Description
7/16/2019
XZ16K~XZ65K TRUCK CRANE SPECIAL CHASSIS.pdf
XZ16K ~ XZ65K TRUCK CRANE SPECIAL CHASSIS OPERATION MANUAL
X U Z H O U H E A V Y M A C H IN E R Y C O ., L T D . X U Z H O U C O N S T R U C T IO N M A C H IN E R Y G R O U P C O . , L T D . C H IN A
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Owner's manual
XZ16K—XZ65K
CONTENTS I . Preface
1
II. Vehicle num ber
2
HI. Vehicle operation
-
4
( I ) Arrangement in cab
4
(II) Preparation before driving
10
(III) Starting and shifting
12
(IV) Co ntrol of clutch
13
(V ) Brake system
14
(VI) Outriggers operation
16
(VII) W inter ope ration
20
(VIII) W heel inspec tion and replace me nt
21
(IX) Run-in of a new truck
23
(X ) Usage of air conditioner
24
IV. Maintenance
26
( I ) Interval mileage of vehicle routine check and maintenance
26
(I I) Each assembly oil change period
26
(III) M aintenance key points
27
(IV) Fuel and lubricant brand and filling amount
33
V . Pneumatic Circuit Principle Diagrams
34
VI. Chass Hydraulic System Diagram VII. Electric System
38 43
VIII. M ain
53
assembly structure features and technical param eters
IX. Main Spare Parts List
55
X. Tightening Torque of Main Bolts and Nuts
56
XI. Supplied Tools List for Truck Crane Special Carrier
57
Packing list
59
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XZ16K—XZ65K
Owner's manual
I. Preface This manual supplies technical information about the performance, structure, operation, service and adjustment of XZ16K to XZ65K "XCM G "-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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II. Vehicle N um ber The vehicle numbers are marked in the nameplate on the front section of the right side beam of the frame and on the front beam of the right side of the frame. The nameplate c6nsists of 1. Product name and model; 2. Product number; 3. Engine number; 4. Delivery date; 5. Vehicle identification number (VIN) (for the chassis supplied outside); 6. Manufacturer Symbols stars (ik) are marked at both end of product number and vehicle identification number. The Vehicle Identification Number (VEST) for truck crane chassis :
China XCMG
Product No.
"XCMG" brand
Assembled by Xuzhou Special Vehicle co.,Ltd.XCM G
Lifting class — Special chassis
-
Total rated weight
Product manufacture date
Inspection code —
Note: the VIN m entioned 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•
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Vehicle Type: Product No.: Engine No.: Delivery Date: Vehicle Identification Number (VIN):
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III. Vehicle Operation (I ) Arrangement in ca b
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
2. Beam indicator lamp
3. Power indicator lamp
4. Oil pressure warning lamp
5. Reversing indicator lamp
6. Foot brake indicator lamp
7. Differential lock indicator lamp
8. Fog lamp indicator light
9. Water temperature warning lamp
10. Fuel warning lam p
II . Low air pressure warning lamp
12. Power take-off indicator lamp
• 4•
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13. Hand brake indicator lamp
14. Right turning indicator lamp
15. Lamp m ain switch
16. Fog lamp switch
17. Engine stop switch
18. Air conditioner switch
19. Emergency signal switch
20. Differential lock switch
21. Cool starting switch
22. Warning lamp switch
23. Radio-cassette player
24. Warm air adjusting knob
25. Hand brake handle
26. Transmission control lever
27. Cigarette lighter
28. Hand accelerator handle
29. Speedometer
30. Ammeter
31. Accelerator pedal
32. Foot brake pedal
33. Starting switch
34. Horn
35. Com bined switch
36. Clutch pedal
37. Steering wheel
38. Fuel gauge
39. Water temperature gauge
40. Power take-off switch
41. Double-pointer air pressure gauge
42. Engine tachometer
43. Engine oil pressure gauge 1. Functions of instrumentation, switches and signal indicators in cab: 1). Starter switch (No. 33 in Fig. 3 - 1 )
Three positions are available for selection after the key is inserted into the starting switch, see Fig. 3 ~ 2 , their functions are as follows: Position 1: with electric power supply cut off, the key
can be pulled out. Position 2: " ON " state, the key must be in the position when engine is running. Position 3: starting engin e state
2). Double-pointer air pressure gauge (No. 41 in Fig.3 —1) Low air pressure warning lamp (No. 11 in Fig. 3 — 1)
F ig . 3 - 2
Double-pointer air pressure gauge indicates pressure in two circuits of service brake system (21 , 2 2 circuit), the normal working pressure is 0.45-0.8 MPa. If the air pressure in any one of st
nd
two circuits decreases below 0.45MPa, stop the vehicle to check the pneumatic circuit system. • 5•
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X Z 1 6 K -X Z 6 5 K
O w n e r's m a nu al
When the air pressure in hand brake circuit (23 circuit) of pneumatic circuit system is below rd
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 w arning 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. • 6•
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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 con ditioner 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 D ifferential indicator lam p (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 m ain 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•
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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 sw itch.
Fig. 3—3 1. Exhaust brake switch •
Combined switches
2. Wiper switch of front windshield
3. Dimm er switch
8
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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 do n'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 sw itch (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 •
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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 no t 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 o il 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 •
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(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 Man ual )) .
(2). Operation of pow er 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 sw itch 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 temp erature 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 no t move, stop engine at once and check the cause. Note: never let the engine run in high speed when it is jus t started.
(6) Preheating of the engine: After starting, engine idle time can't exceed 5 minutes, increase rotation speed gradually up to • 11 •
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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 •
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v>
4. Operations in emergency:
(1) When the transmission has a trouble and the truck must be moved, the traveling speed for the truck towed can not exceed 10 km / h, and the emergency signal switch (No. 19 in Fig. 3 ~ 1) must be turned on and turning indicator lights of towing vehicle should also be turned on. (2) When engine and transmission are damaged, propeller shaft should be disassembled in principle. (3) When driven shaft or drive shaft is damaged, if possible lift the front or rear section of the truck up. (IV) Control of clutch:
Fig. 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 cylinderpush r od c an be adjusted manually, but the pull-type one's c an't. Refer to Fig. 3-5 for push-type clutch control diagram. Clutch pedal free stroke S should be in range of 40~60 mm when clutch release rod does not move. If not, check both clearances of master cylinder pushr od a nd branch cylinder pushr nd oda check if there is air in the static pressure o il circuit. On the condition of clutch pedal depressed to the bottom, the clutch should be disengaged fully, • 13 •
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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 c ould n'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 •
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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 cham ber: 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. Rem ove 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 ~ 6 a
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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w
(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 ou trigger parts of XZ35K , X Z30K 5, 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
F ig . 3 - 7 b
for XZ16K
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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 -8 b
for XZ25K
1. Outrigger beam lock pin 2. Lock pin hole 3. Level gauge 4. Jack cylinder 5. Outrigger float 6. Outrigger control levers
F ig. 3 - 9 a
for XZ30K> XZ30K5 • 17 •
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XZ16K-XZ65K
Owner ' s manual
1. Right front outrigger control lever 2. Left front outrigger control lever 3. Right rear outrigger control lever 4. Left rear outrigger control lever 5. Extension & Jack control lever
Fig. 3 - 9 b
for XZ30K> XZ30K5 1. Outrigger beam lock pin 2. Lock pin hole 3. Level gauge 4. Jack cylinder 5. Outrigger float 6. Outrigger control levers
Fig. 3 - 1 0 a
1
2
forXZ 35K . XZ35K5, XZ50K, XZ60K, XZ65K
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
F ig . 3 - 1 0 b
for XZ35Kn
XZ35K5> XZ50K>
XZ 60K ,
XZ 65K
• 18 •
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Owner's manual
XZ16K-XZ65K
1. Setting outriggers
(1). Pull out the outrigger beam lock pins. (2). Position control levers (1st to 4th) to "Extension". (3). Move Extension & Jack control lever (5th) to "Extend". (4). After outrigger beams are fully extended, return Extension & Jack control lever (5th) to "Neutral". (5). Position control levers to "Jack". (6). Move Extension & Jack control lever (5th) to "Extend". (7). After jacks are fully extended, move Extension & Jack control lever (5th) to "Neutral". Check if the crane is level by using level gauge. If it is level, return all control levers (1st to 4th) to "Neutral". (8). If 5th jack is equipped, move 5th Jack control lever (6th) to "Jack". (9). Move Extension & Jack control lever (5th) to "Extend". (10). After the 5th jack is in contact with the ground, move Extension & Jack control lever (5th) to "Neutral" as well as 5th Jack control lever (6th). 2. How to level crane:
Moving any one or more of control levels (1st to 4th) and positioning Extension & Jack control lever (5th) to "Extend" or "Retract" can extend or retract the selected ex tension 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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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, m ake sure that control levers are in "N eutral". (VH) W inter opera tion 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 m ethods: (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; T ab le 3 - 1
Limited imited temperature of freezing point for anti-freeze coolant
Ethylene glycol -water Glycerin -water Glycerin
Density
Ethylene glycol
Density
(°C) -10
Weight %
D
weight %
D
32
1.0780
28.4
1.0340
-20
51
1.1290
38.5
1.0506
-30
64
1.1647
47.8
1.0627
-40
75
1.1894
54.7
1.0713
Notes:
A A
The engine can not use the antifreeze coolant made of "alcohol -water". Never use sea water to cool the eng ine 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 •
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XZ16K-XZ65K
3. Battery
Regularly check the level and density of the battery electrolyte. The level should be 10-15 mm X Z 3 5 K ^ X Z 3 5 K 5 and X Z 5 0 K w i th s u p e r s t r u c t u r e m e c h n i c a l c o n t r o l e q u i p p e d
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Central rotary joint
X Ja ck cyl i n d e r
N On W I
'Double-way hydraulic valve
X
Exte n si o n cyl i n d e r
N
o\ L H
Variable pump Chassis multi-way valve
O p
CD
H y d r a u l i c oil t a n k Fig .6- 4
C h a s s i s h y d r a u l i c s y s t e m d i a g r a m for X Z 6 0 K a n d X Z 6 5 K C
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XZ16K—XZ65K
Owner's manual
v >
VII. Electric System The rated voltage of electric system is DC 24V , and single cable with negative ground. Refer to Fig.7 — 1 for chassis electric principle diagram s. 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 •
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XZ16K—XZ65K
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• 47 •
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Owner's manual
• 48 •
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XZ16K—XZ65K
• 49 •
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V/
Owner's manual
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XZ16K-XZ65K
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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 XZ16K
Model
XZ25K Standard
Upgraded
Upgraded
XZ30K/XZ30K5 Standard
Standard
6x4
Drive type
2
Crew Length
9512
Width
9657
10735
2500
Dimension imension
Height
2480
2480
2540
(mm)
Wheelbase
4025+1350
4125+1350
5025+1350
Track
2079
12100
13800
15450
Front axle
4630
5080
4740
Rear axle
3735 x 2
5185x2
4115x2
21400
31000
32400
Overall mass Axle load
Front axle Mid, rear axle
Model Engine
6300
7600
6810
7550 x 2
12400 x 2
9580 x 2
YC6A240 - 20
6C215 - 2
WD615.50
Max. Power kW/r/min
177/2300
158/2200
206/2200
206/2100
Max.
890/1400
790/1400
1100/1400
1170/1400
7.25
8.27
9.726
8.82
Torque
Total displacement L Model Transmission ransmission
Type
Clutch Type
Brake rake
6S-120
Mechanical control, fixed axle
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
Speed ratio Service brake
6CL280 - 2
6S-90
Speed ratio
Rear axle
2074
1834
Chassis mass Axle load
Vehicle ehicle mass (kg)
Front axle Rear axle
1—stage main reduction plus wheel rim reduction
6.166
5.938
Double circuit air brake system with shoe brake acting on all wheels
Parking brake
Spring—loaded brake system acting on wheels of mid and rear axles
Auxiliary brake
Engine exhaust brake
Cab Number of leaf spring
Full dimension, all steel welded closed cab with instrument panel, air conditioner and electric windshield wiper, radio-cassette player equipped. Front 8/rear 14
Tire
11.00-20
Electric system
24V of voltage, negative ground
Max. Speed (km/h)
72
Max. grade ability
Vehicle ehicle
Min. turning diameter Braking distance (m )
Approach angle Departure angle
72
69
75
3
Min. Speed (km/h) performance
12.00-20
32%
36%
32%
21
30% 21.5
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. 2°
14.1°
17° 13.1°
19.5° 13.5°
• 53 •
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XZ1 6K -XZ 65K
Owner's manual
T a b le 8 - 2 M a in a s se m b l y st r u c tu r e f ea t u r e s a n d t e c h n ic a l p a ra m e te r s fo r X Z 3 5 K , X Z 3 5 K 5 , X Z 5 0 K , X Z 6 0 K a n d X Z 6 5 K Model
XZ35K
XZ35K5
XZ50K
XZ60K
Standard
Standard
Standard
Standard
Drive type Crew
XZ65 K (QY70K) Upgraded
Standard
8X4 2 Length
10578
10940
Width
2500
2750
Dimension imension Height
2480
2505
(mm)
Wheelbase Track
Front axle
2079
Rear axle
1834
2505
1470+4150+1350
1520+3965+1350
2304
2240
2240
2055
15500
16800
17900
19000
18500
2X3600
2X3500
2X3785
2X4000
2X3910
Rear axle
2X 41 50
2X4900
2X5165
2X5500
2X5340
Overall mass Front axle Axle load Rear axle
32300 2X5575
36930 2X6165
38580 2X6475
40870 2X7500
40500 2X7150
2X12300
2X12815
2X13000
Model Engine
2650
Front axle
Axle load
mass (kg)
11076 2800
1520+3815+1350
Chassis mass Vehicle ehicle
11480
2X10575
6CL320-2
WD615.50
2X13100
WD615.46
WD615.44
Max. Power kW/r/min
206
235
26 6
23 5
Max. Torque N.m/r/min
1100
1250
1460
1250
Total displacement L
9.726
8.82
9.726
QJ6
5S-111GP
RT-11509C
Model Type Transmission Speed ratio
Mechanical control, fixed axle 9.01/5.24/
13.04/8.48/6.04/4.3
3.22/20/1.50
8/3.43/2.47/1.76/
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
1.28/1.0/R11.7
/1.0/R8.30
Single plate, dry type, friction disc diameter d>420
Clutch
Rear axle
Brake rake
Push-type, diaphragm, diameter $430
Type
Pull-type, diaphragm, diameter $ 430
Push-type, diaphragm, diameter $430
1—stage main reduction plus wheel r im reduction
Speed ratio
5.938
5.73
Service brake
Double circuit air brake system with shoe brake acting on all wheels
Parking brake
Spring-loaded brake system acting on wheels of mid a n d rear axles
Auxiliary brake
Engine exhaust brake All steel welded closed cab with instrument panel, heater, electric windshield wiper,
Cab
radio-cassette player, etc equipped. Front8 /rear 14
Number of leaf spring Tire
11.00-20
12.00R24
12.00-20
Max. Speed (km/h)
72
75
Min. Speed (km/h)
2.9
2.7
Vehicle ehicle Max. grade ability performanc M i n . Turning diameter e (m) Braking distance (m ) Approach angle Departure angle
12.00-20
24V of voltage, negative ground
Electric system
30%
40%
35%
24 Brake distance is not more than 10m with upper structure installed and 30km/h of initial speed traveling on dry a n d level asphalt road 16° 14°
17°
16.3°
17.5°
19°
16.5°
15.7°
11.4°
12°
13°
11.3°
• 54 •
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XZ16K—XZ65K
IX. Main Spare Parts List Table 9 - 1
No.
Standard No.
1
GB/T3452.1-1992
"O " sealing ring
2
GB/T3452.1-1992
3
Name
Qty
Remarks
7.5 * 1.8G
10
For hydraulic system
" 0 " sealing ring
9.5 x 1.8G
1
For hydraulic system
GB/T3452.1-1992
" 0 " sealing ring
10.6 * 2.65G
4
For hydraulic system
4
GB/T3452.1-1992
" 0 " sealing ring
14 x 2.65G
4
For hydraulic system
5
GB/T3452.1-1992
" 0 " sealing ring
20 x 2.65G
2
For hydraulic system
6
GB/T3452.1-1992
"O " sealing ring
22.4 x 2.65G
4
For hydraulic system
7
GB/T3452.1-1992
" 0 " sealing ring
37.5 x 3.55G
1
For hydraulic system
8
GB/T3452.1-1992
" 0 " sealing ring
46.2 x 2.65G
1
For hydraulic system
9
GB/T3452.1-1992
" 0 " sealing ring 48.7 x 2.65G
1
For hydraulic system
10
GB/T3452.1-1992
" 0 " sealing ring
51.5 x 2.65G
1
For hydraulic system
11
GB/T3452.1-1992
" 0 " sealing ring
97.5 x 3.55G
1
For hydraulic system
12
GB/T3452.1-1992
" 0 " sealing ring
100 x 2.65G
1
For hydraulic system
13
GB/T3452.1-1992
" 0 " sealing ring
21 2 x 5.3G
1
For hydraulic system
14
JB/T982-1977
Washer 10
10
15
JB/T982-1977
Washer 12
20
16
JB/T982-1977
Washer 14
5
17
JB/T982-1977
Washer 16
4
18
JB/T982-1977
Washer 18
4
19
JB/T982-1977
Washer 22
20
20
JB/T982-1977
Washer 27
2
21
JB/T982-1977
Washer 33
2
• 55 •
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XZ16K-XZ65K
Owner's manual
X . Tightening Torque of M ain 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 M achinery 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 •
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XZ16K—XZ65K
XI. Supplied Tools List for Truck Crane Special Carrier Table 1 1 - 1 No. 1
Name
Specifications
NST-402 toolbox
Qty
Remarks
1
Imported
' 2
Inner-hexagon spanner
2.5
1
Imported
3
Inner-hexagon spanner
3
1
Imported
4
Inner-hexagon spanner
4
1
Imported
5
Inner-hexagon spanner
5
1
Imported
6
Inner-hexagon spanner
6
1
Imported
7
Inner-hexagon spanner
8
1
Imported
8
Inner-hexagon spanner
10
1
Imported
9
Inner-hexagon spanner
12
1
Imported
10
Inner-hexagon spanner
14
1
Imported
11
Double-ended spanner
6x7
1
Imported
12
Double-ended spanner
8x 10
1
Imported
13
Double-ended spanner
12 x 14
1
Imported
14
Double-ended spanner
13 x 15
1
Imported
15
Double-ended spanner
16 x 18
1
Imported
16
Double-ended spanner
17 x 19
1
Imported
17
Double-ended spanner
22x24
1
Imported
18
Double-ended spanner
27x30
1
Imported
19
Double-ended spanner
32x36
1
Imported
20
Double-ended spanner
41 x46
1
Imported
21
Ring spanner
12 x 14
1
Imported
22
Ring spanner
17 x 19
1
Imported
23
Cross-head screwdriver
100x5
1
Imported
24
Plain screwdriver
100x6
1
Imported
Hammer
0.5Kg
1
Imported
25 • 57 •
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Owner's manual
XZ16K—XZ65K
Name
No.
Specifications
Qty
Remarks
26
Pliers
150mm
l
Imported
27
Adjustable spanner
150 x 18
l
Imported
28
Adjustable spanner
300 x 36
1
Imported
29
Grease gu n (lever type)
120CC
l
Imported
30
Tire inflation unit
GAS-1
l
Imported
31
Inflation hose
PUH -12B (8 x 12 x 9m)
l
Imported
32
Socket spanner
10 mm
l
Imported
33
Socket spanner
11 mm
l
Imported
34 35
Socket spanner Socket spanner
12 mm 14 mm
l l
Imported Imported
36
Socket spanner
17 mm
l
Imported
37
Socket spanner
19 mm
l
Imported
38
Socket spanner
22 mm
1
Imported
39
Socket spanner
24 mm
l
Imported
40
Socket spanner
27 mm
41 42
Socket spanner Socket spanner
30 mm 32 mm
l l
Imported Imported
43
Knurled ratchet spanner
10"
l
Imported
44
Handle with a sliding head
.
10"
l
Imported
45
Quick rocker ba r
16-1/4"
l
Imported
46
Connecting rod
5"
l
Imported
47
Connecting rod
10"
l
Imported
48 49
24V working light T971110 tire spanner
1 l
Domestic Domestic
50
T971120 connecting rod
l
Domestic
51
AK-120 First-aid kit
1 box
Domestic
52
YF2004-1 Triangle warning board
1
Domestic
53
Double-ended spanner
50x55
1
Domestic For QY65K
54
Box wrench (high neck)
41
1
Domestic
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Imported
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Owner's manual
XZ1 6K -X Z65 K
XZ16K-XZ65K TRUCK CRANE SPECIAL CHASSIS
PACKING LIST
XUZHOU HEAVY MACHINERY CO., LTD. XUZHOU CONSTRUCTION MACHINERY GROUP CO., LTD. CHINA
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Owner's manual
XZ16K-XZ65K
I .Packing Technical Documents:
1. Operation Manual of Truck Crane Special Chassis
1
2. Truck Crane Special Chassis Certificate
1
(only for chassis sold outside ) 3. Truck Crane Special Chassis Packing List
1
4. Vehicle Rear Fo g Lamp Installation Certificate
1
5. Diesel Engine Product Certificate
1
6. Diesel Engine Operation Manual
1
7. Transmission Product Certificate
1
8. Transmission Operation Manual 9. Axle Operation Manual
1 1
II . Supplied Tools
See " Supplied Tools Li st " in product operation Manual ID. Supplied Spare Parts
See " Supplied Spare Parts List "in product operation Manual
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