XZ130KⅡ TRUCK CRANE ARRIER MAINTENANCE MANUAL

XZJ5559JQZ130K TRUCK CRANE ARRIER

MAINTENANCE MANUAL

XUZHOU HEAVY MACHINERY CO., LTD.

XUZHOU CONSTRUCTION MACHINERY GROUP CO., LTD., CHINA

II
 XZ130KⅡ TRUCK CRANE CARRIER

MAINTENANCE MANUAL

Pages: 1 up to 49

VIN
Date

The maintenance 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 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

III
 Preface
This manual supplies technical information about the performance, structure, operation, service
and adjustment of XZ130KⅡ Truck crane carrier (for QY130K-Ⅰ) to drivers and maintenance
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.
Information about maintenance and service of engine and transmission is not included in the
manual. Please refer to OM460LA Engine maintenance manual and AS-TRONIC Transmission
maintenance manual.
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 item, we reserve the right to modify the design without notice.

IV
Notes:
1) Read the manual carefully and familiar with operating methods & notes before operate the
vehicle. Otherwise, never operate it.
2) 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 maintenance.
3) 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.
4) Keep the manual well for future reference.

V
 Contents
I. Maintenance-------------------------------------------------------------------------------------------------1
(I) Interval mileage of vehicle routine check and maintenance-------------------------------------1
(II) Maintenance key points-----------------------------------------------------------------------------1
(III) Fuel and lubricant brand and filling amount---------------------------------------------------10
II. Trouble diagnosis and solutions------------------------------------------------------------------------11
(I). Drive line---------------------------------------------------------------------------------------------11
(II). Axle and suspension-------------------------------------------------------------------------------12
(III). Steering system------------------------------------------------------------------------------------12
(IV). Hydraulic system---------------------------------------------------------------------------------13
(V). Electric system-------------------------------------------------------------------------------------14
III. Braking system------------------------------------------------------------------------------------------16
IV. Carrier hydraulic system-------------------------------------------------------------------------------19
V. Carrier electric system-----------------------------------------------------------------------------------25
VI. Wheel inspection and replacement--------------------------------------------------------------------
46
VII. Tightening torque of main bolts and nuts-----------------------------------------------------------48
VIII. Main parts----------------------------------------------------------------------------------------------49

VI
 Ⅰ. Maintenance
(Ⅰ) Interval mileage of vehicle routine check and maintenance
Table 1-1 Unit: 1000km

Routine check
Routine check

Routine check

Routine check

Routine check

Routine check

Routine check

Routine check
maintenance

maintenance

maintenance

maintenance

maintenance

maintenance

maintenance

maintenance
First check

2nd class

2nd class
3rd class
1st class

1st class

1st class

1st class

1st class
1.5 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80
85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160

165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

(Ⅱ) Maintenance key points

1. Daily maintenance
(1) Inspect the operation of hand brake and foot brake;
(2) Inspect the function of illuminating, signal system and indicator lamps (indicator lamps for oil
pressure, air reservoir pressure, charging, etc.)
(3) Inspect the operation of air filter negative pressure indicator;
(4) Inspect the operation of windscreen wiper;
(5) Inspect the condition of tire air pressure and the tightness of wheel bolts;
(6) Inspect the levels of engine oil, transmission oil, coolant and fuel;
(7) In winter, inspect anti-freezing condition of pneumatic circuit system;
(8) Drain off the water condensed in air reservoir: check every week in summer, every day in
winter;
(9) Drain off the water in oil-water separator;
(10) Inspect the tightness of universal joint shaft bolts, pushrod bolts of front and rear axles.
2. Each class maintenance item
Table 1-2
First Routine 1st class 2nd class 3rd class 4th class
Maintenance item
check check maint. maint. maint. maint.
Check and maintain according to instructions in Engine maintenance manual
Engine
strictly.
1. Replace engine oil (at least
● ● ● ● ● ●
one time per year)
2. Replace oil filter or filter
● When change engine oil every time
element
3. Replace fuel filter or filter
● ● ● ● ●
element
4. Check fuel filter and
● ● ● ● ● ●
remove impurity.

1
 First Routine 1st class 2nd class 3rd class 4th class
Maintenance item
check check maint. maint. maint. maint.
5. Clean or replace fuel filter
● ● ● ● ● ●
element.
6. Check coolant capacity ● ● ● ● ● ●
7. Replace coolant Every 24 months
8. Check coolant circuit
●
tightening clamp
9. Tighten air inlet circuit and
● ● ● ● ●
connectors
10.Check air filter negative
● ● ● ● ● ●
pressure indicator
11. Clean air filter dust cup ● ● ● ● ● ●
12. Replace air filter main
When air filter negative pressure indicator displays or every 250 hours
element
13. Replace safety filter After 3 times of cleaning main filter element, or safety filter element is
element of air filter damaged
14. Check and tighten the belt ● ● ● ● ● ●
15. Check supercharger ● ● ●
Transmission
1. Check the level and leakage
● ● ● ● ● ●
of lubrication oil
2. Clean or replace breather ● ● ● ● ● ●
3. Replace lubrication oil Initial 12 months of traveling, afterwards every 24 months.
Transfer gear
1. Replace lubrication oil Every 12 months
2. Clean or replace breather ● ● ● ● ● ●
Drive axles
1. Check the level of main
●
reducer and rim reducer
2. Replace lubrication oil of
main reducer and rim reducer ● ● ● ●
(at least one time every year)
3. Clean or replace drive axle
● ● ● ● ● ●
ventilating device
Propeller-shaft
1. Re-tighten shaft bolt ●
2. Carry out visual check of
● ● ● ● ● ●
shaft connection and wearing
Driver ’s cab
1. Check the movement of
● ● ● ● ● ●
wiper
2. Check and adjust every
● ● ● ●
operating component
3. Check and tighten front and
● ● ● ●
rear supports of cab

2
 Routine 1st class 2nd class 3rd class 4th class
Maintenance item First check
check maint. maint. maint. maint.
Brake system
1. Drain off the water in air
● ● ● ● ● ●
reservoir
2. Check air pressure system
sealing (with air pressure ● ● ● ● ●
gauge)
3. Check and adjust output
pressure of pressure
● ● ● ● ●
regulating valve integrated
with air dryer
4. Check brake shoe friction
disc thickness, adjust brake ● ● ●
clearance
5. Clean wheel brake ● ●
6.Check easy-worn positions
● ● ● ● ● ●
of brake circuit
7. Check brake air chambers ● ● ● ●
8. Check the drying agent in The drying agent should be replaced if there is water accumulated in air
air dryer. reservoir.
Electric system
1. Check the condition of
signal light, head light, ● ● ● ● ● ●
wiper, plugs, etc.
2. Check battery voltages in
● ● ● ● ●
each unit
3. Check the fixing of battery
terminals and meantime coat ● ● ● ● ● ●
electric poles with grease
4. Check the function of
● ● ● ● ● ●
speedometer
Steering system
1. Check the condition of
● ●
steering system
2. Check the condition of
● ● ● ● ● ●
ball head and ball pin
Chassis and road traveling
test
1. Check and tighten frame
● ● ● ● ● ●
connecting bolts
2. Tighten the pushing rods
● ● ● ●
and brackets of axle
3. Check the connecting
● ● ● ● ● ●
bolts of axle pushing rods
4. Check the tightness of tire
● ● ● ● ● ●
nuts
5. Check battery fixing ● ● ●
6. Check fuel tank fixing ● ● ●

3
 First Routine 1st class 2nd class 3rd class 4th class
Maintenance item
check check maint. maint. maint. maint.
Short distance test
1. Check the operation of
● ● ● ● ●
hand brake and foot brake
2. Visually check leakage ● ● ● ● ● ●
3. Check the tightness of
● ● ● ● ● ●
each related component
Lubricating positions
1. Steering knuckle bolt and
● ● ● ●
bearing
2. Steering axle hub bearing ● ● ● ● ● ●
3. Suspension system pin
● ● ● ●
shafts
4. Propeller shaft
● ● ● ● ● ●
intermediate bearing
5. Propeller shaft universal
Refill grease one time every 100 working hours.
joint
6. Propeller shaft telescopic
● ● ● ● ● ●
spline
7. Pushrod ball head ● ● ● ●
8. Steering rocker arm
● ● ● ● ●
bearing
9. Accelerator and brake
● ● ● ●
pedal shaft
10. Cab door hinge ● ● ● ●

Notes:
1. “●” is the mark required maintenance.
2. When replace the bulbs of front far beam lamps, any one of the sum power of left front far
beam lamp and the sum power of front right far beam lamp should not be more than 75W.
3. Maintenance of power system
1). Maintain engine strictly according to instructions in Engine
operation manual.
2). Contact local XZHM service crew or MTU Benz engine
service center for help about troubles irremovable.
3). Maintenance of fuel pipeline
Check tightening condition of fuel pipeline as well as leakage
and distortion. In engine oil inlet pipeline, there is a fuel filter
(see Fig. 1-1) fitted on the boom rest at the left side of the
vehicle.
Fig. 1-1

4
1 Hand oil pump
2 Filter element
3 Water collector
4 Drain valve
Method of draining water:
Water will settle on the bottom of water collector, and is different from oil in terms of color.
Driver or maintenance worker should check the collector every day. If there is water emerged,
drain it in time.
Turn the drain valve counterclockwise to drain water. Close the valve after operation by turning
it clockwise. If don’t use the vehicle for a long time, drain water in the collector, otherwise water
and impurity will corrode the filter.
Replacement of filter element:
Frequency of replacing element depends on the cleanliness of diesel fuel. The element will be
clogged with impurity during operation of engine, and the flow resistance of fuel will increase
gradually, eventually engine power decreases obviously and /or it is difficult to start. It is
recommended that replace element every 20,000 km of driving or 500 hours of operation or
when engine power decreases, whichever expires earlier. It is recommended to take a spare
element on board, so that replacement could be performed in time when fuel filter is blocked by
the dirty diesel fuel in tank.
Troubleshooting:
The main reason of engine power decreasing or difficult to start is that air enters into fuel system.
If oil can’t be pumped or no pressure built in the system, first check drain valve for tightness, and
then fuel filter housing and water collector. After that, check all connectors for confirming that
fuel pipeline is not stuck or clogged with impurity. If problem remains after a new filter element
is replaced, please contact the sale or service staff of Parker Racor filter.
4). Maintenance of air filter
Check the dust-removing valve of air filter at least one time every
day, and remove the dust in it by the way shown in the right figure.
Check at least one time every week for confirming that the
connector between air filter and engine is sealed well, as well as all
hose connectors and air filter cover. If any part damaged or fell off
is found, repair immediately and replace the part damaged,
meanwhile keep record in maintenance book.
Carry out maintenance of air filter every 3 months or 250 working hours or red line appears in
the air filter negative pressure indicator. The interval of maintenance should be shortened in

5
dusty circumstance.
Second-stage filter called safety element is mounted in first-stage filter. It is not recommended to
clean the second-stage filter, otherwise they will be damaged. Never disassemble second-stage
filter before replacement.
Remove the air filter element by the followed procedure: open the metal snap at the rear of the
air filter and remove the rear cover of the air filter and then shake the filter element. Take the
element out carefully after it is loose. If safety element is to be replaced, shake it carefully and
take it out. Before install new safety element, clean the surface for mounting safety element with
a clean and wet cloth.

Open the metal snap at the rear of the air filter Remove the rear cover of the air filter

Clean the inner surface of filter housing Remove the air filter element for
with a clean and wet cloth cleaning or replacing
5). Maintenance of radiating system
Observe the indicator of the antifreeze coolant level. If it remains light, refill the antifreeze
coolant in time. If more antifreeze coolant is consumed than usual, check the reason and remedy.
Visual check pipeline and hoses for damage and leakage. Make sure that all pipeline and hoses
are not damaged and scratched, and configured and secured correctly.
6
a. Check the outside of radiator and clean:
The radiator should be cleaned after use in dusty circumstance for a long time. Blow impurity
(dust, dead insects, etc.) out of radiator grate by compressed air, or remove foreign body on the
back of radiator by water (opposed to the flow direction of cooling air). Clean the radiator with
proper pressure, otherwise radiator grate may be damaged. During cleaning, move water gun
continuously and never aim directly at the following in order to avoid components damage:
 Electric components
 Connectors
 Sealing
b. Clean radiator water line:
Add solution with 5% of density formed by water and light alkaline cleaning compound into
cooling system, preheat engine with proper speed to approximately 83℃(coolant thermostat
begins to open), and shut down the engine after running about 5 minutes. When the engine cools
to around 50℃, drain out the cleaning solution, and refill with clean water. Start and preheat
engine, drain out water after 5 minutes and then repeat the operation again.
6). Maintenance of transfer box
Replacement of gear oil in transfer box should be performed
when it is under hot state for completely draining. At the same
time, the oil in cooling circuit should be drained out. The
disposal of waste oil should be done according to the
environmental protection requirements in the place where you
are working.
Clean the drain plug and tighten it with specified tightening
torque.
Warning !
Pay more attention to avoiding scald from hot
transfer box oil and parts, and avoid contacting kindling so
as to prevent catching fire.
Refill new gear oil of about 9L through oil filler. After filler
plug is tightened, start the vehicle to let oil fill heat radiating
pipeline. Oil filler and scupper
Drain
Observe the oil level by removing the scupper plug,
and tighten the plug with the tightening torque of 60N.m when the
Fig. 1-3 Transfer box diagram
level is below the scupper.
4. Structure and adjusting methods of wedge brake

7
1) Structure of wedge brake
The braking force of wedge brake may be transferred to brake shoe directly through the drive of
rollers, with high transferring efficiency. There are some ratchets on the tapered face of wedge
brake, one tooth will be moved inward when the clearance between brake drum and brake shoe
reaches the specified value, so automatic gap compensation is available.

Fig. 1-4 Fig. 1-5

Wedge brake mainly consists of brake bracket, brake shoe, brake cylinder assembly, protective
plate and spring, etc.
Brake cylinder assembly is mounted on the brake bracket, as shown in Figs. 1-6 and 1-7. It is the
main force-transferring mechanism of wedge brake, its working principle is:

Fig. 1-6 Brake cylinder assembly installation diagram Fig. 1-7 Brake cylinder assembly sectional view

The axial pushing force produced by brake air chamber pushes the rod (No. 8 in Fig. 1-6) to
move downwards, and at the end of the rod there are two sets of roller, which tightly touch the
inclined surface of piston (No. 2 in Figs. 1-7, 1-8). When rollers move downwards along the rod,
each No. 2 piston on both sides will extend out by the action of the inclined surface,
consequently brake shoe will stretch to engage brake drum, and then brake effect is gained.
8
No. 3 screw shown in Fig. 1-7 may avoid piston turning and coming off. No. 10 adjusting bolt
may turn around piston by the action of external force. After adjustment, lock the adjusting bolt
by the snap piece outside dust ring (see Fig. 1-9).
2) Adjusting methods of wedge brake
Brake cylinder assembly and other parts are mounted on axle. Even
if there is automatic gap compensation function (the process is
slow, and matches with the wear of brake shoe disc), because of
manufacture error, difference in adjustment and previous uneven
wear, the clearance between brake shoe disc and brake drum will
fail to meet technical specifications, and then the brake distance
will not comply with specified standard.
The clearance between brake shoe disc and brake drum is designed
in the range of 0.25mm～0.5mm. When the clearance is beyond the
range, adjust the adjusting bolts (see No. 10 in Figs. 1-7, 1-9) on
Fig. 1-8 Brake cylinder assembly
two sides of brake cylinder by a plain screwdriver. working principle diagram
Tools for adjusting are a plain screwdriver, a flashlight and a feeler.
Adjusting methods:
1) Check the clearance between brake shoe disc and
brake drum after the rubber plugs on protective
plate are removed, and adjust nuts if necessary.
2) Move the external tooth of adjusting bolt with the
plain screwdriver while observe the position of bolt
adjusted with the aid of flashlight. Check the
clearance with a feeler of 0.25mm if it meets
requirements.
3) Adjust the clearance between brake shoe disc and
Fig. 1-9 Brake cylinder assembly adjusting diagram
brake drum on the other side by the same way.
Notes:
1.) For a new delivery machine, matching requirements and running-in between parts have not
obtained, so the clearances for adjusting should take the minimum limit. For the machine to
carry out routine maintenance (brake shoe disc and brake drum are not to be replaced), the
value may be any one in the specified range, but the clearances for brake shoe disc and brake
drum on the same axle should correspond with each other.
2.) When replace a new axle, the clearances between brake shoe disc and brake drum should be
adjusted into place in advance before the axle is installed on the vehicle, so as to facilitate

9
 inspection and adjustment.
(Ⅲ). Fuel and lubricant brand and filling amount
1. Refer to Table1-3 for Fuel and lubricant brand and filling amount
Table 1-3
Name Brand Capacity
Engine oil RUMULA X CH-4 15W-40 38L
400L according to tank
Engine fuel Depending on ambient temperature
capacity
50% BASF Antifreeze coolant G48-24
Engine coolant 110L
+50% distilled water
Transmission lubrication oil Ecofluid-M 23.5L
Transfer box lubrication oil SHELL SPIRAX G 80W-90 9L
Drive shaft lubrication oil GL-5 80W/90 Heavy duty gear oil 96L
L-HM46（above 5℃）
Hydraulic oil tank (including
L-HM32（5℃～-15℃）
steering, suspension, and carrier 360L
L-HV22（-15℃～-30℃）
hydraulic system)
No.10 aviation hydraulic oil (below -30℃)
Other positions in carrier 3# lithium base grease 3000g
Note: the filling capacity shown in the table is theoretical value, for actual capacities refer to the
readings at dipstick, inspection apertures and sight glass.
2. Comparison between oil brands abroad and domestic
Table 1-4
Category Fuel Axle gear oil Hydraulic oil
0#, 10#, -10#, -20#, -35#
CNPC GL-5 L-HV22,L-HM32,L-HM46
Light diesel fuel
MOBIL The same Mobilube HD MobilDTE 11M, 13M, 15M
SHELL The same Spirax A Tellus 22, 32, 46
CALEX The same Thuban GL-5EP Rando oil DH32, 46
Yspin AWS 15, 32, 46
CASTROL The same Multitrax 85W/140
Hyspin AWH 15, 32, 46
Transmisssion
TOTAL The same AZOLLAZS32, 46
TM80W/90
BP The same Hypogear EP BartranHV22, Energol HLP -HM32, 46
Notes:
1. Oil and coolant are important design factor, which will affect the operational and
service life of all parts in the vehicle. Please refill them according to stipulations in
Table 1-3.
2. More information will be gained by contacting MTU Benz engine and ZF Transmission
Service centers.

Ⅱ. Trouble diagnosis and solutions

10
Only experienced and trained persons may perform trouble diagnosis, repair and
maintenance. For troubles unable to be solved, we suggest you to contact the service center
of Xuzhou Heavy Machinery Co., Ltd.
(Ⅰ). Drive line
Trouble Cause Remedy
Power is off, fuse broken.
Transmission control lever is not in
neutral.
Find cause and remove fault.
Too low battery voltage.
Engine doesn’t work
Too low oil level in oil tank.
Air in suction pipeline.
Contact MTU Benz engine service station for
Engine inner fault.
repair.
Transmission control lever is in neutral.
Brake unreleased.
Too low air pressure for shift gear. Find cause and remove fault.
The vehicle could
Bad connected signal cables between
not start to drive
engine and transmission.
Contact ZF transmission service station for
Transmission inner fault.
repair.
Too long operating time. Stop immediately for radiating.
Excessive high oil
Breather clogged. Clean or replace the breather.
temperature in
Incorrect oil level. Check oil level, and refill or drain oil.
transmission,
Deteriorated oil. Replace with new oil.
transfer box
Unqualified lubricant. Add lubricant according to stipulation .
Signal transmitting faulty. Contact professional service station for repair.
Speed-jump,
Contact ZF transmission service station for
disorder speed Transmission inner fault.
repair.
Large vehicle Loose connection of propeller shaft. Check and tighten.
vibration Rubber support of engine damaged. Check and replace.

(Ⅱ). Axle and suspension

11
 Problem Cause Remedy
Lubricant level too low. Refill enough lubricant.
Contact professional service station for
Abnormal noise in Improper clearance of gear in drive axle.
repair.
drive line
Contact professional service station for
Parts in axles worn or damaged.
repair.
Oil seal worn, loose or damage. Replace oil seal.
Drain plug loose or lining damaged. Tighten the plug or replace lining.
Lubricant leakage
Breather clogged or damaged. Clean or replace the breather.
Axle case deformed due to overload. Rectify or replace axle case.
Check pneumatic circuit and all air
Insufficient pressure or air for braking
valves.
Insufficient brake Contact professional service station for
Brake drum faulty
force repair.
Improper clearance between brake shoe
Check and adjust.
and brake drum
Too long brake time or frequent brake Stop engine for radiating
High brake drum
Something wrong in lubricant Check lubricant quantity, quality
temperature
Breather clogged. Clear or replace it.
(Ⅲ). Steering system
Problem Cause Remedy
Insufficient tire pressure in single side Inflate until sufficient tire pressure is
tires. gained.
Steering on one side
Leakage in one side of steering gear. Repair the steering gear by expert.
is heavy
Turning valve is not in neutral or blocked
Replace the valve.
by dirt.
Inflate until sufficient tire pressure is
Insufficient tire pressure.
gained.
Incorrect steered wheel location. Adjust.
Friction caused by deformed steering
Rectify or replace.
drive shaft or dented steering column.
Parts in steering linkage deformed,
Refill lubricant or replace parts.
It is heavy to steer excessive friction between ball pins.
Improper pressure in steering hydraulic
Adjust the pressure.
system.
Leakage in steering gear. Repair the steering gear.
Insufficient oil pressure or flow in oil
Repair or replace oil pump.
pump.
Boost cylinder inner leakage or damaged. Repair or replace cylinder.
Large free stroke of Loose matching of the steering wheel and
Tighten loose parts.
steering wheel steering shaft.
Loose connection of steering driving Tighten loose parts.
device.

12
 Loose bolt for fixing steering gear and its
Tighten loose parts.
support.
Parts in steering linkage worn. Replace the parts.
Improper adjustment of steering gear. Adjust or repair the steering gear.
Unequal pressure in left and right tires or
Inflate according to stipulation.
insufficient tire pressure.
Steering gear meshing clearance small,
Adjust clearance or replace shaft.
shaft in steering gear damaged.
Bad return capacity
Insufficient oil pressure or flow in oil
Repair or replace oil pump.
pump.
Matching of steering axle parts too tight. Adjust.
Improper steering axle location. Adjust.
Steering drive line loose. Tighten connecting parts.
Abnormal noise in Steering propeller shaft worn. Replace the propeller shaft.
mechanical control Meshing clearance of steering gear large
Adjust or replace.
system or steering gear damaged.
Steering pull rod ball head loose. Adjust or replace.
Oil level in oil tank is too low. Refill according to stipulation.
Noise in steering Find out how the air enters, repair and
Air entering into oil circuit.
gear or oil pump release air.
during steering Oil tank screen or pipeline blocked. Remove deposit and clean pipeline.
Oil pump worn or damaged. Replace oil pump.
Avoid driving at high speed for a long
Overheating of Excessive oil flow in pump.
time.
steering gear (65℃
Oil flow impeded due to folded oil hose Arrange hoses reasonably or replace oil
more than
or internal blockage. hose.
atmospheric
The time for steering to limit position is
temperature) Avoid the time to be more than 5 seconds.
too long.
Parts in steering system loose or worn. Tighten or replace.
Shimmy motion
Loose steering gear installation. Tighten.
(Ⅳ). Hydraulic system
Problem Cause Remedy
Relief valve faulty. Check.
Outriggers will not Solenoid valve faulty. Check.
extend /retract or Oil cylinder sealing damaged. Replace sealing.
movement is sluggish Pilot operated check valve of jack
Repair or replace.
cylinder doesn’t work normally.
Relief valve pressure setting too low. Readjust.
Pressure too low
Serious leakage in oil pump. Replace oil pump.
Jack retract or extend
Internal leakage in cylinder. Replace sealing or cylinder.
automatically
(Ⅴ). Electric system
Trouble 1 No current in crane and chassis electric systems
13
Analysis: power electric circuit consists of battery, power main switch, breaker F1, starter
switch, power relay coil (control circuit) and main contact (main circuit), breaker F19, generator
and connecting cables. So any problem in one of them will cause no current in crane and chassis
electric systems.
Problem Cause Remedy
No current in battery or connecting Charge the battery or reconnect cable.
cable disconnected.
Breaker F1 blown. Repair or replace.
Starter switch faulty. Repair or replace.
No current in crane and
Breaker F19 blown. Repair or replace.
chassis electric systems
Cables between components broken, Reconnect cables, re-plug in
plug-in comes off. components.
Bad earth. Reground.
Power switch faulty. Repair or replace.
Trouble 2: Starting motor doesn’t work
Analysis: most starting circuit troubles are from starter switch, starting circuit and starting coil.
Solution:
1). Check the correctness and tightness of connections between control modules to start engine
and transmission.
2). Check if there is broken circuit in breakers.
3). Check the condition indication for control modules of engine and transmission.
4). Check if transmission is in neutral.
5). Check the condition of starter switch and starting motor.
Trouble 3: Generator does generate electricity
Solution: Check if it is a mechanical problem or an electric problem.
Mechanical problem: belt or screw loose, generator shaft faulty. Repair or replace.
Electric problem: check with an AVO meter. The voltage from generator should be more than
27V. If the voltage is lower than 27V and no change after increasing accelerator, it means there is
problem in generator. Repair or replace.
Trouble 4: Starting motor burned out
Cause and solution:
a) Starting motor is not parallel with the center of flywheel gear ring, re-install the motor.
b) Starting cable or power cable short circuit, check circuit and repair.
c) Starting motor faulty.
Trouble 5: Instrument panel faulty
Instrument panel circuit includes power, fuse F2, instrument, sensor and ground cable.
Solution:
14
1) Check if there is current in fuse F2 or fuse F2 blown first, and then measure the resistance of
instruments and sensor. If resistance is beyond normal value, replace components.
2) If the pointer of speedometer is proper, but counter doesn’t work, replace speedometer.
Trouble 6: Lamp is not light
Solution:
First, check if there is current in fuse F3 or fuse F3 tripping due to overloading, and then check
switch and bulb. After that check ground cable, plug-in and cables. Repair or replace according
to actual conditions.
Note:
Plug-in is small component which is the most applied in electric system as well as easy to
have trouble. The problem is bad contact or reed cracked or deformed. When any one of
problems occurs, replace the component.

Ⅲ. Braking system
(Ⅰ). XZ130KⅡ Carrier braking system introduction
(1). Service brake:
The service brake is compressed air brake, consisting of two circuits. One is comprised by the
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axles 1, 2 and 4, and the other by axles 3, 5 and 6. There is a double-pointer air pressure gauge
fitted in driver’s cab for real-time indication of braking air pressure in two service brake circuits.
In case the reading indicated by one pointer 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 air-release brake acting on axles 3, 4, 5 and 6. It gives effect on all axles by the
spring-loaded air chambers. After stopping the truck, applying hand brake handle can hold the
truck at original place, and the parking brake indicator lamp on control panel in cab comes on.
This is parking brake. Only with hand brake released and the pressure in 23rd circuit of braking
system more than 0.45Mpa (low pressure warning lamp on control panel in cab goes out) and
hand brake indicator lamp go out, as well as the spring returns to its original place by the force of
compressed air, the parking brake could be released fully. Apply hand brake handle for
emergency brake when service brake does not work. When service brake is damaged and the
vehicle has to be towed, apply hand brake instead of service brake.
(3). Auxiliary brake
Auxiliary brake consists of 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, retarder and service brake may be used simultaneously due
to large momentum at high speed;
 When driving on a long downhill road, after travel speed is set, with retard lever at position
B, the retarder will regulate braking force automatically to hold the setting speed. If brake
efficiency is not sufficient, service brake may be used to lower the vehicle speed.
ABS anti-block braking system is optional in the braking system of XZ130KⅡ. It is used to
prevent locking of a vehicle’s wheels as a result of excessive actuation of service braking system,
and shorten braking distance, especially on slippery roads. For vehicle without ABS fitted, driver
has to perform “intermittent brake” to prevent wheels being locked. For vehicle with ABS fitted,
what the driver should do only is to depress & hold brake pedal and let ABS system control brake
automatically. The use of service brake will not be influenced when the system is invalid.
Note: Do not use the parking brake and the service brake at the same time, otherwise the
braking system will be damaged.

(Ⅱ). XZ130KⅡ Carrier braking scheme (without ABS fitted)

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(Ⅲ). XZ130KⅡ Carrier braking scheme (with ABS fitted)

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 Ⅳ. Carrier hydraulic system
(Ⅰ). Carrier hydraulic pump/motor
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Gear pumps are used in outrigger hydraulic system and radiating hydraulic system. Two gear
motors are used for fan in radiating hydraulic system.
1. Gear pump/motor operating principle
A pair of gears with same parameters matches each other as shown in Fig. 4-1, and is enclosed
within the space consisting of pump body and cover plate (shaft bush or side plate). The gap
formed by the tooth top of gear and inner chamber surface of pump body is very small, the gap
formed by gear end face and cover plate is also very small, so two isolated closed chambers are
formed by gear meshing point along tooth width direction. When the main shaft rotates
clockwise as the figure shown, the enclosed volume on the left side of meshing point becomes
large, thus local vacuum is resulted, and then by the effect of negative pressure the oil in oil tank
enters into the pump, a suction chamber is formed. On the other side, the enclosed volume
becomes less and oil is extruded out, and then an exhaust chamber is formed. This is the sucking
and extruding oil process of gear pump. When the gear pump is rotating continuously, the
volumes of suction chamber and exhaust chamber will change continuously, and then the gear
pump will suck and extrude oil continuously.
The working process of gear motor is the reverse process of gear pump. The active shaft of
gear pump inputs torque, high pressure oil is output from outlet; but gear motor inputs high
pressure oil from suction port, and outputs torque from its active shaft.

Inlet Outlet

Fig. 4-1 Gear pump/motor operating principle diagram

2. Notes on usage of hydraulic pump/motor
Use the hydraulic oil stipulated in Table 1-3.
When oil temperature is below 10℃, let the pump/motor run at idle for a while before operation,
as the following shown:
1). After starting engine, let it run at idle for 3-5 minutes;
2). Press down PTO switch to let outrigger oil pump run at idle for 3-5 minutes without a load
applied;

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3). Operate outrigger control switch.
3. Replacement of hydraulic pump/motor
The oil pump/motor must be replaced if there is something wrong with it. The shutoff valve on
the hydraulic oil tank must be closed first. Pay attention to the contamination of the system to
environment in the process of dismounting and remounting and try to minimize the
contamination, cover oil port with plastic sheeting in time.
After the installation of new oil pump/motor, 2~3 cups of hydraulic oil must be filled. After
the pipelines are connected, refill the tank with hydraulic oil.
Open shutoff valve to let the oil pump/motor run at idle for 10 minutes, and then operations
can be carried out.

Notes:
 During operation, the pump being sucked empty should be avoided, and motor over-
speeding.
 Regularly check the oil level, oil temperature and oil cleanliness.
 Longer service life and satisfactory effect will be gained if use the pump/motor correctly.
(Ⅱ). Pilot operated check valve
(1) Construction and function
Pilot operated check valve consists of two check valves, which allows oil flowing along one
direction, but reverse flow could be realized by hydraulic control.

Fig. 4-2 Pilot operated check valve operating principle and structure diagram
(2) Principle of operation:
Pilot operated check valve operating principle and structure diagram is shown in Fig. 4-2. When
oil flows normally, it flows into B1 from A1. However, when controlled oil is supplied through
port A2, it moves piston which in turn pushes taper valve spindle to open to permit reverse flow,
at this time, oil may flow into A1 from B1.
(3) Common troubles
1) Internal leakage is caused by bad matching between taper face of valve spindle and valve
seat, thus pressure could not be remained.
2) Pressure could not be remained because valve spindle is stuck when it is in fully open
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 position, spring broken or bent excessively.
3) Pilot operated check valve could not be opened due to too low control pressure, stuck valve
spindle, clogged leak orifice or wrong connection.
4) Noise and vibration occur due to excess valve flow.
(4) Dismounting and Remounting
Notes on dismounting: don’t start to dismount the valve until the jack cylinder rods are
retracted fully or are not supported by the ground.
Notes on remounting: tighten bolts according to the tightening torque specified (45-59) Nm.
(5) Disassembly and Reassembly
(1). Sealing ring and backup ring
New parts should be replaced in principle. Coat hydraulic oil or grease before reassembly, pay
attention not to break or damage them when assembling.
(2). Valve, piston
 When inserting them into the valve bore, apply hydraulic oil to them, and keep turning them
while pushing them.
 After the insertion, check them for smooth movement.
(Ⅲ). Solenoid change valve
1. Construction

Fig. 4-3 Solenoid change valve construction

1, 2. Solenoid change valves 3. Relief valve 4, 5 valve blocks

2. Function
Solenoid valve blocks shown in Fig. 4-3 serve to control the extension and retraction of outrigger
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beams and jacks separately, and could prevent them from overload through relief valves.
3. Principle of operation:
Solenoid coils will produce electromagnetic force after being energized, and then solenoid valve
spool is moved by armature through pushrod to control the on and off of oil passages, thus
pressurized oil port P is connected with port A or B, which in turn actuator (hydraulic cylinder) is
extended/retracted, therefore extension or retraction of outrigger beams and jacks are realized.
The solenoid valve with O-type operation characteristic serves to prevent the extension cylinder
from extending during vehicle travel; the solenoid valve with J-type operation characteristic
serves to vent the pressure of pressure valve working oil port after jacks are lowered.
4. Common troubles
1) Normal voltage for controlling electromagnet is 24±2.4V. If the voltage is too low, the
direction change of valve spool could not realized due to insufficient electromagnet thrust; if
the voltage is too high, or bad insulated coil, the solenoid coil will be burnt.
2) Valve spool is stuck, so valve spool does not change direction even if the electromagnet is
energized, or the electromagnet is de-energized, valve spool does not return.
3) Oil leakage due to aging or damaged O-ring.

Table for movements of outriggers and electric cable codes

Jack cylinder extending /retracting Outrigger beam cylinder extending /retracting

Front left Front right Rear left Rear right Front left Front right Rear left Rear right
-Y14 -Y14 -Y14 -Y14 -Y14 -Y14 -Y14 -Y14
Codes of cables
-Y10 -Y12 -Y11 -Y13 -Y6 -Y7 -Y8 -Y9
powered

When both electric circuits each column shown in the table above are powered, the movement of
corresponding outrigger may realized normally.
(Ⅳ) Hydraulic oil cylinder
1. Jack cylinder
Dismounting and remounting
Note on dismounting: stop the engine and manipulate the jack control lever several times in
order to release any residual pressure within the hydraulic devices and piping.
Notes on mounting:
(1) Coat coupling face with grease.
(2) The tightening torque for mounting bolts is 540-650Nm.
2. Extension cylinder
Dismounting and remounting
Note on dismounting: stop the engine and manipulate the outrigger beam control lever several
times in order to release any residual pressure within the hydraulic devices and piping.
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Notes on mounting:
(1) Coat coupling face with grease.
(Ⅴ) Maintenance for carrier hydraulic system
1. Clean or replace oil filter
Hydraulic system is subject to be contaminated, so suction filter and return filter are fitted on
hydraulic tank in order to ensure normal working and a clean hydraulic system. Suction filter and
return filter are the places where dust is likely to accumulate. Excessive contamination will
influence filter flow and normal hydraulic system running. Clean filter after first 100 working
days for a new vehicle with gasoline and polyester cloth or silk, afterwards clean every 300
working days. If there is damage found in the filter, replace it with a new one.
2. Filter or replace hydraulic oil, clean oil tank
Whenever oil becomes excessively contaminated, filter or replace it even before the scheduled
filtration or replacement time. Refer to Table 1-3 for hydraulic oil brands and filling amount.
Refer to Table 4-1 for the judgment method of hydraulic oil contamination.
Table 4-1 Visual observation of oil contamination
Oil color Oil odor Possible oil contamination Treatment
Transparent Normal No contamination Continue to use
Further lab analysis needed or change
Transparent but darken Normal Mixed other oils
oil
Transparent but flashing Normal Mixed metal particles Filtrate or change oil
Transparent with darken
Normal Mixed metal particles Filtrate or change oil
spots
Black brown Smelly Oxidized Change oil
Cream white Normal Mixed with air or water Separate waste or change oil

Note:
Clean the oil tank before replacing hydraulic oil in order to avoid the contamination of
liquid oil.
The method is as follows:
1) Remove the plug under the hydraulic oil tank, and drain out the oil completely;
2) Clean the inside of the tank with gasoline, and clean the inner walls of the tank with brush;
3) After cleaning, put the tank at a shady and ventilating place for a while. When gasoline has
volatilized completely, same brand hydraulic oil can be filled into the tank.

(Ⅵ). XZ130KⅡ Carrier hydraulic scheme

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 Ⅴ. Carrier electric system
The rated voltage of electric system is DC 24V, and single cable with negative ground. Refer
24
to carrier electric system principle diagram (1) for the system layout.
Explanation of electric schemes:
1) In every page, there are 6 districts (A-F) from top to bottom, and there are 8 districts (1-8)
from left to right. Look for components according to every district, for example, “3/1A”
indicates that the component is in the coordinate intersection of 1st district and A district on
page 3.
2) One wire code indicates one line. Lines with same wire code have same function.
3) “⊥” indicates circuit cathode.
4) Refer to Fig. (20) for components key, symbols explanation and fuses distribution.

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28
29
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32
33
34
35
36
37
38
39
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42
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44
45
 Ⅵ. 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 fixed on steered wheels.
2. Rim inspection: The rim is one of the important parts in truck traveling system. When
changing the wheels, the following items should be checked:
(1) Rim rustiness;
(2) Rim 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.

Caution: neither weld 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.6-1.
Order for transposing tires is as follows:
1→6→15→17→16→5→2→3→4→1;
7→13→11→9→14→8→10→12→7.

Fig. 6-1 Tire transposition reference diagram

46
(2). Do not scratch bolt thread when replace wheels. No painting, grease and other dirty on the
coupling face between brake drum and rim.
(3). Keep pressing faces of wheel nuts clean.
(4). Coat threads of wheel bolts and nuts with a little grease, oil or other anti-engaging agent.
(5). 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.
(6). After tires are remounted, retighten wheel nuts once every 50km of traveling according to
stipulations.

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 VII. Tightening torque of main bolts and nuts
Table 7-1
Tightening torque
No. Name Remarks
(N.m)
1 Tire nuts 600~660
2 Suspension pushrod clamping bolts 264.6~323.4 Coat with thread sealant
3 Suspension pushrod tightening bolts 380~450 Coat with thread sealant
4 Suspension U-bolt 300~350 Coat with thread sealant
Connecting bolts and nuts of propeller
5 180~210 Self lock nut
shaft flange M14×1.5
6 Steering gear tightening bolts 333.2~450.8 Coat with thread sealant
Fixing bolts of engine front suspension
7 380 Coat with thread sealant
M20×50
Fixing bolts of engine front suspension
8 100 Coat with thread sealant
M12×1.5×30
Connecting bolts of engine flywheel casing
9 45~59 Coat with thread sealant
M10×70
Connecting bolts of clutch pressure plate
10 45~59 Coat with thread sealant
M10×90

Notes about tightening torque of bolts and nuts:

1. Engine flywheel casing and transmission housing are aluminum casting parts, so the
tightening torque of connecting bolts and plugs for them should comply with the
requirements in their instructions.
2. For the tightening torque of bolts and nuts not specified in the table above, the
corresponding value of 8.8 class should be adopted according to the requirements of
Appendix A in JB/T5945-1991 General Technical Specifications for Construction Machinery
Installation. The corresponding value of 5.6 class should be adopted for the tightening
torque of bolts for less important connecting parts such as hose clip, etc.

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 VIII. Main parts
Table 8-1 XZ130KⅡMain parts list

Mark
No. Code Name Manufacturer
certified
1 800100202 Engine MTU Germany
2 819904297 Transmission ZF Germany
3 819904298 Transfer gear ZF Germany
4 138900244 Propeller shaft Xuchang Yuandong Propeller Shaft Co., Ltd.
138900506
138900507 Xuzhou Meritor Axle Co., Ltd.
5 139100610 Axles
139100671
KESSLER Germany
139100669
Jiangmen Xingjiang Steering Gear Co., Ltd.
6 803000662 Steering gear
Nantong Huanqiu Steering Gear Co., Ltd.
7 130000099 Cab Hubei qixing cabin manufacturing Co., ltd.
8 138900526 Radiator AKG (Taicang) Co., Ltd.
9 800100228 Air filter Mann-hummel
10 138900527 Muffler Danyang Changjiang Auto Mobile Part CO., Ltd.

11 800300538 Tire Double Coin 3C

12 803002269 Radiating oil pump PERMCO (Tianjin) Hydraulic INC., LTD.
13 803000320 Outrigger oil pump Xuzhou Keyuan
14 803001066 Fan motor PERMCO (Tianjin) Hydraulic INC., LTD.
15 800900013 Four-way protection valve Shandong Mingshui

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XUZHOU HEAVY MACHINERY CO., LTD.
XUZHOU CONSTRUCTION MACHINERY GROUP CO., LTD., CHINA
Add：No.165 Tongshan Road, Xuzhou, Jiangsu Province, China
Tel：0086-0516-83462242, 83462350
Fax：0086-0516-83461669
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 December, 2009