XZ16K ~ XZ65KTRUCK 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 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 Owner's manual XZ16K—XZ65K 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• please give the following correctly and clearly: •2• . order spare parts or contact with our service department. Product name and model. Delivery date. Manufacturer Symbols stars (ik) are marked at both end of product number and vehicle identification number. Vehicle identification number (VIN) (for the chassis supplied outside). 4. 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. 5.. Product 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. Engine number. 2. The nameplate c6nsists of 1. Assembled by Xuzhou Special Vehicle co. 3.XCMG Product manufacture date Note: the VIN mentioned above is only used for the chassis supplied outside.Ltd. 6.XZ16K-XZ65K Owner's manual II. When you claim compensation. : Delivery Date: Vehicle Identification Number (VIN): • 3• .Owner's manual XZ16K-XZ65K Vehicle Type: Product No.: Engine No. Fog lamp indicator light 10. Vehicle Operation (I ) Arrangement in cab Arrangement in cab consists of controllers and instrument panel including instrumentation.XZ16K-XZ65K Owner's manual III. Beam indicator lamp 4. 3 . Differential lock indicator lamp 9.1 Arrangement in cab I. Water temperature warning lamp II. switches and indicators. Foot brake indicator lamp 8. Fig. Reversing indicator lamp 7. Power indicator lamp 5. Power take-off indicator lamp . Low air pressure warning lamp •4• 2. Oil pressure warning lamp 6. Refer to figure 3 — 1. Left turning indicator lamp 3. Fuel warning lamp 12. Horn 36. 3 . Water temperature gauge 41. Position 2: " ON " state. Differential lock switch 22. Engine oil pressure gauge 14. 33 in Fig. Radio-cassette player 25. 3 . 3~2. Cigarette lighter 29. st nd • 5• . the normal working pressure is 0.45MPa.1 ) Three positions are available for selection after the key is inserted into the starting switch. switches and signal indicators in cab: 1).Owner's manual XZ16K-XZ65K 13. Starter switch (No. Right turning indicator lamp 16. see Fig.8 MPa. Combined switch 37. Hand accelerator handle 30. Double-pointer air pressure gauge (No. Double-pointer air pressure gauge 43. Transmission control lever 28. Power take-off switch 42. stop the vehicle to check the pneumatic circuit system. Hand brake indicator lamp 15. the key can be pulled out. Air conditioner switch 20. Fog lamp switch 18. Clutch pedal 38. Warm air adjusting knob 26. Starting switch 35. Foot brake pedal 34.45-0. Ammeter 32. Accelerator pedal 33. Functions of instrumentation. Position 3: starting engine state 2). 22 circuit). the key must be in the position when engine is running. Speedometer 31. Engine tachometer 1.2 Low air pressure warning lamp (No. Engine stop switch 19. their functions are as follows: Position 1: with electric power supply cut off. Emergency signal switch 21. Hand brake handle 27. 3 — 1) Double-pointer air pressure gauge indicates pressure in two circuits of service brake system (21 . Warning lamp switch 24. Lamp main switch 17. Cool starting switch 23. Fuel gauge 40. 41 in Fig. Steering wheel 39. If the air pressure in any one of two circuits decreases below 0. 11 in Fig.3 —1) Fig. when truck drives in high speed or climbs a slope. Ammeter (No. Engine oil pressure gauge (No. Release the switch. 3 — 1) Oil pressure warning lamp (No. Ammeter pointer pointing to " + " area indicates power generated by alternator is more than that consumed by electric equipments. 3 — 1) Fuel warning lamp (No. 5). 29 in Fig. braking or climbing up and down slope. 3 . 43 in Fig. 3 -1) The ammeter indicates charging and discharging of the battery. in reverse. the pointer is near middle position. the battery is in discharging. 42 in Fig. Speed meter indicates vehicle traveling speed and mileage meter registers vehicle total traveling miles. 3 — 1) Water temperature warning lamp (No. so that to stop engine. 38 in Fig. 10 in Fig. The pointer of fuel gauge will vary when the vehicle is in state of accelerating. 17 in Fig. Provide guarantee for using the engine reasonably. 7). rotational speed. 8). the lamp lights. and let the engine runs in idle to lower the water temperature to normal condition. Note: don't release the switch before shutting the engine off. 39 in Fig. 3 — 1) Water temperature gauge indicates coolant temperature. 4). 3 — 1) When starting switch key is in position 2. 9).XZ16K-XZ65K rd Owner's manual When the air pressure in hand brake circuit (23 circuit) of pneumatic circuit system is below 0. the fuel gauge approximately indicates the fuel level remained in tank. Engine stop switch (No. If the water temperature is too high. 3—1) Engine tachometer indicates engine rotational speed for driver to adjust engine idle and control engine max. In normal condition. 9 in Fig. Fuel gauge (No. indicating that the tnick can not be started or the PTO can not be operated. 6). 3 —1) The switch is used to cut out the power supply to engine. Engine tachometer (No.1 ) Speedometer consists of speed meter and mileage meter. 3).e. 4 in Fig. 3 — 1) It displays the oil pressure value of engine lubrication system. i. In tropical zone (area). it will reset. 30 in Fig. Engine water temperature gauge (No. the truck must be stopped. •6• .45MPa. the battery is in charging. Please refer to engine operation instruction for the engine oil pressure values either in idle speed or in normal operation. the pointer will move to the red sector of the gauge. Speedometer (No. indicating engine normal working temperature of 80-90°C. When use the switch. engine power output must be cut off and the truck must be in static condition or in pedestrian speed. this switch must be used. In case the truck drives on a good road. 3 —1 optional) When a cold starting device is equipped. Differential lock switch (No. After engine runs normally. 19 in Fig. air conditioner can work (refer to air conditioner operation manual). the switch is used in control of ether sprayed into inlet pipe. reset the switch when don't use air conditioner. When use the switch. 7 in Fig. it indicates that generator doesn't work. 11). the fog indicator lamp illuminates. stop the vehicle and check cause. 15). 3 .1 ) and Differential indicator lamp (No. 15 in Fig. Turning on the switch. the indicator lamp lights. 3—1) When starting switch is on position 2. the warning lamp lights and all the steering indicator lights flash.Owner's manual 10). If the lamp does not go out yet. the indicator lamp goes out. 8 in Fig. the switch must be disengaged at once. 14). you can start the engine. Power indicator lamp (No. Cold starting switch (No. 3 — 1) During traveling in foggy days. If the lamp does not go out. it indicates that generator begins to work. • 7• . 3 — 1) Fog indicator lamp (No. If the indicator is not light. 16 in Fig. 16). Lamp main switch (No. press the switch to link the drive axle rigidly by electric-pneumatic control devices. Air conditioner switch (No. Note: Before engaging or disengaging the differential lock. 13). 3 — 1) The emergency signal switch must be used when truck has to park in dangerous place. the lamp main switch must be used. Keeping on use of the switch will result damage of transmission and increase fuel consumption. It is only used when environmental temperature is below 0°C. 3 —1) Press down the switch. 12). Turning off the switch to release the danger warning. 20 in Fig. Let it reset when don't use it. 18 in Fig. Emergency signal switch (No. speedup engine accelerator to mid-rotational speed. 3 1) When traveling in night. 3 in Fig. 3 — 1) When rear wheels get into a pit and couldn't get out. 21 in Fig. The warning lamp activates even if the starting key in position 1. Only when the truck drives in straight line can the switch be used. it indicates that power is ON. the differential lock indicator lights. Fog lamp switch (No. Hand brake handle (No. When emergency brake is necessary in danger and foot brake is out of order.1 ) Hand brake indicator lamp (No. 3 . When service brake is damaged and the vehicle has to be towed. 3 — 1) Before leaving the truck.XZ16K-XZ65K Owner's manual stop the engine and check. apply the hand brake instead of service brake. 3 -1) Refer to Fig 3 . hand brake indicator lamp illuminates. Exhaust brake switch 2. Before traveling. 35 in Fig. At this time. it means that the vehicle is in parking brake. 13 in Fig. apply hand brake handle to brake the vehicle. 25 in Fig. release it (hand brake indicator lamp goes out). 18). 3—3 Combined switches 1. Warning: do not use the parking brake and the service brake at the same time to prevent the braking system from damage. Combined Switch (No. apply the hand brake handle. Fig. Dimmer switch . 17). Wiper switch of front windshield • 8 3.3 for combined switch. 1 ) PTO indicator lamp (No. pulling the switch backwards can realize exhaust brake. pulling the switch backwards can control wiper motor to run in low speed or high speed. With button 1 on the front end of hand accelerator pressed down. 20). the second gear is for turning on headlight. Operation of changing roadway is the same as the operation of steering signal switch. pull it backwards to turn on right steering lamp. depress clutch pedal to disengage clutch. Operation method: see Fig.1 ) A PTO intending to drive the hydraulic pump for crane lifting operation is installed on the rear of the transmission. 3 — 1) pressed. 3 . to decelerate. 3 . pull it downward for beam light. turn handle 2 directly. let engine running in idle speed. Lift the switch up for dimmer. left steering indicator lamp and traveling left steering lamp illuminate. at this time. in reverse. push PTO switch downward (PTO indicator lamp goes out) and release clutch •9• . The control lever should be returned to neutral after steering. PTO gear will mesh smoothly with transmission gear. right steering indicator lamp and traveling right steering lamp illuminate. position it in mid-position for dim light. In reverse. 28 in Fig. 40 in Fig.Owner's manual XZ16K—XZ65K Operation of exhaust brake switch: when the vehicle travels on a long downhill. PTO switch (No. turning small switch on the end of dimmer switch. 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. Hand accelerator handle (No. the first gear is for turning on traveling lamp. clockwise to decelerate. It can be used when operate outriggers or when truck is traveling in long distance and no need to change gears. Operation of XZ16K~XZ35K: after parking the truck. 3—4 Accelerator handle engine accelerator is necessary. Operation of dimmer switch: with lamp main switch (No. If micro-adjust Fig. Operation of wiper switch of front windshield: lifting the switch up can start washing motor to clean front windshield. Reset the switch when don't use it. PTO begins to work. Turn it counter clockwise to accelerate. depress clutch pedal to disengage the clutch. 3 — 1) The hand accelerator handle is a manual device for operating engine accelerator rocker. position the shift lever to neutral. Note: never stop the engine when the vehicle travels on a long downhill with the switch applied. 1 2 Accelerate 19). 3 4. pull handle 2 out to accelerate. 12 in Fig. push the switch forwards to turn on left steering lamp. 15 in Fig. pull PTO switch up (PTO indicator lamp comes on) and release the clutch pedal. XZ16K-XZ65K Owner's manual pedal. 21). depress clutch pedal to disengage the clutch. depress clutch pedal to disengage the clutch. PTO gear will disengage with transmission gear smoothly. set the shift lever to 4th position. PTO begins to work. (6) Check the tire pressure. push PTO switch downward and release clutch pedal. when it is running at approx. not lower than the centerline of transmission countershaft. Warning lamp switch (No. If no coolant is found. Note: Awhen operate the PTO switch. replenish the specified engine oil depending on the level mark of the dipstick. check fuel level on fuel gauge. i. Operation of XZ50K~XZ65K: after parking the truck. 1.e. fill coolant till it is found. at this time. pressure in pneumatic circuit should be more than 0. and replenish fuel if necessary. Check fuel level: Position the key switch of power supply to position 2. Do not fill coolant when engine still in hot temperature. AWhen traveling. let engine running in idle speed. 22 in Fig. the PTO switch must be in off position. Then start engine. Check transmission oil level: The transmission oil level must be not lower than the position of the side sight-hole on the transmission case. (4).45 MPa (low air pressure warning lamp goes out). (2). 3-1) The switch and warning lamp are optional parts. In reverse.. PTO gear will mesh smoothly with transmission gear. The lamp only can be used when lifting operation is performing if it is equipped. checking coolant level must prevent hot water and steam from injury of person. • 10 • . PTO gear will disengage with transmission gear smoothly. at this time. Check engine oil level: Pull out the dipstick (see ((Engine Operation Manual)) ). and inflate the tire if necessary. (5) Drain the water condensed in the air reservoir by removing the manual drain valve under the air reservoir.1000 rpm refill coolant to specified level. pull PTO switch up and release clutch pedal. (3). (II) Preparation before driving The preparation before driving includes routine inspection before driving and engine starting. Note: When truck in normal traveling. at this time. Routine inspection before driving: (1). Check coolant level Check coolant level through inlet of water tank. The requirements for engine operation see ((Engine Operation Instruction Manual )) . set hand accelerator in appropriate position or depress accelerator pedal to 1/4 of its stroke. press the ether spray switch while turning on the starting switch. engine idle time can't exceed 5 minutes. Note: never let the engine run in high speed when it is just started. (10) Check air filter. Empty and clean the dust-collector everyday if the truck works in dusty environment. release your hand. Operation of power supply switch (see Fig. (2). turn the starting key to position 3 to start the engine. (8) Check function of all the electric system. stop starting and check the cause.3—3). return the key to position 2. Engine starting: (1). Note: when starting the engine by wire-contact. (9) Check leakage of oil and coolant. When starting. It is recommended to use the cold start device in temperature range of 0°C~ -12°C. 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). stop engine at once and check the cause.Owner's manual XZ16K—XZ65K (7) Check the tightness of tire bolts. clean the filter element. (3) Cold starting device: When starting the engine in lower temperature. After starting engine. The cold starting device is an ether sprayer. If continually fail starting for 3 times. (4) Starting process: With hand brake handle in braking condition. the engine can be started rapidly with the low burning point of ether. If the pointer does not move. and it must be used when temperature is below -12°C. Turning the key from position 2 to position 3 can start the engine. it is necessary to start with the aid of cold starting device (optional). increase rotation speed gradually up to • 11 • . (6) Preheating of the engine: After starting. after 2 minutes to start again. If fail to start within 12 seconds. and then the starting switch resets. put shift lever in neutral position. After ether is sprayed into inlet pipe and mixed with fuel gas. 2. the key will automatically return to position 2. (5) Engine oil pressure after starting: After starting. the wire can only be connected to the battery and never to the starting motor. If red line in air filter negative pressure indicator occurs. Only when water temperature is higher than 75 °C. Never travel with a shift lever in neutral or slide with an engine stopped for transmission lubricating and safety. Only when the pressure of air reservoir in braking system is up to 0. (2) Shift to 1st gear to start running the truck. Operating method of transmission: Shift up: (1) Set the shift lever (No. operating lever position may not be changed. and finally to the highest gear. Note: especially after starting the engine in low ambient temperature. If leaving the track for a long time. the operating lever must be in neutral position. Stopping the engine: Press the engine stop switch to shut it off. For temporary stopping. 26 in Fig. 3. • 12 • . 3 — 1) in neutral position for engine starting. Shift down: when shifting down. apply the hand brake. the hand brake indicator light and low air pressure warning light go out. check regularly oil pressure gauge. When parking is necessary. engine oil pressure is higher than 0. During traveling. the 3rd and the 4th.45Mpa. Stopping and parking: The vehicle can be stopped with foot brake or hand brake whenever operating lever is in whatever gears. (3) Consecutively change gears in order from the 1st one to the 2nd. 3. Notes: Use the 1st gear for starting the track. the rotation speed should be increased slowly to make sure that the bearings get sufficient lubricating and stable oil pressure. 2.Owner's manual 1000 ~ 1200 r/min and begin running with a partial load. After the hand brake indicator light goes out. can the engine run with a full load. The truck can't be started before the hand brake indicator light goes out. all the air-powered systems can be operated. And then the truck can be started. (HI) Starting and shifting: 1. Never shift gears with accelerator pedal depressed. speedometer and water temperature gauge. shifting from the highest gear to the 1st gear can be operated consecutively.25 MPa. Starting Release the hand brake handle. the spring brake can be released. (IV) Control of clutch: Fig. if possible lift the front or rear section of the truck up. (2) When engine and transmission are damaged. but the pull-type one's can't. If not. check both clearances of master cylinderpushrodand branch cylinderpushrodand check if there is air in the static pressure oil circuit. Operations in emergency: (1) When the transmission has a trouble and the truck must be moved. 3~ 1) must be turned on and turning indicator lights of towing vehicle should also be turned on. On the condition of clutch pedal depressed to the bottom. the traveling speed for the truck towed can not exceed 10 km / h. The length of the push-type clutch branch cylinderpushrodcan be adjusted manually. (3) When driven shaft or drive shaft is damaged. • 13 • . 19 in Fig. Refer to Fig.Owner's manual XZ16K-XZ65K v> 4. 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 clutch should be disengaged fully. and the emergency signal switch (No. propeller shaft should be disassembled in principle. 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. and then the truck unable to move. In case the air pressure of one air reservoir in two circuits drops below 0. Its working pressure is 0. that means there is air in the static pressure oil circuit. and the 2nd circuit acts on the wheels of the 2nd and 3rd axles. stop the • 14 • . inspect all clearances. that means there is air in the static pressure oil circuit too. The 1st circuit acts on the wheels of the 1st axle. and fill brake oil into the oil cup until the oil level up to the 3/4 to 4/5 of the cup height. that means the adjusting screw of the branch cylinder is in wrong position.Owner's manual the branch cylinder pushrod stroke L of push-type should be in range of 23-25 mm. the slipping of clutch will happen. the clearance of the pull-type clutch pedal will gradually be enlarged.45Mpa. (2) Remedy for common troubles: When pressure in the pneumatic circuit rises above 0. For the truck with four axles.45Mpa. If continue to use it. first fill the system with static pressure oil and bleed the system. So after traveling 4000km. 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. check the branch cylinder pushrod clearance. 32 in Fig. do the following: Loosen the bleeding cap on the branch cylinder. it needs to be readjusted. or the branch cylinder is assisted without depressing the pedal. and the 2nd circuit acts on the 3rd and 4th axles. If the pull-type clutch couldn't be disengaged fully. repeatedly depress the clutch pedal until brake oil sprays out of the bleeding cap. if pedal is heavy to operate. (1) The adjusting method of clutch control system: Since the clutch system is controlled by static pressure oil. (V) Brake system: The brake system consists of service brake (foot brake). 3-1) with double-circuit air pressure brake. 2) Remove the rubber cover on the branch cylinder bleeding cap.8Mpa. Service brake: The service brake is foot pedal control (No. if not. the 1st circuit acts on the wheels of the 1st and 2nd axles. the clearance of the push-type clutch pedal will gradually be shortened. check the branch cylinder and its air supply. With the wear of clutch friction lining. If the branch cylinder is assisted slowly after depressing pedal. If the clearance is very small or zero. 1) Open the cover of oil cup in driver's cab. And then depress the clutch pedal and tighten the bleeding cap. 1. parking brake (hand brake) and auxiliary brake (engine exhaust brake). During operation pay attention to the oil level in the oil cup and replenish oil according to requirements. wedges must be put under the wheels to block the truck in prevention of slipping. applying hand brake handle can hold the truck at original place.45Mpa. Letting the bolt out by tightening the nut can release braking. Notes on brake system operation: (1) Releasing of spring brake air chamber: When self-braking happens due to leakage of pipeline. Fig. 2. apply hand brake instead of service brake. 3-3). When service brake is damaged and the vehicle has to be towed. spring brake air chamber can be fully released as well as parking brake. After stopping the truck. This is parking brake. 3 ~6a Brake air chamber Fig.Owner's manual XZ16K-XZ65K truck and find the cause of low pressure. 3-6b). 1 in Fig. Parking brake: Parking brake is exhaust brake acting on rear two axles. Repeated braking in a short time may cause pressure down below 0. Apply hand brake handle for emergency brake when service brake does not work. (2) When use exhaust brake. In order to prolong brake life during a long downhill travel. c. 3 — 6b Brake air chamber d. Remove the nut on bolt and take off the bolt. close butterfly-valve on exhaust pipe by solenoid valve and cylinder to realize engine exhaust brake. 3—6a): a. 3.45Mpa (low pressure warning lamp goes out) and hand brake indicator lamp went out. never disengage transmission. do the following to release (see Fig. Only with hand brake released and the pressure in 23 circuit of brake system more than 0. and never depress clutch pedal. 4. Open the plug at the tail of brake air chamber. • 15 • . Insert the bolt into brake air chamber from its tail and lock (see Fig. It gives effect on all axles by the spring-loaded air chamber on each axle respectively. b. Auxiliary brake Auxiliary brake is engine exhaust brake. before releasing the spring brake. press down exhaust brake switch (No. When parking the truck on a slope. 3 . 3 —8b for its control levers. XZ60K and XZ65K. XZ30K5. Left front outrigger control lever 4. Jack cylinder Fig. 3 .7 a for XZ16K 1.7 b for XZ16K • 16 • .10b for their control levers 1. Level gauge 3. refer to Fig. and Fig. 3—9b for their control levers. Extension & Jack control lever Fig. 3—7a for names of outrigger parts of XZ16K. and Fig. refer to Fig. Outrigger beam lock pin 4.w XZ16K-XZ65K Owner's manual (VI) Outriggers operation: Refer to Fig. 3 —10a for names of outrigger parts of XZ35K. Right front outrigger control lever 5. Left rear outrigger control lever 2. Right rear outrigger control lever 3. Outrigger control levers 2. 3 —8a for names of outrigger parts of XZ25K. 3—7b for its control levers. 3 . XZ50K. Lock pin hole 5. and Fig. and Fig. refer to Fig. 3~ 9a for names of outrigger parts of XZ30K and XZ30K5. 5th Jack control lever Fig. Jack cylinder 5. Level gauge 4.9 a for XZ30K> XZ30K5 • 17 • .Owner's manual XZ16K-XZ65K 1. Outrigger control levers Fig. Left rear outrigger control lever 2. Lock pin hole 3. 3 . Outrigger beam lock pin 2. Outrigger float 6. Outrigger control levers for XZ25K 1. Right rear outrigger control lever 3. Right front outrigger control lever 5. Lock pin hole 3. Extension & Jack control lever 6. Outrigger float 6. 3 -8b for XZ25K 1. Outrigger beam lock pin 2. Left front outrigger control lever 4. Level gauge 4. Jack cylinder 5. 1 0 b • 18 • for XZ35Kn XZ35K5> XZ50K> X Z 6 0 K . Right front outrigger control lever 2.XZ16K-XZ65K Owner's manual 1. Lock pin hole 3. Outrigger control levers Fig. 3-10a forXZ35K. 3 . Left front outrigger control lever 3. Left rear outrigger control lever 5. Left front outrigger control lever 3. Right rear outrigger control lever 4. Extension & Jack control lever 6. XZ65K . Outrigger float 6. XZ60K. Jack cylinder 5. Outrigger beam lock pin 2. Left rear outrigger control lever 5. Level gauge 4. XZ65K 1 2 3 4 6 5 1. 5th Jack control lever Fig.9 b for XZ30K> XZ30K5 1. Right rear outrigger control lever 4. XZ35K5. Right front outrigger control lever 2. Extension & Jack control lever Fig. 3 . XZ50K. While observing level gauge. Stowing outriggers: Caution: stow the main boom and jib of the upper carriage beforehand. (7). After the 5th jack is in contact with the ground. (3). Position control levers (1st to 4th) to "Extension". After jacks are fully extended. return the "Right front" and "Right rear" control levers to "Jack". inch Extension & Jack control (5th) lever to "Retract". Move Extension & Jack control lever (5th) to "Extend". The operation site must be flat before the chassis entering it. Move control levers to "Jack" and then move Extension & Jack control lever (5th) to "Retract". 4. Do not set the outriggers without extending them. (4).Owner's manual XZ16K-XZ65K 1. After outrigger beams are fully extended. move Extension & Jack control lever (5th) to "Neutral" as well as 5th Jack control lever (6th). (9). make sure that all outrigger floats are in complete contact with • 19 • . Position control levers to "Extension" and then move Extension & Jack control lever (5th) to "Retract". (3). (1). (8). (3). Pull out the outrigger beam lock pins. (2). Check if the crane is level by using level gauge. (4). return all control levers (1st to 4th) to "Neutral". move 5th Jack control lever (6th) to "Jack". Setting outriggers (1). Move Extension & Jack control lever (5th) to "Extend". 2. After setting up outriggers. (6). Move Extension & Jack control lever (5th) to "Extend". After the crane is leveled. Return all control levers to "Neutral". 3. Example: when the crane right side is higher. If 5th jack is equipped. (2). (5). 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. Insert beam lock pins. (2). Position control levers to "Jack". return the remaining control levers to "Neutral". Notes on operation: (1). move Extension & Jack control lever (5th) to "Neutral". return Extension & Jack control lever (5th) to "Neutral". (10). If it is level. 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 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 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 -20 -30 -40 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 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. (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 • < 2 (2). Do not put tools on the battery. 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 • And avoid abrupt accelerating and emergent braking. (3) In traveling. (4) Check and control engine oil pressure and coolant working temperature. (2) During run-in time. do not accelerate the engine immediately. 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. the truck should travel on level and flat roads. select proper shift gears according to load and road conditions. routine inspection should be carried out for ensuring the truck in normal working condition. tighten wheel nuts according to the specified torque.Owner's manual XZ16K-XZ65K Fig. If serious overheating occurs. the engine rotation speed should be limited within 80 ^ % of its highest speed. Notes on run-in: (1) After cold starting. In run-in time. (5) Check regularly wheel hubs of all axles and brake drum temperature. only after normal working temperature is reached. • 23 • . (6) After initial traveling of 50Km or every time changing tires. find the cause and adjust or repair. Refer to air conditioner operation manual for details. 3~ 12). Note: be sure to close hot water valve when use cold air. close hot water valve in warm air pipeline and then press down the No. In winter. In winter when use the warm air. 3 — 1. when it is necessary to drain off the water in engine cooling system.XZ16K-XZ65K Owner's manual After run-in time. 18 switch in Fig. and last press down A/C switch on the air conditioner. Maintenance " and the requirements in engine and transmission operation manuals. and then press down the No. (X) Usage of air conditioner The products adopt cold-warm air conditioner. 3 — 1. open hot water valve in warm air pipeline (on connection of engine and warm air hot water pipe. check and maintain the truck according to the "first check " items specified in chapter "IV. In summer when use the cold air. 18 switch in Fig. be sure to open hot water valve when use warm air. the water in warm air pipeline must be drained off too. refer to Fig. cold air is supported by refrigerant circulated in air conditioner system. • 24 • . Warm air is utilizing engine cyclical hot water. Owner's manual XZ16K-XZ65K Hot-water valve Engine made by Shanghai Diesel Engine Factory Close state of hot-water valve Hot-water valve WD615 Series Engine Hot-water valve Open state of hot-water valve Mil Series Engine Fig. 3~12 Positions and states of engine hot-water valves . 1 Routine 3rd class Check 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. 80 160 240 (II) Each assembly oil change period Classification First check Routine check 1st class maintenance 2nd class maintenance 3rd class maintenance 4th class maintenance • 26 • Table 4 .2 Transmission • Engine Front. 55 60 65 145 135 140 215 220 225 1st class maint. 70 150 230 Table 4 . 35 40 120 115 200 195 Routine check 75 155 235 4th class maint.XZ16K-XZ65K Owner's manual IV. Maintenance ( I ) Interval mileage of vehicle routine check and maintenance Unit: 1000km Routine 1st class Routine 2nd class Routine 1st class check maint. maint. 50 130 210 Routine 2nd class Routine check check maint. rear axle Remarks 1500km of traveling • • • • • • • • • • • • • • . check check maint. coolant and fuel. (8) In winter. signal system and indicator lights (indicator lamp for oil pressure. (6) Inspect the level of engine oil. Daily maintenance (1) Inspect the operation of hand brake and foot brake. leaf spring U-bolt. (5) Inspect the condition of tire air pressure and the tightness of wheel bolts.) (3) Inspect the operation of air filter negative pressure indicator. 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 • . (9) Drain off the water condensed in air reservoir. etc.Owner's manual XZ16K-XZ65K (IE) Maintenance key points 1. maint. (2) Inspect the function of illuminating. Each class maintenance item Table 4 . (10) Inspect the tightness of universal joint bearing cover bolts. (7) Inspect oil level of transmission. air reservoir pressure. charging. maint.3 First Routine 1st class 2nd class 3rd class 4th class Maintenance item maint. check check maint. (4) Inspect the operation of windscreen wiper. 2. inspect anti-freezing condition of pneumatic circuit system. XZ16K-XZ65K Owner's manual 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 Check oil spray pump First Routine 1st class 2nd class 3rd class 4th class check check maint. maint. afterwards every 20000km. 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 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. washer Every time when replace oil and "O" seal ring • 28 • . Oil Replace oil filter. maint.Owner's manual XZ16K-XZ65K Maintenance item Driven axles (front axles) Replace wheel hub grease Check and adjust the front shaft bearing clearance Drive axles First Routine 1st class 2nd class 3rd class 4th class check check maint. maint. maint. • • Beginning from the first time of 2nd class maintenance 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 • . head light. 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 • First Routine 1st class 2nd class 3rd class 4th class check check maint. maint. heater. maint.XZ16K-XZ65K Owner's manual Maintenance item 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. wiper. 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. etc. • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • . maint. Owner's manual XZ16K-XZ65K 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 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 First Routine 1st class 2nd class 3rd class 4th class check check maint. maint. • • # # • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 31 • . maint. maint. • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • . maint. maint. • 32 • First Routine 1st class 2nd class 3rd class 4th class check check maint. maint.XZ16K-XZ65K Owner's manual Maintenance item 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. Owner's manual XZ16K—XZ65K (IV ) Fuel and lubricant brand and filling amount Name Engine oil Engine fuel Engine coolant Note: the filling capacity shown in the table is theoretical value. hydraulic oil Ambient temperature -15°C~-30°C: L-HV22 650L for XZ35K and XZ50K. 10#. Comparison between oil brands domestic and abroad Table 4—5 Classification Petrol China MOBIL SHELL CALTEX Engine oil CD CF-4 Fuel Light fuel 0#. series DTE light 13M. for actual capacities refer to the readings at dipstick. 46 Steering system 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 . 46 Hyspin AWS 15. 46 Bartran HV 22. Hyspin AWH 15. RX Grades Super TOTAL Rubia C Rubia XT BP Energol Venellus c3 Extra DS3 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. -35# The same The same The same The same The same The same Lubrication oil GL-4 Mobiube GX GSPIRAXG Thuban GL-4 GL-5 Hydraulic system L-HV 22 L-TSA 32 L-HM 32 L-HM 46 DETEOIL Named Mobil DTE11M. Energol HLP-HM 32. 32. 32. inspection apertures and sight glass.4 Delvac Delvac 1330-1340 super Rimula C Rimula D EDLA500 / CRD RX Turbo CASTROL MONO 15W/40. 46 • 33 • .38 °C) lubrication oil GL-4 75W lubrication oil (-40°C ~ 38 °C) Steering system 6. 10 740L for XZ65K. (Kunlun branded) Ambient temperature below -30°C: No. 32. 46. 15M Turbo T oil 32 Tellus 22. 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 .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.-10#.38°C) 13L lubrication oil GL-5 lubrication oil for S6-90. 46 AZOLLAZS 32. 450L for Hydraulic system Ambient temperature -15 °C -5 °C: L-HM32 XZ25K. -20#. aviation hydraulic oil Other positions in 3000g 3 lithium base grease chassis # Table 4 . 5 . 3. • 34 • . 5 — 1. XZ30K and XZ30K5. 6. 5 . In the 1st code. 5—2 is for chassis of XZ35K and XZ35K5. 1 indicates air inlet. Pneumatic Circuit Principle Diagrams Explanation of the pneumatic circuit principle diagrams: 1. In Fig.7Mpa.81Mpa.3 is for chassis of XZ50K.5—2 and 5—3.1 is for chassis of XZ16K.XZ16K-XZ65K Owner's manual V. XZ25K. 2. and its closing pressure is 0. there are extinguish cylinders only when Steyr WD615 engines are equipped. 2 indicates air outlet. 5. Fig. Transmission regulator is available only when 5S — 111 GP transmission is equipped on XZ35K5. Fig. The opening pressure of the pressure regulator valve is 0. the number in the 2nd code indicates the order number of air connecting port of the component (valve-block) with same function. Fig. 4. XZ60K and XZ65K. There is numeral code consisting of one or two numbers in pneumatic circuit connecting port of component (valve-block) of pneumatic circuit principle diagrams. 3 indicates air vent and 4 indicates the inlet to control air supply. 05MPa Brake lamp switch Foot brake valve Double-pointer air-pressure gauge 1st axle left air-chamber •3D 12 -w 2nd axle left air-chamber .5MPa 4 Extinguish cylinder = » Solenoid valve 4 4 Foot relay valve Srts 2 2 21 22 0.w 12 3rd axle left air-chamber F i g . Four-circuit protection valve 2nd axle right air-chamber 3rd axle right air-chamber 21 Horn r t-OOrO^H Air compressor Air reservoir PTO cylinder r r&r? 22 n 23 12 3rd axle inter-wheel differential lock 12 r era 2 PTO switch 0q_2_ 22 2nd axle inter-axle differential lock 21st circuit reservoir Check volve B | Hand relay valve 42 41 ft: 22nd circuit reservoir 1 2 3 Hand brake valve Clutch control valve 22nd circuit reservoir.05MPa 0. 23rd circuit reservoir • 9 2nd axle inter-wheel differential lock Warning lamp switch 0.1 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 . 5 .5MPa Exhoust broke cylinder 2 2 vWarning lamp switch Foot relay valve Brake lamp switch 0.1st axle right air-chamber Air dryer m. 5MPa Hand broke valve 12 J Cfn Exhaust brake cylinder Foot relay valve 4 N.5MPa Warning lamp switch Brake lamp switch 0.05MPa Hfi 12 2nd axle left air-chamber 3rd axle left air-chamber -W 12 4th axle left air-chamber F i g . volve 4 Brake lomp Double-pointer Foot brake valve air-pressure gauge 1st axle left air-chamber switch 0.2 Pneumatic circuit principle diagram for XZ35K and XZ35K5 . 5 .22nd circuit reservoir 21st circuit reservoir Check valve B Solenoid valve =0 P T 0 c ^ » Transmission regulator cylinder in(Jer Air reservoir Hand relay valve 42 Clutch control valve tz> Solenoid valve circuit reservoir^ 23rd circuit reservoir. 3rd axle inter-wheel differential lock Warning lamp switch 0.1st axle right air-chamber 2nd axle right air-chamber HIl Sq! Air compressor Four-circuit protection valve 3rd axle right air-chamber 4th axle right-air chamber 12 Air dryer fPr £ Pi £ 22 23 12 11 4th axle inter-wheel differential lock 3rd axle inter-axle differential lock Horn 24 n=3_~ PTO switch — [ 22 .05MPa 2 Foot relay .0. 05MPa 4 Brake lamp switch Warning lamp switch 0.{ I t J 1st axle right air-chamber r^: Air rlr\/or 2nd axle right air-chamber r^ Four-circuit wotection valve r j r d a x l e ri9ht a i r . PTO cylinder Hffl= 22 TransmissioO nn cylIinAder ' Transmission requlotor cyl'inder ™= r«= Clutch control volve HI] 1 \22nd circuit reservoir/ 22nd circuit reservoir 2 Foot relay valve Hand relay valve 4 2 9 23rd circuit reservoir N 2 3rd axle 0. 5 .3 Pneumatic circuit principle diagram for XZ50K<XZ60K and XZ65K .c h a m b e r . r-.5MPa inter-wheel Warning lamp switch lis uuiid brake valve a 2 Double-Pointer air-pressure gauge Exaust Solenoid valve brake cylinder C n i T T ^ 0.05MPa 12 trrLli 21 Foot brake valve O 22 12 1st axle left air-chamber -w 3rd axle left air-chamber -w 4th axle left air-chamber 12 11 HID 2nd axle left air-chamber F i g .5MPa 4B&= Foot relay valve lock Brake lamp 2 switch 0. • 4th axle right air-chamber 4th axle inter-wheel differential loci Horn Air compressor Check valve 3rd axle inter-axle J differential lock 12 11 e Solenoid valve E. XZ35K. refer to Fig. XZ35K5 and XZ50K with superstructure mechanical control equipped. 6—4 for the chassis hydraulic system diagrams of XZ60K and XZ65K.XZ16K-XZ65K Owner's manual VI. 6—3 for the chassis hydraulic system diagrams of XZ25K. XZ35K.2 for the chassis hydraulic system diagrams of XZ25K. Chass Hydraulic System Diagram Refer to Fig. • 38 • . XZ35K5* and XZ50K with superstructure pilot control equipped. 6— 1 for the chassis hydraulic diagrams of XZ16K. refer to Fig. 6 . XZ30K and XZ30K5. refer to Fig. Central rotary joint Jack cylinder | Double-way hydraulic valve Extension cylinder H A2 B2 A3 B3 A4 B4 A5 B5 20MPa \ri} X J? X I& .w a y valve Hydraulic oil tank Fig.Chassis hydraulic system diagram for XZ16K^XZ30K and XZ30K5 . 5MPa 5 nr° ] T f Quadruple gear pump T t Chassis m u l t i .6— 1 . 6-2 Chassis hydraulic system diagram for XZ25K-XZ35K-XZ35K5 and XZ50K with superstructure pilot control equipped .Fig. w a y valve 20MPa| ft] r Triple gear pump £ i Hydrau ic oil tank Fig.6-3 Chassis hydraulic system diagram for XZ25K> XZ35K^XZ35K5 and XZ50K with superstructure mechnical control equipped .Central rotary joint Jack cylinder j Double-way hydraulic valve Extension cylinder 5th jack cylinder r It X x 5MPa 3 B1 A2 B2 A3 B3 A4 B4 A5 B5 IT J? Chassis m u l t i . Central rotary joint Jack cylinder Extension cylinder 'Double-way hydraulic valve X N O n W I X N o\ L H Variable pump Chassis multi-way valve O Hydraulic oil tank Fig.6-4 Chassis hydraulic system diagram for XZ60K and XZ65K p CD C . 3. "3/1A" indicates that the component is in coordinate point of intersection of 1st district and A district on page 3. 2. • 43 • . For example. 7 — 1 used for 6CL and WD615 series engines with mechanical transmission. symbols explanation and fuses distribution. Explanation of electric principle diagrams: 1. 7 — 1 (9) for components key.7 — 1 for chassis electric principle diagrams. 4. Fig. Look for components according to every district. Refer to Fig. there are six districts (A-F) from top to bottom. and single cable with negative ground. One wire code indicates one line. Refer to Fig. " 1 " indicates circuit cathode. and there are eight districts (1-8) from left to right. Electric System The rated voltage of electric system is DC 24V. Lines with same wire code have same function.Owner's manual XZ16K—XZ65K v > VII. 5. In every page. o XZ16K—XZ65K Owner's manual oo 9ZXduuD| JD9J }i|6iy 1 S3 C13C\ J CNI CO OO I LU oo I d U U D [ JD3J ]j3] S2X-93.913- zi- [3.Z13cr> CNJ x CNJ I o cn o oO *C C O *£E cr <o cr oo X.duiD[ ]uojj jqbiy S13-3ZX. u CJ _cd a. O r-oocDr—^ XX XXX u u ^ I LL IL A s 1 ' q 6 XX XX CNI Cxjr-O-^-LO XXX j 1 xI ^I 53duJD| ]U0Jj JJ3] HH3-IZX.0.LllCJ> . 00 (D C N J O O 1 ct: l rO O i1 ^ 1 1 < D C = "cn LU 'ooo o o 1 fx O x— wCDw Cw .63.01]. Owner's manual XZ16K-XZ65K . . Owner's manual XZ16K—XZ65K L D L O O O I—' rO I ^CM lO LO CO o X co m irr o I xr .OvJ OO CO L O I CL. I C N I Q _ C O _Q L O "S I 00 o o cn o "O L O X CXI I CO U_J I rO C N I X C D if) > n U_J lO I in C D -c— CXI X C N J X Cs) I X u o Q) CD CO CO lO _Q C T > 02 S I "cn GO O co lO YW1 o C D -vf" co ! CXI O _C CJ cr> C N J X UJ -c— CsJ C N I I XI \ cni- ^oo^oo "C oo CN^>CM CM n OC T > X 2° 8 O O • 47 • . XZ16K-XZ65K Owner's manual • 48 • . Owner's manual XZ16K—XZ65K • 49 • . . Owner's manual XZ16K-XZ65K V/ . • 52 • . Speed (km/h) Vehicle Max.24/3.0/R8.00-20 12. Speed (km/h) Min.50/1. rear axle Model Max.938 6. fixed axle 6S-120 11. XZ25K.22/2. dry type. Main assembly structure features and technical parameters Table 8-1 Main assembly structure features and technical parameters for XZ16K. Torque Total displacement L Model Transmission Type Speed ratio Clutch Type Rear axle Speed ratio Service brake Parking brake Brake Auxiliary brake XZ16K Standard Upgraded 9512 2480 4025+1350 XZ25K Upgraded Standard 6x4 2 XZ30K/XZ30K5 Standard 10735 2540 5025+1350 2074 15450 4740 4115x2 32400 2500 2079 9657 2480 4125+1350 4630 3735 x 2 21400 6300 7550 x 2 YC6A240 . Power kW/r/min Engine Max.20 6C215 . 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. air conditioner and electric windshield wiper.27 7.2 206/2100 1170/1400 8.2 177/2300 158/2200 890/1400 790/1400 8.2° 13.1° 14.00-20 .Owner's manual XZ16K—XZ65K Vffl.25 12100 13800 5080 5185x2 31000 7600 12400 x 2 WD615.30 6S-90 Mechanical control.20/1.166 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.726 1834 206/2200 9580 x 2 6CL280 . friction disc diameter $ 420 1—stage main reduction 1—stage main reduction plus wheel rim reduction 5. 19. turning diameter Braking distance (m) Approach angle Departure angle Single plate.5° 13.5 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. Front 8/rear 14 24V of voltage. radio-cassette player equipped. all steel welded closed cab with instrument panel.82 6810 Cab Number of leaf spring Tire Electric system Max.5° 17° 16.50 1100/1400 9.01/5.1° • 53 • 9. negative ground 72 72 69 75 3 32% 32% 36% 30% 21. grade ability performance Min. 48/6. fixed axle 12.73 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.5° 11. diaphragm. fixed axle Type Transmission 9.04/8. XZ60K and XZ65K 8X4 2 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. Front8 /rear 14 12. radio-cassette player. diameter $430 1—stage main reduction plus wheelrimreduction 5.3° . grade ability performanc Min.3 8/3.7 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. diameter $430 2800 Clutch Rear axle Type Speed ratio Service brake Brake Parking brake Auxiliary brake Cab Number of leaf spring Tire Electric system Max.938 5.81/1.36/2.42/8.47/1. etc equipped.28/1. Speed (km/h) Vehicle Max.00-20 24V of voltage.46 WD615. Turning diameter e (m) Braking distance (m) Approach angle Departure angle • 54 • Push-type.00-20 11.24/ 13.5° 16° 17° 19° 16.0/R11.08/4. Torque N.99 Pull-type.35/1. dry type.0/R8.726 RT-11509C Mechanical flexible shaft control. XZ50K.726 Model QJ6 5S-111GP Mechanical control.30 1. Speed (km/h) Min.76/ 3. diameter $ 430 Push-type.4° 12° 14° 15.04/4.m/r/min 1250 1100 8.9 2. electric windshield wiper.00R24 12. negative ground 72 75 2.82 Total displacement L 9.00-20 12.26/6.43/2.50 Speed ratio Single plate.44 266 235 1460 1250 9.53/3.7° 13° 11.3° 17.22/20/1.00/R12.7 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. Power kW/r/min 206 235 Engine Max. heater.47/1. friction disc diameter d>420 /1.XZ16K-XZ65K Model Drive type Crew Length Width Dimension Height (mm) Wheelbase XZ35K Standard XZ35K5 Standard XZ50K Standard 10940 2750 2505 XZ60K Standard 11480 Owner's manual XZ65K (QY70K) Upgraded Standard 11076 Table 8-2 Main assembly structure features and technical parameters for XZ35K. XZ35K5. diaphragm. diaphragm.50 Max.01/5. Owner's manual XZ16K—XZ65K IX.65G 1 For hydraulic system "0" sealing ring 97.2 x 2.65G 4 For hydraulic system "0" sealing ring 37.1-1992 GB/T3452. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Standard No.7 x 2.55G 1 For hydraulic system 1 For hydraulic system "0" sealing ring 100 x 2.55G 1 For hydraulic system "0" sealing ring 46.5 x 3. GB/T3452.8G "0" sealing ring 10.5 * 1.1-1992 GB/T3452.1-1992 GB/T3452.8G 10 For hydraulic system For hydraulic system 1 "0" sealing ring 9.65G 4 For hydraulic system 4 For hydraulic system "0" sealing ring 14 x 2.1-1992 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. Main Spare Parts List Table 9 .1-1992 GB/T3452.5 x 2.6 * 2.5 x 3.65G 2 For hydraulic system "0" sealing ring 20 x 2.65G 1 For hydraulic system "0" sealing ring 51.1-1992 GB/T3452.1-1992 GB/T3452.5 x 1.1-1992 GB/T3452.1-1992 GB/T3452.1-1992 GB/T3452.65G "O" sealing ring 22.65G 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 • .4 x 2.1-1992 GB/T3452.65G 1 For hydraulic system "0" sealing ring 48.1 No.1-1992 GB/T3452. The bolt strength class is 8.6-323.4 333. 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)) .8 3 4 5 6 Notes about tightening torque of bolts and nuts: 1. 2.6. 1 2 Name Tire nuts Suspension rod clamping bolts Suspension rod tightening bolts Suspension U-bolts and nuts Connecting bolts and nuts of drive shaft flange Steering wheel tightening nuts Torque (Nm) 600-660 Remarks 264. 3. the bolt strength class is 5. • 56 • . after repair. Tighten leaf spring U-bolts with truck in full load. their threads need to be coated with sealing glue before reassemble (Le Tai 262 or 271 high strength thread sealing glue are recommended).8 750 290-310 333.2-450. Tightening Torque of Main Bolts and Nuts No..XZ16K-XZ65K Owner's manual X. etc. For less important parts connecting decks and hose clip.2-450.8. For the bolts connecting suspension and other bolts and nuts having no special requirements for connection. Supplied Tools List for Truck Crane Special Carrier Table 11-1 No.Owner's manual XZ16K—XZ65K XI.5Kg 16 x 18 8x 10 Qty 1 1 1 1 1 1 1 1 1 1 1 1 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 • .5 3 4 5 6 8 10 12 14 6x7 12 x 14 13 x 15 17 x 19 22x24 27x30 32x36 41 x46 12 x 14 17 x 19 100x5 100x6 0. ' 2 3 4 5 6 1 7 8 10 11 9 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 Specifications 2. 26 27 29 30 31 28 Pliers Adjustable spanner Adjustable spanner Grease gun (lever type) Tire inflation unit Inflation hose 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 Box wrench (high neck) Name 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 54 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 10" .XZ16K—XZ65K Owner's manual No. 10" Qty l l 1 l l l l l l l l l 1 l l l l l l l l 1 l l 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 16-1/4" 5" 10" 1 box 1 53 Double-ended spanner 50x55 41 1 1 . XUZHOU CONSTRUCTION MACHINERY GROUP CO.. LTD. CHINA .. LTD.Owner's manual XZ16K-XZ65K XZ16K-XZ65K TRUCK CRANE SPECIAL CHASSIS PACKING LIST XUZHOU HEAVY MACHINERY CO. Supplied Spare Parts See " Supplied Spare Parts List "in product operation Manual 1 1 1 1 1 1 1 1 1 • 60 • . Vehicle Rear Fog Lamp Installation Certificate 5.Packing Technical Documents: 1. Diesel Engine Product Certificate 6.XZ16K-XZ65K Owner's manual I . Transmission Operation Manual 9. Diesel Engine Operation Manual 7. Truck Crane Special Chassis Certificate (only for chassis sold outside ) 3. Supplied Tools See " Supplied Tools List" in product operation Manual ID. Transmission Product Certificate 8. Truck Crane Special Chassis Packing List 4. Axle Operation Manual II. Operation Manual of Truck Crane Special Chassis 2.
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