QY110K (XZ110K) Operation Manual

XZ110K TRUCK CRANE CARRIER
OPERATION MANUAL
XUZHOU HEAVY MACHINERY CO., LTD.
XUZHOU CONSTRUCTION MACHINERY GROUP CO., LTD., CHINA

XZ110K TRUCK CRANE CARRIER
OPERATION MANUAL
Pages: 1 up to 49
VIN
Date
The operation manual is part of the crane!
Always keep on hand!

This equipment is designed and manufactured by complying with the
standard of Q/320301JAF51.

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
XZ110K Truck Crane Carrier Operation Manual
Preface
This manual supplies technical information about the performance, structure, operation and
adjustment of XZ110K Truck crane chassis (for QY110K) to drivers and operation workers for
reading and vehicle managers and technicians for reference.
Please operate and maintain the vehicle strictly in accordance with the specified requirements
in this manual and keep record of periodical maintenance.
It is recommended to understand notes and cautions in relation to operation and maintenance in
the manual.
Always use original parts for eventual replacement of parts in order to ensure machine’s
performance.
All staff in the service stations authorized by our company has been trained professionally and
able to supply service of technical support and spare parts. If there is any problem that couldn’t
be solved there, please directly contact the office of our company nearest to you.
About the manual:
Metric units for measurement are adopted in the manual.
Illustrations and symbols are used for helping understand the meanings of text in the manual.
Symbols and their meanings are as the following:
Note: the term “Note” is used whenever the nonobservance of certain instructions or notes
may injure persons and damage to parts of the crane.
Caution: the term “Caution” is used whenever serious injury to persons or damage to the
crane can occur if the operating instruction(s) is not observed and adhered to.
Check: carry out relative check according to requirements specified by the

manufacturer.
Due to the product modification and improvement, what described in this manual may vary
from the real product, and we reserve the right to modify the design without notice.
I
Notes:
1) Read the manual carefully and familiar with operating methods & notes before operate the
vehicle. Otherwise, never operate it.
2) Before starting, make sure that there is no unauthorized person around the machine. Only
when there is no person within the dangerous area, the machine can be operated. Otherwise,
never activate it.
3) Never extend hand and any part of body or clothing into the moving parts during operation.
Personal protective equipment such as spectacles, protective clothing and safety shoes has to
be worn during operation.
4) The beacon selected by customer only can be used during lifting operation. And it is
mounted by customer.
5) Keep the manual well for future reference.
II
Contents
I. Safety---------------------------------------------------------------------------------------------------------1
(I). Cautions--------------------------------------------------------------------------------------------------1
(II). Safety requirements during driving-----------------------------------------------------------------2
II. Product description -----------------------------------------------------------------------------------------3
III. Main technical parameters---------------------------------------------------------------------------------5
IV. Vehicle operation--------------------------------------------------------------------------------------------7
(I). Arrangement in cab-------------------------------------------------------------------------------------7
(II). Preparation before driving -------------------------------------------------------------------------21
(III). Starting and shifting--------------------------------------------------------------------------------24
(IV). Braking system--------------------------------------------------------------------------------------29
(V). Outriggers operation---------------------------------------------------------------------------------31
(VI). Transferring within job site-------------------------------------------------------------------37
(VII). Winter operation-----------------------------------------------------------------------------------37
(VIII). Wheel inspection and replacement-----------------------------------------------------------38
(IX). Run-in of a new truck -----------------------------------------------------------------------------39
(X). Usage of air conditioner ---------------------------------------------------------------------------40
(XI). Description of engine state display---------------------------------------------------------------45
(XII). Protective measures during welding operation------------------------------------------------48
III
I. Safety
(I). Cautions
● Related certificate is necessary for person who operates the vehicle. Avoid injury to person
due to mis-operation.
● Never perform any operation and maintenance when the operator is unable to do work
normally due to bad health or drinking alcohol or taking medicine.
● Any improper operation or casualness will cause injury or death of persons and damage to
the crane.
● Comply with road travel and crane operating regulations in the place where you are working.
● Before driving, make sure that all outriggers are retracted fully in place and secure with lock
pins.
● During traveling, no person is allowed to stay in the operator’s cab or outside of the driver’s
cab.
● During traveling, observe the conditions of instrumentation and indicator lamps in the
driver’s cab. If any abnormality occurs, park the vehicle in a safe place and repair in time.
● When the vehicle has to be towed, the propeller shaft must be disengaged.
● There is an increased danger of accidents if parts are damaged due to the machine has not
been maintained according to the operating instructions.
● Personal protective equipment such as spectacles, protective clothing and safety shoes has to
be worn during maintenance.
● Before perform maintenance, confirm that the machine has been set up well, and a warning
board of “In maintenance, no operation” in the driver’s cab must be 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.
● 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 scald, watch out for scorching parts and pipelines as well as liquid and gas
in pipelines and cavities.
● Hydraulic oil is toxic and flammable. Store it in a place where children are not likely to reach.
Avoid breathing evaporative emission or contact used oil for a long time. Clean skin with
soap and water as soon as possible after touching oil. If there is oil entering into eyes, rinse
with water for 15 minutes and then see a doctor.
● In order to avoid being stifled or frostbite, maintenance of fuel system and air conditioner
system must be carried out in a well-ventilated environment. In order to protect environment,
special equipment must be used for emptying and filling refrigerant so as to not let its gas
1
emit into air.

● Position transmission control lever to neutral prior to moving PTO switch.
● When shift transfer box, the vehicle must be in static state.
● After an overload protective device as a fuse function has tripped, if intend to reset it, the
main power source must be turned off.
● Set outriggers to the places specified in load chart, and secure outrigger beams with lock pins
before lifting operation.
● Operating instructions on the machine are valid equally with instructions in this operation
manual.
(II). Safety requirements during driving
1. During driving, constantly pay attention to the readings of oil pressure gauge and water
temperature gauge.
— If any one of the readings is beyond the safe range, stop the vehicle immediately for check.
2. When the first 50km of driving and 100km of driving are arrived, the following maintenance
should be done:
 Check the connecting bolts of wheels for tightness, the bolt tightening torque should be
600～660 N.m;
 Check engine coolant level and oil level;
 Check transmission oil level and transfer box oil level;
 Check the connections of engine, transmission and axle for tightness and leakage (visual
check);
 Check the connections of propeller shaft for tightness;
 Check carrier and other parts for tightness;
 Check the tire pressure and its conditions (visual check).
3. Highway traffic regulation
Make sure that the total weight, axle load and outline dimension, etc. do not exceed the limited
value prescribed in municipal and local traffic regulations. Refer to Table 3-1 for data of the
crane in travel configuration.
4. Keep the importance of maintenance in mind
20% of failures are resulted from improper maintenance:
 Lack of lubricant, grease or coolant;
 Accumulation of dirt;
 Brake or transmission failures;
 Hydraulic system troubles;
 Loose bolts;
 Worn lines or loose plugs.
2
Ⅱ. Product description
XZ110K is the special carrier for matching with QY110K Truck crane. International advanced
parts are adopted for XZ160K. It has strong power and excellent performance with each
technology leading the same industry. It’s suitable for large lifting operation and applications in
complex working circumstance such as in oil field, mines, water conservancy and construction
industry, etc.
General description:
1) Carrier arrangement
Four axles with single tire, two axles with double-tire; the front outrigger box is located
between 2nd and 3rd axle;
Full dimension driver’s cab with pneumatic suspension; aluminum coverings for walking
surface, aluminum edgings and nonmetal skirts are available.
2) Drive line
MTU electric injection engine, compliant with GB17691 Ⅲ and Euro Ⅲ;
ZF automatic transmission;
ZF transfer box;
Large torque propeller shaft with cross serrated flange;
KESSLER axle;
Xuzhou Meritor axle;
Double coin tire.
3) Main performance
Drive type: 12×6 (axles 3, 5 and 6 for driving)
Steering type: 12×8 (axles 1, 2, 3 and 6 for steering), the min. turning diameter is 24m;
Min. stable vehicle speed: 2.6 km/h；
— The maximum vehicle speed is 80km/h, the max. grade ability is 40% when a load of 55t is
applied, without counterweight, jib and auxiliary winch equipped.
— The maximum vehicle speed is 80km/h, the max. grade ability is 40% when a load of 62t is
applied with counterweight on board, without jib and auxiliary winch equipped.
— During transfer within job site, the maximum vehicle speed is 50km/h when a load of 67t is
applied with a counterweight of 8.5t, jib and auxiliary winch equipped and the max. grade
ability is 40% when transfer box is in low speed.
4) Location of engine nameplate
Engine nameplate is located at the left of the engine, under
the button “START/STOP”, as pointed by the red arrow.
Engine nameplate
3
Content on the nameplate:
① Engine model
② Engine number
③ Engine approval number
④ Engine serial number
5) Carrier nameplate and vehicle identification number

Carrier nameplate and vehicle identification number are positioned on the right side beam of
the frame between axles 1 and 2.
The carrier nameplate consists of:

① Product name and model;
② Carrier number;
③ Engine number;
④ Delivery date;
⑤ Manufacturer
Symbols stars (☆) are marked at both ends of product number and vehicle identification number.
When you claim compensation, order spare parts or contact with our service department,
please give the following correctly and clearly:
Vehicle Model:
Carrier No.:
Engine No.:
Delivery Date:
VIN:
4
III. Main technical parameters

Main assembly structure features and technical parameters
Table 3-1 Main assembly structure features and technical parameters
Model XZ110K
Driving type 12×6
Crew 2
Length mm 14800
Width mm 3000
Dimension Height mm 3920
Wheel base mm 1420+2420+1800+1420+1505
Track mm Single tire: 2610; double tires: 2315
Total vehicle mass kg 54900
1st axle kg 7500
2nd axle kg 7500
Mass Axle 3rd axle kg 8300
load 4th axle kg 12000
5th axle kg 12000
6th axle kg 7600
Max. vehicle speed (km/h) 80
Min. stable vehicle speed
2.6
(km/h)
Max. grade ability 40%
Min. turning diameter (m) 24
Performance
Brake distance is not more than 10m when the
Braking distance (m) vehicle of 55t is traveling on a dry and level
asphalt road at an initial speed of 30km/h.
Approach angle 20°
Departure angle 14°
Engine Model OM460LA
Max. power （kw/r/min） 360/1800
Max. torque（N.m/r/min） 2200/1100
0.5bar at idle speed; 2.5bar at rated rotational
Oil pressure
speed
Transmission Model 12 AS 2302 IT
5
Automatic shift gearbox, 12 forward, 2

Type
reverse, mechanical clutch
Propeller Tubular, open spider universal joint,
Type
shaft ISO12667-T180 cross serrated flange
Model VG2000
Transfer box With differential and emergency steering
Type
pump
Camber angle of front (left/right) wheel 0°
Caster angle (left/right wheel) 0°
Negative camber angle of kingpin (left/right
6°
wheel)
Toe-in 0 mm
Axles 1, 2, 3 and 6 for steering, axles 3, 5 and
Axle Type
6 for driving
Welded box structure, made of high tension
Frame Type
structural steel
Suspension Type Leaf spring suspension
Tire 12.00 R24, single tire for axles 1, 2, 3 and 6; double-tire for axles 4 and 5
Tire pressure (0.84±0.05) MPa
Semi-integral steering gear, single circuit hydraulic boost
Steering Type
system
Double-circuit air brake system, shoe brake, acting on all
Service brake
wheels
Spring-loaded braking system acting on wheels of axles
Brake Parking brake
3~6
Auxiliary Engine retarded brake, exhaust brake, transmission
brake retarded brake
Full dimension, all metal welded closed type, supported by
Cab elastic suspension, with instrumentation, air conditioner,
electric windshield wiper and CD player, etc. fitted.
Indication of transmission and engine state is available,
Electric system 24V of system voltage, two sets of battery each180A.h,
negative ground
6
IV. Vehicle Operation

(I). Arrangement in cab
Arrangement in cab consists of seats, front control and indicator devices, right control panel,
instrument panel and fire extinguisher, refer to Figs. 4-1~ 4-6.
1. Seat
1. Backrest angle adjusting lever

2. Head rest unlocking switch
3. Seat damping control lever
4. Seat cushion front adjusting lever
5. Seat cushion rear adjusting lever
6. Seat sliding control lever
4
1
5
3
6
2
Fig. 4-1 Seat
(1) Backrest angle adjusting lever

Function: to adjust backrest angle
Operating method: moving the lever forward, the backrest will
incline forward; with the lever moved forward, if a force is applied
backward to the backrest, the backrest will incline backward; release
the lever, and then the backrest will be locked.
(2) Head rest unlocking switch

Function: to adjust head rest
Operating method: with the switch pressed, the head rest may be
moved up or down. Release the switch, the head rest will be locked.
7
(3)Seat damping control lever

Function: to control damping
Operating method: with the lever turned anti-clockwise, the
damping of air bag is locked; in reverse, it is unlocked, and then
damping is available.
(4) Seat cushion front adjusting lever

Function: to adjust the front of seat cushion in height and angle
Operating method: with the lever pulled, the front of seat cushion
may be adjusted in height and angle by using occupant’s weight.
(5) Seat cushion rear adjusting lever

Function: to adjust the rear of seat cushion in height and angle
Operating method: with the lever pulled, the rear of seat cushion
may be adjusted in height and angle by using occupant’s weight.
(6) Seat sliding control lever

Function: to move the seat forward or backward
Operating method: with the lever lifted，if a force is applied
forward (backward) to the seat, it will move forward (backward).
8
2. Instrumentation, switches and indicator lamps in cab
STOP
TEST
Fig. 4-2 Front control and indicator devices in cab
1. Display of transmission state 2. Engine tachometer

3. Indicator lamp assembly (see Fig. 4-5) 4. Double-pointer air pressure gauge
5. Engine oil pressure gauge 6. Engine OBD
7. Engine water temperature gauge 8. Fuel gauge
9. Speedometer 10. Steering wheel
11. Combined switch 12. Key switch
13. Brake pedal 14. Electronic accelerator pedal
9
STOP
TEST
Fig. 4-3 Front control panel
1. Heater indication panel 2. CD player

3. Engine shutdown condition indicator lamp 4. Retarder fail switch
5. Rear mirror heating switch 6. ABS fail switch (optional)
7. Beacon lamp switch (optional) 8. PTO switch
9. Inter-axle differential switch 10. Reverse monitor
11. Inter-axle differential indicator lamp 12. Low water level warning lamp
13. ABS indicator lamp (optional) 14. Inter-wheel differential indicator lamp
15. Engine test indicator lamp 16. Left rear mirror adjuster
17. Right rear mirror adjuster 18. Reserve switch
19. Stop switch 20. Inter-wheel differential switch
21. Transfer box differential switch 22. Transfer box low-speed switch
10
Fig. 4-4 Right control panel
1. Transmission shift lever 2. Retarder lever 3. Parking brake lever
Fig. 4-5 Indicator lamp assembly
1. Left turning indicator lamp 2. Far beam indicator lamp

3. Power indicator lamp 4. Oil pressure warning lamp
5. Reverse indicator lamp 6. Transfer box low-speed indicator lamp
7. Service brake indicator lamp 8. Engine preheating indicator lamp
9. Water temperature warning lamp 10. Transfer box differential indicator lamp
11. Fog lamp indicator lamp 12. Low-air pressure warning lamp
13. PTO indicator lamp 14. Retarder running indicator lamp
15. Parking brake indicator lamp 16. Right turning indicator lamp
11
3. Instruction of instruments, switches and indicator lamps in the cab:

(1) Double-pointer air pressure gauge (No. 4 in Fig. 4-2)
Double-pointer pressure gauge indicates the pressures in two circuits (21st and 22nd circuit) of
service brake system, the normal working pressure is 0.45 ~ 0.8 Mpa. If the air pressure in any
one of two circuits decreases below 0.45 Mpa, stop the vehicle to check the air circuit system.
When the pressure in hand brake circuit (23rd circuit) is lower than 0.45 Mpa, the display of
carrier state and low-pressure warning lamp on indicator lamp assembly come on; when the
pressure in transmission reservoir is lower than 0.58 Mpa, “AL” is shown on the display of
transmission state, it indicates that there is no enough pressure for starting the vehicle.
(2) Engine tachometer (No. 2 in Fig. 4-2)
Engine tachometer indicates engine rotational speed and the vehicle working time for driver to
observe and control engine max. rotational speed so as to provide guarantee for using the engine
reasonably, in 100 r/graduation.
(3) Engine oil pressure gauge (No. 5 in Fig. 4-2)
And Oil pressure warning lamp (No. 4 in Fig. 4-5)
Engine oil pressure gauge displays the oil pressure value of engine lubrication system. Oil
pressure is≥0.05MPa at idle speed, and oil pressure is≥0.25MPa at 1800r/min. When oil
pressure is ≥0.05MPa and oil pressure warning lamp goes out, the engine can work normally.
(4) Fuel gauge (No. 8 in Fig. 4-2)
When starter switch key is in ON position, the fuel gauge approximately indicates the fuel
level remained in tank. The pointer of fuel gauge will vary when the vehicle is in different states
such as accelerating, braking or climbing up and down a slope.
(5) Engine water temperature gauge (No. 7 in Fig. 4-2)
And water temperature warning lamp (No. 9 in Fig. 4-5)
Water temperature gauge indicates coolant temperature. In normal condition, the engine water
temperature should be 83~95℃. If the water temperature is higher than 95℃, water temperature
warning lamp will come on, the truck must be stopped, and let the engine run in idle to lower the
water temperature to normal condition.
(6) Speedometer (No. 9 in Fig. 4-2)
Speedometer consists of speed meter and mileage meter. Speed meter indicates the vehicle
traveling speed and mileage meter registers the vehicle total traveling miles.
(7) Display of transmission state (No. 1 in Fig. 4-2)
It can display information such as transmission working state, cautions and system faults.
12
(8) Combined switch (No. 11 in Fig. 4-2)
Fig. 4-6 Combined switch
1. Light control switch (see Fig. 4-7)

2. Fog lamp switch (see Fig. 4-8)
3. Combined switch 1 (see Fig. 4-9)
Small switch
Fig. 4-7 Light control switch
Operating method:
 Turning the small switch on the end of the switch, the first gear is for turning on travel lamp,
the second gear is for turning on headlamp;
 In the second gear, when the control lever is at middle position, dim light comes on; lift up
the control lever to turn on far beam lamp, at this time, the far beam indicator lamp (No. 2 in
Fig. 4-5) on indicator lamp assembly comes on. Moving the control lever up and down can
realize dimming.
 Pushing the control lever forwards can turn on the right turning lamp, pulling it backwards
can turn on the left turning lamp.
 When overtaking is to be carried out, lifting up the control lever and then releasing it, the
overtaking lamp will come on and then go out to warn the vehicle ahead of the crane.
13
Fig. 4-8 Fog lamp switch

Operating method:
 After the fog lamp switch is pressed, fog lamp comes on, and the fog lamp indicator lamp
(No. 11 in Fig. 4-5) on the display of carrier state comes on.
Small switch
Fig. 4-9 Combined switch 1

Operating method:
 Lifting up the control lever can activate danger warning switch, at the same time, the turning
indicator lamps in cab light and the left and right turning lamps flash;
 Pulling the control lever backward can activate engine brake;
 Turning the small switch on the end of the switch can control the wiper motor, “LO” gear is
for low speed, “HI” gear is for high speed, “INT” gear is for intermittent operation, “OFF”
gear is for stop.
 With the switch on the end of the control lever pressed, water injector begins to work, at the
same time wiper begins to wipe windshield glass until the switch is released.
Cautions:
△ If the vehicle has to be parked in a dangerous place, the danger warning switch must
be turned on, and then the front and rear turning lamps will flash to give a warning to
the passersby. Turn off the switch to release danger warning.
△ When passing a vehicle is necessary at night, the light control switch should be used for
dimming.
(9) Starting switch (No. 12 in Fig. 4-2)
Four positions are available for selection after the key is inserted into
the switch, see Fig. 4-10, their functions are as follows:
LOCK: electric power supply is turned off and engine is shut down, the
key can be pulled out.
ACC: when engine does not work, turning the key to the position is for Fig. 4-10
14
using attachments such as CD player.

ON: “ON” state, the key must be in this position when engine is running.
S: turning the key to the position can start engine when transmission control lever is in neutral
position, the “N” or “N” and “AL” will be indicated alternately on the display of transmission
state, and the key may automatically return to position ON after it is released.
Caution:
△ Never turn the key to position S after starting of engine.
(10) Engine test indicator lamp (No. 15 in Fig. 4-3)
When common trouble in engine occurs, the amber lamp will light. At this time, the vehicle
must be parked at a safe place as soon as possible for check.
(11) Engine shutdown condition indicator lamp (No. 3 in Fig. 4-3)
When serious trouble in engine occurs, the red lamp will come on. At this time, the vehicle
must be parked at a safe place immediately for check.
(12) Heater indicator panel (No. 1 in Fig. 4-3)
Fig. 4-11 Heater indicator panel

Heater indicator panel consists of a LCD screen and 10 push keys, which are employed for
setting temperature and wind direction in the cab when heater or air conditioner is used, refer to
Fig. 4-11.
(a) Explanation of the indicator panel and symbols
◆For setting: ◆ Internal circulation:
◆Temperature: ◆ External circulation：
◆1st gear wind speed: ◆ Automatic:
◆2nd gear wind speed: ◆ Refrigerating:

15
◆3rd gear wind speed: ◆ For foot direction:
◆4th gear wind speed: ◆ For face direction:
◆5th gear wind speed: ◆ Defrosting:
◆6th gear wind speed: ◆ Vehicle body symbol:
(b) Push keys
◆ Keys for adjusting temperature:
① Key for increasing temperature:
With the actual temperature in the cab indicated, press the key, setting temperature will be
displayed; with the setting temperature indicated, press the key, the setting temperature will
increase 1℃, press the key continuously, the setting temperature wi ll increase continuously.
When the setting temperature is more than 29℃, HI will occur. The setting temperature will flash
for 5 seconds, and then the actual temperature in the cab is indicated automatically.
② Key for decreasing temperature:
With the actual temperature in the cab indicated, press the key, setting temperature will be
displayed; with the setting temperature indicated, press the key, the setting temperature will
decrease 1℃, press the key continuously, the setting temperature will decreas e continuously.
When the setting temperature is less than 17℃, LO will occur. The setting temperature will flash
for 5 seconds, and then the actual temperature in the cab is indicated automatically.
◆Keys for adjusting wind speed:
① Key for increasing wind speed:
When there is no wind, press the key, wind speed will become 1 speed; when there is wind,
press the key, wind speed will increase 1 gear. When max. wind speed is reached, it is no use to
press the key.
② Key for decreasing wind speed:
When there is no wind, press the key, wind speed will become 1 speed; when there is wind,
16
press the key, wind speed will decrease 1 gear. When min. wind speed is reached, it is no use to
press the key.
◆A/C:
In case it is permissible to start compressor, press the key to open compressor; press the key
again to close the compressor.
◆ Key for defrosting:
System will enter into defrosting mode after the key is pressed.
◆ Key for changing modes:
Press the key to change the modes of wind blowing direction towards face, foot and
windshield.
◆ Circulation key:
Press the key to switch-over internal and external circulation.
◆ AUTO key:
Press the key to enter automatic mode. Exit the mode by pressing the key again or A/C, or
Defrosting key.
◆ OFF key:
With the heater or air conditioner turned on, press the key to turn off the heater or air
conditioner.
(13) PTO switch (No. 8 in Fig. 4-3)
PTO installed on the rear end of transmission can drive the hydraulic pump for operations of
extending/retracting outriggers.
Operating method:
 When engine runs at idle, position transmission control lever to neutral;
 PTO begins to work after the lower end of PTO switch is pressed, at the same time PTO
indicator lamp on indicator lamp assembly (No. 13 in Fig. 4-5) comes on, and code “PN” is
shown on the display of transmission state.
 Press the upper end of PTO switch, PTO does not work.
Notes:
△ When operate the PTO switch, pressure in air circuit should be more than 0.45 MPa. At
this time, low air pressure warning lamp on indicator lamp assembly (No. 12 in Fig. 4-5)
goes out.
△ The PTO switch must be positioned at OFF if there is no need to use it.
17
(14) Inter-wheel differential switch (No. 20 in Fig. 4-3)

Inter-axle differential switch (No. 9 in Fig. 4-3)
Transfer box differential switch (No. 21 in Fig. 4-3)
Transfer box low speed switch (No. 22 in Fig. 4-3)
When parts of wheels get into a pit and couldn’t get out or the vehicle slips, pressing the said
differential switches and using electric control pneumatic drive can link three drive axles rigidly
so as to enable the vehicle driving. After the differential switches are pressed, the transfer box
differential indicator lamp (No.10 in Fig. 4-5), the inter-axle differential indicator lamp (No.11 in
Fig. 4-3) and inter-wheel differential indicator lamp (No.14 in Fig. 4-3) will light successively. If
any one of the lamps is not light, stop the vehicle and check cause.
High or slow speed may be selected for transfer box when different power and economy
performance are needed. In normal state, transfer box runs at high speed. After the transfer box
low-speed switch is pressed, the transfer box low-speed indicator lamp (No.6 in Fig. 4-5) will
come on, and transfer box will run at low speed.
Notes:
△ Before engaging or disengaging the said switches, engine power output must be cut off and
the truck must be in static condition;
△ Only when the truck drives in straight line can the inter-wheel and inter-axle switches be
used;
△ As soon as the truck is driven on a good road, the said differential locks must be disengaged
at once. Keeping on use of the switches will result in damage of transmission and increase
fuel consumption.
(15) Stop switch (No. 19 in Fig. 4-3)
Pressing down the switch can cut off the oil supply to the engine so as to shut down the engine.
The switch will reset automatically after being released.
Note: don’t release the switch until the engine is shut down.
(16) Left rear mirror adjuster (No. 16 in Fig. 4-3)
Right rear mirror adjuster (No. 17 in Fig. 4-3)
Right rear mirror adjuster and left rear mirror adjuster can individually adjust right rear mirror
and left rear mirror at left, right, up and down four directions.
(17) Beacon lamp switch (No. 7 in Fig. 4-3)
During superstructure operation, after the switch is turned on, beacon lamp flashes. Let the
switch reset when no need to use it.
Note: Beacon lamp and its switch are optional, which are equipped at user’s option. It is
prohibited to use the beacon lamp during traveling on a road.
18
(18) Electric heating rear mirror switch (No. 5 in Fig. 4-3)

After the switch is turned on, right rear mirror and rear left mirror can be electrically heated to
defrost and defog.
(19) Retarder fail switch (No. 4 in Fig. 4-3)
It is not allowed to use retarder when travel on an ice and snow road or transmission oil
temperature is excessive high (max. permissible oil temperature is 145℃). With the switch
applied, retarder will not work even if transmission retarder lever (No. 2 in Fig. 4-4) is in
working position, and at this time retarder running indicator lamp (No. 14 in Fig. 4-5) is not
light.
(20) Low-water level warning lamp (No. 12 in Fig. 4-3)
When the water level in expansion tank is lower than 85mm (i.e. 0.33 times of tank height),
the warning lamp comes on to warn user to add coolant.
(21) Transmission control lever (No. 1 in Fig. 4-4)
Operation of changing shift may be realized by turning the switch on the rear of the lever and
the control lever. Refer to Transmission instruction for details.
Note: position the control lever and the switch on it to neutral before engine is shut
down.
(22) Parking brake lever (No. 3 in Fig. 4-4)
Before leaving the vehicle, apply the parking brake lever. At this time, the parking brake
indicator lamp on indicator lamp assembly (No. 15 in Fig. 4-5) comes on, it means that the
vehicle is in parking brake. Before driving, release it (parking brake indicator lamp on the
indicator lamp assembly goes out).
△ When emergency brake is necessary in danger and service brake is out of order, apply
parking brake lever to stop the vehicle.
△ When service brake fails and the vehicle has to be towed, the parking brake may be used
instead of service brake.
△ When start engine at outrigger control station, the vehicle must be in parking brake state.
Note: Never use the parking brake and the service brake simultaneously to prevent the
braking system from damage.
(23) Retarder lever (No. 2 in Fig. 4-4)
There are seven shifts in transmission retarder lever, refer to Fig.
4-12, its function as the following:
Position 0: retarder does not work;
Position B: position for setting speed. When the retarder lever is in the
position, the retarder will regulate the braking force automatically, so
Fig. 4-12 Retarder lever
19
as to make the vehicle speed maintain in current speed during downhill. When the vehicle speed
is lower than the setting speed during traveling on a downhill road, the retarder does not work.
The retarder will continue to work as long as the vehicle speed reaches the setting speed.
Position 1~5: retarder working positions, braking force will increase in turn from position 1 to
position 5.
When trouble in retarder occurs, retarder running indicator lamp (No. 14 in Fig. 4-5) on the
indicator lamp assembly will flash.
Notes:
Precondition that the retarder works:
a. Accelerator pedal is at idle position;
b. The vehicle speed is more than 3 km/h.
(24) ABS fail switch (No. 6 in Fig. 4-3) (optional)
When traveling on a soft road, pressing down the switch may release ABS braking system so
as to recover the function of normal brake. And ABS indicator lamp goes out.
(25) Engine OBD display (No. 6 in Fig. 4-2)
After the vehicle is powered, it can display engine current working state. Main homepage is
shown as in Fig. 4-13.
Fig. 4-13 Engine OBD Faceplate Features

Engine OBD is a multifunction tool that enables equipment operators to view many different
engine parameters and service code. The following are some of the engine and transmission
parameters displayed:
• Engine RPM • Engine Hours • Oil consumption at the current RPM
• System Voltage • % Engine Load at the current RPM • Coolant Temperature
• Oil Pressure • Fuel Economy • Throttle Position
• Engine Manifold Air Temperature • Transmission Oil Pressure
• Transmission Oil Temperature • Transmission Gear Position • Active Service Codes
• Stored Service Codes (when supported) • Engine Configuration Parameters
See “(XI). Description of engine state display” for details.

20
(II). Preparation before driving

1. Routine inspection before driving:
(1). Check coolant level
Check coolant level through inlet of expansion water tank. If no coolant is found, fill coolant
till it is found. Then start engine, and refill coolant again when it is running at approx.1000 rpm,
until the level is at half of the tank. And make sure the low-water level warning lamp (No. 12 in
Fig. 4-3) on instrument panel is not light.
Notes:
△When vehicle in normal traveling, checking coolant level must prevent hot water and
steam from injury of person. Never check coolant level before system becomes cooling.
△Never fill coolant when engine still in hot temperature.
(2). Check fuel level:
Position the key switch (Fig. 4-10) to position “ACC” or “ON”, check fuel level on fuel gauge,
and replenish fuel if necessary.
Note:
△ When the pointer on fuel gauge is in red area, it means fuel insufficient, it must be
added. Always refill before the tank is empty, otherwise re-bleeding air in fuel circuit
must be done.
(3). Check engine oil level:
Pull out the dipstick when engine is cool or more than half an hour after engine is shut down,
and replenish the specified engine oil depending on the level mark of the dipstick. Refer to Table
1-3 in Maintenance Manual for oil models.
(4). Check transmission oil level:
Check the oil level by removing the plug in sight hole. Refer to supplied 12/16 speed
AS-TRONIC transmission instruction for details.
(5). Drain the water in the air reservoir of brake system
Drain the water condensed in the air reservoir by removing the manual drain valve under the
air reservoir.
(6). Check oil-water separator
Check the separator and drain the water presented in its bottom in time.
(7). Check the tire:
△ The tread depth of tire crown is not less than 3.2mm, including spare tire.
△ The tire pressure should be 0.84±0.05MPa.
△ Check tire for tightness, the bolt tightening torque is 600～660 N.m.
△ During inflation of tire, make sure that there is no person in dangerous area, and no splashing
21
elements to damage man body.

(8). Check function of all the electric system.
(9). Check leakage of oil and coolant.
Make sure that there is no leakage in pipeline. If there is leakage, repair in time and refill
related fluid.
(10). Check air filter.
Empty and clean the dust-collector everyday if the vehicle works in a dusty environment. If red
line in air filter negative pressure indicator (near the outlet of air filter) occurs, clean the filter
element.
2. Preparation before driving
(1). Secure all loose parts on the vehicle before driving;
(2). Retract outrigger beams into place and secure with lock pins to prevent them from extending
out automatically;
(3). Superstructure must be in travel configuration and secured with locking system to prevent it
from rotating;
(4).Boom must be located at travel position and secured to prevent it from telescoping
automatically;
(5). Secure the door of toolbox on each side of the vehicle and the door of control box to prevent
unexpected opening;
(6).With power source switch turned on, check all lamps. Lack of lamp or failure will increase
the probability of accident, so never drive the vehicle before maintenance is finished;
(7). The local traffic regulations must be observed while driving on a highway.
3. Engine starting
(1). Refer to Engine Operation Manual for the details.
(2). Operation of starting switch (see Fig. 4-10).
Moving the starting key from position “LOCK” to position “ON” can turn on power supply,
which is indicated on the instrument, and then the engine is ready to be started. The indicator
lamp of engine preheating will come on according to ambient temperature.
 If the lamp lights up for about 2 seconds, it is only performing function check, the auxiliary
starting system has not run;
 If the lamp lights up for about 20 seconds, it means that the auxiliary starting system runs for
max. preheating time;
 If the lamp does not go out after 20 seconds of lightening, it means that there is fault in the
auxiliary starting system. It’s necessary to repair the system.
(3). Starting process:
With hand brake lever in braking condition, put transmission control lever in neutral position.
22
After the indicator lamp of engine preheating goes out, turn the starting key to position “S” to
start the engine. If fail to start within 10 seconds, return the key to position “ON”, after 1 minute
to start again. If continually fail to start for 3 times, stop starting and check the cause.
Note:
a. During each starting, starter should not run more than 10 seconds, at most 3 times
starting is allowed and at 1 minute interval.
b. During operation, generator should connect to battery set.
(4). Engine oil pressure after starting:
After starting, the engine oil pressure gauge should display the reading, which should be in line
with the engine operation requirement, i.e. oil pressure at idle should be ≥0.05MPa, oil pressure
at rated speed should be ≥0.25MPa (see engine operation manual). If the pointer does not move,
stop engine at once and check the cause.
Note: Never let the engine run in high speed when it is just started.
Caution: When any one of the situations below occurs, shut down the engine
immediately:
 Oil pressure fluctuates or drops;
 Without accelerator regulated, power and rotational speed drop;
 Black smoke;
 Abnormal noise.
(5). Preheating of the engine:
After starting, engine idle time can’t exceed 5 minutes, increase rotation speed gradually up to
1000 ~ 1200 r/min and begin running with a partial load. Only when water temperature is higher
than 75 ℃, engine oil pressure is higher than 0.05 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.
(6). Stop the engine:
Press the stop switch (No. 19 in Fig. 4-3) to shut down the engine.
23
(III). Starting and shifting

1. Starting
Release the hand brake lever. Only when the pressure of air reservoir in braking system is up to
0.45Mpa, and the hand brake indicator lamp and low air pressure warning lamp go out, the spring
brake can be released fully.
The vehicle can’t be started before the hand brake indicator lamp goes out. After the hand
brake indicator lamp goes out, all the air-powered systems can be operated.
Note: Transmission can work only when the air pressure of clutch branch pump
reaches 0.6MPa.
2. Operating methods of transmission:
Transmission controller consists of a control switch and a selector lever.
There are five positions on the control switch:
DM: drive forward creepily
D: drive forward
N: neutral
R: reverse Control switch
RM: reverse creepily xuan Selector lever
Fig. 4-14
The lever is used to select and change gears.
Meaning of symbols on indication plate of selector lever:
A/M: gear changing between automatic and manual mode by moving the lever left.
+: Increase one gear;
+: Increase two gears;
-: Decrease one gear;
-: Decrease two gears;
S: Select proper gear automatically
Two modes of automatic/manual gear for the transmission are available.
Move the lever left to select automatic or manual gear. Under automatic gear mode,
transmission can control driving speed automatically; under manual gear mode, move the lever
forwards/backwards to increase/decrease present gear. Moving the lever towards “+ / +”or “– /
–”, changing from automatic mode to manual mode is also available.
Before driving, turn control switch to position “D” or “R”. With the selector lever unchanged,
the system will take automatic mode. Operation of moving the lever left to activate manual mode
is permitted, or moving the lever left again to activate automatic mode.
The information about transmission working state, cautions and system faults can be shown on
24
the display of transmission state (No. 1 in Fig. 4-2). Before driving, parking brake lever (No. 3 in
Fig. 4-4) should be applied, and turn starting key to position “ACC” or “ON” to turn on power
supply. At this time, the system begins to perform self-check, and information is indicated on the
display screen as Fig. 4-15 shown:
Fig. 4-15
If “AL” occurs on the display screen, and alternately appears with other normal indication, it
means insufficient pressure in transmission air assisted system, as Fig. 4-16 shown.
Fig. 4-16
Note: System will perform self-check after power supply is turned on, so start engine
after power supply is applied 15 seconds!
Neutral state
After finishing self-check, start engine, and then transmission is in neutral state as Fig. 4-17
shown:
Fig. 4-17
Automatic mode
Move the control switch from position “N” to “D”, the system will activate automatic mode,
and select driving gear, refer to Fig. 4-18.
Fig. 4-18
Depressing accelerator pedal while releasing parking brake, the vehicle may start.
Present gear:
When the vehicle is driving in manual shift mode, only the digit of present gear is shown on
the display screen, refer to Fig. 4-19.
Fig. 4-19
25
Gear changing signs:

When the vehicle is driving in manual shift mode, if shift gear selected does not match the
present state, signs will appear on the display screen. Arrow direction indicates that gear needs to
be increased or decreased, the numbers of straight line indicate how many shift gears should be
increased or decreased. For example: signs on the display screen as Fig. 4-20 shown mean that
shift gear should be decreased from 8 to 5.
Fig. 4-20
Faulty signs:
During driving, if faults are present, faulty signs will appear on the right side of the display
screen. See Fig. 4-21, if this sign appears, you may continue to drive.
F
Fig. 4-21
Sign for stopping to check:
During travel, if “STOP” appears on the left of the display screen, as Fig. 4-22 shown, stop the
vehicle immediately for checking.
Fig. 4-22
Reversing sign
During reversing, reversing sign will appear on the display screen,
“RH” means reversing in high speed, “RL” means reversing in low
speed. See Fig. 4-23.
Fig. 4-23
26
Creeping mode sign:

When the working condition of extreme low speed is necessary, creeping mode may be used.
Turning the control switch to “DM” or “RM” may select the mode of
driving or reversing creepily.
Under creeping mode, creeping mode sign will appear on the display screen,
“DM” means driving forward creepily, “RM” means reversing creepily, see
Fig. 4-24.
Fig. 4-24
Refer to Transmission instruction for details.
Note:
a) During driving, monitor the vehicle state constantly through instrumentation and
displays;
b) Automatic shift mode is recommended to use on the normal road.
c) In manual shift mode, there is no engine over-speed protection function, please pay
attention to avoiding engine over-speed;
d) When gear 1 for driving forward or reversing is used, the accelerator pedal should be
depressed less than 85% of its stroke, and the clutch is in partial engagement state;
when more than 85% of its stroke, the clutch will engage fully, and then abnormality
such as shock, sudden rise in engine rotational speed will occur. So, pay attention to
preventing accident!
e) No automatic shift mode for reversing is available, please change reversing gear
manually.
f) During a long downhill travel, the selector lever shouldn’t be in position “N”, otherwise,
engine retarded brake doesn’t work.
3. Uphill starting/reversing
Depress the accelerator pedal slightly, and release the parking brake when clutch engagement
is felt to prevent the vehicle from coasting. Control the vehicle’s speed by accelerator pedal.
Never release the accelerator pedal fully except parking, otherwise, shock in drive line may be
caused.
4. Creeping/clutch partial engagement operation
Change to manual gear mode, and take gear 1 for driving forward (or reversing). Adjust clutch
engaging state by controlling the accelerator pedal, and then the vehicle can move slowly. Pay
attention to the change when accelerator opening is more than 85%.
27
Note:
a) Never let the vehicle in creeping mode for a long time, otherwise clutch will be worn
badly.
b) Starting several times in a short time or during starting releasing the parking brake too
slow may result in clutch overload, and “CL” will be shown on the display while buzzer
sounds. At this time, operation may continue, but pay attention to reducing clutch
sliding wear, and preventing further overload.
c) Please read transmission instruction carefully.
5. Stopping and parking:
(1). Stopping during driving
 Release accelerator pedal, decrease the vehicle speed by applying retarder brake until it
stops;
 Driving gear selected may be remained;
 Parking by service brake or parking brake, so as to prevent the vehicle from coasting.
(2). The vehicle stops, but engine is running
 Release accelerator pedal, decrease the vehicle speed by applying retarder brake until it
stops;
 Position the transmission selector lever to “N” before leaving the driver’s seat;
 Parking the vehicle by parking brake, so as to prevent coasting.
(3). Driving finished
 Release accelerator pedal, decrease the speed of the vehicle by applying retarder brake until
it stops;
 Position the transmission selector lever to “N”;
 Parking the vehicle by parking brake, so as to prevent coasting.
Note: When engine runs at a full load or coolant temperature is higher (more than
95℃), do not stop the engine before the engine runs for 1~2 minutes at idle with no load.
(4). Parking
After driving is finished, do the following:
a) Turn off all current functions;
b) Turn off the starting key, and remove the key;
c) Turn off main power supply switch;
d) Close the cab’s door
e) Prevent the vehicle from coasting by putting wedges under the wheels.
Note:
a) Never stop the vehicle while the transmission selector lever is in neutral, because it will
28
damage drive line seriously.

b) After stopping, never shut down the engine until the transmission selector lever is
positioned in neutral.
6. Emergency operation:
(1). When the drive line has a trouble and the vehicle has to be moved, the traveling speed for
the vehicle towed should not exceed 10 km / h. Lift up the control lever shown in Fig. 4-9 to turn
on danger warning lamp switch, at this time, the warning lamps and turning indicator lamps
should come on.
(2). When engine and transmission are damaged, the propeller shafts should be disassembled.
(IV). Brake system

The brake system consists of service brake (foot brake), parking brake (hand brake) and
auxiliary brake (engine exhaust brake and retarded brake, transmission retarded brake).
1. Service brake:
The service brake is compressed air brake. It consists of two circuits, one is composed of 1st,
2nd and 4th axle, and the other is composed of 3rd, 5th and 6th axle. There is a double-pointer air
pressure gauge in the cab for indicating the air pressure in two circuits.
In case the air pressure in any one of the two circuits drops below 0.45Mpa during driving,
stop the vehicle and find the cause of low pressure.
In addition, repeated braking in a short time may cause pressure down below 0.45Mpa.
2. Parking brake:
Parking brake is releasing brake acting on the axles 3~ 6. It gives effect on all axles by the
spring-loaded air chambers. After stopping the truck, applying parking brake lever can hold the
truck at original place, at this time, the parking brake indicator lamp on instrument panel in cab
comes on. Only with hand brake released and the pressure in 23rd circuit of brake system more
than 0.45Mpa (low air pressure warning lamp on instrument panel goes out) and hand brake
indicator lamp goes 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 during traveling.
When service brake is damaged and the vehicle has to be towed, apply hand brake instead of
service brake.
3. Auxiliary brake
Auxiliary brake means engine exhaust brake, retarded brake and transmission retarded brake.
When transmission retarded brake is applied, engine retarded brake also works.
 When driving on a city road, brake efficiency at low speed is higher, so retard lever should
be used instead of service brake while pass through a curve or a crossing;
 When driving on an expressway, momentum is large at high speed, retarder and service brake
may be used smoothly;
29
 When driving on a long downhill road, set traveling speed with retard lever in position “B”,
and then retarder will regulate braking force to hold the setting speed. If brake efficiency is
not sufficient, service brake may be used to lower the vehicle speed.
Note:
a) Increase the gear step by step to avoid abrupt braking and monitor the vehicle’s state at
any time;
b) During braking, if tire slides, change brake lever to next gear, and then perform
braking;
c) After stopping, or when it is not necessary to brake, close retarder by pulling control
lever back to position “0” to avoid unnecessary power consumption. Decreasing the
gear may be finished in one stroke, no need to decrease gradually.
4. Retard lever position and brake classification
Lever
Engine exhaust brake Engine retarded brake Transmission retarded brake
position
0 0 0 0
B Automatically regulate the braking force according to the vehicle’s speed
1 1 1 1
2 1 1 2
3 1 1 3
4 1 1 4
5 1 1 5
5. Cautions in brake system operation:
(1). Releasing of spring brake air chamber:
When self-braking happens due to leakage of spring brake air chamber pipeline, do the
following to release (see Fig. 4-25):
Leting the bolt out by turning the nut on it can release braking.
When parking the vehicle on a slope, before releasing the spring brake, wedges must be put
under the wheels to block the vehicle in prevention of slipping.
Nut
Nut
Bolt
Bolt
Before releasing brake After releasing brake
Fig. 4-25 Releasing of spring brake

30
(2). Engine rotational speed

When driving on a long downhill road, engine rotational speed must be less than 2200r/min,
high rotational speed may damage engine.
(V). Outriggers operation

1. Check the level of hydraulic oil tank
Before lifting operation, first check the hydraulic oil level. If the level is lower than the
specific position, refill in time. Open the cap of air filter on the top of the tank and add the same
brand hydraulic oil.
Fig. 4-26 Hydraulic oil tank Fig. 4-27 Thermo-liquidometer

2. Check shutoff valve
Check the shutoff valve, it must be in open state before hydraulic system begins to work, as
Fig. 4-28 shown, the one in Fig. A shown is open state, the other in Fig. B shown is close state.
Fig. A Fig. B
Fig. 4-28 Shutoff valve state
31
3. Outrigger structure assembly

Refer to Fig. 4-29 for outrigger structure and Figs. 4-30, 4-31 for its control buttons.
Fig. 4-29 Outrigger structure
1. Outrigger float 2. Jack cylinder 3. 2nd section of outrigger beam

4. Outrigger beam lock pin 5. 1st section of outrigger beam
6. Outrigger beam lock pin 7. Outrigger box
Fig. 4-30 Right outrigger control panel
1. Outrigger working lamp switch

2. Rear left outrigger cylinder extended /retracted
3. Front left outrigger cylinder extended/retracted
4. Rear left jack cylinder extended /retracted
5. Front left jack cylinder extended /retracted
6. Front right jack cylinder extended/retracted
7. Rear right jack cylinder extended /retracted
8. Front right outrigger cylinder extended/retracted
32
9. Rear right outrigger cylinder extended/retracted

10. Accelerator switch
Fig. 4-31 Left outrigger control panel

1. Outrigger working lamp switch
2. Front right outrigger cylinder extended /retracted
3. Rear right outrigger cylinder extended/retracted
4. Front right jack cylinder extended /retracted
5. Rear right jack cylinder extended /retracted
6. Rear left jack cylinder extended/retracted
7. Front left jack cylinder extended /retracted
8. Rear left outrigger cylinder extended/retracted
9. Front left outrigger cylinder extended/retracted
10. Accelerator switch
 Outriggers only can be operated after PTO switch (No. 8 in Fig. 4-3) is pressed and
PTO begins to work.
 No. 1 is outrigger working lamp switch, which is used to control outrigger illumination
for night work. No. 10 is engine accelerator switch, with which moved up engine
output speed is decreased, with it moved down engine output speed is increased.
 There is a level gauge in outrigger control box. When the indicating ball in the level
gauge is in middle position, it means the vehicle is leveled. Otherwise, continue to
adjust outrigger control buttons until the vehicle is leveled and secure outriggers with
lock pins before lifting operation.
 There is an outrigger control box respectively located on the board between axles 4
and 5 on each side of the vehicle, which there is an outrigger control panel in it. The
one shown in Fig. 4-30 is the right control panel. The operating method and function
33
of both left and right control panels are same, except some difference in the
arrangement of control buttons, refer to Fig. 4-31.
Note:
a) Before perform operation of outriggers, the parking brake lever (No. 3 in Fig. 4-4)
in the cab must be applied and secured.
b) Two spans of outrigger extended fully and half are available. Operation is prohibited
with outrigger in other positions.
4. Setting/stowing outrigger floats (see Fig. 4-32):
Pull out the outrigger floats from traveling state (Fig. A) before extending outriggers. First pull
out lock pin (Fig. B), and then the float (Fig. C), last insert the lock pin into inside pin hole (Fig.
D). During driving, the floats should be stowed and secured. Follow the reverse setting procedure
for stowing.
Fig. A Fig. B Fig. C Fig. D

Fig. 4-32
5. Stowing/setting outrigger beams:

Press four outrigger beam cylinder control buttons respectively or simultaneously for
controlling outrigger beams.
6. Stowing/setting jack cylinders:
Press four jack cylinder control buttons respectively or simultaneously for controlling jacks.
7. How to level crane:
If the crane is not level with the jacks extended, level it as follows:
(1). Adjust each jack cylinder until the indicating ball in level gauge is in middle position, which
means the crane is level.
(2). After the crane is leveled release the adjusting button immediately.
Note:
When perform operation on outriggers, make sure that all outrigger floats are in
complete contact with the ground, and keep all tires off the ground. And apply wood blocks
under outrigger floats if necessary.
34
Notes on operation:
a) Make sure the job site is firm and level.
b) Do not lower jack cylinders before extending outrigger beams.
c) After setting up outriggers, make sure that all outrigger floats are in complete contact
with the ground.
d) Keep the tires off the ground, and the bubble of level gauge is in middle position.
e) After stowing the outriggers, make sure that the outrigger beam lock pins are completed
inserted, and floats are stowed.
35
Memorandum
36
(VI). Transferring within job site

Transferring for a short distance within job site is permitted. But driving speed must be not
more than 50km/h.
(VII). Winter operation

1. Cooling system
The coolant for cooling system is a mixture of BASF anti-freezing coolant (G48-24) and
distilled water by proportion of 1:1, and can be used when the ambient temperature is above
-37℃.
Note:
a) Never use sea water to cool the engine directly!
b) Antifreeze coolant can be added according to the operation requirement of engine.
When using antifreeze coolant, the freezing point of antifreeze coolant should be lower
5℃ than the lowest temperature in the area where operation is performing.
2. Braking device:
Do not forget to drain the water condensed in the air reservoir before driving.
3. Battery
Regularly check the level and density of the battery electrolyte. The level should be 10-15 mm
above the electrode plates and the density should be more than 1.24g/cm 3. If do not use the
vehicle for a long time and ambient temperature is very low, it is better to remove the battery
from carrier and stow it in a warm room.
(1). Notes on battery checking:
a) Keep the battery clean and dry. Release the terminal for cleaning if it is contaminated, and
then lubricate it with clean, no-acid and acid-proof grease. Do not coat the grease on the
filling port.
b) Do not put tools on the battery.
c) It is forbidden to remove the battery wire while the engine is running.
d) In summer, check the electrolyte acid quantity once a week, in other seasons check it once a
month, and fill distilled water if necessary.
(2). Charging the battery:
Use hydrometer to check the electrolyte density once a month and the value measured can
indicate battery charging condition (see Table 4-2). If distilled water has been refilled, measure
the battery after half an hour. Ambient temperature for measuring the electrolyte density should
be 20℃.
In very cold season, due to heavy power consumption for the battery, especially pay attention
37
to charging the battery for its service requirement.

Table 4-2
Density Battery charging condition
1.28 Good
1.20 Half charged, filling in time
1.12 Lack of power, charging at once

If charging the battery, only charge with DC power and charging power can’t exceed 1/10 of
battery capacity. For example: charge a 180Ah battery, the charging currency should not be more
than 18 A.
(VIII). Wheel inspection and replacement

1. Tire inspection:
(1). The tread depth of tire crown is not less than 3.2mm.
(2). The tire ply should not be exposed due to the partial wear of tire tread face.
(3). There should not be crack and cut of more than 25mm length and ply exposed depth on
tire tread face and side wall.
(4). Type and tire tread of tires installed on an axle should be same. Tires renewed should not
be used.
2. Rim inspection:
The rim is one of the important parts in truck traveling system. When changing the wheels, the
following items should be checked:
(1) Rim rustiness;
(2) Rim deflection and deformation;
(3) Rim cracks;
(4) Opening of rim flange, mounting hole and rim bolts and nuts.
After checking, repair or replace the parts damaged or deformed at once, if paint stripped,
repaint after rust is removed.
Note: Neither welding connections of rim bolt, nor repair deformed rim bolts.
Replace with new ones.
3. Wheel replacing:
(1). After 10000Km of traveling, tires should be transposed. Refer to Fig.4-33.
Order for transposing tires is as follows:
17→15→9→1→12→4→7→6→11→16→8→2→13→3→10→5→14→17
38
Fig. 4-33 Tire transposition reference diagram
(2). Do not scratch bolt thread when replace wheels.

(3). No painting, grease and other dirty on the touching face between brake drum and rim.
(4). Keep the pressing faces of wheel nuts clean.
(5). Coat threads of wheel bolts and nuts with a little grease, oil or other anti-engaging agent as
well as the opening of rim flange and its touching faces.
(6). Threads of all wheel nuts are right-handed. With tires mounted and wheels suspended,
tighten nuts in the order of diagonal transposition. Lower wheels on the ground, and
tighten wheel nuts with tightening torque of 600~660 Nm.
(7). After tires are remounted, retighten wheel nuts once every 50km of traveling according to
stipulations.
(IX). Run-in of a new truck

The run-in mileage for a new truck is 1500km. Before run-in, routine inspection should be
carried out for ensuring the truck in normal working condition.
Notes on run-in:
1) After cold starting, do not accelerate the engine immediately until the 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 road.
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 wheel hub and brake drum on each axle. If serious
overheating occurs, find the cause and adjust or repair.
6) After initial traveling of 50km or every time changing tires, tighten wheel nuts according to
the specified torque.
39
Note:
After run-in time, check and maintain the truck according to the “first check” items
specified in the carrier maintenance manual and the requirements in engine and
transmission operation manuals.
(X). Usage of air conditioner

Cold-warm air conditioning is available.
Warm air is utilizing engine cyclical hot water, cold air is supplied by refrigerant circulated in
air conditioner system. In winter when use the warm air, open hot water valve (see Fig. 4-34) in
warm air pipeline, and then press down the related keys shown in Fig. 4-11 for setting
temperature and wind direction.
In summer when use the cold air, close the hot water valve (see Fig. 4-34) in warm air pipeline
first and then press down the related keys shown in Fig. 4-11 for setting temperature and wind
direction.
Note:
a) Be sure to close hot water valve when use cold air; and to open hot water valve when use
warm air.
b) In winter, when it is necessary to drain off the water in engine cooling system, the water in
warm air pipeline must be drained off too.
Hot water valve switch
Emergency switch
Fig. 4-34
1. Setting temperature
Temperature can be adjusted between 17℃~29℃ by pressing increasing or decreasing key.
After adjustment is finished, waiting for 5 seconds, the actual temperature in cab will be
indicated. When the setting temperature is lower than 17℃, “LO” is indicated; when the setting
temperature is more than 29℃, “HI” is indicated .
40
2. The temperature in cab

The range of temperature in cab indicated is -30.0℃～+80.0℃. When the temperature sensor
in cab fails, the temperature value indicated is 25.0℃ .
3. Wind directions
Press the modes selector key to select any one of modes of wind blowing direction towards
face, foot and windshield.
4. Circulation key
a). Manual mode
Press the key to switch-over air internal and external circulation manually.
b). Automatic mode
Initial setting is internal circulation, manual adjustment is available.
5. Water valve and compressor
Data codes as the following:
◆The (return air inlet) temperature in cab:RT;
◆The (evaporator) temperature for defrosting: PT;
◆The setting temperature (ideal temperature): ST.
1). Manual mode
① Refrigerating
Select compressor working state by pressing A/C key, at this time refrigeration signal lamp
comes on. When RT＞0℃, water valve is closed fully; when RT＜0℃, water valve is open fully.
Fan motor will run at the previous speed. When the setting temperature is more than 29℃, “HI”
is shown, refrigeration signal lamp goes out, and compressor does not run. Compressor can run
when wind speed is at least 1 speed. Pressing the key again can close compressor, and heating
mode is activated.
② Heating
a) Water valve position from fully close to fully open: when 6℃ ＞ST-RT≥3℃, 2/3 of water
valve is open; when ST-RT≥6℃, water valve is fully open.
b) Water valve position from fully open to fully close: when 3℃≤ST-RT＜6℃ , 2/3 of water
valve is open; when -3℃＜ST-RT＜3℃, 1/3 of water valve is open; when ST-RT≤ -3℃ , water
valve is fully close.
c) When ST is HI, water valve is fully open; when ST is LO, water valve is fully close.
2). Automatic mode

When RT-ST≥1℃, the compressor is opened and then refrigeration signal lamp comes on;
when RT-ST≤ -1℃, the compressor is closed and then refrigeration signal lamp goes out.
41
3). Manually defrosting mode

Pressing defrosting key could activate defrosting mode. And then water valve is fully open,
external circulation wind valve is open, and max. fan motor speed is gained (it may be adjusted
manually), the compressor is closed. The compressor could be opened by pressing A/C key.
4). Automatically defrosting mode
When PT≤1℃, defrosting mode is activated automatically, the compressor is closed, but the
refrigeration signal lamp does not go out; when PT≥4℃, the compressor is opened automatically.
Note:
The compressor should not be restarted until it has been closed for 6 seconds.
6. Fan motor
1). Manual mode
Manual adjustment of wind speed is available. There are six speeds, which the lowest one is
speed 1, and the highest one is speed 6.
2). Automatic mode
Wind speed may be adjusted either automatically or manually.
When RT-ST≥1℃, the compressor is opened; when ST-RT≥1℃, the compressor is closed.
① Adjust wind speed from low speed to high speed:
When 0≤|ST-RT|＜2℃, wind speed is speed 1 (the lowest one);
When 2≤|ST-RT|＜4℃, wind speed is speed 2;
When 4≤|ST-RT|＜6℃, wind sp eed is speed 3;
When |ST-RT|≥10℃, wind speed is speed 6 (the highest one).
When the setting temperature is “HI” or “LO”, wind speed is speed 6 (the highest one).
② Adjust wind speed from high speed to low speed:
When 7＜|ST-RT|≤9℃, wind speed is speed 5;
When 5＜|ST-RT|≤7℃, wind speed is speed 4;
When 3＜|ST-RT|≤5℃ , wind speed is speed 3;
When 1＜|ST-RT|≤3℃ , wind speed is speed 2;
When 0＜|ST-RT|≤1℃, wind speed is speed 1.
7. Memory mode
When controller is powered again after power off, it is in ready state. The states before power
is off, such as the temperature, wind direction mode, internal/external circulation mode, etc. are
memorized.
42
8. Turn off
The system will be turned off by pressing OFF key. Pressing any key except OFF can activate
the system.
9. Diagnostic function
When there is fault in the system, press key OFF for 10 seconds, fault code will be shown in
temperature indicator area, the meanings as the following:
C0: normal;
C3: the sensor for sensing the cab temperature is not fitted or damaged. Once the sensor is
normal, the fault will eliminate automatically.
C5: evaporator temperature sensor is not fitted or damaged. Once the sensor is normal, the fault
will eliminate automatically.
C6: water valve steering gear is not fitted or damaged. After repair, turn off the air conditioner.
When turn on the air conditioner again, the fault will eliminate automatically.
C7: mode wind valve is not fitted or damaged. After repair, turn off the air conditioner. When
turn on the air conditioner again, the fault will eliminate automatically.
C8: internal /external circulation wind valve is not fitted or damaged (do not test temporarily).
After repair, turn off the air conditioner. When turn on the air conditioner again, the fault will
eliminate automatically.
Only by pressing key OFF fault can be looked up. Key OFF is not pressed for 5 seconds, the
consulting mode is exited.
43
Memorandum
44
(XI). Description of engine state display
Red Shutdown
Amber Warning LED
LED
Display
Bezel
Enter key
Menu key
Left Arrow key (Scroll Up) Right Arrow key (Scroll Down)
Fig. 4-35 Engine OBD Faceplate Features
Keypad on the engine OBD faceplate is a capacitive touch sensing system. The keys on the
keypad perform the following functions:
Menu key: The Menu Key is touched to either enter or exit the
menu screens
Left Arrow: The Left Arrow Key is touched to scroll through the screen
either moving the parameter selection toward the left or upward.
Right Arrow: The Right Arrow Key is touched to scroll through the screen
either moving the parameter selection toward the right or downward.
Enter key: The Enter Key (also known as Enter Button) is touched to
select the parameter that is highlighted on the screen
For example:
1. Go to Main Menu by touching “Menu Button”.
Go to 4-UP display
Languages
Stored Codes
Engine Configuration
Setup 1-UP Display
45
2. Touching the “Arrow Buttons” will scroll through the menu selection.
Go to 4-UP display
Languages
Stored Codes
Engine Configuration
Setup 1-UP Display
3. There are many pages in some menus. The screen will automatically be turned to the
previous or next page when the cursor reaches the top or bottom of the page selected.
Setup 1-UP Display

Setup 4-UP Display
Select unit
Adjust backlight
Adjust contrast
4. When cursor is moved to the desired item, press Enter key, the content in the item could be
seen.
5. If word “More” occurs as shown in the screen below, it means there are more information,
which can be looked up by left/right arrow key.
More
46
Trouble and warning indication:

Engine OBD supplies two ways for indicating engine trouble and warning: through visible
warning LEDs on the faceplate and trouble indication on the screen.
Visible warning LEDs:
Amber LED: common fault
Red LED: shutdown condition fault
Trouble indication on the screen as follows:
Indicates instrument fault
Indicates fault warning
Indicates shutdown condition fault
Note: The fault can only be cleared by correcting the cause of the fault condition.
Confirmation of fault information:
(1) Touching the “Enter Button” will redisplay the hidden fault. Touching the “Enter Button”
once again will hide the fault and return the screen to the single or four parameter display, but
the display will contain the “Active Fault” warning icon.
(2) Touching the “Enter Button” will redisplay the “Active Fault”. Touching the “Enter Button”
once again will return the screen to the single or four parameter display.
47
(XII). Protective measures during welding operation
In order to prevent control system being damaged by the current when welding is performing,
the insulating tape must be applied if the welding to load has to be carried out when the load is
lifted up, or if the welding to the vehicle body has to be performed, the plugs described below
should be removed!
(1) Turn off main power supply switch, and remove conductors both on positive electrode and
negative electrode from power source;
(2) Remove the plugs of transmission computer and engine computer under fuse box. (see Fig.
4-36 The plugs shown below haven’t been pulled out.)
Fig. 4-36
(3) Remove the plugs of engine pre-heating computer (see Fig. 4-37) after opening the cover on
the front of assistant driver.
Fig. 4-37
48
(4) Remove the computer plug on the right side under engine (see Fig. 4-38);
Fig. 4-38
(5) Open the cover on the right side of engine shield, and remove the computer plug on
transmission (see Fig. 4-39).
Fig. 4-39
Fig. 4-39
Welding to load or to vehicle body can be performed after all plugs mentioned above are
removed. During welding, the part to be welded and the welding ground should be as close as
possible. If this cannot be ensured, the distance between them should be less than 500mm, and
computer panel should not be spanned. After welding, reinsert these plugs and secure them.
49
XUZHOU CONSTRUCTION MACHINERY GROUP CO., LTD. CHINA
Add：No. 165 Tongshan Road, Xuzhou, Jiangsu, China
Tel：0086-(0)516-83462242 83462350
Fax：0086-(0)516-83461669
Post Code：221004
Website：http://www.xzzx.com.cn
E-mail：fw@xzzx.com.cn
Service Tel：0086-(0)516-83461183
Service Fax：0086-(0)516-83461180
Spare Parts Tel：0086-0516-83461542
First edition in August, 2009

QY110K (XZ110K) Operation Manual

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XZ110K TRUCK CRANE CARRIER

XUZHOU HEAVY MACHINERY CO., LTD.

XUZHOU CONSTRUCTION MACHINERY GROUP CO., LTD., CHINA

The operation manual is part of the crane!

Always keep on hand!

XUZHOU HEAVY MACHINERY CO., LTD.

Check: carry out relative check according to requirements specified by the

emit into air.

Content on the nameplate:

5) Carrier nameplate and vehicle identification number

The carrier nameplate consists of:

III. Main technical parameters

Automatic shift gearbox, 12 forward, 2

IV. Vehicle Operation

1. Backrest angle adjusting lever

Fig. 4-1 Seat

(1) Backrest angle adjusting lever

(2) Head rest unlocking switch

(3)Seat damping control lever

(4) Seat cushion front adjusting lever

(5) Seat cushion rear adjusting lever

(6) Seat sliding control lever

2. Instrumentation, switches and indicator lamps in cab

Fig. 4-2 Front control and indicator devices in cab

1. Display of transmission state 2. Engine tachometer

Fig. 4-3 Front control panel

1. Heater indication panel 2. CD player

Fig. 4-4 Right control panel

1. Transmission shift lever 2. Retarder lever 3. Parking brake lever

Fig. 4-5 Indicator lamp assembly

1. Left turning indicator lamp 2. Far beam indicator lamp

3. Instruction of instruments, switches and indicator lamps in the cab:

(8) Combined switch (No. 11 in Fig. 4-2)

Fig. 4-6 Combined switch

1. Light control switch (see Fig. 4-7)

Fig. 4-8 Fog lamp switch

Fig. 4-9 Combined switch 1

using attachments such as CD player.

Fig. 4-11 Heater indicator panel

◆For setting: ◆ Internal circulation:

◆Temperature: ◆ External circulation：

◆1st gear wind speed: ◆ Automatic:

◆2nd gear wind speed: ◆ Refrigerating:

◆3rd gear wind speed: ◆ For foot direction:

◆4th gear wind speed: ◆ For face direction:

◆5th gear wind speed: ◆ Defrosting:

◆6th gear wind speed: ◆ Vehicle body symbol:

(b) Push keys

◆ Keys for adjusting temperature:

① Key for increasing temperature:

② Key for decreasing temperature:

◆Keys for adjusting wind speed:

① Key for increasing wind speed:

press the key.

② Key for decreasing wind speed:

press the key.

again to close the compressor.

◆ Key for defrosting:

◆ Key for changing modes:

Press the key to switch-over internal and external circulation.

(14) Inter-wheel differential switch (No. 20 in Fig. 4-3)

(18) Electric heating rear mirror switch (No. 5 in Fig. 4-3)