XZ20G.5 M.O（英文）

XZ20G.
5 Truck Crane Chassis Operation Manual

XZ20G.5 Truck Crane Chassis Operation Manual

(Equipped with China national Ⅲ compliant Hangzhou engine)
VIN
Date
The operation manual is part of the crane!
Always keep on hand!
Please read the manual before operating the product.
This equipment is designed and manufactured by complying with the standard of
Q/320301JAF179.
XUZHOU HEAVY MACHINERY CO., LTD.

XUZHOU CONSTRUCTION MACHINERY GROUP CO., LTD., CHINA
Address: No.165 Tongshan Road, Xuzhou, Jiangsu Province, China
Tel: 0086-0516-83462242, 83462350
Fax: 0086-0516-83461669
Post code: 221004
Service Tel: +86-516-83461183
Service Fax: +86-516-83461180
Spare Parts Tel: +86-516-83461542
Contents
Preface ...... ..................................................................................................................................................III
Chapter 1 Safety operation......................................................................................................................... 1-1
Chapter 2 Product description.................................................................................................................... 2-1
2-1 Vehicle number ............................................................................................................................ 2-1
2-2 Main assembly structure features and technical parameters ....................................................... 2-1
Chapter 3 Chassis operation....................................................................................................................... 3-1
3-1 Arrangement in cab...................................................................................................................... 3-1
3-1-1 Instruments and control mechanism ..................................................................................... 3-1
3-1-2 Indicator lamp assembly ....................................................................................................... 3-3

3-1-3 Seat........................................................................................................................................ 3-4
3-2 Functions of instrumentation, switches and indicator lamps in cab ............................................ 3-5
3-3 Preparation before driving ......................................................................................................... 3-11
3-4 Operation of engine ................................................................................................................... 3-12
3-4-1 Starting engine .................................................................................................................... 3-12
3-4-2 Pre-heating engine .............................................................................................................. 3-13
3-4-3 Stopping engine .................................................................................................................. 3-13
3-5 Operation of PTO ...................................................................................................................... 3-14

3-6 Vehicle starting and shifting ...................................................................................................... 3-14
3-6-1 Vehicle starting.................................................................................................................... 3-14
3-6-2 Method for operating transmission ..................................................................................... 3-15
3-6-3 Stopping and parking .......................................................................................................... 3-15
3-6-4 Operation in emergency ...................................................................................................... 3-16
3-7 Control of clutch ........................................................................................................................ 3-16
3-8 Control of steering ..................................................................................................................... 3-17
3-9 Braking system .......................................................................................................................... 3-20
3-10 Operation of outriggers............................................................................................................ 3-22
3-10-1 Names of outrigger parts and outrigger control levers .................................................... 3-22
3-10-2 Preparation before operation ............................................................................................. 3-24
3-10-3 Engaging PTO ................................................................................................................... 3-24
Contents I
3-10-4 Setting outriggers .............................................................................................................. 3-25
3-10-5 How to level crane ........................................................................................................... 3-26
3-10-6 Stowing outriggers ............................................................................................................ 3-27
3-10-7 Notes on operation ............................................................................................................ 3-27
3-11 Winter operation ...................................................................................................................... 3-28
3-12 Run-in of a new truck .............................................................................................................. 3-29
3-13 Usage of air conditioner .......................................................................................................... 3-29
Total pages ..................................................................................................................................................43
II Contents
Preface
Methods about operation, inspection and adjustment of XZ20G.5 Truck Crane Chassis are supplied
in the manual. Lifting operation is a work that may be involved with risk, in order to ensure safety while
give full rein to the crane high performance, please read, understand and use the operating instructions
in this manual. And pay more attention to the contents of “Danger”, “Warning”, “Caution” and
“Check” in this manual.
All cranes have been checked strictly in our factory and are supplied to Customers with all control
components correctly set. Please don’t regulate them randomly. 。
Only the trained and qualified personnel can work on this crane.
Pay attention to periodic inspections of crane safety devices and don’t use reluctantly the devices
with any defects and abnormalities. What you should always keep in mind is “Safety Is a Top Priority”.
Please keep the supplied technical documents and operation manual carefully, and operate the
machine according to instructions in them. We don’t take any liability in case of unfavorable result due
to nonobservance of the operation manual. For special application, please contact our company, we would
like to supply technical support in time and effectively.
All products made by our company have gained “3C” certification. In order to keep
the conformity of products, during maintenance and service, replace parts with those, which have same
models and are made by original manufacturers, otherwise our company will not bear the responsibility
for loss resulted.
Due to the product modification and improvement, what described in this manual may vary from the real
one. We reserve the right to modify the design without notice.
First edition, May 2012
Preface III
Symbols and their meanings are as follows:
——It means there is an imminent danger, serious injury or death will be caused if
it could not be avoided.
——it means there is a potential danger, injury or death may be caused if it could
not be avoided.
—— It means there is a potential danger, light or medium injury may be
caused if it could not be avoided.
——Check: related inspections are required by requirements.
III Preface
Chapter 1 Safety operation Chapter 1
Safety cautions: ● Prior to driving, make sure that there is
● Only the trained and qualified person is no person or obstacle underneath and around the
allowed for operating the crane. vehicle.
● Never perform any operation and ● During traveling, only two persons are
maintenance when the operator is unable to do allowed in the driver’s cab, and no person is
work normally due to bad health or drinking allowed to stay outside of the cab.
alcohol or taking medicine. ● The PTO switch must be in position
● Any improper operation or casualness “OFF” during traveling. Otherwise, PTO and
will cause injure or death of persons and hydraulic pump may be damaged.
damage to the crane. ● During traveling, observe the
● Hydraulic oil is toxic and flammable. conditions of instrumentation and indicator
Do not swallow internally. Store it in a place lamps in the driver’s cab. If any abnormality
where children are not likely to reach. Avoid occurs, park the vehicle in a safe place and
breathing evaporative emission or contact used repair in time.
oil for a long time. Clean skin with soap and ● Prior to lifting operation set outriggers
water as soon as possible after touching oil. If to the places specified in load chart and secure
there is oil entering into eyes, rinse with water them with lock pins.
for 15 minutes and then visit a doctor. ● Position shift lever in neutral before
● Never extend hand and any part of operating PTO. Otherwise, the transmission
body or clothing into the moving parts during may be damaged.
operation. ● When the vehicle has to be towed, the

● Comply with road travel and crane propeller shaft must be disengaged and spring
operating regulations in the place where you are energy storing chamber be adjusted to release
working. brake or drive wheels be cleared off the ground.
● Before driving, make sure that all ● Prior to leave the cab, parking brake
outriggers are retracted fully in place and must be engaged.
secure with lock pins. Otherwise, walker may ● There is an increased danger of
be injured or other vehicle may be damaged by accidents if parts are damaged due to the
outrigger beam extended out during traveling.
Safety operation 1-1

machine has not been maintained according to The distance between the part to be welded
Chapter 1
the operating instructions. and the welding ground should be as short as
● Personal protective equipment such as possible, and not be more than 500mm, and
spectacles, protective clothing and safety shoes computer board should not be spanned. After
has to be worn during maintenance. welding, the said plugs should be reinserted and
● Before perform maintenance, confirm secured.
that the machine has been set up well, and ● Operating instructions on the machine
a warning board of “In maintenance, no are valid equally with instructions in this
operation” in the driver’s cab must be operation manual.
present.
● Prior to maintaining engine and other
moveable parts, in order to prevent accidental
engine starting, the battery must be disconnected
(the negative cable first), and all condensers be
discharged.
● In order to avoid scald, watch out for
scorching parts and pipelines as well as liquid
and gas in pipelines and cavities.
● Prior to disassembling pipelines,
connectors or related parts, release the pressure
in them to prevent injury to person. Never check
leakage of pressure with hand.
● In order to avoid being stifled or
frostbite, maintenance of fuel system must be
carried out in a well-ventilated environment.
● In prevention of damage to components
of control system, all computer plugs should be
disconnected from power source before carrying
out welding operation, and positive and negative
conductors disconnected from battery.
1-2 Safety operation

Chapter 1
1-3
Chapter 1
1-4
Chapter 2 Product description
2-1 Vehicle number

Chapter 2
Vehicle number is respectively marked in the chassis nameplate located on the right front
longitudinal beam of the frame, and on the right front longitudinal beam of the frame.
Chassis nameplate consists of:
1. Product name and model;
2. Chassis series number;
3. Engine number;
4. Delivery date;
5. Manufacturer.
Vehicle identification number (VIN) is below the chassis nameplate.
2-2 Main assembly structure features and technical parameters
Model XZ20G.5
Driving type 6×4
Crew 2
Wheel base (mm) 4425+1350

Track (mm) 2074 (front axle), 1834 (rear axle)
Permissible total vehicle weight (kg) 31000

Permissible axle load (kg) 7000 (front axle), 2×12000 (rear axle)
Engine model WD615.92E WD615.92A SC8DK260Q3

Rated. power (kw/r/min) 196/2200 198/2200 192/2200
Max. torque (N.m/r/min) 1100/1100～1600 1150/1300～1600 1000/1400
Total displacement (L) 9.726 9.726 8.27
Transmission model 6J90TA-B

Type Manual, mechanical type
Speed ratio 9.03/5.25/3.19/2.00/1.36/1.00/R8.15
Product description 2-1

Clutch model JL420IC

Type Single-disc spring clutch
Friction disc diameter φ420
Drive axle type 1-stage main reduction plus wheel rim reduction
Chapter 2
Reduction ratio 5.938
Brake
Service brake Double-circuit air pressure brake system with drum
brake acting on the wheels
Parking brake Spring-loaded brake acting on the wheels of mid and rear axles
Auxiliary brake Engine exhaust brake
Full dimension, all metal welded enclosed cab with

Cab instrument panel, heater, air conditioner, electric
windshield wiper and CD player fitted.
Number of leaf spring Front 8/ rear 14

Tire 11.00-20-18PR
Electric system 24V, negative ground
Vehicle performance
Max. traveling speed (km/h) 75
Min. stable speed (km/h) 3～4
Max. grade ability (%) 33

Min. turning diameter (m) ≤20
Braking distance is not more than 10m with upper
Braking distance (m) structure installed and traveling on dry and level asphalt
road at 30km/h of initial speed.
Approach angle 16°

Departure angle 13°
2-2 Product description

Chapter 2
2-3
Chapter 2
2-4
Chapter 3. Chassis operation
3-1 Devices in cab

Devices in cab consist of instrument panel, controllers and seat, etc.
Instrument panel includes instruments, switches and indicator lamps, etc. (see Fig. 3-1 and Fig.
3-2).
3-1-1 Instruments and controllers Chapter 3
Fig. 3-1 Devices in cab
Chassis operation 3-1

No. Name No. Name

1 Starting switch 16 Air conditioner switch
2 Steering wheel 17 Emergency signal switch
3 Clutch pedal 18 Differential lock switch
4 PTO switch 19 Engine diagnostic switch
5 Double-pointer air pressure gauge 20 Beacon lamp switch (optional)
6 Engine tachometer 21 CD player
7 Engine oil pressure gauge 22 Air conditioner adjusting switch
8 Fuel gauge 23 Hand brake lever
Chapter 3
9 Water temperature gauge 24 Shift lever
10 Voltmeter 25 Hand accelerator
11 Indicator lamp assembly 26 Accelerator pedal
12 Speedometer 27 Combined switch
13 Lamp master switch 28 Foot brake pedal
14 Fog lamp switch 29 Vent
15 Stop switch
3-2 Chassis operation

3-1-2 Indicator lamp assembly
Fig. 3-2 Indicator lamp assembly Chapter 3
No. Name No. Name

1 Left turning indicator lamp 9 Fog lamp indicator lamp
2 Beam indicator lamp 10 Water temperature warning lamp
3 Charging indicator lamp 11 Pre-heating indicator lamp
4 Oil pressure warning lamp 12 Low air pressure warning lamp
5 Reverse indicator lamp 13 PTO indicator lamp
6 Engine diagnostic indicator lamp 14 Hand brake indicator light
7 Foot brake indicator lamp 15 Right turning indicator lamp
8 Differential lock indicator lamp

3-1-3 Seat
Chapter 3
Fig. 3-3 Seat outline
No. Name No. Name

1 Head rest adjustor switch 4 Seat cushion depth adjusting lever
2 Backrest angle adjusting lever 5 Seat cushion depth adjusting lever
3 Seat damper control lever 6 Seat sliding adjusting lever
There are two seats in the driver’s cab, they may be adjusted to fit any body size. Controllers on
both seats are installed symmetrically. Take one of them for an example: the seat height may change
in range of 60mm, the distance adjusted forward and backward is 170mm, the adjustment of backrest
angle is 120°. The stroke of seat damper can be adjusted steplessly according to body weight of
40~130kg, max stroke is 50mm. Headrest height may be changed 40mm.

3-2 Functions of instrumentation,

switches and indicator lamps in
cab
1. Starting switch (No. 1 in Fig. 3-1)
Four positions1 are available for selection
after the key is inserted into the starting switch,
see Fig. 3-4, their functions are as follows:

Chapter 3
Position OFF: with electric power supply
cut off, the key can be pulled out.
Position Acc: with engine shutdown, turn the

Fig. 3-4 Starting switch
key to the position when intend to use CD player,
wiper, etc.
Position ON: “ON” state, the key must
be in the position when engine is running.
Position START: when the key is turned to
this position, the engine will be started. The key
will return to position ON automatically after it
is released.
● When operate the PTO switch, the
2. PTO switch (No. 4 in Fig. 3-1) and PTO
pressure in pneumatic circuit should be
indicator lamp (No. 13 in Fig. 3-2)
more than 0.45 MPa. (Low air pressure
PTO installed on the right lower end of
warning lamp goes out).
transmission can drive the hydraulic pump to
● During traveling, the PTO switch
provide power for outrigger operation or lifting
must be in position OFF.
operation. When it is running, power take-off
indicator lamp is light. time, PTO gear will mesh with transmission
Operating method: gear smoothly, and PTO begins to work.
After the crane is parked at its working In reverse, depress clutch pedal to
position, with engine running at idle speed and disengage clutch fully, push PTO switch
shift lever in neutral depress clutch pedal to backward, and release clutch pedal, at this time,
disengage the clutch fully, and then pull PTO PTO gear will disengage with transmission gear
switch out and release the clutch pedal, at this smoothly.

3. Double-pointer air pressure gauge (No. 5 in 7. Engine water temperature gauge (No. 9 in
Fig.3-1) and low air pressure warning lamp (No. 12 Fig. 3-1)
in Fig. 3-2) Water temperature gauge indicates coolant
Double-pointer air pressure gauge indicates the temperature. In normal travel condition, the pointer
pressure in two circuits of service brake (21st, 22nd is near middle position, i.e. indicating engine water
circuits), the normal working pressure is 0.45~0.8 temperature of 80~90℃ for normal operation. In
MPa. If the air pressure in any one of two circuits tropical zone, when the truck crane drives in high
decreases below 0.45MPa, stop the vehicle to check speed or climbs slope, the pointer will move to the
the pneumatic circuit system. red sector of the gauge. If the water temperature is
When the air pressure in the hand brake circuit too high, water temperature warning lamp (No. 10 in
Chapter 3
(23rd circuit) of pneumatic circuit system is below Fig. 3-2) will come on, at this time, the crane must
0.45MPa, the warning lamp lights, it indicates that be parked at a safe place, and let the engine run at
the truck could not be started or the PTO could not be idle so as to lower the water temperature to normal
operated. condition.
4. Engine tachometer (No. 6 in Fig. 3-1) 8. Voltmeter (No. 10 in Fig. 3-1)
Engine tachometer consists of tachometer and The voltmeter indicates charging and
hour meter. Engine tachometer indicates engine discharging state of the battery. Voltmeter pointer
rotational speed for driver to adjust engine idle and pointing to “ + ” area indicates that power
control engine max. rotational speed so as to provide generated by generator is larger than that consumed
guarantee for using the engine reasonably. The hour by electric equipments, at this time the battery is in
meter in it may record the total engine running time. charging state; in reverse, the battery is in discharging
5. Engine oil pressure gauge (No. 7 in Fig. 3-1) state.
and oil pressure warning lamp (No. 4 in Fig. 3-2) 9. Indicator lamp assembly (No. 11 in Fig. 3-1)
It displays the oil pressure value of engine It is a combination of indicator lamps that
lubrication system. Engine oil pressure values at indicate the running condition of each system, refer
idle speed and in normal operation are different. Oil to Fig. 3-2.
pressure of engine at idle speed is ≥ 100 kPa and the 10. Speedometer (No. 12 in Fig. 3-1)
oil pressure at rated rotation speed is ≥ 350 kPa. If oil Speedometer consists of speed meter and
pressure is too low, oil pressure warning lamp (No. 4 mileage meter. Speed meter indicates the vehicle
in Fig. 3-2) will come on, at the time, stop the engine, traveling speed and mileage meter registers the
check engine lubricating system and remove trouble vehicle total traveling miles.
so as to avoid the mechanical wear aggravating 11. Lamp master switch (No. 13 in Fig. 3-1)
during engine running. Refer to engine operation When driving at night, the switch should be
manual for details. used. Reset it when it is not used.
6. Fuel gauge (No. 8 in Fig. 3-1) 12. Fog lamp switch (No. 14 in Fig. 3-1) and
When starting switch key is in position ON, fog lamp indicator lamp (No. 9 in Fig. 3-2)
the fuel gauge approximately indicates the fuel level When traveling in foggy days, this switch must
remained in tank. The pointer of fuel gauge will vary be used. When the switch is turned on, the fog lamp
when the vehicle is in state of accelerating, braking indicator lamp, front and rear fog lamps illuminate.
or climbing up and down slope.

13. Stop switch (No. 15 in Fig. 3-1)
Pressing down the switch can cut off the Don’t release the switch until the
oil supply to the engine so as to shut down the engine is shut down.
engine. The switch will reset automatically after
being released.
14. Air conditioner switch (No. 16 in Fig.
3-1)
Chapter 3
Press down the switch, air conditioner
begins to work (refer to air conditioner
instruction). Reset the switch when air
conditioner isn’t used.
15. Emergency signal switch (No. 17 in
Fig. 3-1)
The emergency signal switch must be used
when the truck crane has to park in a dangerous
place. Turn on the switch, the danger warning

When use the d ifferential lock
lamp lights and all turning indicator lamps flash.
switch, the following should be observed:
The danger warning lamp works even if the
● Before engaging or disengaging the
starting key in position OFF. Return the switch
differential lock, engine power output must
to release the danger warning.
be cut off and the truck crane must be in static
16. Differential lock switch (No. 18 in Fig.
condition or at person-walking speed;
3-1) and differential lock indicator lamp (No. 8
● Only when the truck crane drives in
in Fig. 3-2)
straight line can the switch be used;
When rear wheel gets into a pit and
● In case the truck crane drives on a
couldn’t get out, pressing the differential lock
good road, the switch must be disengaged at
switch and using electric control pneumatic
once. Keeping on use of the switch will result
drive can link the drive axle rigidly so as to
in damage of transmission and increase of fuel
enable the vehicle driving. After the switch is
consumption.
pressed, the differential lock indicator lamp will
come on. If it is not light, stop the vehicle and
check cause.

17. Engine diagnostic switch (No. 19 in
Fig. 3-1) and engine diagnostic indicator lamp
(No. 6 in Fig. 3-2)
During driving, press down this switch
when engine diagnostic indicator lamp comes
on. If TEST indicator lamp flashes at even
interval, it means the engine works normally;
if the lamp does not flash at even interval, it

Chapter 3
means there is trouble in engine.
Find the cause according to the flashing
number of TEST indicator lamp and trouble
codes shown in the diesel engine operation
manual supplied.
18. Beacon lamp switch (No. 20 in Fig. 3-1)
Beacon lamp begins to flash after the
switch is turned on. Reset the switch when it is
not used.
19. Air conditioner adjusting switch (No.
22 in Fig. 3-1)
Air flow and temperature may be adjusted
by the switch according to requirements.

Do not use the parking brake and the
20. Hand brake lever (No. 23 in Fig. 3-1)
service brake at the same time to prevent
and hand brake indicator lamp (No. 14 in Fig.
the braking system from damage.
3-2)
When the truck is stopped or driver is to At this time, the hand brake indicator lamp
leave the cab, move the hand brake lever to the goes out.
range of 55°～77°. At this time, hand brake When emergency brake is necessary in
indicator lamp illuminates, it indicates that the danger due to foot brake out of order, apply
vehicle is in parking brake. Before traveling, hand brake lever to brake the vehicle.
when intend to release the parking brake, pull When service brake is damaged and the
the locking sleeve on the control lever and move vehicle has to be towed, apply hand brake
the lever to the range of 0°～10°. instead of service brake.

21. Combined switch (No. 27 in Fig. 3-1)
Refer to Fig 3-5 for combined switch.

a. Exhaust brake switch:
When the vehicle travels on a long
downhill, pulling the switch backwards can
Never stop engine when the vehicle
realize exhaust brake. This can avoid not only
travels on a long downhill with the switch
the vehicle speeding up to dangerous extent by
activated, and position shift lever in
deadweight but also the brake temperature going
higher gear, rather than neutral or lower
too high by less use of brake. Reset the switch Chapter 3
gear.
when it isn’t used.
b. Windshield wiper switch:
Lifting the switch up can start washer
motor to clean the windshield; pulling the
switch backwards can control the wiper motor
to run at low speed or high speed.
c. Dimmer switch (No. 13 in Fig. 3-1):
Push the switch forwards to turn on left
turning lamp, left turning indicator lamp
(No. 1 in Fig. 3-2) on instrument panel and
traveling left turning lamp flash; pull the switch
backwards to turn on right turning lamp, and
right turning indicator lamp (No. 15 in Fig. 3-2)
on instrument panel and traveling right turning
lamp flash. The control lever should be returned
to neutral position after turning. 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 the 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.

Chapter 3
Fig. 3-5 Combined switch
No. Name No. Name

1 Exhaust brake switch 3 Dimmer switch
2 Windshield wiper switch
22. Charging indicator lamp (No. 3 in Fig. 3-2)
The lamp comes on when starting switch is in position ON, indicating that power is turned on
and the engine may be started. When engine is running normally, if the lamp goes out, it means that
generator begins to work. If it does not go out, accelerate engine to middle rotation speed. If it still
remains light, it means that generator doesn’t work, stop for check.

3-3 Preparation before driving

1. Check coolant level
Check coolant level through the sight-hole
of expansion tank. If no coolant is found, fill

● Only after the vehicle is parked,
coolant of same brand till it is found. After that,
engine is stopped and engine cools down
start engine and refill coolant to specified level
coolant level can be checked, so as to
when it is running at approx.1000 r/min.
prevent hot water and steam from injuring
2. Check fuel level person. Chapter 3
Turn the key switch to position ON, check ● It is prohibited to fill coolant
fuel level on fuel gauge, and replenish fuel if when engine is still in high temperature.
necessary.
3. Check engine oil level
Pull out the dipstick (see Engine Operation
Manual), and replenish the specified engine oil
depending on the level mark of the dipstick.
4. Check transmission oil level
The transmission oil level should not be
lower than the position of the side sight-hole on
the transmission case, i.e., not lower than the
centerline of transmission countershaft.
5. Check the water condensed in the air
reservoir
Drain the water condensed in the air
reservoir by turning off the drain valve under
the air reservoir. If there is water out, drain out
fully and replace drying agent in dryer.
6. Check the tire pressure, and inflate the
tire if it is necessary.
7. Check the tightness of tire bolts.
8. Check function of entire electric system.

9. Check leakage of oil, gas and coolant.
10. Check air filter.
Empty and clean the dust-collector
everyday if the crane works in dusty
environment. If red line in air filter negative
pressure indicator (near the outlet of air filter)
occurs, clean the filter element.
Chapter 3
3-4 Operation of engine
3-4-1 Starting engine
1. Refer to Engine Operation Manual for
details.
2. Operation of power source switch (see
Fig. 3-4) When starting the engine by wire-
Turn the starting key from position OFF contact, the wire can only be connected
to ON to turn on power. Engine may be started to the battery and never to the starting
after self-checking is finished for 5~8 seconds. motor.
Turn the key from position ON to START to
start engine. After starting, release your hand,

the key will automatically return to position
ON.
3. Cold weather starting device
A pre-heating device is equipped in engine.
When the temperature of coolant in the engine
is lower than 0℃, the device is automatically
activated to heat inlet air.
Before starting, insert the key and turn
it from position OFF to ON to turn on the
pre-heating device. At this time, pre-heating
indicator lamp (No. 11 in Fig. 3-2) comes on.

After indicator lamp flashes and goes out,

3-4-3 Stopping engine
turn the key from position ON to START to start
After running with a full load, let the engine
the engine.
run at idle for 3~5 minutes before stop it, so that
4. Starting process
the engine cools down gradually.
Wi t h h a n d b r a k e h a n d l e i n b r a k i n g
Press the stop switch (No. 15 in Fig. 3-1) to
condition, shift lever in neutral position and
stop the engine.
accelerator pedal (No. 26 in Fig. 3-1) not
depressed, turn the starting key to position

Chapter 3
START to start the engine. Generally, the
starting time is 2~3 seconds, if fail to start
within 12 seconds, return the key to position ON
immediately, and start again after 2 minutes.
If continually fail starting for 3 times, stop
starting and check the cause.
5. Engine oil pressure after starting
After starting, the engine oil gauge should
display the reading within 15 seconds and
the reading should be in line with the engine
operation requirement (see Engine Operation
Manual). If the pointer does not move, stop

engine at once and check the cause.
3-4-2 Preheating engine
After starting, engine idle time can’t exceed

The rotation speed should be increased
5 minutes. Increase rotation speed gradually up
slowly to make sure that the bearings get
to 1000~1200 r/min and let it begin running with
sufficient lubricating and oil pressure becomes
a partial load. Only when water temperature is
stable, especially after the engine is started
higher than 75 ℃, engine oil pressure is higher
in cold weather. It is not allowed to depress
than 0.05MPa, can the engine run with a full load.
accelerator pedal abruptly without a load applied.

3-5 Operation of PTO
After parking the truck on a safe place
for extending outriggers and lifting operation,
position shift lever (No. 24 in Fig. 3-1) to

● Before operate the PTO switch,
neutral. With engine running at idle speed,
the pressure in pneumatic circuit should
depress clutch pedal (No. 3 in Fig. 3-1) to
be more than 0.45MPa. (Low air pressure
disengage the clutch fully. After that, pull out
warning indicator lamp goes out).
Chapter 3
PTO switch (No. 4 in Fig. 3-1) and release the
● During traveling, the PTO switch
clutch pedal. At this time, PTO gear will mesh
must be in position OFF.
with transmission gear smoothly, and PTO
● When operate the PTO switch,
begins to work.
clutch must be disengaged fully.
In reverse, depress clutch pedal to
d i s e n g a g e c l u t c h a n d p u s h P TO s w i t c h
backward, and then position the shift lever to
neutral and release the clutch pedal. At this time,
PTO gear will disengage with transmission gear
smoothly.
3-6 Vehicle starting and shifting
3-6-1 Vehicle starting
Only when the air pressure in the air
reservoir of braking system reaches 0.45Mpa,
and hand brake indicator lamp and low air
pressure warning lamp go out, the spring
brake can be released fully. And then the truck
can start and all air-powered systems can be
operated.

3-6-2 Method for operating transmission
Before driving, depress clutch pedal to
disengage clutch fully. And then move shift
lever to the position required and release clutch
pedal for driving.
Shift up:
1. Set the shift lever (No. 24 in Fig. 3-1) in
neutral position for engine starting. Chapter 3

2. Shift to 1st gear to start running the
● During shifting, the clutch must
truck.
be disengaged fully, and shift lever in
3. Consecutively change gears in order
place.
from the 1st one to the 2nd, the 3rd and the 4th,
● Use the 1st gear for starting the
and finally to the top gear.
truck.
Shift down: When shifting down, shift
● During traveling, regularly check
from the top gear to the 1st gear can be operated
oil pressure gauge, speedometer and water
consecutively.
temperature gauge.
● Never travel with a shift lever in
neutral or slide with an engine stopped
for transmission lubricating and safety.

3-6-3 Stopping and parking Never depress clutch and put shift lever
The vehicle can be stopped with foot in neutral while engine exhaust brake is
brake or hand brake whenever shift lever is in engaging.
whatever gear. For temporary stopping, engine ● Select different gear according
may not be shut down and shift lever position to road conditions to meet traveling
may not be changed. If leaving the truck for requirements.
a long time, the lever must be positioned in ● Never shift gear with accelerator
neutral position. When parking is necessary, pedal depressed.
apply the hand brake and stop the engine, as
well as position the shift lever to neutral, and

turn off lamps and close cab door.

3-6-4 Operation in emergency
1. When there is trouble in transmission 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. 17 in Fig. 3-1) must be
turned on and all turning indicator lights should also be turned on.
2. When engine and transmission are damaged, if the vehicle is to be towed, the propeller shaft
must be disconnected.
3. When driven axle or driving axle is damaged, if the vehicle is to be towed, the front or rear
Chapter 3 section of the vehicle must be lifted up.
3-7 Control of clutch

Clutch is controlled by static pressure oil with the aid of air-assisted device. When clutch pedal is
depressed to 3/4 of its stroke, clutch friction disc can disengage from engine flywheel fully, and then
power is cut out.
Fig. 3-6 Clutch control diagram

Free stroke S of clutch pedal should be in the range of 40~60 mm when clutch branch cylinder
pushrod does not move. If not, check the clearance of master cylinder pushrod and check if there is air
in the static pressure oil circuit.
When clutch pedal is depressed to 3/4 of its stroke, the clutch should be disengaged fully, if not,
check if there is air in the static pressure oil circuit.
a. Method for adjusting clutch control system
The clutch control system is controlled by static pressure oil, so check the oil level in oil cup
regularly and make sure it remains at 4/5 of the oil cup height or between the upper and lower mark. If
Chapter 3
it is necessary to replace the clutch branch cylinder, the air in the system must be removed.
1. Open the rear cover outside driver’s cab and pull out the inlet tube, and then fill brake oil into
the oil cup until the oil level up to 3/4 to 4/5 of the cup height, or between the upper and lower mark.
After that, return the inlet tube to its previous place and secure the oil cup cap. Refer to Table 1-4 in
Maintenance manual for oil brand.
2. Remove the rubber cover on the branch cylinder bleeding cap, and do the following:
1) Loosen the bleeding cap on the clutch branch cylinder
2) Depress the clutch pedal to maximum stroke
3) Tighten the bleeding cap
4) Release the clutch pedal
Repeat the said procedure until there is no bubble in the brake oil spraying out of the bleeding
cap. And then tighten the bleeding cap immediately, and install the rubber cover. During operation pay
attention to the oil level in the oil cup and replenish oil according to requirements.
b. Method for adjusting pushrod length of clutch branch cylinder
Loose the lock nut on the pushrod and rotate the pushrod to prolong or shorten its length according
to actual requirement. A clearance of 3±0.5mm between the bearing end face of clutch sleeve and the
end face of declutching lever should be ensured. Tighten the lock nut after adjustment.
● When changing shift gear, the clutch pedal must be depressed.
● Before use PTO switch, the clutch pedal must be depressed to disengage the clutch fully.
● Two persons are needed to coordinate for system bleeding.
● The pushrod length of clutch branch cylinder may be adjusted manually.

3-8 Control of steering
Mechanical steering with hydraulic servo is available. Driver may drive the vehicle straightly or steer by
controlling the steering wheel.
Chapter 3
Fig. 3-7 Steering system diagram
No. Name No. Name

1 Steering wheel 3 Steering oil tank
2 Steering gear 4 Steering pump

Steering procedure:
a. Mid-position: the vehicle is driven to
go straight while the steering wheel is in the

● The movement of steering gear is
position. The steering wheel remains unmoved
realized through the steering pump activated
if driver does not apply steering force on it.
by engine. The vehicle should not slide with
b. Steering procedure: when it is necessary
the engine shutdown, otherwise steering is
to change driving direction, driver may move
heavy and it is easy to result in accident.
the steering wheel for steering. Move the
● When steering system trouble
Chapter 3
steering wheel left to turn the vehicle left; move
caused by oil pump or circuit appears, the
it right to turn the vehicle right.
steering gear may be taken as a mechanical
c. Return: after steering is finished, with
steering gear for forcing the vehicle to reach
the steering wheel static the vehicle wheels
repair station. But compulsory steering for a
will move towards straight-line motion
long time may damage the steering gear.
direction under return moment of force, till
● It should be avoided as far as
reaches straight-line motion direction. Turning
possible to move the steering wheel to its limit
the steering wheel may return the vehicle to
position. If it could not be avoided, the time
straight-line motion direction immediately.
the steering wheel stays at the limit position
d. Road sense effect: it is a direct sense
should be controlled within 1 minute.
to road conditions and the change of steering
resistance obtained by the driver from the
steering wheel while steering motion is
performing. When the driver applies force to the
steering wheel, the force works on the steering
arm on the steering gear at the same time and
makes it deform. Deformation is in direct
proportion to steering resistance. The driver can
gain “road sense” effect by judging steering
resistance according to the force applied to
steering wheel.

3-9 Braking system
The braking system consists of service brake (foot brake), parking brake (hand brake) and auxiliary brake
(engine exhaust brake).
a. Service brake
The service brake is controlled by foot pedal (No. 28 in Fig. 3-1), and it is double-circuit air
pressure brake. The max. 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. In case the air pressure of one air
Chapter 3
reservoir in two circuits drops below 0.45Mpa, park the truck at a safe place immediately and find the
cause.
Repeated braking in a short time may cause pressure down below 0.45Mpa.
b. Parking brake
Parking brake is air-release spring brake acting on the mid and rear axles. It gives effect by the
spring-loaded air chamber on each axle. After stopping the truck, applying hand brake handle can hold
the truck stationary. Only after hand brake is released and the pressure in the 23rd circuit of braking
system is more than 0.45Mpa (low pressure warning lamp goes out) and hand brake indicator lamp
goes out, as well as the spring returns to its original place by the force of compressed air, the parking
brake could be released fully. Hand brake may be used as 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.
c. 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. 3-4), and then the butterfly-valve on exhaust pipe
is closed by the action of solenoid valve and air cylinder, consequently engine exhaust brake is realized.
Never disengage gearbox and depress clutch pedal while engine exhaust brake is used.

d. Releasing of spring brake air chamber
When self-braking happens due to leakage
of the pipeline for connecting spring brake air
chamber, do the following to release (see Fig.
3-8a):
a. Open the blocking cover at the tail of
brake air chamber;
b. Remove nut on bolt and take off the bolt;

Chapter 3
c. Insert the bolt (Fig. 3-8b) into brake air
chamber from its tail and lock it;

Fig. 3-8a Brake air chamber
d. Leting 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 so as to prevent the truck from
sliding.
Fig. 3-8b Brake air chamber

3-10 Operation of outriggers
3-10-1 Names of outrigger parts and outrigger control levers
Chapter 3
Fig. 3-9 Names of left outrigger parts
No. Name No. Name

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

Chapter 3
Fig. 3-10 Outrigger control levers
No. Name No. Name

1 Outrigger position select lever 4 Left rear outrigger select lever
2 5th jack select lever 5 Right front outrigger select lever
3 Right rear outrigger select lever 6 Left front outrigger select lever

3-10-2 Preparation before operation
Prior to operation of outriggers, check
hydraulic oil level and temperature from the
thermo-liquidometer (Fig. 3-11) on the side of
hydraulic oil tank. If the level is lower than the
mark required, refill to specified level.
Method: open the cover of air filter on the
Chapter 3 upper side of the hydraulic oil tank, and then
refill the same brand hydraulic oil through filter
screen.
For L-HM32 hydraulic oil, the min.
temperature for starting oil pump is -10°C;
for L-HM46 hydraulic oil, it is -5°C. If the
temperature is lower than the said value,
increase hydraulic oil temperature or select to
use L-HV22 (No. 10 aviation hydraulic oil). It is
not forbidden to increase hydraulic oil by means
of heating hydraulic oil tank with fire directly. Fig. 3-11 Thermo-liquidometer
3-10-3 Engaging PTO
Start the engine with the starting key. When
low air pressure warning lamp (No. 12 in Fig.
3-2) goes out, depress the clutch pedal (No. 3
in Fig. 3-1) and position the shift lever (No. 24
in Fig. 3-1) in neutral. After that, pull out PTO
switch (No. 4 in Fig. 3-1) and let the clutch
pedal return to its original position by removing
your foot slowly.

3-10-4 Setting outriggers
1. Pull out outrigger beam lock pins.
2. Position select levers (No. 3~ 6 in Fig.
3-10) to “Extension”.
3. Move outrigger position select lever
(No. 1 in Fig. 3-10) to “Extend” to extend
outrigger beams.
4. After outrigger beams are extended into

Chapter 3
place, return the outrigger position select lever
to Neutral.
5. Position the select levers (No. 3~ 6 in
Fig. 3-10) to “Jack”.
6. Move the outrigger position select lever
(No. 1 in Fig. 3-10) to “Extend” to extend
outrigger jacks.
7. After outrigger jacks are extended fully,
return the outrigger position select lever to
“Neutral”.
8. Move the 5th jack select lever (No. 2 in
Fig. 3-10) to “Jack”.
9. Move the outrigger position select lever
(No. 1 in Fig. 3-10) to “Extend” for lowering

All floats must rest on a firm ground
down the 5th jack float on the ground or wood
or wood blocks.
block.
10. After outrigger jacks are extended fully,
check if the chassis is level or not by observing the
level gauge. If it is level, return all select levers to
“Neutral”. If it is not level, level it according to
the method described in How to level crane.

3-10-5 How to level crane
1) Move the 5th jack select lever (No. 2 in
Fig. 3-10) to “Jack”;
2) Move the outrigger position select lever
(No. 1 in Fig. 3-10) to “Retract”, and retract
the 5th jack until it is not supported;
3) Move the 5th jack select lever (No. 2 in
Chapter 3 Fig. 3-10) to Neutral;
4) M o v e t h e s e l e c t l e v e r s ( a n y o n e
or more of No. 3~6) to Jack, and move the
outrigger position select lever (No. 1) to
“Extend” or “Retract” to extend or retract
the selected jack cylinders until the level gauge
shows it is in horizontal state.
5) After the chassis is leveled, return the
select levers (No. 3~6) to “Neutral”.
6) Lower the 5th jack until it contact the Prior to lifting operation, the chassis
ground slightly, and then move the 5th jack must be leveled.
select lever (No. 2 in Fig. 3-10) to “Jack”, at
this time, chassis operation is finished.
For example: when the right side of crane
is higher, move the right front and the right rear
outrigger select levers to “Jack”, and then
move the outrigger position select lever (No.1)
to “Retract”. Meanwhile, observe the level
gauge until the crane is level. After the crane is
leveled, move all select levers to “Neutral”.

3-10-6 Stowing outriggers
1. Move the 5th jack select lever (No. 2 in
Fig. 3-11) to “Jack”, and move the outrigger
position select lever (No. 1 in Fig. 3-11) to

Before retracting outriggers, stow the
“Retract”, so as to retract the 5th jack fully;
main boom with jib onto boom rest.
2. Move the select levers to “Jack”, and
then move the outrigger position select lever
(No. 1) to “Retract” to retract jacks fully. Chapter 3

3. M o v e t h e s e l e c t l e v e r s t o
“Extension”, and then move the outrigger
position select lever (No. 1) to “Retract” to
retract outrigger beams fully.
4. Move the select levers to “Neutral”.
5. Insert the outrigger beam lock pin 1
into hole 2.
6. Turn off the PTO switch.
3-10-7 Notes on operation
1. The ground on the job site for crane 6. R e t u r n t h e l e v e r s t o N e u t r a l

operation must be level. immediately after operation of outriggers is
2. Do not set the outrigger jacks before finished.
extending outrigger beams. In addition, before starting crane operation,
3. After setting up the crane, make sure make sure that the levers are in Neutral.
that all the outrigger floats are in complete
contact with the ground.
4. Keep all tires off the ground.
5. After setting and stowing the outriggers
make sure that the outrigger beam lock pins are
completely inserted.

3-11 Winter operation
1. Cooling system
The coolant for cooling system should comply with the requirements of engine. Soft water or soften water
should be used, otherwise the scales formed and deposited will affect the cooling effect.
Hard water can be softened by the following methods:
a. Heating and boiling;
b. Add sodium carbonate (Na 2 CO3) 0.5~1.5g to each liter of water;

Chapter 3
c. Add sodium hydroxide (NaOH) 0.5~0.8g to each liter of water.
Antifreeze coolant JFL-318 (0℃～-10℃), JFL-336 (-10℃～-26℃) and JFL-345(-26℃～-35℃) may be
used.
Antifreeze coolant can also be made according to the methods recommended in Table 3-1.
Please replace coolant in time according to ambient temperature.
Limit temperature of
freezing point for Glycerin—water Glycol—water
antifreeze coolant
（ ℃） Glycerin weight % Specific gravity D Glycol weight % Specific gravity D
-10 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
● Never use sea water to cool engine directly.
● Antifreeze coolant may be added according to the operation requirements of engine,
When using antifreeze coolant, its freezing point should be lower 5℃ than the lowest temperature
in the area.
b. Braking device
Do not forget to drain the water condensed in the air reservoir before traveling.

3-12 Run-in of a new truck
The run-in mileage for a new truck is 1500km. Before run-in, routine inspection should be carried out for
ensuring the truck in normal working condition.
1. After cold starting, do not accelerate the engine immediately, firstly let it run at 1000r/min of idle speed
for 3~5 minutes. Increase engine speed only when normal working temperature is reached. In run-in time, the
engine rotation speed should be limited within 80% of its highest speed.
2. During run-in time, the truck should travel on level and flat roads.
Chapter 3
3. In traveling, select proper shift gear according to load and road conditions. And avoid abrupt accelerating
and emergent braking.
4. Check and control engine oil pressure and coolant working temperature.
5. Check regularly the temperature of mid and rear axle wheel hubs and brake drum. If serious overheating
occurs, find the cause and adjust or repair immediately.
6. After initial traveling of 50km or every time changing tires, tighten wheel nuts according to the specified
torque (Refer to Table 6-1 in XZ20G.5 Truck crane chassis maintenance manual).
7. After run-in time, check and maintain the truck according to the “First check” items specified in
XZ20G.5 Truck crane chassis maintenance manual and the requirements in engine and transmission operation
manuals.
3-13 Usage of air conditioner
Cold-warm air conditioning is available.
Warm air is utilizing engine cyclical hot water. In winter when intend to use warm air, first open hot water
valve (see Fig. 3-12) in warm air pipeline, and then press down the air conditioner switch (No. 17 in Fig. 3-1).
Air conditioner is optional. In summer when intend to use cold air, close the hot water valve in warm air pipeline
first and then press down the air conditioner switch, last press down A/C switch on the air conditioner. Refer to air
conditioner operation manual for details.
Be sure to close hot water valve when use cold air, be sure to open hot water valve when use
warm air. In winter, the water in warm air pipeline also should be drained off when it is necessary
to drain off the water in engine cooling system.

Chapter 3
3-30

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XZ20G.

5 Truck Crane Chassis Operation Manual

XZ20G.5 Truck Crane Chassis Operation Manual

The operation manual is part of the crane!

Always keep on hand!

Please read the manual before operating the product.

This equipment is designed and manufactured by complying with the standard of

XUZHOU HEAVY MACHINERY CO., LTD.

Preface ...... ..................................................................................................................................................III

Chapter 1 Safety operation......................................................................................................................... 1-1

Chapter 2 Product description.................................................................................................................... 2-1

2-1 Vehicle number ............................................................................................................................ 2-1

Chapter 3 Chassis operation....................................................................................................................... 3-1

3-1 Arrangement in cab...................................................................................................................... 3-1

3-1-1 Instruments and control mechanism ..................................................................................... 3-1

3-1-2 Indicator lamp assembly ....................................................................................................... 3-3

3-3 Preparation before driving ......................................................................................................... 3-11

3-4 Operation of engine ................................................................................................................... 3-12

3-4-1 Starting engine .................................................................................................................... 3-12

3-4-2 Pre-heating engine .............................................................................................................. 3-13

3-4-3 Stopping engine .................................................................................................................. 3-13

3-5 Operation of PTO ...................................................................................................................... 3-14

3-6-1 Vehicle starting.................................................................................................................... 3-14

3-6-2 Method for operating transmission ..................................................................................... 3-15

3-6-3 Stopping and parking .......................................................................................................... 3-15

3-6-4 Operation in emergency ...................................................................................................... 3-16

3-7 Control of clutch ........................................................................................................................ 3-16

3-8 Control of steering ..................................................................................................................... 3-17

3-9 Braking system .......................................................................................................................... 3-20

3-10 Operation of outriggers............................................................................................................ 3-22

3-10-2 Preparation before operation ............................................................................................. 3-24

3-10-3 Engaging PTO ................................................................................................................... 3-24

3-10-4 Setting outriggers .............................................................................................................. 3-25

3-10-5 How to level crane ........................................................................................................... 3-26

3-10-6 Stowing outriggers ............................................................................................................ 3-27

3-10-7 Notes on operation ............................................................................................................ 3-27

3-11 Winter operation ...................................................................................................................... 3-28

3-12 Run-in of a new truck .............................................................................................................. 3-29

3-13 Usage of air conditioner .......................................................................................................... 3-29

Total pages ..................................................................................................................................................43

“Check” in this manual.

components correctly set. Please don’t regulate them randomly. 。

like to supply technical support in time and effectively.

for loss resulted.

one. We reserve the right to modify the design without notice.

First edition, May 2012

Symbols and their meanings are as follows:

it could not be avoided.

—— It means there is a potential danger, light or medium injury may be

caused if it could not be avoided.

——Check: related inspections are required by requirements.

Chapter 1 Safety operation Chapter 1

Safety cautions: ● Prior to driving, make sure that there is

allowed for operating the crane. vehicle.

alcohol or taking medicine. ● The PTO switch must be in position

damage to the crane. ● During traveling, observe the

● Hydraulic oil is toxic and flammable. conditions of instrumentation and indicator

body or clothing into the moving parts during may be damaged.

operation. ● When the vehicle has to be towed, the

outriggers are retracted fully in place and must be engaged.

outrigger beam extended out during traveling.

Safety operation 1-1

● Prior to maintaining engine and other