction applies to such vehicle models as rectangle tank front-jacked dumper, corrugated tank front-jacked dumper, Type-U tank front-
jacked dumper, front-jacked dumper for mining use, front-jacked dumper for muck and etc.

2 匠心品质 创富万家
 二、产品使用指南
II. Guide for Product Operation

3 匠心品质 创富万家
前顶自卸组成：
Composition of front-jacked dumper:

1、底盘；2、车厢；3、副车架；4、液压系统；5、防护装置；6、自锁机构；7、加热装置（选装）
；8、环保盖（选

装）；9、智能系统（定位、控制）（选装）
。
1. Chassis; 2. Tank; 3. Auxiliary frame; 4. Hydraulic system; 5. Protective device; 6. Self-locking mechanism; 7. Heating device
(optional); 8. Environmental protection cover (optional); 9. Intelligence system (locating and control) (optional)

二、液压系统
II． II. Hydraulic System

1、液压系统组成
1. Composition of Hydraulic system

液压系统组成：取力器、传动轴、齿轮泵、液压油箱、手动操纵阀、分配阀、限位阀、液压油管、液压油缸等

组成。
Composition of Hydraulic system: power-take-off, drive shaft, gear pump, hydraulic oil tank, manual control valve, distribution valve, limit
valve, hydraulic oil tube, hydraulic oil cylinder and etc.

2、液压系统组成图示
2. Illustration of Hydraulic System Composition

4 匠心品质 创富万家
 液压油缸
分配阀 Hydraulic oil
限位阀
Distribution
valve Limit valve cylinder

液压油箱
Hydraulic oil
tank 液压油管
手动操纵阀 Hydraulic oil
Manual tube
control valve

齿轮泵
Gear pump

三、自卸车操作使用说明
III. Operation Instruction for Dumper

具体各车型可能存在差异，请以实物为准，如有疑惑，请与客户服务机构联系咨询。
Different truck models may vary with each other, subject to actual product. For any doubt, please contact customer service organ for
consultation.

1、操作步骤及注意事项
1. Operation Steps and Notices

5 匠心品质 创富万家
序号 操作步骤 注意事项
No. Operation Steps Notices

手动打开后门边钩 卸料前必须确认边钩已打开
1
Manually unlatch back door hook Confirm hook is unlatched before unloading

启动车辆，使气压达到系统工作压力
车辆气压≥7MPa
2 Start truck to make air pressure reach system working
Vehicle air presure≥7MPa
pressure

踩下离合器踏板
3
Step on clutch pedal

打开取力器开关，启动取力器
4
Switch on power-take-off switch and start power-take-off

挡位挂入低速档（1-4 档）
5
Engage gear to low gear (gear 1-4)

6 匠心品质 创富万家
 如发生打齿现象（听声音判断）说明变速箱齿轮和取力器
齿轮未能完全啮合应立即重新踩下离合器再缓慢抬起，直

至变速箱齿轮和取力器齿轮完全啮合。
缓慢抬起离合器踏板
In case of gear collision (judged by sound), it indicates gearbox gear and
6
Slowly release clutch pedal power-take-off gear are not fully engaged, for which clutch shall be re-stepped and

released slowly to the extent of full engagement between gearbox gear and

power-take-off gear.

卸料前，一定要确认车体两侧及后部没有人或物，做好安
全防范工作，并经常查看举升限位装置是否完好（若损坏

， 请停止使用并速与我公司客户服务机构联系），如因举升
将驾驶员座椅左手边操纵阀手柄扳至举升
限 位装置出现问题致使车辆翻车而造成的一切后果与我公
位置，货箱开始进行举升动作
7 司 无关。
Pull control valve at the left of driving seat to hoisting
It is a must to confirm there is no person or object at both sides of truck body and
position, when tank starts to hoist
truck rear and well perform safety protection before unloading. In addition,

constantly observe whether hoisting limit device is in good condition (if damaged,

please stop use and contact our customer service organ immediately). We assume no

7 匠心品质 创富万家
 responsibility for all the consequences of truck turnover as a result of faulty hoisting

limit device.

货箱在举升过程中，举升速度是依靠调节车
辆发动机的转速来实现的，通过加大油门的

方式提高转速 转速不得高于 2000 转/分钟

8
Hosting speed in tank hoisting process is adjusted by Rotary speed shall not be higher than 2000rpm

adjustment of engine rotary speed, which is accelerated by

stepping on the accelerator.

货物卸载完毕，将操纵阀手柄扳至下降位
置，货箱开始依靠自重下降，货箱下降的速

度是由操纵阀手柄扳动的角度大小来控制。 严禁货箱货物未完全卸载时，操作货箱下降动作。

9 When goods are fully unloaded, pull control valve to Operation for tank descending is strictly forbidden when goods in the tank are not

descending position, when tank starts to descend with its self fully unloaded.

weight, of which speed is controlled by angle of control

valve handle pulled.

8 匠心品质 创富万家
 在货箱举升或下降过程中，如要停止当前动 货箱下降到位后，请保持下降动作 10 秒，确保液压油缸无
作，需将操纵阀手柄扳至中停位置或踩下离 任何残余压力，防止货箱自动举升危及人、车安全。

合器踏板。 After tank fully descends, please keep descending operation for 10s to make sure
10
For a stop in the process of tank hoisting or descending, pull hydraulic oil cylinder is without residual pressure so as to prevent risk to person and

control valve handle to stop position or step on clutch pedal. truck safety in case of automatic tank hoisting.

升降操作完成后行车前，必须关闭取力器开关、使取力器
车辆行驶之前，先踩下离合踏板，将手动操
齿轮与变速箱齿轮完全分离，齿轮泵停止工作，再将操纵
纵阀扳至中停位置，挡位摘至空挡，关闭取
阀手柄置于中停位置，避免行车过程中出现自动举升的危
力器开关后，方可按正常行车程序行驶车
险，因此出现的问题与我公司无关。
辆。
11 After hoisting and descending operation and before truck running, it is a must to
Before truck running, first step on clutch pedal, pull manual
switch off power-take-off switch, fully separate power-take-off gear and gearbox
control valve to stop position, shift gear to neutral gear and
gear, stop working of gear pump, and pull control valve handle to stop position in
switch off power-take-off switch, and to this moment truck
order to prevent the risk of automatic hoisting during running, for which we assume
may run as per normal running procedures.
no responsibility.

9 匠心品质 创富万家
举升卸料时禁止事项：

Operations Forbidden during Hoisting and Unloading:

禁止重车时不开后门边钩进行举升。(造成翻车)
Hoisting without unlatching of back door hook is forbidden (which may cause turnover).

禁止举升状态下行驶车辆。（
造成翻车）
Truck running in hoisting state is forbidden (which may cause turnover).

禁止限位阀动作后，移动车辆进行卸料作业。
（造成限位阀损坏）
Movement of truck for unloading after limit valve action is forbidden (which may cause damage of limit valve).

禁止举升时发动机转速超过 2000 转/分钟。（

加大液压机件磨损使其寿命缩短）
Engine rotary speed higher than 2000 rpm during hoisting is forbidden (which accelerates wear of hydraulic part and shortens its
service time).

禁止操纵阀放在举升或下降位置时移动车辆。
（造成货箱自动举升）
Truck movement when control valve is at hoisting or descending position is forbidden (which may cause automatic tank hoisting).

10 匠心品质 创富万家
特别注意 如果用户未按正确操作说明使用，造成人员和部件损伤，我公司恕不承担任何责任。
Special Note: we assume no responsibility for personal injury and part damage caused by operation incompliant with correct operation
instruction by users.

11 匠心品质 创富万家
2、装卸、维修和行驶注意事项
2. Notices for Loading & unloading, Repair and Running

A、超载行驶或举升， 将会导致：
A. Overloaded running or hoisting, will cause:

 翻车
 Unguaranteed truck and personal saf
 车辆使用寿命缩短
 Loss of truck service life
 上装以及底盘早期损坏
 Early damage of upper part and chassis

B、偏载举升 ， 将会导致：
B. Unbalanced hoisting will cause:

 车辆与人身安全无保障
 Turnover

 爆胎，底盘以及上装损坏
 Flat tire, damage of chassis and upper part

 举升系统变形
 Deformation of hoisting system

12 匠心品质 创富万家
C、大于 5°的斜坡或松软地面举升，将会导致：
C. Hoisting on slope over 5° or soft ground will cause:

 翻车事故，直接威胁人身安全
 Turnover accident with direct threat to personal safety

 举升系统发生损坏，如：拉缸 α>5°
 Damage of hoisting system, for example: scuffing of cylinder

D、在部分卸载的情况下向前行车，将会导致：
D. Running with partial unloading will cause:

 前轮离地、翻车等
 Front wheel above ground, turnover, etc

 举升机构、后铰链变形

Deformation of hoisting mechanism and back hinge

13 匠心品质 创富万家
E、人员站在没有支撑牢固的车厢下，将会导致：
E. Person standing underneath not firmly supported tank will cause:

 液压系统泄漏危及生命
 Hydraulic system leaks with life threat

 旁人误操作危及生命
 Misoperation by non-staff with life threat

F、卸料未净快速下降车厢将会导致：
F. Rapid descending of tank with materials not fully unloaded will cause:

 举升机构受损变形
 Damage and deformation of hoisting mechanism

 底盘车架受冲击损坏
 Impacted damage of chassis frame

14 匠心品质 创富万家
3、日常维护、保养
3. Routine Maintenance

（1）、每举升 50—100 次所有润滑部位加注润滑油脂

(1) Fill lubrication grease to all lubrication positions for every 50-100 times of hoisting

润滑部位：油缸上、下托（四处）；平衡板（六处）；后翻转座（四处）
Lubrication position: upper and lower pallets of oil cylinder (four places); balance plate (six places); back tilt bases (four places)

润滑油脂加注部位
Positions to be filled with
lubrication grease

15 匠心品质 创富万家
（2）、每半个月检查紧固连接部位螺栓一至两次，新车使用 15—30 天所有紧固件紧固一遍。
(2) Check bolts at fastening connection positions one to two times per half a month and fasten all fasteners after 15-30 days operation of new

truck

此部位为重点
部位，保证螺
栓紧固强度
This position is critical, of
which bolt fastening strength 紧固点
shall be guaranteed Fastening point

（3）、液压油路接头密封，由于密封圈的老化等原因，液压油路可能会出现渗漏、漏油现象，请经常性的检查所

有油路、油管接头处，渗漏处紧固或者更换密封圈。
(3) Check sealing of hydraulic oil circuit joint as hydraulic oil circuit may be exposed to penetration and oil leakage due to such reasons as

aging of sealing ring. Please check joints of all oil circuits and oil tubes on a regular basis and fasten leaking position or replace sealing ring.

（4）、油路、气路走向检查，避免与转动、发热部位干涉，并保证油管、气管与底盘捆绑牢固，布局合理可靠；请

每天进行检查。
(4) Check route of oil circuit and gas circuit to avoid interference with rotating and heating part and make sure oil tube and air tube are firmly
bound with chassis and in reasonable arrangement; please check on a daily basis;

16 匠心品质 创富万家
 发热部位
Heating part

（5）、经常检查液压油箱内的液压油量以及使用状况。为保证车辆的正常举升，液压油量不得低于油箱容积的

80%, 液压油变质应立即更换。北方地区冬季使用 N32 号液压油， 夏季选用 N46 号液压油；建议使用品牌：长城

牌。具 体可参照下表：
(5) Check constantly amount and application conditions of hydraulic oil inside the hydraulic oil tank. For normal hoisting of truck, amount of
hydraulic oil shall not be lower than 80% of oil tank volume, and replace immediately deteriorated oil if any. For Northern China, use N32
hydraulic oil in winter and N46 hydraulic oil in summer; recommended brand: Great Wall. Refer to following table for details:

17 匠心品质 创富万家
 粘度等级 工作温度(℃)

使用环境 (GB3441) Working Temperature (℃)

Service Environment Viscosity Class 最低启动 最低运行 最高运行

(GB3441)
Minimum Start Minimum Operation Maximum Operation

东北地区冬季(-40℃以下地区)
10
Winter of Northeast China(Area blow -40℃)

东北地区冬季(-10℃～－40℃)
15 -18 5 38
Winter of Northeast China(-10℃- -40℃)

华北、西北地区
22 -10 16 48
North China and Northwest China

华中、华东、西南
32 0 23 58
Central China, East China and Southwest China

华南
46 5 30 65
South China

南方夏季 40℃以上
68 10 38 65
South with temperature above 40℃ in summer

18 匠心品质 创富万家
（6）、注意定期更换液压油滤清器和高低压油管。每次更换液压油时必须更换液压油滤清器；使用
两年的车辆需及时更换高低压油管，经常检查油管使用状况，如发现油管表皮开裂、磨损、起鼓等现象，必须立即

更换同等规格的油管。
(6) Pay attention to replace hydraulic oil filter and high and low pressure oil tube on a periodical basis. For every replacement of hydraulic
oil, replace also hydraulic oil filter; replace high and low pressure oil tubes of truck with over two-year operation, check constantly
application conditions of oil tubes and replace with oil tube with the same specification in case of skin crack, wear, bulge and etc. of oil
tube.

（7）、限位阀经过长时间使用后可能出现调节螺丝松动、油污使伸缩限位杆伸缩不灵敏、限位阀固定螺丝松动，
造成举升角度变化或限位阀失灵、必须每周检查、紧固并清理污物，保证举升角度在 43°-45°之间。
(7) After long-time use, limit valve may be exposed to looseness of adjustment screw, insensitive stretch of stretchable limit rod due to oil stain
and looseness of limit valve fixation screw that lead to change in hoisting angle or failure of limit valve, therefore, it is a must to check,
fasten and remove impurities on a weekly basis and make sure hoisting angle is within 43°-45°.

19 匠心品质 创富万家
 举升角度 43°-45°
Hoisting angle
43°-45°

限位阀伸缩杆
Stretchable rod of
limit valve

（8）、进行车辆检测与维修时必须将安全支架之气，将车厢与安全支架牢固接触，手动操纵阀确认在中停位置后

人员方可进入车厢下面进行维修作业。
(8) For truck testing and repair, it is a must to put up safety support, firmly contact tank with safety support, and confirm manual control valve is
at stop position, when personnel is allowed to go under the tank for repair.

安全支架
Safety

20 匠心品质 创富万家
4、新车及底盘保养
4. Maintenance of New Truck and Chassis

自卸车的使用寿命，工作可靠性及经济性，在很大程度上取决于新车的合理使用及维护保养，因此在使用

时须认真检查并遵守下述要求。

As service life, working reliability and economical efficiency of dumper is dependant on reasonable operation and maintenance of new truck to
a large extent, following requirements shall be observed carefully for operation.

（1）、新车检查
(1) Check of NewTruck

①、检查液压油箱中的油量是否充足，如不足须按规定的油品规格型号进行添加。在气压不低于 0.78MPa 的情况下

检查手动操纵阀，检查气路有无漏气，液压系统有无渗漏。

①. Check whether oil amount in the hydraulic oil tank is sufficient and fill according to specified oil quality and specification if insufficient.
With air pressure not lower than 0.78MPa, check manual control valve, check whether gas circuit leaks gas and whether hydraulic system leaks.

②、在空载情况下，反复操作使用车辆，检查液压油缸、齿轮泵、手动操纵阀等部件工作是否正常。例如：液压油

缸在升降过程中有无卡滞、窜动、弹跳及异响等。

21 匠心品质 创富万家
②. With truck unloaded, operate repeatedly the truck to check whether such parts as hydraulic oil cylinder, gear pump, manual control valve
and so forth function well. For example: whether there is jamming, violent movement, jump and abnormal sound during hoisting and
descending of oil cylinder.

③、经过空载整车操作 8-10 次后，未发现存在上述问题，则该车工况良好。

③. Truck working condition is deemed as good when no above listed issue is found after 8-10 times of operation of complete unloaded truck.

（2）、新车走合
(2) Running-in of Newtruck

①、自卸车倾卸机构的走合期，用车厢升降次数来衡量，升降次数达 1000 次后须更换液压油。

①. Running-in period of dumper dumping mechanism is measured by tank lifting and descending times. Replace hydraulic oil after 1000 times
of lifting and descending.

②、在走合期内，其装载重量要求逐渐增加，并加以控制，具体规定如下：
②. Within running-in period, loading weight shall increase gradually and be under control, detailed as following:

升降次数 装载重量

Times of Hoisting and Descending Loading Weight

22 匠心品质 创富万家
 100 次内 ≤50%

Within 100 times

100-300 次内 ≤60%

Within 100-300 times

300-600 次内 ≤75%

Within 300-600 times

600-1000 次内 ≤90%

Within 600-1000 times

③、车厢在举升时，发动机转速不允许超过 2000 转/分。

③. Engine rotary speed shall not exceed 2000 rpm during tank hoisting.

④、走合期内，应经常检查液压系统、操作系统有无渗漏油、气现象，注意液压油量。
④. Within running-in period, check constantly whether hydraulic system and operation system have the phenomena of oil leakage and gas
leakage and pay attention to hydraulic oil amount.

23 匠心品质 创富万家
⑤、走合期内，应经常检查取力器和齿轮泵啮合和分离是否正常，有无异响或高温现象。
⑤. Within running-in period, check constantly whether engagement and separation of power-take-off and gear pump are normal and whether
there is abnormal sound or high temperature.

24 匠心品质 创富万家
5、技术保养
5. Technical Maintenance

一级技术保养 二级技术保养 三级技术保养

Primary Technical Maintenance Secondary Technical Maintenance Tertiary Technical Maintenance

25 匠心品质 创富万家
 当举升机构的升降次数达到
800—1000 次时，可进行一级 当举升机构的升降次数达到 3000
技术保养，其内容有： —4000 次时，可进行二级技术保
1.结合新车磨合期保养规定， 养，其内容有：
按其规定项目进行； 1. 执行一级保养的所有项目；
2.注意并检查液压油缸上下支 2.检查车厢、副车架、备胎架等
架，观察各运动部件及其相邻 状况，特别要注意检查焊
的固定件是否有损坏或变形； 缝是否有开焊、裂纹等现象；
技术保养
Technical
3.打开液压油箱底部的放油塞 3.检查齿轮泵、取力器、液压缸
Maintenance
及底部球阀，待油放尽后，清 等运动部件工况并保养和维修或
除积存在油箱内污物并更换液 更换易损件。
压油。 Secondary technical maintenance is carried out
Primary technical maintenance is carried
out when hoisting times of hoisting
mechanism is up to 800-1000, involving:
1. Maintain in accordance with
maintenance regulations for new truck
running-in period;
2. Notice and check upper and lower
supports of hydraulic oil cylinder and
observe whether all moving parts and
their adjacent fixation parts are
damaged or deformed;
当举升机构的升降次数达
20000 次左右时，可进行
三级技术保养，其内容有：
1.执行二级保养的所有项
目；
2.拆检液压缸、取力器、操
纵阀等部件中运动件的磨
损及易损件的损坏状况，并
更换某些损坏的元件；
3.清洗液压油箱，更换液压
油和加注各部件的润滑油
脂。
when hoisting times of hoisting mechanism is Tertiary technical maintenance is
up to 3000-4000, involving: carried out when hoisting times of
1. Perform all items of primary maintenance; hoisting mechanism is up to 20000
2. Check conditions of tank, auxiliary frame, approximately, involving:
spare tire rack and etc. and give special 1. Perform all items of secondary
notice to check whether welding seam maintenance;
breaks and cracks; 2. Overhaul wear of moving parts
3.Check working conditions of such and damage of consumable parts
moving parts as gear pump, power-take-off, inside hydraulic cylinder,
hydraulic cylinder and etc., and maintain, power-take-off, control valve and
repair or replace consumable parts. etc. and replace some damaged

3. Unplug oil drain plug at hydraulic oil elements;

26 匠心品质 创富万家
tank bottom and open bottom ball valve to 3. Clean hydraulic oil tank, replace
fully drain oil, remove impurities hydraulic oil and fill lubrication grease
accumulated inside the oil tank and replace of each part.
hydraulic oil after oil drainage.

27 匠心品质 创富万家
 三、产品常见故障检查与处理办法
III. Check and Handling Methods for Common Product Troubles

序号 故障名称 原因分析 排除方法

No. Name of Trouble ReasonAnalysis Troubleshooting

按规定油品规格型号加足液压油
1、液压油量不足
Fill hydraulic oil as per specified oil quality,

1. Insufficient hydraulic oil

specification and model

车厢不能举升 2、液压油箱下方球阀未打开
1 打开球阀
2. Ball valve at lower part of hydraulic oil tank is not
Failed tank hoisting
Open ball valve
open

3、取力器未打开 重新开启取力器

3. Power-take-off is not open Reopen power-take-off

28 匠心品质 创富万家
 4、手动操纵阀气管漏气或损坏
重新接好气管或更换操纵阀
4. Gas leakage or damage of manual control valve gas

Reconnect air tube or replace control valve

tube

5、分配阀阀芯卡滞或分配阀损坏
清洗阀芯或更换分配阀
5. Jamming of distribution valve core or damage of

Clean valve core or replace distribution valve

distribution valve

6、限位阀伸缩杆不能回位或损坏
调整伸缩杆或更换限位阀
6. Stretchable rod of limit valve fails to reset or

Adjust stretchable rod or replace limit valve

damages

车厢举升有窜动 反复升降操作，排尽空气
1、液压系统存有空气
现象或举升太慢 Repeat lifting and descending operation to full
2
1. Air inside hydraulic system
Violet movement exhaust air

29 匠心品质 创富万家
 during tank hoisting or 2、操纵阀闭合不严 检查、调整操纵阀

over slow hoisting 2. Untight closing of control valve Check and adjust control valve

3、齿轮泵轻度泄漏 检修或更换齿轮泵

3. Minor leakage of gear pump Overhaul or replace gear pump

按规定油品规格型号加足液压油
4、液压油量不足
Fill hydraulic oil as per specified oil quality,

4. Insufficient hydraulic oil

specification and model

1、操纵阀气室窜气、漏气
检修或更换操纵阀
1. Air blow and air leakage in air chamber of control

车厢不能下降 Overhaul or replace control valve

valve
3
Failed tank descending
2、分配阀阀芯卡滞或分配阀损坏 清洗阀芯或更换分配阀

2. Jamming of distribution valve core or damage of Clean valve core or replace distribution valve

30 匠心品质 创富万家
 distribution valve

3、液压油缸变形或涨缸 检修或更换

3. Deformation or scuffing of hydraulic oil cylinder Overhaul or replace

按规定油品规格型号加足液压油
1、液压油量不足
Fill hydraulic oil as per specified oil quality,

1. Insufficient hydraulic oil

specification and model
车厢举升不到位

4 Failed tank hoisting 2、操纵阀闭合不严 检修或更换操纵阀

right position 2. Untight closing of control valve Overhaul or replace control valve

3、限位阀伸缩杆伸出长度过长 调整限位阀伸缩杆

3. Excessive stretch of stretchable rod of limit valve Adjust stretchable rod of limit valve

车厢自动下降 1、操纵阀闭合不严 检修或更换操纵阀

5
Automatic tank 1. Untight closing of control valve Overhaul or replace control valve

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descending 2、分配阀内泄漏 检修或更换分配阀

2. Leakage inside distribution valve Overhaul or replace distribution valve

32 匠心品质 创富万家