Thank you for purchasing Chengli Special Automobile Co., Ltd Fecal suction truck series products produced. In order for you to make better use of our products and use the truck to create benefits, we provide you with this manual.
How to get the best performance of your fecal suction truck is our common goal. It depends more on your proficiency in vehicle operation and the quality of vehicle maintenance. Our factory strongly hopes that you Before use, if you can read this manual thoroughly and have a good grasp of the structure introduced in it, we will provide you with the corresponding second-class vehicle chassis "Instruction Manual" as an attachment to the manual.
The fecal suction truck in our factory is modified from high-quality automobile chassis at home and abroad. It absorbs the advantages of similar truck s at home and abroad. It has the characteristics of reasonable structure, reliable performance, convenient operation, and beautiful appearance. It is suitable for pumping and discharging water. Various fluids such as feces, oil, and mud.
In order to fully meet the different requirements of users as much as possible, the structure of the suction truck is continuously improved and perfected. Therefore, it may appear that the introduction of the description is different from the actual structure. Please understand it without notice.
1. Partial composition
1.1 Tank body
The tank is the main body of the manure truck, and the top of the tank is provided with air holes and suction and discharge holes. The air hole communicates with the water-gas separator as a channel for air to enter and exit the tank. The inlet hole is usually sealed and can be opened for maintenance, and the suction and discharge hole is connected with a suction hose and a siphon pipe is connected to the bottom of the siphon to enter and exit the tank.
There are walk-in boxes in the middle of both sides of the tank, which are usually used to store the suction hose and stand up during maintenance. The tank body is equipped with an anti-sway plate to reduce the damage to the tank body and the connection part of the frame caused by the violent sloshing impact of the liquid caused by the driving of the vehicle. The front head is equipped with an observation measuring tube, which is convenient for monitoring the loading capacity and preventing overloading. There is a cleaning hole at the bottom, which is usually sealed. When cleaning the tank, the cleaning hole cover can be opened to allow the sewage to flow out.
The tank body is rigidly connected and installed on the frame, with a cushion between the two, which can reduce the damage to the tank body caused by vehicle vibration.
Since the suction hose is always immersed on the liquid surface, the air in the tank becomes thinner and thinner because it cannot be replenished after being sucked. As a result, the pressure in the tank is lower than atmospheric pressure, and the liquid is under the action of compressed air. , Discharge the tank through the fecal suction hose.
1.2, vacuum pump
XD-70 vacuum pump is mainly used to refit manure trucks. The modified fecal suction truck is pumped out of the air in the tank and the pipe through the pump, so as to suck flowable fecal water and other liquids. This pump is widely used in the sewage pumping equipment of the environmental sanitation department. The XD-70 rotary vane vacuum pump is an advanced product after improvement. It mainly adds a babbitt alloy boss, so that the rotary vane always maintains a reasonable gap with the pump body, and avoids the safety of centrifugal force when rotating at high speed. The noise thrown by the blades and the high temperature friction caused by this increase the vacuum and service life of the pump, and the vacuum pump must be short of oil.
1.3, power take-off
The operation of the vacuum pump of the fecal suction truck is driven by the power of the engine through the power take-off and the drive shaft. The power take-off is installed on the right side of the transmission, and the upper part of the operating handle is located on the middle plate of the cab.
This kind of power take-off is composed of input gear, input shaft, intermediate gear, intermediate shaft, output shaft, output gear, fork shaft, fork shaft, etc. and an operating handle.
The input gear and the transmission output gear are normally meshed pairs. Before starting the vacuum pump, set the transmission output gear to a constant meshing pair. Before starting the vacuum pump, put the transmission into neutral, then start the engine, disconnect the clutch, and turn on the power take-off switch. At this time, the fork shaft moves forward, and the fork drives the output gear on the output shaft to slip and mesh with the intermediate gear. The output shaft is transmitted to the input gear by the spline and the output gear, the intermediate gear is transmitted to the output gear, and then the output coupling is transmitted to the drive shaft. Thereby driving the vacuum pump to rotate.
1.4 Four-way valve
The vacuum pump can only rotate counterclockwise (facing the front of the truck ). To inhale air from the tank or discharge air into the tank, you need to use a four-way valve.
The four-way valve communicates with the atmosphere of the tank, vacuum pump, and oil return tank respectively. A partition is arranged in the four-way valve. Change the suction direction of the vacuum pump. When the four-way valve connects the tank with the vacuum pump, the manure truck will start the discharge operation.
1.5 Water and gas separator
The water-gas separator is located at the front top of the container, and passes through the container at the rear. There is an air pipe inside and rectangular holes are opened on both sides of the pipe for air to enter and exit the tank. During the suction operation, the air in the tank comes out of the rectangular hole, the volume suddenly expands, the flow rate decreases, and the number of heavy water molecules decreases, which can reduce the harm to lubricating oil and mechanical parts.
1.6, oil and gas separator
The compressed air discharged from the vacuum pump has a high speed and truck ries a large number of oil droplets when it breaks through the oil film layer. An oil and gas separator is installed to reduce oil consumption and prevent pollution. The oil and gas separation is located in the right middle part of the dung truck frame, connected to the front of the vacuum pump, and back to the fuel tank. There is an oil baffle pipe in the oil and gas separation. When compressed air enters, its volume suddenly expands, the flow rate decreases, and the flow direction is changed. It flows out through the porous oil baffle pipe. As the flow rate of oil and gas molecules decreases, the impact on the wall of the vessel and the pore wall is intensified, and part of the heavy oil molecules adhere On the vessel wall, the buckle-shaped oil droplets are condensed, along the vessel wall and the spill pipe, flow into the oil return tank, and the compressed air after the primary purification flows to the upper side of the oil return tank.
1.7. Oil return tank
The oil return tank is located in the right middle part of the frame, with an oil-air separator on the left and a four-way valve on the right.
There is an oil retaining net in the oil return tank, and the inlet and outlet are not connected. The compressed air flowing in from the oil-air separator must pass through multiple obstacles before being discharged to the four-way valve. Because the volume of the oil return tank suddenly doubles, the air flow rate is obvious Reduced, coupled with obstacles such as oil retaining nets, compressed air must pass through multiple obstacles here before it can be discharged to the four-way valve. Because the volume of the return tank suddenly doubles, the air flow rate is significantly reduced. The oil molecules in the oil intensify the collision, adhere to the inner wall and the mesh surface, and then flow into the bottom, and the compressed air that has been purified again flows to the four-way valve.
There is a through cock below the oil return tank, which can control the lubricating oil blades supplied to the vacuum pump. There is no liquid level tube, and the oil storage and oil quality can be observed.
The boom is located at the top of the rear of the container. It is composed of a boom seat, a connecting pipe counterweight, a support frame and other parts. The front is connected with a fecal suction hose, and the rear siphon boom seat can operate. The boom can rotate more than 270. Due to the counterweight, it can withstand the labor intensity of the suction tube. The angle of the connecting pipe at both ends of the support tube is 90, and the curved outer diameter is equipped with ceramic holes, which are usually sealed. When the suction hose or When the straw is blocked, you can open the ceramic cleaning hole cover to remove the blockage.
1.9 Indentation mechanism
The locking mechanism is mainly composed of fixing devices, and its function is to ensure the sealing of the cleaning hole cover. The fixing device is located under the right middle part of the frame and is mainly composed of an operating rod, a locking pin, a positioning plate, etc., and the two are connected by a tie rod, a threaded fork joint, etc. When the operating rod moves backward, the pull rod moves forward, and the rotating shaft drives the plate arm to swing counterclockwise, so that the cleaning hole cover is tightly blocked to achieve the sealing purpose. The operating rod is provided with a locking pin, a spring, a pull rod and a pinch handle. When the joystick moves backward and the locking lock slides into the positioning groove along the outer ring of the positioning plate, it is pushed into the positioning groove by the spring at the back end. Because the five sides of the locking pin are restricted, it cannot be ejected. The positioning groove can ensure that the rod is not locked. Due to the vibration and turbulence during driving, it is later called to realize the tight function.
2.1. Lubricating oil volume adjustment
The oil storage in the oil return tank should not be too much, and the oil level pipe should be slightly lower in the middle. Excessive oil storage and supply will easily affect the oil-gas separation effect and increase the oil consumption. On the contrary, it will affect the cooling and make the vacuum pump temperature. Rise too fast.
The size of the oil supply is controlled by a straight plug. When the handle is at right angles to the axis of the oil inlet pipe, it is fully open, when it is parallel, it is fully open, and when it is parallel, it is fully closed. When there is obvious oil mist at the exhaust port of the four-way valve, The oil supply should be reduced.
2.2. Adjustment of locking mechanism
A. The locking mechanism should be adjusted when there is leakage at the cleaning hole cover, and the pressing force of the plate arm on the cleaning hole cover should be increased to improve the tightness. The specific steps are as follows:
Twist the rod end at the left-handed screw to the left (viewed from the front to the rear) to shorten the threaded fork joint
Between the head connecting rod fixing sleeves, the connecting rod drives the rotating shaft and the plate arm to swing counterclockwise, and the lower cleaning hole cover is tightly supported until the leakage is eliminated.
If it is impossible to continue to tighten the cleaning hole cover, and the leakage has not been eliminated, the sealing gasket should be replaced.
1. Clean the hole cover 2. Seal gasket
B. Replacing the sealing gasket or cleaning the tank corresponds to the lower left-hand screw and screwing the end to the right, but it extends the distance between the threaded fork joint and the connecting rod fixing sleeve, causing the plate arm to swing clockwise, loosening the cleaning hole Then push the operating rod backward to make the locking pin out of contact with the two sides of the positioning groove, grasp the pinch handle, pull the locking pin out, and then pull the operating rod toward the front of the truck to force the rail to move to the rear of the truck , The connecting rod drives the rotating shaft and the cleaning hole cover to swing clockwise to disengage from the cleaning hole.
C. After the replacement and cleaning operation is completed, push the joystick toward the rear of the truck to make the locking pin fall into the positioning groove, and adjust the sealing performance of the cleaning hole cover after heating.
Three, use and operation
3.1. Preparation before homework
A. Make the rear of the manure truck as close to the operating point as possible;
B. Lower the oil tank straight through the cock handle plate to an angle of about 45° with the axis of the oil inlet tank, observe the oil inlet pipe, there should be lubricating oil flowing;
C. Open the side door of the walking platform and take out the suction hose to swing it backwards without bending.
3.2, suction operation
A. Insert the fecal suction hose as deep as possible into the fecal liquid to ensure that the end of the pipe is always below 300mm from the liquid level during operation;
B. Push the handle of the four-way valve to be perpendicular to the ground;
C. Put the transmission into neutral, then start the engine, disconnect the clutch, pull the power take-off switch backwards to engage the power take-off, and the vacuum pump starts to run;
D. Increase the throttle and observe the vacuum gauge to keep the vacuum gauge reading at 53-80kpa;
E. Open the toolbox in the cab, pull out the buzzer switch, and turn on its power;
F. Workers should pay attention to monitor the situation near the entrance of the suction hose, and use appropriate tools to block debris to avoid blockage;
G. The operator can pass through the observation mirror on the upper part of the rear head. When the liquid level reaches the middle of the observation mirror, the driver should be notified, and the manure suction hose should be quickly pulled off the ground or the four-way valve should be closed. Under normal circumstances, the buzzer will emit a sound and light signal at this time, the driver should reduce the throttle when receiving the signal, push the power take-off switch forward and out, the vacuum pump stops, press the buzzer switch to cut off its power;
H. Close the fuel tank through cock handle parallel to the axis of the fuel inlet tank;
I. After flushing the hose, put it back into the platform box, close the side door, and make the boom facing the upper part of the cab;
J. Make the handle perpendicular to the road axis;
K. The dung truck drives away from the operating point.
3.3. Discharge operation
1. Point the suction hose towards the manure tank;
2. Pull the rear handle of the four-way valve parallel to the ground, open the anti-overflow valve and make its handle parallel to the pipeline axis;
3. Repeat the operation steps c and d in 3.2;
4. After the fecal liquid in the tank is discharged, the driver should lower the power take-off handle in time and push it forward, and the vacuum pump will stop running;
5. Repeat the operation steps h and i in 3.2;
6. The dung truck drives away from the operating point.
3.4, working principle diagram
A. When sucking feces: vacuum to form negative pressure
C. In standby mode:
4.1, daily routine maintenance
A. Check the oil in the return tank. The oil level should be in the middle of the liquid level pipe. If the oil level is not visible, it indicates that it needs to be added. If the oil becomes white or obvious impurities, the oil should be changed in time;
B. Check whether the operating handle of the locking mechanism is in the closed position, and whether there is any leakage at the seal of the cover;
C. Check whether the vacuum pump and the power take-off work normally.
4.2. Routine weekly maintenance
A. Clean the exterior of the vehicle;
B. Check and tighten the bolt connections of various parts of the vacuum pipeline.
4.3, 3000Km maintenance
A. Check the tightness of the connecting bolts of the cross shaft flange between the vacuum pump and the power take-off;
B. Check and tighten the connecting parts of the vacuum pump frame;
C. Check and tighten the bolt connections of the tank, return tank, four-way valve, etc.
4.4, 1200km maintenance
A. After cleaning the oil return tank and the filter screen, replace the lubricating oil. Use 30# mechanical oil in summer and 20# mechanical oil in winter;
B. Check whether the cross shaft bearing of the transmission shaft is loose or not, and check the fastening of each fork flange female.
4.5, 4800km maintenance
A. Check the working condition of the bearing of the power take-off and replace it in time if necessary;
B. Disassemble and inspect the vacuum pump for adjustment;
C. Repair empty cans, remove rust and paint on the exterior.
Five, failure analysis and elimination
|Failure phenomenon||Cause Analysis||elimination method|
|1. Can't suck feces or suck feces for too long||1.1. The four-way valve is switched in place
1.2, the anti-overflow valve is not opened
1.3. The suction and discharge hose is inserted into the fecal liquid and the lower is less than 300mm
1.4. The road is blocked and the rubber layer in the hose falls off
1.5. Pipeline connection
|1.1, lower the handle to the vertical state
1.2. Open the anti-overflow valve
1.3. Make it always more than 300mm away from the liquid level
1.4. Clear the blockage and replace the hose
1.5. Tighten the pipe clamp fasteners and replace the sealing gasket
|2. After the vacuum pump stops rotating, the fecal liquid flows back.||2.1. The suction and discharge tube was not pulled out in time||2. Pull out the suction and discharge hose in time to get rid of the fecal liquid|
|3. The noise of the vacuum pump is abnormal and the temperature rise is too high.||3.1. Impurities or debris in the pump cavity
3.2, cam sleeve wear
3.3. Insufficient lubricating oil, mixed with impurities
|3.1. Dismantling, cleaning the vacuum pump and replacing worn parts
3.2. Replace the cam sleeve
3.3 add enough or replace lubricating oil
|5. Oil leakage in the return tank||5.1. Loose connection bolts
5.2. Replace the sealing gasket
5.3, too much lubricant
|5.1 Tighten the bolts
5.2. Replace the sealing gasket
5.3. The lubricating oil level is located in the middle of the liquid
|6. The vacuum gauge has a low reading or no indication.||6.1, the vacuum pump speed is too low
6.2. The vacuum gauge tube is blocked
6.3, the vacuum gauge is damaged
6.4 Same as 1.1
|6.1 Increase the throttle
6.2 Clear blockage
6.3 Update vacuum gauge
6.4 Replacing the rotary vane
|7. Clean the leaking hole cover||7.1, the left-hand screw is not in place
7.2. Damage to the gasket is invalid
7.3, the tie rod is too long
|7.1. Screw down the left-hand screw in place
7.2. Replace the sealing gasket
7.3. Adjust the length of the rod
|8. The locking handle cannot be opened||8.1. The left-hand screw is not loosened||8.1. Loosen the left-hand screw first, and then squeeze the spring lever to lock the lock|
6. List of accompanying documents, tools and spare parts
1. Qualification certificate of suction truck.
2. Manual for the suction truck
3. Qualification certificate of type truck.
4. Instruction manual for type truck.
5. Type truck-mounted tools.
The main accessories are as follows:
|Serial number||Material name||Specification model||Dosage||Remarks|
|2||Vacuum pump||5T vacuum pump||1|
|3||Big four-way valve||1|
|6||Oil and gas separator||1|
|7||Water vapor separator||1|
|8||Butterfly valve||φ219 butterfly valve||1|
Seven, after-sales service
1. When you need cbm consultation or maintenance, please contact our after-sales service department and keep the truck purchase certificate properly to confirm that the truck is within the warranty period.
2. The after-sales service of the chassis vehicle is the responsibility of the chassis vehicle manufacturer; the factory only implements the "three guarantees" for the special modified part of the vehicle. If there is a failure or problem during use, please call or write to us. We will receive The information will be analyzed within 24 hours, and a clear answer and processing will be given.
3. New truck s should be run and maintained in accordance with regulations before they can enjoy the "three guarantees"
(1) Three packs content and time limit:
a. The vehicle can enjoy the "Three Guarantees" for one year from the date of purchase (subject to the vehicle purchase invoice) and the mileage within 3000 kilometers (both conditions must be met);
b. The whole vehicle is fully packaged within ten days from the date of sale (subject to the date filled in the after-sales service truck d), that is, all parts are damaged due to manufacturing quality or cannot meet the performance requirements of the whole machine , Our factory implements "Three Guarantees";
c. During the "three guarantees" period, if the failure is caused by quality reasons, our company implements the guarantee;
d. During the "Three Guarantees" period, the assembly has quality problems. After the company, supporting units and maintenance service outlets have repaired more than two consecutive times (referring to the same failure), the assembly or component cannot reach its technical performance and cannot be used. Be replaced
e. The vulnerable parts of the truck can enjoy three guarantees for half a year.
(2) The following items are not within the scope of "Three Guarantees":
a. Vehicles that do not follow the regulations of the vehicle and have not undergone compulsory running-in period maintenance;
b. Vehicles that fail due to abnormal use and self-change of vehicle structure;
c. Traffic accident vehicles (including unlicensed driving and illegal vehicles);
d. Vehicles that have been disassembled or adjusted improperly without the consent of the company;
e. Vehicles whose assembly or components are disassembled into parts without the consent of the company, and the place of origin cannot be identified and the responsibility and cause analysis cannot be confirmed;
f. Accident vehicles handled without the company's consent or identification;
g. Vehicles that malfunction due to improper adjustment or failure to check and adjust;
h. Low-value, easily-consumable and vulnerable parts (such as electrical appliances, glass, rubber, plastic parts, etc.); various standard parts, bearings.
4. For vehicles that do not fall within the scope of the "Three Guarantees", our company is responsible for the users and provides convenient maintenance services, but should be charged appropriately.
5. For your reasonable suggestions for this product or other products of our factory, please put it forward to our service department in the future so that our factory can adopt it in time. All the staff of our factory express our most sincere thanks to you!