GENLYON- KINGKAN
BODYBUILDERS INSTRUCTIONS SAIC-IVECO HONGYAN
ISSUE2013 IVECO S.p.A. Technical Application Strada delle Cascinette, 424/34 10156 Torino (TO) - Italy www.iveco.com Printed 603.95.640 -1st ed. 09/2013 GENLYON - KINGKAN Bodybuilders instructions Printed 603.95.640 - 1st ed. Base - 09/2013
UPDATE DATA
Section Paragraph Description Revision date
Update data
Printed 603.95.640 Base - 09/2013 Update data Base - 09/2013 Printed 603.95.640 Notes
This document is compiled from technical data for Hongyan Genlyon and Hongyan Kingkan products from SAIC-IVECO HONGYAN Commercial Vehicle Company (hereinafter referred to as ’our company’); national regulations and standards for motor vehicles; the IVECO STRALIS and IVECO TRAKKER refitting guides; and the ’Hongyan STEYR Guide to Refitting (2005)’. This document provides specific guidance for refitting factories on how to refit a Hongyan Genlyon or Hongyan Kingkan, methods for measuring key dimensions, and relevant parameters for chassis and assemblies for certain vehicle models. In addition to this docu- ment, readers should also refer to the latest versions of compulsory national standards such as GB 7258 ”Safety specifications for power-driven vehicles operating on roads” and GB1589 ”Limits of dimensions, axle load and masses for road vehicles” in designing arefit. This document contains parameters relevant to refitting our mainstream chassis. However, due to the fact that Genlyon products are constantly being improved, some information contained herein may not be up to date. Should you require more specific technical parameters during the refitting design or manufacturing process, please contact your local sales representative or technical staff from our Sales Division or R&D Centre. Please note that our company is happy to provide information on how to refit our products as required, and also to give guidance on refits that are not covered in this document. If you have any suggestions regarding this document,pleasefeelfreetocontactthe relevant department of our company.
Warning signs If you have any suggestions regarding this document,pleasefeelfreetocontactthe relevant department of our company.
Warning! ! Ignoring or not fully complying with these instructions may cause severe damage to the vehicle the loss of entitlement to warranty services (repair, replacement, and return), and also injury to yourself.
Notes
Printed 603.95.640 Base - 09/2013 Notes
Base - 09/2013 Printed 603.95.640 TABLE OF CONTENTS
Section
General Rules
Chassis Parameters 1
Parameter Settings 2
Refitting the Chassis 3
Structure and Installation of the Body 4
Refitting Special Vehicles 5
Power take-off 6
Points for Attention during the Refitting of China IV Emissions Standards Vehicles 7
Appendix A - Relevant special vehicle standards A
Table of contents
Printed 603.95.640 Base - 09/2013 Table of contents
Base - 09/2013 Printed 603.95.640 I GENLYON - KINGKAN GENERAL RULES
SECTION General Rules
Page
1 Basic refitting principles III
2 GB 1589-2004 body refit regulations (see Standard for more details) VII
3 Product coding rules IX
4 Selecting the chassis XII
Printed 603.95.640 Base - 09/2013 II GENERAL RULES GENLYON - KINGKAN
Base - 09/2013 Printed 603.95.640 III GENLYON - KINGKAN GENERAL RULES
This document provides guidance on how to build a special vehicle using chassis made by our company, such as the Hongyan Genlyon or Hongyan Kingkan chassis.Intended for skilled personnel from refitting factories, it provides the necessary technical data and relevant principles for certain refittings.Read this document carefully before refitting a vehicle, and strictly comply with the rules herein in the course of refitting a vehicle.In the case that the rules do not apply to a specific vehicle, please contact our staff before taking any action. The refitting factory shall be responsible for the complete vehicle that it designs and refits. Purpose of this document:This document aims to guide refitting factories in the refitting of vehicles and the design, manufacture, and installation of bodies, while ensuring that the performance of refit vehicles and various systems are not affected, and while ensuring the safety and reliability of complete vehicles. Basic refitting principles
1 Basic refitting principles
1. Approval principles To build a special vehicle, one usually needs to refit the chassis by modifying some of the assemblies and relocating some parts, unless the chassis is specialized or specially designed and made for a user. Such modifications are broad in scope and may involve:changing the speed limiter;increasing or decreasing the wheel base;relocating the beam, pipelines, batteries, and fuel tanks;strengthening the frame;or mounting devices such as power take-offs, where necessary. Before making the aforementioned modifications or when undertaking refitting work not covered in this document, please first provide the necessary explanations or technical documents to our R&D Centre, so as to enable us to evaluate whether the refit is appropriate.
The refitting factory should never modify our products without receiving formal approval from our company. ! If, during a refit without our approval, a chassis is damaged due to the unsuitability of the body, the refitting factory shall be responsible for all damage caused by the refit (including losses by end users). Meanwhile, our company shall not undertake any economic or legal responsibilities for such losses.
2. Technical materials for approval should contain the following information: Purpose and service condition of the vehicle General drawing of the body, including body dimensions, or dimensions of parts to be refitted and those of new devices Centre of gravity of the body and that of the payload, a list of weights of body components, indicating their centres of gravity, when necessary Rear overhang of the body and that of the complete vehicle Total length, width, and height of the complete vehicle Technical documents relating to the attachment between the chassis and the body and that between the lower edge of the body floor (considering maximum wheel jump height) and the chassis, and other structures that may affect the chassis Structure and dimensions of the subframe, and how this is mounted on the chassis Force and torque of such devices as a crane, cement mixer, winch, or concrete pump
3. Approval for technical documents only covers the technical feasibility for refitting our vehicles. The refitting factory shall be responsible for: The structure of refitted chassis and/or bodies Selecting products and their features The industrial process for making and mounting refitted chassis and/or bodies Ensuring that refitted chassis and/or bodies and relevant actions comply with regulations in our refitting guides Ensuring that refitted chassis and/or bodies and relevant actions comply with current national regulations on motor vehicles The performance, safety, reliability, and maintainability of refitted vehicles, and the effects of the refit and installation on perform- ance and technical parameters of such vehicles
Basic refitting principles
Printed 603.95.640 Base - 09/2013 IV GENERAL RULES GENLYON - KINGKAN
4. The refitting factory must guarantee to fully comply with technical regulations in this guide, and to design and refit vehicles to a professional standard. Our company has the right to deny warranty services on a refitted vehicle in the following instances: The refitting factory violates technical regulations, or installs devices not approved by our company; or a refit is not approved by us. The chassis does not fit the device, or is inappropriate for the intended purpose of the vehicle. Our technical specifications, standards, or notes are violated. Authentic spare parts or components specially made by our company for a refit are not used.
5. Prohibition principles The overall dimensions for refitted road vehicles should comply with relevant regulations in GB 7258 ”Safety specifications for power-driven vehicles operating on roads” and GB1589 ”Limits of dimensions, axle load and masses for road vehicles”. To ensure the safety and manoeuvrability of a vehicle, the following items are in principle not to be modified: Wheelbase of the chassis Specifications and layout of major assemblies such as the engine, driver cab, transmission, and axle Steering system of the chassis Braking system and brakes of the chassis Suspension on the chassis Suspension and tilt devices on the driver cab Electrical and electronic systems on the chassis
The aforementioned items may be modified only after relevant refit plans have been signed and approved by our R&D ! Centre.
6. Refit design principles In a refit design, the kerb mass should not exceed the maximum permitted gross vehicle mass, and the following principles should be followed in setting the centre of gravity of the body: The centre of gravity should be as low as possible; the maximum tilt angle should comply with relevant regulations in GB 7258; and sufficient space should be saved for wheel jump. The load should be evenly distributed; the maximum axle load should comply with regulations in this document; and the load difference between left and right tyres should be no more than 3%. When running at a low speed and in good working conditions, a special vehicle may have a moderate extra load, though it is best to stay within the maximum axle load. Adjust the automatic load sensing valve accordingly after a refit, if the vehicle has such a valve. The axle load should not exceed the limits given in relevant regulations, and the load should be evenly distributed, rather than being concentrated on one side. Whatever the load, the front axle load is crucial to ensuring correct steering in any road condi- tions. In all events, the front axle load should be more than 20% of the current gross vehicle mass. Special attention should be paid to vehicles with weights concentrated on the rear suspension, with small wheel tracks, and with a high centre of gravity (for example, a cement mixer). For such a vehicle, the front axle load should be more than 25% of its current gross vehicle mass. For an empty semi-trailer truck, the drive axle load should be more than 25% of its kerb mass. In the case that a tail lift device is installed, the front axle load should be at least 30% of the kerb mass. For a special vehicle running at a low speed and in good working condition, the axle load may be large, but without affecting the braking system. To achieve the upper limits specified in relevant regulations, ensure that the centre of gravity of the body and that of the payload are the same when the payload is evenly distributed. To obtain correct axle load data, it is recommended that you measure the axle load of the chassis before a refit, and measure the axle load of an empty vehicle and that of a vehicle with a full load, respectively, after a refit.
Basic refitting principles Base - 09/2013 Printed 603.95.640 V GENLYON - KINGKAN GENERAL RULES
7. Instructions for correctly operating and maintaining vehicle components In principle, any refit or installation of any device should not hamper the proper operation of assemblies or components under any working condition. Ensure easy access to all parts that need check-ups or regular maintenance (such as the lubrication points, fuel filling hole, observa- tion hole, battery, and driver cab tilt fuel pump). Appropriate service lids must be available on a box body. If the driver cab can be tilted, maintain sufficient space for the tilt.If the upper part of the driver cab has to be modified, maintain sufficient space for an air inlet passage (see picture 0-1). Ensure easy maintainability for chassis and transmission components.For instance, the gearbox or clutch can be repaired without removing any added major components. Do not modify the cooling system (e.g. radiator cover, radiator, air passage, and cooling circuit), fuel supply (e.g. position of pump, fuel filter, and fuel pipe), or engine air intake. To maintain the approved noise level, do not modify or relocate the sound deadening panel.If a hole must be drilled in this panel (for example, in order for the body under-frame longitudinal beam to pass through), use identical fire retardant and sound dead- ening materials to fill the hole. Ensure good ventilation inside the brake box and battery box (especially on a canopy truck). Ensure that rear wheels can move freely with splash guards, wheel arch, and anti-skid chains. Sufficient space should also be saved for a raised axle. Some vehicles are equipped with self-steering axles and are able to turn when the axles are raised. Space should also be allowed for such a function (see Section 7 of Chapter 4). After assembling a vehicle, check the status of headlamps and adjust these according to instructions in the maintenance guide, in the interest of safety. If knockdown delivery is used for some components (such as spare wheels and chocks), the refitting factory shall be responsible for fixing them safely at a position with easy access, according to relevant national regulations. Prompt signs for using the vehicle correctly should not be damaged or obstructed by the body.
Maintain the proper operation of components and the vehicle. ! For all approved refits and applications, please ensure that the various components of the vehicle can operate properly, and that these components comply with relevant national and international standards, as well as accident prevention standards.
8. Do not damage any chassis parts during a refit, especially rubber and plastic parts. When exposed to heat, parts such as the seats, interior trim, sealing parts, and modesty panel may catch fire.These parts should therefore be removed before welding or flame cutting. 9. Do not modify the trademark, logo, or name when designing the body or refitting the vehicle. The body should not obstruct the visibility of the trademark, nameplate, or labels. Do not change the appearance of the vehicle. Trademarks shall not be used without prior authorization from our company, and should never be placed beside our original trademark or emblem. If a refit or installation is not up to standard, our company has the right to retract our trademark and emblem, with the refitting factory to take responsibility for the complete vehicle. 10. Legal regulations and accident prevention After a refit, the refitting factory must check that the refitted chassis, body, and devices comply with relevant national regulations (such as those regarding weight, dimensions, brakes, noise, and emissions). All vehicles manufactured by our company comply with compulsory national standards and regulations.Refitted vehicles must also comply with such regulations.
Accident prevention ! Any structures or device mounted on the vehicle must comply with accident prevention regulations and safety regulations in the country in which the vehicle is used. Various technical prevention measures must be taken to prevent accidents occurring with the vehicle or its components, or defects in function. It is the duty of the structure and device maker and refitting factory to comply with these regulations.
Basic refitting principles
Printed 603.95.640 Base - 09/2013 VI GENERAL RULES GENLYON - KINGKAN
Warning! ! When exposed to heat, parts such as the seats, interior trim, sealing parts, and modesty panel may catch fire. These parts should therefore be removed before welding or flame cutting.
11. Vehicle handover Before handing over a vehicle to the user, the refitting factory should check the following items: All required devices are correctly mounted. The vehicle and devices can be used at any time, with all functions working properly. The performance and safety of the vehicle and/or devices meet relevant criteria. The vehicle comes with all documentation relating to added devices, their maintenance guides, and complete lists of parts (if necessary). New data is marked on relevant signs (if applicable). When handing over a vehicle to the user, the refitting factory must provide maintenance guides for added devices and complete lists of parts (if necessary).
Basic refitting principles Base - 09/2013 Printed 603.95.640 VII GENLYON - KINGKAN GENERAL RULES
GB 1589---2004 body refit regulations (see Standard for more details) 2 GB 1589-2004 body refit regulations (see Standard for more details)
Maximum permitted length:
Total length of 2-axle cargo truck: 9 m Total length of semi-trailer truck: 16,5 m Total length of 2-axle box truck: 10 m Total length of trailer truck: 20 m Total length of 3-axle truck and above: 12 m Maximum permitted width:2.5 m, 2.55 m for box truck Maximum permitted height:4 m (empty) Maximum axle load (single axle) (kg)
Vehicle type Maximum permitted axle load Trailer and 2-axle cargo truck Single tyre on each side 6000 Doubletyresoneachside 10000 Bus, semi-trailer tractor truck, and 3-axle Single tyre on each side 7000 cargo truck and above (including 3-axle) Double tyres Non-drive axle 10000 on each side Drive axle 115000
Maximum axle load (tandem axle) (kg)
Vehicle type Maximum permitted axle load Wheelbase for tandem axle <1000 mm 11500 Wheelbase for tandem axle 1000 mm and 16000 Truck 2tandemaxle <1300 mm Wheelbase for tandem axle 1300 mm and 18000 <1800 mm Wheelbase for tandem axle <1000 mm 11000 Wheelbase for tandem axle 1000 mm and 16000 <1300 mm 2tandemaxle Wheelbase for tandem axle 1300 mm and 18000 <1800 mm Trailer Wheelbase for tandem axle 1800 mm 20000 Distance between two adjacent axles 21000 <1300 mm 3tandemaxle Distance between two adjacent axles 24000 1300 mm and 1400 mm
GB 1589-2004 body refit regulations (see Standard for more details)
Printed 603.95.640 Base - 09/2013 VIII GENERAL RULES GENLYON - KINGKAN
Maximum gross vehicle weight limits:
Maximum limit for Minimum limit for Vehicle type maximum gross maximum gross vehicle weight vehicle weight Semi-trailer tractor 2-axle semi-trailer tractor truck 18000 - truck 3-axle semi-trailer tractor truck 25000 Truck 2-axle cargo truck 16000 - Cargo truck 3-axle cargo truck 25000 16000 4-axle truck with two steer axles 31000 24000 1-axle trailer 18000 10000 Semi-trailer 2-axle trailer 35000 19000 3-axle trailer 40000 28000 2-axle trailer, with single tyre on 12000 8000 Trailer each side of axle 2-axle trailer, with single tyre on one Other trailer side of axle, and double tyres on 16000 11000 other side 2-axle trailer, with double tyres on 20000 14000 each side of axle Truck comprising 2-axle tractor truck 27000 and 1-axle trailer Truck comprising 2-axle tractor truck 35000 Tractor truck and 2-axle trailer - 5-axle tractor truck 43000 6-axle tractor truck 49000
GB 1589-2004 body refit regulations (see Standard for more details) Base - 09/2013 Printed 603.95.640 IX GENLYON - KINGKAN GENERAL RULES
Product coding rules 3 Product coding rules
1. Constituents of Hongyan product model The Hongyan product model consists of the company name code, vehicle type code, major parameters code, product serial number, and company custom code. The company custom code follows the following standard, while the remaining codes comply with GB9417 regulations.
Company custom code Product serial number
Major parameters code Vehicle type code
Company name code ’CQ’
2. Company custom code The company custom code consists of (in sequential order) the driver cab assembly code, engine assembly code, suspension code, wheelbase code, drive type code, frame height code, frame width code, and other characteristics code (may be omitted if no other characteristics are involved).
2.1) Driver cab assembly code
Driver cab assembly code Driver cab model (flat roof) Driver cab model (raised roof) QXPW4C (Suizhou) / TQ QXPW4C -A (Suizhou) QXPW4C -A (Suizhou) CP8150G (Changsha) / TC CP8150G -A (Changsha) CP8150G -A (Changsha) S Updated version of T model driver cab Hongyan Bawang standard (for Hongyan brand product) Hongyan stretch and raised roof (for Hongyan T2 Hongyan Bawang stretch (for Hongyan brand brand product) product) T8 XinDaKang (QXPW21C (Suizhou)) XinDaKang (QXPW21C(Suizhou)) T14 XinDaKang (QXPW21C (Suizhou)) B Steyr standard driver cab (for Star-Steyr products) L Steyr stretch driver cab (for Star-Steyr products) X1 Steyr King standard driver cab (for Star-Steyr products) X2 Steyr King stretch driver cab (for Star-Steyr products) X3 Steyr King stretch and raised roof driver cab (for Star-Steyr products) H1 Genlyon driver cab with raised roof, long driver cab, low engine hood, and no rear window H2 Genlyon driver cab with flat roof, long driver cab, low engine hood, and no rear window
Product coding rules
Printed 603.95.640 Base - 09/2013 X GENERAL RULES GENLYON - KINGKAN
Driver cab assembly code Driver cab model (flat roof) Driver cab model (raised roof) H3 Genlyon driver cab with flat roof, short driver cab, high engine hood, and no rear window H4 Genlyon driver cab with flat roof, long driver cab, high engine hood, and no rear window H5 Genlyon driver cab with flat roof, short driver cab, low engine hood, and no rear window H6 Genlyon driver cab with flat roof, short driver cab, high engine hood, and rear window H7 Genlyon driver cab with flat roof, short driver cab, low engine hood, and rear window H8 Genlyon driver cab with raised roof, long driver cab, high engine hood, and no rear window H9 Genlyon driver cab with flat roof and four doors Genlyon C100 driver cab with raised roof, long driver cab, low engine hood, and no rear M1 window M2 Genlyon C100 driver cab with flat roof, long driver cab, low engine hood, and no rear window M3 Genlyon C100 driver cab with flat roof, short driver cab, high engine hood, and no rear window M4 Genlyon C100 driver cab with flat roof, long driver cab, high engine hood, and no rear window M5 Genlyon C100 driver cab with flat roof, short driver cab, low engine hood, and no rear window M6 Genlyon C100 driver cab with flat roof, short driver cab, high engine hood, and rear window M7 Genlyon C100 driver cab with flat roof, short driver cab, low engine hood, and rear window M8 Genlyon C100 driver cab with raised roof, long driver cab, high engine hood, and no rear window New Kingkan and Genlyon M100 driver cab with flat roof, long driver cab, high engine hood, and C4 rear window New Kingkan and Genlyon M100 driver cab with flat roof, short driver cab, high engine hood, and C6 rear window New Kingkan and Genlyon M100 driver cab with raised roof, long driver cab, high engine hood, and C8 rear window Genlyon C100 light dump truck driver cab with flat roof, short driver cab, high engine hood, and N3 no rear window Genlyon C100 light dump truck driver cab with flat roof, long driver cab, high engine hood, and no N4 rear window Genlyon C100 light dump truck driver cab with flat roof, short driver cab, high engine hood, and N6 rear window Genlyon C100 light dump truck driver cab with raised roof, long driver cab, high engine hood, and N8 no rear window DT Low T model driver cab RT XinDaKang RHD driver cab R1 Genlyon RHD driver cab
Product coding rules Base - 09/2013 Printed 603.95.640 XI GENLYON - KINGKAN GENERAL RULES
2.2) Engine supplier code
Code Engine supplier Code Engine supplier C Chongqing Cummins Engine Co., Ltd. D Shanghai Diesel Engine Co., Ltd. E Dongfeng Cummins Engine Co., Ltd. H Hangzhou Engine Co., Ltd K Cummins Engines Company R Shanghai Hino Engine Co., Ltd. V SAIC-FIAT-HONGYAN (SFH) W Weichai Power Co., Ltd. Y Guangxi Yuchai Machinery Co., Ltd
2.3) Rear suspension code A - Air suspension E - Rubber spring suspension G - Multi-leaf spring S- Mono-leafspring
2.4) Wheelbase code The code for the wheelbase is ’dm’. In multi-axle vehicles, the wheelbase is the round value of the distance (mm) between the centres of the adjacent drive and steer wheels, divided by 100.
2.5) Drive type code
Drivetypecode Drive type Drivetypecode Drive type 1 4x2 2 4x4 3 6x2 4 6x4 5 6x6 6 8x4 7 8x8 8 8x2 9 10x4 0 12x4
2.6) Cross-sectional frame height code
Cross-sectio Cross-sectio nal frame Cross-sectional frame height nal frame Cross-sectional frame height height code height code C 243 mm (8+5 mm) D 280 mm (8+5 mm) E 305 mm (8 mm) F 305 mm (10 mm) G 317 mm (8+8 mm) H 325 mm (8 mm) T 380 mm (10+10 mm) S 305 mm (8+4 mm)
2.7) External frame width code
External External frame width External frame width frame width External frame width code code P 780 mm K 865 mm Front width: 940 mm. Front width: 940 mm. A B Rear width: 780 mm Rear width: 865 mm W 1120 mm
Product coding rules
Printed 603.95.640 Base - 09/2013 XII GENERAL RULES GENLYON - KINGKAN
2.8) Other characteristic code
Other Other characteristic Other characteristic characteristic Other characteristic code code Variable speed vehicle A Automatic transmission B (e.g. China II emissions standard engine from Hangzhou Engine Co., Ltd) J Military vehicle M Mixer chassis T Natural gas vehicle X Fire truck chassis Z Special vehicle chassis
We will create new codes for other characteristics as new products are developed.
3. Hongyan internal vehicle code example
CQ4254H1V34S324EA
Other characteristic code (can be omitted) External frame width code (front width 940 mm, rear width 780 mm) Cross-sectional frame height code (305 mm (8 mm)) Drivetypecode(6x4) Wheelbase code (3225 mm) Rear suspension code (mono-leaf spring) Engine assembly code (C9-340) (’V’ indicates an engine from SFH) Driver cab assembly code (Genlyon raised roof, long driver cab) Product serial number (indicates China IV emissions standard) Major parameters code (Gross vehicle weight = 25 tons) Vehicletypecode(tractortruck) Company name code (’CQ’)
’CQ4254H1V34S324EA’ indicates the following: Semi-trailer tractor truck with raised roof, long driver cab, low engine hood, and no rear window; gross vehicle weight 25 t; China III emissions standard C9 340 engine; mono-leaf spring; wheelbase between first and second axles 32 dm; drive type 6x4; frame height 305 mm, thickness 8 mm; frame front width 940 mm, rear width 780 mm. In this vehicle code, ’CQ’ is the company name code; ’4’ stands for ’semi-trailer tractor truck’; ’25’ indicates a gross vehicle weight of 25 t; ’4’ is the product serial number (China III emissions standard engine); ’H1’ stands for ’Genlyon driver cab with raised roof, long driver cab, low engine hood, and no rear window’; ’V34’ stands for C9 340 engine; ’S’ stands for ’mono-leaf spring’; ’32’ indicates a wheelbase between the first and second axles of 32 dm; ’4’ indicates a drive type of 6x4; ’E’ indicates a frame height of 305 mm and longitudinal beam thickness of 8 mm; and ’A’ indicates a frame front width of 940 mm and rear width of 780 mm. Selecting the chassis
4 Selecting the chassis
Selecting the right chassis is crucial to a successful refit. Before refitting a vehicle, check the order specifications and technical documents provided by the manufacturer to make sure that you have received the exact chassis you ordered.
Selecting the chassis Base - 09/2013 Printed 603.95.640 1-1 GENLYON - KINGKAN CHASSIS PARAMETERS
Index
SECTION 1 Chassis Parameters
Page
1.1 Chassis appearance drawing ...... 1-3
1.2 Chassis parameters ...... 1-4
1.3 Frame structure ...... 1-5
1.4 Wheel jump height ...... 1-6
1.5 Rear overhang ...... 1-7
1.6 Location for installing a lift oil pump on a dump truck ...... 1-9
Index
Printed 603.95.640 Base - 09/2013 1-2 CHASSIS PARAMETERS GENLYON - KINGKAN
Index Base - 09/2013 Printed 603.95.640 1-3 GENLYON - KINGKAN CHASSIS PARAMETERS
Chassis appearance drawing If you plan to refit any of our chassis, such as the Hongyan Genlyon or Hongyan Kingkan, our company can provide you with the following information through the Internet or by other means: chassis appearance drawings;chassis parameters;centre of gravity height for chassis with driver cab (e.g. drawings of such chassis); Mmaximum fully loaded centre of gravity height (national type approval document); and braking capability of each axle (e.g. brake data).
1.1 Chassis appearance drawing
For appearance drawings of chassis (for classic vehicles such as the tractor truck, dump truck, and mixer) for the Hongyan Genlyon, Hongyan Kingkan and other such vehicles, please refer to our external-use chassis drawings.
Chassis appearance drawing
Printed 603.95.640 Base - 09/2013 1-4 CHASSIS PARAMETERS GENLYON - KINGKAN
Chassis parameters
1.2 Chassis parameters
We provide technical parameters relevant to refitting such vehicles as the Hongyan Genlyon in technical materials such as external-use chassis drawings. Please contact our local Sales and Service Centre, Sales Division Technical Department or R&D Centre to obtain external-use chassis drawings, which contain detailed parameters relevant to refits. The aforementioned drawings and technical materials contain details of dimensions and maximum permitted axle loads, while our official company documents contain further details of such technical information. Kerb mass refers to the total weight of a vehicle with standard equipment. Special equipment may significantly change kerb mass and its distribution among axles. Due to production factors, the chassis weight may vary by up to +/- 5%. Therefore, before mounting a body and equipment or confirming the axle load, please check the weight of the chassis with driver cab and its distribution among axles.
Chassis parameters Base - 09/2013 Printed 603.95.640 1-5 GENLYON - KINGKAN CHASSIS PARAMETERS
Frame structure
1.3 Frame structure
Figure 1.1 shows the major frame structure for the Hongyan Genlyon, Hongyan Kingkan and other vehicles. You will find frame-related parameters in our technical materials, such as external-use chassis drawings. The front axle central line and balance (rear) axle central line should be taken as the benchmark for mounting various assemblies.
Frame structure
Printed 603.95.640 Base - 09/2013 1-6 CHASSIS PARAMETERS GENLYON - KINGKAN
Wheel jump height
1.4 Wheel jump height
The maximum wheel jump height is measured from the upper frame surface, as shown in Figure 1.2. The values for various models of vehicles can be found in Appendix C. The tabular data provided indicates the minimum space required for wheel jump. An extra 45 mm is required when an anti-skid chain is mounted.
Wheel jump height Base - 09/2013 Printed 603.95.640 1-7 GENLYON - KINGKAN CHASSIS PARAMETERS
Rear overhang
1.5 Rear overhang
’Section 4.3: Rear Overhang’ of the GB7258-2012 ”Safety specifications for power-driven vehicles operating on roads” stipulates that: ’For a bus, box truck, or tank truck, the rear overhang must not exceed 65% of the wheelbase. For a special motor vehicle or wheeled machinery truck, the rear overhang may follow the relevant regulations for a bus, provided that these are safe. For other motor vehicles, the rear overhang of other vehicles cannot exceed 55% of their wheel base. The rear overhang of a motor vehicle should not exceed 3.5 m. For a multi-axle motor vehicle, the wheelbase is the distance between the centres of the first front and last rear axles, while the rear overhang is calculated from the central line of the last rear axle. For an articulated bus, the wheelbase is the distance between the centres of the first front and second axles. For a bus, the rear overhang is calculated from the exterior body panel, or from the bumper bar when this lies beyond the rear body panel, but excluding the rear ladder. When modifying the rear overhang of a vehicle or chassis, its must be remembered that the axle load distribution will change after such modification. The refitted vehicle must comply with national regulations in terms of minimum ground clearances and the distance between the rear edge of the chassis and that of the body. In principle, the distance between the rear edge of the chassis and that of the body should not exceed the range 350 mm-400 mm.
Figure 1.1
Front axle central line Balance (rear) axle central line
xxx
Wide front and narrow rear frame Height Front width Rear width Height Frame width
198148 Genlyon, Kingkan and Steyr frame assembly
NOTE 1. For two-steer-axle vehicles, the front axle central line is the central line of the first front axle. 2. For single-rear-axle vehicles, the balance axle central line is the central line of rear axle.
Rear overhang
Printed 603.95.640 Base - 09/2013 1-8 CHASSIS PARAMETERS GENLYON - KINGKAN
Figure 1.2
198149 Maximum wheel jump height In the case that a vehicle requires a towing hook, a distance of around 350 mm should be kept between the rear crossbeam and the second adjacent crossbeam, for ease of mounting and removing the hook. Provided that the refit is professional and complies with the technical regulations in this document, the original towing power can be maintained.
Rear overhang Base - 09/2013 Printed 603.95.640 1-9 GENLYON - KINGKAN CHASSIS PARAMETERS
Location for installing a lift oil pump on a dump truck 1.6 Location for installing a lift oil pump on a dump truck
The dump truck frame comes with holes for installing an oil pump installation, as shown in Figure 1.3. For the layout and location of these holes on specific vehicles, refer to the relevant external-use chassis drawings.
Figure 1.3
Distance to front axle central line x Distance to front axle central line x Distance toframe lower surface y Distance toframe lower surface y Layout A Layout B
Distance to front axle central line x Distance to front axle central line x
Layout C Layout B Distance toframe lower surface y Distance toframe lower surface y
198150
Location for installing lift oil pump
Location for installing a lift oil pump on a dump truck
Printed 603.95.640 Base - 09/2013 1-10 CHASSIS PARAMETERS GENLYON - KINGKAN
Location for installing a lift oil pump on a dump truck Base - 09/2013 Printed 603.95.640 2-1 GENLYON - KINGKAN PARAMETER SETTINGS
SECTION 2 Parameter Settings
Page
2.1 Determining the best location for the centre of gravity...... 2-3
2.1.1 Centre of gravity (vertical) ...... 2-3
2.1.2 Centre of gravity height ...... 2-4
2.1.3 Tilt angle ...... 2-5
2.2 Determining the carriage length ...... 2-7
2.3 Calculating the specific power of a vehicle ...... 2-8
2.4 Determining axle loads ...... 2-9
2.4.1 Symbols used in this section ...... 2-9
2.4.2 2-axle cargo truck ...... 2-10
2.4.3 3-axle cargo truck (assuming that load is evenly distributed between rear tandem axles) ...... 2-11
2.4.4 3-axle cargo truck (assuming that load is unevenly distributed between rear tandem axles) ...... 2-12
2.5 Calculating the payload utilization factor ...... 2-13
2.6 Maximum speed ...... 2-14
2.7 Maximum gradeability ...... 2-15
2.8 Power and torque of power take-off ...... 2-16
2.8.1 Transmission power take-off ...... 2-16
2.8.2 Transfer case power take-off ...... 2-16
2.8.3 Engine power take-off ...... 2-16
2.9 Calculating the power balance ...... 2-17
2.10 Minimum turning circle diameter ...... 2-18
Printed 603.95.640 Base - 09/2013 2-2 PARAMETER SETTINGS GENLYON - KINGKAN
Base - 09/2013 Printed 603.95.640 2-3 GENLYON - KINGKAN PARAMETER SETTINGS
Determining the best location for the centre of gravity
2.1 Determining the best location for the centre of gravity
2.1.1 Centre of gravity (vertical)
The chassis data contained in this guide or provided by our company by other means includes the chassis kerb mass, front and rear axle loads, and the recommended location for the centre of gravity of the body (including all added equipment and cargo). The best location (Y) for the centre of gravity of a body with cargo is determined by the axle load distribution, as shown in Figure 2.1 and the vehicle appearance drawings in Appendix B. When setting the best location for the centre of gravity of a body with cargo, if the sum of the maximum permitted front axle load and permitted rear axle load is not equal to the maximum gross vehicle weight, the actual conditions or maximum front axle load or rear axle load can be used, on the precondition that the maximum permitted gross vehicle weight remains unchanged, and that no axle load exceeds the maximum permitted axle load. See Appendix C for recommended locations for the centre of gravity on Hongyan Genlyon vehicles.
Figure 2.1
Centre of gravity of cargo
198151
Determining the location for the vertical centre of gravity on a body with cargo In which: ’ W1 = Maximum (tandem) permitted front axle load on complete vehicle ” W1 = (Tandem) front axle load on chassis W1 = Body load on (tandem) front axle ’ W2 = Maximum permitted (tandem) rear axle load on complete vehicle ” W2 = (Tandem) rear axle load on chassis W2 = Body load on (tandem) rear axle W = Body weight including cargo L = Wheelbase (distance between centres of (tandem) front and (tandem) rear axles (balance axle central line)) L1 = Location for centre of gravity of body
Determining the best location for the centre of gravity
Printed 603.95.640 Base - 09/2013 2-4 PARAMETER SETTINGS GENLYON - KINGKAN
2.1.2 Centre of gravity height
In terms of lateral stability, a vehicle should side slip before it rolls over. The conditions for this are as follows:
B > 2hg
In which: B = Front wheel track (mm) = Floor attachment factor, =0.7~0.8,recommended =0.7 h = Centre of gravity height (mm) g = Gravitational acceleration (g=9.8 m/s2)
For example: 1) When the front wheel track of a vehicle is 2006 mm, to ensure driving security, the maximum fully loaded 2006 centre of gravity height should be hg < = 1433 mm. 2 x 0.7 If the maximum centre of gravity height of the body with cargo is X, its kerb mass around 10 tons, the empty chassis centre of gravity height 820 mm, load 20 tons, and full load 30 tons, then: 10x820+20X = 30x1433 X = 1739.5 mm To obtain the fully loaded centre of gravity height for driving safety for other models of vehicle, the above formulas may be used. The centre of gravity height of a liquid tank truck should be 10% lower than the maximum permitted centre of gravity height. The centre of gravity height of the chassis can be found in the chassis-related technical materials provided by our company. When designing the vehicle body, the refitting factory should check that the centre of gravity height of the refitted complete vehicle complies with relevant national or international regulations, to ensure its tilt stability. See Figure 2.2 for details of how to calculate the centre of gravity height of a complete vehicle.
Wv = Chassis kerb mass
Determining the best location for the centre of gravity Base - 09/2013 Printed 603.95.640 2-5 GENLYON - KINGKAN PARAMETER SETTINGS
Figure 2.2
198152
Calculating the centre of gravity height of a complete vehicle
Hv = Chassis centre of gravity height (from ground) Ws = Body (with cargo) kerb mass Hs = Body (with cargo) centre of gravity height (from ground) Wt = Gross vehicle (with cargo) weight Wt = Complete vehicle (with cargo) centre of gravity height (from ground)
2.1.3 Tilt angle
Section 4.7.2 of the standard GB7258-2012 stipulates that the maximum left and right tilt angle should be no less than 23˚ for a static and fully loaded tank truck and tank trailer. Section 4.7.3 of the standard GB7258-2012 stipulates that the maximum left and right tilt angle should be no less than 35˚ for other motor vehicles (except two-wheel and light motorcycles). The tilt angle of the refitted complete vehicle must be calculated and calibrated to see whether it complies with relevant regulations. A heavy vehicle chassis has a high centre of gravity height, and will be higher when special devices are added after refitting, for example, a tank truck, box truck, or heavy cargo truck. The tilt angle of a tractor truck should be measured when the unladen trailer is attached. At present, different methods are used to measure the tilt angle. Based on relevant national and international materials, we recommend the following method, which introduces the concept of stability width, as shown in Figure 2.3.
Determining the best location for the centre of gravity
Printed 603.95.640 Base - 09/2013 2-6 PARAMETER SETTINGS GENLYON - KINGKAN
Figure 2.3
Location for the centre of gravity
198153
Stability width In which: B = Stability width (mm) A = Wheelbase (mm) VA = Unladen front axle load (kg) HA = Unladen rear axle load (kg) B1 = Front wheel track (mm) B2 = Distance between central lines of the two external rear axle wheels (mm) MK = Unladen weight (kg) = Tilt angle (˚) HZK = Unladen centre of gravity height of the complete vehicle (mm) To ensure the tilt stability of a special vehicle, you may also use the following method for controlling the centre of gravity height: The centre of gravity height should be measured when the vehicle is running at 35 km/h along a curve whose radius is 44 m. Under such conditions, its tilt angle should be 6˚ (or 5.5˚ for a vehicle with a support axle). For a liquid tank truck, the centre of gravity height should be 10% lower.
Determining the best location for the centre of gravity Base - 09/2013 Printed 603.95.640 2-7 GENLYON - KINGKAN PARAMETER SETTINGS
Determining the carriage lenght
2.2 Determining the carriage length
A truck has the largest carrying capacity when the centre of gravity of the body and payload is equal to the load bearing centre of gravity of the chassis. The centre of gravity of a truck with carriage is fixed, and users may load cargo accordingly. During the body design, the correct body layout should be determined according to the available chassis axle load, so as to utilize theaxleloadfully. The recommended carriage length applies only when the load is evenly distributed. A shorter carriage should be selected when other devices are added. If the required carriage is not already available, please consult our R&D Centre and place a customized order with the carriage supplier. See Figure 2.4 for details of how to calculate carriage length.The carriage length can be calculated by the following formula: (A-B) x 2 = C
Figure 2.4
Centre of gravity of cargo
198154
Calculating carriage length
In which: A = Distance between the rear edge of driver cab to centre of gravity of cargo (including carriage) (mm) - B = Distance between rear edge of driver cab to carriage, usually 150 mm - C = Overall length of carriage (mm) - D = Distance between ends of frame and carriage, usually does not exceed 300 mm (except for back dump truck).
Determining the carriage lenght
Printed 603.95.640 Base - 09/2013 2-8 PARAMETER SETTINGS GENLYON - KINGKAN
Calculating the specific power of a vehicle
2.3 Calculating the specific power of a vehicle
The specific power of a vehicle is the ratio between the net engine power and gross vehicle weight (kW/t). The standard GB7258-2012 ”Safety specifications for power-driven vehicles operating on roads” stipulates that the specific power should be no less than 5.0 kW/t for the Hongyan Genlyon, Hongyan Kingkan, and Hongyan Steyr series. For example, if the engine nominal power is 213 kW, and the gross vehicle weight is 25 tons, then the specific power is (213x0.9)/25=7.668 kW/t.
Calculating the specific power of a vehicle Base - 09/2013 Printed 603.95.640 2-9 GENLYON - KINGKAN PARAMETER SETTINGS
Determining axle loads
2.4 Determining axle loads
2.4.1 Symbols used in this section
In which: A = Distance between centres of front axle and first rear axle (mm) A1 = Distance between centres of first and second rear axles (mm) AX = Distance between centres of front axle and tandem rear axle load (mm) a = Distance between centres of front axle and permitted axle load (mm) LV = Axle load (kg) LH,LH1,LH2 = Rear axle load, first rear axle load, second rear axle load, respectively (kg) LZ = Permitted axle load (kg) LZV,LZH,LZH1,LZH2 = Permitted front axle load, permitted rear axle load, permitted first rear axle load, permitted second rear axle load, respectively (kg) FV = Chassis front axle load (kg) FH = Chassis rear axle load (kg) GX = When the stipulated distance ’Y’ is met, the chassis carrying capacity, which is determined by its gross vehicle, weight (kg) GV = When the stipulated distance ’Y’ is violated, the loss in carrying capacity (kg) T = Chassis carrying capacity (kg) Y = For a 2-axle vehicle, the distance between the centre of gravity and centre of rear axle (mm). For a 3-axle vehicle, the distance between the centre of gravity and centre of rear tandem axle (balance axle) (mm) For a vehicle with two or more axles, check that the front axle load meets the standard stipulated in relevant regulations. If not, the body layout should be redesigned so that the front axle load complies with relevant regulations.
Determining axle loads
Printed 603.95.640 Base - 09/2013 2-10 PARAMETER SETTINGS GENLYON - KINGKAN
2.4.2 2-axle cargo truck
Figure 2.5
198155
Calculating the centre of gravity of a 2-axle vehicle
Determining axle loads Base - 09/2013 Printed 603.95.640 2-11 GENLYON - KINGKAN PARAMETER SETTINGS
2.4.3 3-axle cargo truck (assuming that load is evenly distributed between rear tandem axles)
Figure 2.6
198156
Calculating the centre of gravity of a 3-axle vehicle (with load evenly distributed between rear tandem axles)
Determining axle loads
Printed 603.95.640 Base - 09/2013 2-12 PARAMETER SETTINGS GENLYON - KINGKAN
2.4.4 3-axle cargo truck (assuming that load is unevenly distributed between rear tandem axles)
When the load is unevenly distributed between the rear tandem axles, first calculate the equivalent axle load AX.
Figure 2.7
198157
Calculating the centre of gravity of a 3-axle vehicle (load unevenly distributed between tandem axles)
Determining axle loads Base - 09/2013 Printed 603.95.640 2-13 GENLYON - KINGKAN PARAMETER SETTINGS
Calculating the payloadutilization factor 2.5 Calculating the payload utilization factor
Complete Vehicle Payload (L) + Number Of People (N) x 65 kg / person Payload utilization factor (f) = Kerb Mass (G) In principle, the larger the value obtained for the payload utilization factor (also called payload factor) the better.
Taking the cargo truck CQ1314HTG466 as an example, it has a payload, L, of 17000 kg and kerb mass, G, of 13870 kg, giving a payload utilization factor of f = 17000 + 2 x 65 = 1.235 13870
Calculating the payload utilization factor
Printed 603.95.640 Base - 09/2013 2-14 PARAMETER SETTINGS GENLYON - KINGKAN
Maximum speed
2.6 Maximum speed
The maximum speed Vmax is the top speed of a vehicle on flat ground. When the engine power is high enough, Vmax can be calculated using the following formula:
Rotational Speed Mot (r / min) Vmax = 0.3769 x x Tyre Rolling Radius R dyn (m) Overall Gear Ratioi ges
Mot is the maximum rotational speed of the engine. The overall gear ratio is usually the total speed ratio of the gear and axle. The minimum gear ratio is used to calculate the maximum speed. If no overdrive gear is available, use a gear ratio of 1. If an overdrive gear is available, use the relevant overdrive gear ratio. The axle ratios for Hongyan vehicles are 5.73, 4.8, 4.42, 4.625, and 4.11.
Maximum speed Base - 09/2013 Printed 603.95.640 2-15 GENLYON - KINGKAN PARAMETER SETTINGS
Maximum gradeability
2.7 Maximum gradeability
Maximum Driving Force (N) = arcsin [ Rolling Resistance Coefficient (fr)] 9.8 x Gross Vehicle Weight (kg)
Maximum driving force (N) =
Maximum Engine TorqueM mot x Minimum Overall Gear Ratioi ges x Overall Transmission Efficiency ges
Tyre Rolling Radius R stat
The rolling resistance coefficient is 0.01.
Maximum gradeability
Printed 603.95.640 Base - 09/2013 2-16 PARAMETER SETTINGS GENLYON - KINGKAN
Power and torque of power take/off
2.8 Power and torque of power take-off
2.8.1 Transmission power take-off
Power P = PMot G Torque M = MMot G iG i
2.8.2 Transfer case power take-off
Power P = PMot VG Torque M = MMot VG G iG/i
2.8.3 Engine power take-off
Power P = PMot Torque M = MMot i In which: PMot = Engine power (kW/t) G, VG = Transmission efficiency of transmission at ~0.98, and transmission efficiency of transfer case at ~0.96 = Transmission efficiency of power take-off at ~0.95 MMot = Maximum engine torque (Nm) iG,i = Transmission ratio of transmission, transmission efficiency of power take-off
Power and torque of power take/off Base - 09/2013 Printed 603.95.640 2-17 GENLYON - KINGKAN PARAMETER SETTINGS
Calculating the power balance
2.9 Calculating the power balance
The driving power required by a running special vehicle, Pt, can be calculated using the following formula:
1 mgf C A P D D 3 0 P t = Vmax + V max + 3600 76140 In which: m = Gross vehicle weight f = Rolling resistance coefficient = Mechanical efficiency of chassis transmission CD = Air drag efficient AD = Frontal area of complete vehicle Vmax = Maximum speed PO = Special equipment power taken from a running chassis O = Mechanical efficiency of special equipment g = Gravitational speed
Calculating the power balance
Printed 603.95.640 Base - 09/2013 2-18 PARAMETER SETTINGS GENLYON - KINGKAN
Minimum turning circle diameter 2.10 Minimum turning circle diameter
Semi-trailer and trailer makers should be responsible for the driving performance of their combination vehicles, ensuring that the vehicles, turning circle diameter complies with relevant regulations.
Figure 2.8
198158
Illustration of turning clearance circle and out value (vehicle) Section 6.10 of the standard GB7258 stipulates that a vehicle, combination vehicle (excluding the protruding part of the functioning equipment), or wheeled towing tractor must be able to travel along the same turning clearance circle whose outer circle diameter, D1, is 25.00 m and inner circle diameter, D2, is 10.60 m, as shown in Figure 2.8. As a vehicle, combination vehicle, or wheeled towing tractor travels from a straight line to the turning clearance circle, no part should exceed the vertical plane of the vehicle (out value) by any more than 0.80 m (the out value for an articulated bus, or articulated trolley bus should not exceed 1.20 m), as shown in Figure 2.9. See Appendix A of GB 1589-2004 for this method.
Minimum turning circle diameter Base - 09/2013 Printed 603.95.640 2-19 GENLYON - KINGKAN PARAMETER SETTINGS
Figure 2.9
198159
Illustration of turning clearance circle and out value (combination vehicle)
Minimum turning circle diameter
Printed 603.95.640 Base - 09/2013 2-20 PARAMETER SETTINGS GENLYON - KINGKAN
Minimum turning circle diameter Base - 09/2013 Printed 603.95.640 3-1 GENLYON - KINGKAN REFITTING THE CHASSIS
Index
SECTION 3 Refitting the chassis
Page
3.1 Drilling and welding the chassis ...... 3-3
3.1.1 Drilling on the chassis ...... 3-3
3.1.2 Welding the chassis ...... 3-5
3.1.3 Repair welding of holes on the original chassis frame ...... 3-5
3.2 Lengthening the longitudinal beam of the frame ...... 3-7
3.2.1 Instructions for lengthening the frame ...... 3-7
3.3 Changing the wheelbase ...... 3-11
3.3.1 General technical instructions ...... 3-11
3.3.2 Effect of wheelbase change on steering ...... 3-12
3.3.3 Strengthening the frame structure ...... 3-12
3.3.4 Adding frame crossbeams ...... 3-12
3.3.5 Modifying the wheelbase ...... 3-13
3.4 Refitting the drive shaft ...... 3-14
3.4.1 Refitting the drive shaft ...... 3-14
3.4.2 Layout of the drive shaft ...... 3-14
3.5 Changing the rear overhang of the frame ...... 3-17
3.5.1 Shortening the rear overhang ...... 3-17
3.5.2 Lengthening the rear overhang ...... 3-18
3.6 Lengthening the driver cab ...... 3-21
3.6.1 Refitting the cab body due to length change ...... 3-21
3.6.2 Refitting the interior and exterior trim due to driver cab length change ...... 3-22
3.6.3 Adding additional equipment to the driver cab ...... 3-22
3.7 Installing additional axles ...... 3-24
3.7.1 General technical instructions ...... 3-24
3.7.2 Strengthening the chassis frame ...... 3-24
3.7.3 Components and suspension used for refit ...... 3-26
3.7.4 Sway bar ...... 3-26
3.7.5 Connection between the installed additional axle and frame ...... 3-26
Index
Printed 603.95.640 Base - 09/2013 3-2 REFITTING THE CHASSIS GENLYON - KINGKAN
Page
3.7.6 Brake system ...... 3-26
3.7.7 Installing a lift device for an installed additional axle ...... 3-27
3.8 Refitting the suspension ...... 3-28
3.9 Refitting the engine intake and exhaust systems ...... 3-29
3.10 Refitting the engine cooling system ...... 3-30
3.11 Installing an additional independent heating system ...... 3-31
3.12 Installing an air conditioning system ...... 3-32
3.13 Changing specifications and tyre size ...... 3-33
3.14 Brake system ...... 3-34
3.14.1 Principles for refitting the brake system ...... 3-34
3.14.2 Brake pipeline ...... 3-34
3.14.3 Electronic brake control system ...... 3-36
3.14.4 Additional gas equipment ...... 3-37
3.15 Refitting the electrics ...... 3-39
3.15.1 General technical instructions ...... 3-39
3.15.2 Installing a wireless vehicle communication system ...... 3-42
3.15.3 Installing a battery and alternator ...... 3-44
3.15.4 Power supply for added electrical equipment ...... 3-46
3.15.5 Refitting the electrical wiring harness due to changes to the wheelbase or rear overhang ...... 3-46
3.15.6 Requirements for installing electrical equipment on the cargo tank ...... 3-47
3.15.7 Refitting the grounding device ...... 3-49
3.15.8 Specifications and standards for installing the cables in the electrical system ...... 3-49
3.16 Relocating components and installing auxiliary equipment ...... 3-50
3.17 Installing the retarder ...... 3-53
3.18 Paint and anti-rust ...... 3-54
3.19 Safety regulations ...... 3-56
Index Base - 09/2013 Printed 603.95.640 3-3 GENLYON - KINGKAN REFITTING THE CHASSIS
33333.
Drilling and welding the chassis
3.1 Drilling and welding the chassis
As shown in Figure 3.1, parts such as the brake lining, plastic materials, and harness should be well pro- ! tected when welding, drilling, polishing, or cutting close to these parts, or even removed if necessary. Before welding a chassis made by our company, the power cable should be removed from the battery.
Figure 3.1
198160
Special notes on welding, drilling, polishing, and cutting the chassis
3.1.1 Drilling on the chassis
To attach the body and chassis and install special equipment, first use or enlarge the existing holes on the chassis frame. Only drill new holes in the following conditions (also remember to remove burrs and ream them; never cut a hole using gas welding, as this may cause chassis parts such as frame to fracture; and please pay attention to the location of and spacing between holes): 1) Spacing between holes:Do not drill holes on the upper and lower frame surface. However, if drilling is absolutely necessary, make sure that only one hole is drilled horizontally, and that the distance between the two adjacent longitudinal holes is more than 70 mm. When drilling on the beam web, ensure that the distance between two adjacent horizontal and longitudinal holes is more than 50 mm, and that the hole diameter is proportional to the steel plate thickness, but smaller than 17 mm, as shown in Figure 3.2. 2) Never drill on high stress areas such as the lower surface of the longitudinal beam between the front and rear axles, and the upper frame surface of the rear suspension.When drilling on crossbeams, follow the rules regarding hole sizing and spacing for longitudinal beams. 3) Do not drill within 30 mm of the edge of the longitudinal beam, within 25 mm of its corner edge, or within 25 mm of the lower corner edge on the beam web, as shown in Figure 3.3. 4) Never drill on high stress areas (e.g. on the steel spring carrier) or areas near the part of the crossbeam where its cross-sectional area varies dramatically.
Drilling and welding the chassis
Printed 603.95.640 Base - 09/2013 3-4 REFITTING THE CHASSIS GENLYON - KINGKAN
Figure 3.2
198161 Drilling on the chassis frame
Figure 3.3
Do not drill on lower frame surface
198162 Areas on the longitudinal beam that cannot be drilled (highlighted areas)
5) When bolts are required, use bolts of the same type and class as those on the original vehicle. For high stress equipment such as spring carriers, rods, and shock absorbers, use class 10.9 bolts and self-locking nuts. When space permits, use hex flange bolts and nuts. Bolt holes are best drilled on the double-layer longitudinal beam. It is also best to install devices with a higher torque bias onto the double-layer longitudinal beam.
Drilling and welding the chassis Base - 09/2013 Printed 603.95.640 3-5 GENLYON - KINGKAN REFITTING THE CHASSIS
3.1.2 Welding the chassis
The Genlyon and New Kingkan use 16MnL, 09SiVL, Shanghai Baosteel high-strength steel plate QstE500TM, and Ansteel P610L that are of the same welding performance. Do not weld on the frame until welding plans have been submitted to and approved by our R&D Centre. Please comply with the following rules on welding: 1) To weld and lengthen a frame made from Shanghai Baosteel high-strength steel plate QstE500TM or Ansteel P61L, please submit welding plans to our Sales Division and R&D Centre for approval. Only after the plans are approved can welding begin. 2) Do not weld within 20 mm from the edge of the upper and lower frame surfaces, within 20 mm from its corner edge, within 12 mm from its interior frame edge, or within 20 mm from its lower corner edge on the beam web, as shown in Figure 3.4. 3) Clean the welding parts before welding.
Figure 3.4
Welding
189163
Areas on the longitudinal beam that cannot be drilled (highlighted welded)
4) In order not to damage electrical equipment, the power cable should be removed from the battery before welding. Connect thegroundwirefromtheelectricweldingmachinetotheweldingparts.Removeormoveasideelectricalwiresandpipesfrom around the welding parts, so as not to damage them or stop them working. 5) Select the correct welding rod, while also noting that the welding rod should be dried as required. Weld the part at a reasonable pace, and maintain an appropriate and stable electric current for welding. 6) Do not leave welding defects such as missed welding, tack welding, undercuts, slag inclusion, pores, cracks, and depressions. 7) Cool the welded parts slowly and evenly. Use water or other means to cool the crossbeam, rather than air blasting. 8) Thoroughly clean up welding slag.
3.1.3 Repair welding of holes on the original chassis frame
When a newly drilled hole is too close to the original hole, a refitting factory may need to repair weld the original hole.To ensure successful repair welding, chamfer the edge of the original hole, and put a copper part inside the hole.
Do not carry out any welding on the frame until welding plans have been submitted to and approved ! by our R&D Centre. To weld a hole with a diameter of 20 mm or above, place a chamfered plug inside the hole and then weld the plug and the hole.
Drilling and welding the chassis
Printed 603.95.640 Base - 09/2013 3-6 REFITTING THE CHASSIS GENLYON - KINGKAN
Only skilled, trained and professional welders using appropriate welding equipment are allowed to weld ! the vehicle, to ensure welding quality.
Before welding, disconnect the power for the complete vehicle, and disconnect such electrical devices ! as the body control unit and engine ECU from the electric circuit of the complete vehicle.
Attention:Please take the following precautions before welding, drilling, or polishing near plastic pipes: ! - Expel air pressure from the pipe, remove air from all air reservoirs, and connect spring brakes. - Cover up the pipes so as to protect them from splashed slag and sparks. - An air pipe with no air pressure can stand a maximum heat of 130 C for up to 60 minutes. When testing the tightness of sealing with the brake system and pneumatic actuator not working, the air pressure in the pipe should remain at no more than 0.5 bar for two hours.
Protect steel springs and air springs from damage from welding slag. ! Separate springs from the welding rod and electrode holder.
Drilling and welding the chassis Base - 09/2013 Printed 603.95.640 3-7 GENLYON - KINGKAN REFITTING THE CHASSIS
Lengthening the longitudinal beam of the frame 3.2 Lengthening the longitudinal beam of the frame
Please submit an industrial process plan to our Sales Department before carrying out the lengthening of the longitudinal beam of the frame. The plan should only be implemented after approval from us has been obtained. Lengthen the longitudinal beam only from the rear of the frame. Never lengthen the frame by cutting the frame before the rear axle. For a 2-axle vehicle, the butt joint must be behind the rear lifting eye bracket of the rear leaf spring. For a 3-axle vehicle, the butt joint must be behind the crossbeam of the balance axle, and as far behind as possible.When modifying the rear overhang, please follow the rules in Section 3.5 “Changing the rear overhang of the frame” in this chapter. When lengthening the frame, use materials of the same specifications, performance, and quality as those on the frame.If no material of the same thickness is available, use thicker materials. For example, if the material on the frame is 6.7 mm, when no 6.7 mm material is available, 7 mm materials may be used.Selected materials must meet these minimum requirements.If the extended length is within 200 mm, only butt welding is required, and not reinforcement.
3.2.1 Instructions for lengthening the frame
1) Long frames should be welded by experienced and specially trained welders with corresponding qualifications, such as welder work licenses or operational certificates. 2) Cut the longitudinal beam web vertically, and the upper and lower frame surfaces at an angle of 45˚. Remember to polish the cut, and please note that no holes should be located on the butt-welding joint of the cut beam, as showninFigure3.5. 3) Make the cut surface into V- or U-shaped bevelled edges (with bevel angles of 30˚, and weld seam angles of 60˚), as shown in Figure 3.6. V-shaped bevelled edges should be positioned at the outer flank of the longitudinal beam and lining beam. 4) Welding method:Manual arc welding or gas-shielded arc welding. 5) Welding rod:Select appropriate welding rods based on the strength of the longitudinal beam. Please note that welding rods should be dried as required. 6) In order not to damage electrical equipment, please retain the ground wire of the battery, and connect the ground wire of the electric welding machine to the welded parts.
Figure 3.5
189164
Cutting the longitudinal beam
Lengthening the longitudinal beam of the frame
Printed 603.95.640 Base - 09/2013 3-8 REFITTING THE CHASSIS GENLYON - KINGKAN
Figure 3.6
Inner flank of the longitudinal beam
Polishing
Polishing and welding 189165
Welding joint of the longitudinal beam
7) Thoroughly weld the bottom and top of the inner flank from the bottom upwards. 8) Do not undercut at the edge of welding joint. The transition should be mild and less than 10˚,as shown in Figure 3.7. 9) Chisel or polish out the exterior root welding joint, and then butt weld it. 10) Polish the exterior welding joint on the beam longitudinally, and do not cause any depression. 11) If angle stiffeners are used, the angle stiffeners must fit inside the beam perfectly, as shown in Table 3.1 and Figure 3.8.
Figure 3.7
Polished transition area Polished transition area
Welding joint Welding joint
Longitudinal beam web Longitudinal beam web
189166 Transition for longitudinal beam welding
Lengthening the longitudinal beam of the frame Base - 09/2013 Printed 603.95.640 3-9 GENLYON - KINGKAN REFITTING THE CHASSIS
Figure 3.8
189167
Structure and dimension of angle stiffener of the longitudinal beam
12) To fix the angle stiffener from inside and connect it to the longitudinal beam, angle weld or plug weld it to the beam web. The thickness of the angle-welding joint should be 5 mm, as shown in Figure 3.9.
Figure 3.9
Angle welding
Do not weld here.
Plug weld
Do not weld here.
189168
Welding angle stiffeners
Lengthening the longitudinal beam of the frame
Printed 603.95.640 Base - 09/2013 3-10 REFITTING THE CHASSIS GENLYON - KINGKAN
Table 3.1 - Dimensions of longitudinal beam and angle stiffeners Beam (mm) Interior angle stiffener (mm) (H) (B) (S) (r) (L) (b) (h) (s) Height Width Thickness Corner radius Length Lower width Beam web Thickness height 243 80 8 12 350 57 70 8 280 80 8 12 350 57 70 8 317 80/90 8 10 350 57 80 8
13) To lengthen the interior reinforcement beam, use the same method to cut it and make grooves, place a copper plate or wedge between the longitudinal beam and reinforcement beam, and then weld the interior reinforcement beam, as shown in Figure 3.10. The extended longitudinal beam should not hang down, but can protrude upward by no more than 5 mm per any one meter, while the overall protruding height should not exceed 8 mm. For notes on welding, please refer to the notes and requirements in Section 3.1 “Drilling and welding the chassis” in this chapter.
Figure 3.10
Copper plate or wedge 198169
Welding the interior reinforcement beam (adding a copper plate or wedge)
Lengthening the longitudinal beam of the frame Base - 09/2013 Printed 603.95.640 3-11 GENLYON - KINGKAN REFITTING THE CHASSIS
Changing the wheelbase 3.3 Changing the wheelbase
3.3.1 General technical instructions
Attention: If the electric circuit is likely to be affected when changing the wheelbase, or the mounting ! location for electrical or electronic parts have to be moved, please first submit the refit plan to our Sales Division and R&D Centre for approval. Once approval for the plan has been received, please follow closely the instructions in this guide on refit- ting electrical equipment.
The original wheelbase is generally not to be modified. However, if changes must be made due to reasons of layout, installation or body structure, please comply with the following rules during the refit: - Change the wheelbase by moving the rear axle (or balance axle), and not by cutting the frame before the rear axle (or balance axle) and extending the frame. - Leave the Z or W layout of the drive shaft unchanged. - The angle between the two universal joint ends should be no larger than 2˚ (or ideally parallel), as shown in Figure 3.11. - Modify the wheelbase according to the latest relevant requirements. - Always follow the approved technical plan, especially when lengthening the maximum standard wheelbase. - Modify the frame assembly according to the relevant requirements in this guide. - Wherever possible, select a wheelbase already available from our company, so that the original drive shaft and crossbeam location can be used. - If the modified wheelbase is longer than our maximum wheelbase, the chassis belonging to the longest wheelbase should be used so as to ensure the reasonable structure of the refitted frame assembly. Please note that a refitted vehicle must comply with relevant national regulations on overall vehicle dimensions. - Carry out surface protection according to Section 3.18 “Paint and rust prevention“ in this chapter. - Restore the electrical system and brake system according to Section 3.15 on “Refitting electrical equipment” and Section 3.14 on the “Brake system” in this chapter, respectively. - For details of how to refit the transmission, see Section 3.4 on “Refitting the drive shaft“ in this chapter and proceed accordingly. Figure 3.11
Flange parallel
198170 Angle between the two universal joint ends
Changing the wheelbase
Printed 603.95.640 Base - 09/2013 3-12 REFITTING THE CHASSIS GENLYON - KINGKAN
3.3.2 Effect of wheelbase change on steering
A lengthened wheelbase may affect a vehicle s steering performance.If relevant national regulations exist, the wheelbase should not exceed the specified range, while the operation force and time on the steering wheel should not exceed limits stipulated in the regulations. The maximum front axle load and tyre type will determine the effect of a wheelbase change on the steering system.In the case that a special vehicle requires a longer wheelbase, devices should be mounted to improve steering performance (for example, devices that may decrease the maximum front axle load or increase the steering power, or tyres with a shorter scrub radius).
3.3.3 Strengthening the frame structure
When lengthening the wheelbase, the refitting factory should properly strengthen the framework assembly and the welding joint of the lengthened frame, in order to ensure that the section modulus of the frame assembly is not less than that designed by our company.If local regulations permit, a subframe of a larger section modulus may be used. When required by local regulations, a refitting factory must check that the stress of the longitudinal frame is within the specified range.Under no circumstances should the stress exceed the original stress for maintaining the original wheelbase (supposing that the load is evenly distributed, and treating the chassis as a beam resting on a spring hanger). If the new wheelbase is longer than the original, the reinforcement structure should be determined based on the increased length, body type, and vehicle purpose.
3.3.4 Adding frame crossbeams
The following factors determine the necessity of adding one or more crossbeams: - Extended length of the wheelbase - Support position of the drive shaft - Welding position - Point of introduction of force from the body - Usage condition of the vehicles. Added crossbeams must have the same features as the original ones in terms of flexural strength, torsional strength, quality, and connection with the beam). Figure 3.12 shows such an example. A crossbeam must be installed whenever the extended length of the wheelbase is 600 mm or above.In principle, the distance between two crossbeams should be no larger than 1000 mm to 1200 mm. For a heavy load vehicle, the minimum distance between two adjacent crossbeams should be no less than 600 mm. This regulation is not valid for light crossbeams supporting the transmission system.
Changing the wheelbase Base - 09/2013 Printed 603.95.640 3-13 GENLYON - KINGKAN REFITTING THE CHASSIS
Figure 3.12
198171 Adding frame crossbeams
3.3.5 Modifying the wheelbase
In order to ensure a smooth and quality modification and reliable performance of the refitted complete vehicle, please be sure to carry out the following measures: - Place the vehicle on a proper bracket to make sure that the chassis is completely horizontal. - Remove the drive shaft, brake system pipeline, harness, and any components that may obstruct the modification. - Locate the reference points on the chassis (e.g. the location hole and suspension support point). - Mark the reference points with punches on the flanges of the two beams, and connect them using a thin line. Check that the connection of the two reference points is vertical to the longitudinal line of the vehicle, and mark the reference points. - Before re-mounting the bracket for the leaf spring, locate the new location using the previously marked reference points. Check whether the new measurements are the same on both the left and right. If the diagonal line is less than 1500 mm, the difference between left and right should not exceed 2 mm. If this is not the case, new holes should be drilled using the gussets of the bracket and crossbeam as a template. Mount the bracket and crossbeam using rivets and bolts. If bolts are used, ream the holes, and use class 10.9 bolts and screws with anti-loosening devices to fix the bracket. Use flange bolts and screws if space permits. - If the chassis must be cut, mark a second line between the reference points, so as to limit the area within these points to be affected by the refit. Under no circumstances should the diagonal line be longer than 1500 mm after a refit. Mark the area for cutting between the two reference lines, and cut the chassis according to the section on “Welding the chassis“ in Section 3.1 “Drilling and welding the chassis“ in this chapter. - Before welding, check that the two longitudinal beams match each other completely, including any accessories, and that the side and diagonal measurements are all correct. Then weld the beams according to Section 3.1 “Drilling and welding the chassis” in this chapter.
Changing the wheelbase
Printed 603.95.640 Base - 09/2013 3-14 REFITTING THE CHASSIS GENLYON - KINGKAN
Refitting the drive shaft 3.4 Refitting the drive shaft
3.4.1 Refitting the drive shaft
The length of a drive shaft may change when the wheelbase is shortened or lengthened, when transmission parts such as the gearbox and drive axle are replaced, or when an axle or full-power power take-off is added. The precision with which a drive shaft is built will have a significant effect on the vibration and noise in the transmission system for high-speed running vehicles, and will affect both the transmission efficiency and the lifespan of relevant transmission parts. Our company’s original drive shafts are made using jigs, with their dynamic balance tested to eliminate abnormal vibration and noise. When the length of the drive shaft is altered, the original dynamic balance is damaged, causing vibration and noise. The length of the drive shaft should generally not be modified. However, when it is absolutely necessary to modify the length of a drive shaft, attention should be paid to the following points: 1) Use steel piping of the same quality and dimensions as the original drive shaft to lengthen the axle.Make sure that the drive shaft angle does not exceed the angle of the original maximum drive shaft. 2) Weld the drive shaft using carbon dioxide arc welding. Adjust the arc voltage, arc current, and welding speed as appropriate to ensure thorough welding. 3) Use the following formula to calculate the critical speed nCR (rpm) of the drive shaft:
In which: D = External diameter of the transmission axle pipe (mm), d = Internal diameter of the transmission axle pipe (mm), L = Distance between the centres of the two universal joints of the drive shaft (mm). The maximum rotational speed of a drive shaft should also be designed to be lower than 0.7nk. 4) When the drive shaft is longer than 1900 mm, a larger-diameter axle pipe is required so as to avoid abnormal vibration in the drive shaft. (Please contact our company or the axle supplier for this). 5) When the drive shaft is longer than 2000~2100 mm, an intermediate support device is required. 6) Please refer to the minimum drive shaft length in Table 3.2.
Table 3.2 - Minimum drive shaft length Length of cross universal joint drive shaft Length of universal joint drive shaft 600 mm 400 mm The swing diameter of the drive shaft flange is its flange diameter plus 30 mm. The axle jump should also be taken into account. The intermediate drive shaft is not to be lengthened or shortened, but should be custom-made by a professional drive shaft supplier. If the telescopic drive shaft is shorter than 800 mm and you wish to shorten the wheelbase, it is recommended that you remove the intermediate drive shaft.
3.4.2 Layout of the drive shaft
In the case that the transmission system consists of more than one segmented drive shaft, the length of the various drive shafts must fundamentally be the same.In principle, the difference in length between an intermediate drive shaft and telescopic drive shaft should not exceed 600 mm.The difference in length between different drive shafts should not exceed 400 mm.Sufficient allowance for expansion and contraction should be maintained, allowing the drive shaft to be shortened by 30 mm at its minimum working length, and the slide bush to overlap the spline shaft by around two times the spline shaft’s diameter at the drive shaft’s maximum working length.
Refitting the drive shaft Base - 09/2013 Printed 603.95.640 3-15 GENLYON - KINGKAN REFITTING THE CHASSIS
If, after the wheelbase has been changed, a drive shaft is longer than the original maximum permitted drive shaft length, an intermediate drive shaft (not a telescopic drive shaft) should be added, as shown in Figure 3.13.
Figure 3.13
198172 Spatial layout of drive shaft 1. Axis of engine, clutch, and transmission - 2. First intermediate drive shaft (not a telescopic drive shaft) - 3. Intermediate drive shaft support - 4. Telescopic drive shaft - 5. Angle of central input line of drive axle (permitted load) - 6. Angle of central input line of drive axle (maximum upward jump) - 7. Angle of central input line of drive shaft (unladen) - 8. Intermediate drive shaft and central input line of drive shaft must be of same angle. The intermediate drive shaft and central input line of the drive axle must be of the same angle.The angle between these two points and the central line of the engine, clutch, and transmission should not exceed 1˚. To achieve this, one can either add a wedge between the rear axle and its leaf spring, or adjust the track bar of the rear axle.The angle of the rear axle should not exceed 5˚30’. When the vehicle is fully loaded, if the input flange of the drive shaft is lower than the flange of the transmission output, please make sure that the angle of the differential shell and drive shaft is larger than that of the axis of the engine and transmission. On the other hand, when the vehicle is fully loaded, if the input flange of the drive shaft is higher than the flange of the transmission output, the angle of the differential shell and drive shaft must be smaller than that of the axis of the engine, clutch, and transmission.
Refitting the drive shaft
Printed 603.95.640 Base - 09/2013 3-16 REFITTING THE CHASSIS GENLYON - KINGKAN
If the wheelbase is lengthened significantly, an intermediate drive shaft may be required, as shown in Figure 3.14. In such a case, the axis of the engine and transmission, the second intermediate drive axle, and differential shell must be of the same angle. The support for the added intermediate drive shaft should have the same performance as the original support on the vehicle.
Figure 3.14
198173 Spatial layout of the drive shaft 1. Axis of engine, clutch, and transmission - 2. First intermediate drive shaft (not a telescopic drive shaft) - 3. Intermediate drive shaft support - 4. First intermediate drive shaft (not a telescopic drive shaft) - 5. Telescopic drive shaft - 6. Angle of central input line of drive axle (permitted load) - 7. Angle of central input line of drive axle (maximum upward jump) - 8. Angle of central input line of drive shaft (unladen) - 9. Intermediate drive shaft and central input line of drive shaft must be ofthesameangle.
Important ! - After the refitting of the transmission or any of its components, the dynamic balance of every transmission component should be checked carefully. - Transmission is crucial to the driving safety of a vehicle. Always bear in mind that any refit of the transmission must uphold the safety of a vehicle, and that only professional, certified transmission makers are permitted to refit the transmission.
Refitting the drive shaft Base - 09/2013 Printed 603.95.640 3-17 GENLYON - KINGKAN REFITTING THE CHASSIS
Changing the rear overhang of the frame 3.5 Changing the rear overhang of the frame
The rear overhang of a vehicle frame may either be shortened or lengthened.As stipulated in the standard GB7258, ”For a bus, box truck, or tank truck, the rear overhang cannot exceed 65% of the wheelbase. For a special motor vehicle or wheeled machinery truck, the rear overhang may follow the relevant regulations for a bus, provided that these are safe. For other motor vehicles, the rear overhang of other vehicles cannot exceed 55% of their wheel base. The rear overhang of a motor vehicle should not exceed 3.5 m.”
NOTE For a multi-axle motor vehicle, the wheelbase is the distance between the centres of the first front and last rear axles, while the rear overhang is calculated from the central line of the last rear axle. For an articulated bus, the wheelbase is the distance between the centres of the first front and second axles. For a bus, the rear overhang is calculated from the exterior body panel, or the bumper bar when this lies beyond the rear body panel, but excluding the rear ladder.
The locations of the rear towing device and rear bottom protection device must comply with relevant regulations. After the rear overhang has been lengthened, the centre of gravity of the cargo must not lay behind the axis of the rear (balance) axle, while the refitted vehicle must comply with national regulations in terms of minimum ground clearances and distance between the rear edge of the chassis and that of the body.In principle, the distance between the rear edge of the chassis and that of the body should not exceed the range 350 mm-400 mm, except for back dump trucks. The rear crossbeam should be positioned at around 50 mm in front of the rear edge of the frame. After the rear overhang has been changed, the axle load distribution will also change. Please check the axle load distribution to ensure that the new axle loads comply with relevant national regulations, and also to ensure that this does not have any negative effect on the main vehicle performance. After the rear crossbeam has been moved, it should be connected to the longitudinal beam using the original method (rivets, bolts of class 8.8 or above, and self-locking nuts).If the rear crossbeam was originally connected to the longitudinal beam using rivets, flange bolts and nuts or larger-diameter class 8.8 hex bolts and self-locking nuts may also be used to connect the crossbeam to the longitudinal beam. If a towing hook is required on the relocated rear crossbeam, a distance of around 350 mm should be kept between the rear crossbeam and the second adjacent crossbeam, for ease of mounting, removing, and maintaining the hook.
In the case that the rear electrical equipment has to be moved, or the length of the rear electrical har- ! ness has to be changed, please modify these according to Section 3.15 “Refitting the electrics” in this chapter.
3.5.1 Shortening the rear overhang
After shortening the rear overhang (in order to create a dump truck, for instance), the rear crossbeam should be moved forward. If the rear crossbeam is too close to its adjacent crossbeam after the rear overhang has been shortened, remove the adjacent crossbeam while ensuring that the installation, function and stress on the various parts of the suspension are not affected. The original rear crossbeam may also be removed, with an original crossbeam placed close to the suspension support as the new rear crossbeam. When removing the crossbeam, remember also to remove rivets, and bolts.
Changing the rear overhang of the frame
Printed 603.95.640 Base - 09/2013 3-18 REFITTING THE CHASSIS GENLYON - KINGKAN
3.5.2 Lengthening the rear overhang
After lengthening the rear overhang, the distance between the rear overhang and its adjacent crossbeam should not exceed the range 1200~1400 mm, while an additional crossbeam should be installed on the extended frame, as shown in Figure 3.15.
Figure 3.15 Direction of polishing
198174 Altering the rear overhang
The additional crossbeam should be identical to the existing crossbeams.After removing the rear crossbeam, remove the rivets and bolts, repair weld the original holes, and then polish. For details of how to weld the extended frame, see Section 3.2 “Lengthening the longitudinal beam of the frame“.
Changing the rear overhang of the frame Base - 09/2013 Printed 603.95.640 3-19 GENLYON - KINGKAN REFITTING THE CHASSIS
Figure 3.16 illustrates the typical method used for lengthening the rear overhang by 300~350 mm, the typical crossbeam structure, and the connection between the crossbeam and longitudinal beam. In this case, the L-shaped reinforcement rod connecting the frame and crossbeam must be of the same thickness and width as the original gusset. The crossbeam and gusset must be connected by bolts, nuts, and bolt hold-down systems of class 8.8 or above. For details of how to lengthen the longitudinal beam, see Section 3.2 “Lengthening the longitudinal beam of the frame” in this chapter.
Figure 3.16
198175 Structure for lengthening the rear overhang (1) 1. Added part for lengthening frame - 2. Reinforcement beam - 3. Reinforcement beam (alternative solution) - 4. Original rear beam
Changing the rear overhang of the frame
Printed 603.95.640 Base - 09/2013 3-20 REFITTING THE CHASSIS GENLYON - KINGKAN
Figure 3.17 illustrates the typical method for lengthening the rear overhang (longitudinal beam length) by above 350 mm, the typical crossbeam structure, and the connection between the crossbeam and longitudinal beam. In this case, the L-shaped reinforcement rod connecting the frame and crossbeam must be of the same thickness and width as the original gusset. The crossbeam and gusset must be connected by bolts, nuts, and bolt hold-down systems of class 8.8 or above. For details of how to lengthen the longitudinal beam, see Section 3.2 “Lengthening the longitudinal beam of the frame“ in this chapter.
Figure 3.17
198176
Structure for lengthening the rear overhang (2) 1. Added part for lengthening frame - 2. Reinforcement beam - 3. Original rear beam - 4. Added auxiliary crossbeam (if necessary)
Changing the rear overhang of the frame Base - 09/2013 Printed 603.95.640 3-21 GENLYON - KINGKAN REFITTING THE CHASSIS
Lengthening the driver cab 3.6 Lengthening the driver cab
Our Genlyon long driver cab is 440 mm longer than the Genlyon short driver cab at the X direction, with the difference lying in the left and right side panel assemblies and floor assemblies on the cab body. Our company has custom-designed a four-door Genlyon fire truck driver cab. Its chassis can be used for fire trucks or other special vehicles.
3.6.1 Refitting the cab body due to length change
In principle, in order to protect its strength, the length of the driver cab is not to be modified. Nonetheless, in the case that our long and short four-door Genlyon driver cabs do not meet your requirements, the following rules should be adhered to when removingthesidepanelsandfloorofthecabbody: - Maintain the integrity of the left and right door frames (including the B-pillar and positions for fixing safety belts) and also the integrity of the rear panel when removing or cutting the welding joint between the side and rear panels. Maintain the integrity of the left and right floors when removing or cutting the welding joint between the side panel and floor. The left and right floors of the short driver cab are not to be damaged, while the rear floors of the long driver cab may be cut.
Figure 3.18
Long driver cab Short driver cab Door frame
Driver cab floor Left and right 198177 Major components relevant to refitting the cab body
- When re-welding the side panels and floor assemblies of a driver cab that have been cut or lengthened, reinforcements should be added to the inner side panel and longitudinal beam of the driver cab, in order not to tear the cab body. In addition, the top of the left and right side panels should be reinforced, and a smooth connection ensured between the roof and side panels, in order not to force the roof on the side panels. - When re-welding the long driver cab, ensure that the left toolbox is closed and sealed, in order not to tear it or allow water to leak in.
Lengthening the driver cab
Printed 603.95.640 Base - 09/2013 3-22 REFITTING THE CHASSIS GENLYON - KINGKAN
- Before any measures are taken to refit any cab body made by our company, a refit plan must first be submitted to our company for approval. Do not take any action before the plan is approved by us. Otherwise, the refitting factory will be held responsible for any issues regarding structural strength and tightness.
3.6.2 Refitting the interior and exterior trim due to driver cab length change
When changing the length of the driver cab, the interior and exterior trim of the driver cab may be modified according to the following rules: - The front grille, left and right air deflectors, bumper bars, steps, and exterior door trim do not need to be modified. - After side panel extensions are removed, these may be replaced with handmade fibreglass doors, as required. - In the case that the original driver cab has an SMC roof, attention should be paid to the reinforcement method and installation of the roof interior trim, regardless of whether handmade fibreglass or steel plate welding is used for the refit, in order not to cause hidden risks or difficulty in installing the roof interior trim. The user may decide whether to keep the original roof hatch or not. If the roof hatch is required, attention should be paid to the tightness of the refitted roof. We do not recommend cutting the roof and pasting it together with handmade fibreglass, as this cannot guarantee roof strength and therefore poses hidden safety risks. - The following parts of the refitted driver cab do not need to be modified: interior trim, dashboard, upper sundries box assembly (front roof interior trim assembly), carpet and gear control box, seat and safety belt, rear panel interior trim. The side panel and roof interior trim need to be cut or remade according to the user’s requirements. - After a refit, the original lower sleeping berth in the short driver cab can still be used. If a long driver cab is shortened, an existing lower sleeping berth from a short driver cab may be used, while the original upper sleeping berth will have to be rebuilt or discarded. - The original lower heat-insulating layer in the short driver cab may still be used, or may be refit, based on the user’s requirement.
3.6.3 Adding additional equipment to the driver cab
1) When installing devices on the dashboard, attention should be paid to the following points: - Do not obscure the driver’s view from any angle, including the view from the left and right rearview mirrors and the instrument cluster display. - The operation of added devices must under no circumstances interfere with any existing switches on the dashboard, parking brake, or trailer brake. - It is best not to add any part that obstructs the defrost grill or air outlet, so as to maintain driver comfort and protect the added devices from cold air. - Devices may be installed on the dashboard using bond or self-tapping screws.If self-tapping screws are used, be careful never to damage the pipeline and harness inside the dashboard, and to maintain a distance of at least 30 mm between the tip of the screw and the pipeline and harness. - If a wiring harness is required for added devices, the relevant technical plan on using the reserved harness should first be submitted to our company for approval. Do not take any action before the plan is approved by us. Never randomly make series or parallel wiring. Otherwise, the user must bear all consequences. 2) When installing devices on the upper sundries box (front roof interior trim), attention should be paid to the following points: - Do not obscure the driver’s view from any angle, including the view from the left and right rearview mirrors. - The operation of added devices must under no circumstances interfere with the operation of any existing devices on the roof, such as a tachograph or central ceiling light. - It is best not to install video entertainment systems on the roof of driver cab. This is because the arm must be raised above the head to operate the system, and the head raised to watch the video, thus resulting in hidden driving risks. If you insist on installing such a system, you shall be held accountable for all consequences.
Lengthening the driver cab Base - 09/2013 Printed 603.95.640 3-23 GENLYON - KINGKAN REFITTING THE CHASSIS
- Devices may be installed on the upper sundries box using self-tapping screws.When using self-tapping screws, be careful never to damage the harness inside the box, and to maintain a distance of at least 30 mm between the tip of the screw and the harness. - If a wiring harness is required for added devices, the relevant technical plan on using the reserved harness should first be submitted to our company for approval. Do not take any action before the plan has been approved by us. Never randomly make series or parallel existing wiring. Otherwise, the user shall bear all consequences. 3) When installing devices on the interior trim and floor of the driver cab, attention should be paid to the following points: - The operation of added devices must under no circumstances interfere with the operation of any existing devices, such as the transmission, combination pedal, accelerator pedal, toolbox, safety belts, sleeping berth hinges, or roof hatch. - Devices may be installed on the upper sundries box using bond, buckle, and self-tapping screws.If self-tapping screws are used, be careful never to damage the relevant pipeline, and to maintain a distance of at least 30 mm between the tip of the screw and the pipeline. - If an added device must pass through the interior trim or floor in order to be fixed on the cab body, drill small diameter holes (10 mm or less) and take care not to penetrate the externally visible part of the driver cab. When drilling on an externally invisible part of the cab body, the driver cab’s waterproofness and tightness must be maintained. Otherwise, the user shall bear all consequences.If a large area of the cab body must be modified, the relevant technical plan should be submitted to our company for approval. Do not take any action before the plan is approved by us. Otherwise, the user must bear all consequences. 4) When installing devices on the exterior of the driver cab, attention should be paid to the following points: - Do not obscure the driver’s view from any angle, including the view from the left and right rearview mirrors. - The operation of added devices must under no circumstances interfere with the operation of any existing devices, such as the wipers, rearview mirrors, or major assemblies inside front grille. Please ensure that no such refit affects the cooling and air conditioning of the complete vehicle. - Exterior devices may be installed using bond and drilling bolts. When drilling the exterior trim of the driver cab, be careful never to damage the relevant pipeline, and to harness inside the exterior trim and maintain a distance of at least 30 mm between the tip of the bolt and the pipeline and harness. - If a wiring harness is required for added devices, use the reserved harness, and communicate the relevant technical plan with our electrical engineers. Never randomly make series or parallel wiring. Otherwise, the user shall bear all consequences. After a driver cab has been lengthened, do not use the original driver cab support. Instead, strengthen the driver cab support based on the increased weight of the driver cab.The new driver cab support must ensure that the door can be opened and closed freely whenthechassisistorqued. A strengthened hydraulic lift mechanism must be used for a lengthened driver cab.
Lengthening the driver cab
Printed 603.95.640 Base - 09/2013 3-24 REFITTING THE CHASSIS GENLYON - KINGKAN
Installing additional axles 3.7 Installing additional axles
The installation of additional axles has a significant impact on a vehicle’s systems, especially the brake ! system, air compression system, wiring harness, and electrical system. As such, the technical plan for installing additional axles must first be approved by our company, while the refitting factory must also comply with the instructions in Section 3.15 “Refitting the electrics” in this chapter.
3.7.1 General technical instructions
To increase the payload, additional axles may be installed so as to increase the gross vehicle weight. Before installing extra axles, a refitting factory must submit the relevant technical plan to our company for approval. The plan must contain information about components, reinforcement, and refitting relevant to the connection between the chassis and axle, as well as relevant technical drawings. Do not install additional axles until the plan has been approved by us. When installing additional axles, a refitting factory must act within the ranges specified by our company in the approved technical plan, and must comply with regulations given by our company in the approved technical plan and in relevant national regulations. In addition, all refits must ensure the driving safety and normal operations of the vehicle. When refitting the chassis, please comply with relevant regulations on refitting, welding, drilling, and connecting the frame. After additional axles have been installed, the payload increases, meaning that the stress on such bearing parts as the frame also increases. As such, the chassis must be strengthened accordingly.Reinforcements must fully comply with current relevant local regulations.The flexural stress on the refitted chassis should not exceed that on the original chassis.
3.7.2 Strengthening the chassis frame
Figures 3.19 and 3.20 show two methods for refitting the chassis.The entire frame (to the driver cab) must be strengthened.If L-shaped rods are used for connecting the reinforcement beam and frame, class 8.8 bolts must be used, while the diameter and distribution of the bolts must ensure the required strength in the reinforcement beam. In the case that the subframe is required for reinforcement, the body installation bracket on the chassis (if any) should be used for connection.It is recommended that a shear connector be used at the rear overhang area (from the rear end of the chassis to the centre of the wheel track, and that the shear connector should be less than 2 m from the front axle), as shown in Figure 3.19.
Installing additional axles Base - 09/2013 Printed 603.95.640 3-25 GENLYON - KINGKAN REFITTING THE CHASSIS
Figure 3.19
198178 Reinforcement of the chassis frame 1. Reinforcement connection bracket - 2. Reinforcement connection - 3. Holes for bolts, rivets, or plug welding (2030 mm)
Do not weld the reinforcement plate on the crossbeam flange by the hole for welding filler metal.Otherwise, poor welding technique may affect the strength of the original longitudinal beam. Only in the event that it proves difficult to mount the body, and also that the relevant technical plan has been approved by our company, can you weld the reinforcement plate by the hole for welding filler metal.
Figure 3.20
198179
Reinforcement of the chassis frame when lengthening the rear overhang 1. Installed additional axle - 2. Rear overhang of lengthened frame - 3. Reinforcement for refit - 4. Reinforcement connection - 5. Reinforcement beam of longitudinal beam
When reinforcement is required, welding weakens the performance of material. As such, when calculating the load on different sections, it should be assumed that the material strength has decreased by 15%. In principle, the thickness of a reinforcement beam should not exceed that of the original longitudinal beam. Only proficient personnel may conduct such an operation. If the frame is damaged by poor technique, the refitting factory must bear all consequences.
Installing additional axles
Printed 603.95.640 Base - 09/2013 3-26 REFITTING THE CHASSIS GENLYON - KINGKAN
3.7.3 Components and suspension used for refit
To ensure driving safety and operability, use only guaranteed quality components, such as axles, suspension, brakes and brake systems. Suspension is crucial to the performance of a vehicle on the road, and thus special attention should be paid to its design and manufacture. A suspension can take the form of a leaf spring suspension, air spring suspension, or combination suspension. No matter which type suspension is used, the suspension should never negatively affect the operability of the vehicle and its components, which includes the quality of driving, comfort, floor attachment of tyres, operating angle of transmission, and workspace for installing additional axles. If the installed additional axle has its own independent suspension, the feature of its suspension must match that of the original rear suspension, so as to ensure appropriate static loads on the two axles.
3.7.4 Sway bar
When there is air suspension on the installed additional axle, a sway bar may be required, especially when the centre of gravity of the body is high.When there is combination suspension on the installed rear axle, similar measures should be taken to improve stability.
3.7.5 Connection between the installed additional axle and frame
The installed additional axle must be able to withstand all horizontal and longitudinal stress, without passing this stress on to the drive axle. At the points of introduction of force, such as at the spring bracket or air suspension bracket, a proper crossbeam or reinforcement must be used. Please ensure that the installed additional axle is vertical to the longitudinal axis of the vehicle and is aligned to the drive axle.
3.7.6 Brake system
The brake system is crucial to a vehicle’s safety, meaning that the brake system should be carefully de- ! signed and refitted.
Thesametypeofbrake,hoseandjointsastheoriginalsmustbeused. The same brake assembly as that of the front axle must be installed on the auxiliary axle. A hose should be used to connect the brake air channel between the fixed system (chassis) and flexible components (axle). The braking torque must be proportional to the static and dynamic loads in order for an even braking force to be applied on every axle. In principle, the overall braking capability of the refitted vehicle must be proportional to that of the original, taking the weight change into account. The brake system must always comply with current relevant national regulations in terms of deceleration, high temperature performance, response time, and engine braking efficiency. In the case that our company requires technical documents relevant to the brake system for approval purposes, the refitting factory, or supplier of the installed additional axle must provide such documents. Examples of such documents are the attachment curve and compatibility range drawing. Please contact our company for the technical documents, features, and performance indices relating to the original brake system. It is best to use the same components as the originals when refitting the brake circuit of the auxiliary axle. The air channel of the installed additional axle can be directly connected to that of the original drive axle.
Installing additional axles Base - 09/2013 Printed 603.95.640 3-27 GENLYON - KINGKAN REFITTING THE CHASSIS
Please make sure that the air supply and capacity of the gas reservoir meets the requirements of the brake cylinder of the original drive axle and that of the installed additional axle. An extra gas reservoir should also be installed, where necessary. The refitted vehicle must comply with relevant national regulations on emergency brakes and parking brakes.It is recommended that the parking brake also applies braking force on the installed additional axle.
When refitting the brake system, please adhere to the regulations in Section 3.14 “Brake system” in ! this chapter. When refitting the electrical system, please adhere to the regulations in Section 3.15 “Refitting the electrics” in this chapter.
3.7.7 Installing a lift device for an installed additional axle
A lift device may be installed for an installed extra axle to improve the attachment between the drive axle and floor under certain conditions, such as on uphill, slippery, snowy, or icy roads, and when the following two conditions are met: - The vehicle is refitted according to the proposals given by our company on approval of the technical plan, and the drive axle load of the running vehicle does not exceed its specified maximum load capacity. - The lift device can only be used in the above cases for a short distance, and the speed of the vehicle shall not exceed the top speed proposed by us on approval of the technical plan. In some countries and regions, the axle lift device can be used when the vehicle is running, provided that the maximum permitted axle load and the maximum permitted speed are not exceeded, according to relevant regulations. Please make sure that the following items also comply with relevant regulations: the centre of gravity of the body and cargo; the axle load distribution of the complete vehicle; the attachment of the drive axle; and the braking performance.
After a refit, the vehicle should be sent to the relevant inspection authorities for performance inspec- ! tion, such as type approval and single item inspection.
After installing additional axles, the plan and procedure for maintenance of the vehicle should be specified and included in such documents as the Operating Instructions for the finished vehicle. Such plans and procedures for maintenance should correspond to those of the original vehicle.
Installing additional axles
Printed 603.95.640 Base - 09/2013 3-28 REFITTING THE CHASSIS GENLYON - KINGKAN
Refitting the suspension 3.8 Refitting the suspension
Suspension is crucial to the driving safety of a vehicle, and thus refits should not be made until relevant ! technical plans have been approved by our company.
In principle, the parabolic spring is not to be refitted.Our company may agree for rubber components to be added to special vehicle models with such springs, so as to improve the rigidity of suspension for special purposes. Only on very special occasions and for special reasons will we evaluate the feasibility of installing leaf springs on the parabolic spring. Such refitting should take place after relevant technical plans have been approved by our company, and should only be carried out by professionally competent companies. Do not use both a parabolic spring and trapezoidal spring on the same axle.
Refitting the suspension Base - 09/2013 Printed 603.95.640 3-29 GENLYON - KINGKAN REFITTING THE CHASSIS
Refitting the engine intake and exhaust systems 3.9 Refitting the engine intake and exhaust systems
Unless formal approval has been obtained from our company, no refitting work should be carried out that may change the performance of the engine intake or exhaust systems. Care should be taken to ensure that refitting work that is carried out on the engine intake system does not affect the intake resistance and exhaust back pressure of the original vehicle. The exhaust pipeline of the engine must be as smooth as possible, with bend angles not exceeding 90˚, and a bend radius greater than 2.5 times the external diameter. Please make sure that there are no kinks in the pipe, and that the cross-sectional area of the pipe exceeds that of the original corresponding pipe. All connectors for the intake pipes should enable the pipeline to withstand water and dust. A sufficient distance (greater than 150 mm) should be maintained between the exhaust pipe and the electrical system, plastic hoses, and spare wheel. When a proper heat-insulating metal panel is used, this distance can be decreased (to 80 mm, for example). To further decrease this distance, use heat-insulating material and replace the plastic hoses with steel pipes. For all refitting work on the exhaust system of original vehicles from our company, the refitted vehicles must comply with relevant standards and regulations in terms of noise and exhaust. No heat discharged from the engine or dusty air, rain or snow should enter the air intake port. The effective area of the air intake hole of the canopy truck should be greater than 2.5 times the area of the main pipe before the filter. These holes (such as the holes on the grid) should be large enough as to not easily become blocked. Do not refit or replace the original air filter. Do not adjust key engine components, such as the fuel injection pump, adjuster, or fuel injector, due to the fact that such adjustments may affect the normal operations of the engine and may negatively affect the exhaust.
Refitting the engine intake and exhaust systems
Printed 603.95.640 Base - 09/2013 3-30 REFITTING THE CHASSIS GENLYON - KINGKAN
Refitting the engine cooling system 3.10 Refitting the engine cooling system
In principle, the cooling systems on chassis made by our company are not to be refitted, especially cooling components associated with the radiator and the effective area (dimensions and layout) of the radiator and hose. If you must refit a cooling system during refitting work (such as when refitting the driver cab, for example), attention should be paid to the following points: - The effective ventilation area for the cooling radiator should exceed that of the original vehicle. Please ensure that air can be expelled from the engine compartment to the largest degree, and that no static vapour cavity or air backflow is formed (a guard plate or baffle may be required). Do not modify the performance of the cooling fan, due to the fact that this may affect the original vehicle design. - In the case that the hose has to be relocated, this relocation should not affect the fullness of the system (when the flow constantly stays at 8~10 L/min, the system is full and no jams form at the port) or the normal water flow. Even under the poorest working conditions, the highest stable temperature of the water coolant should not exceed that of the original. - A hose cannot be placed at a location in which vapour cavity forms (i.e., a siphon effect is avoided by offering proper outlets). Check that when the engine starts and runs at a low speed, the pre-filled water is not pulled out, and that when no pressure is in the circuit, the water is only pulled out temporarily. If necessary, accelerate for a short period of time. In addition, check that the water pump output pressure is no less than 1 bar when the engine is running at its maximum speed. - It has been verified that the anti-clogging device of the radiator should be refitted together with the engine cooling system.
Refitting the engine cooling system Base - 09/2013 Printed 603.95.640 3-31 GENLYON - KINGKAN REFITTING THE CHASSIS
Installing an additional independent heating system 3.11 Installing an additional independent heating system
Certain vehicle models made by our company, such as the Genlyon and New Kingkan, come with a driver cab heating system.If the user or refitting factory deems it necessary to install an extra independent heating system, it is best to use a heating system from one of our suppliers. If an independent heating system is not covered in the original vehicle design, the refitting factory should follow instructions from the supplier (such as those relating to the layout, pipeline, and electrical system of the heater), as well as the following instructions, when installing this heating system. The installation of a heating system must comply with all relevant national standards and regulations (such as those relating to inspection and dangerous goods trucks). If a device is not specially designed for a vehicle, it should not be used on that vehicle during a refit. Otherwise, the performance of the refitted device may be altered or damaged. As such, the relevant technical plan should be submitted to our company for approval before such refitting work is conducted.
Other points for attention 1) Ensure that the components and device (i.e., the cooling system) of the vehicle work properly, and are not affected by the installation of the additional independent heating system. 2) Check the electrical system to make sure that the battery and generator have sufficient capacity for offering larger currents and more power (please refer to the instructions in the section in this chapter titled “Refitting the electrics“.). The newly added electrical circuit must be fitted with a safety device. 3) Connect the newly added fuel supply system inlet to the fuel accumulator (the fuel accumulator is connected to the fuel return pipe of the engine). The newly added fuel supply system can be connected to the fuel tank of the vehicle only when it is independent of the engine fuel supply system, and when the new circuit is absolutely free from leaks. 4) When designing the layout of the fuel pipeline, heat pipeline, electrical circuit, and their installation, please ensure that high-temperature components do not affect the normal operation of the existing pipeline and other devices, and that the installation and layout of the pipeline do not pose any risk to the operation of the vehicle.A guard plate or heat insulating device may be used if necessary. 5) If the installation of an extra heater involves the existing heat and cooling circuits, the following instructions should be complied with to ensure the reliability and safety of the heating system: - Clearly specify the connections between the newly added system and the existing system.Please obtain guidance from our company if necessary. - Design a reasonable pipeline layout, in order to avoid necking or siphon effects. - Install proper vent valves (outlets) in order to ensure a proper water supply in the system. - Install a drain bolt if necessary, to ensure that the system is able to drain off water. - Use proper heat-insulating materials to avoid heat dissipation. 6) If an air heater is installed inside the driver cab, please ensure that the engine exhaust system stays well away from the added device (so as to avoid pollution), and that heat is properly distributed (so as to avoid direct air blow). 7) During the design of the entire system, the speed and convenience of maintenance should also be taken into account.
Installing an additional independent heating system
Printed 603.95.640 Base - 09/2013 3-32 REFITTING THE CHASSIS GENLYON - KINGKAN
Installing an air conditioning system 3.12 Installing an air conditioning system
Certain vehicle models made by our company, such as the Genlyon and New Kingkan, come with an air-conditioning system option. If an air-conditioning system is required, it is best to use an air-conditioning system from one of our suppliers. The air-conditioning system must be installed according to the instructions from the supplier and the following points: - The installed A/C does not affect the normal operation of the different vehicle components that may be connected to the A/C. - Check the electrical system to make sure that the battery and generator have sufficient capacity for offering larger currents and more power (please refer to the instructions in the section in this chapter titled “Refitting the electrics“.).The newly added electrical circuit must be fitted with a safety device. - Please contact our company for details of how to install an air compressor. If an air compressor needs to be installed on the engine, the air compressor used must be compatible with our engine. - When designing the layout for the A/C pipeline, electrical circuit, and their installation, please ensure that the pipeline and circuit do not affect the normal operation of the existing pipeline and other devices, and also that the installation and layout of the pipeline do not pose any risks to the operation of the vehicle. A guard plate or heat insulating device may be used if necessary. - During the design of the entire system, the speed and convenience of maintenance should be taken into account. The refitting factory should provide the necessary maintenance guides at the time of the vehicle’s handover. If an air-conditioning system is installed inside the driver cab, the following rules should be complied with: - The installation of the condenser shall not damage the radiating capacity of the original engine cooling system, or decrease the radiating area of the original cooling radiator. - The evaporator is properly laid out in the driver cab, so as not to affect the ease of use of controlling and operating devices.
Installing an air conditioning system Base - 09/2013 Printed 603.95.640 3-33 GENLYON - KINGKAN REFITTING THE CHASSIS
Changing specifications and tyre size 3.13 Changing specifications and tyre size
Before replacing original tyres with tyres of different specifications, size or load capacity, approval should first be obtained from our company. To change the size of tyres, you may need to replace the original wheels with wheels with a larger load capacity.In this case, please consider whether the spare wheel carrier also requires refitting. Never install tyres of different specifications or structure on the same axle. Changing the tyre size may change the ground clearance of the rear bottom and side protection devices. Therefore, please check whether the refitted vehicle complies with the relevant national regulations and standards after the tyres have been replaced.If necessary, replace the existing rear bottom and side protection devices according to relevant regulations (installation and strength). If larger tyres are required, check the safety margin of the mechanical components, fenders, and splash guards under various steering and driving conditions. If wider tyres are required, check the axle and evaluate the space required for the suspension and the length for wheel studs. A complete vehicle with replaced tyres must comply with local and national regulations in terms of vehicle width. Tyres of different external diameters will affect the performance of a vehicle, including its speed, maximum gradeability, towing force, and brake power. The tachometer must be recalibrated according to relevant national regulations and standards. The load capacity and reference relative speed should always match the performance of the vehicle. If tyres with lower load capacity and speed limits are used, the maximum permitted load and performance of the vehicle should be reduced accordingly. On the other hand, tyres with larger load capacity do not automatically increase the maximum permitted axle load. Verify tyre specifications and load capacity according to relevant international and national standards. Please note that tyre specifications and load capacity are also listed by tyre suppliers in their product brochures. For special purpose vehicles (e.g. fire trucks, winter vehicles, airport oil tank trucks, and buses), national regulations may set special performance indicators. If this is the case, the refitted vehicle should be sent to the relevant inspection authorities to assess whether the performance of the vehicle complies with relevant regulations, and whether the documents attached with the vehicle have recorded the relevant refit.
Changing specifications and tyre size
Printed 603.95.640 Base - 09/2013 3-34 REFITTING THE CHASSIS GENLYON - KINGKAN
Brake system 3.14 Brake system
3.14.1 Principles for refitting the brake system
- The brake system and its components are crucial to the safety of a vehicle. - Never refit any safety components, such as the brake control system, distributor, brake cylinder, or brake valve. - Any modification to the brake system (such as changes to the pipeline and the addition of operating cylinders) must receive advance authorization from our company. - The braking torque must be proportional to the static and dynamic loads in order for an even braking force to be applied on every axle. - After a refit, the vehicle should be sent to the relevant inspection authorities for comprehensive performance inspection. The overall braking capability of the refitted vehicle must be proportional to that of the original (taking the weight change into account). The brake system must always comply with current relevant national regulations (in terms of deceleration, high temperature performance, response time, and engine braking efficiency).
3.14.2 Brake pipeline
If the wheelbase or overhang of a vehicle is altered, the relevant brake pipes should be replaced with new ones. If they cannot be replaced, pipes and connectors of the same type as the originals should be used. The new pipes must meet the requirements of the minimum internal dimensions of the original pipes.
Never weld brake pipes. !
The replacement brake pipes must have the same features and be made of the same material as the original pipes. When replacing the brake pipes, the pipes should be well protected, so as to ensure that the brake system works properly after the refit. It is recommended that the refitting factory obtains components for the refit from the part supply system of our company or a professional part supplier. 1) Metal pipes During the installation or refitting work of the pipeline of the pneumatic brake system and pipeline between the air compressor and adjuster, the following regulations and standards must be complied with: - ISO 4038 for the brake pipeline (materials, models, and connectors) - DIN 390 for the air compressor pipeline (materials, models, and connectors) - Bend radius (with reference to the central line of the pipe): must be no smaller than two times the external radius. The tightening torque used during the brake pipeline refitting should comply with the following regulations: - Diameter of the brake pipeline = 6x4 (connector M12x1): 20 Nm - Diameter of the air compressor pipeline = 19x15 (connector M26x1.5): 90 Nm
Brake system Base - 09/2013 Printed 603.95.640 3-35 GENLYON - KINGKAN REFITTING THE CHASSIS
2) Plastic pipeline When refitting the brake pipeline, plastic pipes must not be used in the following areas: - Air compressor outlet pipeline - Areas where the temperature is above 80 ˚C (for example, within 100 mm of the engine exhaust system) - Connections between fixed components and moving components a special hose should be used in these locations. - Hydraulic pipeline During the refitting work, the following regulations and standards must be complied with: - DIN 74324 (maximum working pressure: 11 bars) for the materials and dimensions - Bend radius (using the central line of the pipe as a reference): must be no smaller than six times the external radius 3) Refitting the brake pipeline The pipeline should be cut vertically using special tools (the cut deviation should not exceed 15˚), and in a way that avoids defects that may affect the tightness of the pipeline. An appropriate length, L, of the brake pipe should be placed inside the connector (as shown in Figure 3.21) in order to ensure the tightness of the connector. The pipe should be marked with fadeless ink or sticky tape, for ease of identification in later phases so as to avoid mistaken connections. In principle, it is recommended that connectors of the same type as the originals are used.Where necessary (near the bend, for example), metal plug-in connectors may also be used. Before placing the pipe into the connector, the following level of tightening torque should be applied so as to push the connector into the threaded hole of the pneumatic component (such as the pneumatic valve).
Figure 3.21
198179 Connections for the brake pipe
Table 3.3
Screw thread Tightening torque (Nm ± 10%) M 12x1.5 mm 24 M 14x1.5 mm 28 M 16x1.5 mm 35 M 22X1.5 mm 40
Brake system
Printed 603.95.640 Base - 09/2013 3-36 REFITTING THE CHASSIS GENLYON - KINGKAN
A force of 30 to 120 N (depending on the dimension of the pipe) should be applied in order to insert the previously identified L length of pipe into the connector. Some components (such as the valve) may need to be replaced due to the fact that connectors may turn during the tightening or loosening process.
When pipes are replaced, use new connectors.The removed connectors can no longer be used. !
Before installing a pipe, clean the interior of the new pipe thoroughly (by blowing the pipe with compressed air, for example). Then fix the pipe at the correct position.The pipe must be fastened firmly by either plastic, metal, or rubber pipe clamps. An appropriate distance should be maintained between various pipe clamps. Generally, the maximum distance between clamps for plastic pipes is 500 mm, while the maximum distance between clamps for metal pipes is 600 mm. In order to avoid distorting or tensing the plastic pipe connectors, precautions should be taken when designing the pipeline layout and installing relevant brackets on the chassis. When the brackets are correctly installed, there should be no conflict between the pipeline and the fixed components on the chassis. Maintain a safe distance between moving parts and heat sources. In the case that the pipeline must pass through the chassis frame (longitudinal beams or crossbeams), corresponding protective measures should be taken to avoid friction between the pipeline and metal components on the chassis. Alternatively, bulkhead connectors may also be used, as shown in Figure 3.22.
After refitting the brake system, check the braking performance of the complete vehicle. ! Apply the maximum working pressure on the brake air pipeline, and check for pipeline leaks.
3.14.3 Electronic brake control system
Please read carefully the instructions on electrics and electronics in this document. !
As changes to the wheelbase will affect the brake system, attention should be paid to the following instructions during the refitting process: Keep the brake adjuster connected to the rear axle at its original location. Adjust the wire between the rear axle and control unit and the wire between the control unit and regulator accordingly (by installing the wire produced by our suppliers for longer-wheelbase vehicles). In addition, adjust the upstream brake pipe of the adjuster by replacing the short brake pipe with a longer integral one.
Brake system Base - 09/2013 Printed 603.95.640 3-37 GENLYON - KINGKAN REFITTING THE CHASSIS
Figure 3.22
198180
Bulkhead connections for the brake pipeline 1. Brake air pipe - 2. Bulkhead connector - 3. Chassis components
3.14.4 Additional gas equipment
1) In principle, the additional gas equipment can only obtain gas from the 20 L auxiliary air reservoir and auxiliary air pipeline. 2) In the case that it is difficult for the additional gas equipment to obtain gas from the auxiliary air reservoir and auxiliary air pipeline, the gas equipment can obtain gas from the brake air reservoir and its air pipeline provided that the following three conditions are met: - When gas consumption is low, the additional gas equipment consumes no more than 1 L of air; or when the vehicle is parked, the gas equipment works and consumes no more than 2 L of air. - A check valve is added between the additional gas equipment and the main air pipeline, so as to protect the main brake from leaks and damage in the additional gas equipment and air pipeline. - When the additional gas equipment is connected to the brake air reservoir, the air pressure of the compressed air in the brake system must exceed 4x105 Pa after five times full service braking (the air compressor does not work at this time), and the air pressure must be no larger than 0.6x105 Pa during every full service braking.
3) If it is difficult for the additional gas equipment to obtain gas from the auxiliary air reservoir and auxiliary air pipeline, the gas equipment can obtain gas from the air spring brake reservoir and its air pipeline provided that the following conditions are met: - When the additional gas equipment is connected to the air spring brake reservoir, the air pressure in this reservoir exceeds 5.2x105 Pa after at least three brake releases when the nominal maximum air pressure is in the brake system and the air compressor does not work. Additional air reservoirs can be installed to achieve this. - Relay valves are added at proper locations to ensure that the relaxation time of the spring accumulator (from manual braking until the indicator light of the spring accumulator goes out) does not exceed one second.
Brake system
Printed 603.95.640 Base - 09/2013 3-38 REFITTING THE CHASSIS GENLYON - KINGKAN
4) When the additional gas equipment consumes such amounts of gas and its working pressure is so high that the gas equipment cannot obtain gas from the service brake or spring brake pipeline, an auxiliary air reservoir should be installed, with the size of this air reservoir depending on actual conditions. It is best to use an auxiliary air reservoir belonging to the same series as the existing air reservoir, for ease of manufacture and to minimize cost. The auxiliary air reservoir should be connected to the service brake air reservoir. An excess flow check valve should be installed between this air reservoir and the front axle circuit, so that the air pressure in the service brake air reservoir can be maintained as high as possible (at least 5 bar) when the auxiliary air reservoir does not work properly and its air pressure drops. 5) If a large amount of compressed air is required by the trailer, a separate circuit should be installed between the auxiliary air reservoir of the tractor truck and the trailer, using an automatic connector at the joint. This connector should be obviously different from that of the brake system.If necessary, a conspicuous instruction sign can be installed near the connector. 6) Do not connect the air reservoir for the spring accumulator or trailer to the newly added gas equipment. 7) The control components of the brake equipment and brake valve are related to the safety of the vehicle, meaning that they must not fracture during operation. The pull rod must either be integral, or consist of two parts using a casing thread connection. The pull rod is not to be extended by welding.It is recommended that the same components as those on the Genlyon and Hongyan Kingkan be used to add to or replace the various brake valves. 8) Use special corrosion-resistant high-pressure pipes for the brake circuit. It is recommended that the same brake pipes, hoses, pipe clamps, and thread connectors as those on the Genlyon and Hongyan Kingkan be used, considering safety and spare part sourcing. During the pipeline layout, please note that sufficient space should be left between the brake chamber and brake hoses and between the axle and its stop blocks.In addition, sufficient space should be left between the new circuit and relevant moving parts. During the installation of long plastic pipes, take care to avoid friction between the pipe and adjacent components. A pipe clamp should be installed at every 500 mm along the plastic pipe. The plastic pipe is highly sensitive to temperature, and possesses a maximum constant working temperature of 80 ˚C. It is recommended that steel pipes be used on unprotected areas exposed to high temperatures and high pressure.
Brake system Base - 09/2013 Printed 603.95.640 3-39 GENLYON - KINGKAN REFITTING THE CHASSIS
General technical instructions 3.15 Refitting the electrics
3.15.1 General technical instructions
Do not modify electrical equipment such as the CAN bus. ! Our company also does not recommend for other electrical circuits or wires to be modified. Any modification of the system will decrease the quality and safety of the electrical system of the com- plete vehicle. If an electrical system must be modified, the refitting factory must use original authentic spare parts from our company. Our company shall not be responsible for any faults caused by improper refitting, with the refitting fact- ory to be held responsible for all consequences.
To protect rubber parts (which help ensure the connection tightness), do not connect and disconnect the ECU relevant connectors more than three times. The refitting factory should install electrical equipment such as switches, sockets, and lamps of the same models and quality as the originals on the chassis. It is best to install additional switches and indicator lights using the existing holes on the dashboard.When installing other electrical equipment, connect these to the reserved ports on the chassis, and make sure that the electrical devices and their circuits are correctly connected and fastened tightly. Wires and connectors should be of the same colours and codes as the originals used on the vehicle, to ensure consistency in installation and ease of maintenance. In the case that the electrics are not refitted according to the instructions stipulated by our company (including those on the removal of wiring harnesses, adding electrical circuits, replacing equipment, and replacing fuses), or are refitted by incompetent personnel, the entire electrical system (i.e., the control equipment, circuits, and sensors) of the complete vehicle may be severely damaged, affecting the safety and normal operation of the vehicle (a short circuit may cause a fire and destroy the vehicle, for instance). Our company will not be held responsible for any maintenance relating to such problems. Never modify the cable (CAN bus) for the electrical control equipment, or connect any device to such a cable. Such a cable should not be modified under any circumstances. Only equipment certified by our company and used by professionals may be used to diagnose problems with or maintain the cable. In the case that electrical devices on the body are connected to the electrical circuit of the chassis, the refitting factory should check whether the original battery and generator have sufficient capacity and power. A more powerful generator and a special battery with higher capacity should be used, or an auxiliary battery added, if necessary. Before refitting the electrical system, disconnect the wire between the battery and the electrical system by starting with the positive cable followed by the negative cable. To protect the electrical system of the chassis from damage caused by large electric welding currents, all power supply cables should be disconnected from the electrical system before the welding of any chassis components begins. In the case that the electrical equipment is battery-powered, a protective device (such as an integrated fuse) that corresponds to the power consumption of the device should be installed. The breaking capacity of the fuse must comply with relevant technical specifications. Never use a fuse whose breaking capacity is larger than the specified amount. The fuse should be replaced after the electrical equipment has been turned off. It is best to connect the ground wire of the electrical equipment to the negative pole of the battery or the ground wire location of the complete vehicle. Make sure that the ground wire is properly connected.
General technical instructions
Printed 603.95.640 Base - 09/2013 3-40 REFITTING THE CHASSIS GENLYON - KINGKAN
The following measures should be taken to protect the electrical components of the vehicle: - Never remove the connector from the control device when the engine is running or when the control device is powered. - Do not provide nominal power to electrical components in the electronic module of the vehicle by connecting the components directly to the power source. - Unless otherwise specified, a control device with a metal cover must be connected to the ground wire using bolts or screws. - When installing an electrical device, a diode should be installed to protect the electrical device from damage by a peak-induced current. - Connections in the electrical system must comply with the standards of the original vehicle (including those on length, conductors, layout, clamps, and braided shields).After the refitting work is complete, the original electrical system of the vehicle should be restored. We recommend that electrical, electromechanical and electronic equipment that meets anti-electromagnetic interference standards (on electromagnetic radiation and conduction interference) be used: The anti-electromagnetic interference level of the electronic equipment on the vehicle should meet the following criteria at a distance of one meter from the antenna: - Secondary devices should have a maximum resistance of 50 V/m and a frequency range of 20 MHz ~ 1 GHz - Primary devices should have a maximum resistance of 100 V/m and a frequency range of 20 MHz ~ 1 GHz For electrical equipment with a 24 V power supply, the maximum permitted transient voltage fluctuation measured on the simulation network terminal (L.I.S.N) is +80 V during the bench test. When the test is conducted on the vehicle, the transient voltage fluctuation should be measured at the point closest (that is realistically accessible) to the interference source. Please refer to the following table for maximum radiation and conduction levels:
Table 3.4
Interference level (dBuVis the common unit for the measurement of radiation levels according to CISPR) Interference Transmitter Band Detector 70-108 MHz, 150 kHz 530 kHz 5.9 MHz 30 MHz 144-172 MHz 300 kHz 2MHz 6.2 MHz 54 MHz 420-512 MHz, 820-960 MHz Quasi-peak Radiation Broadband 63 54 35 35 24 Antenna (1 value Radiation meter from Broadband Peak value 76 67 48 48 37 equipment) Narrow Radiation Peak value 41 34 34 34 24 band Quasi-peak Conduction Broadband 80 66 52 52 36 LISN value d50ohm/ Conduction Broadband Peak value 90 76 62 62 46 5 H / 0, 1 Narrow Conduction F Peak value 70 50 45 40 30 band
A relevant technical plan should be sent to our company for approval before the following devices, ! which may interact with the original electrical equipment (e.g. the ABS or EDC) of a vehicle, are in- stalled.
General technical instructions Base - 09/2013 Printed 603.95.640 3-41 GENLYON - KINGKAN REFITTING THE CHASSIS
-Retarder - Auxiliary heater - Power take-off - Air conditioning system - Automatic gearbox - Fleet management - Speed-limiting device
NOTE To ensure normal installation, please test all operations that may interfere with the basic system of the vehicle. An ECU (electrical control unit) may be used, or maintenance personnel from our company can also perform the test if so requested. The additional circuit must be separated from the main circuit of the vehicle and must be protected by the fuse. The cable must have appropriate specifications that match the functions of the cable, must have good insulation performance, and must be protected by a sheath (non-PVC). Inmostcases,thecableshouldbelaidinsidethehose(ahosemadefrompolyamide6isrecommen- ded) and should be placed away from shock and heat. Do not wind the cable around other components, especially the edge of the body. A proper cable sealing plug or sheath must be used if the cable passes through structural components (crossbeams and structural steels). The cable should be fixed separately using cable clamps (nylon cable clamps, for example) and a good distance (of about 350 mm) should be kept between two adjacent cable clamps. If conditions permit, signal cables with strong interference (cables for the electric motor and magnet- ic valve, for example) and low signal cables (cables for the sensor) should be laid separately. In all events, these two kind of cables should be laid as close to the metal structure of the vehicle as possible.
Please select the cable and fuse from the following table, according to the working current of the additional electrical equipment:
General technical instructions
Printed 603.95.640 Base - 09/2013 3-42 REFITTING THE CHASSIS GENLYON - KINGKAN
Table 3.5
Maximum continuous working current1 Nominal fuse value2 (A) Cross-sectional area of the cable (A) (mm2) 0-4 5 0.5 4-8 10 1 8-16 20 2.5 16 - 25 30 4 25 - 33 40 6 33 - 40 50 10 40 - 60 70 16 60 - 80 100 25 80 - 100 125 35 100 - 140 150 50
Notes:1) The electrical equipment works continuously for more than 30 seconds. Our company has the right to deny warranty services on a refitted vehicle if the refitting work does not comply with relevant regulations pertaining to our company or if the refitting work affects the normal operation of the electrical system of the complete vehicle. The refitting factory is to bear all consequences in such circumstances.
3.15.2 Installing a wireless vehicle communication system
The most common wireless vehicle communication systems are as follows: - Amateur radio transceivers (CB, 2 M bandwidth) - Transceivers for cellular phone - GPS receivers and satellite navigation devices When installing a CB (27 MHz)/2 M amateur radio device, cellular phone (GSM), or satellite navigator (GPS), the device should be connected to the power source of the vehicle, and the fuses connected to terminal #30 (and terminal #15, if necessary). The wireless vehicle communication system must receive the approvals required by relevant regulations, while the system must also be fixed (i.e., not mobile). An appropriate 24-12 V DC/DC converter should be installed when the wireless vehicle communication system equipment requires a 2 V voltage.The converter power cable must be as short as possible and must not form a circle. The distance between the converter power cable and the ground should not be smaller than the specified minimum length.
Do not use an uncertified transceiver or amplifier due to the fact that this may affect the normal opera- ! tion of the standard electrical and electronic equipment, posing negative effects on the safety of the vehicle and the driver cab.
1) Installing a 2 M HAM radio system Install the transmitter of the 2 M HAM radio system at a flat, dry location free from electronic components, vibrations, and moisture. Install the antenna on a large metal bracket outside the vehicle. It is best if the antenna is vertical, with the connecting cables hanging downward.Install the antenna according to the instructions provided by the supplier. Choosing an appropriate antenna and installing this antenna correctly is crucial to achieving the best performance for the equipment.The antenna must be of a high quality. Ensure that the antenna is correctly installed.Installation quality is also important, due to the fact that the installation quality determines the performance and distance measured by the radio.
General technical instructions Base - 09/2013 Printed 603.95.640 3-43 GENLYON - KINGKAN REFITTING THE CHASSIS
There are two installation methods, namely:fixed installation (permanent installation) and installation on formed parts (or other brackets).The second method is preferable due to the fact that the body does not have to be drilled. The distance between the installation of the antenna and other antennas should be at least 1/2 lambda (wavelength).It is best if the antenna is installed in the centre of the roof. During the connection and layout of the cable line, the following requirements must be met: - Use a top-class coaxial antenna cable with low losses, and with the same electrical resistance as the transmitter and antenna. - Keep a proper distance (at least 50 mm) between the coaxial cable line and the original lines (TV, radio, telephone, amplifier, and other electronic devices) to avoid interference. Ensure that the distance between the cable line and the metal structures in the driver cab exceeds the specified minimum length. It is best to install the cables on the left or right side. - To ensure a good connection between the antenna bracket and the vehicle, clean the lower part of the antenna mounting hole on the body. - Be extremely careful when installing coaxial cables between the antenna and wireless devices (radio). Do not create bends that may clamp or twist the cables, so as to avoid these cables becoming entangled. The shorter the cables are the better. - Please note that any defects in the coaxial cables will severely interfere with the wireless transmitter. - Lay out the cables using the existing holes.If new holes must be drilled, necessary measures should be taken to protect the body (using anti-rust paint) and to avoid damage caused by friction between the cables and body parts (using a sheath). - To improve the quality of receiving and transmitting signals, ensure that the antenna mount and equipment are connected to the vehicle. 2 M HAM radio devices are usually installed in the gear stick area or on the dashboard in front of the driver. 2) Installing a cellular phone Install the cellular phone at a flat, dry location free from electronic components, vibrations, and moisture.Install the antenna on a large metal bracket outside the vehicle. It is best if the antenna is vertical, with the connecting cables hanging downward.Install the antenna according to the instructions provided by the supplier. The ideal location for installing the antenna is at the front of the driver cab roof. The distance between the installation of the antenna and other antennas should be at least 300 mm. - Use high-quality cables and cable sheaths. - Keep a proper distance (at least 50 mm) between the cable line and the original lines. Ensure that the distance between the cable line and the metal structures in the driver cab meets the specified minimum length. Do not overstretch or twist the cables. It is best to install the cables on the left or right side. - Do not cut or extend the coaxial cables. - Lay out the cables using the existing holes.If new holes must be drilled, necessary measures should be taken to protect the body (using anti-rust paint) and to avoid damage caused by friction between the cables and body parts (using a sheath). - To improve the quality of receiving and transmitting signals, ensure that the antenna mount and equipment are connected to the vehicle. The cellular phone is usually installed in the gear stick area or on the dashboard in front of the driver. 3) Installing GPS antenna cables and a navigation system The correct and careful installation of a GPS antenna is crucial to achieving the best performance of the equipment. It is best to install the antenna in a hidden location. The power of satellite signals is so weak (around 136 dBm) that any obstacles may affect the quality and performance of the receiver. The GPS antenna should be installed at a point where the view of the sky is the broadest and the angle of view is at least 90˚. The view of the sky should not be obstructed by objects or metal structures, and the antenna should be installed in a horizontally.Ideal locations for GPS antennae are: below the plastic dashboard, in the centre of the windscreen, and at the mount of a windscreen. Do not install an antenna inside any metal structures in the driver cab. The distance between the GPS antenna and other antennas must be at least 300 mm. During the connection and layout of a GPS cable line, the following requirements must be met: - Use high-quality cables and cable sheaths.
General technical instructions
Printed 603.95.640 Base - 09/2013 3-44 REFITTING THE CHASSIS GENLYON - KINGKAN
- Keep a proper distance (at least 50 mm) between the cable line and the original lines.Ensure that the distance between the cable line and the metal structures in the driver cab meets the specified minimum length.Do not overstretch or twist the cables.It is best to install the cables on the left or right side. - Do not cut or extend the coaxial cables. - Lay out the cables using the existing holes.If new holes must be drilled, necessary measures should be taken to protect the body (using anti-rust paint) and to avoid damage caused by friction between the cables and body parts (using a sheath). - To improve the quality of receiving and transmitting signals, ensure that the antenna mount and equipment are connected to the vehicle.
3.15.3 Installing a battery and alternator
The electrical system is designed to provide the necessary power for all standard equipment on the vehicle. Each piece of electrical equipment possesses its own overload protection and appropriately sized cables.Install an overload protection device together with the added electrical equipment, so as to avoid overloading the vehicle system. The added equipment must be connected to the ground by a proper ground wire. This wire should be as short as possible, but with sufficient length left to allow for movement between the chassis and equipment. It is best to install a larger capacity battery or optional alternator parts when a larger capacity battery is required due to a load increase. It is recommended that the battery capacity shall under no circumstances increase by more than 20-30% of the original standard capacity, so as to avoid damage to certain system components (such as the starting motor).Install an extra battery and alternator if a larger power supply is required. When installing high power-consuming electrical equipment (such as a starter that is used frequently or for long periods when the engine is not operating) or a large number of electrical devices, an additional battery with proper capacity should be used due to the fact that the electricity consumption is much higher than the power supply of the vehicle. Install a separate charging system when adding a battery to the circuit of the vehicle (see Figure 3.23). This charging system must be integrated with the original charging system of the vehicle.In this case, it is best to use a battery with the same capacity as the original battery to ensure that all of the batteries can be charged normally.
Figure 3.23
198181 Adding a battery 1. Original standard battery - 2. Added battery - 3. Alternator with the voltage regulator - 4. Starting motor - 5. Start key switch - 6. Start power relay - 7. Instrument cluster
Check that the alternator has sufficient charging capacity when installing the battery. If is does not, use an alternator with higher power or install an extra generator.
General technical instructions Base - 09/2013 Printed 603.95.640 3-45 GENLYON - KINGKAN REFITTING THE CHASSIS
See Figure 3.24 for the layout of the electrical circuit for an added generator. Do not install extra batteries for a generator which works only when the engine is operating. Use a larger-power generator or install an extra generator instead.
Figure 3.24
198182
Electrical circuit for added generator
To avoid damage to the original electrical and electronic system, install a Zener diode rectifier for this alternator. Without a Zener diode rectifier, the electrical and electronic system may become damaged in the case that the battery is accidentally disconnected. Be extremely careful when installing a cooling unit powered by a second alternator driven by the engine. The alternator may generate a voltage of 270~540 V in the circuit for the cooling equipment. The output line of the alternator may generate electromagnetic interference with nearby lines, which can easily lead to danger. As such, high-insulating wires should be installed separately and should be kept away from other original wires in the vehicle. These devices should also meet the aforementioned electromagnetic output standards.
General technical instructions
Printed 603.95.640 Base - 09/2013 3-46 REFITTING THE CHASSIS GENLYON - KINGKAN
3.15.4 Power supply for added electrical equipment
The intended voltage for the electrical system of the vehicle is 24 V. There is a connector in the driver cab for the voltage reducer (from 24-12 V). The battery should not be directly used to provide 12 V power to the electrical system.
The maximum output current of the voltage reducer on our chassis is 20 A (this is the current as meas- ! ured at the up-down device of the windscreen inside the driver cab at 30 ˚C). At temperatures of 60 ˚C, the maximum output current of this voltage reducer decreases to 10 A. Do not use any other electrical equipment requiring a higher electric current.
3.15.5 Refitting the electrical wiring harness due to changes to the wheelbase or rear overhang
If the wiring harness has to be lengthened due to changes to the wheelbase of rear overhang, use the same waterproof electrical junction box as the originals on the chassis. All components (such as cables, connectors, terminal blocks, and cable conduits) must be the same as the originals on the vehicle and must be installed correctly.
General technical instructions Base - 09/2013 Printed 603.95.640 3-47 GENLYON - KINGKAN REFITTING THE CHASSIS
3.15.6 Requirements for installing electrical equipment on the cargo tank
1) When installing the cargo tank, the refitting factory should install side marker lamps, reflex reflectors, and front and rear outline marker lamps, all of which should comply with the relevant regulations (GB 18099-2000 Photometric characteristics of side-marker lamps for motor vehicles and their trailers). Components should be connected to the power source through the electrical junction box at the rear of the chassis, as shown in Figure 3.25.
Figure 3.25
Power source for right side Power source for Ground left side wire
198183 Connection between the body side marker lamps and power
2) If the user requires additional lighting equipment (such as a rear spotlight), do not connect this equipment to the power source at the left or right side marker lamps. Instead, connect such equipment to the power source on the general fuse box inside the driver cab through an electrical junction box, as shown in Figure 3.26. 3) The tractor truck offers a power source for various signal lamps through the trailer power interfaces.In the case that the user requires additional lighting equipment (such as rear spotlight), do not connect this equipment to the trailer power interfaces. Instead, connect such equipment to the power source on the general fuse box inside the driver cab through an electrical junction box,asshowninFigure3.26. 4) Vehicle models such as the Genlyon and Kingkan come with a dumper lift alarm device in the driver cab. When refitting such dump trucks, the refitting factory should connect the switch for the lift alarm device, whose control schematic diagram and ports are shown in Figure 3.27.
General technical instructions
Printed 603.95.640 Base - 09/2013 3-48 REFITTING THE CHASSIS GENLYON - KINGKAN
Added inductive electrical equipment (such as a power relay or electric motor) should contain anti-electromagnetic interference devices (such as a free-wheeling diode).
Figure 3.26 Power supply locations for the added electrical equipment (not larger than 25 A)
198184 Power supply ports for added electrical equipment (the lines indicate power supply cables)
Figure 3.27
Control schematic diagram for the dumper lift alarm device
24 V power Chassis wiring harness ports
Alarm buzzer
Dumper alarm control device Dark brown Blue black cable Blue grey Blue black cable Blue grey Connected to Blue white Brown the chassis Blue grey cable
Dumper lift switch Lift signal lamp Note: Ground wire The chassis wiring harness ports should be aligned with the terminal block. Flash frequency of lift alarm signal: 70±5 times/min The junction box is white.
198185 Control schematic diagram and cable connection for dumper lift alarm device
When installing high-power electrical equipment of 70 W or above, connect it to the reserved ports with the fuse in the drive cab to obtain power. Lighting equipment is not to be directly connected to the original lighting circuit. Instead, such equipment should be controlled by a power relay.When installing other high-power electrical equipment on vehicle models such as the Genlyon C100, M100, new Kingkan and Kingkan, the equipment should be connected to the reserved 25 A fuse in the driver cab to obtain power, as shown in Figure 3.26. Take precautions with the alternator and electrical and electronic equipment.When the engine is operating, do not disconnect the battery or the battery isolator, in order to protect the diode rectifier. If a tow start is required, ensure that the battery is connected.If the battery must use a quick charge, disconnect the electric circuit of the vehicle and the battery. Do not use the START function (if this function is available) when the external charging device is used, in order to start the engine using an external device, and to protect the electric and electronic components from the peak battery.
General technical instructions Base - 09/2013 Printed 603.95.640 3-49 GENLYON - KINGKAN REFITTING THE CHASSIS
3.15.7 Refitting the grounding device
In principle, the original grounding device is not to be modified.In the case that the ground position must be relocated, or an extra ground position added, it is best to use the existing holes on the chassis and to carry out the refitting work according to the following steps: - Clean the paint on the chassis and on the ground terminal using mechanical means or proper chemicals for the junction, which shall be free of any jagged marks or bulging. - Apply conductive coatings (such as galvanized PPG paint) on the junction surface of the cable terminal and that of the metal. - Connect the ground wire within five minutes of applying the conductive coatings.
3.15.8 Specifications and standards for installing the cables in the electrical system
- The power cable (positive pole cable) should be placed inside the hose (of an appropriate diameter) and should be placed separately-not together with-other thin cables (signal cable and negative pole cable). - A distance of at least 100 mm (the standard distance is 150 mm) must be maintained between the cable and high heat sources (such as the engine turbine and exhaust manifold). - A distance of at least 50 mm should be maintained between the cable and chemical containers (such as batteries). The same specification also applies for the cable and moving components. - At points where the cable passes through a hole on the metal plate or passes by sharp edges on the metal plate, the cable should be protected with a proper sheath or a corrugated protection tube (in addition to the flexible sleeve). - A flexible sleeve must be used to protect the entire cable, with this sleeve being connected to the rubber cap on the terminal block (through shrink wrap or tape).In addition, the clamps used to fasten the flexible sleeve (longitudinal cut) must not cause the sleeve to change shape. This will prevent the cable from coming out of the flexible sleeve or touching the edges of the surrounding cut. - The rubber cab must be used to protect all positive terminals (+) and blade terminals of the cable (a sealing cap should be used on areas exposed to wind, rain, or water). - Proper measures should be taken to fix the blade terminals of the cable on the terminal block (including the negative terminal block), so as to avoid loosening in the connection. The connection should be tightened if possible. In the case that there are multiple connections (multiple connections are best avoided), the connections should be laid out in the shape of a star. - It is best to lay out the cables using special brackets and cable ties. A short distance should be maintained between the brackets and/or cable ties, so as to avoid loosening in the connections, and to ensure quick restoration during the repair or installation of extra equipment. - When installing a cable between the chassis and the tilt driver cab, check for obstructions or tears to the cable when the driver cab is in a horizontal position (operating) and when the driver cab is lifted, respectively. If this cable is obstructed or torn, the cable layout must be rectified accordingly. - In the case that equipment such as the ECU is relocated during the refitting work, the length of the wiring harnesses (CAN cable and electrical wire) will be altered.If the cable becomes too long after relocating the electrical equipment, it may be folded- except in a ring, as this may cause electromagnetic effects. It is best to fold the cable in the pattern of the figure “8“. A cable connected to the ECU cannot be easily bent or folded, meaning that this cable must be replaced.In the case that the cable becomes too short, an original spare part from our factory should be used.
The CAN cable shall not be modified under any circumstances. Any refitting work on this cable is pro- ! hibited. After the refitting work is complete, please check that the front headlamps and other lights are work- ing properly.
General technical instructions
Printed 603.95.640 Base - 09/2013 3-50 REFITTING THE CHASSIS GENLYON - KINGKAN
Relocating components and installing auxiliary equipment 3.16 Relocating components and installing auxiliary equipment
If necessary, some components (such as the fuel tank, battery, and spare wheels) may be relocated-on the precondition that these components work properly and that their performance remains unchanged. However, please note that the same connectors must be used for the brake air pipeline and the electrical circuit as those originally used on the vehicle. The relocation of heavy components must not alter the weight distribution of the chassis significantly. In the case that a vehicle does not have a spare wheel carrier, or that the spare wheel carrier has to be relocated, the spare wheel carrier should be installed at an appropriate position that is safe, easy to access, and grips the spare wheel tightly. On vehicles with short rear overhang (such as the dumper truck), there is insufficient space for a spare wheel on the rear of the vehicle.As such, the spare wheel may be positioned at locations such as the front panel of the cargo tank (see Figure 3.28). On a dump truck with a short rear overhang, the spare wheel may be placed under the chassis.The spare wheel may be placed between the driver cab and the body, so as to lower the height of the dump truck. The spare wheel should be installed in a way that minimizes the overall length of the vehicle and the height of the body. When a spare wheel is side mounted, please note that the spare wheel carrier should be installed around the crossbeam, or that a reinforcement plate should be installed at the interior of the longitudinal beam, as shown in Figure 3.28. To protect the frame assembly from abnormal damage caused by added heavy equipment, we recommend that the heavy equipment be installed close to the crossbeam, or on the interior of the frame where a reinforcement plate or a channel beam is installed. Equipment (such as fuel tanks and compressors) should be installed according to proper procedure. The weight distribution of various components of the vehicle must be taken into account when determining the location for installing equipment.In addition, please ensure an appropriate ground clearance for when the vehicle is operating properly.
Relocating components and installing auxiliary equipment Base - 09/2013 Printed 603.95.640 3-51 GENLYON - KINGKAN REFITTING THE CHASSIS
Figure 3.28
Chassis wiring harness ports Joystick
Control schematic diagram and cable connection for dumper lift alarm device
Chassis frame Spare wheel carrier Stiffening plate
198186
Side mounted spare wheel carrier
To refit chassis components or install auxiliary equipment, first use the existing holes on the chassis frame. If necessary, new holes may be drilled according to the instructions in Section 3.1 “Drilling and welding the chassis”. In the case that the body structure hampers adding fuel to the fuel tank or adding water to the water tank, the bracket for installing the fuel or water tanks can be lowered. However, an appropriate ground clearance required for the vehicle’s proper operation should be ensured. If an extra fuel tank is required, it is best to lay out this fuel tank in the same way as the original, and to use existing parts wherever possible. Two fuel changeover switches should be installed, for ease of obtaining the fuel from both tanks alternatively, as shown in Figure 3.29. The simultaneous changeover switch should also be installed for the fuel sensor circuit. It is best to use the aforementioned system if an extra fuel tank is installed opposite to the original fuel tank. The original fuel tank may supply the fuel first, after which the added fuel tank will supply the fuel-if the two fuel tanks are laid out abreast on the same side and the added fuel tank is connected to the original fuel tank by the hose. After an extra fuel tank is installed, the entire fuel supply system must comply with relevant national standards and regulations. The hose connecting the two fuel tanks shall not leak, and its interior dimensions should be sufficient. Thehosemusthavethesamefeatureastheoriginal,andthishosemustbecorrectlyfixed.
Relocating components and installing auxiliary equipment
Printed 603.95.640 Base - 09/2013 3-52 REFITTING THE CHASSIS GENLYON - KINGKAN
Figure 3.29
198187
Power supply system with dual fuel tank
If different types or grades of fuel are used to fill the added and original fuel tanks, two fuel changeover switches should be installed, while a simultaneous changeover switch should also be installed on the fuel sensor circuit.
Relocating components and installing auxiliary equipment Base - 09/2013 Printed 603.95.640 3-53 GENLYON - KINGKAN REFITTING THE CHASSIS
Installing the retarder 3.17 Installing the retarder
Do not install an unlisted retarder on our Genlyon and New Kingkan. It is prohibited to install any retarder from the auto component market. We do not allow the application of such retarders. Any non-permitted intervention or modification of the braking performance shall incur the loss of entitlement to warranty services. The installation regulations from the electric turbine retarder must be followed. When installing the retarder on the transmission, please select an appropriate retarder bracket. Do not relocate the brake valve of the brake system without good reason. When relocation is absolutely necessary, the brake valve should be moved as little as possible. The brake valve should be installed at least 150 mm away from the retarder. All plastic pipes within a distance of up to 200 mm from the retarder must be replaced with steel pipes, and a proper distance should be kept between these pipes and the retarder. The electrical equipment and pipeline around the retarder should be shielded from radiation by cover plates suited to this purpose.
Installing the retarder
Printed 603.95.640 Base - 09/2013 3-54 REFITTING THE CHASSIS GENLYON - KINGKAN
Paint and anti---rust 3.18 Paint and anti-rust
All the refitted components (chassis, driver cab, and body) of the vehicle must be painted according to our company standard Q/CQ 31009-2011 Vehicle paint coating, so as to avoid oxidation corrosion and rusting. To improve anti-rust performance, a spray wax may be sprayed onto the refitted complete vehicle according to the user-s needs (such as for a commercial contract). The wax spraying must be carried out according to our company standard Q/CQ 31013-2013 Technical conditions and industrial process for anti-rust wax spray. During the anti-rust wax spraying, please be extremely careful with relevant components, especially such parts as the frame, driver cab, and various parts exposed to air and sunlight. Anti-rust wax spraying involves the following steps: Degreasing by iron phosphate, anti-corrosion, sealing, applying the primer, and applying surface paint (power coating may be used to replace enamel paint, except on the body). The following procedures should be taken when dealing with miscellaneous, complex shaped components fixed onto the frame, such as boxes and the protecting grille (the traditional painting method should be used for box-shaped components, connectors, overlap and areas which cannot be accessed): - Iron phosphorus degreasing, electro dip coating or immersion corrosion, enamel paint, or powder coating. - Weldable paint is crucial during the connection by welding without the electro dip coating process. - The process can be simplified for components that are not exposed to the surrounding atmosphere (such as the atmosphere inside the driver cab). - Iron phosphorus degreasing, power coating or phosphorus degreasing, electro dip coating or phosphorus degreasing, anti-corrosion. - Phosphorus degreasing may be substituted by solvent and wash primer (5~10 m) degreasing. - Some specific products (such as elastic material and acrylic resin) may damage the connection and overlapping (joint) parts easily if they are used for sealing open and semi-open box-shaped components that have been properly painted with wax and have been treated for anti-corrosion. Components (such as the brackets and bolts) installed outside the driver cab must either be made from stainless steel, or undergo Dacromet 500 surface treatment.Connectors (such as hinges and handles) on the frame and/or body (such as the floor and box) must undergo Dacromet or plating (thicker than 12 m) surface treatment.In all events, ensure that the components on the driver cab are of a consistent quality.
Points for attention Proper precautions must be taken to protect components that may be damaged by paint during the refitting work or operation. Some examples are as follows: - Rubber and plastic pipes for pneumatic and hydraulic equipment - Gaskets and components made from rubber or plastic - Power take-off or drive shaft flange -Radiator - Shock absorber and fuel cylinder or cylinder piston rod - Water drain valve and air release valve (such as mechanical components, gas tank, warm-up case for cold start) - Fuel filter - Nameplate and emblem - ECU installed on the vehicle
Paint and anti-rust Base - 09/2013 Printed 603.95.640 3-55 GENLYON - KINGKAN REFITTING THE CHASSIS
Engines with electrical and electronic components - All wiring harnesses for the engine and on the vehicle, including the ground wires - All connectors for the sensors, actuators, and relevant wiring harnesses - All brackets for installing the sensors, actors, flywheel, and flywheel velocity sensor - All pipelines (plastic and metal pipes) in the entire diesel engine circuits - Entire diesel filter bracket - Control unit and its bracket - All components inside the soundproof shield (injector, rail, and pipeline) - Common rail pump with control valve - Electric pump of the vehicle - Tanks - Front belt and relevant belt pulleys - Power assisted pump and relevant pipeline In the case that the wheels need to be removed (including the steel rims), be sure to protect the interface of the drum and hub from thickening. Please note that the contact points between the wheel and flange and between the wheel and the bolts must not be painted. The disc breaks must be fully protected. Electrical components and electronic modules must be removed.After the baking finish (with a temperature of up to 80 ˚C)/i.e., after the painting process-all components that may have been damaged due to excessive heat must be removed. During the refitting work on the driver cab, soundproof and thermal insulation materials must be used inside the driver cab and below the floor, so as to eliminate vibration, decrease noise, and retain the thermal insulation performance of the original vehicle.
Paint and anti-rust
Printed 603.95.640 Base - 09/2013 3-56 REFITTING THE CHASSIS GENLYON - KINGKAN
Safety regulations 3.19 Safety regulations
Before the painting process, the following areas must be covered:the interface between the wheel and brake drum; the interface between the two wheels and between the wheel nuts when twin tyres are used;the interface between the coupling interface between the drive shaft and the power take-off;the piston rod in the hydraulic cylinder (such as the hydraulic device for the driver cab);and the air release valve for such devices as the transmission and axle. To be on the safe side, no person or object should stand in the front of the driver cab when this cab is lifted.
Safety regulations Base - 09/2013 Printed 603.95.640 4-1 GENLYON - KINGKAN STRUCTURE AND INSTALLATION OF THE BODY
Index
SECTION 4 Structure and Installation of the Body
Page
4.1 Structure and dimensions of the subframe...... 4-3
4.2 Attaching the subframe to the body ...... 4-12
4.2.1 Thrust connection plate ...... 4-13
4.2.2 Fixing U-bolts ...... 4-14
4.2.3 Elastic connection ...... 4-15
4.2.4 Combination connection ...... 4-17
4.2.5 Quick lock device for the replaceable body ...... 4-17
4.2.6 Connection between the tails of the main frame and subframe ...... 4-18
4.2.7 Front mounted crane ...... 4-21
4.2.8 Rear mounted crane ...... 4-24
4.2.9 Mobile truck mounted crane ...... 4-26
4.3 Tail lift truck ...... 4-27
4.4 Lateral and rear under-run protection devices ...... 4-29
4.4.1 Lateral protection devices ...... 4-29
4.4.2 Rear under-run protection device ...... 4-31
4.5 Splash guards ...... 4-32
Index
Printed 603.95.640 Base - 09/2013 4-2 STRUCTURE AND INSTALLATION OF THE BODY GENLYON - KINGKAN
Index Base - 09/2013 Printed 603.95.640 4-3 GENLYON - KINGKAN STRUCTURE AND INSTALLATION OF THE BODY
Structure and dimensions of the subframe
4.1 Structure and dimensions of the subframe
In order to distribute the load evenly and to avoid a concentrated load on the longitudinal beams, a [-shaped subframe should be installed, without damaging the main framework structure when refitting the body of the special vehicle on the chassis, as shown in Figure 4.1.
Figure 4.1
198188
Subframe
The subframe for a dump truck or tank truck should be designed as a constant structure in order to avoid concentrated stress on the main framework caused by rapid changes in rigidity due to the installation of the subframe. The front section of the subframe should be formed in a wedge shape with diminishing rigidity (upward with a wedge angle of no more than 30˚),asshowninFigure4.2.
Structure and dimensions of the subframe
Printed 603.95.640 Base - 09/2013 4-4 STRUCTURE AND INSTALLATION OF THE BODY GENLYON - KINGKAN
Figure 4.2
198189
Shape of the subframe front section
The front section of the subframe should be long enough that its front section is as close to the rear of the driver cab as possible, and so that it passes across the rear-lifting lug of the front spring.If the rear suspension components of the driver cab do not allow for the entire subframe to pass across, the front section of the subframe can be made into the shape shown in Figure 4.2 (e). The section of least resistance may need to be estimated if the front section is likely to experience moments of high bending (e.g. when a crane is installed behind the driver cab, and this crane operates in front of the vehicle.). ThestructureshowninFigure4.3canbeadoptedifthestructure in Figure 4.2 is difficult to manufacture. The distance between the back of the driver cab and the front of the special carriage is usually around 200 mm. If this distance is less than 100 mm, please note that abnormal vibrations and concentrated stress from the driver cab may damage the frame. If the distance is larger than 200 mm, the subframe should be extended to the back of the driver cab and fastened to the main frame. It is best to install U-bolts as far forward as possible, as shown in Figure 4.4.
Structure and dimensions of the subframe Base - 09/2013 Printed 603.95.640 4-5 GENLYON - KINGKAN STRUCTURE AND INSTALLATION OF THE BODY
Figure 4.3
198190 Simple shape of the subframe front section When determining the shape of the longitudinal beam of the subframe, the function of the subframe and the structure above this should both be taken into account. If an elastic connection is required between the subframe and the chassis, it is best to use a longitudinal channel beam. If higher rigidity is required, it is best to use a longitudinal beam with a reinforcement plate or rectangular steel pipe
Figure 4.4
198191 Installing U-bolts as far forward as possible If a longitudinal beam consists of both channel beams and channel beams with reinforcement plates, please ensure that the transitions between these are smooth. Figure 4.5 is used to illustrate one form of transition structure.
Figure 4.5 Tail of a subframe Tail of a subframe without transition with transition (not recommended) (recommended)
198192 Transition between longitudinal beams comprising different sections The tail of the subframe shall be made into a box-shaped sectional structure (e.g. a rear mounted crane truck). The transition of the longitudinal beam with a reinforced plate is shown in Figure 4.5.
Structure and dimensions of the subframe
Printed 603.95.640 Base - 09/2013 4-6 STRUCTURE AND INSTALLATION OF THE BODY GENLYON - KINGKAN
The front section still uses the common structure.In addition, in order to maintain the torsionality of the frame, box-shaped sectional structures must not be used on the front of a mounted crane truck. The subframe must not be of the shape shown in Figure 4-6.
Figure 4.6
198193 Disallowed subframe structure Thesubframeshouldpossessthesamewidthandexternalwidthasthemainframe. For a loading crane truck, the subframe should be strengthened at the installation area of the lift device. The structure of the subframe is shown in Figure 4.7. A sufficient number of crossbeams are required for the two longitudinal beams of the subframe. The crossbeams should be as close to the fastening connectors as possible. Theusualstructureforthesubframecrossbeamisanopenform,asshowninFigure4.8.
Figure 4.7
198194
Structure of loading crane truck subframe
Figure 4.8
198195 Structure of the subframe crossbeam If the beam requires a higher rigidity to ensure higher torsional strength in the subframe (e.g. a rear mounted loading crane truck), pipe beams may be used to connect the longitudinal beams, as shown in Figure 4.9. The rigidity of the connection between the crossbeams and the longitudinal beam must be properly handled.
Structure and dimensions of the subframe Base - 09/2013 Printed 603.95.640 4-7 GENLYON - KINGKAN STRUCTURE AND INSTALLATION OF THE BODY
Figure 4.9
Subframe longitudinal beam Pipe crossbeam
198196
Reinforcement structure for the subframe crossbeam If a reinforcement plate is used on the longitudinal beam, a box-shaped sectional structure can be used from the rear end of frame to the front bracket beyond the rear suspension. Diagonal structure support can be used at the rear of the subframe (up until the rear axle central line or the balance shaft central line of the rear tandem axle), in order to improve its torsional resilience, as shown in Figure 4.10.
Figure 4.10
Frame
Diagonal beam
198197 Diagonal structure support of the subframe An anti-torsional pipe beam can also be used at the central line of the frame in order to connect the crossbeams, as shown in Figure 4.11.
Structure and dimensions of the subframe
Printed 603.95.640 Base - 09/2013 4-8 STRUCTURE AND INSTALLATION OF THE BODY GENLYON - KINGKAN
Figure 4.11
Frame
Anti-torsional beam
198198 Diagonal anti-torsional pipe beams on the subframe In order to make the carriage lower, square sectional pipes may be welded into the interior of the subframe for a cargo truck, box truck, or a stake truck, forming a cross-type subframe for a low box truck, as shown in Figure 4.12. Space should be left to allow for wheel jump height and wheel radius, and the strength of an appropriate standard subframe should be ensured. The strength of a dump truck subframe can be classified by service condition as follows. The specific strength grades and applicable service conditions are listed in Table 4.1. The material for the subframe of the dump truck should be of 16MnL or an equivalent grade, and the material should be the same as that used for the longitudinal beam, so as to better match the main frame.
Figure 4.12
198199 Low carriage truck subframe
Structure and dimensions of the subframe Base - 09/2013 Printed 603.95.640 4-9 GENLYON - KINGKAN STRUCTURE AND INSTALLATION OF THE BODY
Table 4.1 - Dump truck subframe strength grade and description Subframe structure Applicable load and vehicle Applicable service Strength grade (sectional parameter) models conditions Rectangular steel pipe of Poor road conditions; mainly 1 25 t 4x2 dump truck or under 180x80x6 or equivalent used on concrete roads Soil transportation at Rectangular steel pipe of 30 t 6x4 construction dump 2 construction sites; difficult 190x80x6 or equivalent truck or under unloading Good road conditions; mainly Rectangular steel pipe of 2 60 t 8x4 dump truck or under used on concrete roads; smooth 180x80x8 or equivalent unloading Good road conditions; mainly Rectangular steel pipe of 40 t 6x4 dump truck (with 6 3 used on concrete roads; smooth 200x80x8 or equivalent meters above carriage) or under unloading Poor road conditions; mainly Rectangular steel pipe of 3 60 t 8x4 dump truck or under used on concrete roads; difficult 200x80x8 or equivalent unloading/longer unloading times Good road conditions; mainly Rectangular steel pipe of 60 t~70 t 8x4 dump truck or 3 used on concrete roads; smooth 200x80x8 or equivalent under unloading Good road conditions; mainly Rectangular steel pipe of 4 60 t 6x4 dump truck or under used on concrete roads; smooth 230x80x8 or equivalent unloading Poor road conditions; mainly Rectangular steel pipe of 70 t~80 t 8x4 dump truck or 4 used on concrete roads; difficult 230x80x8 or equivalent under unloading/longer unloading times Good road conditions; mainly Rectangular steel pipe of 4 80 t 8x4 dump truck used on concrete roads; smooth 230x80x8 or equivalent unloading
The material and sectional sizes for the crane truck subframe are listed in Table 4.2.
Table 4.2 - Material and sectional sizes for crane truck subframe Load moment Sub-beam section modulus Minimum material Kgm (Nm) Sectional size (mm) (cm3) requirements 6000 (60000) 140X80X6 76.6 16MNL-GB3273 9000 (90000) 160X80X6 91.4 16MNL-GB3273 10000 (100000) 200X80X6 123.6 16MNL-GB3273 12000 (120000) 220X80X6 140.8 16MNL-GB3273 15000 (150000) 220X80X8 182.3 16MNL-GB3273
The material and sectional sizes for the rear lift truck subframe are listed in Table 4.3.
Structure and dimensions of the subframe
Printed 603.95.640 Base - 09/2013 4-10 STRUCTURE AND INSTALLATION OF THE BODY GENLYON - KINGKAN
Table 4.3 - Material and sectional sizes for crane truck subframe
Lifting force Material 3 (kg) (minimum requirements) Section modulus (cm ) Notes 1000 91 4x2, 6x2 vehicle models 1500 109 4x2, 6x2 vehicle models 2000 128 4x2, 6x2 vehicle models 16MNL-GB3273 1000 128 6x4, 8x4 vehicle models and 1500 128 multiple axle vehicle models 2000 128
The material and sectional sizes for the carriage truck and stake truck subframe (carriage longitudinal beam) are listed in Table 4.4.
Table 4.4 - Material and sectional sizes for carriage truck and stake truck subframe Longitudinal Longitudinal beam Longitudinal beam material beam sectional Vehicle model sectional parameters (minimum requirements) Notes drawing
4X2 140X80X6 Steel plate 09SiVL-6-GB3273 -
6X4 220X80X6 Steel plate 09SiVL-6-GB3273 -
8X4 220X80X8 Steel plate 09SiVL-8-GB3273 -
The above tables list the minimum strength requirements for the subframes on different vehicle models. The refitting factory should adjust these specifications according to actual conditions, and provided that the load capacity of the subframe is greater than that listed in the table. For vehicle models not listed above, the refitting factory may determine the structure and size of the subframe based on the load capacity, service conditions, and strength of the main frame, or may also consult with our R&D Centre. The above tables list vehicles by models, and these models do not match the gazette models exactly. In the case that the refitting factory is unable to match two vehicle models exactly, please consult any of our nationwide Sales and Service Centres, Sales Division technical support engineers, or relevant personnel from our R&D Centre. If aluminium subframes are suitable for use on some bodies, please adjust the structure and size accordingly to ensure an appropriate overall strength of the subframe due to the fact that aluminium and steel have different mechanical properties. An aluminium longitudinal beam of the same size as the steel beam can be used when the main function of the subframe is to distribute the load more evenly, and when the body and the vehicle carry the majority of the load. Typical examples include a rigid body with a frame of continuous and close spacings, a box truck, tank truck, or a bracket directly installed on the suspension. Aluminium subframes are not recommended when the subframe needs to bear the load together with the main frame (e.g. when the body produces a concentrated load on the subframe). If it is absolutely necessary for an aluminium subframe to be used, the relevant technical plan must be submitted to our company for formal approval. When illustrating the minimum size of the subframe, please take into account both the stress limit of the aluminium and the difference in the elastic modulus of the steel. This will make the structural components of the subframe larger. Accordingly, if the shearing stress (thrust connection plate) can be transferred by the connection between the main frame and subframe, a new relevant neutral axle should be built based on the different elastic modulus of the two materials when checking the stress at both ends of the connector.
Structure and dimensions of the subframe Base - 09/2013 Printed 603.95.640 4-11 GENLYON - KINGKAN STRUCTURE AND INSTALLATION OF THE BODY
In the final analysis, if the subframe must increase the strength and rigidity of the main frame, aluminium beams of a larger sectional size should be used due to the fact that the material being used is aluminium, not steel. The external width of the subframe longitudinal beam should be consistent with that of the main frame (both are equally wide, or the front is wider and rear is narrower) due to the fact that the chassis produced by our company is fixed. Only under certain special circumstances (e.g. when a container with rollers driven by a mechanical or hydraulic system may slide onto the subframe (main frame) can the subframe be made wider or narrower than the chassis. In this case, please ensure that the force is correctly transferred between the subframe and main frame longitudinal beam. The solution for the aforementioned case is to add a transition beam (an L-shaped beam with a stiffener or channel beam made according to the longitudinal beams). If the front part of the subframe is narrower than the chassis, an appropriate number of U-shaped brackets should be installed outside the auxiliary frame, as shown in Figure 4.13.
Figure 4.13
L-shaped transition beam U-shaped bracket
Channel transition beam
198200
Connections for main frame and subframe of unequal widths
Structure and dimensions of the subframe
Printed 603.95.640 Base - 09/2013 4-12 STRUCTURE AND INSTALLATION OF THE BODY GENLYON - KINGKAN
Attaching the subframe to the body
4.2 Attaching the subframe to the body
Choosing the appropriate method for connecting the subframe and the main frame is crucial for the subframe in terms of ensuring the strength and rigidity of the vehicle. The connections between the subframe and main frame can either be elastic or rigid, depending on the body type (see Chapter 5 ’Refitting special vehicles’). When selecting the connection type, the stress of the added equipment under static and dynamic situations on the chassis should be analysed. Appropriate connectors should be installed between the main frame and subframe, along the subframe. The number, size and type of these connectors must ensure an effective connection between the chassis and the subframe, and should maximize the performance of the main frame and subframe. The subframe should be fastened onto the main frame using mounting brackets, thrust connection plates, U-bolts and elastic connections. The main frame has holes for mounting the subframe. Fixing the subframe onto the upper or lower surfaces of the main frame by drilling or welding is not permitted. In the case that the main frame and subframe do not fit closely together because of protruding bolts used for fixing the crossbeams onto the main frame, the lower surface of the subframe can be drilled to solve this issue. The strength class of bolts and other connectors used for connecting the main frame to the subframe must be of a minimum class 8.8. The nuts must be equipped with locking devices. An appropriate distance of 250 mm ~350 mm must be maintained between the first front connector of the subframe and the front end of the subframe. In order to avoid concentrated stress on the chassis frame, the recommended overhead distance must be kept if the body is to apply a concentrated load on the back of the driver cab and higher stability is required (e.g. for a crane or front dumping device).If necessary, the number or strength of the connectors should be increased. Common-use holes for mounting the body are reserved on the chassis. When designing and implementing the connection between the main frame and the subframe, the refitting factory should ideally use the existing reserved holes on the chassis.If absolutely necessary, new holes for connecting the main frame to the subframe can be drilled according to the instructions in Section 3.1 ’Drilling and welding on the chassis’ in Chapter 3 of this document. In the case that holes must be drilled, a drilling plan should be submitted to our R&D Centre for formal approval before drilling starts. When designing and making the connection between the main frame and subframe, do not weld the frame or drill on either the upperorlowersurfacesontheframe. Thecharacteristicsoftheconnectionbetweenthemainframeandsubframeareasfollows: The elastic connection (see figures 4.18 and 4.19) allows for a certain amount of motion space between the main frame and subframe, and also allows for the use of two parallel stress-bearing surfaces.Each stress-bearing surface bears a bending moment proportional to its respective moment of inertia. The rigid connection between the subframe and the chassis requires one thrust connection plate, provided that the number and position of the thrust connection plates (connectors) are sufficient for the shearing stress. When fixing the subframe onto the longitudinal beam, the connection formed by the single thrust connection plate is higher than that formed by brackets or U-bolts.Its characteristics are listed below: - The lower section height of the subframe is higher when the structural steels have an equal bending moment. - The bending moment of the subframe is higher when the section size of the subframe is the same. - The strength of the subframe can be further improved when made from materials possessing higher mechanical functions.
Attaching the subframe to the body Base - 09/2013 Printed 603.95.640 4-13 GENLYON - KINGKAN STRUCTURE AND INSTALLATION OF THE BODY
4.2.1 Thrust connection plate
To achieve longitudinal and lateral thrust forces, install thrust connection plates on both sides. Figures 4.14 and 4.15 illustrate the installation and size of the thrust connection plates. In Figure 4.15, ’A’ indicates the spacing (centre distance) between the thrust connection plates. The best spacing is 500 mm~1000 mm, and should not exceed 1000 mm. It is best to use neck bolts of class 10.9 or above along with self-locking nuts.
Figure 4.14 xxxxx
Thrust connection plate Bracket 198201 Thrust connection plate connection
Figure 4.15
Class 10.9 bolt
198202
Thrust connection plate dimensions Genlyon and Hongyan Kingkan (such as 6x4 and 8x4) vehicles with balanced suspension come with a bracket at the central line of the balance axle. This bracket can also be used for connecting the main frame and the subframe. Drill the subframe according to existing holes on this bracket (allow for enough operation space when designing the subframe), and connect them using class 10.9 bolts, as shown in Figure 4.16. In the case that it is difficult to drill holes or install bolts due to structural reasons, the number of bolts can be reduced. However, the total number of bolts must be no less than 2/3 of the number of existing holes on the bracket. Cutting out large areas of the bracket at random when adapting the body structure is prohibited.
Attaching the subframe to the body
Printed 603.95.640 Base - 09/2013 4-14 STRUCTURE AND INSTALLATION OF THE BODY GENLYON - KINGKAN
If cutting the bracket is absolutely necessary, the relevant plan for cutting and making up the bracket, and also the plan for connecting the main frame to the subframe, should be submitted to our R&D Centre for verification, and should only be implemented after approval from our company has been received.
Figure 4.16
xxx
Existing holes for mounting the subframe Class 10.9 bolts should be used for the connection
Subframe Balance axle central line Main frame Upper surface of the main frame Lower surface of the subframe 198203 Bracket connection When connecting the main frame to the subframe by the bracket and thrust connection plate, attention should be paid to the following points: Make sure that the number and thickness of the thrust connection plates and the number of bolts are both sufficient for transferring shearing and bending moments, and that the usual thickness of the thrust connection plate is the same as that of the longitudinal beam of the vehicle. The thrust connection plate should only be fixed onto the beam web of the longitudinal beam on the main frame. Before making this connection, ensure that the subframe is correctly installed onto the upper surface of the main frame and that no space is left between interfaces. Fixing the body onto the upper or lower surface of the main frame by drilling or welding is not permitted. Use the bracket in front of the rear suspension and the thrust connection plate behind the front bracket of the rear suspension for connection. Purchase brackets from the chassis manufacturer, and choose connection plates according to the available sizes. Make sure that the material and performance of the brackets and connection plates meet relevant requirements.
4.2.2 Fixing U-bolts
In the case that using other connection methods proves difficult, clamping U-bolts can be used, as shown in Figure 4.17. U-bolts must not be used on areas at which the main frame holds its maximum range of torsional load.In order to prevent the deforming of the longitudinal beam of the main frame, wooden blocks should be placed inside the longitudinal beam. Angle stiffeners should be placed inside the longitudinal beam at high temperature points, such as around the muffler, as shown at point 2 of Figure 4.17. Cushion blocks should be used to increase the stress-bearing area of the longitudinal beam surface, thereby decreasing the deformation, as shown at points 3 and 4 in Figure 4.17. To achieve longitudinal thrust, the thrust connection plate should be installed on both sides, or the subframe tail should be fastened to the upper surface of the main frame using bolts. In the case that the main frame and subframe do not fit closely together because of protruding bolts used for fixing the crossbeams onto the main frame, the lower surface of the subframe can be drilled to solve this issue.
NOTE The aforementioned refitting work should not affect the operation of the towing device. Otherwise, the refitting factory shall bear all consequences.
Attaching the subframe to the body Base - 09/2013 Printed 603.95.640 4-15 GENLYON - KINGKAN STRUCTURE AND INSTALLATION OF THE BODY
Figure 4.17
U-bolt Lining Cushion block Base plate
198204 U-bolt connection
4.2.3 Elastic connection
Figure 4.18 illustrates the elastic connection between the main frame and the subframe. The elastic connection should be used before the centre of the rear axle (balance axle of three- or three-or-more-axle vehicles) to connect the main frame and the subframe tightly by high strength bolts (in principle, bolts of the same type and class as the originals should be used).
Attaching the subframe to the body
Printed 603.95.640 Base - 09/2013 4-16 STRUCTURE AND INSTALLATION OF THE BODY GENLYON - KINGKAN
Figure 4.18
A: Leave a space of 1~2 mm before tightening the bolts.
198205 Elastic connection between main frame and subframe 1. Subframe - 2. Mainframe - 3. Spacer shim To ensure a successful elastic connection, a space of 1~2 mm should be left between the frame bracket and the subframe bracket before bolts are tightened.If the space between the two brackets is too large, use an appropriate spacer shim to reduce this space. Use bolts of an appropriate length to improve the flexibility of the connection. Bolts or rivets should be used to fix the bracket on the longitudinal beam of the chassis frame. For ease of lateral positioning and better bearing of the lateral load, it is recommended that the bracket protrude slightly from the upper plane of the frame. Take other means to prevent lateral moving of the body when the bracket is level with the upper surface of the frame (e.g. using a guide plate connected to the chassis, as shown in Figure 4.14 and 4.15). If an elastic connection is used in the front areas, ensure that the longitudinal fixation is strong, even under maximum torsion (e.g. off-road driving).
Attaching the subframe to the body Base - 09/2013 Printed 603.95.640 4-17 GENLYON - KINGKAN STRUCTURE AND INSTALLATION OF THE BODY
If the chassis is equipped with mounting brackets for the box truck body before it leaves the factory, such mounting brackets must be used during the structural installation. The brackets on the subframe and the body must be of a higher strength than the original brackets. For the connection between the chassis and such bodies as the oil tank truck and carriage truck, the front of the subframe can use a connection with more elasticity,asshowninFigure4.19.
Figure 4.19
198206 Elastic component connection 1. Belleville spring - 2. Spiral spring (such as compression or disc spring)
4.2.4 Combination connection
Various connection methods (such as brackets, U-bolts, or elastic components) may be used together with the thrust connection plate. However, the brackets, U-bolts, and elastic components can only be used in the front of the subframe; the thrust connection plate can be used behind the real axle central line.
4.2.5 Quick lock device for the replaceable body
For vehicles with replaceable bodies, fasten the body using quick lock devices, and pay attention to regulations on drilling the frame. The number of quick lock devices should be enough to withstand the braking and lateral forces of the vehicle. The design and use of quick lock devices should ensure operational safety and reliability. Once quick lock devices for connecting the body and frame have been locked, there should be no space left between the body and the frame, as shown in Figure 4.20.
Attaching the subframe to the body
Printed 603.95.640 Base - 09/2013 4-18 STRUCTURE AND INSTALLATION OF THE BODY GENLYON - KINGKAN
Figure 4.20
198207
Quick lock devices for replaceable body
4.2.6 Connection between the tails of the main frame and subframe
To improve longitudinal and lateral fixation, the tail of the longitudinal beam on the frame can be drilled up to a maximum length of 150 mm, provided that this does not weaken the connection on the crossbeams.
Figure 4.21
198208 Connection between the tails of the main frame and subframe 1. Subframe - 2. Main fram - 3. U-bolt connection - 4. Longitudinal and lateral bolt connection
Attaching the subframe to the body Base - 09/2013 Printed 603.95.640 4-19 GENLYON - KINGKAN STRUCTURE AND INSTALLATION OF THE BODY
Vehicles such as the flat box truck and refrigerator truck usually use a monocoque body, as shown in Figure 4.22.
Figure 4.22
Chassis frame
198209
Monocoque body The maximum spacing between the crossbeams is 500~700 mm, depending on the load of the vehicle. As the load of the vehicle increases, the spacing between the crossbeams should be decreased. The longitudinal beams should be embedded into the crossbeams, forming a frame, to prevent the longitudinal or horizontal force damaging the main frame. Please pay attention to the wheel jump height, saving sufficient space for this. If an anti-skid chain is mounted, an extra 50 mm is required.
Attaching the subframe to the body
Printed 603.95.640 Base - 09/2013 4-20 STRUCTURE AND INSTALLATION OF THE BODY GENLYON - KINGKAN
The lifting load and load moment must be taken into account when determining the structure of the truck mounted crane, due to the fact that these two factors are related to the performance and reliability of the crane, and also the stability of the complete vehicle when the crane is in operation. Figure 4.23 shows how the stability of a truck mounted crane should be calculated. The number of stability devices to be used, the type of the subframe, and in particular the torsional rigidity (box-shaped steel and cross parts) should be determined by the maximum load moment and the position of the crane. The truck mounted crane supplier and refitting factory are responsible for determining the crane’s location.
Figure 4.23
198210 Stability of truck mounted crane The stability of the vehicle when the crane is operation must be tested according to relevant national standards and regulations. The location for mounting the crane should be determined by the laden axle load. The crane may be mounted between the driver cab and the body (for a front mounted crane truck), or at the back of the frame through the mounting plate and subframe (for a rear mounted crane truck). The rear mounted crane can be connected to the frame using a quick release bracket. The body of the crane truck must always comply with the maximum permitted load specified in relevant national regulations, and should be laid out in a way that balances the axle load distribution. The crane can only be mounted either behind the driver cab or at the back of the frame through the mounting plate and subframe. During the design process, make sure that stability devices are used (ground-based outriggers) when the crane is in operation, and that the outriggers can be adjusted accordingly as the load increases. Stability devices (outriggers) can only be mounted on the subframe holding the crane, and not on the main frame of the chassis.If an unnecessary special subframe is mounted, the crane must still be mounted on the bracket on the standard subframe (the length of the structural steel components should be 2.5 times the width of the crane base), so that the load and accumulated stress during the operation of the crane is shared.In the case that a vehicle uses its own subframe (such as with the dump truck), the crane may also be mounted on this subframe, provided that the dimensions are sufficient.
Attaching the subframe to the body Base - 09/2013 Printed 603.95.640 4-21 GENLYON - KINGKAN STRUCTURE AND INSTALLATION OF THE BODY
4.2.7 Front mounted crane
For a front mounted crane truck (when the crane is mounted between the driver cab and the carriage), the crane and carriage must be mounted on the same constant subframe, made from the same material as the main frame. The subframe should be mounted from the back of the driver cab to the end of the frame on the mainframe using a thrust connection plate.The crane can only be mounted through a crane mounting plate specially designed by our company. A web plate should be installed within the installation area of the crane, in order to improve the closeness of the subframe, as shown in Figure 4.24. The subframe must be mounted in an anti-shearing fashion and attached to the frame using a connection plate or fastening bolts for a road vehicle, in which case the height of the subframe longitudinal beam must be decreased. The mounting base of the crane and mounting plate should be on the same central line as the main frame and subframe, as shown in Figure 4.25 and Figure 4.26. The subframe for the crane can be integrated with the longitudinal beam, as shown in Figure 4-26. When the longitudinal beam possesses a small sectional area, the length of the subframe for the crane, Lv, should be at least 35% of the wheelbase, including the driver cab. Do not fasten with U-bolts, as this may cause the frame surface to distort.
Figure 4.24
198211 Reinforcement subframe around the crane When a crane is mounted onto a truck with a large driver cab (operator cab), if the subframe cannot extend to the rear bracket (lifting eye) of the front leaf spring, the turning angle may need to be restricted in accordance with the lifting capability of the crane, so as not to exceed the bending moment of the chassis. If a crane is mounted on an off-road vehicle, elastic connectors may be required between the subframe and the front and middle parts of the frame (as shown in Figure 4.18), in order not to restrict the turning of the chassis. In this case, the crane is only connected to the subframe, and therefore the size and structural strength of the subframe longitudinal beam must be able to withstand the moment of the operating crane.
Attaching the subframe to the body
Printed 603.95.640 Base - 09/2013 4-22 STRUCTURE AND INSTALLATION OF THE BODY GENLYON - KINGKAN
Figure 4.25
Crane subframe
Crane connection plate
Lifting eye for fixing crane
198212
Fastening the crane The performance of equipment (such as the gear stick, air filter, and locking device for the flexible driver cab) should not be decreased during the installation of the crane.
Attaching the subframe to the body Base - 09/2013 Printed 603.95.640 4-23 GENLYON - KINGKAN STRUCTURE AND INSTALLATION OF THE BODY
Figure 4.26
198213 Structure of subframe for mounting crane 1. Subframe - 2. Connector between the subframe and the carriage - 3. Key lifting points - 4. Crane stability devices (outriggers) Components such as the battery box and fuel tank can be relocated, provided that they are installed in the same way as the original after the relocation. The size of the subframe is determined by the load moment, with the recommended sizes listed in Table 4.2. When a crane is mounted, the distance between the back of the driver cab and carriage, A, should be 700~1100 Kgm, or slightly larger in accordance with the model of the crane, as shown in Figure 4.27.
Attaching the subframe to the body
Printed 603.95.640 Base - 09/2013 4-24 STRUCTURE AND INSTALLATION OF THE BODY GENLYON - KINGKAN
4.2.8 Rear mounted crane
For a rear mounted crane truck, the crane is mounted on the subframe behind the rear axle, or on the subframe at the end of the frame, as shown in Figure 4.28. If a vehicle uses balanced suspensions, side plates will be installed at the frame around the rear axle area, as shown in Figure 4.29. These side plates can be used to mount the crane. For a two-axle vehicle, the connection plate is not related in any way to the type of suspension. For a crane truck, the mounting plate should be at least 800 mm long (wide), while the maximum spacing between the thrust connection plates is 1000 mm, as shown in Figure 4.30.
Figure 4.27
198214 Installation space for the crane
Figure 4.28
198215 Rear mounted crane 1. Subframe - 2. Subframe thrust connection plate - 3. Connection brackets between the main frame and the subframe - 4. Major support point for the crane - 5. Crane stability devices (outriggers) - 6. Connection plate between the main frame and the subframe
Attaching the subframe to the body Base - 09/2013 Printed 603.95.640 4-25 GENLYON - KINGKAN STRUCTURE AND INSTALLATION OF THE BODY
During the design of a rear mounted crane truck, the subframe should be used to strengthen the frame, in order to avoid overloading in certain areas. The subframe should be mounted from the rear end of the vehicle, where the crane is mounted to the rear lifting eye of the front leaf spring (first front axle).
Figure 4.29
198216 Side reinforcement plate for main frame and subframe
Figure 4.30
198217
Connection between main frame and subframe for a rear mounted crane truck In the case that the load is concentrated on the rear suspension, the subframe must be strengthened in accordance with the lifting load of the crane, in order to ensure the rigidity of the subframe required for the vehicle to operate on the road and for the crane to work. The frame section should be closed from the rear end of the frame up until beyond the front bracket of the rear suspension. For a 6x4 vehicle, the frame section should be closed from the rear end of the frame until at least 150 mm in front of the middle axle. Please note that the transition between the box-shaped and open longitudinal beams should be made very smooth, as shown in Figure 4-5. In closed section areas, the subframe must be fixed on the main frame using thrust connection plates (i.e., a sufficient number of thrust connection plates, with spacing of less than 700 mm), and elastic connections should be used on the front section. For the rear section of the frame, the subframe should use a diagonal structure support, which may increase the torsional resilience of the frame, as shown in Figure 4-10. It is not possible to provide more detailed requirements in this document, due to the fact that the rigidity of the subframe depends on many factors (i.e., the lifting load of the crane, size of the mounting base, kerb mass of the vehicle, and rear overhang of the chassis). The refitting factory must evaluate the stable performance of the refitted complete vehicle by conducting real performance tests. If tests prove the rigidity of the subframe to be insufficient, the refitting factory should achieve the necessary rigidity of the frame using other means.
Attaching the subframe to the body
Printed 603.95.640 Base - 09/2013 4-26 STRUCTURE AND INSTALLATION OF THE BODY GENLYON - KINGKAN
The distance (’Lu’, as shown in Figure 4.29) between the mounting centre of the crane and the central line (balance axle central line) of the rear axle must be as short as possible, so as to ensure the good driving performance of the vehicle and the reliability of structural components. This distance should not exceed 50% of the wheelbase. A rear mounted crane truck must always comply with the maximum permitted load as specified in relevant national regulations, and should be laid out in a way that balances the axle load distribution.
4.2.9 Mobile truck mounted crane
A rear mounted crane can be designed to be detachable, i.e., the crane can be removed after all relevant connecting bolts are loosened from the chassis frame. The load distribution of a detachable crane truck varies depending on whether the crane is on or off. In order to ensure an appropriate axle load distribution on both occasions, the centre of the load of the vehicle under both conditions must be marked on the body.
Attaching the subframe to the body Base - 09/2013 Printed 603.95.640 4-27 GENLYON - KINGKAN STRUCTURE AND INSTALLATION OF THE BODY
Tail lift truck
4.3 Tail lift truck
The installation of a tail lift must not cause a vehicle to exceed the maximum permitted rear axle load. The structure, operation and maintenance instructions for tail lifts can be found in the relevant standards. The width of the tail lift must comply with relevant national regulations, while the structural parameters of the subframe can be found in Table 4.3. The subframe of a tail lift truck should be of a higher strength than that of the corresponding vehicle models (box truck or flat-bed truck). When a medium tonnage tail lift (1500 kg) is installed, the length of the carriage can be shortened by a maximum of around 300 mm. Hydraulic outriggers must be used for a heavy duty tail lift (with a lifting load greater than 1500 kg). Lifting any load without using outriggers is forbidden (as this can damage the frame). If using a heavy duty tail lift (with a lifting load greater than 1500 kg) is absolutely necessary, it is recommended for reinforced leaf springs to be used. Electrical equipment should use a 24 V voltage from a reinforced battery, and it is also best to use alternators with high power and large capacity. It is best if the subframe extends from the rear end of the frame to beyond the rear bracket of the front suspension, which is behind the driver cab. The subframe should be connected to the frame using thrust connection plates and U-shaped bolts, from the rear end of the frame up until beyond the rear axle. The refitting factory or tail lift supplier must ensure the safety and operational stability of the tail lift truck. Figure 4-31 illustrates the stability of the tail lift truck should be calculated. The torque of the tail lift on the chassis during the lifting process is as follows: - With hydraulic outriggers:M=(QxA)+(GxB) - Without hydraulic outriggers: M=(QxE)+(GxF) The refitting factory should evaluate the necessity of using hydraulic outriggers.
Tail lift truck
Printed 603.95.640 Base - 09/2013 4-28 STRUCTURE AND INSTALLATION OF THE BODY GENLYON - KINGKAN
Even if the chassis can withstand the force from the tail lift when hydraulic outriggers are not used, the changes to the stability and position of the vehicle should still be considered, as the suspensions tilt when the tail lift truck is loading.It is best to install hydraulic outriggers on the mounting base of the tail lift.
Figure 4.31
Calculating the operational stability of the tail lift truck
xxx
xxx
Hydraulic outrigger
Subframe Rear axle central line Unladen weight of Overload capacity combination the tail lift during of the tail lift section solution the lifting process
198218 Illustration of a tail lift truck The refitting factory must use a subframe of higher rigidity than that for the normal box truck, in order to carry the extra load on the chassis frame during the lifting process of the tail lift, and to improve the reliability of the chassis frame. When installing a rear mounted crane, please note that the axle load should not exceed the maximum permitted value specified by our company, and also that the minimum front axle load should be greater than 20% of the current gross vehicle weight. During the installation of an electric-hydraulic tail lift, the battery capacity and power generating capacity of the alternator must be checked to see if these meet the user’s needs. The installation of a tail lift may affect the original rear under-run protection device and combination tail light, and thus the refitting factory should relocate these two components to ensure that their performance meets the user’s needs and complies with relevant national standards and regulations.
Tail lift truck Base - 09/2013 Printed 603.95.640 4-29 GENLYON - KINGKAN STRUCTURE AND INSTALLATION OF THE BODY
Lateral and rear under---run protection device
4.4 Lateral and rear under-run protection devices
The standard GB7258 stipulates that a vehicle must be fitted with lateral and under-run protection devices. The refitting factory may design and install these two types of protection devices according to GB11567.1 and GB11567.2-2001 ”Motor Vehicles and Trailer-Lateral and rear under-run protection requirements”.
4.4.1 Lateral protection devices
The standards GB11567.1 and GB11567.2-2001 ”Motor Vehicles and Trailer-Lateral and rear under-run protection requirements” stipulate that vehicles must be fitted with lateral protection devices. The refitting factory must design and install lateral protection devices that meet the aforementioned standards, unless the lateral protection devices are mounted on the chassis before leaving our factory. When the body adopts a fixed structure (such as with a flat-bed body or cargo tank), lateral protection devices (lateral protection plates) must be installed onto the basic structure (reinforced floor crossbeams). If the body adopts a mobile structure (such as with a dump truck, interchangeable equipment, and detachable container), lateral protection plates should be connected to the subframe using proper brackets, or should be directly installed on the longitudinal beams of the chassis.If lateral protection plates are installed on the longitudinal beam, it is recommended that the refitting factory uses as many of the existing holes as possible. According to relevant national standards and regulations, lateral protection devices can either take the form of a single integral structure (lateral protection plate) or longitudinal structural steels (longitudinal segments) with appropriate size and spacings. The section area of the lateral protection device material should comply with the aforementioned standards and regulations. In addition, the material and section areas should ensure that the strength of the protection device complies with relevant standards and regulations. The structure and installation of lateral protection devices should ensure that the adjacent assemblies and components can be easily maintained. Lateral protection devices must be connected to their own brackets, so that they can be quickly removed or tilted. When mounting lateral protection devices, make sure that the ground clearance of relevant components and the spacings between various components comply with relevant regulations. The structure and installation of lateral protection devices can be seen in Figure 4.32, which shows a lateral protection device for a fixed structure body according to the aforementioned standards. The same figure also shows a combination mounting bracket for the lateral protection device, and a rear wheel splash guard mounted on the mobile auxiliary subframe. It is impossible to provide universally applicable instructions for all equipment, and thus the refitting factory should carefully prepare and lay out lateral protection devices (lateral protection plates) according to the type of the auxiliary subframe used. Ensure that the following components can be operated easily and are easily accessible when the vehicle is in operation. - Brake system - Air intake system - Fuel supply system - Battery - Suspension - Spare wheels - Engine exhaust system It is best to make the lateral protection device continuous from front to back. Overlappings are allowed, but these should be made on the rear or lower sections.If the rear section is not so wide as to protrude over the front section, overlappings need not be made. A distance of 25 mm should be allowed between different segments. Chamfering bolts and rivets should not protrude by more than 10 mm, and the minimum radius for all angles and edge circles is 2.5 mm.
Lateral and rear under-run protection device
Printed 603.95.640 Base - 09/2013 4-30 STRUCTURE AND INSTALLATION OF THE BODY GENLYON - KINGKAN
When one of two segments protrudes laterally, the maximum permitted distance between the two segments is 25 mm. Brake pipelines, air pipelines, and hydraulic pipelines are not to be installed around lateral protection devices. Equipment installed on the vehicle, such as the battery, air reservoir, fuel tank, spare wheel, and tool box, may form part of a lateral protection device, provided that such equipment complies with regulations on lateral protection devices. The spacings between different equipment should also comply with relevant regulations on lateral protection devices.
Figure 4.32
A: Installation dimensions recommended by our company B: The lower edge of the body exterior exceeds 1300 mm, or the width of the lower edge of the body exterior is smaller than the wheel width C: Checking the permitted deformation at a 1 kN load: under 30 mm within 250 mm of the rear end of the lateral protection device; under 150 mm for other areas D: Combination mounting bracket for lateral protection device 198219
Technical requirements of a lateral protection device
Lateral and rear under-run protection device Base - 09/2013 Printed 603.95.640 4-31 GENLYON - KINGKAN STRUCTURE AND INSTALLATION OF THE BODY
4.4.2 Rear under-run protection device
The standard GB11567.1 and GB11567.2-2001 ”Motor Vehicles and Trailer-Lateral and rear under-run protection requirements” stipulates that cargo trucks made by our company are equipped with rear under-run bumper bars. For dump trucks made by our company, the refitting factory needs to design and install rear under-run bumper bars according to the aforementioned standards. As long as the chassis refit has an impact on the rear overhang, the under-run bumper bars must be relocated according to current relevant regulations, in order to ensure that the under-run bumper bars are connected in the same fashion as the original. During the refit of a vehicle or installation of special equipment (such as a rear lift table), the structure of the rear under-run bumper bar may need to be modified. Such modifications should not alter the strength or rigidity of the original vehicle (relevant local regulations must be complied with, if such regulations are available). The refitting factory must be prepared to provide relevant specification document if so requested. If the installed under-run bumper bar is different from the original, check that the new bumper bar complies with current relevant regulations. The refitting factory should apply to the relevant inspection agency for inspection based on relevant standards and regulations. Under-run bumper bars (rear under-run protection devices) should comply with the following technical requirements: - The ends of cross structural components on a rear under-run protection device should not bend toward the back of the vehicle, nor should sharp edges point backward. The ends of cross structural components should be rounded, with a diameter of no less than 2.5 mm; the cross section of cross structural components should be at least 100 mm in height. - Rear under-run protection devices can be designed to have moveable installation positions at the rear of the vehicle.Reliable methods should be used to ensure that these protection devices do not move randomly. The maximum force applied by an operator when moving an installation position must not exceed 400 N. - For vehicles with moveable rear under-run protection devices, the ground clearance for the protection device should not exceed 450 mm; during the ground clearance test, force should be applied on the device within a distance of 500 mm from the ground. - For vehicles with fixed under-run protection devices, the ground clearance for the protection device should not exceed 550 mm; during the ground clearance test, force should be applied on the device within a distance of 600 mm from the ground. - The width of a rear under-run protection device must not exceed the distance between the two outermost points of the rear axle wheels (excluding tyre deformation). The lateral horizontal distance between any outermost edge of the under-run protection device and the outermost edge of the rear axle wheel on the same side must not exceed 100 mm.If the vehicle has more than two axles, the longest rear axle should be used for measurements. - The rear under-run protection device should be as close to the rear of the vehicle as possible. - Regardless of where it is located, the under-run protection device should be connected to the frame or other similar component. The rear under-run protection device must have sufficient resistance against under-running vehicles, so as to prevent such accidents. - In the case that, during tests stipulated in GB11567.2-2001 ”Motor Vehicles and Trailer-Lateral and rear under-run protection requirements”, an under-run protection device is deformed due to the static loading force or collisions from moveable barriers, the longitudinal horizontal distance between the rear end of this deformed protection device and that of the vehicle (excluding parts with a distance of 3 m above the ground on an unladen vehicle) must not exceed 400 mm. - A rear under-run protection device must not affect the passing ability of the vehicle, or appropriate measures may be taken to modify the status of the rear under-run protection device temporarily so as to ensure that the vehicle’s departure angle meets the required passing ability.
Lateral and rear under-run protection device
Printed 603.95.640 Base - 09/2013 4-32 STRUCTURE AND INSTALLATION OF THE BODY GENLYON - KINGKAN
Splash guards 4.5 Splash guards
All tractor trucks made by our company are equipped with splash guards, while second-class chassis do not have splash guards. When refitting the body for a chassis without splash guards, splash guards should be installed by the refitting factory. Attention should be paid to the following points when refitting or adding splash guards: - Ensure that the splash guards do not conflict with the wheels under any circumstances (including splash guards carrying mud, tyres fitted with anti-skid chains, and motion space limits for the tyres), and that the splash guard can meet the limits as specified in materials provided by our company. - For vehicles with raised axles, ensure that the dirt generated by the tyres under all possible circumstances (including wheel steering movements when the axle is raised to its upper limit) does not pollute any other structural components on the vehicle. As shown in Figure 4-33, sufficient motion space should be allowed for various steering movements by raised axle tyres.
Figure 4.33
198220 Motion space for raised axle tyres - The maximum width of the tyres should comply with relevant regulations. - Splash guard brackets should be of a sufficient strength, so as to avoid excessive concentrated stress at sudden section changes. - If a splash guard bracket is installed on the longitudinal beam of the frame, this bracket should be only fastened with bolts, and not by welding (as shown in Figure 4-34).If a splash guard bracket is installed on the subframe and its accessory structures, this bracket should be fastened using welding or bolts. - The distance between the splash guard and the tyre should be set based on the maximum wheel jump height.
Figure 4.34
198221 Fastening the splash guard bracket
Splash guards Base - 09/2013 Printed 603.95.640 5-1 GENLYON - KINGKAN REFITTING SPECIAL VEHICLES
Index
SECTION 5 Refitting Special Vehicles
Page
5.1 Semi-trailer tractor truck 5-3
5.1.1 Fifth wheel mounting plate 5-6
5.1.2 Fifth wheel 5-7
5.1.3 Mounting bracket for the fifth wheel 5-9
5.1.4 Centre of the fifth wheel coupling pin 5-10
5.1.5 Motion data of the semi-trailer 5-10
5.1.6 Brake advancing for the semi-trailer 5-10
5.1.7 Heavy-duty off-road tandem rear axle semi-trailer tractor truck for dump truck 5-11
5.1.8 Leaf spring 5-11
5.1.9 Trailer turntable and its rotation 5-11
5.1.10 Refitting a dump truck or cargo truck as a semi-trailer tractor truck 5-12
5.2 Tank truck 5-13
5.3 Dump truck 5-18
5.4 Body of the flat-bed, box and refrigerator trucks 5-20
5.5 Concrete mixer truck 5-22
5.6 Installing a towing device 5-24
5.6.1 Installing a towing device 5-24
5.6.2 Increasing the towing weight 5-25
5.6.3 Lowering the rear towing-use crossbeam 5-25
5.6.4 Central axle trailer 5-28
5.6.5 Reinforcing the standard rear crossbeam 5-29
5.6.6 Trailer 5-31
5.7 Fire truck chassis 5-32
5.8 Replaceable body 5-33
5.9 Dangerous goods truck 5-34
5.9.1 Electrical system 5-34
5.9.2 Brake system 5-34
5.9.3 Driver cab protection 5-34
Index
Printed 603.95.640 Base - 09/2013 5-2 REFITTING SPECIAL VEHICLES GENLYON - KINGKAN
Page
5.9.4 Exhaust system 5-34
5.9.5 Fuel tank 5-34
5.9.6 Independent heater 5-35
5.9.7 Speed limiter 5-35
5.9.8 Safety equipment 5-35
Index Base - 09/2013 Printed 603.95.640 5-3 GENLYON - KINGKAN REFITTING SPECIAL VEHICLES
55555.
Semi---trailer tractor truck 5.1 Semi-trailer tractor truck
A semi-trailer tractor truck must use specially designed equipment (chassis, suspension, and brake system) provided by the supplier. Vehicle models with air suspension are especially suited for use as transporting containers, due to the fact that their fifth wheels have stable heights. The Genlyon series of vehicles comes with a specially designed chassis for use on semi-trailer tractor trucks. If the user wants to refit a semi-trailer tractor truck with another type of chassis, the subframe and rigid corrugated plates must be installed, as shown in Figure 5.1. If the corrugated plates cannot be used due to the height limits of the upper plane of the fifth wheel, consider substituting with 20 mm thick steel plates, as shown in Figure 5.2. The mounting plate for the fifth wheel should not be installed on the longitudinal beam of the frame, and the upper surface of the frame should never be drilled or welded when installing this mounting plate. Parts such as the subframe should be used to distribute the force of the fifth wheel onto the frame. If the fifth wheel on a tractor truck chassis does not meet the relevant requirements, the user may contact our Sales Department to exchange the fifth wheel with an appropriate one, or can order a semi-trailer tractor truck with a fifth wheel that meets the relevant requirements.
Semi-trailer tractor truck
Printed 603.95.640 Base - 09/2013 5-4 REFITTING SPECIAL VEHICLES GENLYON - KINGKAN
Figure 5.1
198222
Installing the fifth wheel (with corrugated mounting plate)
A. A-direction view B. B-direction view
1. Coupling pin central line 6. Hexagon bolt flange (class 10.9 M16x1.5) 2. Rear axle (balance axle) central line bolt 7. Thrust washer (h=15 mm) 3. Location dimensions for fifth wheel 8. Hexagon self-locking nut 4. Longitudinal articulated beam 9. Longitudinal beam of chassis frame 5. Corrugated mounting plate for fifth wheel
Semi-trailer tractor truck Base - 09/2013 Printed 603.95.640 5-5 GENLYON - KINGKAN REFITTING SPECIAL VEHICLES
Figure 5.2
198223
Installing the fifth wheel (with flat mounting plate)
1. Coupling pin central line 6. Hexagon flange bolt (class 10.9 M16x1.5) 2. Rear axle (balance axle) central line 7. Thrust washer (h=15 mm) 3. Location dimension for fifth wheel 8. Hexagon self-locking nut 4. Longitudinal articulated beam 9. Longitudinal beam of chassis 5. Flat mounting plate for fifth wheel
Users who have already selected a trailer should carefully check the front and rear turning radii of the tractor truck to ensure that the semi-trailer tractor truck and semi-trailer work properly when attached to one another.
Semi-trailer tractor truck
Printed 603.95.640 Base - 09/2013 5-6 REFITTING SPECIAL VEHICLES GENLYON - KINGKAN
5.1.1 Fifth wheel mounting plate
In the case that the tractor truck delivered to the user is not equipped with a fifth wheel, this tractor truck should be refit according to the following requirements: - The mounting plate must be of sufficient strength to withstand the longitudinal and horizontal load transferred from the fifth wheel.The height of the mounting bracket must meet the requirements for attaching the semi-trailer and the fifth wheel. - The upper and lower surfaces of the fifth wheel must be flat in order to ensure that the chassis and fifth wheel are well attached and that the load of the fifth wheel can be effectively transferred. - In the case that the mounting plate (bracket) consists of many components, these components must be connected together by welding and/or rivets so as to form an independent structure. - The mounting plate for the fifth wheel must be installed on the beam web of the longitudinal beam of the frame using connectors such as angle stiffeners, and should not be directly mounted on the frame, as shown in Figure 5.1. The mounting plate for the fifth wheel must be fixed by bolts of class 10.9 or above (the amount and dimensions of the bolts must meet relevant requirements on fastening the fifth wheel and transferring the load) and self-locking screws or other screws with thread-locking devices. When installing the fifth wheel and the longitudinal thrust component for the mounting plate, direct welding or drilling to the upper surface of components such as the longitudinal beam is not allowed. Adding a longitudinal rail when installing the fifth wheel and its mounting plate on the chassis is not allowed. However, please pay attention to the following points during the installation and fastening process: - The dimensions of the rail should ensure that the semi-trailer and fifth wheel are correctly attached. - Direct welding or drilling to the upper surface of components such as longitudinal beam when mounting the fifth wheel on the chassisisprohibited.
Semi-trailer tractor truck Base - 09/2013 Printed 603.95.640 5-7 GENLYON - KINGKAN REFITTING SPECIAL VEHICLES
5.1.2 Fifth wheel
Our company offers a variety of unidirectional fifth wheels with different specifications, and with a longitudinal swing angle of ±15˚ and lateral swing angle of 0˚, as shown in Figure 5.3. See Table 5.1 for details of the dimensions of the fifth wheel.
Figure 5.3
198224
Unidirectional fifth wheel
Table 5.1 - Dimension of the fifth wheel
Distance, H, between mounting plate and fifth wheel (mm) Diameter of coupling pin (mm) Drawing No. 150 50 199100930217 200 90 8700-18260
For a tractor truck serving mainly on normal roads (when the manufacturer does not have other special specifications), it is best to mount the fifth wheel on the corrugated plate, and to fasten the stop plates tightly on the mounting plate and subframe, in order to prevent the fifth wheel or mounting plate from loosening or moving back and forth. See figures 5.1 and 5.4 for details of how to install the fifth wheel. After installation, the fifth wheel should have a longitudinal swing angle of at least 13˚. Check that the load capacity, size, and performance of a fifth wheel fits its specified purpose before mounting the wheel onto a vehicle made by our company. The fifth wheel should be selected according to the vehicle model and the transportation type. For example, the fifth wheel on an off-road vehicle should have a larger lateral swing angle, so as to avoid excessive torsional stress on the chassis. The fifth wheel must comply with relevant standards and regulations, if such standards and regulations exist. The product description of a fifth wheel will contain information about its fixing position, number of bolts, and dimension, material, and position of the longitudinal and lateral thrust components.
Semi-trailer tractor truck
Printed 603.95.640 Base - 09/2013 5-8 REFITTING SPECIAL VEHICLES GENLYON - KINGKAN
Figure 5.4
198225
Installing the fifth wheel (without the mounting plate)
1. Coupling pin central line 6. Hexagon flange bolt (class 10.9 M16x1.5) 2. Rear axle (balance axle) central line 7. Thrust washer (h=15 mm) 3. Location dimension for fifth wheel 8. Hexagon self-locking nut 4. Longitudinal articulated beam 9. Longitudinal beam of chassis 5. -
The fifth wheel and its mounting plate are extremely important safety components (and must even undergo certification in certain countries). The mounting plate and installation of the fifth wheel must comply with relevant regulations in this document, and must not be modified.
Semi-trailer tractor truck Base - 09/2013 Printed 603.95.640 5-9 GENLYON - KINGKAN REFITTING SPECIAL VEHICLES
5.1.3 Mounting bracket for the fifth wheel
Under certain special conditions or when used on large towing load tractor trucks, a mounting bracket with a similar structure to the subframe is required (as shown in Figure 5.5), so as to distribute the weight on the fifth wheel and to transfer torsion and flexure to the chassis.
Figure 5.5
198226
Mounting bracket for the fifth wheel
1. Coupling pin central line 8. Reinforced connection crossbeam 2. Rear axle (balance axle) central line 9. Tail reinforced connection crossbeam (L>400 mm) 3. Location dimension of fifth wheel 10. Separate mounting plate (minimum thickness = 8 mm) 4. Connection bolts, M14 11. Integral mounting plate (minimum thickness = 10 mm) 5. Connection bolts for front mounting bracket, M16 12. Corrugated plate 6. Connection bolts for connection plate, M14 13. Longitudinal channel beam 7. Longitudinal reinforced beam 14. Angle fixer
AV Distance between centre of coupling pin and front axle central line LV -LH Minimum length of longitudinal reinforced beam for special structures B: Front axle central line C: Plan 1 D: Plan 2
Semi-trailer tractor truck
Printed 603.95.640 Base - 09/2013 5-10 REFITTING SPECIAL VEHICLES GENLYON - KINGKAN
The longitudinal reinforced beam for the fifth wheel mounting bracket must be connected using crossbeams. Some of the crossbeams should be located around the fifth wheel support, with the remaining crossbeams to be located on either side of the reinforced longitudinal beam. Thefifthwheelmountingbracketcanbemadeinoneoftwoways: - A flat plate of a similar size to the fifth wheel bearing surface, with an appropriate thickness, length and width; or two identical and relatively long plates. - A corrugated plate (with a height of 30 mm or 40 mm) provided by the fifth wheel supplier, provided that the height of the fifth wheel is not an issue. A rigid connection must be used between the longitudinal beam or crossbeam of the frame and the fifth wheel mounting bracket. Brackets (longitudinal and/or lateral components) provided by the fifth wheel and mounting plate supplier must be used to install the fifth wheel mounting bracket on the main frame. It is best to use flat plates at the closed area behind the fifth wheel to prevent longitudinal and lateral movement, and to install the mounting bracket at the front (see Figure 5.5).
5.1.4 Centre of the fifth wheel coupling pin
In order to ensure ideal load distribution, it is necessary to measure the weight of the tractor truck and all accessory equipment, and to calculate the centre of the fifth wheel coupling pin. When a different fifth wheel is used, please pay attention to the changes to the front and rear turning radii. For positioning data pertaining to the coupling pin on the Genlyon semi-trailer tractor truck, the refitting factory may refer to external-use chassis drawings provided by our company when refitting the trailer.
5.1.5 Motion data of the semi-trailer
The connection between the tractor truck and semi-trailer must be able to cope with relevant movements under all service conditions, while space must be kept to allow for sufficient motion and safety margins (there may be regulations and standards on this topic for road vehicles). The front swing angle for the semi-trailer tractor truck fifth wheel is shown in Figure 5.6. The front and back turning radii of the semi-trailer tractor truck are shown in Figure 5.7. For the front and back turning radii of the Genlyon semi-trailer tractor truck, the refitting factory may refer to external-use chassis drawings provided by our company when refitting the trailer. The tilt angle will depend on the particular structure of the fifth wheel; please refer to the corresponding fifth wheel parameters.
5.1.6 Brake advancing for the semi-trailer
A pressure advancer should be set in the brake system, so as to achieve a distributed braking effect that is as evenly distributed as possible by eliminating the lag time in the valves. Vehicle models in the Genlyon series are equipped with a double circuit pneumatic brake system, designed in accordance with EEC regulations. For trailers that come with a brake advancing adjusting device on the control valve, the movements of the trailer will be able to coordinate most effectively with a Genlyon tractor truck only when the trailer also complies with EEC regulation. For trailers that do not comply with EEC regulation, it is possible to adjust the advancing through the control valve on the trailer, if necessary. Adjustments to such brake advancings must only be carried out by professional repair workshops, in accordance with actual brake test results.
Semi-trailer tractor truck Base - 09/2013 Printed 603.95.640 5-11 GENLYON - KINGKAN REFITTING SPECIAL VEHICLES
Figure 5.6
198227
Swing angle for the semi-trailer tractor truck fifth wheel (front of the trailer)
Maximum front swing angle for semi-trailer tractor truck fifth wheel (min 6˚) Maximum front swing angle for semi-trailer tractor truck fifth wheel (min 7˚)
5.1.7 Heavy-duty off-road tandem rear axle semi-trailer tractor truck for dump truck
Reliableoff-roadfifthwheelsmustbeusedforsuchvehicles.Ifitisnotpossibleforacorrugatedplatetobeinstalled,a20mm-thick mounting plate can be used. The rear overhang of the chassis should be as short as possible. It is best to place a crossbeam near the rear leaf spring bracket to act as the rear crossbeam.
5.1.8 Leaf spring
When the front and rear leaf springs on a non-semi trailer tractor truck are semi-elliptical leaf springs rather than the softer parabolic leaf springs, this vehicle is suited for normal long distance freight transportation, due to the fact that the overload is unpredictable. Parabolic leaf springs must not be used on a semi-trailer tractor truck (high centre of gravity) or a three-axle off-road vehicle (semi-trailer dump truck).
5.1.9 Trailer turntable and its rotation
The semi-trailer coupling pin must be installed on a constant structure subframe due to the fact that this coupling pin bears approximately the same stress as the fifth wheel. If the vehicle has an automatic load sensing valve, this valve should be adjusted accordingly after the refit.
Semi-trailer tractor truck
Printed 603.95.640 Base - 09/2013 5-12 REFITTING SPECIAL VEHICLES GENLYON - KINGKAN
5.1.10 Refitting a dump truck or cargo truck as a semi-trailer tractor truck
Not all dump truck and cargo truck chassis are equipped with towing equipment. If absolutely necessary, such vehicles can be refitted as semi-trailer tractor trucks after relevant technical plans have been formally approved by our company. The technical requirements relevant to such a refit will be made on a case-by-case basis, with such requirements including the installation of a fifth wheel and a chassis refit plan (such as for the suspension and brake system) based on the vehicle’s service condition.
Figure 5.7
198228
Front and back turning radii of the semi-trailer tractor truck
E: Front turning radius of the semi-trailer tractor truck (available turning space) EI: Front turning radius of the semi-trailer F: Rear turning radius of the semi-trailer tractor truck (available turning space) FI: Rear turning radius of the semi-trailer
Semi-trailer tractor truck Base - 09/2013 Printed 603.95.640 5-13 GENLYON - KINGKAN REFITTING SPECIAL VEHICLES
Tank truck 5.2 Tank truck
The tank is connected to the chassis by support legs and fastening devices on the bottom of the tank. Keep away from high stress areas when installing the tank body or structures with extremely high torsional rigidity, in order to maintain sufficient and gradual torsional flexibility. The support legs can either be integral or distributed. The distributed support legs can be further divided into three types, namely: longitudinal beam distributed, crossbeam distributed, and longitudinal beam and crossbeam distributed. All of the support legs should be welded to the bottom of the tank and integral with the tank body. The most common connections are rigid and elastic connections. It is recommended that elastic connections be used for installing the tank body, at the front of the subframe and between rigid supports. For elastic connections, a soft elastic pad should be placed between the support legs and the subframe, and then fastened together using bolts, as shown in Figure 5.8. Examples of such pads include hard rubber and wood blocks. The rigid connection should be able to withstand the rear longitudinal and lateral forces, as shown in Figure 5.9.
Figure 5.8
198229
Elastic connection between tank body and chassis
The rigidity, connection areas, and expected applications of the chassis should all be considered when determining the elastic connection. Generally speaking, the first front elastic connection should ensure that the space between the subframe and the frame is roughly 10 mm during the torsion process of the chassis during road transportation.
Tank truck
Printed 603.95.640 Base - 09/2013 5-14 REFITTING SPECIAL VEHICLES GENLYON - KINGKAN
Figure 5.9
Rear rigid support
Support plate
Rigid support Subframe
Chassis frame
Rear elastic steel plate bracket
198230
Rigid support on the tank body When installing the tank on the body, make sure that the torsion of the chassis frame is not affected. It is recommended that a three-point support be used for the connection between the body and subframe, and that an elastic support be used in the front and rigid support at the back, as shown in Figure 5.10. Alternatively, a four-point support may be used at both the front and back.It is best to install the tank body bracket above the lifting eye of the front leaf spring, so as to reduce the stress on the frame.
Tank truck Base - 09/2013 Printed 603.95.640 5-15 GENLYON - KINGKAN REFITTING SPECIAL VEHICLES
Figure 5.10
Front view of the three point support Low structure
Point of support
Elastic support
Subframe
Chassis frame
Front view of the three point support Support
Elastic support
Subframe
Chassis frame
198231
Three-point support on the tank body
For a 4x2 chassis, it is best to install a double bracket above the rear bracket of the rear leaf spring; for a 6x4 chassis, it is best to install a double bracket above the central line of the balance axle, so as to maintain the good operating performance of the vehicle. Generally speaking, appropriate subframes are required for installing various containers and shipping containers on chassis made by our company. In the case that a vehicle is fitted with two or more independent tanks, the subframe should be used to better distribute the load, while the anti-shearing connection should be used between the chassis and subframe to provide sufficient torsional rigidity.It is good practice for these tanks to be connected together so as to form a rigid connection. To meet the maximum permitted axle load limits, it is essential that the maximum volume, filling volume and intensity of the load are calculated. If the tanks are placed in separate compartments, the filling volume of every tank must comply with the maximum permitted axle loads, and also the minimum required ratio must be maintained between the front axle load and gross vehicle weight.
Tank truck
Printed 603.95.640 Base - 09/2013 5-16 REFITTING SPECIAL VEHICLES GENLYON - KINGKAN
When designing the overall layout of the tank body, special attention should be paid to reducing the centre of gravity height as much as possible, so as to ensure the operating stability of the complete vehicle.It is recommended that vehicles are equipped with horizontal stabilizer bars. Tanks used for liquid transportation should be fitted with special lateral and longitudinal partition plates, so as to reduce the dynamic load transferred from the liquid during the vehicle’s operation. The filling volume of the truck body must not negatively affect the carrying capacity and operation of the vehicle. The trailer and semi-trailer should follow the same path to avoid extra dynamic load produced by the trailer connecting device. The installation of a tank for transporting gasoline and other flammable liquids must meet the relevant national standards and regulations. The subframe should be extended to the front as much as possible (at least to the rear bracket of the front leaf spring), and should be connected to the chassis frame by thrust connection plates. The tank can be directly installed on the chassis without the subframe in the following conditions: - The mounting bases of the tank body must be able to distribute the load evenly on a large plane.Appropriate brackets must be installed among the mounting bases to limit the longitudinal and lateral thrusts. - A sufficient number of tank body mounting bases must be installed to distribute and transfer the tank load effectively. The spacings between the mounting bases should be determined based on the amount of load to be transferred, and these spacings should under no circumstances exceed one meter. - Self-supporting tanks can be directly installed on the chassis by using proper mounting brackets, which should be installed close to the back of the driver cab. The number and layout of the mounting brackets depend on the number of axles and the wheelbase;for a short wheelbase 4x2 vehicle, at least two mounting brackets should be installed on either side; for a short wheelbase 6x4 or 8x4 vehicle, at least three mounting brackets should be installed on either side. The fixing devices must be long enough (about 600 mm) and should be located beside the hanging mounting bracket (with a maximum distance of 400 mm between them). The structure of the tank body mounting base is shown in Figure 5.11. In the case that the tank is laden with flammable liquids, the distance between the rear end (rear crash beam) of the chassis frame and the rear end of the tank body shall exceed 150 mm, as shown in Figure 5.9. The vehicle will tilt when operating on a curved road, meaning that the centre of gravity should be as low as possible.If this cannot be achieved, horizontal stabilizer bars should be used. If the tank body is further separated into several compartments, the refitting factory should clearly mark the sequences for loading and unloading on the most conspicuous part of the vehicle. Please ensure that the axle load is reasonably distributed and that the specified minimum axle load is achieved under all load conditions. The fixed oil tank must be integrated with the chassis frame, as shown in Figure 5.12. A two-point connection should be used around the rear axle.
Tank truck Base - 09/2013 Printed 603.95.640 5-17 GENLYON - KINGKAN REFITTING SPECIAL VEHICLES
Figure 5.11
198232
Support structures for the tank body
Figure 5.12
198233
Fixed connection between the frame and tank body 1. Longitudinal beam of the chassis frame - 2. Subframe - 3. Elastic pad - 4. Mounting bracket for the fixed oil tank
Tank truck
Printed 603.95.640 Base - 09/2013 5-18 REFITTING SPECIAL VEHICLES GENLYON - KINGKAN
Dump truck 5.3 Dump truck
The dump truck requires a special chassis to suit its particular service characteristics. The dump body should only be installed on a chassis specially designed for this purpose. Installing the dump body onto a different type of chassis will mean more time and money expended on refitting the vehicle. For a dump truck, the length of the mounting plate, A, at the rear lifting ram (back dump truck) should be at least 600 mm, while the maximum spacing, B, between the thrust connection plates is 1000 mm, as shown in Figure 5.13.
Figure 5.13
198234
Connection between the main frame and subframe for dump truck
The material and sectional size of the subframe for the dump truck is shown in Figure 4-1. To determine the pressure of the lifting mechanism for the dump truck, first calculate the carriage volume based on the maximum permitted total mass of the chassis and the kerb mass of the chassis and the driver cab; then calculate the position of the centre of gravity for the dump body and the cargo according to the axle load distribution. The pressure of the lifting mechanism relates to the lifting type, centre of the lifting ram, lifting mechanism, and its upper and lower points of support. It is best to use a lifting type that uses less pressure, so that the hydraulic system of the body has better stability and longer lifespan. The refitting factory may select different lifting types based on the actual features of their products. In order to minimize the stress on the frame, the front supporting beam of the dump truck may be installed directly at the rear bracket of the front suspension, and the rear supporting beam may be installed at the rear bracket of the rear suspension. Please note that sufficient motion space should be allowed between the tail board and rear end of the frame or towing hook, as showninFigure5-14. In addition, please ensure that there is sufficient space between the ground and the carriage and its moving door when the dump truck is unloading.
Dump truck Base - 09/2013 Printed 603.95.640 5-19 GENLYON - KINGKAN REFITTING SPECIAL VEHICLES
Figure 5.14
198235 Tail space for back dump truck
To prevent the incorrect operation or over-tilting of the dump body, install a stopper steel wire rope between the subframe and the floor of the dump body, or install a stopper unit at the rear end of the frame. In order to prevent accidental lifting when the vehicle is operating caused by mechanical faults and incorrect operation, and to reduce damage and loss, the Hongyan Genlyon and Hongyan Kingkan series of vehicle models all come with lift alarm devices in the driver cab. The refitting factory must connect the lift alarm switch when refitting the dump body. The lift alarm switch is installed on the subframe. When the dump body is lifted away from the subframe, the lift alarm device will be powered on, meaning that this device will send out sound and light alarms in the driver cab. For further details regarding the electrics, see the instructions in Section 3.15 ’Refitting the electrics’. The dump angle should be determined according to the angle of repose of the cargo. The dump angle is usually 50˚ or above, but can be 45˚ under certain conditions. When the dump body is installed on a standard frame, the chassis is only suited for operating on roads, and not for off-road conditions such as construction sites and mining areas. The back dump angle of 35˚~45˚ can be determined by the length of carriage. For transporting and unloading sliding goods with low densities (such as food and mineral waste residue), the back dump truck should be used due to the fact that these vehicles operate on flat and hard surfaces. It is best to install the rear hinge behind the central line of rear axle. The rear section of the subframe should be strengthened and connected to the chassis frame using thrust connection plates and bolts. The front section of the subframe should be connected to the chassis frame using mounting brackets and U-bolts. Reinforced rear suspension and higher load-bearing tyres should be installed on the vehicle to replace the original tyres, and a stabilizer should be installed. The subframe must be interconnected, and its crossbeams should be of a sufficient size to ensure sufficient strength. The crossbeam and longitudinal beam should be connected from the interior side of the subframe using compression brackets. It is best for the layout of the subframe to overlap with the crossbeams of the chassis frame and to have the same torsion feature as the main frame when the subframe and main frame are connected together. At the front of the vehicle, the main frame and subframe should be connected using elastic connections; at the rear of the vehicle, the main frame and subframe should be connected through thrust connection plates (behind the battery compartment). For an excavating or hoist dump truck (with steel wire ropes, chains, and towing hooks), not all chassis are able to fit such bodies. It is therefore recommended that the dump truck chassis be used due to the fact that the excavator bucket will transfer large forces to the chassis during the excavating and unloading processes. Before deciding on the wheelbase, check that there is sufficient space for the oil cylinder of the lifting device to frequently protrude out from the subframe.For an excavating dump truck, it is best to install a support device at the rear end of the frame. For a hoist dump truck, good stability must be maintained during the loading and unloading processes. Lifting the cargo without using support devices is prohibited.
Dump truck
Printed 603.95.640 Base - 09/2013 5-20 REFITTING SPECIAL VEHICLES GENLYON - KINGKAN
Body of the flat---bed, box and refrigerator trucks 5.4 Body of the flat-bed, box and refrigerator trucks
In order to distribute the stress on the chassis frame evenly, the body must be mounted on the frame through a [-shaped longitudinal beam. Table 4.4 lists the sectional size of this subframe. However, the information in the aforementioned table is limited. If you cannot find a certain vehicle model from this table or the information is not completely compatible with actual conditions, please contact our R&D Centre. If the bottom structure of the carriage can function as a subframe, the subframe may not be required (e.g. for a light cargo carriage). For a self-loading box body, the longitudinal beam (subframe) can be replaced with interconnected crossbeams. It is recommended that a baffle plate (heat shield) be installed behind the driver cab to prevent the heat from the engine from transferring to the vehicle body. This is crucial for the refrigerator truck and box truck. The carriage should be connected by connection brackets installed on the longitudinal beam of the frame. If such connection brackets are available for the chassis from our company, these connection brackets should be installed in accordance with the technical instructions in Section 4.2 ’Attaching the subframe to the body’. It is good practice to use thrust connection plates (see Figures 4.14 and 4.15) or bolts for connecting the interface between the main frame and the subframe (only at frame tail) (see Figure 4.21) to provide sufficient strength in the longitudinal connection. Except for such cases, drilling to the surface of the frame is not allowed. If refrigeration equipment on a refrigerator box truck is above the driver cab, this equipment should not affect the tilting of the driver cab,asshowninFigure5.15. For details of different vehicle models, please refer to external-use chassis drawings provided by our company.
Figure 5.15
198236
Space required for tilting of driver cab 1. Required space for tilting the driver cab - 2. Required space for operation of transmission and engine tail above transmission - 3. Tilting centre of driver cab - 4. Minimum required space between upper components and driver cab
Body of the flat-bed, box and refrigerator trucks Base - 09/2013 Printed 603.95.640 5-21 GENLYON - KINGKAN REFITTING SPECIAL VEHICLES
If the body is designed to be replaceable, it is necessary to install a body lifting mechanism or to reduce the chassis height using the air suspension of the chassis, and then to place the replaceable body on four support legs. Normally, the body should have sufficient rigidity and strength to bear the total mass of the body and cargo under the support of the four legs, with the body structure being intact. If the lifting mechanism is found to be putting a concentrated load on the chassis, the concentrated load area must be sufficiently reinforced. To ensure optimum operation, it is essential for the application conditions of vehicle to be checked against the specifications of the suspension. The replaceable body can be mounted on vehicles equipped with air suspension or with air suspension for the rear axle. A vertical lifting mechanism can be installed on the subframe, and under certain circumstances, this mechanism can also be installed on a sufficiently-sized connection plate between the subframe and chassis. The body connection should have sufficient support so as to be able to bear the dynamic lateral and longitudinal thrust, especially when the quick lock system is used. In the case that the vehicle does not have any subframes and special structures, permission for the refitting work must be obtained from our company, with the following conditions being met: - The entire replaceable body must be placed on the chassis, or must at least cover the major areas of the connections for the suspension attachments. - A sufficient number of connection devices must be installed along the lower surface of the frame longitudinal beam. - The load from the lifting mechanism to the chassis must be limited. Reinforced front suspension and higher load-bearing tyres are required for the tail lift box truck due to the fact that this truck unloads cargo only from the rear by the lift. As the cargo is loaded from the back to the front, the centre of gravity of the cargo also moves to the front axle, resulting in the overloading of the front axle and tyres. The loading layouts of the tail lift truck and box truck is shown in Figures 5.16~5.19.
Figure 5.16
198237
Loading plan A, applicable to the back dump truck
Body of the flat-bed, box and refrigerator trucks
Printed 603.95.640 Base - 09/2013 5-22 REFITTING SPECIAL VEHICLES GENLYON - KINGKAN
Concrete mixer truck 5.5 Concrete mixer truck
The strength of the subframe should match that of the concrete mixer truck body. Table 5.1 lists the capacities and their corresponding subframe data. A horizontal stabilizer bar must be used if the service conditions and structure permit. The chassis designed by our company for the concrete mixer truck has the following key characteristics:
Figure 5.17
198238
Loading plan B, applicable to the side back dump truck
Figure 5.18
198239 Loading plan C, applicable to the side dump truck
Figure 5.19
198240
Loading plan D, applicable to the side dump truck
Concrete mixer truck Base - 09/2013 Printed 603.95.640 5-23 GENLYON - KINGKAN REFITTING SPECIAL VEHICLES
Concrete mixer truck - Special rear overhang for the frame. - Large subplate for installing the subframe and connecting the main frame and subframe around the balance axle assembly.
Table 5.2 - Sectional size of the subframe for the Genlyon concrete mixer truck Body capacity Shape Sectional size Material 6m3 Rectangle 120x80x7 7~9 m3 Rectangle 140x80x7 16MnL-GB3273 10 m3 Rectangle 140x80x8
Please follow all standards and regulations relevant to the concrete mixer truck, and as well as taking the following into account: - An independent constant structure subframe must be installed for the concrete mixer, so as to distribute the concentrated load as evenly as possible throughout the entire chassis. The sectional size of the subframe should be larger than that listed in Table 5.2. - Appropriate crossbeams must be installed, so as to protect the chassis from the impact of certain geometrical shapes and functions of the concrete mixer by offering sufficient rigidity in the mounting base between the concrete mixer and its basic frame. In the case that an anti-shearing (thrust plate) connection is used between the main frame and subframe, the following conditions must be met: - The spacings between the thrust connection plates are 500~800 mm. - The main frame and subframe are tightly pressed by at least 10 kN force before drilling with the drilling machine. In order to optimize the bending stress, the connection plates behind the rear bracket shall must not be cut. When installing the concrete mixer body, please note that the centre of gravity must be reasonable, and that the maximum permitted axle load must be appropriate. The swing of the load in the mixer must be taken into account, in order to ensure the operating stability and safety of the vehicle, especially on bumpy roads with cross and/or longitudinal slopes. The reason for this is that the swing may alter the dynamic centre of gravity of the load, thus posing a negative impact on the stability of the vehicle.
Concrete mixer truck
Printed 603.95.640 Base - 09/2013 5-24 REFITTING SPECIAL VEHICLES GENLYON - KINGKAN
Installing a towing device 5.6 Installing a towing device
5.6.1 Installing a towing device
In the case that formal approval from our company has not been obtained, a towing device can only be installed on the special beam designed by our company and meant for installing a towing device and tractor truck. Should the refitting factory want to install a towing device on a vehicle not designed for this purpose, formal approval from our company must first be obtained. Except for the towing weight, the documents submitted for approval should also specify other compulsory technical requirements, such as the vehicle’s purpose, transmission ratio, brake system type, technical requirements for the reinforced structure mounted on the rear crossbeam, and whether a special crossbeam for installing the towing device is required. If the installed towing device is intended for the central axle trailer, please pay attention to the suggestions on reinforcing the rear frame structure given in Section 5.6.4 ’Central axle trailer’, considering the stress from the towing device of the vertical dynamic load on the end rear crossbeam. The towing device must be suited to the permitted range of load, and its structure must comply with relevant national standards.
A towing device is crucial to the driving safety of a vehicle (and must even undergo certification in some ! countries), and therefore this device must not be refitted in any form.
When installing the towing device on the crossbeam, please closely follow technical requirements provided by the towing device supplier and current relevant standards, such as the minimum space required for connecting the brake and electrical systems, and the maximum distance between the swivel hook axis and the rear end of the body. The aforementioned regulations may vary significantly between different regions.In the European Union, the maximum distance between the swivel hook axis and the rear end of the body is 420 mm. Therefore, in the case that the distance exceeds 420 mm, please carefully refer to relevant European Union regulations. If the connection flange (edge) of the towing hook does not fit the hole on the rear crossbeam of the vehicle, the crossbeam may be drilled in certain cases where proper reinforced parts are added.
Installing a towing device Base - 09/2013 Printed 603.95.640 5-25 GENLYON - KINGKAN REFITTING SPECIAL VEHICLES
5.6.2 Increasing the towing weight
If the tractor truck is capable of towing weights greater than the normally permitted towing weight, the refitting factory and user may submit a formal application to our company for evaluation and approval. The approval documents will specify the compulsory conditions and technical requirements for the refitting work and vehicle, if necessary. In the case that the original end rear crossbeam requires reinforcement components (as shown in Figures 5.23 and 5.24), the approval documents will also include instructions for installing the reinforced crossbeam (if any) and the technical requirements for the brake system (e.g. installing a larger capacity air compressor). The towing hook must be suited to the increased towing weight, and the mounting hole on the towing hook must match that on the crossbeam. To fix the crossbeam on the frame, please use the same drilling method as drilling gussets. The towing hook and crossbeam should be connected by hexagon flange bolts and nuts, or hexagon bolts of class 8.8 or above (larger diameter with self-locking nuts).
5.6.3 Lowering the rear towing-use crossbeam
In the case that the trailer requires the position of the towing hook to be lower than the original one, lowering the height of the original crossbeam, or installing another crossbeam at a lower position (the installed crossbeam should be the same as the original one in terms of type and structure) are both permitted, as shown in Figure 5.20 and Figure 5.21. The new crossbeam should be installed at the new position using the same method as the original crossbeam, and using the same type of bolts as the original ones (bolts of the same diameter and class). Outer reinforced connection plates must be thicker than the longitudinal beam of the chassis frame, and longer than 2.5 times the height of the longitudinal beam. The reinforced connection plates must be made from materials that comply with the specifications in Section 4.1 ’Structure and size of the subframe’. Fix the reinforced connection plate on the longitudinal beam of the chassis frame using the same bolts as those used to fix the crossbeam on the frame. These bolts can work together with other bolts, and thus they are able to withstand more carryover torque.In principle, if the crossbeam is lowered by roughly the same height as the longitudinal beam, the number of bolts should increase by around 40%.
Installing a towing device
Printed 603.95.640 Base - 09/2013 5-26 REFITTING SPECIAL VEHICLES GENLYON - KINGKAN
Figure 5.20
198241
Newly added end rear towing-use crossbeam (lower position) 1. Original end rear crossbeam - 2. Reinforced connection plate - 3. Reinforced connection plate - 4. Reinforced connection plate - 5. Lowered mounting base for crossbeam (same structure as original longitudinal beam) - 6. Original longitudinal beam (mounting base for original last rear crossbeam)
Installing a towing device Base - 09/2013 Printed 603.95.640 5-27 GENLYON - KINGKAN REFITTING SPECIAL VEHICLES
During the installation of the crossbeams (as shown in Figure 5.20), a central connection plate (’3’ in Figure 5.20) of approximately thesamethicknessasthecrossbeammustbeused. Self-locking bolts or thread-locking glue should be used to connect the connection plate.
Figure 5.21
198242 Lowering the towing-use end rear crossbeam 1. Original end rear crossbeam - 2. Connection plate for crossbeam - 3. Connection plate for crossbeam - 4. Angle reinforced connection plate
Please ensure that the amount of movement between the drawbar and vehicle complies with current relevant regulations.In principle, our company may confirm the towing weight of the original vehicle. However, in any event, the refitting factory will be responsible for the refitting work. The refitted vehicle must be sent for inspection if local regulations so require. Figure 5.20 illustrates a lower newly-installed crossbeam. If this plan is applied to a short rear overhang vehicle, the outer connection plate must have the same layout as that shown in Figure 5.20. If the bracket of the rear under-run bumper bar has to be refitted during the process of lowering the crossbeam, the refitted bumper bar must be equivalent to the original one in terms of connection, strength, and rigidity. Please also check whether the locations of the lights comply with relevant standards.
Installing a towing device
Printed 603.95.640 Base - 09/2013 5-28 REFITTING SPECIAL VEHICLES GENLYON - KINGKAN
5.6.4 Central axle trailer
If an articulated drawbar trailer or central axle trailer is used, changes to the vertical static load and dynamic load will increase the bending stress at the chassis rear overhang, and the torsional stress at the rear towing crossbeam. Fix the subframe on the chassis frame using a combination reinforced structure from the rear overhang to the front bracket of the rear suspension, or reinforce the existing connections between the main frame and subframe connection plates (as shown in Figure 5.22).
Figure 5.22
198243
Reinforcement for central axle trailer at the rear end of the chassis 1. Combination reinforced connection device - 2. Connection plate between main frame and subframe - 3. Longitudinal beam of subframe - 4. Vertical load at coupling pin
The maximum vertical load (static load plus dynamic load) transferred from the trailer to the towing hook can be more accurately calculated by using the following formula: 2 2 FV =a x /I C 0.6 + S FV = maximum vertical load (static load plus dynamic load) transferred from trailer to towing hook (kN) a = Vertical acceleration at the connection between draw bar and towing hook, depending on the tractor truck rear suspension - For vehicles with air suspension (or equivalent), a = 1.8 m/s2 - For vehicles using other suspensions, a = 2.4 m/s2 x = Overall length of loading area of trailer (m). I = Wheelbase of trailer (distance between centre of coupling pin and centre of trailer, or distance between central lines of trailer axles) (m). C = Gross trailer weight (R) minus static load S (in tons). S = Vertical static load at coupling pin (kN). 0.6 = Deceleration coefficient. The central axle trailer must be equipped with a towing device that is suited to the trailer’s characteristics. The trailer load and permitted vertical load should fall within the range specified on the nameplate or technical documents belonging to the towing device supplier. There are also specially customized towing devices, whose towing hooks are of better performance than normal hooks. These towing devices can only be used on certain trailers (depending on the specific trailer (e.g. the length of the drawbar)). If special towing devices are used, the rear crossbeam may need to be further reinforced, and a larger subframe longitudinal beam may be required. When using a central axle trailer, please note that the static load of the towing device must not cause the rear axle load to exceed its upper limit, and that the front axle load must be larger than its lower limit.
Installing a towing device Base - 09/2013 Printed 603.95.640 5-29 GENLYON - KINGKAN REFITTING SPECIAL VEHICLES
5.6.5 Reinforcing the standard rear crossbeam
In the case that the original standard crossbeam does not meet the requirements for towing the trailer, the refitting factory should reinforce the crossbeam structure appropriately. The refitting factory is responsible for the working performance of the reinforced structure. A C-shaped steel may be placed inside the end rear crossbeam for reinforcement. Whenever a reinforced structure with greater carrying capacity is required, the connection between the crossbeam and longitudinal beam must be reinforced using the following method: - Install the channel reinforced beam inside the crossbeam, and connect the channel reinforced beam and the frame beam or the adjacent crossbeam (if they are very close), according to the layout shown in Figure 5.23. - To reinforce the lower part of the end rear crossbeam, install an appropriately-sized rectangular reinforced steel pipe under the crossbeam, and connect this reinforced pipe to the longitudinal beam of the frame using bolts or rivets. The centre of this reinforced pipe should be connected to the centre of the crossbeam using reinforced brackets.For a rear overhang vehicle with a subframe, this reinforced steel pipe may be connected to the end rear crossbeam of the subframe using connection plates (as shown in Figure 5.24).
Figure 5.23
198244
Structure of channel reinforced beam for end rear crossbeam of frame 1. Original last rear crossbeam - 2. Reinforced beam - 3. Connection gusset
Installing a towing device
Printed 603.95.640 Base - 09/2013 5-30 REFITTING SPECIAL VEHICLES GENLYON - KINGKAN
Figure 5.24
198245
Structure of rectangular reinforced beam for end rear crossbeam on frame 1. Original last rear crossbeam - 2. Rectangular reinforced beam - 3. Crossbeam connection plate - 4. Reinforced connection bracket
If the rear under-run protection device hampers the installation of the rectangular reinforced pipe, the reinforced pipe may be installed using other methods. However, the connection strength should be approximately the same as the original structure, and should comply with relevant compulsory national regulations and standards. As this device is installed on the rear crossbeam, the rear crossbeam needs to be strengthened, as shown in Figures 5.23 and 5.24.
Installing a towing device Base - 09/2013 Printed 603.95.640 5-31 GENLYON - KINGKAN REFITTING SPECIAL VEHICLES
5.6.6 Trailer
If a towing device is installed on a normal cargo truck chassis for towing the trailer, the distance between the centre of the towing device master pin and the rear end of the truck must not exceed 300 mm, while the distance between this centre and the trailer must not exceed 950 mm, as shown in Figure 5.25.
Figure 5.25
198246
Trailer
If the master pin of the towing device is too low to the ground, the towing device must be redesigned, so as to lower the height of the end rear crossbeam for installing the towing device, as shown in Figures 5.20 and 5.21. Please free feel to consult with our Sales Division or R&D Centre is help is required.
Installing a towing device
Printed 603.95.640 Base - 09/2013 5-32 REFITTING SPECIAL VEHICLES GENLYON - KINGKAN
Fire truck chassis 5.7 Fire truck chassis
Our company has specially developed the four-door Genlyon fire truck chassis. The driver cab of the chassis is based on the original Genlyon driver cab, and lengthened to create a four-door Genlyon driver cab. The core specifications of the chassis are as follows: CURSOR (FPT Industrial) series of engine assembly from SAIC Fiat Powertrain Hongyan; ZF 5S-111GP transmission; PF60 series of full-power power take-off; PR70 series of transmission power take-off.The refitting factory and user may select the specifications according to their own needs. Our company can custom design strengthened fire truck chassis based on the needs of the refitting factory and the user. Chassis made by our company are registered for China III emissions standards and China IV emissions in standard special fire truck gazettes.
Fire truck chassis Base - 09/2013 Printed 603.95.640 5-33 GENLYON - KINGKAN REFITTING SPECIAL VEHICLES
Replaceable body 5.8 Replaceable body
A replaceable body can be mounted on the chassis using air suspension. In order to make the body replaceable (e.g. through the lifting mechanism or pneumatic suspension), four support legs should be mounted on the body. The refitting factory and supplier may check the following items to see whether the chassis is suited to the replaceable system: - Do the front and rear heights of the chassis and the maximum lifting height of the air suspension ensure that the support legs are smoothly installed (unladen specified gross weight according to relevant regulations and unladen technically possible gross weight)? - Is there sufficient space below the lift lever? - Is there sufficient space below the support leg? - The curve characteristics of the spring Support devices must be installed on the subframe, in order to minimize the lateral force transferred to the chassis and the frame. If both sides of the subframe longitudinal beam require support devices (e.g. four hydraulic support legs), connection plates should be used to connect the chassis to the subframe. Quick lock devices should comply with relevant regulations.
Replaceable body
Printed 603.95.640 Base - 09/2013 5-34 REFITTING SPECIAL VEHICLES GENLYON - KINGKAN
Dangerous goods truck 5.9 Dangerous goods truck
Special vehicles used to transport dangerous goods (inflammables and explosives) as specified in such standards as GB 12268 ”List of Dangerous Goods” must comply with GB 18564.1-2006 ”Road tankers for dangerous liquid goods transportation - Part 1: Technical requirements of atmospheric pressure metal tanks”; GB 18564.2-2008 ”Road tankers for dangerous liquid goods transportation - Part 1: Technical requirements of atmospheric pressure non-metal tanks”; GB 13392-2005 ”Vehicle marks for road transportation of dangerous goods”; and GB 21668-2008 ”Provisions of vehicles for the carriage of dangerous goods with regard to their specific constructional features”. During the refitting work of dangerous goods truck, careful attention should be paid to the following areas:
5.9.1 Electrical system
Electrical wires must have good insulation performance and be well protected from impacts, graphite, and high temperatures. A fuse or automatic circuit breaker should be used to prevent electric circuit overload. The main power switch should be installed as close to the battery as possible, and a control device should be installed in the driver cab for controlling the main power switch. This control device should be installed at a place which is easy to operate and be clearly marked. The device for preventing incorrect operation should also be installed for this control device.
5.9.2 Brake system
An ABS, front disc brake, and retarder are all required when selecting a chassis.
5.9.3 Driver cab protection
The interior trim material should comply with GB 8410-2006 ”Flammability of automotive interior materials”, while the combustion rate should not exceed 100 mm/min. A protective wall should be installed between the driver cab and the transported goods.
5.9.4 Exhaust system
Exhaust system parts must be fully thermally insulated if their will reach temperatures of more than 200 ˚C and if they cannot be removed from behind the protective wall in the driver cab. If it is not possible for an exhaust outlet to point outward, a sparkproof device must be installed during the transportation of inflammables and explosives. During the refitting work of the exhaust pipe, the instructions in Section 3.9 ’Refitting the engine intake and exhaust systems’ must be followed.
5.9.5 Fuel tank
The mounting position of the fuel tank should protect the fuel tank from jolting. When the vehicle rolls over or fuel leaks, the fuel should flow to the ground directly.
Dangerous goods truck Base - 09/2013 Printed 603.95.640 5-35 GENLYON - KINGKAN REFITTING SPECIAL VEHICLES
5.9.6 Independent heater
Installed independent heaters must comply with relevant fireproof regulations. The heaters should be installed on the rear panel of the driver cab, at least 800 mm from the ground. The heating components should be subject to effective fireproof and heat insulating treatment.
5.9.7 Speed limiter
Dangerous goods trucks should be equipped with speed limiters, which should set the maximum speed as 80 km/h.
5.9.8 Safety equipment
Dangerous goods trucks must be equipped with at least two fire extinguishers, and two portable lamps that are independent of the electrical system of the vehicle. The lamps must not cause an the operating vehicle to set on fire. Dangerous goods trucks should also meet the following specific requirements: - Special vehicles used for transporting inflammables and explosives should be equipped with fire-fighting equipment. The exhaust pipe should be installed in front of the front panel of the tank or box body and below the upper plane of the longitudinal beam. A motor vehicle exhaust spark arrester, which complies with GB 13365 regulations, should be installed. A grounding device should be mounted at the rear of the motor vehicle. - For dangerous goods tank trucks, an overturning protection device of sufficient strength should be installed at the top of the tank. This device should contain a drain valve for draining away accumulated liquid. The highest point of this protection device should be at least 20 mm higher than that of the pipe joints, valves, and other accessories at the top of the tank body. For dangerous goods tank trucks, the tank body, relevant pipelines, and relevant pipeline accessories must not exceed the side of the vehicle, or the rear under-run protection device. The longitudinal distance between the rear under-run protection device and the rear enclosure of the tank, relevant pipelines and relevant pipeline accessories should be at least 150 mm.
Dangerous goods truck
Printed 603.95.640 Base - 09/2013 5-36 REFITTING SPECIAL VEHICLES GENLYON - KINGKAN
Dangerous goods truck Base - 09/2013 Printed 603.95.640 6-1 GENLYON - KINGKAN POWER TAKE-OFF
Index
SECTION 6 Power Take Off
Page
6.1 Introduction ...... 6-3
6.1.1 Please consider the following aspects when selecting a power take-off: ...... 6-3
6.1.2 The power take-off can be classified into the following three types, according to its purpose: ...... 6-3
6.1.3 Power take-off application type ...... 6-3
6.1.4 Principles for selecting the power take-off ...... 6-3
6.1.5 Drive shaft of the power take-off ...... 6-4
6.2 Transmission power take-off ...... 6-6
6.3 Engine power take-off ...... 6-7
6.3.1 Engine crankshaft power take-off ...... 6-7
6.3.2 Engine flywheel power take-off ...... 6-7
6.4 Powertrain system power take-off ...... 6-8
6.5 Selecting the power take-off ...... 6-9
6.5.1 Gear ratio and transmission ratio of the power take-off ...... 6-9
6.5.2 Output torque and power of the power take-off ...... 6-10
6.6 Lists of power take-offs ...... 6-12
6.7 Main parameters of the power take-off ...... 6-15
6.8 Engine flywheel shell power take-off ...... 6-19
6.9 Transfer case power take-off ...... 6-22
Index
Printed 603.95.640 Base - 09/2013 6-2 POWER TAKE-OFF GENLYON - KINGKAN
Index Base - 09/2013 Printed 603.95.640 6-3 GENLYON - KINGKAN POWER TAKE-OFF
55655.
Introduction 6.1 Introduction
Most special vehicles power special devices using the chassis engines. For auxiliary devices powered by the engine, different power take-off specifications can be used.
6.1.1 Please consider the following aspects when selecting a power take-off:
- The drive torque required for the power output shaft - The type of power take-off, based on the required torque for driving the auxiliary device - The position and direction of turning for the power take-off, based on the position and structure of the auxiliary device - The structure of the transmission power output end - The mode of control for the power take-off
6.1.2 The power take-off can be classified into the following three types, according to its purpose:
- Transmission type:front transmission power take-off (full-power power take-off), and side, bottom, and rear transmission power take-off - Engine type crank axle (front end) power take-off, and flywheel (rear end) power take-off - Drivetrain type:transfer power take-off or special power take-off added between the separated drive shaft
6.1.3 Power take-off application type
The power take-off working time must be considered (i.e., whether it is to be used for intermittent short or continuous periods). The time for incidental use will not usually exceed 30 minutes. Continuous working power refers to the constant output power of the power take-off when operatingstablyforalongtime. The preset output is also applicable for when the frequency and range of torque do not undergo any significant changes. To avoid overload, devices such as the clutch and safety valve may be required on certain occasions (e.g. for hydraulic pump or compressor).
6.1.4 Principles for selecting the power take-off
After determining the type of power take-off to be used, the gear ratio should be selected based on the required revolutions of the auxiliary device. The maximum torque of the power take-off is calculated at stable working conditions when there is no additional weight, impact or vibrations. For commonly-used power ranges, the engine revolution should be at least 1200 rpm. When designing and selecting the transmission system and relevant components for the auxiliary device, the appropriate engine revolution (the recommended engine revolution range is 1200~1500 rpm) and high engine load rate should be selected, due to the fact that the fuel economy of the engine is relatively good under this condition.
Introduction
Printed 603.95.640 Base - 09/2013 6-4 POWER TAKE-OFF GENLYON - KINGKAN
6.1.5 Drive shaft of the power take-off
During the design phase, careful consideration should be paid to the motion characteristics (angle, revolution, and torque) of the drive shafts between the application devices and the power take-off, while it should also be noted whether the dynamic features of the power take-off during operation fit the requirements of the drive shaft supplier. When determining the specifications of the drive shaft, the forces that may occur at the maximum output power and torque must also be considered. Since most auxiliary devices are fixed onto the frame or subframe, and the power take-off is fixed onto the transmission or engine, it is best to use a telescopic drive shaft to connect the power take-off and auxiliary device. In the case that conditions do not permit, at least one end of the drive shaft should be adjustable. The angles of the universal joint flanges at both ends of the drive shaft should be the same, and should not exceed 7˚,asshown in Figure 6.1. The maximum permitted deviation in the two angles is 1˚. If the angles are too large, the vibration in the drive shaft will intensify, reducing the transmission efficiency and the lifespan of the auxiliary device. A Z layout is better than a W layout, due to the fact that there is less load on the bearing of the power take-off and driven equipment.
Figure 6.1
Wlayout Power take-off
Auxiliary device
Zlayout 198247
Layout of the power take-off drive shaft
If different space tilts () are required, the shifting fork layout illustrated in Figure 6.2 should be used to adapt to the changes in the revolution.
Introduction Base - 09/2013 Printed 603.95.640 6-5 GENLYON - KINGKAN POWER TAKE-OFF
Figure 6.2
198248
Layout of the power take-off drive shaft
For a multi-section drive shaft, please follow the regulations of Section 3.4.2 ’Layout of the drive shaft’. The drive shaft must be qualified in terms of dynamic balance before it is installed on a vehicle.
Introduction
Printed 603.95.640 Base - 09/2013 6-6 POWER TAKE-OFF GENLYON - KINGKAN
Transmission power take---off 6.2 Transmission power take-off
Depending on the type of transmission, power can be output from the auxiliary shaft through the power take-off installed at the rear upper left or lower right, side, or bottom of the transmission. For further information about the technical features of the power take-off, please refer to the materials on different gearboxes. The power take-off can offer higher torque when working for a short time, while the value of the output torque is determined by the actual working time. As the continuous working time decreases, the maximum output torque may increase accordingly. The power take-off can be engaged or disengaged only when the clutch is released. Otherwise, the stress on the synchronizer shall be excessively large when a gear shift is made. Gear shifts should not be made when the power take-off is in use and the vehicle is operating. In the case that the power take-off output end is driving the power pump of another device without using an intermediate drive shaft, please check the safety margin of the pump, chassis and engine equipment (such as crossbeam and drive shaft), and then check whether the quality of the pump and the static and dynamic torque produced by output power are suited to the bearing capacity of the transmission and the power take-off.It has been proven that the torque produced by added weight should not exceed 3% of the engine’s maximum torque. In the case that the transmission and engine are both used in one unit, it is essential for the inertia effect of the added mass to be verified in order to prevent resonance within the operating revolution range of the engine.
Points for attention during the design and selection of the power take-off. !
- When selecting the power take-off, please note that the required torque must not exceed the permitted torque values of the power take-off under different working conditions. - In the case that the power take-off has been working continuously for a long period of time, the temperature of the lubricating oil in the powertrain must not exceed 120 ˚C, while the temperature of the coolant must not exceed 100 ˚C. - Not all power take-offs available on the market are suited for continuous use. When selecting a power take-off, please follow the specifications in the Technical Instructions (such as those for work time and intervals). Use a magnetic valve to turn the power take-off on and off with compressed air from the auxiliary air channel.
Transmission power take-off Base - 09/2013 Printed 603.95.640 6-7 GENLYON - KINGKAN POWER TAKE-OFF
Engine power take---off 6.3 Engine power take-off
The engine power take-off is used for body devices requiring a continuous power supply.
6.3.1 Engine crankshaft power take-off
Limited power can be obtained from the rear crankshaft of the engine through the belt transmission system (e.g. the air conditioning system). Shaft coupling is usually required in order to gain more output power. When no special design has been made, the front structure of the vehicle needs to be properly refitted for these applications, with such refitting work possibly including the radiator, driver cab and bumper bar.Particular attention should be paid to the following points: - Systems containing added mass and relative rigidity must be able to disconnect from the crankshaft flexibly, in terms of torque and deformation. - The impact of the added mass and relative moment of inertia on the original power and powertrain systems. The distance between the centre of gravity and the central line of the first main bearing should be as short as possible. - The cooling capability of the radiator should not be reduced, and no stagnant water area should appear in the cooling system. - If components (such as the crossbeam or bumper bar) are to be modified, their rigidity and strength should be maintained. - When the power take-off is working continuously for a long period of time, the temperature of the coolant should be kept below 100 ˚C, and the temperature of the engine oil below 110~120 ˚C. It is best to maintain a safety margin of 10% and to install an auxiliary cooling device when necessary.
6.3.2 Engine flywheel power take-off
The Cursor 13 and Cursor 9 engines installed on the Genlyon series of vehicles may be installed with the flywheel power take-off to obtain power from the timing gear. The power take-off may be connected to the hydraulic pump or may be equipped with a flange for connecting the drive shaft.
In the case that this type of power take-off is required, a request must be presented at the placement ! of the order. Should this type of power take-off need to be installed after the vehicle has been handed over, the entire engine may need to be replaced.
The specific location, structure and size of the power take-off output flange can be found in our external-use chassis drawings and other technical materials. In order to maximize the torque, the moment of inertia of all rotating components connected to the power take-off should not exceed 0.03 kgm2. The output torque of the power take-off on the engine flywheel should not exceed its maximum output torque under any condition. The flywheel power take-off is connected to the inline pump (the oil pump is directly connected to the power take-off). he static moment of oil pump on its mounting surface shall not exceed 90 Nm. If this limit is exceeded, the power take-off output flange can only be connected to the oil pumps mounted on other components of the chassis through the drive shaft.
Engine power take-off
Printed 603.95.640 Base - 09/2013 6-8 POWER TAKE-OFF GENLYON - KINGKAN
Powertrain system power take---off 6.4 Powertrain system power take-off
In the case that a special body device needs to take power from the drive shaft or transfer case due to reasons of its structure, installation, or power output, please first submit the specific refitting plans and relevant information about the required power of the body device to our Sales Division and R&D Centre for formal approval. Only after the plans are approved can refitting be started. Thepowerandtorqueshouldbecalculatedbasedonworking conditions and other specific circumstances. Please pay attention to the following points: - The drive shaft and transfer case power take-off can only be used when the vehicle is stationary. The transfer case and power take-off must have a neutral gear function, so that the vehicle is stationary when power take-off is operated. - The revolution of the power take-off depends on the gear shift of the selected transmission. - The power take-off must be installed close to the transmission and at its downstream direction.If the vehicle is equipped with a two-section or multi-section drive shaft, the power take-off can also be installed on the flexible support between the first section and second section of the drive shaft. - It is best to keep the angles of the drive shaft on a horizontal and vertical plane close to the initial value. - To avoid abnormal vibrations or damage on the powertrain components, such as (between the engine and axle) when the vehicle or power take-off is operating, components added to the powertrain system should undergo strict dynamic balance tests. - The power take-off must be fixed on the chassis using a special mount. - Transmission is crucial to the safety of a vehicle. Transmission refits should only be carried out by professional technical personnel, provided that the powertrain system supplier (such as the transmission supplier) permits the refitting work.
Powertrain system power take-off Base - 09/2013 Printed 603.95.640 6-9 GENLYON - KINGKAN POWER TAKE-OFF
Selecting the power take---off 6.5 Selecting the power take-off
The choice of power take-off will depend mainly on the accessory device, which determines the position, direction of turning, torque, and gear ratio. The following describes a normal power take-off. The refitting factory should select a power take-off based on actual conditions, and without being restricted by this document.
6.5.1 Gear ratio and transmission ratio of the power take-off
The transmission ratio and overall gear ratio of the power take-off is determined by the required output speed of the accessory device. The transmission ratio and overall gear ratio of the power take-off are two different concepts. The former relates to the structure of the power take-off itself, and to the ratio of the input speed to output speed of the power take-off. The overall gear ratio refers to the ratio of the speed of the power take-off output end to the speed of the engine, and relates not only to the gear ratio of the power take-off, but also to the transmission and its gear shift or transfer case. The user or refitting factory should pay attention to the differences between these two concepts when selecting a power take-off. The overall gear ratios of power take-offs made by our company are listed in Table 6.1.
Table 6.1 - Nominal output torque and overall gear ratio of commonly used power take-offs
Power Nominal output Gear ratio Transmission take-off torque (Nm) 1st gear 2nd gear 3rd gear 4th gear 5th gear 6th gear QH50 500 2.42 1.78 1.32 0.98 - - 9JS119 QH70 700 2.37 1.74 1.29 0.96 - - 9JS135 QJ330 338 3.01 2.76 1.48 1.09 - - QH50 500 2.42 1.78 1.32 0.98 - - RT-11509C QH70 700 2.37 1.74 1.29 0.96 - - QJ330 338 3.01 2.76 1.48 1.09 - - QJ330 10JSD120 QH50 10JSD140 QH70 10JSD160 QH50 10JSD180 QH70 12JS160T QH70 700 3.29 2.76 2.15 1.67 12JS180T PR70 700 0.789 5S-111GP PR101 1000 1
Selecting the power take-off
Printed 603.95.640 Base - 09/2013 6-10 POWER TAKE-OFF GENLYON - KINGKAN
The recommended purposes for the gear ratios are listed as follows: - i=0.37~0.48: for use on the lift pump of a dump truck - i=0.48~0.88: for use on the hydraulic pump of a hydraulic crane truck - i=0.88~1.54: for use on the hydraulic pump of a liquid tank truck - i=1.51~1.87: for used on the high pressure pump of a municipal engineering vehicle - i=1.00 (full-power power take-off): for use on a concrete mixer truck and hydraulic transmission vehicle The transfer case power take-off is for use on the hydraulic pump of a liquid tank truck, winch, hydraulic crane, and lumber crane.
6.5.2 Output torque and power of the power take-off
The maximum torque of the power take-off is calculated at stable working conditions when there is no additional weight, impact or vibrations. When determining the required power for the application, especially when high power is required, consideration should be paid to the power loss during the driver transmission process (the power loss for the mechanical, belt, and gear transmission is 5~10%, and the power loss for the hydraulic control device is larger). The transmission ratio of the power take-off should ensure that the power loss occurs within the flexible operation range of the engine. Slow speeds should be avoided, (less than 1000 rpm) so as to prevent abnormal operations. The power of the power take-off at the specified torque and revolution is as follows:
M n P(kW)= 9550
In which: P Output power of the power take-off (kW) M Output torque of the power take-off (Nm) n Output evolution of the power take-off (rpm) Selecting the power take-off is an important part of the chassis application.If the chassis purchased by the user is already equipped with power take-off, the relevant materials and instructions for the power take-off should be obtained from the Sales Department of our company. In the case that the chassis is not equipped with power take-off, or the installed power take-off does not suit the user’s needs, the user and refitting factory should inform our Sales Department of the power take-off required, and confirm this with our Sales Department. When selecting a power take-off or refitting the existing power take-off, the user and refitting factory should carefully fill in the Power Take-off Questionnaire, so as to ensure that the selected power take-off fulfils their requirements. ThePowerTake-offQuestionnaireisshowninTable6.2.
Selecting the power take-off Base - 09/2013 Printed 603.95.640 6-11 GENLYON - KINGKAN POWER TAKE-OFF
Table 6.2 - Power Take-off Questionnaire 1 2 3 a - transmission power take-off b - engine power take-off
source c - transfer case power take-off
Power take-off d-others Engine model
Revolution of the engine nMot take-off
the power Output revolution of the power take-off nNA Revolution of
Direction of turning of the power take-off output Output power of the power take-off (kW) Output torque of the power take-off (Nm) a - spline shaft b - spline housing
end c - flange () Type and the output dimension of d-others
a-parking
b-operating Service condition c-bothaandb
a - continuous operation (min)
b - short operation (min) Working condition c-others
Vehicle model Notes
In the case that the user selects two or more kinds of power take-offs, the coordinate dimensions of one of the power take-offs will change. The user may consult our Sales Department or R&D Centre in order to obtain relevant materials.
Selecting the power take-off
Printed 603.95.640 Base - 09/2013 6-12 POWER TAKE-OFF GENLYON - KINGKAN
Lists of power take---offs
6.6 Lists of power take-offs
The main power take-offs used on the Genlyon series of chassis are listed in Table 6.3.
Table 6.3 - Power take-off list Model Relative position between input and output shafts Relative position of the power take-off assembly and its output end to the transmission: Centre of the transmission output shaft Installation interface of the power take-off
QJ330
Centre of the power take-off output shaft 198249
Relative position of the power take-off assembly and its output end to the transmission:
Centre of the transmission output shaft Installation interface of the power take-off
QJ331
Centre of the power take-off output shaft 198250 Relative position of the power take-off assembly and its output end to the transmission:
Centre of the transmission Installation inter- output shaft face of the power take-off
QH70
Centre of the power take-off output shaft 198251
Lists of power take-offs Base - 09/2013 Printed 603.95.640 6-13 GENLYON - KINGKAN POWER TAKE-OFF
Table 6.3 - Power take-off list contd.
Drawing Name and relative position between the input and output shafts No Relative position of the power take-off assembly and its output end to the transmission:
Centre of the transmission output shaft Installation inter- face of the power take-off
QH50
Centre of the power
take-off output shaft 198252
Relative position of the power take-off assembly and its output end to the transmission:
Centre of the transmission output shaft
QQ60B Centre of the power take-off output shaft
198253
Lists of power take-offs
Printed 603.95.640 Base - 09/2013 6-14 POWER TAKE-OFF GENLYON - KINGKAN
Table 6.3 - Power take-off list contd.
Drawing Name and relative position between the input and output shafts No. Relative position of the power take-off assembly and its output end to the transmission:
Centre of the transmission output shaft
PR70 Centre of the power take-off output shaft
198254
Relative position of the power take-off assembly and its output end to the transmission: Centre of the transmission output shaft
Installation inter- face of the power take-off
PF61
Centre of the power take-off output shaft 198255
Lists of power take-offs Base - 09/2013 Printed 603.95.640 6-15 GENLYON - KINGKAN POWER TAKE-OFF
Main parameters of the power take---off 6.7 Main parameters of the power take-off
The main parameters of the power take-offs installed on the Genlyon series of chassis are listed in Table 6.4~Table 6.10.
Table 6.4 - QJ330 power take-off list The output end has the same direction of turning as the engine. Dimensions of the output flange
198256
1 2.37 Nominal output torque 500 Nm Overall gear ratio at 2 1.74 different gear shifts Gear ratio of the power 3 1.30 0.8 (RT-11509C) take-off 4 0.96
Table 6.5 - QJ331e power take-off assembly The output end has the same direction of turning as the engine. Dimensions of the output flange
198257
1 3.36 Nominal output torque 500 Nm Overall gear ratio at 2 2.49 different gear shifts 3 1.82 Gear ratio of the power 0.8 (10JSD120) 4 1.36 take-off 5 1.01
Main parameters of the power take-off
Printed 603.95.640 Base - 09/2013 6-16 POWER TAKE-OFF GENLYON - KINGKAN
Table 6.6 - QH70 power take-off assembly The output end has the same direction of turning as the engine. Dimensions of the output flange
198258 1 2.37 Nominal output torque 700 Nm Overall gear ratio at 2 1.74 different gear shifts Gear ratio of the power 3 1.30 0.8 (RT-11509C) take-off 4 0.96
Table 6.7 - QH50 power assembly The output end has the same direction of turning as the engine. Dimensions of the output flange
198259 1 2.42 Nominal output torque 500 Nm Overall gear ratio at 2 1.78 different gear shifts Gear ratio of the power 3 1.32 0.818 (RT-11509C) take-off 4 0.98
Main parameters of the power take-off Base - 09/2013 Printed 603.95.640 6-17 GENLYON - KINGKAN POWER TAKE-OFF
Table 6.8 - PR70 power take-off assembly The output end has the same direction of turning as the engine. Dimensions of the output flange
198260 Gear ratio of the power Nominal output torque 700 Nm 0.36/0.51/0.789 take-off iQ S6-120 (direct gear):2.12xi Overall gear ratio of the Q S6-120 (over gear):1.66xi power take-off Q 5S-111GP (direct gear):1.21xiQ
Table 6.9 - QQ60B power take-off assembly The output end has the same direction of turning as the engine. Dimensions of the output flange
198261
Gear ratio of the power Nominal output torque 600 Nm 1 take-off
Main parameters of the power take-off
Printed 603.95.640 Base - 09/2013 6-18 POWER TAKE-OFF GENLYON - KINGKAN
Table 6.10 - QF61 power take-off assembly The output end has the same direction of turning as the engine. Dimensions of the output flange
198262 Gear ratio of the power Nominal output torque 600 Nm 0.976/0.585 take-off
Main parameters of the power take-off Base - 09/2013 Printed 603.95.640 6-19 GENLYON - KINGKAN POWER TAKE-OFF
Engine flywheel shell power take---off 6.8 Engine flywheel shell power take-off
The CURSOR9 series of engine from the SAIC Fiat Powertrain Hongyan and WP10 series of engine from Weichai Power are all equipped with engine flywheel power take-off. Table 6.11 lists the parameters, flange, and position of the engine flywheel power take-off for the CURSOR9 series of engine from SAIC Fiat Powertrain Hongyan. Table 6.12 lists the parameters, flange, and position of the engine flywheel power take-off for the WP10 series of engine from Weichai Power.
Engine flywheel shell power take-off
Printed 603.95.640 Base - 09/2013 6-20 POWER TAKE-OFF GENLYON - KINGKAN
Table 6.11 - Parameters, flange, and position of engine flywheel power take-off for CURSOR9 series of engine from SAIC Fiat Powertrain Hongyan
Direction of turning of the output end:clockwise (the side facing the flywheel) Dimensions of the output flange
Even distribution
198258
Output revolutions 1.14:1 Nominal output torque 800 Nm Position
A direction enlarged
Distance to the front axle axis 576 198259
Applicable engines: China III emissions standards C9-290, C9-310, C9-340, and C9-380; China IV emissions standards C9-290, C9-310, C9-350, C9-390
Engine flywheel shell power take-off Base - 09/2013 Printed 603.95.640 6-21 GENLYON - KINGKAN POWER TAKE-OFF
Table 6.12 - Parameters, flange, and position of engine flywheel power take-off for WP10 series of engine from Weichai Power The output end has the same direction of turning as the engine. Dimensions of the output flange
Even distribution
198260 Gear ratio of the power 1(N =N ) Maximum output torque 650 Nmm take-off output engine Maximum output Working revolutions 650~2400 rpm 150 kW/2200 rpm power/revolution Position
A direction enlarged
Distance to the front axle axis 576 198261
Applicable engines: WP10.270, WP10.290, WP10.336, WP10.375, WP10.270 E32, WP10.290E32, WP10.310E32, WP10.340E32, WP10.380E32
Engine flywheel shell power take-off
Printed 603.95.640 Base - 09/2013 6-22 POWER TAKE-OFF GENLYON - KINGKAN
Transfer case power take---off 6.9 Transfer case power take-off
The transfer case power take-off is for use on the hydraulic pump of the liquid tank truck, winch, hydraulic crane, and lumber crane. Selecting the power take-off is an important part of the chassis application. The power can be output from the flange or spline shaft at the rear, side, or bottom of the power take-off. If a chassis purchased by the user bought is already equipped with power take-off, the relevant materials and instructions for the power take-off should be obtained from the Sales Department of our company.In the case that the chassis is not equipped with a power take-off, or the installed power take-off does not suit the user’s needs, the user should inform our Sales Department of the type of power take-off required, and confirm this with our Sales Department.In the case that the user selects two or more types of power take-off, the coordinate dimensions of one of the power take-offs will change. The user may consult our Sales Department in order to obtain relevant materials. Please note that the transfer case power take-off can only be used when the vehicle is stationary, and that the output shaft can only be engaged or disengaged when the clutch is released. Otherwise, the stress on the synchronizer shall be excessively large when gear shifts are made. Gear shifts should not be made when the power take-off is in use and the vehicle is operating.
Points for attention during the use of the power take-off ! - Please pay attention to the torque when using power take-off. - The temperature of the lubricating oil in the powertrain should not exceed 120 ˚C, while the temperature of the coolant should not exceed 100 ˚C. - Not all power take-offs available on the market are suited to continuous use.When selecting a power take-off, please follow the specifications in the Technical Instructions (such as those for work time and intervals).
Transfer case power take-off Base - 09/2013 Printed 603.95.640 POINTS FOR ATTENTION DURING THE REFITTING OF CHINA 7-1 GENLYON - KINGKAN IV EMISSIONS STANDARDS VEHICLES
Index
SECTION 7 Points for Attention during the Refitting of China IV Emissions Standards Vehicles
Page
7.1 Content and scope ...... 7-3
7.2 Reference standards ...... 7-3
7.3 Definition of the after-treatment system ...... 7-3
7.3.1 Engine exhaust after treatment system ...... 7-3
7.3.2 DeNOx system ...... 7-3
7.3.3 Exhaust control system ...... 7-3
7.4 Illustration of the exhaust after-treatment system ...... 7-4
7.5 Illustration of China IV emissions standards after-treatment system urea pipe and water pipe connections..... 7-4
7.6 Points for attention ...... 7-5
Index
Printed 603.95.640 Base - 09/2013 7-2 POINTS FOR ATTENTION DURING THE REFITTING OF CHINA IV EMISSIONS STANDARDS VEHICLES GENLYON - KINGKAN
Index Base - 09/2013 Printed 603.95.640 POINTS FOR ATTENTION DURING THE REFITTING OF CHINA 7-3 GENLYON - KINGKAN IV EMISSIONS STANDARDS VEHICLES
55755.
Content and scope 7.1 Content and scope
These ’Points for Attention’ are applicable for vehicles with common rail SCR engines that comply with China IV emissions standards.
7.2 Reference standards
The reference standards and regulations are listed as follows: GB17691-2005 ”Limits and measurement methods for exhaust pollutants from compression ignition and gas-fuelled positive ignition engines of vehicles (III, IV, V)” HJ 437-2008 ”Technical specification for on-board diagnostic (OBD) system of compression ignition and gas-fuelled positive ignition engines of vehicles” HJ 438-2008 ”Durability of emission control systems of compression ignition and gas-fuelled positive ignition engines of vehicles” HJ 439-2008 ”In-service conformity of compression ignition and gas-fuelled positive engines of vehicles”
7.3 Definition of the after-treatment system
7.3.1 Engine exhaust after treatment system
A catalytic converter (oxidation or three-way), particulate filter, deNOX system, combined abatement system for NOX and particles and any other devices, which can reduce exhaust pollutants, but excluding the exhaust gas recirculation (EGR) system.
7.3.2 DeNOx system
An exhaust after-treatment system for reducing NOX, for example, an active or passive lean-burn engine NOX converter, NOX-absorbing converter, or selective catalytic reduction (SCR) system.
7.3.3 Exhaust control system
An exhaust after-treatment system, engine electronic control unit (ECU), components installed in the engine exhaust system which provide input signals or receive output signals for the ECU, and the communication interfaces between the ECU and other engine assemblies or exhaust control unit (hardware or software, if applicable).
Content and scope
Printed 603.95.640 Base - 09/2013 7-4 POINTS FOR ATTENTION DURING THE REFITTING OF CHINA IV EMISSIONS STANDARDS VEHICLES GENLYON - KINGKAN
Illustration of the exhaust after---treatment system 7.4 Illustration of the exhaust after-treatment system
The exhaust after-treatment system is illustrated in Figure 7.1.
7.5 Illustration of China IV emissions standards after-treatment system urea pipe and water pipe connections
The reference standards and regulations are listed as follows:
Figure 7.1
Air intake system Intercooler Sensor Air intake
Fuel system Intake air pressure sensor
Commonrail pipe
Common rail Booster pressure sensor Accelerator pedal Intake air temperature sensor
Fuel injec- Revolution sensor tion pump After-treatment system Cam angle sensor Exhaust temperature sensor NOX catalyst Nitrogen catalyst NOx detection sensor
Urea injection nozzle Exhaust Exhaust pipe pressure sensor
Nozzle pressure CAB Bus sensor Urea solution injection system CAB Bus Urea temperature sensor UREA Tank Liquid level sensor
198263 Illustration of the China emissions standards engine after-treatment system
The China IV emissions standards exhaust after-treatment system urea and water pipe connections are illustrated in Figure 7.2.
Please note that the urea pipe must not be connected to the compressed air connector. ! Otherwise, the urea pipe will be permanently damaged.
Illustration of the exhaust after-treatment system Base - 09/2013 Printed 603.95.640 POINTS FOR ATTENTION DURING THE REFITTING OF CHINA 7-5 GENLYON - KINGKAN IV EMISSIONS STANDARDS VEHICLES
Figure 7.2
198264
Illustration of China IV emissions standards exhaust after-treatment system urea and water pipe connections
Points for attention
7.6 Points for attention
Points for attention during refitting work ! 1) Ensure that the wiring harness is not excessively bent at the harness connectors, that the electrical wire plugs are free of such foreign matter as dust, mud water, and scraps, that no electrical wires are exposed, and that there are no short circuits. 2) The electromagnetic valve pipe should be installed in the direction of the water flow, not against it. 3) The vehicle power supply must be shut off during the welding of the chassis. Never weld with the power on. 4) After the vehicle stops, in whatever environment and at whatever temperature, the temperature of the compressed air electromagnetic solenoid on the urea pump will remain very high for a certain period of time. As such, contact with the skin should be avoided in order to prevent scalding. 5) The power source can supply 24 V steady power (the battery is also controlled by the main power switch-please make sure that the main power switch is not turned off within one minute of the diesel engine shutting down, so as to allow the compressed air to blow into the urea pipe and injection nozzle, as indicated in the instructions for the complete vehicle.). 6) Refitting the after-treatment system is prohibited.
Points for attention
Printed 603.95.640 Base - 09/2013 7-6 POINTS FOR ATTENTION DURING THE REFITTING OF CHINA IV EMISSIONS STANDARDS VEHICLES GENLYON - KINGKAN
Points for attention Base - 09/2013 Printed 603.95.640 A-1 GENLYON - KINGKAN APPENDIX A
Index
APPENDIX A
Page
A.1 Relevant special vehicle standards A-3
Index
Printed 603.95.640 Base - 09/2013 A-2 APPENDIX A GENLYON - KINGKAN
Index Base - 09/2013 Printed 603.95.640 A-3 GENLYON - KINGKAN APPENDIX A
AAAAA.
Relevant special vehicle standards A.1 Relevant special vehicle standards
GB/T 17350-2009 Terms, marks and designation for special purpose vehicles and special trailers GB/T 4606-2006 Road vehicles - 50 semi-trailer fifth wheel coupling pin - Basic and mounting/interchangeability dimensions GB/T 4607-2006 Road vehicles - 90 semi-trailer fifth wheel coupling pin - Basic and mounting/interchangeability dimensions GB/T 4781-2006 Commercial road vehicles - 50 mm drawbar eye - Interchangeability GB/T 6068-2008 Test codes for truck cranes and mobile cranes GB/T 6420-2004 Freight trailer series pedigree GB 7956-1998 Fire performance requirements and test methods for vehicles GB/T 9465-2008 Vehicle-mounted mobile elevating work platforms GB/T 12503-1995 Generic specifications for TV vans GB/T 13872-2002 Test rules for product quality inspection for trailers GB/T 13873-2009 Road vehicles - Trailer test procedures GB/T 13880-2007 Road vehicles - Fifth wheels - Interchangeability GB/T 15087-2009 Road vehicles - Drawbar couplings and eyes for hinged drawbars - Strength tests GB/T 15088-2009 Road vehicles - Fifth wheel kingpins - Strength tests GB/T 17275-1998 Technical requirements for freight full trailers GB/T 17350-2009 Terms, marks and designation for special purpose vehicles and special trailers GB 18564.1-2006 Road tankers for dangerous liquid goods transportation - Part 1: Technical requirements of atmospheric pressure metal tank GB 18564.2-2008 Road tankers for dangerous liquid goods transportation - Part 2: Technical requirements of atmospheric pressure non-metal tank GB/T 20069-2006 Road vehicles - Fifth wheel couplings strength tests GB/T 20070-2006 Road vehicles - Mechanical coupling between tractors and semi-trailers - Interchangeability GB/T 23336-2009 General technical requirements for semi-trailers GB/T 25977-2010 Snow blowers GB/T 25981-2010 Guardrail clean-out vehicles GB/T 25987-2010 Armoured anti-riot vehicles GB/T 26408-2011 Concrete truck mixers GB/T 26473-2011 Cranes-Safety requirements for loader cranes QC/T 21-1992 Technical conditions for bulk-calcium carbide pneumatic delivery tankers QC/T 22-1992 Metrology inspection vehicles QC/T 23-1992 Milk tankers
Relevant special vehicle standards
Printed 603.95.640 Base - 09/2013 A-4 APPENDIX A GENLYON - KINGKAN
AAAAA.
QC/T 24-1992 Technical conditions for mail trucks QC/T 40-1992 Performance test methods for bulk-calcium carbide pneumatic delivery tankers QC/T 41-1992 Environmental monitoring vehicles QC/T 51-2006 Sweeping trucks QC/T 52-2000 Garbage trucks QC/T 53-2006 Faecal suction trucks QC/T 54-2006 Street sprinklers QC/T 75-1998 Test rules for mining dump truck approval evaluation QC/T 76.1-1993 Test methods for the mining dump truck - general rules QC/T 76.2-1993 Test methods for the mining dump truck - measurement method for the driver seat reference point R QC/T 76.3-1993 Test methods for the mining dump truck - gradeability test QC/T 76.4-1993 Test methods for the mining dump truck - revolution or speed test for automatic gear shifting QC/T 76.5-1993 Test methods for the mining dump truck - constant power test QC/T 76.6-1993 Test methods for the mining dump truck - fuel consumption test QC/T 76.7-1993 Test methods for the mining dump truck - emergency steering capability test QC/T 76.8-1993 Test methods for the mining dump truck - riding comfort test QC/T 76.9-1993 Test methods for the mining dump truck - air conditioning performance test QC/T 76.10-1993 Test methods for the mining dump truck - cooling system cooling capability test QC/T 76.11-1993 Test methods for the mining dump truck - operational reliability test QC/T 202-1995 Test methods for the mining dump truck - towing performance test QC/T 203-1995 Measurement method and limits for the mining dump truck driver cab noise QC/T 222-2010 General technical conditions for dump trucks QC/T 223-2010 Test method for dump truck QC/T 250-1998 Test methods for the mining dump truck - braking performance test QC/T 251-1998 Emergency steering performance requirements for the mining dump truck QC/T 252-1998 Test rules for special vehicle approval evaluation QC/T 254-1998 Technical conditions for bank trucks QC/T 255-1998 Bank truck protection performance test method QC/T 310-1999 Trailer supporting devices QC/T 319-2011 Special vehicle power take-off QC/T 439-1999 Technical conditions for swept-body dump trucks QC/T 440-1999 Test method for swept-body dump trucks QC/T 446-1999 Tractor truck fifth wheel QC/T 447-1999 Technical conditions for building panel transporters
Relevant special vehicle standards Base - 09/2013 Printed 603.95.640 A-5 GENLYON - KINGKAN APPENDIX A
AAAAA.
QC/T 448-1999 General technical conditions for cooking trucks QC/T 449-2010 Technical conditions and test methods for insulated trucks and refrigerator trucks QC/T 451-1999 General technical conditions for vending vehicles QC/T 452-1999 General technical conditions for camping vehicles QC/T 453-2002 Box trucks QC/T 454-1999 Technical conditions for bee-keeping trucks QC/T 455-1999 Technical conditions for livestock trucks QC/T 456-1999 Technical conditions for bulk grain trucks QC/T 457-2002 Ambulances QC/T 458-2004 Technical conditions for family planning vehicles QC/T 459-2004 Crane trucks QC/T 460-2010 Technical conditions for dump truck hydraulic cylinders QC/T 461-1999 Technical conditions for dump truck reversing valves QC/T 464-1999 General technical conditions for shower vehicles QC/T 466-1999 Technical conditions for side-open lift trucks QC/T 493-1999 General technical conditions for workshop trucks QC/T 503-1999 General conditions for special trailers QC/T 560-2010 Technical conditions and performance test methods for bulk cement trucks QC/T 587-1999 Quality inspection method for tank trucks QC/T 588-1999 Quality inspection method for dump trucks QC/T 589-1999 Quality inspection method for box trucks QC/T 645-2005 Wreckers QC/T 651-2000 Quality inspection method for complete mining dump trucks QC/T 652-2000 Suction-type sewer scavenger QC/T 653-2000 Technical conditions for fuel tankers and refuelling trucks QC/T 667-2010 Technical conditions and test methods for concrete mixer trucks QC/T 679-2002 Car carrier trucks QC/T 699-2004 Tail lift for vehicles QC/T 718-2004 Concrete pump trucks QC/T 733-2005 Desert off-road vehicles QC/T 739-2005 General technical conditions for oil field vehicles QC/T 749-2006 Tree sprinkling tankers QC/T 750-2006 General technical conditions for cleaning trucks QC/T 782-2007 Technical conditions for dump truck sealed lid
Relevant special vehicle standards
Printed 603.95.640 Base - 09/2013 A-6 APPENDIX A GENLYON - KINGKAN
AAAAA.
QC/T 825-2010 Technical conditions for dump truck hydraulic system QC/T 846-2011 Technical conditions for heavy flat-bed trucks QC/T 848-2011 Swept-body dump devices QC/T 29015-1991 Technical conditions for dump truck board locking devices QC/T 29100-1992 Technical conditions for library trucks QC/T 29104-1992 Solid pollution limit of the special vehicle hydraulic system hydraulic oil QC/T 29105.1-1992 Test method for solid pollution limit of the special vehicle hydraulic system hydraulic oil - terms and definitions QC/T 29105.2-1992 Test method for solid pollution limit of the special vehicle hydraulic system hydraulic oil - equipment and equipment cleaning QC/T 29105.3-1992 Test method for solid pollution limit of the special vehicle hydraulic system hydraulic oil - sampling QC/T 29105.4-1992 Test method for solid pollution limit of the special vehicle hydraulic system hydraulic oil - microscopic particle counting method JB/T 4199-1986 Technical conditions for tail lift trucks JB/T 9737.1-2000 Crane truck and wheel mounted crane hydraulic oil - solid particle pollution level JB/T 9737.2-2000 Crane truck and wheel mounted crane hydraulic oil - solid particle pollution measurement method JB/T 9737.3-2000 Crane truck and wheel mounted crane hydraulic oil - selection and replacement JB/T 9738-2000 Crane truck and wheel mounted crane - lifting mechanism test specifications Q/CQ 31009-2011 Vehicle paint coating (SIH company standards) Q/CQ 31013-2013 Technical conditions and industrial process for rustproof wax Compulsory standards for Genlyon and Hongyan Kingkan series of vehicles GB 1495-2002 Limits and measurement methods for noise emitted by accelerating motor vehicles GB 1589-2004 Limits of dimensions, axle load and masses for road vehicles GB/T 2977-2008 Size designation, dimensions, inflation pressure and load capacity for truck tyres GB 3847-2005 Limits and measurement methods for exhaust smoke from C.I.E. (Compression Ignition Engine) and vehicle equipped with C.I.E. GB 4094-1999 Motor vehicles - Symbols for controls, indicators and tell-tales GB 4599-2007 Motor vehicle headlamps equipped with filament lamps GB 4660-2007 Motor vehicle front fog lamps equipped with filament lamps GB 4785-2007 Prescription for installation of the external lighting and light-signalling devices for motor vehicles and their trailers GB 5763-2008 Brake linings for automobiles GB 5920-2008 Photometric characteristics of front and rear position lamps, end-outline marker lamps and stop lamps for motor vehicles and their trailers GB 7258-2012 Safety specifications for power-driven vehicles operating on roads GB 8410-2006 Flammability of automotive interior materials
Relevant special vehicle standards Base - 09/2013 Printed 603.95.640 A-7 GENLYON - KINGKAN APPENDIX A
AAAAA.
GB 9656-2003 Safety glazing materials for road vehicles GB 9744-2007 Truck tyres GB/T 9969-2008 General principles for preparation of instructions for use of industrial products GB 11550-2009 Strength requirement and test for automobile seats head restraints GB 11554-2008 Photometric characteristics of rear fog lamp for power-driven vehicles and their trailers GB 11557-2011 Stipulations protecting drivers from being injured by motor vehicle steering mechanisms GB 11564-2008 Retro-reflector device for motor vehicles GB 11567.1-2001 Motor vehicles and trailers lateral protection requirements GB 11567.2-2001 Motor vehicles and trailers rear under-run protection requirements GB 11568-2011 Motor vehicles hood latch system GB 12676-1999 Road vehicles - Braking systems - Structure, performance and test methods GB 13392-2005 Vehicle marks for the road transportation of dangerous goods GB/T 13594-2003 Anti-lock braking performance and test procedure for motor vehicles and their trailers GB 14023-2011 Vehicles, boats and internal combustion engines - radio disturbance characteristics - limits and methods of measurement for the protection of off-board receivers GB 14166-2003 Safety belts and restraint systems for adult occupants of motor vehicles GB 14167-2006 Safety-belt anchorages for vehicles GB 15082-2008 Speed meters for motor vehicles GB 15083-2006 Strength requirements and tests for automobile seats, their anchorages, and head restraints GB 15084-2006 Motor vehicles - Rearview mirrors - Requirements for performance and installation GB 15235-2007 Photometric characteristics of reversing lamps for power-driven vehicles GB 15740-2006 Protective devices against unauthorized use of motor vehicles GB 15741-1995 License plates (brackets) and their position on motor vehicles and trailers GB 15742-2001 Performance requirements and test methods for horns for motor vehicles GB 15766.1-2008 Packaging - Flexible aluminium tubes - Test methods to determine the polymerization of internal coating with acetone GB 16897-2010 Brake hose - Structure, performance and test methods GB 17509-2008 Photometric characteristics of direction indicators for motor vehicles and their trailers GB 17675-1999 Steering systems for motor vehicles - Basic requirements GB 17691-2005 Limits and measurement methods for exhaust pollutants from compression ignition and gas-fuelled positive ignition engines of vehicles (III, IV, V) GB/T 17692-1999 Measurement methods for net power for automotive engines GB 18099-2000 Photometric characteristics of side-marker lamps for motor vehicles and their trailers GB 18296-2001 Safety property requirements and test methods for automobile fuel tanks
Relevant special vehicle standards
Printed 603.95.640 Base - 09/2013 A-8 APPENDIX A GENLYON - KINGKAN
AAAA.
GB 18408-2001 Photometric characteristics of devices for the illumination of rear registration plates of motor vehicles and their trailers GB/T 18411-2001 Road vehicles - Manufacturer’s plate GB/T 18655-2010 Vehicles, boats and internal combustion engines - Radio disturbance characteristics - Limits and methods of measurement for the protection of on-board receivers GB 19151-2003 Warning triangles for motor vehicles GB 20182-2006 Commercial vehicles cabs - External projections GB 20300-2006 Safety specifications for road transportation vehicles with explosive substances and chemical toxic substances GB 21259-2007 Headlamps equipped with gas-discharge light sources for motor vehicles GB 21260-2007 Headlamp cleaners GB 21668-2008 Provisions of vehicles for the carriage of dangerous goods with regard to their specific constructional features GB 23254-2009 Retro-reflective markings for trucks and trailers GB 24409-2009 Limits of harmful substances for automobile coatings GB 25990-2010 Rear-marking plates for vehicles and their trailers GB 25991-2010 Automotive headlamps with LED light sources and/or LED modules GB 26511-2011 Front under-run protective requirements for commercial vehicles GB 26512-2011 Protection of occupants in the cabs of commercial vehicles JT 719-2008 Operation truck fuel consumption limits and measurement methods QC/T 924-2011 Heavy duty commercial vehicle fuel consumption limits State Machinery Use of non-fluorine refrigerants Industry Administration on Vehicle Emissions (97) No. 099 Q/CQ 10076-2008 Vehicle identification number (VIN) content and locations
Relevant special vehicle standards Base - 09/2013 Printed 603.95.640