XZ40K TRUCK CRANE CHASSIS

(Equipped with WD615.334 Engine)

Operation Manual

Xuzhou Heavy Machinery Co., Ltd.

Xuzhou Construction Machinery Group Co., Ltd. China

 Truck Crane Chassis
XZ40K
Operation Manual

Page 1 up to 28

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/320301JAF02—2005!

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
 Preface
This operation manual supplies technical information about the performance,
structure, operation, service and adjustment of XZ40K truck crane chassis to
drivers and maintenance workers for reading and vehicle managers and technicians
for reference.
Only operate and maintain the vehicle strictly in accordance with the specified
requirements in the manual can the normal service life of the truck crane chassis be
guaranteed.
Comprehend the safety warnings and notes on equipment operation in the
manual.
In order to ensure products’ performance, we advice customers to use spare parts
that are the same with original supplied parts.
The personnel working at service station authorized by Xuzhou Heavy
Machinery Co., ltd. have all accepted professional training so that they can render
service support and parts supply. If you come across problems that service station
cannot resolve, please directly contact the nearest office of our company.
Due to the product modification and improvement, what described in this
manual may vary from the real chassis, we reserve the right to modify the design
without notice.

About this manual:

This manual is suitable for QY40K truck crane chassis.
This manual includes information about how to use and maintain vehicles
correctly.
Metric measurement unit is used in this operation manual.
This operation manual uses many iconographs and symbols to help understand
the meanings. See the symbols and meanings as reference:

Note — the nonobservance of the “note ” will lead to the personal

injury and parts damage.

Caution — nonobservance of the terms specified in the cautions will

cause the serious personal damage and huge financial
losses.
 Check — check according to the specified regulations.
Notes:
1) Read this operation manual carefully and get familiar with procedure and
notes before operation, otherwise the machine should not be operated;
2) Do not put hands and other parts of body or clothes into machine moving
positions. Operators should wear safety helmet, glove and protection glass;
3) Note whether there are persons around the machine before starting, start
the machine when there is no person in the dangerous areas, otherwise it is
forbidden to start!
4) If customers select warning lamp function, they should install by
themselves only during lifting operation;
5) Preserve this manual carefully for reference in future.

Jan. 2012
 Contents
I. Safety Operation………………………………………………………………….1
II. Crane Description……………………………………………………………….4
(I) Vehicle number……………………………………………………………….5
(II) Main assembly structure features and technical parameters………………...5
III. Vehicle Operation………………………………………………………………7
(I) Arrangement in cab…………………………………………………………..8
(II) Preparation before driving………………………………………………….15
(III) Starting and shifting……………………………………………………….17
(IV) Control of clutch…………………………………………………………..18
(V) Control of steering…………………………………………………………20
(VI) Brake system………………………………………………………………21
(VII) Operation of PTO………………………………………………………...22
(VIII) Outriggers operation…………………………………………………….23
(IX) Winter operation…………………………………………………………..26
(X) Run-in of a new truck……………………………………………………...27
(XI) Usage of air conditioner…………………………………………………..28
(XII) Usage of low temperature preheating device…………………………….29
I. Safety Operation

1
Safety cautions:
● Related certificate is necessary for person who operates the vehicle. Avoid injury to personal
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 injure or death of persons and damage to
the crane.
● Before driving, make sure that all outriggers are retracted fully in place and secure with lock
pins.
● Comply with road travel and crane operating regulations in the place where you are working.
● During traveling, no person is allowed to stay 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 or the drive wheel
must clear off the ground.
● 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 personal. 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 visit 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 the
environment, a special equipment should be used to collect or dispose of freon to avoid it
diffuse into air.
2
● The clutch must be disengaged fully while PTO is being operated.
● Set outriggers fully and secure with lock pins before lifting operation.
● Operating instructions on the machine are valid equally with instructions in this operation
manual.

3
II. Crane Description

4
(I) Vehicle number
Vehicle number consists of chassis number and vehicle identification number (VIN), which are
marked respectively 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. Series number.
3. Engine number.
4. Delivery date.
5. Manufacturer.
Vehicle identification number (VIN) is below the chassis nameplate.
When you claim compensation, order spare parts or contact with our service department, please
give the following correctly and clearly:
Vehicle Model:
Series No.:
Engine No.:
Delivery Date:

(II) Main assembly structure features and technical parameters

Table 2-1 Main assembly structure features and technical parameters
Model XZ40K
Driving type 8×4
Crew 2
Length mm 10940
Width mm 2800
Outline Height mm 2505
dimension Wheel base mm 1520+3815+1350
Track mm 2240 (front), 2075 (rear)
Total chassis curb weight kg 18500
Total chassis weight kg 40000
Weight
Permissible Front axle kg 7000×2
axle load Rear axle kg 13000×2
Max. Speed (km/h) 75
Min. Speed (km/h) 2～3
Vehicle Max. grade ability 40%
performance Min. turning diameter (m) 24
Brake distance is not more than 10m with upper
Braking distance (m) structure installed and 30km/h of initial speed
traveling on dry and level asphalt road

5
 Approach angle 16°(max.)
Departure angle 11°(max.)
Min. ground clearance (mm) 291
Model WD615.334
Max. power KW/r/min 247/2200
Engine
Max. torque N.m/r/min 1350/1400
Total displacement L 9.726
Model RT-11509C/RTD-11509C
Transmission Type Mechanical flexible operation, fixed spindle
Speed ratio 12.42/8.26/6.08/4.53/3.36/2.47/1.81/1.35/1.00/R12.99
SQP1601W-010 (Equipped with
Model
RT-11509C/RTD-11509C transmission)
Clutch
Type Pull-type diaphragm spring clutch
Clutch friction disc diameter φ430
Model 9JS150T-B
Transmission Type Mechanical flexible operation, fixed spindle
Speed ratio 13.22/12.65/8.38/6.22/4.57/3.40/2.46/1.83/1.34/1
HY430L (Equipped with 9JS150T-B
Model
transmission)
Clutch
Type Pull-type diaphragm spring clutch
Clutch friction disc diameter φ430
Tubular open type，cross axle universal joint,
Propeller shaft Type
tooth joint plate
Type 1-stage main reduction plus wheel rim reduction
Driving shaft
Reduction ratio 5.73
Full dimension, all metal welded closed type
Cab Type with instrument panel, heater, air conditioner,
electric windshield wiper and CD player fitted
Number of leaf spring Front 8/ rear 14
Tire 12.00－20－18PR
Steering Type Half entirety steering gear
Double circuit air brake system, two separate
Service brake circuits that the 1st acts on wheels of double front
axles, 2nd acts on wheels of mid and rear axle.
Brake
Exhaust brake system acts on wheels 3rd axle
Parking brake
and 4th axle
Auxiliary brake Engine exhaust brake
Electric system 24V of voltage, negative ground

6
III. Vehicle Operation

7
(I) Arrangement in cab
Arrangement in cab consists of instrument panel and controllers, instrument panel consists of
kinds of instruments, switches and indicator lamps, refer to Fig. 3-1 and 3-2.

Fig. 3-1 Instrument panel and controllers location diagram

1. Starting switch 16. Emergency signal switch
2. Fuel gauge 17. Differential lock switch
3. Power take-off switch 18. Engine diagnosis switch
4. Double-pointer air pressure gauge 19. Ventilating hole
5. Engine tachometer 20. Radio-cassette player
6. Cover 21. Warm air adjusting knob
7. Ventilating hole 22. Warning lamp switch (optional)
8. Engine oil pressure gauge 23. Hand brake handle
9. Water temperature gauge 24. Transmission control lever
10. Signal lamps assembly 25. Cigarette lighter (optional)
11. Speedometer 26. Ammeter
12. Lamp master switch 27. Accelerator pedal
13. Fog lamp switch 28. Combined switch
14. Stop switch 29. Foot brake pedal
15. Air-conditioner switch 30. Steering wheel
31. Clutch pedal 32. Low temperature preheating switch

8
 Fig. 3-2 Signal lamps assembly

1. Left turning indicator lamp 9. Fog lamp indicator light

2. Beam indicator lamp
3. Charging indicator lamp
4. Oil pressure indicator lamp
5. Reversing indicator lamp
6. Engine diagnosis indicator lamp
7. Foot brake indicator lamp
8. Differential lock indicator lamp
10. Water temperature indicator lamp
11. Pre-heating indicator lamp
12. Low air pressure warning lamp
13. Power take-off indicator lamp
14. Engine trouble indicator lamp
15. Hand brake indicator light
16. Right turning indicator lamp

2. Functions of instrumentation, switches and signal indicators in cab

1) Starter switch (No. 1 in Fig. 3-1)
Three positions are available for selection after the key is inserted
into the starting switch, see Fig. 3-3, their functions are as follows:
OFF position: with electric power supply cut off, the key cannot
be pulled out.
Acc position: the key must be in the position when engine does
not run and radio, cigarette lighter and wiper should be used.
ON position: “ON” state, the key must be in the position when Fig. 3-3 Starter switch

engine is running.
START position: starting engine state, after starting, release the switch and the key will return
to ON position automatically.
2) Double-pointer air pressure gauge (No. 4 in Fig.3-1)
Low air pressure warning indicator lamp (No. 12 in Fig. 3-2)
Double-pointer air pressure gauge indicates pressure in two circuits of service brake system
(21st, 22nd circuit), the normal working pressure is 0.45~0.8MPa. If the air pressure in any one of
two circuits decreases below 0.45MPa, stop the vehicle to check the pneumatic circuit system.
When the air pressure in hand brake circuit (23rd circuit) of pneumatic circuit system is below
0.45MPa, the lamp lights, indicating that the truck can not be started or the PTO can not be
9
operated.
3) Speedometer (No. 11 in Fig. 3-1)
Speedometer consists of speed meter and mileage meter. Speed meter indicates the vehicle
traveling speed and mileage meter registers the vehicle total traveling miles.
4) Engine tachometer (No. 5 in Fig. 3-1)
Engine tachometer indicates engine rotational speed for driver to adjust engine idle and control
engine max. rotational speed and provide guarantee for using the engine reasonably. The hour
meter in it may record the vehicle working time.
5) Ammeter (No. 26 in Fig. 3-1)
The ammeter indicates charging and discharging of the battery. Ammeter pointer pointing to
“+” area indicates power generated by alternator is more than that consumed by electric
equipments, the battery is in charging; in reverse, the battery is in discharging.
6) Fuel gauge (No. 2 in Fig. 3-1)
When starting 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 state of
accelerating, braking or climbing up and down slope.
7) Engine water temperature gauge (No. 9 in Fig. 3-1)
Water temperature gauge indicates coolant temperature. In normal condition, the pointer is
near middle position, i.e. indicating engine normal working temperature of 80~90℃. In tropical
zone (area), when truck drives in high speed or climbs slops, the pointer will move to the red
sector of the gauge. If the water temperature is too high, the truck must be stopped, and let the
engine runs in idle to lower the water temperature to normal condition.
8) Engine oil pressure gauge (No. 8 in Fig. 3-1)
Oil pressure warning lamp (No. 4 in Fig. 3-2)
It displays the oil pressure value of engine lubrication system. Please refer to engine operation
instruction for the engine oil pressure values either in idle speed or in normal operation. Oil
pressure at idle speed for Hangzhou WD615.334 engine≥100kPa, and oil pressure≥350 kPa at
rated rotation, or refer to Engine Operation Manual.
9) Stop switch (No. 14 in Fig. 3-1)
Press down this switch to cut off the oil supplying to the engine so that the engine can stop.
The switch will reset automatically after being released.
△Note: release this switch after the engine stops.
10) Air conditioner switch (No. 15 in Fig. 3-1)
Press backward this switch, air-conditioner can work (refer to Air-conditioner Operation
Manual), and press forward this switch, air-conditioner stops work.
11) Emergency signal switch (No. 16 in Fig. 3-1)
10
 The emergency signal switch must be used when truck has to park in dangerous place. Press
down this switch, the danger warning light lights and makes all the steering indicator light flash.
The danger warning light activates even if the starting key in KEY position. Turning off the
switch to release the danger warning.
12) Differential lock switch (No. 17 in Fig. 3-1)
Differential indicator lamp (No. 8 in Fig. 3-2)
When rear wheels get into a pit and couldn’t get out, press the switch to link the drive axle
rigidly by electro-pneumatic control devices. When use the switch, the differential lock
indicator lights. If the indicator is not light, stop the vehicle and check cause.
△Note:
1) Before engaging or disengaging the differential lock, engine power output must be cut
off and the truck must be in static condition or in very lower speed;
2) Only the truck drives in straight line can the switch be used;
3) In case the truck drives on good road, the switch must be disengaged at once. Keeping on
use of the switch will result in damage of transmission and increase fuel consumption.
13) Fog lamp switch (No. 13 in Fig. 3-1)
Fog indicator lamp (No. 9 in Fig. 3-2)
During traveling in foggy days, this switch must be used. When the switch is pressed down,
the fog light indicator lamp and front, rear fog lamps illuminate.
14) Lamp master switch (No. 12 in Fig. 3-1)
When traveling in night, the lamp master switch must be used. Press down this switch
backward, head lamp, dim lamp, license lamp and instrument lamp illuminate. Press down this
switch forward, all the lamps go out.
15) Charging indicator lamp (No. 3 in Fig. 3-2)
The lamp lights up when starter switch is in ON position, it indicates that power is turned on
and the engine may be started. When engine is running normally, the lamp goes out. If it doesn’t
goes out, increase engine accelerator to middle rotation speed. If it still remains light, it means
that engine doesn’t work, stop for check.
16) Hand brake handle (No. 23 in Fig. 3-1)
Hand brake indicator lamp (No. 15 in Fig. 3-2)
When the vehicle is stopped or before the driver leaves it, pull the hand brake selector lever
backwards to locking position in the range of 55°~77°. At this time, hand brake indicator
lamp illuminates, it indicates that the vehicle is in parking brake. When the vehicle starts and
parking brake is released, first pull the lock sleeve on selector lever upwards, and then push the
selector lever forwards to make it in the range of 0°~10°, at this time, hand brake indicator
lamp goes out.
11
 When emergency brake is necessary in danger and foot brake is out of order, apply hand brake
handle to brake the vehicle.
When the service brake is damaged and the vehicle must be trailed, hand brake can be used
instead of service brake.
△Note: it is forbidden to use the parking brake and the service brake at the same time to
prevent the braking system from damage.
17) Combined Switch (No. 28 in Fig. 3-1)
Refer to Fig 3-4 for combined switch.
Operation of exhaust brake switch (No. 1 in Fig. 3-4): when the vehicle travels on a long
downhill, pulling the switch backwards can realize exhaust brake. This can avoid not only the
vehicle speeding up to dangerous extent by deadweight but also the brake temperature going too
high by less use of brake. Reset the switch when it isn’t used.
△Note:
1) Never stop engine when the vehicle travels on a long downhill with the switch activated.
2) The gear positions of transmission cannot be in neutral position.
3) With the decrease of gear positions, braking torque increases.
Operation of wiper switch of front windshield (No. 2 in Fig. 3-4): lifting the switch up can
start washing motor to clean front windshield; pulling the switch backwards can control wiper
motor to run in low speed and high speed.

Fig. 3-4 Combined switches

1. Exhaust brake switch 2. Wiper switch of front windshield 3. Dimmer switch
Operation of dimmer switch: with lamp master switch (No.12 in Fig. 3-1) pressed down,
push the switch (No. 3 in Fig. 3-4) forwards to turn on left steering lamp, left steering indicator
12
lamp and traveling left steering lamp illuminate; pull it backwards to turn on right steering lamp,
right steering indicator lamp and traveling right steering lamp illuminate. The control lever
should be returned to neutral after steering. Operation of changing roadway is the same as the
operation of steering signal switch. Lift the switch up for dimmer; position it in mid-position for
dim light; pull it downward for beam light; turning 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.
18) Power take-off switch (No. 3 in Fig. 3-1)
Power take-off indicator lamp (No. 13 in Fig. 3-2)
A PTO is installed on the rear end of transmission, and it drives hydraulic pump after operation,
PTO indicator lamp illuminates for outrigger operation or crane lifting operation.
XZ40K PTO operation method:
Run the engine at idle speed after stop the vehicle, step on clutch pedal to disengage clutch,
position the selector lever to gear 4, pull the PTO switch and release clutch pedal, at this time
PTO gear smoothly engaged with transmission gear, and PTO works. In reverse, step on clutch
pedal to disengage clutch, pull PTO switch, turn selector lever to neutral position to release
clutch pedal, at this time PTO gear smoothly disengaged with transmission gear.
△Notes:
1) When operating PTO switch, pneumatic pressure should be above 0.45MPa. (Low
pressure warning indicator lamp goes out)
2) While traveling, PTO switch must be in OFF position.
19) Engine diagnosis indicator lamp (No. 6 in Fig. 3-2)
When there is trouble during engine running period, this lamp illuminates.
20) Engine trouble indicator lamp (No. 14 in Fig. 3-2)
When there is something wrong with engine or work in abnormal state, this lamp illuminates.
In safe situation, the driver must stop the vehicle on roadside at once so as to decrease the
possibility of engine damage.
21) Engine diagnosis switch (No. 18 in Fig. 3-1)
This is trouble diagnosis switch Hangzhou WD615.334 engine. During vehicle traveling
period, when No. 6 and No. 14 indicator lamps in Fig. 3-2 illuminate, press down this switch, if
“TEST” indicator lamp illuminates evenly, it indicates that engine is running normally; if
“TEST” indicator lamp does not illuminate evenly, it indicates that there is something wrong with
the engine. Confirm trouble codes according to the illuminating times of “TEST” indicator lamp
so as to judge which trouble is in the engine.
22) Warning lamp switch (optional) (No. 22 in Fig. 3-1)
Warning lamp begins to flash after the switch is turned on. Reset the switch when it is not
used.
13
3. Adjust the driver’s seat

Fig. 3-5 Seat outline

1. Head rest adjustor switch 2. Back rest angle adjusting lever

3. Seat damper adjusting lever 4. Seat height adjusting lever
5. Seat height adjusting lever 6. Seat sliding control lever
There are two seats in the driver’s cab, they may be adjusted to fit any body size. Take one of
them for an example: the seat height may change 60mm, the distance adjusted forward and
backward is 170mm, the adjustment of back rest angle is 120°. The stroke of seat damper may
be adjusted steplessly according to body weight of 40~130kg, max. stroke is 50mm. Headrest
height may be changed 40mm.
1. Forward and backward adjusting: pull seat sliding control lever 6 lightly, push the seat forward
and backward to perfect position, release select lever to lock automatically.
2. Seat backrest angle adjusting: move backrest angle adjusting lever 2 to adjust backrest
forwards or backwards, releasing the control lever can lock backrest in specified position.
3. Rigidity adjusting: according to operator’s weight, turn seat damper adjusting lever until
feeling comfortable. Turn clockwise load select lever, weight increases, whereas weight
decrease.
4. Height adjusting: pull select lever 5, the front part of seat cushion will bounce automatically,
when pulling select lever 4, the rear part of seat cushion will bounce automatically. When
pressing, pull select lever 5 and 4, and then press down hardly, the seat cushion position can be
fixed by releasing front and rear levers.
△ Note:
1. During forward and backward adjusting and seat backrest angle adjusting, pull the select
lever upwards to ensure locking after steady suspension.
2. After adjusting, all the select levers should return to ensure each position is locked reliably.

14
(II) Preparation before driving
The preparation before driving includes routine inspection before driving and engine starting.
1. Routine inspection before driving
1) Check coolant level
Check coolant level through inlet of water tank. If no coolant is found, fill coolant till it is
found. Then start engine, when it is running at approx.1000 rpm refill coolant to specified level.
△Note:
1) When truck in normal traveling, checking coolant level must prevent hot water and steam
from injury of person.
2) Do not fill coolant when engine still in hot temperature.
2) Check fuel level
Position the key switch of power supply to ON position, check fuel level on fuel gauge, and
replenish fuel if necessary.
3) Check engine oil level
Pull out the dipstick (see Engine Operation Manual), replenish the specified engine oil
depending on the level mark of the dipstick.
4) Check transmission oil level
The transmission oil level must be not lower than the position of the side sight-hole on the
transmission case, i.e., not lower than the centerline of transmission countershaft.
5) Check the water condensed in the air reservoir
Drain the water condensed in the air reservoir by removing the manual drain valve under the
air reservoir, and replace drying agent in dryer.
6) Check the tire pressure, and inflate the tire if necessary.
7) Check the tightness of tire bolts.
8) Check function of all the electric system.
9) Check leakage of oil and coolant.
10) Check air filter.
Empty and clean the dust-collector everyday if the truck works in dusty environment. When If
red line in air filter negative pressure indicator occurs, clean the filter element.
2. Engine starting
1) The requirements for engine operation see Engine Operation Manual.
2) Operation of power supplies switch (see Fig.3-3).
Turning the key from OFF position to ON position can turn on power for starting the engine.
Turning the key from ON position to START position can start engine. After starting engine,
release your hand, the key will automatically return to ON position, and then the starting switch
resets.
15
△Note:
When starting the engine by wire-contact, the wire can only be connected to the battery and
never to the starting motor.
3) Auxiliary starting device
A pre-heating device is equipped in engine. When the temperature of coolant in the engine is
lower than -10℃, the device is automatically activated to heat inlet air.
① Before starting, insert key switch and turn it from OFF position to ON position to turn on the
pre-heating device. At this time, indicator lamp comes on.
② After indicator lamp flashes and goes out, turn the key switch from ON position to START
position to start engine.
4) Starting process
With hand brake handle in braking condition, put shift lever in neutral position, turn the
starting key to START position to start the engine. Generally the starting time is 2~3 seconds, if
fail to start within 12 seconds, return the key to ON position immediately, 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.
6) 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 0.25MPa, can the engine run with a full load.
△Note:
The rotation speed should be increased slowly to make sure that the bearings get sufficient
lubricating and stable oil pressure, especially after starting the engine in low ambient
temperature. It is not allowed to depress accelerator pedal abruptly without a load applied.
3. Stop the engine
After finishing of running with a full load, let the engine run idle for 3~5 minutes to cool down
gradually. Press the stop switch to stop the engine.
△Note: stop the engine immediately if the following situations happen:
Oil pressure decreases obviously or pressure fluctuates.
Power or speed decreases, while accelerator position does not change.
Much soot smoke is discharged from exhaust pipe, or coolant or oil temperature increase
quickly.
Abnormal noise comes from engine or supercharger.
16
(III) Starting and shifting
1. Starting
Release the hand brake handle.
△Note:
Only when the pressure of air reservoir in braking system is up to 0.45Mpa, the hand brake
indicator light and low air pressure warning light go out, the spring brake can be released. And
then the truck can be started. The truck can’t be started before the hand brake indicator light
goes out. After the hand brake indicator light goes out, all the air-powered systems can be
operated.
2. Operating method of transmission
2.1 Operation of mechanical 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.
(2) Shift to 1st gear to start running the truck.
(3) Consecutively change gears in order from the 1st one to the 2nd, the 3rd and the 4th, and
finally to the highest gear.
Shifting down: shift from the highest gear to the 1st gear can be operated consecutively.
△Notes:
1) During shifting, the clutch must be disengaged, and shift lever in place.
2) Use the 1st gear for starting the truck.
3) During traveling, check regularly oil pressure gauge, speedometer and water temperature
gauge.
4) Never travel with a shift lever in neutral or slide with an engine stopped for transmission
lubricating and safety.
5) Select different gears according to road conditions to meet traveling requirements.
6) Never shift gears with accelerator pedal depressed.
7) When shift gear from 4 to 5 (or from 5 to 4), wait a moment intentionally to facilitate
auxiliary transmission changing between high and low gears.
3. Stopping and parking
The vehicle can be stopped with foot brake or hand brake whenever operating lever is in
whatever gears. For temporary stopping, operating lever position may not be changed. If leaving
the truck for a long time, the operating lever must be in neutral position.
△Note: when parking is necessary, apply the hand brake.
4. Operations in emergency
17
1) When the transmission has a trouble and the truck must be moved, the traveling speed for the
truck towed can not exceed 10 km/h, and the emergency signal switch (No. 16 in Fig. 3-1)
must be turned on and turning indicator lights of towing vehicle should also be turned on.
2) When engine and transmission are damaged, propeller shaft should be disassembled in
principle.

(IV) Control of clutch

The clutch of XZ40K truck crane chassis is pull-type diaphragm spring clutch.
Clutch is controlled by static pressure oil with the aid of air-assisted device. With clutch pedal
depressed to bottom, clutch friction disc can disengage with engine flywheel fully to cut out
power.

Foot pedal

Oil cup

Lock nut Clutch master cylinder pushrod

Clutch operating fork

Clutch branch cylinder

Fig. 3-7 Pull-type clutch control diagram

Clutch pedal free stroke S should be in range of 40~60 mm when clutch release rod does not
move. If not, check the clearance of master cylinder pushrod and check if there is air in the static
pressure oil circuit.
On the condition of clutch pedal depressed to the bottom, the clutch should be disengaged fully,
if not, that means there is air in the static pressure oil circuit.
1. The adjusting method of clutch control system
18
 Since the clutch system is controlled by static pressure oil, so always check the level of oil cup
to the 4/5 of the cup height, if replace clutch cylinder, air in the system must be exhausted.
Detailed methods:
1) Open the cover of oil cup in driver’s cab, pull out the oil inlet pipe, and fill brake oil into the
oil cup until the oil level up to the 3/4 to 4/5 of the cup height, after filling oil, place the inlet
oil pipe, and compress oil cup cover. Refer to Table 1-4 in Chassis Maintenance Manual for oil
brand.
2) Remove the rubber cover on the branch cylinder bleeding cap, do the following.
3) Continuously step on the clutch pedal to maximum stroke until feeling pedal is heavy, and then
stop it at the maximum stroke position.
4) Loosen the bleeding cap on the clutch branch cylinder, at this time the air bubble in system
spurts out from bleeding cap, then tighten the cap at once.
5) Release clutch pedal, and continuously step on the clutch pedal to maximum stroke until
feeling pedal is heavy, and then stop it at the maximum stroke position. Loosen the bleeding
cap on the clutch branch cylinder until brake oil sprays out of the bleeding cap. Then tighten
the cap at once, assemble the rubber cover on the bleeding cap. During operation pay attention
to the oil level in the oil cup and replenish oil according to requirements.
△Note:
1) If barges up against road obstruction during traveling, step on the clutch pedal to
maximum stroke, the vehicle can be stopped temporarily.
2) When changing gears, step on clutch pedal.
3) When operating PTO switch, step on clutch pedal.
4) Two operators should cooperate when exhausting air in system.
5) The length of clutch cylinder rod is fixed, do not adjust manually.

19
(V) Control of steering
Power steering and hydraulic steering are available. Driver may drive the vehicle straightly or
steer by controlling the steering wheel.

Fig. 3-8 Steering system diagram

1. Steering wheel 2. Steering gear 3. Steering oil tank
4. Steering pump 5. Power cylinder
Steering procedure:
1. Mid-position: the vehicle is driven to go straight while the steering wheel is in the position.
Driver does not apply steering force on the steering wheel. The steering wheel remains
unmoved.
2. Steering procedure: when it is necessary to change driving direction, driver steer the steering
wheel for steering. Move the steering wheel left to turn the vehicle left; move it right to turn
the vehicle right.
3. Return: after finishing steering, with the steering wheel static the vehicle wheels will move
towards straight-line motion direction under return moment of force, till reach straight-line
motion direction.
4. Road sense effect: it is a direct sense 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 make it deform. Deformation is in direct proportion to steering
resistance.
△Note:
1) The movement of power steering gear is performed through the steering pump activated by
engine. The vehicle should not slide with the engine shutdown, otherwise heavy steering
and accident will occur.
2) When steering system trouble caused by oil pump or circuit appears, the steering gear may

20
 be taken as a mechanical steering gear for forcing the vehicle to reach repair station. But
compulsory steering for a long time may damage the steering gear.
3) When steering, never move the steering wheel to limit. The stop time should be controlled in
1 minute. Steering resistance varies according to diffident road conditions, so driver should
apply diffident force to the steering wheel.

(VI) Brake system

The brake system consists of service brake (foot brake), parking brake (hand brake) and
auxiliary brake (engine exhaust brake).
1. Service brake
The service brake is foot pedal control (No. 29 in Fig. 3-1) with double-circuit air pressure
brake. Its working pressure is 0.8Mpa. The 1st circuit acts on the wheels of the 1st and 2nd axles,
and the 2nd circuit acts on the wheels of the 3rd and 4th axles. In case the air pressure of one air
reservoir in two circuits drops below 0.45Mpa, stop the truck and find the cause of low pressure.
Repeated braking in a short time may cause pressure down below 0.45Mpa.
2. Parking brake
Parking brake is exhaust spring brake acting on the wheels of 3rd and 4th axles. It gives effect
on all axles by the spring-loaded air chamber. After stopping the truck, applying hand brake
handle can hold the truck at original place. This is parking brake. Only with hand brake released
and the pressure in 23 circuit of brake system more than 0.45Mpa (low pressure warning lamp
goes out) and hand brake indicator lamp went out, spring brake air chamber can be fully released
as well as parking brake. Apply hand brake handle for emergency brake when service brake does
not work or there is no enough time to use foot brake. When service brake is damaged and the
vehicle has to be towed, apply hand brake instead of service brake.
3. Auxiliary brake
Auxiliary brake is engine exhaust brake. In order to prolong brake life during a long downhill
travel, press down exhaust brake switch (No. 1 in Fig. 3-4), the butterfly-valve on exhaust pipe
may be closed by solenoid valve and air cylinder to realize engine exhaust brake.
4. Cautions in brake system operation
1) Releasing of spring brake air chamber
When self-braking happens due to leakage of pipeline, do the following to release (see Fig.
3-8): a. Open the plug at the tail of brake air chamber; b. Remove nut on bolt and take off the bolt;
c. Insert the bolt into brake air chamber from its tail and lock (see Fig. 3-9); 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 to block the truck in prevention of slipping.
2) When use exhaust brake, never disengage transmission, and never depress clutch pedal.
21
△Note: never disengage transmission, and never depress clutch pedal.
Nut
Blocking cover

Bolt

Bolt

Nut

Fig. 3-8 Brake air chamber Fig. 3-9 Brake air chamber

(VII) Operation of PTO

After parking the truck on a safe place for extending outriggers and lifting operation, let engine
running in idle speed, depress clutch pedal to disengage the clutch, position the shift lever to 4th
gear, pull PTO switch up and release the clutch pedal, at this time, PTO gear will mesh with
transmission gear smoothly, PTO begins to work.
In reverse, depress clutch pedal to disengage clutch, push PTO switch backward, position the
shift lever to 4th speed and release clutch pedal, at this time, PTO gear will disengage with
transmission gear smoothly.
△Notes:
(1) Before operate the PTO switch, pressure in pneumatic circuit should be more than
0.45MPa. (Low air pressure warning indicator light goes out).
(2) When traveling, the PTO switch must be in off position.
(3) When operate the PTO switch, clutch must be disengaged.

22
(VIII) Outriggers operation Oil level
Thermo-
1. Before operate outriggers, check hydraulic oil level, if the level is liquidometer

lower than the mark required, refill to specified level.

2. Engage PTO
Start engine by the key, when the reading on air pressure gauge is
0.45Mpa and low pressure warning indicator lamp goes out, depress the
clutch pedal, move the transmission control lever to 4th gear and pull PTO
Fig. 3-10 Hydraulic oil
switch out. At this time, PTO indicator lamp comes on. Make the clutch
temperature gauge
pedal in natural position by removing your foot slowly.
3. Operation of outriggers
Note: all floats must rest on firm ground or pads.
3.1 Outrigger and names of outrigger parts

1. Outrigger beam dowel pin

2. Pin hole
3. Level gauge
4. Jack cylinder
5. Outrigger float
6. Outrigger select levers
7. Outrigger select lever lock pin
Fig. 3-11 Names of outrigger parts

1. Right front outrigger select lever

2. Left front outrigger select lever
3. Right rear outrigger select lever
4. Left rear outrigger select lever
Extension 5. 5th jack select lever
Neutral
Jack Retract Extend 6. Outrigger position select lever
Neutral

Fig. 3-12 Control levers

23
3.2 Setting outriggers
1) Pull out the outrigger beam lock pins.
2) Turn on outrigger accelerator power switch.
3) Position select levers (No.1~No. 4) to “Extension”.
4) Move outrigger position select lever (No. 6) to “Extend” to extend
outrigger beams.
5) After outrigger beams are fully extended, release the outrigger
position select lever (No.6) and it returns to “Neutral” automatically, then return select levers (No.
1~4) to “Neutral”.
6) Position select levers (No.1~No. 4 in Fig. 3-11) to “Jack”.
7) Move outrigger position select lever (No. 6) to “Extend” to extend outrigger jacks.
8) After outrigger jacks are fully extended, release the outrigger position select lever (No.6) and
it returns to “Neutral” automatically, then return select levers (No. 1~4) to “Neutral”.
9) After outrigger jacks are fully extended, check if the carrier is level by using level gauge.
Position 5th jack select lever (No. 5) to front cylinder position.
10) Push outrigger position select lever (No. 6) to make 5th jack outrigger float contact ground or
pads. Release outrigger position select lever (No. 6), it will reset automatically. Then return 5th
jack select lever (No. 5) to middle position.
11) After outrigger jack cylinder is fully extended, again make sure that all select levers are in
neutral position and turn off power switch of outrigger accelerator.
12) Insert the lock pin of outrigger select lever into the lock hole of outrigger position select
lever.
3.3 How to level crane
If carrier is not in level state after supporting, do as the following procedures:
1) Moving any one or more of the select levers (No.1~No. 4), and position outrigger position
select lever (No. 6) to “Extend” or “Retract” may extend or retract outrigger jack(s) selected.
After the carrier is leveled, move the select levers (No.1~No. 4) to “Neutral”, and insert the
outrigger select lever lock pin. Operation of leveling carrier is finished.
2) Move 5th jack select lever to front cylinder position, push outrigger position select lever (No. 6)
to make front cylinder extend to contact ground with slight force. Release outrigger position
select lever (No. 6), it will reset automatically. Then return 5th jack select lever (No. 5) to middle
position, and insert the lock pin of outrigger select lever into the lock hole of outrigger position
select lever, the operation of chassis leveling is completed.
For example: when the crane right side is higher, return the “Right front” and “Right rear”
select levers to “Jack”. While observing level gauge, inch outrigger position select lever (No. 6)
to “Retract”. After the crane is leveled, return the remaining select levers to “Neutral”. Then
24
operate front outrigger cylinder to slight force state, and return select lever on selector valve to
middle position.
△Note:
1) After operation, every tire should be off the ground.
2) The front outrigger cylinder can be extended only after confirming the carrier is leveled.
3) After operating outriggers, make sure all the select levers should be in neutral position.
3.4 Stowing outriggers
1) Turn on outrigger accelerator power switch.
2) Push 5th jack select lever (No. 5) to front cylinder position, pull outrigger position select lever
(No. 6), operate it to “Retract” position to make 5th jack cylinder fully retracted. After releasing
outrigger position select lever (No. 6), it will reset to middle position automatically. Then return
5th jack select lever (No. 5) to middle position.
3) Push select levers (No.1~No. 4) to jack cylinder position, pull outrigger position select lever
(No. 6), operate it to “Retract” position to make jack cylinder fully retracted. After releasing
outrigger position select lever (No. 6), it will reset to middle position automatically. Then return
select levers (No.1~No. 4) to middle position.
4) Pull select levers (No.1~No. 4) to extension cylinder position, pull outrigger position select
lever (No. 6), operate it to “Retract” position to make extension outrigger fully retracted. After
releasing outrigger position select lever (No. 6), it will reset to middle position automatically.
Then return select levers (No.1~No. 4) to middle position.
5) Again make sure that all the select levers are in neutral position.
6) Insert outrigger beam dowel pin 1 into pin hole 2.
7) Turn off outrigger accelerator power switch.
8) Turn off PTO switch according to operation procedures.
△Note:
1) Before stowing outriggers, position boom and jib onto boom bracket and in stowing state.
2) Stow front outrigger cylinder when stowing outriggers.
3) After outrigger operation, make sure all the select levers in neutral position.

25
(IX) Winter operation
1. Cooling system
The coolant for cooling system should comply with the requirements of engine. It may be soft
water or soften water, otherwise the scales formed and deposited will affect the cooling effect.
Hard water can be softened by the following methods:
1) Heating and boiling;
2) Add sodium carbonate (Na 2 CO3) 0.5~1.5g to each liter of water;
3) Add sodium hydroxide (NaOH) 0.5~0.8g to each liter of water.
Antifreeze can use JFL-318 (0℃～-10℃) or JFL-336 (-10℃～-26℃), or JFL-345 (-26℃～
-35℃), also can be self-made according to the methods recommended in Table 3-1.
Please replace coolant in time according to ambient temperature.
Table 3-1
Limit temperature Glycerin——water Glycol——water
of coolant freezing Glycerin Specific gravity Glycol weight Specific gravity
point (℃) weight % D % 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
Note:
△ Antifreeze made of “alcohol—water” cannot be used in engine.
△ Never use seawater to cool engine directly.
△ Antifreeze coolant may be added according to the operation requirements of engine, also
can be self-made according to the methods recommended in Table 3-1. When using
antifreeze coolant, the freezing point of antifreeze coolant should be lower 5℃ than the
lowest temperature in the area.
△ Refill brand JFL-318 or JFL-336, JFL-345 coolant directly according to ambient
temperature.
2. Braking device
Do not forget to drain the water condensed in the air reservoir before traveling.
3. Battery
If do not use the truck for a long time and ambient temperature is very low, it is better to
remove the battery from chassis and stow it in a warm room.
1) Notes on battery checking
△ 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.
△ Do not put tools on the battery.
26
△ Forbid to remove the battery wire while the engine is running.
2) Charging the battery
If charging the battery, only charge with DC power and charging power can’t exceed 1/10 of
battery capacity. For example: charge a 165Ah battery, the charging currency should not be more
than 16.5 A.

(X) 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 650r/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.
3) In traveling, select proper shift gears according to load and road conditions. And avoid abrupt
accelerating and emergent braking.
4) Check and control engine oil pressure and coolant working temperature.
5) Check regularly wheel hubs of mid/rear axles and brake drum temperature. 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.
After run-in time, check and maintain the truck according to the “First check” items specified
in Maintenance manual and the requirements in engine and transmission operation manuals.

27
(XI) Usage of air conditioner
The products adopt heating and air conditioning system. Warm air is utilizing engine cyclical
hot water; cold air is supported by refrigerant circulated in air conditioner system. In winter when
use the warm air, open hot water valve (on connection of engine and warm air hot water pipe,
refer to the Fig. 3-14) in warm air pipeline, and then press down the No. 15 switch in Fig. 3-1. In
summer when use the cold air, close hot water valve in warm air pipeline and then press down the
No. 15 switch in Fig. 3-1, and last press down A/C switch on the air conditioner. Refer to air
conditioner operation manual for details.
△Note: be sure to close hot water valve when use cold air, be sure to open hot water valve
when use warm air. In winter, drain off the water in engine cooling system as well as in warm
air pipeline.

Warm air water inlet

WD615 series engine Open state of hot-water valve

Fig. 3-14 Engine hot water valve position and state

28
XUZHOU HEAVY MACHINERY CO., LTD.
XUZHOU CONSTRUCTION MACHINERY GROUP CO., LTD., CHINA
Add: No.165 Tongshan Road, Xuzhou, Jiangsu Province, 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: 0086-0516-83461183
Service Fax: 0086-0516-83461180
Spare Parts Tel: 0086-0516-83461183
First edition Jan. 2012