VaticanMaintenance and Repair Guide for Electric Ash Dump Trucks

Electric Ash Hopper Truck Maintenance and Repair Guide \ n \ nI. Key Points for Battery System Maintenance

Before charging, make sure there is 15% to 20% of the battery remaining to avoid battery capacity attenuation caused by deep discharge (below 20%) or overcharging (more than 8 hours).

Using the original charger, keep the air circulating during charging and avoid charging in high-temperature environments (above 65℃), which can extend the battery life by 30%.

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Before charging in winter, the battery temperature needs to rise above 0℃. In an environment of -30℃, the charging efficiency should be guaranteed in conjunction with a preheating system.

When idle for a long time, charge it at least once a month to prevent the battery from being damaged due to low power.

Ii. Maintenance Specifications for Mechanical Components

Check the lubricating oil level of the gearbox every month and replace the grease that complies with the ISO VG320 standard regularly to reduce the wear of components.

The key parts such as the tensioning screws of the lifting chain and the hydraulic cylinders need to be reinforced every quarter to ensure the stability of the load-bearing structure.

The tire pressure should be maintained at 2.5-3.0 bar. A deviation of more than 10% will lead to a reduction of more than 9% in the range. Wear depth exceeding 3mm requires immediate replacement.

Ceramic brake pads should be checked for thickness every 3,000 kilometers, and the replacement cycle is three times longer than that of ordinary brake pads.

Iii. Electrical System Inspection Process

Clean the oxide of the controller connectors every week to prevent circuit failures caused by poor contact.

Regularly monitor the communication status of the CAN bus. Abnormal signals need to be promptly investigated for sensor or wiring harness issues.

The remote diagnosis system monitors over 120 parameters in real time, including motor temperature (threshold 85℃) and battery SOH (alarm when health degree < 80%).

When the indicator light on the dashboard is abnormal, prioritize checking the fuse (specification 30A) and the relay contacts.

Iv. Daily Work Protection

Use neutral car wash agent (concentration 1:10) to clean the car body, avoiding charging ports, controllers and other precision components to prevent high-pressure water from penetrating.

After construction, concrete residues at the transmission shaft and bearings should be removed to prevent hardening and mechanical jamming.

For construction sites with a dust content greater than 200mg/m³, motors with an IP69K protection level should be selected, and the heat dissipation grille should be cleaned weekly.

When parked in coastal areas, the frame needs to be sprayed with an anti-rust coating, and the salt spray corrosion protection period is shortened to the normal working condition.

V. Maintenance Operation Standards

Requirements for fault type handling plan tools

Motor overheating ‌ Shut down, after cooling, check the cooling fan, replace the thermal grease (thermal conductivity ≥5W/m·K) infrared thermometer and thermal paste syringe

 Hydraulic failure ‌ Check for clogged oil passage (filter element replacement cycle 500 hours) or stuck solenoid valve (clean valve element) Pressure gauge, ultrasonic cleaner

 Steering failure ‌ Calibrate the steering Angle sensor, check the wear of the universal joint (replace if > 2mm), laser calibrator, vernier caliper

Through the above-mentioned standardized maintenance process, the service life of the equipment can be extended by more than 30%, and the rate of sudden failures can be reduced by 60%. It is suggested that enterprises establish digital maintenance archives to achieve full life cycle management.