XZ16K ~ XZ65K TRUCK CRANE SPECIAL CHASSIS OPERATION MANUAL
XUZHOU HEAVY MACHINERY CO., LTD. XUZHOU CONSTRUCTION MACHINERY GROUP CO., LTD. CHINA
Owner's manual
XZ16K—XZ65K
CONTENTS I. Preface II. Vehicle number HI. Vehicle operation ( I ) Arrangement in cab (II) Preparation before driving (III) Starting and shifting (IV) Control of clutch (V) Brake system (VI) Outriggers operation (VII) Winter operation (VIII) Wheel inspection and replacement (IX) Run-in of a new truck (X) Usage of air conditioner IV. Maintenance ( I ) Interval mileage of vehicle routine check and maintenance (II) Each assembly oil change period (III) Maintenance key points (IV) Fuel and lubricant brand and filling amount V. Pneumatic Circuit Principle Diagrams VI. Chass Hydraulic System Diagram VII. Electric System VIII. Main assembly structure features and technical parameters IX. Main Spare Parts List X. Tightening Torque of Main Bolts and Nuts XI. Supplied Tools List for Truck Crane Special Carrier Packing list
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1 2 4 4 10 12 13 14 16 20 21 23 24 26 26 26 27 33 34 38 43 53 55 56 57 59
XZ16K—XZ65K
Owner's manual
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.
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Owner's manual
XZ16K-XZ65K
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 "XCMG" brand Lifting class — Special chassis Total rated weight Inspection code —
Product No. Assembled by Xuzhou Special Vehicle co.,Ltd.XCMG 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):
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Owner's manual
XZ16K-XZ65K
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 •4•
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
Owner's manual
13. Hand brake indicator lamp 15. Lamp main switch 17. Engine stop switch 19. Emergency signal switch 21. Cool starting switch 23. Radio-cassette player 25. Hand brake handle 27. Cigarette lighter 29. Speedometer 31. Accelerator pedal 33. Starting switch 35. Combined switch 37. Steering wheel 39. Water temperature gauge 41. Double-pointer air pressure gauge 43. Engine oil pressure gauge
XZ16K-XZ65K
14. Right turning indicator lamp 16. Fog lamp switch 18. Air conditioner switch 20. Differential lock switch 22. Warning lamp switch 24. Warm air adjusting knob 26. Transmission control lever 28. Hand accelerator handle 30. Ammeter 32. Foot brake pedal 34. Horn 36. Clutch pedal 38. Fuel gauge 40. Power take-off switch 42. Engine tachometer
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 (21 , 22 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. st
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XZ16K-XZ65K
Owner's manual
When the air pressure in hand brake circuit (23 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. 3—1) 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 80-90°C. 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. rd
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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 0°C. 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. 3—1) 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, • 7•
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. 3—3 Combined switches 1. Exhaust brake switch 2. Wiper switch of front windshield •
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3. Dimmer switch
Owner's manual
XZ16K—XZ65K
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. 1 2 Accelerate 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 Fig. 3—4 Accelerator handle 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•
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
XZ16K—XZ65K
(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.3—3). 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 0°C~ -12°C, and it must be used when temperature is below -12°C. (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 • 11 •
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. Notes: 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. • 12 •
Owner's manual
XZ16K-XZ65K
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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. 3—5 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 cylinderpushrodcan 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 cylinderpushrodand branch cylinderpushrodand 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 • 14 •
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. 3—6a): 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).
Fig. 3 ~6a Brake air chamber
Fig. 3 — 6b Brake air chamber
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. • 15 •
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Owner's manual
XZ16K-XZ65K
(VI) Outriggers operation: Refer to Fig. 3—7a for names of outrigger parts of XZ16K, and Fig. 3—7b 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. 3—9b 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 • 16 •
XZ16K-XZ65K
Owner's manual
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
Fig. 3 -8b 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 • 17 •
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
Fig. 3 - 1 0 b • 18 •
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
for XZ35Kn XZ35K5> XZ50K> X Z 6 0 K , XZ65K
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 • 19 •
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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 0°C. 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) -10
-20 -30 -40
Glycerin -water Glycerin Weight % 32 51 64 75
Density D 1.0780 1.1290 1.1647 1.1894
Ethylene glycol -water Ethylene glycol weight % 28.4 38.5 47.8 54.7
Density D 1.0340 1.0506 1.0627 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
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3. Battery Regularly check the level and density of the battery electrolyte. The level should be 10-15 mm <2
above the electrode plates and the density should be more than 1.24g/cm . If do not use the truck for a long time and ambient temperature is very low, it is better to remove the battery from chassis and stow it in warm room. 1) Notes on battery checking: (1). Keep the battery clean and dry. Release the terminal for cleaning if it is contaminated, and then lubricate it with clean, no-acid and acid-proof grease. Do not coat the grease on the filling port. (2). Do not put tools on the battery.
(3). Forbid to remove the battery wire while the engine is running. (4). In summer, check the electrolyte acid quantity once a week, in other seasons check it once a month, and fill distilled water if necessary. 2) Charging the battery: use hydrometer to check the electrolyte density once a month and the value measured can indicate battery charging condition (see Table 3-2). If distilled water has been refilled, measure the battery after half an hour. Ambient temperature for measuring the electrolyte density should be 20 °C. Table 3 - 2 Density Battery charging condition 1.28 Good 1.20 Half charged, filling in time 1.12 Lack of power, charging at once In very cold season, due to heavy power consumption for the battery, pay more attention to charging the battery for its service requirement. If charging the battery, only charge with DC power and charging power can't exceed 1/10 of battery capacity. For example: charge a 165Ah battery, the charging currency should not be more than 16.5 A. 4.Engine cold starting device: The operation of engine cold starting device see its operation manual. (VDI) Wheel inspection and replacement 1. Tire inspection: (1). The tread depth of tire crown is not less than 3.2mm. • 21 •
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 rimflange,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 •
XZ16K-XZ65K
Owner's manual
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 •
XZ16K-XZ65K
Owner's manual
Hot-water valve
Engine made by Shanghai Diesel Engine Factory
Close state of hot-water valve
Hot-water valve
WD615 Series Engine
Open state of hot-water valve
Hot-water valve
Mil Series Engine
Fig. 3~12 Positions and states of engine hot-water valves
Owner's manual
XZ16K-XZ65K
IV. Maintenance ( I ) Interval mileage of vehicle routine check and maintenance Unit: 1000km Routine 1st class Routine 2nd class Routine 1st class check maint. check check maint. maint. 5 10 15 20 25 30 110 105 100 85 90 95 185 165 170 175 180 190 Routine check 45 125 205
1st class maint. 50 130 210
Routine 2nd class Routine check check maint. 55 60 65 145 135 140 215 220 225
1st class maint. 70 150 230
(II) Each assembly oil change period
Table 4 - 1 Routine 3rd class Check maint. 35 40 120 115 200 195 Routine check 75 155 235
4th class maint. 80 160 240
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 First Routine 1st class 2nd class 3rd class 4th class Maintenance item maint. maint. check check maint. maint. Engine Replace engine oil (at • • • • • • least one time per year) Change oil filter or filter • When change engine oil every time element 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
Maintenance item Replace coolant 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 Replace air filter main element Replace safety filter element of air filter Check and tighten the belt Check turbocharger compressor
Owner's manual
First Routine 1st class 2nd class 3rd class 4th class check check maint. maint. maint. maint. Every 24 months
•
• •
•
•
•
•
•
•
•
•
•
•
•
•
When air filter negative pressure indicator displays or every 100 hours When air filter main element is damaged After 5 times of cleaning main filter element •
•
•
•
•
•
•
•
•
Check oil spray pump Check and adjust engine • • accelerator opening Adjust engine idle rotation • speed Transmission Check transmission Once a week lubrication oil level Replace lubrication Initial 1000km of traveling, afterwards every 20000km. Oil Replace oil filter, washer Every time when replace oil and "O" seal ring • 28 •
•
XZ16K-XZ65K
Owner's manual
Maintenance item
First Routine 1st class 2nd class 3rd class 4th class check check maint. maint. maint. 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 Beginning from the first time of 2nd class maintenance bearing clearance 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 •
Owner's manual
XZ16K-XZ65K
Maintenance item
First Routine 1st class 2nd class 3rd class 4th class check check maint. maint. maint. 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 •
•
•
• •
•
XZ16K-XZ65K
Owner's manual
Maintenance item 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
First Routine 1st class 2nd class 3rd class 4th class check check maint. maint. maint. maint. #
#
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
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 •
Owner's manual
XZ16K-XZ65K
Maintenance item
First Routine 1st class 2nd class 3rd class 4th class check check maint. maint. maint. maint.
Lubricating positions • • Engine water pump spindle • • Engine regulator • Clutch yoke shaft • Clutch release bearing Transmission—bearing • 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 •
•
• •
• • •
• • • •
• • • •
•
•
•
•
•
• • •
•
• •
•
•
•
•
•
• • •
• • •
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• • • • • • •
•
• • • •
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• • • •
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• •
•
•
XZ16K—XZ65K
Owner's manual
(IV ) Fuel and lubricant brand and filling amount
Table 4 - 4
Capacity Brand See engine operation manual See engine operation manual According to tank capacity See engine operation manual Soft water or antifreeze coolant 50L GL-4 85W/90 lubrication oil (above -12°C) GL-4 80W/90 lubrication oil (-26°C ~ 38 °C) Transmission GL-4 75W lubrication oil (-40°C - 38°C) 13L lubrication oil GL-5 lubrication oil for S6-90, S6-120 and 5S-111 GP transmission GL-4 85W/90 lubrication oil (above -12°C) Drive shaft 20L GL-4 80W/90 lubrication oil (-26°C - 38 °C) lubrication oil GL-4 75W lubrication oil (-40°C ~ 38 °C) Steering system 6.6L L-TSA32 antioxidant and antirust steamer oil hydraulic oil Shock absorber C-27 mobile shock absorber oil ZG-S graphite calcium base grease Leaf spring grease 1500g Hydraulic oil for HZY3 (above 15 °C) clutch master cylinder HZY4 (15°C~-20°C) and branch cylinder HZY5( below -20°C) Ambient temperature above 5 °C: L-HM46 390L for XZ16K, 450L for Hydraulic system Ambient temperature -15 °C -5 °C: L-HM32 XZ25K; hydraulic oil Ambient temperature -15°C~-30°C: L-HV22 650L for XZ35K and XZ50K; (Kunlun branded) Ambient temperature below -30°C: No. 10 740L for XZ65K; aviation hydraulic oil Other positions in 3000g 3 lithium base grease chassis Name Engine oil Engine fuel Engine coolant
#
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 4—5 Classification Petrol China MOBIL SHELL
Engine oil
CD
CF-4
Delvac Delvac 1330-1340 super Rimula C Rimula D
Fuel Light fuel 0#, 10#,-10#, -20#, -35# The same The same
EDLA500 / CRD RX Turbo CASTROL MONO 15W/40, RX Grades Super TOTAL Rubia C Rubia XT
The same
Energol Venellus c3 Extra DS3
The same
CALTEX
BP
The same The same
Lubrication oil
GL-4
GL-5
Mobiube GX GSPIRAXG Thuban GL-4
Steering system
Hydraulic system L-HV 22 L-TSA 32 L-HM 32 L-HM 46 DETEOIL Named Mobil DTE11M, series DTE light 13M, 15M Turbo T oil 32 Tellus 22, 32, 46
Mobiube HD Spirax A Thuban Regal R&032 GL-5EP Perfecto SMX 80W/90 Multitrax 85W/140 T32 BOLD Transmission Preslia turbine oil TM 80W/90 32 ORBV Energol EP Hypo Gear EP
Turbinol 32
Rando oil HD 32, 46 Hyspin AWS 15, 32, 46; Hyspin AWH 15, 32, 46 AZOLLAZS 32, 46 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. 5—2 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 — 1,5—2 and 5—3, there are extinguish cylinders only when Steyr WD615 engines are equipped.
• 34 •
m.
r
r t-OOrO^H
Horn
0q_2_
era
21
Air dryer
r&r?
22
n 23
12
Air compressor 22nd circuit reservoir
3rd axle inter-wheel differential lock
Hand relay valve
21st circuit reservoir
PTO cylinder
2
22nd circuit reservoir,
Clutch control valve
1
23rd circuit reservoir
2 Extinguish cylinder = »
3 Hand brake valve
4 4
Solenoid valve
2
2
4
2nd axle inter-wheel differential lock
9
•
Exhoust broke cylinder
ft:
Warning lamp switch 0.5MPa
vWarning lamp switch Foot relay valve
0.5MPa
2 2
Srts
Brake lamp switch 0.05MPa
Foot relay valve
21 22
Foot brake valve Double-pointer air-pressure gauge
•3D
1st axle left air-chamber
r
42 41
Check volve B | PTO switch
12
2nd axle inter-axle differential lock
22
Air reservoir
3rd axle right air-chamber
2nd axle right air-chamber
Four-circuit protection valve
1st axle right air-chamber
0.05MPa Brake lamp switch
12
12
-w 2nd axle left air-chamber
- w 3rd axle left air-chamber
F i g . 5 - 1 P n e u m a t i c circuit principle d i a g r a m for XZ16K* XZ25K> XZ30K and X Z 3 0 K 5
1st axle right air-chamber 2nd axle right air-chamber
HIl Sq! Air compressor
Air
dryer
Four-circuit protection valve 3rd axle right air-chamber
fPr £ Pi £ 22
n=3_~ =0
[
P T 0
c
^
,22nd circuit reservoir
Transmission regulator cylinder
»
in(Jer
Hand broke valve
Clutch control valve tz>
circuit reservoir^
Cfn
Hand relay valve
21st circuit reservoir
Foot relay valve 4
Exhaust brake cylinder
23rd circuit reservoir.
Solenoid valve
3rd axle inter-wheel differential lock
N- 0.5MPa
Warning lamp switch
Brake lamp switch
Warning lamp switch 0.5MPa
2
12
Double-pointer Foot brake valve air-pressure gauge 2nd axle left air-chamber
Foot relay , volve 4
0.05MPa
12
1st axle left air-chamber
B
42
Brake lomp
Hfi
12
Check valve
Solenoid valve J
4th axle inter-wheel differential lock 3rd axle inter-axle differential lock
22
Air reservoir
—
11
24
Horn
PTO switch
12
23
4th axle right-air chamber
3rd axle left air-chamber
switch 0.05MPa
-W
12
4th axle left air-chamber
F i g . 5 - 2 Pneumatic circuit principle diagram for XZ35K and XZ35K5
{
1st axle right air-chamber
r^:
2nd axle right air-chamber
Air rlr\/or
I
Four-circuit wotection valve
r^
r
t
J
4th axle right air-chamber
j r d a x l e ri9ht a i r - c h a m b e r
, r-, •
12
4th axle inter-wheel differential loci Air compressor
Horn
3rd axle inter-axle J differential lock
E. TransmissioOn ncylIinAder ' Transmission requlotor cyl'inder ™= r«= Clutch control volve HI]
PTO cylinder
\22nd circuit reservoir/
Hand relay valve 4 2
9 23rd circuit reservoir
1
22
e
Hffl=
Check valve
11
22nd circuit reservoir
Solenoid valve
2 3rd axle 0.5MPa inter-wheel Warning lamp switch lock
lis uuiid brake valve
a
2 Foot relay valve
2 Exaust Solenoid valve brake cylinder
Double-Pointer air-pressure gauge
12
C n i T T ^ 0.05MPa 4 Brake lamp switch
N
4B&=
Warning lamp switch 0.5MPa
Brake lamp 2 switch
Foot relay valve
0.05MPa
trrLli 21 Foot brake valve O
22
12
HID
1st axle left air-chamber
2nd axle left air-chamber
-w 3rd axle left air-chamber
12 11
-w 4th axle left air-chamber
F i g , 5 - 3 Pneumatic circuit principle diagram for XZ50K
Owner's manual
XZ16K-XZ65K
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. 6—3 for the chassis hydraulic system diagrams of XZ25K, XZ35K, XZ35K5 and XZ50K with superstructure mechanical control equipped; refer to Fig. 6—4 for the chassis hydraulic system diagrams of XZ60K and XZ65K.
• 38 •
Central rotary joint
| Double-way hydraulic valve
Jack cylinder
Extension cylinder
H
20MPa
Quadruple gear pump
T
\ri}
]
A2
B2
J? X
X
I&
. 5MPa
T f
A3
B3
A4
B4
A5
B5
nr°
5
t
Hydraulic oil tank Fig.6— 1
.Chassis hydraulic system diagram for XZ16K^XZ30K and XZ30K5
Chassis m u l t i - w a y valve
Fig.6-2
Chassis hydraulic system diagram for XZ25K-XZ35K-XZ35K5 and XZ50K with superstructure pilot control equipped
Central rotary joint
j Double-way hydraulic valve
Jack cylinder
Extension cylinder
5th jack cylinder
r It
B1
X
20MPa|
Triple gear pump £
x
ft]
5MPa
r
A2
IT 3
B2
A3
B3
A4
B4
A5
B5
J? Chassis m u l t i - w a y valve
i
Hydrau ic oil tank Fig.6-3
Chassis hydraulic system diagram for XZ25K> XZ35K^XZ35K5 and XZ50K with superstructure mechnical control equipped
XN
Central rotary joint
Jack cylinder
On
'Double-way hydraulic valve
WI XN o\ LH
Extension cylinder
Variable pump
Chassis multi-way valve
O pCD
Hydraulic oil tank Fig.6-4
Chassis hydraulic system diagram for XZ60K and XZ65K
C
XZ16K—XZ65K v >
Owner's manual
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 •
Owner's manual
XZ16K—XZ65K
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Owner's manual
XZ16K-XZ65K
XZ16K—XZ65K
Owner's manual
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• 47 •
XZ16K-XZ65K
• 48 •
Owner's manual
Owner's manual
XZ16K—XZ65K
• 49 •
Owner's manual
XZ16K-XZ65K
V/
• 52 •
Owner's manual
XZ16K—XZ65K
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 Drive type Crew
Length Width Height Dimension (mm) Wheelbase Front axle Track Rear axle Chassis mass Axle Front axle load Rear axle Vehicle mass (kg) Overall mass Axle Front axle load Mid, rear axle Model Max. Power kW/r/min Engine Max. Torque Total displacement L Model Transmission Type Speed ratio Clutch Type Rear axle Speed ratio Service brake Parking brake Brake Auxiliary brake
Cab Number of leaf spring Tire Electric system Max. Speed (km/h) Min. Speed (km/h) Vehicle Max. grade ability performance Min. turning diameter Braking distance (m) Approach angle Departure angle
XZ16K Standard Upgraded
XZ25K Upgraded Standard
6x4 2
9512
12100
9657
10735
2480 4125+1350
2540 5025+1350 2074
2500
2480 4025+1350
2079
4630 3735 x 2 21400 6300 7550 x 2 YC6A240 - 20 6C215 - 2 177/2300 158/2200 890/1400 790/1400 8.27 7.25
XZ30K/XZ30K5 Standard
1834
13800 5080 5185x2 31000 7600 12400 x 2 WD615.50
206/2200
1100/1400 9.726
6S-90 Mechanical control, fixed axle
15450 4740 4115x2 32400
6810
9580 x 2 6CL280 - 2 206/2100 1170/1400 8.82
6S-120
9.01/5.24/3.22/2.20/1.50/1.0/R8.30
Single plate, dry type, friction disc diameter $ 420 1—stage main reduction 1—stage main reduction plus wheel rim reduction 5.938 6.166 Double circuit air brake system with shoe brake acting on all wheels Spring—loaded brake system acting on wheels of mid and rear axles Engine exhaust brake Full dimension, all steel welded closed cab with instrument panel, air conditioner and electric windshield wiper, radio-cassette player equipped. Front 8/rear 14
11.00-20
12.00-20
24V of voltage, negative ground 72 72 69 75 3 32% 32% 36% 30% 21.5 21 Brake distance is not more than 10m with upper structure installed and 30km/h of initial speed traveling on dry and level asphalt road. 19.5° 17° 16.2° 13.5° 13.1° 14.1° • 53 •
XZ16K-XZ65K
Owner's manual
Table 8-2 Main assembly structure features and technical parameters for XZ35K, XZ35K5, XZ50K, XZ60K and XZ65K Model Drive type Crew
XZ35K Standard
XZ35K5 Standard
Length Width Dimension Height (mm) Wheelbase
10578 2500 2480 1520+3815+1350 Front axle 2079 Track 1834 Rear axle Chassis mass 15500 16800 2X3500 2X3600 Front axle Axle load 2X4900 Vehicle Rear axle 2X4150 mass (kg) 32300 36930 Overall mass 2X5575 2X6165 Axle load Front axle 2X10575 2X12300 Rear axle 6CL320-2 Model WD615.50 Max. Power kW/r/min 206 235 Engine Max. Torque N.m/r/min 1250 1100 8.82 Total displacement L 9.726 Model QJ6 5S-111GP Mechanical control, fixed axle Type Transmission 9.01/5.24/ 13.04/8.48/6.04/4.3 8/3.43/2.47/1.76/ 3.22/20/1.50 Speed ratio /1.0/R8.30
Clutch Rear axle Type Speed ratio Service brake Brake Parking brake Auxiliary brake Cab Number of leaf spring Tire Electric system Max. Speed (km/h) Min. Speed (km/h) Vehicle Max. grade ability performanc Min. Turning diameter e (m) Braking distance (m) Approach angle Departure angle • 54 •
Single plate, dry type, friction disc diameter d>420
1.28/1.0/R11.7
Push-type, diaphragm, diameter $430
XZ50K Standard 10940 2750 2505
8X4 2
XZ60K Standard 11480
XZ65K (QY70K) Upgraded Standard
2800
11076
2650 2505 1470+4150+1350 1520+3965+1350 2240 2304 2240 2055 17900 19000 18500 2X4000 2X3785 2X3910 2X5500 2X5165 2X5340 38580 40870 40500 2X6475 2X7500 2X7150 2X12815 2X13000 2X13100 WD615.46 WD615.44 266 235 1460 1250 9.726 RT-11509C Mechanical flexible shaft control, fixed axle 12.42/8.26/6.08/4.53/3.36/2.47/1.81/1.35/1.00/R12.99 Pull-type, diaphragm, diameter $ 430
Push-type, diaphragm, diameter $430
1—stage main reduction plus wheelrimreduction 5.938 5.73 Double circuit air brake system with shoe brake acting on all wheels Spring-loaded brake system acting on wheels of mid and rear axles Engine exhaust brake All steel welded closed cab with instrument panel, heater, electric windshield wiper, radio-cassette player, etc equipped. Front8 /rear 14 12.00R24 12.00-20 11.00-20 12.00-20 24V of voltage, negative ground 72 75 2.9 2.7 30% 40% 35% 24 Brake distance is not more than 10m with upper structure installed and 30km/h of initial speed traveling on dry and level asphalt road 16.3° 17.5° 16° 17° 19° 16.5° 11.4° 12° 14° 15.7° 13° 11.3°
Owner's manual
XZ16K—XZ65K
IX. Main Spare Parts List Table 9 - 1 No. 1
2 3 4 5 6
7 8
9 10 11 12
13 14 15 16 17 18 19 20 21
Standard No. GB/T3452.1-1992 GB/T3452.1-1992 GB/T3452.1-1992 GB/T3452.1-1992 GB/T3452.1-1992 GB/T3452.1-1992 GB/T3452.1-1992 GB/T3452.1-1992 GB/T3452.1-1992 GB/T3452.1-1992 GB/T3452.1-1992 GB/T3452.1-1992 GB/T3452.1-1992 JB/T982-1977 JB/T982-1977 JB/T982-1977 JB/T982-1977 JB/T982-1977 JB/T982-1977 JB/T982-1977 JB/T982-1977
Name Qty Remarks "O" sealing ring 7.5 * 1.8G 10 For hydraulic system For hydraulic system 1 "0" sealing ring 9.5 x 1.8G "0" sealing ring 10.6 * 2.65G 4 For hydraulic system 4 For hydraulic system "0" sealing ring 14 x 2.65G 2 For hydraulic system "0" sealing ring 20 x 2.65G "O" sealing ring 22.4 x 2.65G 4 For hydraulic system "0" sealing ring 37.5 x 3.55G 1 For hydraulic system "0" sealing ring 46.2 x 2.65G 1 For hydraulic system "0" sealing ring 48.7 x 2.65G 1 For hydraulic system "0" sealing ring 51.5 x 2.65G 1 For hydraulic system "0" sealing ring 97.5 x 3.55G 1 For hydraulic system 1 For hydraulic system "0" sealing ring 100 x 2.65G For hydraulic system 1 "0" sealing ring 212 x 5.3G Washer 10 10 Washer 12 20 5 Washer 14 4 Washer 16 Washer 18 4 Washer 22 20 2 Washer 27 2 Washer 33 • 55 •
XZ16K-XZ65K
Owner's manual
X. Tightening Torque of Main Bolts and Nuts No.
Name
Torque (Nm)
1
Tire nuts
2
Suspension rod clamping bolts
264.6-323.4
3
Suspension rod tightening bolts
333.2-450.8
4
Suspension U-bolts and nuts
5
Connecting bolts and nuts of drive shaft flange
6
Steering wheel tightening nuts
Remarks
600-660
750 290-310 333.2-450.8
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.
• 56 •
Owner's manual
XZ16K—XZ65K
XI. Supplied Tools List for Truck Crane Special Carrier Table 11-1 No. 1
' 2 3 4 5 6
7 8
9
10 11
12
13 14 15 16
17 18 19 20
21 22 23 24 25
Name NST-402 toolbox Inner-hexagon spanner Inner-hexagon spanner Inner-hexagon spanner Inner-hexagon spanner Inner-hexagon spanner Inner-hexagon spanner Inner-hexagon spanner Inner-hexagon spanner Inner-hexagon spanner Double-ended spanner Double-ended spanner Double-ended spanner Double-ended spanner Double-ended spanner Double-ended spanner Double-ended spanner Double-ended spanner Double-ended spanner Double-ended spanner Ring spanner Ring spanner Cross-head screwdriver Plain screwdriver Hammer
10 12 14 6x7
Qty 1 1 1 1 1 1 1 1 1 1 1
8x 10
1
Specifications 2.5 3 4 5 6 8
12 x 14 13 x 15 16 x 18
17 x 19 22x24 27x30 32x36 41 x46 12 x 14 17 x 19 100x5 100x6 0.5Kg
1 1 1 1 1 1 1 1 1 1 1 1 1
Remarks Imported Imported Imported Imported Imported Imported Imported Imported Imported Imported Imported Imported Imported Imported Imported Imported Imported Imported Imported Imported Imported Imported Imported Imported Imported • 57 •
Owner's manual
XZ16K—XZ65K
No.
Name
29 30 31
Pliers Adjustable spanner Adjustable spanner Grease gun (lever type) Tire inflation unit Inflation hose
32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52
Socket spanner Socket spanner Socket spanner Socket spanner Socket spanner Socket spanner Socket spanner Socket spanner Socket spanner Socket spanner Socket spanner Knurled ratchet spanner Handle with a sliding head Quick rocker bar Connecting rod Connecting rod 24V working light T971110 tire spanner T971120 connecting rod AK-120 First-aid kit YF2004-1 Triangle warning board
26
27
28
53 Double-ended spanner 54
Box wrench (high neck)
Specifications 150mm 150 x 18 300 x 36 120CC GAS-1 PUH -12B (8 x 12 x 9m) 10 mm 11 mm 12 mm 14 mm 17 mm 19 mm 22 mm 24 mm 27 mm 30 mm 32 mm
Qty
l l 1 l l l l l l l l l 1 l l l
10"
l
. 10"
l
16-1/4" 5" 10"
l l l 1 l l
1 box 1
50x55
1
41
1
Remarks Imported Imported Imported Imported Imported Imported Imported Imported Imported Imported Imported Imported Imported Imported Imported Imported Imported Imported Imported Imported Imported Imported Domestic Domestic Domestic Domestic Domestic Domestic For QY65K 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
Owner's manual
XZ16K-XZ65K
I .Packing Technical Documents: 1. Operation Manual of Truck Crane Special Chassis 2. Truck Crane Special Chassis Certificate (only for chassis sold outside ) 3. Truck Crane Special Chassis Packing List 4. Vehicle Rear Fog Lamp Installation Certificate 5. Diesel Engine Product Certificate 6. Diesel Engine Operation Manual 7. Transmission Product Certificate 8. Transmission Operation Manual 9. Axle Operation Manual 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 •
1 1 1 1 1 1 1 1 1
