XZ16K~XZ65K TRUCK CRANE SPECIAL CHASSIS.pdf

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  • XZ16K ~ XZ65K TRUCK CRANE SPECIAL CHASSIS

    OPERATION MANUAL

    XUZHOU HEAVY MACHINERY CO., LTD. XUZHOU CONSTRUCTION MACHINERY GROUP CO., LTD. CHINA

  • Owner's manual XZ16KXZ65K

    CONTENTS I . Preface 1 II. Vehicle number 2 HI. Vehicle operation - 4

    ( I ) Arrangement in cab 4 (II) Preparation before driving 10 (III) Starting and shifting 12 (IV) Control of clutch 13 (V) Brake system 14 (VI) Outriggers operation 16 (VII) Winter operation 20 (VIII) Wheel inspection and replacement 21 (IX) Run-in of a new truck 23 (X) Usage of air conditioner 24

    IV. Maintenance 26 ( I ) Interval mileage of vehicle routine check and maintenance 26 (II) Each assembly oil change period 26 (III) Maintenance key points 27 (IV) Fuel and lubricant brand and filling amount 33

    V. Pneumatic Circuit Principle Diagrams 34 VI. Chass Hydraulic System Diagram 38 VII. Electric System 43 VIII. Main assembly structure features and technical parameters 53 IX. Main Spare Parts List 55 X. Tightening Torque of Main Bolts and Nuts 56 XI. Supplied Tools List for Truck Crane Special Carrier 57 Packing list 59

  • Owner's manual XZ16KXZ65K

    I. Preface This manual supplies technical information about the performance, structure, operation, service

    and adjustment of XZ16K to XZ65K "XCMG "-branded series truck crane chassis to drivers and maintenance workers for reading and vehicle managers and technicians for reference. Only operate and maintain the vehicle strictly in accordance with the specified requirements in this manual Can the normal service life of the truck crane chassis be guaranteed.

    The manual is applicable to chassis below: XZJ5222JQZ16K XZJ5284JQZ25K XZJ5310JQZ25K XZJ5324JQZ30K XZJ5326JQZ30K XZJ5322JQZ35K XZJ5371JQZ35K XZJ5401JQZ40K XZJ5402JQZ40K XZJ5393JQZ50K XZJ5407JQZ50K XZJ5414JQZ60K XZJ5410JQZ65K XZJ5430JQZ70K Due to the product modification and improvement, what described in this manual may vary

    from the real chassis, we reserve the right to modify the design without notice. Thank for your comments and suggestions to our product. If there are parts of these

    instructions or individual chapters that you do not understand, please do not hesitate to ask the sales department or technical center of our company.

    i

  • XZ16K-XZ65K Owner's manual

    II. Vehicle Number The vehicle numbers are marked in the nameplate on the front section of the right side beam of

    the frame and on the front beam of the right side of the frame. The nameplate c6nsists of

    1. Product name and model; 2. Product number; 3. Engine number; 4. Delivery date; 5. Vehicle identification number (VIN) (for the chassis supplied outside); 6. Manufacturer Symbols stars (ik) are marked at both end of product number and vehicle identification

    number.

    The Vehicle Identification Number (VEST) for truck crane chassis :

    China XCMG Product No. "XCMG" brand Lifting class

    Assembled by Xuzhou Special Vehicle co.,Ltd.XCMG

    Special chassis -Total rated weight Inspection code

    Product manufacture date

    Note: the VIN mentioned above is only used for the chassis supplied outside. When you claim compensation, order spare parts or contact with our service department, please

    give the following correctly and clearly:

    2

  • Owner's manual XZ16K-XZ65K

    Vehicle Type:

    Product No.:

    Engine No.:

    Delivery Date:

    Vehicle Identification Number (VIN):

    3

  • XZ16K-XZ65K Owner's manual

    III. Vehicle Operation ( I ) Arrangement in cab

    Arrangement in cab consists of controllers and instrument panel including instrumentation, switches and indicators. Refer to figure 3 1.

    Fig. 3 - 1 Arrangement in cab

    I. Left turning indicator lamp 3. Power indicator lamp 5. Reversing indicator lamp 7. Differential lock indicator lamp 9. Water temperature warning lamp II. Low air pressure warning lamp

    2. Beam indicator lamp 4. Oil pressure warning lamp 6. Foot brake indicator lamp 8. Fog lamp indicator light 10. Fuel warning lamp 12. Power take-off indicator lamp

    4

  • Owner's manual

    13. Hand brake indicator lamp 14. Right turning indicator lamp 15. Lamp main switch 16. Fog lamp switch 17. Engine stop switch 18. Air conditioner switch 19. Emergency signal switch 20. Differential lock switch 21. Cool starting switch 22. Warning lamp switch 23. Radio-cassette player 24. Warm air adjusting knob 25. Hand brake handle 26. Transmission control lever 27. Cigarette lighter 28. Hand accelerator handle 29. Speedometer 30. Ammeter 31. Accelerator pedal 32. Foot brake pedal 33. Starting switch 34. Horn 35. Combined switch 36. Clutch pedal 37. Steering wheel 38. Fuel gauge 39. Water temperature gauge 40. Power take-off switch 41. Double-pointer air pressure gauge 42. Engine tachometer 43. Engine oil pressure gauge

    1. Functions of instrumentation, switches and signal indicators in cab: 1). Starter switch (No. 33 in Fig. 3 - 1 )

    Three positions are available for selection after the key is inserted into the starting switch, see Fig. 3~2, their functions are as follows: Position 1: with electric power supply cut off, the key can be pulled out. Position 2: " ON " state, the key must be in the position when engine is running. Position 3: starting engine state 2). Double-pointer air pressure gauge (No. 41 in Fig.3 1) Fig. 3 - 2 Low air pressure warning lamp (No. 11 in Fig. 3 1)

    Double-pointer air pressure gauge indicates pressure in two circuits of service brake system (21st, 22 n d circuit), the normal working pressure is 0.45-0.8 MPa. If the air pressure in any one of two circuits decreases below 0.45MPa, stop the vehicle to check the pneumatic circuit system.

    5

    XZ16K-XZ65K

  • XZ16K-XZ65K Owner's manual

    When the air pressure in hand brake circuit (23 r d circuit) of pneumatic circuit system is below 0.45MPa, the lamp lights, indicating that the tnick can not be started or the PTO can not be operated. 3). Speedometer (No. 29 in Fig. 3 - 1 )

    Speedometer consists of speed meter and mileage meter. Speed meter indicates vehicle traveling speed and mileage meter registers vehicle total traveling miles. 4). Engine tachometer (No. 42 in Fig. 31)

    Engine tachometer indicates engine rotational speed for driver to adjust engine idle and control engine max. rotational speed. Provide guarantee for using the engine reasonably; 5). Ammeter (No. 30 in Fig. 3 - 1 )

    The ammeter indicates charging and discharging of the battery. Ammeter pointer pointing to " + " area indicates power generated by alternator is more than that consumed by electric equipments, the battery is in charging; in reverse, the battery is in discharging. 6). Fuel gauge (No. 38 in Fig. 3 1)

    Fuel warning lamp (No. 10 in Fig. 3 1) When starting switch key is in position 2, the fuel gauge approximately indicates the fuel level

    remained in tank. The pointer of fuel gauge will vary when the vehicle is in state of accelerating, braking or climbing up and down slope. 7). Engine water temperature gauge (No. 39 in Fig. 3 1)

    Water temperature warning lamp (No. 9 in Fig. 3 1) Water temperature gauge indicates coolant temperature. In normal condition, the pointer is near

    middle position, i.e. indicating engine normal working temperature of 80-90C. In tropical zone (area), when truck drives in high speed or climbs a slope, the pointer will move to the red sector of the gauge. If the water temperature is too high, the truck must be stopped, and let the engine runs in idle to lower the water temperature to normal condition. 8). Engine oil pressure gauge (No. 43 in Fig. 3 1)

    Oil pressure warning lamp (No. 4 in Fig. 3 1) It displays the oil pressure value of engine lubrication system. Please refer to engine operation

    instruction for the engine oil pressure values either in idle speed or in normal operation. 9). Engine stop switch (No. 17 in Fig. 3 1)

    The switch is used to cut out the power supply to engine, so that to stop engine. Release the switch, it will reset.

    Note: don't release the switch before shutting the engine off. 6

  • Owner's manual

    10). Cold starting switch (No. 21 in Fig. 3 1 optional) When a cold starting device is equipped, the switch is used in control of ether sprayed into inlet

    pipe. It is only used when environmental temperature is below 0C. 11). Air conditioner switch (No. 18 in Fig. 3 1)

    Press down the switch, air conditioner can work (refer to air conditioner operation manual), reset the switch when don't use air conditioner. 12). Emergency signal switch (No. 19 in Fig. 3 1)

    The emergency signal switch must be used when truck has to park in dangerous place. Turning on the switch, the warning lamp lights and all the steering indicator lights flash. The warning lamp activates even if the starting key in position 1. Turning off the switch to release the danger warning. 13). Differential lock switch (No. 20 in Fig. 3 - 1 )

    and Differential indicator lamp (No. 7 in Fig. 3 1) When rear wheels get into a pit and couldn't get out, press the switch to link the drive axle

    rigidly by electric-pneumatic control devices. When use the switch, the differential lock indicator lights. If the indicator is not light, stop the vehicle and check cause. Note:

    Before engaging or disengaging the differential lock, engine power output must be cut off and the truck must be in static condition or in pedestrian speed; Only when the truck drives in straight line can the switch be used; In case the truck drives on a good road, the switch must be disengaged at once. Keeping on use of the switch will result damage of transmission and increase fuel consumption.

    14). Fog lamp switch (No. 16 in Fig. 3 1) Fog indicator lamp (No. 8 in Fig. 3 1) During traveling in foggy days, this switch must be used. When use the switch, the fog

    indicator lamp illuminates. 15). Lamp main switch (No. 15 in Fig. 3 1)

    When traveling in night, the lamp main switch must be used. Let it reset when don't use it. 16). Power indicator lamp (No. 3 in Fig. 31)

    When starting switch is on position 2, the indicator lamp lights, it indicates that power is ON, you can start the engine. After engine runs normally, the indicator lamp goes out, it indicates that generator begins to work. If the lamp does not go out, speedup engine accelerator to mid-rotational speed. If the lamp does not go out yet, it indicates that generator doesn't work,

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  • XZ16K-XZ65K Owner's manual

    stop the engine and check. 17). Hand brake handle (No. 25 in Fig. 3 - 1 )

    Hand brake indicator lamp (No. 13 in Fig. 3 1) Before leaving the truck, apply the hand brake handle. At this time, hand brake indicator lamp

    illuminates, it means that the vehicle is in parking brake. Before traveling, release it (hand brake indicator lamp goes out).

    When emergency brake is necessary in danger and foot brake is out of order, apply hand brake handle to brake the vehicle.

    When service brake is damaged and the vehicle has to be towed, apply the hand brake instead of service brake. Warning: do not use the parking brake and the service brake at the same time to prevent the braking system from damage. 18), Combined Switch (No. 35 in Fig. 3 - 1 )

    Refer to Fig 3 - 3 for combined switch.

    Fig. 33 Combined switches 1. Exhaust brake switch 2. Wiper switch of front windshield 3. Dimmer switch

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  • Owner's manual XZ16KXZ65K

    Operation of exhaust brake switch: when the vehicle travels on a long downhill, pulling the switch backwards can realize exhaust brake. This can avoid not only the vehicle speeding up to dangerous extent by deadweight but also the brake temperature going too high by less use of brake. Reset the switch when don't use it. Note: never stop the engine when the vehicle travels on a long downhill with the switch applied.

    Operation of wiper switch of front windshield: lifting the switch up can start washing motor to clean front windshield; pulling the switch backwards can control wiper motor to run in low speed or high speed.

    Operation of dimmer switch: with lamp main switch (No. 15 in Fig. 3 1) pressed, push the switch forwards to turn on left steering lamp, left steering indicator lamp and traveling left steering lamp illuminate; pull it backwards to turn on right steering lamp, right steering indicator lamp and traveling right steering lamp illuminate. The control lever should be returned to neutral after steering. Operation of changing roadway is the same as the operation of steering signal switch. Lift the switch up for dimmer; position it in mid-position for dim light; pull it downward for beam light; turning small switch on the end of dimmer switch, the first gear is for turning on traveling lamp, the second gear is for turning on headlight. 19). Hand accelerator handle (No. 28 in Fig. 3 1)

    The hand accelerator handle is a manual device for operating engine accelerator rocker. It can be used when operate outriggers or when truck is traveling in long distance and no need to change gears.

    Operation method: see Fig. 3 4. With button 1 on the front end of hand accelerator pressed down, pull handle 2 out to accelerate, in reverse, to decelerate. If micro-adjust engine accelerator is necessary, turn handle 2 directly. Turn it counter clockwise to accelerate; clockwise to decelerate. 20). PTO switch (No. 40 in Fig. 3 - 1 )

    PTO indicator lamp (No. 12 in Fig. 3 - 1 ) A PTO intending to drive the hydraulic pump for crane lifting operation is installed on the rear

    of the transmission. Operation of XZ16K~XZ35K: after parking the truck, let engine running in idle speed,

    position the shift lever to neutral, depress clutch pedal to disengage the clutch, pull PTO switch up (PTO indicator lamp comes on) and release the clutch pedal, at this time, PTO gear will mesh smoothly with transmission gear, PTO begins to work. In reverse, depress clutch pedal to disengage clutch, push PTO switch downward (PTO indicator lamp goes out) and release clutch

    9

    1 2 Accelerate

    Fig. 34 Accelerator handle

  • XZ16K-XZ65K Owner's manual

    pedal, at this time, PTO gear will disengage with transmission gear smoothly. Operation of XZ50K~XZ65K: after parking the truck, let engine running in idle speed,

    depress clutch pedal to disengage the clutch, set the shift lever to 4th position, pull PTO switch up and release clutch pedal, at this time, PTO gear will mesh smoothly with transmission gear, PTO begins to work. In reverse, depress clutch pedal to disengage the clutch, push PTO switch downward and release clutch pedal, at this time, PTO gear will disengage with transmission gear smoothly. Note: Awhen operate the PTO switch, pressure in pneumatic circuit should be more than 0.45

    MPa (low air pressure warning lamp goes out). AWhen traveling, the PTO switch must be in off position.

    21). Warning lamp switch (No. 22 in Fig. 3-1) The switch and warning lamp are optional parts. The lamp only can be used when lifting

    operation is performing if it is equipped. (II) Preparation before driving

    The preparation before driving includes routine inspection before driving and engine starting. 1. Routine inspection before driving: (1). Check coolant level

    Check coolant level through inlet of water tank. If no coolant is found, fill coolant till it is found. Then start engine, when it is running at approx.1000 rpm refill coolant to specified level. Note:

    When truck in normal traveling, checking coolant level must prevent hot water and steam from injury of person. Do not fill coolant when engine still in hot temperature.

    (2). Check fuel level: Position the key switch of power supply to position 2, check fuel level on fuel gauge, and

    replenish fuel if necessary. (3). Check engine oil level:

    Pull out the dipstick (see ((Engine Operation Manual)) ), replenish the specified engine oil depending on the level mark of the dipstick. (4). Check transmission oil level:

    The transmission oil level must be not lower than the position of the side sight-hole on the transmission case, i.e., not lower than the centerline of transmission countershaft. (5) Drain the water condensed in the air reservoir by removing the manual drain valve under the

    air reservoir. (6) Check the tire pressure, and inflate the tire if necessary. 10

  • Owner's manual XZ16KXZ65K

    (7) Check the tightness of tire bolts. (8) Check function of all the electric system. (9) Check leakage of oil and coolant. (10) Check air filter.

    Empty and clean the dust-collector everyday if the truck works in dusty environment. If red line in air filter negative pressure indicator occurs, clean the filter element. 2. Engine starting: (1).The requirements for engine operation see ((Engine Operation Instruction Manual )) . (2). Operation of power supply switch (see Fig.33).

    Turning the key from position 2 to position 3 can start the engine. After starting engine, release your hand, the key will automatically return to position 2, and then the starting switch resets. Note: when starting the engine by wire-contact, the wire can only be connected to the battery and never to the starting motor. (3) Cold starting device:

    When starting the engine in lower temperature, it is necessary to start with the aid of cold starting device (optional). The cold starting device is an ether sprayer. When starting, press the ether spray switch while turning on the starting switch. After ether is sprayed into inlet pipe and mixed with fuel gas, the engine can be started rapidly with the low burning point of ether. It is recommended to use the cold start device in temperature range of 0C~ -12C, and it must be used when temperature is below -12C. (4) Starting process:

    With hand brake handle in braking condition, put shift lever in neutral position, set hand accelerator in appropriate position or depress accelerator pedal to 1/4 of its stroke, turn the starting key to position 3 to start the engine. If fail to start within 12 seconds, return the key to position 2, after 2 minutes to start again. If continually fail starting for 3 times, stop starting and check the cause. (5) Engine oil pressure after starting:

    After starting, the engine oil pressure gauge should display the reading within 15 seconds and the reading should be in line with the engine operation requirements (see engine operation instruction manual). If the pointer does not move, stop engine at once and check the cause. Note: never let the engine run in high speed when it is just started. (6) Preheating of the engine:

    After starting, engine idle time can't exceed 5 minutes, increase rotation speed gradually up to

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  • Owner's manual

    1000 ~ 1200 r/min and begin running with a partial load. Only when water temperature is higher than 75 C, engine oil pressure is higher than 0.25 MPa, can the engine run with a full load. Note: especially after starting the engine in low ambient temperature, the rotation speed should be increased slowly to make sure that the bearings get sufficient lubricating and stable oil pressure. 3. Stopping the engine:

    Press the engine stop switch to shut it off. (HI) Starting and shifting: 1. Starting

    Release the hand brake handle. Only when the pressure of air reservoir in braking system is up to 0.45Mpa, the hand brake indicator light and low air pressure warning light go out, the spring brake can be released. And then the truck can be started. The truck can't be started before the hand brake indicator light goes out. After the hand brake indicator light goes out, all the air-powered systems can be operated. 2. Operating method of transmission:

    Shift up: (1) Set the shift lever (No. 26 in Fig. 3 1) in neutral position for engine starting. (2) Shift to 1st gear to start running the truck. (3) Consecutively change gears in order from the 1st one to the 2nd, the 3rd and the 4th, and

    finally to the highest gear. Shift down: when shifting down, shifting from the highest gear to the 1st gear can be operated

    consecutively. Use the 1st gear for starting the track. Never shift gears with accelerator pedal depressed. During traveling, check regularly oil pressure gauge, speedometer and water temperature gauge.

    Never travel with a shift lever in neutral or slide with an engine stopped for transmission lubricating and safety.

    3. Stopping and parking: The vehicle can be stopped with foot brake or hand brake whenever operating lever is in

    whatever gears. For temporary stopping, operating lever position may not be changed. If leaving the track for a long time, the operating lever must be in neutral position. When parking is necessary, apply the hand brake.

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    Notes:

  • Owner's manual XZ16K-XZ65K v>

    4. Operations in emergency: (1) When the transmission has a trouble and the truck must be moved, the traveling speed for

    the truck towed can not exceed 10 km / h, and the emergency signal switch (No. 19 in Fig. 3 ~ 1) must be turned on and turning indicator lights of towing vehicle should also be turned on.

    (2) When engine and transmission are damaged, propeller shaft should be disassembled in principle.

    (3) When driven shaft or drive shaft is damaged, if possible lift the front or rear section of the truck up. (IV) Control of clutch:

    Fig. 35 Push-type clutch control diagram Both push-type and pull-type clutches are controlled by static pressure oil with air-assisted

    device. The length of the push-type clutch branch cylinder push rod can be adjusted manually, but the pull-type one's can't. Refer to Fig. 3-5 for push-type clutch control diagram.

    Clutch pedal free stroke S should be in range of 40~60 mm when clutch release rod does not move. If not, check both clearances of master cylinder push rod and branch cylinder push rod and check if there is air in the static pressure oil circuit.

    On the condition of clutch pedal depressed to the bottom, the clutch should be disengaged fully, 13

  • Owner's manual

    the branch cylinder pushrod stroke L of push-type should be in range of 23-25 mm, if not, check the branch cylinder pushrod clearance. If the clearance is very small or zero, that means there is air in the static pressure oil circuit. If the pull-type clutch couldn't be disengaged fully, that means there is air in the static pressure oil circuit too. (1) The adjusting method of clutch control system:

    Since the clutch system is controlled by static pressure oil, first fill the system with static pressure oil and bleed the system. 1) Open the cover of oil cup in driver's cab, and fill brake oil into the oil cup until the oil level up to the 3/4 to 4/5 of the cup height. 2) Remove the rubber cover on the branch cylinder bleeding cap, do the following:

    Loosen the bleeding cap on the branch cylinder, repeatedly depress the clutch pedal until brake oil sprays out of the bleeding cap. And then depress the clutch pedal and tighten the bleeding cap. During operation pay attention to the oil level in the oil cup and replenish oil according to requirements. (2) Remedy for common troubles:

    When pressure in the pneumatic circuit rises above 0.45Mpa, if pedal is heavy to operate, check the branch cylinder and its air supply. If the branch cylinder is assisted slowly after depressing pedal, or the branch cylinder is assisted without depressing the pedal, that means the adjusting screw of the branch cylinder is in wrong position, it needs to be readjusted. With the wear of clutch friction lining, the clearance of the push-type clutch pedal will gradually be shortened; the clearance of the pull-type clutch pedal will gradually be enlarged. If continue to use it, the slipping of clutch will happen, and then the truck unable to move. So after traveling 4000km, inspect all clearances. If the control parts are all right but the clutch slips, it's necessary to check the clutch friction lining and compression spring for effectiveness. (V) Brake system:

    The brake system consists of service brake (foot brake), parking brake (hand brake) and auxiliary brake (engine exhaust brake). 1. Service brake:

    The service brake is foot pedal control (No. 32 in Fig. 3-1) with double-circuit air pressure brake. Its working pressure is 0.8Mpa. The 1st circuit acts on the wheels of the 1st axle, and the 2nd circuit acts on the wheels of the 2nd and 3rd axles. For the truck with four axles, the 1st circuit acts on the wheels of the 1st and 2nd axles, and the 2nd circuit acts on the 3rd and 4th axles. In case the air pressure of one air reservoir in two circuits drops below 0.45Mpa, stop the

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  • Owner's manual XZ16K-XZ65K

    truck and find the cause of low pressure. Repeated braking in a short time may cause pressure down below 0.45Mpa. 2. Parking brake:

    Parking brake is exhaust brake acting on rear two axles. It gives effect on all axles by the spring-loaded air chamber on each axle respectively. After stopping the truck, applying hand brake handle can hold the truck at original place. This is parking brake. Only with hand brake released and the pressure in 23 circuit of brake system more than 0.45Mpa (low pressure warning lamp goes out) and hand brake indicator lamp went out, spring brake air chamber can be fully released as well as parking brake. Apply hand brake handle for emergency brake when service brake does not work. When service brake is damaged and the vehicle has to be towed, apply hand brake instead of service brake. 3. Auxiliary brake

    Auxiliary brake is engine exhaust brake. In order to prolong brake life during a long downhill travel, press down exhaust brake switch (No. 1 in Fig. 3-3), close butterfly-valve on exhaust pipe by solenoid valve and cylinder to realize engine exhaust brake. 4. Notes on brake system operation:

    (1) Releasing of spring brake air chamber: When self-braking happens due to leakage of pipeline, do the following to release (see Fig. 36a): a. Open the plug at the tail of brake air chamber; b. Remove the nut on bolt and take off the bolt; c. Insert the bolt into brake air chamber from its tail and lock (see Fig. 3-6b).

    d. Letting the bolt out by tightening the nut can release braking. When parking the truck on a slope, before releasing the spring brake, wedges must be put under

    the wheels to block the truck in prevention of slipping. (2) When use exhaust brake, never disengage transmission, and never depress clutch pedal.

    Fig. 3 ~6a Brake air chamber Fig. 3 6b Brake air chamber

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  • w XZ16K-XZ65K Owner's manual

    (VI) Outriggers operation: Refer to Fig. 37a for names of outrigger parts of XZ16K, and Fig. 37b for its control

    levers; refer to Fig. 3 8a for names of outrigger parts of XZ25K, and Fig. 3 8b for its control levers; refer to Fig. 3 ~ 9a for names of outrigger parts of XZ30K and XZ30K5, and Fig. 39b for their control levers; refer to Fig. 3 10a for names of outrigger parts of XZ35K, XZ30K5, XZ50K, XZ60K and XZ65K, and Fig. 3 - 10b for their control levers

    1. Outrigger control levers 2. Level gauge 3. Outrigger beam lock pin 4. Lock pin hole 5. Jack cylinder

    Fig. 3 - 7 a for XZ16K

    1. Left rear outrigger control lever 2. Right rear outrigger control lever 3. Left front outrigger control lever 4. Right front outrigger control lever 5. Extension & Jack control lever

    Fig. 3 - 7 b for XZ16K

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  • Owner's manual XZ16K-XZ65K

    Fig. 3 -8b

    1. Outrigger beam lock pin 2. Lock pin hole 3. Level gauge 4. Jack cylinder 5. Outrigger float 6. Outrigger control levers

    for XZ25K

    1. Left rear outrigger control lever 2. Right rear outrigger control lever 3. Left front outrigger control lever 4. Right front outrigger control lever 5. Extension & Jack control lever 6. 5th Jack control lever

    for XZ25K

    1. Outrigger beam lock pin 2. Lock pin hole 3. Level gauge 4. Jack cylinder 5. Outrigger float 6. Outrigger control levers

    Fig. 3 - 9 a for XZ30K> XZ30K5

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  • XZ16K-XZ65K Owner's manual

    1. Right front outrigger control lever 2. Left front outrigger control lever 3. Right rear outrigger control lever 4. Left rear outrigger control lever 5. Extension & Jack control lever

    Fig. 3 - 9 b for XZ30K> XZ30K5

    1. Outrigger beam lock pin 2. Lock pin hole 3. Level gauge 4. Jack cylinder 5. Outrigger float 6. Outrigger control levers

    Fig. 3 -10a forXZ35K. XZ35K5, XZ50K, XZ60K, XZ65K

    1 2 3 4 6 5 1. Right front outrigger control lever 2. Left front outrigger control lever 3. Right rear outrigger control lever 4. Left rear outrigger control lever 5. Extension & Jack control lever 6. 5th Jack control lever

    Fig. 3 - 1 0 b for XZ35Kn XZ35K5> XZ50K> X Z 6 0 K , X Z 6 5 K

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  • Owner's manual XZ16K-XZ65K

    1. Setting outriggers (1). Pull out the outrigger beam lock pins. (2). Position control levers (1st to 4th) to "Extension". (3). Move Extension & Jack control lever (5th) to "Extend". (4). After outrigger beams are fully extended, return Extension & Jack control lever (5th) to

    "Neutral". (5). Position control levers to "Jack". (6). Move Extension & Jack control lever (5th) to "Extend". (7). After jacks are fully extended, move Extension & Jack control lever (5th) to "Neutral".

    Check if the crane is level by using level gauge. If it is level, return all control levers (1st to 4th) to "Neutral".

    (8). If 5th jack is equipped, move 5th Jack control lever (6th) to "Jack". (9). Move Extension & Jack control lever (5th) to "Extend". (10). After the 5th jack is in contact with the ground, move Extension & Jack control lever (5th)

    to "Neutral" as well as 5th Jack control lever (6th). 2. How to level crane:

    Moving any one or more of control levels (1st to 4th) and positioning Extension & Jack control lever (5th) to "Extend" or "Retract" can extend or retract the selected extension or jack.

    Example: when the crane right side is higher, return the "Right front" and "Right rear" control levers to "Jack". While observing level gauge, inch Extension & Jack control (5th) lever to "Retract". After the crane is leveled, return the remaining control levers to "Neutral". 3. Stowing outriggers:

    Caution: stow the main boom and jib of the upper carriage beforehand. (1). Move control levers to "Jack" and then move Extension & Jack control lever (5th) to

    "Retract". (2). Position control levers to "Extension" and then move Extension & Jack control lever (5th)

    to "Retract". (3). Return all control levers to "Neutral". (4). Insert beam lock pins.

    4. Notes on operation: (1). The operation site must be flat before the chassis entering it. (2). Do not set the outriggers without extending them. (3). After setting up outriggers, make sure that all outrigger floats are in complete contact with

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  • XZ16K-XZ65K Owner's manual

    the ground. (4). Keep the tires off the ground. (5). After stowing the outriggers, make sure that the outrigger beam lock pins are completed

    inserted. (6). Return control levers to "Neutral" immediately after finishing outrigger operation. Before starting crane operation, make sure that control levers are in "Neutral".

    (VH) Winter operation 1. Cooling system

    The coolant for cooling system may be cooling water or anti-freezing coolant. Use cooling water when the ambient temperature is above 0C. Use soft water or softened

    water as cooling water, otherwise the scales formed and deposited will affect the cooling effect. Hard water can be softened by the following methods: (1). Heating and boiling; (2). Add sodium carbonate (Na 2 CO3) 0.5~1.5g to each liter of water; (3). Add sodium hydroxide (NaOH) 0.5~0.8g to each liter of water;

    Table 3 - 1 Limited temperature of freezing point for anti-freeze coolant

    (C)

    Glycerin -water Ethylene glycol -water Limited temperature of freezing point for anti-freeze coolant

    (C) Glycerin

    Weight % Density

    D Ethylene glycol

    weight % Density

    D - 1 0 32 1.0780 28.4 1.0340 - 2 0 51 1.1290 38.5 1.0506 - 3 0 64 1.1647 47.8 1.0627 - 4 0 75 1.1894 54.7 1.0713

    Notes: A The engine can not use the antifreeze coolant made of "alcohol -water". A Never use sea water to cool the engine directly. A Antifreeze coolant can be added according to the operation requirements of engine and also

    can be made according to the method recommended in Table 3-1. When using antifreeze coolant, its freezing point should be lower 5 C than the lowest temperature in the area.

    2, Braking device: Do not forget to drain the water condensed in the air reservoir before traveling.

    20

  • Owner's manual XZ16K-XZ65K

    3. Battery Regularly check the level and density of the battery electrolyte. The level should be 10-15 mm

  • XZ16K-XZ65K Owner's manual

    (2). The tire ply should not be exposed due to the partial wear of tire tread face. (3). There should not be crack and cut of more than 25mm length and ply exposed depth on tire

    tread face and side wall. (4). Type and tire tread of tires installed on an axle should be same. Tires renewed should not

    be fixed on steering wheels. 2. Rim inspection:

    The rim is one of the important parts in truck traveling system. When changing the wheels, the following items should be checked:

    (1) Rim rustiness; (2) Rim defection and deformation; (3) Rim cracks; (4) Opening of rim flange, mounting hole and rim bolts and nuts. After checking, repair or replace the parts damaged or deformed at once, if paint stripped,

    repaint after rust is removed. Caution: do not weld connections of rim bolt, and also do not repair deformed rim bolts. Replace with new ones. 3. Wheel replacing:

    (1). After lOOOOKm of traveling, tires should be transposed. Refer to Fig. 3 11. (2). Do not scratch bolt thread when replace wheels. (3). No painting, grease and other dirty on the touching face between brake drum and rim. (4). Keep pressure faces of wheel nuts clean. (5). Coat threads of wheel bolts and nuts, rim edge and other touching face with grease, oil or

    other anti-engaging agent. (6). Threads of all wheel nuts are dextrorotary. With tires mounted and wheels suspended,

    tighten nuts in the order of diagonal transposition. Lower wheels on the ground, and tighten wheel nuts with tightening torque of 600-660 Nm.

    (7). After tires are remounted, retighten wheel nuts once every 50Km of traveling according to stipulations.

    22

  • Owner's manual XZ16K-XZ65K

    Fig. 3 11 Tire transposition reference diagram

    (IX) Run-in of a new truck The run-in mileage for a new truck is 1500Km. Before run-in, routine inspection should be

    carried out for ensuring the truck in normal working condition. Notes on run-in: (1) After cold starting, do not accelerate the engine immediately, only after normal working

    temperature is reached. In run-in time, the engine rotation speed should be limited within 80 ^ % of its highest speed.

    (2) During run-in time, the truck should travel on level and flat roads. (3) In traveling, select proper shift gears according to load and road conditions. And avoid

    abrupt accelerating and emergent braking. (4) Check and control engine oil pressure and coolant working temperature. (5) Check regularly wheel hubs of all axles and brake drum temperature. If serious overheating

    occurs, find the cause and adjust or repair. (6) After initial traveling of 50Km or every time changing tires, tighten wheel nuts according to

    the specified torque.

    23

  • XZ16K-XZ65K Owner's manual

    After run-in time, check and maintain the truck according to the "first check " items specified in chapter "IV. Maintenance " and the requirements in engine and transmission operation manuals. (X) Usage of air conditioner

    The products adopt cold-warm air conditioner. Warm air is utilizing engine cyclical hot water; cold air is supported by refrigerant circulated in

    air conditioner system. In winter when use the warm air, open hot water valve in warm air pipeline (on connection of engine and warm air hot water pipe, refer to Fig. 3 ~ 12), and then press down the No. 18 switch in Fig. 3 1. In summer when use the cold air, close hot water valve in warm air pipeline and then press down the No. 18 switch in Fig. 3 1, and last press down A/C switch on the air conditioner. Refer to air conditioner operation manual for details.

    Note: be sure to close hot water valve when use cold air, be sure to open hot water valve when use warm air. In winter, when it is necessary to drain off the water in engine cooling system, the water in warm air pipeline must be drained off too.

    24

  • Owner's manual XZ16K-XZ65K

    Fig. 3~12 Positions and states of engine hot-water valves

    Mil Series Engine

    Hot-water valve

    WD615 Series Engine Open state of hot-water valve

    Hot-water valve

    Engine made by Shanghai Diesel Engine Factory Close state of hot-water valve

    Hot-water valve

  • XZ16K-XZ65K Owner's manual

    IV. Maintenance ( I ) Interval mileage of vehicle routine check and maintenance

    Unit: 1000km Table 4 - 1 Routine 1st class Routine 2nd class Routine 1st class Routine 3rd class check maint. check maint. check maint. Check maint.

    5 10 15 20 25 30 35 40 85 90 95 100 105 110 115 120 165 170 175 180 185 190 195 200

    Routine 1st class Routine 2nd class Routine 1st class Routine 4th class check maint. check maint. check maint. check maint.

    45 50 55 60 65 70 75 80 125 130 135 140 145 150 155 160 205 210 215 220 225 230 235 240

    (II) Each assembly oil change period Table 4 - 2

    Classification Engine Transmission Front, rear axle Remarks

    First check 1500km of traveling Routine check

    1st class maintenance

    2nd class maintenance

    3rd class maintenance

    4th class maintenance

    26

  • Owner's manual XZ16K-XZ65K

    (IE) Maintenance key points 1. Daily maintenance

    (1) Inspect the operation of hand brake and foot brake; (2) Inspect the function of illuminating, signal system and indicator lights (indicator lamp for

    oil pressure, air reservoir pressure, charging, etc.) (3) Inspect the operation of air filter negative pressure indicator; (4) Inspect the operation of windscreen wiper; (5) Inspect the condition of tire air pressure and the tightness of wheel bolts; (6) Inspect the level of engine oil, coolant and fuel; (7) Inspect oil level of transmission; (8) In winter, inspect anti-freezing condition of pneumatic circuit system; (9) Drain off the water condensed in air reservoir; (10) Inspect the tightness of universal joint bearing cover bolts, leaf spring U-bolt.

    2. Each class maintenance item Table 4 - 3

    Maintenance item First check Routine check

    1st class maint.

    2nd class maint.

    3rd class maint.

    4th class maint.

    Engine Replace engine oil (at least one time per year)

    Change oil filter or filter element

    When change engine oil every time

    Check and adjust tire air valve clearance

    Check opening pressure of spraying nozzle

    Replace fuel filter or filter element

    Clean fuel pump rough filter

    Check coolant Capacity

    27

  • XZ16K-XZ65K Owner's manual

    Maintenance item First check Routine check

    1st class maint.

    2nd class maint.

    3rd class maint.

    4th class maint.

    Replace coolant Every 24 months Check coolant circuit tightening clamp Tighten air inlet circuit and connectors Check air filter negative Pressure indicator

    Clean air filter dust cup Clean air filter main element

    When air filter negative pressure indicator displays or every 100 hours

    Replace air filter main element When air filter main element is damaged Replace safety filter element of air filter After 5 times of cleaning main filter element

    Check and tighten the belt Check turbocharger compressor

    Check oil spray pump Check and adjust engine accelerator opening

    Adjust engine idle rotation speed

    Transmission Check transmission lubrication oil level Once a week Replace lubrication Oil Initial 1000km of traveling, afterwards every 20000km. Replace oil filter, washer and "O" seal ring Every time when replace oil

    28

  • Owner's manual XZ16K-XZ65K

    Maintenance item First check Routine check

    1st class maint.

    2nd class maint.

    3rd class maint.

    4th class maint.

    Driven axles (front axles) Replace wheel hub grease

    Check and adjust the front shaft bearing clearance Beginning from the first time of 2nd class maintenance

    Drive axles Check the level of main reducer and rim reducer Replace lubrication oil of main reducer and rim reducer (at least one time every year)

    Clean or replace drive axle ventilating device Check and adjust hub bearing clearance Beginning from the first time of 2nd class maintenance

    Propeller-shaft Re-tighten shaft bolt Carry out visual check of shaft connection and wearing

    Driver' s cab Check the movement of wiper

    Check and adjust every operating components

    Check and tighten front and rear supports of cab

    29

  • XZ16K-XZ65K Owner's manual

    Maintenance item First check Routine check

    1st class maint.

    2nd class maint.

    3rd class maint.

    4th class maint.

    Brake system Drain off the water in air reservoir

    Check air pressure system sealing (with air pressure gauge)

    Check and adjust output pressure of pressure regulating valve

    Check brake shoe friction disc thickness, adjust brake clearance

    Clean wheel brake

    Check easy-worn positions of brake circuit

    Check brake air chambers

    Electric system Check the condition of signal light, head light, wiper, heater, etc.

    Check level and density of electrolyte and battery voltages in each unit

    Check the fixing of battery terminals and meantime coat electric poles with grease

    30

  • Owner's manual XZ16K-XZ65K

    Maintenance item First check Routine check

    1st class maint.

    2nd class maint.

    3rd class maint.

    4th class maint.

    Check the function of speedometer # # Steering system Check and adjust the front wheel location Check oil-can level of steering system Replace filter in steering system oil-can Check the condition of steering system Chassis and road traveling test Check and tighten frame connecting bolts Tighten front and rear spring leaf u-bolts and supports Check the operation of balance beam suspension Check the tightness of tire nuts

    Check battery fixing

    Check fuel tank fixing

    Short distance test Check the operation of hand brake and foot brake

    Visual check leakage Check the tightness of each related component

    31

  • XZ16K-XZ65K Owner's manual

    Maintenance item First check Routine check

    1st class maint.

    2nd class maint.

    3rd class maint.

    4th class maint.

    Lubricating positions Engine water pump spindle Engine regulator Clutch yoke shaft Clutch release bearing Transmissionbearing before axle Transmission operating support Drive shaft mid-support Drive shaft universal joint Drive shaft telescopic spline Pins of front leaf spring Front and rear leaf springs Balance beam of rear suspension Pushrod ball head Steering knuckle bolt and bearing Steering rocker arm bearing Front and rear axle hub bearing Front and rear brake camshafts Accelerator and brake pedal shaft Accelerator flexible shaft and pivot point Cab door hinge

    Note: " " is the mark required maintenance.

    32

  • Owner's manual XZ16KXZ65K

    (IV ) Fuel and lubricant brand and filling amount Table 4 - 4

    Name Brand Capacity Engine oil See engine operation manual See engine operation manual Engine fuel See engine operation manual According to tank capacity Engine coolant Soft water or antifreeze coolant 50L

    Transmission lubrication oil

    GL-4 85W/90 lubrication oil (above -12C) GL-4 80W/90 lubrication oil (-26C ~ 38 C) GL-4 75W lubrication oil (-40C - 38C) GL-5 lubrication oil for S6-90, S6-120 and 5S-111 GP transmission

    13L

    Drive shaft lubrication oil

    GL-4 85W/90 lubrication oil (above -12C) GL-4 80W/90 lubrication oil (-26C - 38 C) GL-4 75W lubrication oil (-40C ~ 38 C)

    20L

    Steering system hydraulic oil L-TSA32 antioxidant and antirust steamer oil 6.6L Shock absorber C-27 mobile shock absorber oil Leaf spring grease ZG-S graphite calcium base grease 1500g Hydraulic oil for clutch master cylinder and branch cylinder

    HZY3 (above 15 C) HZY4 (15C~-20C) HZY5( below -20C)

    Hydraulic system hydraulic oil (Kunlun branded)

    Ambient temperature above 5 C: L-HM46 Ambient temperature -15 C -5 C: L-HM32 Ambient temperature -15C~-30C: L-HV22 Ambient temperature below -30C: No. 10 aviation hydraulic oil

    390L for XZ16K, 450L for XZ25K; 650L for XZ35K and XZ50K; 740L for XZ65K;

    Other positions in chassis 3 # lithium base grease 3000g

    Note: the filling capacity shown in the table is theoretical value, for actual capacities refer to the readings at dipstick, inspection apertures and sight glass.

    Comparison between oil brands domestic and abroad Table 45 Classification Engine oil Fuel Lubrication oil Steering system Hydraulic system

    Petrol China CD CF-4 Light fuel 0#,

    10#,-10#, -20#, -35#

    GL-4 GL-5 L-TSA 32 L-HV 22 L-HM 32 L-HM 46

    MOBIL Delvac 1330-1340 Delvac super The same

    Mobiube GX

    Mobiube HD

    DETEOIL Named series DTE light

    Mobil DTE11M, 13M, 15M

    SHELL Rimula C Rimula D The same GSPIRAXG Spirax A Turbo T oil 32 Tellus 22, 32, 46 CALTEX / EDLA500 The same Thuban GL-4

    Thuban GL-5EP Regal R&032 Rando oil HD 32, 46

    CASTROL CRD

    MONO Grades

    RX Turbo 15W/40, RX

    Super The same SMX 80W/90 Multitrax 85W/140

    Perfecto T32

    Hyspin AWS 15, 32, 46; Hyspin AWH 15,

    32, 46 TOTAL Rubia C Rubia XT The same BOLD ORBV

    Transmission TM 80W/90

    Preslia turbine oil 32 AZOLLAZS 32, 46

    BP Energol DS3 Venellus c3

    Extra The same Energol EP Hypo Gear EP Turbinol 32 Bartran HV 22,

    Energol HLP-HM 32, 46

    33

  • XZ16K-XZ65K Owner's manual

    V. Pneumatic Circuit Principle Diagrams

    Explanation of the pneumatic circuit principle diagrams: 1. The opening pressure of the pressure regulator valve is 0.7Mpa, and its closing pressure is

    0.81Mpa. 2. There is numeral code consisting of one or two numbers in pneumatic circuit connecting

    port of component (valve-block) of pneumatic circuit principle diagrams. In the 1st code, 1 indicates air inlet, 2 indicates air outlet, 3 indicates air vent and 4 indicates the inlet to control air supply; the number in the 2nd code indicates the order number of air connecting port of the component (valve-block) with same function.

    3. Fig. 5 - 1 is for chassis of XZ16K, XZ25K, XZ30K and XZ30K5. 4. Fig. 52 is for chassis of XZ35K and XZ35K5. Transmission regulator is available only

    when 5S 111 GP transmission is equipped on XZ35K5. 5. Fig. 5 - 3 is for chassis of XZ50K, XZ60K and XZ65K. 6. In Fig. 5 1,52 and 53, there are extinguish cylinders only when Steyr WD615 engines

    are equipped.

    34

  • Horn

    e r a

    2 PTO switch 1

    1st axle right air-chamber

    m. Air dryer r t -OOrO^ H

    Four-circuit protection valve

    21 r 2nd axle right air-chamber 3rd axle right air-chamber

    r & r ? n 23

    0q_2_ Air compressor

    22

    Air reservoir

    22

    PTO cylinder

    Clutch control valve

    2

    Exhoust broke cylinder

    3

    Hand brake valve

    21 4 4

    Extinguish cylinder =

    2

    Solenoid valve

    22nd circuit reservoir

    22nd circuit reservoir,

    2 4 Foot relay valve

    Brake lamp switch 0.05MPa

    22

    Double-pointer air-pressure gauge

    Foot brake valve

    3D

    21st circuit reservoir

    Check volve B |

    23rd circuit reservoir

    9

    12

    vWarning lamp switch 0.5MPa

    12

    - w

    3rd axle inter-wheel 12 differential lock

    2nd axle inter-axle differential lock

    r

    Hand relay valve 42

    2nd axle inter-wheel differential lock

    41 ft:

    Warning lamp switch 0.5MPa

    2 2

    S r t s Foot relay

    valve

    0.05MPa Brake lamp switch

    12

    - w

    1st axle left air-chamber 2nd axle left air-chamber 3rd axle left air-chamber

    F i g . 5 - 1 P n e u m a t i c c i rcu i t p r inc ip le d iag ram for XZ16K* XZ25K> XZ30K and XZ30K5

  • 1st axle right a i r - c h a m b e r 2nd axle right a i r - c h a m b e r F o u r - c i r c u i t protect ion valve 3rd axle right a i r - c h a m b e r 4th axle r i g h t - a i r chamber H I l S q !

    H o r n

    n=3_~

    PTO switch

    Air compressor

    =0

    A i r d r y e r

    22

    Air reservoir

    22

    fPr P i 23 24

    Transmiss ion regulator cylinder [

    P T 0 c ^ i n ( J e r Clutch control valve tz>

    J Hand broke valve

    12

    Solenoid valve

    Exhaust brake cylinder

    Double-pointer Foot brake valve air-pressure gauge Hfi

    C f n

    ,22nd circuit reservoir

    circuit reservoir^

    Foot relay valve 4 Brake lamp switch

    0.05MPa

    21st circuit reservoir

    Check valve

    23rd circuit reservoir.

    12

    N- 0.5MPa Warning lamp switch

    12

    11 4th axle inter-wheel 12 differential lock

    3rd axle inter-axle differential lock Hand relay 4 2

    valve

    3 r d ax le inter-wheel differential l ock

    Warning lamp switch 0.5MPa

    2 Foot relay , volve 4

    Brake lomp switch 0.05MPa

    12 -W

    B

    Solenoid valve

    1st axle left air-chamber 2nd axle left air-chamber 3rd axle left air-chamber 4th axle left air-chamber

    F i g . 5 - 2 Pneumat ic c i rcu i t principle d iagram for XZ35K and XZ35K5

  • { I t J

    Horn

    E .

    PTO cylinder

    22

    Double-Pointer air-pressure gauge

    1st axle right air-chamber 2nd axle right air-chamber Four-circuit wotection valve j r d a x l e r i 9 h t a i r - c h a m b e r r^ : Air rlr\/or r^ r , r-, Air rlr\/or 4th axle right air-chamber

    Air compressor

    Check valve

    Transmission cylinder Transmission requlotor cylinder On I AA ' 1 ' = r = Clutch control volve H I ]

    lis uuiid brake valve a 2

    Exaust Solenoid valve brake cylinder

    trrLli 21 12

    O 22 Foot brake valve

    H I D

    \ 2 2 n d circuit r ese rvo i r /

    22nd circuit reservoir

    2 Foot relay valve

    C n i T T ^ 0.05MPa 4 Brake lamp switch

    9 23rd circuit reservoir

    N Warning lamp switch 0.5MPa

    12 - w

    12 4th axle inter-wheel differential loci

    3rd axle inter-axle J -differential lock

    H f f l = Hand relay valve 4 2

    3rd axle inter-wheel

    lock 4B&=

    Foot relay

    2 0.5MPa

    Warning lamp switch

    Brake lamp 2 switch

    valve 0.05MPa

    12 - w

    11

    e

    Solenoid valve

    11

    1st axle left air-chamber 2nd axle left air-chamber 3rd axle left air-chamber 4th axle left air-chamber

    F ig ,5 -3 Pneumat ic circuit principle diagram for XZ50K

  • XZ16K-XZ65K Owner's manual

    VI. Chass Hydraulic System Diagram

    Refer to Fig. 6 1 for the chassis hydraulic diagrams of XZ16K, XZ30K and XZ30K5; refer to Fig. 6 - 2 for the chassis hydraulic system diagrams of XZ25K, XZ35K, XZ35K5* and XZ50K with superstructure pilot control equipped; refer to Fig. 63 for the chassis hydraulic system diagrams of XZ25K, XZ35K, XZ35K5 and XZ50K with superstructure mechanical control equipped; refer to Fig. 64 for the chassis hydraulic system diagrams of XZ60K and XZ65K.

    38

  • Central rotary joint

    Quadrup le gear pump

    Hydraul ic oil tank

    Jack cyl inder | D o u b l e - w a y hydrau l i c valve

    Extens ion cy l inder

    20MPa

    T

    X

    \ri}]

    H A2

    J?

    I& . 5MPa

    B2 A3

    X 5

    T f

    B3 A4 B4 A5

    nr

    t

    B 5

    Chass is m u l t i - w a y valve

    Fig.6 1 .Chassis hydraul ic s y s t e m d iag ram for XZ16K^XZ30K and XZ30K5

  • F i g . 6 - 2 Chassis hydraul ic sys tem d iag ram for X Z 2 5 K - X Z 3 5 K - X Z 3 5 K 5 and XZ50K with supe rs t r uc tu re pi lot con t ro l equ ipped

  • Central rotary joint

    Triple gear pump

    Jack cylinder j Doub le -way hydraul ic valve

    Extension cylinder

    5 th jack cylinder

    r 20MPa|

    It X

    f t ]

    r

    x 3

    5MPa

    B1 A2

    I T

    B2 A3

    J? B3 A4 B4 A5

    i

    B5

    Chassis m u l t i - w a y valve

    Hydrau ic oil tank

    F i g . 6 - 3 Chassis hydraulic sys tem d iagram for XZ25K> XZ35K^XZ35K5 and XZ50K with supers t ruc tu re mechnica l con t ro l equipped

  • Central rotary joint Jack cylinder

    Extension cylinder

    ' D o u b l e - w a y hydraulic valve

    Variable pump

    Chassis m u l t i - w a y valve

    Hydraulic oil tank F i g . 6 - 4 Chassis hydraulic system diagram for XZ60K and XZ65K

    X N On W I X N o\ LH

    O p CD

    C

  • Owner's manual XZ16KXZ65K v >

    VII. Electric System The rated voltage of electric system is DC 24V, and single cable with negative ground. Refer

    to Fig.7 1 for chassis electric principle diagrams. Explanation of electric principle diagrams: 1. In every page, there are six districts (A-F) from top to bottom, and there are eight districts (1-8)

    from left to right. Look for components according to every district. For example, "3/1A" indicates that the component is in coordinate point of intersection of 1st district and A district on page 3.

    2. One wire code indicates one line. Lines with same wire code have same function. 3. " 1 " indicates circuit cathode. 4. Refer to Fig. 7 1 (9) for components key, symbols explanation and fuses distribution; 5. Fig. 7 1 used for 6CL and WD615 series engines with mechanical transmission.

    43

  • o XZ16KXZ65K Owner's manual

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  • Owner's manual XZ16K-XZ65K

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    48

  • Owner's manual XZ16KXZ65K

    49

  • Owner's manual XZ16K-XZ65K V/

  • 52

  • Owner's manual XZ16KXZ65K

    Vffl. Main assembly structure features and technical parameters Table 8-1 Main assembly structure features and technical parameters for XZ16K, XZ25K, XZ30K and XZ30K5

    Model XZ16K XZ25K XZ30K/XZ30K5 Model Upgraded Standard Upgraded Standard Standard Drive type 6x4 Crew 2

    Dimension (mm)

    Length 9512 9657 10735

    Dimension (mm)

    Width 2500 Dimension

    (mm) Height 2480 2480 2540 Dimension

    (mm) Wheelbase 4025+1350 4125+1350 5025+1350 Dimension

    (mm) Track Front axle 2079 2074

    Dimension (mm)

    Track Rear axle 1834

    Vehicle mass (kg)

    Chassis mass 12100 13800 15450

    Vehicle mass (kg)

    Axle load

    Front axle 4630 5080 4740 Vehicle

    mass (kg)

    Axle load Rear axle 3735 x 2 5185x2 4115x2 Vehicle

    mass (kg) Overall mass 21400 31000 32400 Vehicle

    mass (kg) Axle load

    Front axle 6300 7600 6810

    Vehicle mass (kg)

    Axle load Mid, rear axle 7550 x 2 12400 x 2 9580 x 2

    Engine Model YC6A240 - 20 6C215 - 2 WD615.50 6CL280 - 2

    Engine Max. Power kW/r/min 177/2300 158/2200 206/2200 206/2100 Engine Max. Torque 890/1400 790/1400 1100/1400 1170/1400 Engine Total displacement L 7.25 8.27 9.726 8.82

    Transmission Model 6S-90 6S-120

    Transmission Type Mechanical control, fixed axle Transmission Speed ratio 9.01/5.24/3.22/2.20/1.50/1.0/R8.30 Clutch Single plate, dry type, friction disc diameter $ 420

    Rear axle Type 1stage main reduction 1stage main reduction plus wheel rim reduction Rear axle Speed ratio 6.166 5.938

    Brake Service brake Double circuit air brake system with shoe brake acting on all wheels

    Brake Parking brake Springloaded brake system acting on wheels of mid and rear axles Brake Auxiliary brake Engine exhaust brake

    Cab Full dimension, all steel welded closed cab with instrument panel, air conditioner and electric windshield wiper, radio-cassette player equipped. Number of leaf spring Front 8/rear 14 Tire 11.00-20 1 2 . 0 0 - 2 0 Electric system 24V of voltage, negative ground

    Vehicle performance

    Max. Speed (km/h) 72 69 72 75

    Vehicle performance

    Min. Speed (km/h) 3 Vehicle

    performance Max. grade ability 36% 32% 32% 30% Vehicle

    performance Min. turning diameter 21 21.5 Vehicle

    performance

    Braking distance (m) Brake distance is not more than 10m with upper structure installed and 30km/h of initial speed traveling on dry and level asphalt road. Approach angle 16.2 17 19.5 Departure angle 14.1 13.1 13.5

    53

  • XZ16K-XZ65K Owner's manual

    Table 8-2 Main assembly structure features and technical parameters for XZ35K, XZ35K5, XZ50K, XZ60K and XZ65K Model XZ35K XZ35K5 XZ50K XZ60K XZ65K (QY70K) Model Standard Standard Standard Standard Upgraded Standard Drive type 8X4 Crew 2

    Dimension (mm)

    Length 10578 10940 11480 11076

    Dimension (mm)

    Width 2500 2750 2800 Dimension

    (mm) Height 2480 2505 2650 2505 Dimension

    (mm) Wheelbase 1520+3815+1350 1470+4150+1350 1520+3965+1350 Dimension

    (mm) Track Front axle 2079 2240 2304 2240

    Dimension (mm)

    Track Rear axle 1834 2055

    Vehicle mass (kg)

    Chassis mass 15500 16800 17900 19000 18500

    Vehicle mass (kg)

    Axle load Front axle 2X3600 2X3500 2X3785 2X4000 2X3910 Vehicle mass (kg)

    Axle load Rear axle 2X4150 2X4900 2X5165 2X5500 2X5340 Vehicle mass (kg) Overall mass 32300 36930 38580 40870 40500 Vehicle

    mass (kg) Axle load Front axle 2X5575 2X6165 2X6475 2X7500 2X7150

    Vehicle mass (kg)

    Axle load Rear axle 2X10575 2X12300 2X12815 2X13000 2X13100

    Engine Model WD615.50 6CL320-2 WD615.46 WD615.44

    Engine Max. Power kW/r/min 206 235 266 235 Engine Max. Torque N.m/r/min 1100 1250 1460 1250 Engine Total displacement L 9.726 8.82 9.726

    Transmission

    Model QJ6 5S-111GP RT-11509C

    Transmission Type Mechanical control, fixed axle Mechanical flexible shaft control, fixed axle

    Transmission Speed ratio

    9.01/5.24/ 3.22/20/1.50 /1.0/R8.30

    1 3 . 0 4 / 8 . 4 8 / 6 . 0 4 / 4 . 3 8 / 3 . 4 3 / 2 . 4 7 / 1 . 7 6 /

    1 . 2 8 / 1 . 0 / R 1 1 . 7 12.42/8.26/6.08/4.53/3.36/2.47/1.81/1.35/1.00/R12.99

    Clutch Single plate, dry type, friction disc diameter d>420

    Push-type, diaphragm, diameter $430 Pull-type, diaphragm, diameter $ 430

    Push-type, diaphragm, diameter $430

    Rear axle Type 1stage main reduction plus wheel rim reduction Rear axle Speed ratio 5.938 5.73

    Brake Service brake Double circuit air brake system with shoe brake acting on all wheels

    Brake Parking brake Spring-loaded brake system acting on wheels of mid and rear axles Brake Auxiliary brake Engine exhaust brake

    Cab All steel welded closed cab with instrument panel, heater, electric windshield wiper, radio-cassette player, etc equipped. Number of leaf spring Front8 /rear 14 Tire 11.00-20 12.00-20 12.00R24 12.00-20 Electric system 24V of voltage, negative ground

    Vehicle performanc

    e

    Max. Speed (km/h) 72 75

    Vehicle performanc

    e

    Min. Speed (km/h) 2.9 2.7 Vehicle

    performanc e

    Max. grade ability 30% 40% 35% Vehicle performanc

    e Min. Turning diameter (m) 24

    Vehicle performanc

    e Braking distance (m) Brake distance is not more than 10m with upper structure installed and 30km/h of initial speed traveling on dry and level asphalt road

    Approach angle 16 17 16.3 17.5 19 16.5 Departure angle 14 15.7 11.4 12 13 11.3

    54

  • Owner's manual XZ16KXZ65K

    IX. Main Spare Parts List

    Table 9 - 1 No. Standard No. Name Qty Remarks

    1 GB/T3452.1-1992 "O" sealing ring 7.5 * 1.8G 10 For hydraulic system 2 GB/T3452.1-1992 "0" sealing ring 9.5 x 1.8G 1 For hydraulic system 3 GB/T3452.1-1992 "0" sealing ring 10.6 * 2.65G 4 For hydraulic system 4 GB/T3452.1-1992 "0" sealing ring 14 x 2.65G 4 For hydraulic system 5 GB/T3452.1-1992 "0" sealing ring 20 x 2.65G 2 For hydraulic system 6 GB/T3452.1-1992 "O" sealing ring 22.4 x 2.65G 4 For hydraulic system 7 GB/T3452.1-1992 "0" sealing ring 37.5 x 3.55G 1 For hydraulic system 8 GB/T3452.1-1992 "0" sealing ring 46.2 x 2.65G 1 For hydraulic system 9 GB/T3452.1-1992 "0" sealing ring 48.7 x 2.65G 1 For hydraulic system 10 GB/T3452.1-1992 "0" sealing ring 51.5 x 2.65G 1 For hydraulic system 11 GB/T3452.1-1992 "0" sealing ring 97.5 x 3.55G 1 For hydraulic system 12 GB/T3452.1-1992 "0" sealing ring 100 x 2.65G 1 For hydraulic system 13 GB/T3452.1-1992 "0" sealing ring 212 x 5.3G 1 For hydraulic system 14 JB/T982-1977 Washer 10 10 15 JB/T982-1977 Washer 12 20 16 JB/T982-1977 Washer 14 5 17 JB/T982-1977 Washer 16 4 18 JB/T982-1977 Washer 18 4 19 JB/T982-1977 Washer 22 20 20 JB/T982-1977 Washer 27 2 21 JB/T982-1977 Washer 33 2

    55

  • XZ16K-XZ65K Owner's manual

    X. Tightening Torque of Main Bolts and Nuts No. Name Torque (Nm) Remarks

    1 Tire nuts 600-660 2 Suspension rod clamping bolts 264.6-323.4 3 Suspension rod tightening bolts 333.2-450.8 4 Suspension U-bolts and nuts 750 5 Connecting bolts and nuts of drive shaft flange 290-310 6 Steering wheel tightening nuts 333.2-450.8

    Notes about tightening torque of bolts and nuts: 1. The tightening torque of bolts and nuts not specified in the table above should be in

    compliance with the requirements of Appendix A in JB/T5945-91 General Technical Specifications for Construction Machinery Installation)) . The bolt strength class is 8.8. For less important parts connecting decks and hose clip, etc., the bolt strength class is 5.6.

    2. For the bolts connecting suspension and other bolts and nuts having no special requirements for connection, after repair, their threads need to be coated with sealing glue before reassemble (Le Tai 262 or 271 high strength thread sealing glue are recommended).

    3. Tighten leaf spring U-bolts with truck in full load.

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  • Owner's manual XZ16KXZ65K

    XI. Supplied Tools List for Truck Crane Special Carrier Table 1 1 - 1

    No. Name Specifications Qty Remarks 1 NST-402 toolbox 1 Imported

    ' 2 Inner-hexagon spanner 2.5 1 Imported 3 Inner-hexagon spanner 3 1 Imported 4 Inner-hexagon spanner 4 1 Imported 5 Inner-hexagon spanner 5 1 Imported 6 Inner-hexagon spanner 6 1 Imported 7 Inner-hexagon spanner 8 1 Imported 8 Inner-hexagon spanner 10 1 Imported 9 Inner-hexagon spanner 12 1 Imported 10 Inner-hexagon spanner 14 1 Imported 11 Double-ended spanner 6 x 7 1 Imported 12 Double-ended spanner 8x 10 1 Imported 13 Double-ended spanner 12 x 14 1 Imported 14 Double-ended spanner 13 x 15 1 Imported 15 Double-ended spanner 16 x 18 1 Imported 16 Double-ended spanner 17 x 19 1 Imported 17 Double-ended spanner 22x24 1 Imported 18 Double-ended spanner 27x30 1 Imported 19 Double-ended spanner 32x36 1 Imported 20 Double-ended spanner 41 x46 1 Imported 21 Ring spanner 12 x 14 1 Imported 22 Ring spanner 17 x 19 1 Imported 23 Cross-head screwdriver 100x5 1 Imported 24 Plain screwdriver 100x6 1 Imported 25 Hammer 0.5Kg 1 Imported

    57

  • XZ16KXZ65K Owner's manual

    No. Name Specifications Qty Remarks 26 Pliers 150mm l Imported 27 Adjustable spanner 150 x 18 l Imported 28 Adjustable spanner 300 x 36 1 Imported 29 Grease gun (lever type) 120CC l Imported 30 Tire inflation unit GAS-1 l Imported 31 Inflation hose PUH -12B (8 x 12 x 9m) l Imported 32 Socket spanner 10 mm l Imported 33 Socket spanner 11 mm l Imported 34 Socket spanner 12 mm l Imported 35 Socket spanner 14 mm l Imported 36 Socket spanner 17 mm l Imported 37 Socket spanner 19 mm l Imported 38 Socket spanner 22 mm 1 Imported 39 Socket spanner 24 mm l Imported 40 Socket spanner 27 mm Imported 41 Socket spanner 30 mm l Imported 42 Socket spanner 32 mm l Imported 43 Knurled ratchet spanner 10" l Imported 44 Handle with a sliding head . 10" l Imported 45 Quick rocker bar 16-1/4" l Imported 46 Connecting rod 5" l Imported 47 Connecting rod 10" l Imported 48 24V working light 1 Domestic 49 T971110 tire spanner l Domestic 50 T971120 connecting rod l Domestic 51 AK-120 First-aid kit 1 box Domestic 52 YF2004-1 Triangle warning board 1 Domestic 53 Double-ended spanner 50x55 1 Domestic For QY65K 54 Box wrench (high neck) 41 1 Domestic

  • Owner's manual XZ16K-XZ65K

    XZ16K-XZ65K TRUCK CRANE SPECIAL CHASSIS

    PACKING LIST

    XUZHOU HEAVY MACHINERY CO., LTD. XUZHOU CONSTRUCTION MACHINERY GROUP CO., LTD. CHINA

  • XZ16K-XZ65K Owner's manual

    I .Packing Technical Documents: 1. Operation Manual of Truck Crane Special Chassis 1 2. Truck Crane Special Chassis Certificate 1

    (only for chassis sold outside ) 3. Truck Crane Special Chassis Packing List 1 4. Vehicle Rear Fog Lamp Installation Certificate 1 5. Diesel Engine Product Certificate 1 6. Diesel Engine Operation Manual 1 7. Transmission Product Certificate 1 8. Transmission Operation Manual 1 9. Axle Operation Manual 1

    II. Supplied Tools See " Supplied Tools List" in product operation Manual

    ID. Supplied Spare Parts See " Supplied Spare Parts List "in product operation Manual

    60