List of Manuals

1. Safety Manual for Truck and All Terrain Cranes XCA160H

Operation Manual
2. XCA160H All Terrain Crane Physical Information and
Rated Load Charts Manual

3. XCA160H All Terrain Crane Operation Manual

4. XCA160H All Terrain Crane Accessories Manual

5. XCA160H All Terrain Crane Transporting Manual

6. XCA160H All Terrain Crane Maintenance and Service Manual

7. XCA160H All Terrain Crane Troubles and Solution Manual

 XCA160H All Terrain Crane Operation Manual

XCA160H All Terrain Crane

Operation Manual

First edition, April 2022

VIN

Engine number

Date

This manual is part of the crane and must be kept with the unit and accessible by the operator.

Please read and understand this manual before operating the crane.

This equipment is designed and manufactured to comply with

Q/320301JAF691-2021,

GB/T 6067.1-2010 Safety rules for lifting appliances-Part 1: General,

GB 7258-2017 Safety specifications for power-driven vehicles operating on roads,

GB/T 6068-2021 Test code for truck crane and mobile crane,

and GB/T 27996-2011 All terrain crane.

All rights reserved

No part of this publication may be reproduced or used in any form by any means-graphic, electronic

or mechanical, including photocopying, recording, taping or information storage and retrieval systems

-without the written permission of XCMG.

 XCA160H All Terrain Crane Operation Manual

Preface

Sincerely thank you for trusting and using this XCMG-branded All terrain crane made by Xuzhou

Heavy Machinery Co., Ltd.

This manual applies to XCA160H All Terrain Cranes.

Instructions for the procedures of driving and operation, and safety of XCA160H All Terrain Crane

(hereinafter called crane) are supplied in the manual.

Any lifting work involves risks. In order to reduce these risks, please read and understand the

instructions in this manual, And pay special attention to the contents of “Danger”, “Warning” and
“Caution” in this manual.

The crane has been tested and calibrated at the factory. Parameters and pressures must be maintained

according to this manual. Pay attention to periodic inspections of crane safety devices and do not use the

crane when any defect or abnormality has been detected. Keep in mind that safety is your top priority and

you are responsible for the safe operation of the crane.

Please keep this manual and the supplied technical documents in good condition and with the crane,

and operate the machine according to instructions in them. We don’t take any liability in case of accident

or damage due to nonobservance of the manual.

Due to product improvements or modifications, there may be differences between this manual and the

crane. XCMG reserves the right to modify the manual or the crane without notice of improvement. The

illustrations used in this manual are intended as representative reference views only. Thus, information,

illustrations and/or specifications to explain and/or exemplify a product, service or maintenance

improvement may be changed at any time without notice.

Preface I
 XCA160H All Terrain Crane Operation Manual

Symbols and their meanings are as follows:

This safety alert symbol means ATTENTION! Become alert-your safety is involved!

Obey all safety messages that follow this symbol to avoid possible death or injury.

——Identifies hazards that will result in death or serious injury if the message
is ignored.

——Identifies hazards that may result in death or serious injury if the message
is ignored.

——Identifies hazards that could result in minor or moderate injury if the message
is ignored.

——It indicates a dangerous situation that, if not avoided, could result in damage to

the equipment, personal property and/or the environment or decrease in crane’s

performance.

or ——It means the operation does not comply with operating practices, which is

prohibited or is likely to cause casualty accident.

—— "Notice" is used to supply indication or additional explanation for

individual items.

II
 XCA160H All Terrain Crane Operation Manual

Contents

Preface............................................................................................................................................................ I

Chapter 1 About the manual ...................................................................................................................... 1-1

Chapter 2 Chassis operation....................................................................................................................... 2-1

2-1 Driver’s cab.................................................................................................................................... 2-1

2-1-1 Instrument panel ..................................................................................................................... 2-2

2-1-2 Display screens ...................................................................................................................... 2-4

2-1-3 Control switches ................................................................................................................... 2-20

2-1-4 Control panel ........................................................................................................................ 2-25

2-1-5 Air conditioner control panel ............................................................................................... 2-27

2-1-6 Control mechanism .............................................................................................................. 2-28

2-2 Inspection before driving ............................................................................................................ 2-34

2-2-1 Driving conditions................................................................................................................ 2-34

2-2-2 Check the coolant level ........................................................................................................ 2-35

2-2-3 Check fluid levels and filters ................................................................................................ 2-37

2-2-4 Check the tires ...................................................................................................................... 2-41

2-2-5 Check the windshield cleaning solution............................................................................... 2-41

2-2-6 Check the lamps and mirrors ............................................................................................... 2-41

2-3 Enter the driver’s cab ............................................................................................................... 2-42

2-3-1 Seat and seat belt .................................................................................................................. 2-42

2-3-2 Steering wheel ...................................................................................................................... 2-46

2-4 Operation of the engine............................................................................................................... 2-47

2-4-1 Start the engine..................................................................................................................... 2-47

2-4-2 Checklist after start-up ......................................................................................................... 2-51

2-5 Driving operation ........................................................................................................................ 2-52

2-5-1 Transmission operation ........................................................................................................ 2-52

2-5-2 Steering operation ................................................................................................................ 2-66

2-5-3 Braking operation ................................................................................................................. 2-71

2-5-4 Suspension operation ........................................................................................................... 2-80

2-5-5 Stopping and parking ........................................................................................................... 2-82

Contents III
 XCA160H All Terrain Crane Operation Manual

2-5-6 Operation of differentials ..................................................................................................... 2-83

2-6 After travel .................................................................................................................................. 2-84

2-6-1 Stop the engine ..................................................................................................................... 2-84

2-6-2 Close and lock the door ........................................................................................................ 2-84

2-7 Towing operation ........................................................................................................................ 2-85

2-8 Winter operation ......................................................................................................................... 2-86

Chapter 3 Crane operation ......................................................................................................................... 3-1

3-1 Operator's cab ............................................................................................................................... 3-1

3-1-1 Instrument panel ..................................................................................................................... 3-4

3-1-2 Switches and indicator lamps ................................................................................................. 3-6

3-1-3 Control mechanism .............................................................................................................. 3-12

3-1-4 Air conditioner control panel ............................................................................................... 3-14

3-1-5 Control panel of radio .......................................................................................................... 3-15

3-1-6 Other devices........................................................................................................................ 3-16

3-2 Safety devices ............................................................................................................................. 3-17

3-2-1 Load moment indicator ........................................................................................................ 3-17

3-2-2 Lowering limiter .................................................................................................................. 3-21

3-2-3 Electric control handle enable switch (pilot pressure switch).............................................. 3-22

3-2-4 Turntable locking device ...................................................................................................... 3-23

3-2-5 Slewing brake foot pedal...................................................................................................... 3-24

3-2-6 Rope guard ........................................................................................................................... 3-24

3-3 Inspection before crane operation ............................................................................................... 3-25

3-3-1 Site condition ....................................................................................................................... 3-25

3-3-2 General items of inspection before lifting operation ........................................................... 3-25

3-3-3 Inspection of safety devices ................................................................................................. 3-26

3-3-4 Inspection of wire rope ........................................................................................................ 3-27

3-4 Operation of PTO........................................................................................................................ 3-28

3-5 Operation of outriggers ............................................................................................................... 3-29

3-5-1 Preparation before operation ................................................................................................ 3-29

3-5-2 Outrigger structure and outrigger control panel ................................................................... 3-35

3-5-3 Extend the outriggers ........................................................................................................... 3-38

3-5-4 How to level the crane ......................................................................................................... 3-42

IV Contents
 XCA160H All Terrain Crane Operation Manual

3-6 Enter the operator’s cab...............................................................................................................3-42

3-6-1 Open and close the door .......................................................................................................3-42

3-6-2 Adjustment of seat ................................................................................................................3-43

3-6-3 Operation of PTO .................................................................................................................3-45

3-6-4 Power switch ........................................................................................................................3-46

3-6-4 Operation of accelerator .......................................................................................................3-48

3-7 Operation of crane control levers................................................................................................3-49

3-7-1 Winch operation ...................................................................................................................3-49

3-7-2 Boom telescoping operation.................................................................................................3-53

3-7-3 Boom luffing operation ........................................................................................................3-69

3-7-4 Slewing operation ................................................................................................................3-71

3-7-5 Simultaneous movements ....................................................................................................3-74

3-7-6 Operation of turntable locking device ..................................................................................3-76

3-7-7 Tilt the operator’s cab ........................................................................................................3-77

Contents V
 XCA160H All Terrain Crane Operation Manual

VI
 XCA160H All Terrain Crane Operation Manual

Chapter 1 About the manual

1. The manual is an integral part of the

crane. Keep it in a proper place in the operator's

cab during the service life of the crane for

reference regarding crane operation.

使用说明书

2. To prevent machine damage and personal

injury or death, fully understand and master all

information in this manual and strictly comply

with all safety precautions.

● Read the operation instructions before

operation. Improper operation will result in
damage to the machine and personal injury or
death.
● If any action, which is not recommended
or allowed in the manual, is to be used, the
operator should carry out risk assessment and
take necessary measures to ensure safety. The
operator should take full responsibility for all
consequences.

About the manual 1-1

 XCA160H All Terrain Crane Operation Manual

4. The safety information in the manual

cannot cover all potential risks under all working

conditions, so the operator, rigger and supervisor

must take other potential safety hazards into

consideration.

5. If a guideline in the manual differs from

that issued by the local government or authorities,

follow the stricter one.

6. Correctly understanding and mastering

what is described in the manual will help you:

a) know the structure and performance of

the machine;

b) avoid misoperation and minimize

danger; ● Prior to operation of the machine, be

c) improve working efficiency of the familiar with all safety warnings in the manual
machine; and safety signs on the machine, and follow
d) prolong the service life of the machine; related safety requirements. Otherwise, it may
e) reduce maintenance costs. cause machine damage and even personal injury
7. If you have questions about anything or death.
in the manual, contact your dealer or XCMG's

service department.

8. If the manual is lost or damaged, contact

the XCMG service department for a replacement

copy.

9. Keep this manual with the crane and

● The manual is not a training manual for a
ensure that it is included with the crane if it is
crane driver. All operation instructions are aimed
sold.
at a trained crane driver.

● The manual is only for reference, which

provides simple or detailed operation instructions

for trained operator or driver.

1-2 About the manual

XCA160H All Terrain Crane Operation Manual

1-3
 XCA160H All Terrain Crane Operation Manual

1-4
 XCA160H All Terrain Crane Operation Manual

Chapter 2 Chassis operation

2-1 Driver’s cab

The brand new metal driver's cab features an attractive appearance, luxurious and comfortable

interior decoration, spacious inner space and reasonable layout of devices.

Devices in the cab consist of instruments and display, indicator lamp assembly, control switches,

control mechanism and seat, etc. as shown in Figure 2-1.

Figure 2-1 Devices in the driver's cab

No. Name No. Name

1 Display 2 Steering wheel
3 Control switches 4 Control mechanism
5 Seat 6 Accelerator pedal
7 Foot brake pedal

Chassis operation 2-1

 XCA160H All Terrain Crane Operation Manual

2-1-1 Instrument panel

The Instrument panel consists of the indicator lamp assembly, display, etc., as shown in Figure 2-2.

F1
F2
F3
F4
F5

Figure 2-2 Instrument panel

No. Name No. Name

1 Indicator lamp assembly 2 Display
3 USB port

2-2 Chassis operation

 XCA160H All Terrain Crane Operation Manual

The keys on the display and their functions.

F1
F2
F3
F4
F5

Figure 2-3 Display

No. Name No. Name

1 Key 1 2 Key 2
3 Key 3 4 Key 4
5 Key 5

Chassis operation 2-3

 XCA160H All Terrain Crane Operation Manual

2-1-2 Display screens

1. Main screen

The main screens of the display are as shown in Figure 2-4 and Figure 2-5.

Figure 2-4 Main screen 1

2-4 Chassis operation

 XCA160H All Terrain Crane Operation Manual

No. Name Function

1 Engine tachometer Its pointer indicates the rotation speed of engine, in 100 r/min.

The scale mark indicates the coolant temperature of engine at

2 Coolant temperature
present, in ℃.

3 Hour meter It records the number of hours the engine is running, in h.

4 Speedometer Its pointer indicates the current traveling speed, in km/h.

It indicates the percentage of current fuel amount to total fuel tank

5 Fuel level
volume.

6 Odometer It records the distance driven, in km.

7 Transmission gear The gear of transmission is shown.

8 Time and date It shows the current date and time.

9 Temperature It indicates the current ambient temperature, shown in ℃.

10 Air pressure indication It shows the current air pressure, in bar.

11 CANbus status indication CANbus status is shown here.

12 Indication of steering status It indicates the steering status

It indicates the current and target steering modes, namely, normal

road steering mode, tight-turning radius mode, anti-drifting mode,
13 Indication of steering mode rear axle locked mode, crab walk steering mode and rear axle
independent steering mode. When the steering mode is changed,
the display zone will flash for 5 seconds to remind the driver.

Each icon represents a related state. The illumination of an icon is

14 Driving state icons
in response to the related traveling state.

Always make sure the information shown on the main screen is correct before driving the

crane.

Chassis operation 2-5

 XCA160H All Terrain Crane Operation Manual

The indicators and icons are shown as follows:

Icon Name Icon Name

Front fog lamp Rear fog lamp

Dim indicator lamp Beam indicator lamp

Daytime travel lamp Travel lamp

Steering pre-warning (yellow）

Reverse indicator lamp
Steering fault (red)

Suspension pressure sensor fault

Fault of sterring circuit 1
indiacator lamp

Fault of sterring circuit 2 Brake wear indicator lamp

High hydraulic oil temperature

Transmission gear limit
indicator lamp

Transfer case high oil

Low engine coolant level
temperature

Transmission fault indicator

Low air pressure
lamp

PTO indicator Engine exhaust brake

2-6 Chassis operation

 XCA160H All Terrain Crane Operation Manual

Icon Name Icon Name

Hydraulic oil filter plugged

Retarder fault
warning

Retarder enable Inter-axle differential

Blocked suspension Suspension leveling

Engine fault Inter-wheel differential

Transfer case low gear Water in fuel

Engine preheating ABS warning

Braking indicator lamp

Expressway traveling
(1~4 gears)

Town road traveling Off-road traveling

Heavy load traveling Safety belt detection

Chassis operation 2-7

 XCA160H All Terrain Crane Operation Manual

Icon Name Icon Name

Parking brake indicator lamp Low engine oil pressure

Cruise indicator lamp

2-8 Chassis operation

 XCA160H All Terrain Crane Operation Manual

The icons on the right side of Figure 2-5 will appear when pressing the keys in Figure 2-3. If no

operation continues, these icons will disappear automatically after 5 seconds. Press the key for the

required item to open the related screen. Press F1 in Figure 2-3 to enter the terminal status screen; press

F2 in Figure 2-3 to enter the J1939 fault diagnosis screen; press F3 in Figure 2-3 to enter the network state

screen; press F4 in Figure 2-3 to enter the steering monitoring screen; press F5 in Figure 2-3 to enter the

main system screen.

Figure 2-5 Main screen 2

No. Function No. Function

1 For entering terminal status screen 2 For entering J1939 screen
3 For entering network state screen 4 For entering steering monitoring screen
5 For entering into main system screen

Chassis operation 2-9

 XCA160H All Terrain Crane Operation Manual

2. Main system screen

Fault 故障诊断
diagnosis System
系统设置 setting

Subsidiary辅助页面
screen Reserve
预留界面

Reserve
预留界面 Factory default
工厂设置

Maintenance and维护保养
service Back to main screen
返回主页

Figure 2-6 Main system screen

The main system screen is a navigation screen. Press key F1 or F2 on the right side of the screen to

move upwards or downwards to select a screen; press F3 to enter the related screen; press F4 to return to

the previous menu; press F5 to enter the main system screen.

3. Fault diagnosis navigation screen

J1939 fault
J1939故障 Network
网络状态state

Version management
版本管理 Terminal state
端口状态

Back to main screen

返回主页

Figure 2-7 Fault diagnosis navigation screen

Press the keys on the right side to enter the related screens (See Figure 2-8 to Figure 2-11).

2-10 Chassis operation

 XCA160H All Terrain Crane Operation Manual

a. J1939 fault diagnosis screen

J1939 fault diagnosis

Affected parts Fault code Affected parts Fault code

Figure 2-8 J1939 fault diagnosis screen

If there is fault in any electric components of 1939 CANbus, the fault code and affected part(s) will

be displayed on this screen. Move the cursor to select a fault, and press F3 to check the cause of the fault

in detail.

b. Version management screen

Version management
Current Standard
P1 version
P2 version
P3 version
P4 version
P8 version
P9 version

Control system software version

Figure 2-9 Version management screen

The present version is the program version of controller, standard version shows the version number

stored in the display. When the present version is incompatible with the standard version, the indicator

light at the left side of controller's version number will turn red.

Chassis operation 2-11

 XCA160H All Terrain Crane Operation Manual

c. Network fault diagnosis screen

Figure 2-10 Network fault diagnosis screen

If there is fault in a controller or an electric component or J1939 bus, the related indicator will

become red to give an alarm.

d. Controller terminal diagnosis screen

Figure 2-11 Controller terminal diagnosis screen

The state and value of a controller's terminal as well as fault are shown on this screen. The terminal

state of rest controllers may be viewed by pressing Key F1 or F2.

2-12 Chassis operation

 XCA160H All Terrain Crane Operation Manual

4. Subsidiary navigation screen

Chassis state Steering monitoring

Brake monitoring Outrigger monitoring

Axle load monitoring Suspension monitoring

Lamplight monitoring Back to main screen

Figure 2-12 Subsidiary navigation screen

Subsidiary navigation screen includes the information about chassis state, brake monitoring, axle

load monitoring, lamp monitoring, steering monitoring, outrigger monitoring, suspension monitoring, and

main navigation. Press the keys at right side to enter the corresponding screens.

a. Chassis state screen

Under the subsidiary navigation screen, press key 1 to enter the chassis state screen. The chassis state

screen mainly shows some warning information, indication information, and numeric information, as

shown in Figure 2-13 and Figure 2-14.

Figure 2-13 Chassis state screen 1

Chassis operation 2-13

 XCA160H All Terrain Crane Operation Manual

Figure 2-14 Chassis state screen 2

b. Brake monitoring screen

In the subsidiary navigation screen, press Key 2 to enter into brake monitoring screen. In this screen

the input and output parameters related to vehicle braking are shown. See Figure 2-15.

Brake system monitoring

Input Auxiliary brake 2nd gear
Current traveling speed km/h Auxiliary brake 3rd gear
Engine rotation speed rpm Auxiliary brake 4th gear
Location of accelerator pedal % Output
Current gear position Auxiliary brake 1st gear
System voltage V Auxiliary brake 2nd gear
Transmission oil temperature ℃ Auxiliary brake 3rd gear
System air pressure bar Auxiliary brake 4th gear
Brake air pressure bar Engine brake
Auxiliary brake operative Hand brake
Auxiliary brake 1st gear Service brake

Figure 2-15 Brake monitoring screen

2-14 Chassis operation

 XCA160H All Terrain Crane Operation Manual

c. Axle load monitoring screen

In the subsidiary navigation screen, press the key on the right side to enter the axle load monitoring

screen. This screen mainly shows the warning for the incorrect information of each axle load, total axle

load, the center of gravity of the vehicle and the configuration of the vehicle. As shown in the figure.

Axle load monitoring system

Explanation: X: Forward direction of 1st axle
Current rotation speed is positive, backward direction is negative.
Y: Left side of axle centre is negative, right
Current traveling speed side of axle centre is positive.
Z: Above the ground is postive direction.
Correct configuration
Total axle load Coordinate:

Figure 2-16 Axle load monitoring screen

d. Lamplight monitoring screen

In the subsidiary navigation screen, press the key on the right side to enter the lamplight monitoring

screen, which shows the current lamplight usage of the chassis, as shown in the figure.

Figure 2-17 Lamplight monitoring screen

Chassis operation 2-15

 XCA160H All Terrain Crane Operation Manual

e. Steering monitoring screen

In the subsidiary navigation screen, press the key on the right side to enter the steering monitoring

screen, as shown in the figure. If fault code is not zero, press F2 to check the fault.

Figure 2-18 Steering monitoring screen

f. Outrigger monitoring screen

Press the key on the right side to enter the outrigger monitoring screen, as shown in the figure.

Figure 2-19 Outrigger monitoring screen 1

2-16 Chassis operation

 XCA160H All Terrain Crane Operation Manual

g. Suspension monitoring screen

In the subsidiary navigation screen, press the key on the right side to enter the suspension monitoring

screen, which shows the action status of suspension, suspension position, suspension leveling status,

suspension pressure, etc. as shown in the figure.

Suspension monitoring

Suspension pressuer: (bar)

Left front pressure:
Right front pressure:
Left rear pressure:
Right rear pressure:

Figure 2-20 Suspension monitoring screen

Chassis operation 2-17

 XCA160H All Terrain Crane Operation Manual

5. Maintenance and service screen

In the main system screen, press the key on the right side to enter the maintenance and service

screen, as shown in the figure. Press Key UP or Key DOWN to scroll through the items available to be

checked, and then press F3 to enter the detailed screen.

Maintenance and service items

Daily maintenance items

Engine

Maintenance interval

Oil replacement schedule

Maintenance and service items

Figure 2-21 Maintenance and service screen

6. System setup screen

In the main system screen, press the key on the right side to enter the system setup screen, as shown

in the figure. Press Key UP or Key DOWN to increase or decrease the parameters, and press the key on

the right side to choose different setting.

System setting

2020/02/01

[Link]

Metric

100%

A Chinese

Figure 2-22 Setting screen

2-18 Chassis operation

 XCA160H All Terrain Crane Operation Manual

7. Factory default setting screen

In the main system screen, press the key on the right side to enter the factory default setting screen,

as shown in the figure. Before entering into this screen, you need to input dynamic password to prevent

the parameters being altered by others at random.

Factory default setting

Inputting password...

Random password:

Please input password:

Figure 2-23 Password screen

Factory default setting

Movement parameter setting Traveling parameter setting

Display function selection Fuel sensor setting

Other function settings Total mileage and time setting

Data import and export J1939 fault analysis setting

Figure 2-24 Factory setting screen

Chassis operation 2-19

 XCA160H All Terrain Crane Operation Manual

2-1-3 Control switches

Illustrations and function of switches are as shown below.

No. Illustration Name Function

1 Reserve ——

Front left suspension Press this switch, and front left suspension
2
up switch goes up.

Front left suspension Press this switch, and front left suspension
3
down switch goes down.

Front right Press this switch, and front right suspension

4
suspension up switch goes up.

Front right
Press this switch, and front right suspension
5 suspension down
goes down.
switch

Assisting
6 transportation Reserve
switch

Prior to outrigger operation, press this switch

Rigid suspension to switch to the rigid suspension, and the
7
switch rigid suspension indicator lamp on the display
illuminates, as shown in Figure 2-4.

2-20 Chassis operation

 XCA160H All Terrain Crane Operation Manual

No. Illustration Name Function

Rear left suspension Press this switch, and the rear left
8
up switch suspension goes up.

Rear left suspension Press this switch, and the rear left
9
down switch suspension goes down.

Rear right suspension Press this switch, and the rear right
10
up switch suspension goes up.

Rear right suspension Press this switch, and the rear right
11
down switch suspension goes down.

Press this switch, the vehicle can be

Suspension auto leveled automatically, meanwhile, the

12
leveling switch auto leveling indicator lamp on the

display illuminates.

Only after the enable switch 13 is

pressed, switches 6, 7, 17, 18, 19 and 25
13 Enable switch
and knob 1, 2 and 4 on the control panel
may be respectively activated.

Press this switch to cut off fuel supply

to the engine, in order to stop the engine.
14 Engine stop switch
When the switch is released, it will
automatically reset.

Chassis operation 2-21

 XCA160H All Terrain Crane Operation Manual

No. Illustration Name Function

Press this switch to turn on the front fog lamps.

Front fog lamp
15 Always use fog lamps during travel in foggy
switch
days.

During lifting operation, press the switch to turn

Beacon lamp on the beacon lamp. Reset the switch when it is
16
switch not in use. Never use the beacon lamp when the
vehicle is traveling on the road.

Switch the two speed transfer box between high

and low range. Use low range when low speed
Transfer box
is needed. Press once to switch to the low speed,
17 low-speed
press again to return to the high speed. Crane
switch
must be stopped before switching between
speeds.

Inter-wheel
18 differential
When some wheels get into a pit and can not get
switch
out, press the inter-wheel differential, the inter-
axle differential and the transfer box differential
switches, and the drive axle will be linked
rigidly by electric controlled pneumatic device,
Inter-axle
and then the vehicle is able to get out of the pit.
19 differential
switch

2-22 Chassis operation

 XCA160H All Terrain Crane Operation Manual

No. Illustration Name Function

Cruise speed up
20 RES/+
switch

When the traveling speed approaches

the min. cruise speed, press No. 21
and then No. 20 “RES/+” or No. 22
Cruise enable
21 “SET/-” to enter the cruise mode,
switch switch
then the cruise speed may be increased
or decreased. Reset No. 21 to exit the
cruise mode.

SET/- Cruise speed

22
down switch

Press this switch to turn on the rear fog

Rear fog lamp
23 lamps. Always use fog lamps during
switch
travel in foggy days.

R Camera selector
24
switch

Press this button to engage the PTO, and

the PTO indicator lamp comes on. Press
25 PTO switch
this button again to disengage the PTO,
and the PTO indicator lamp goes out.

Engine
26 TEST diagnostic Reserve
button

Chassis operation 2-23

 XCA160H All Terrain Crane Operation Manual

No. Illustrations Name Function

In case of emergency, press this switch to

27 Warning lamp switch
turn on the turn lamps, which will flash.

2-24 Chassis operation

 XCA160H All Terrain Crane Operation Manual

2-1-4 Control panel

Ⅱ Ⅲ C P

ABS ！
Ⅰ Ⅳ
H G

a f

Figure 2-25 Control panel

No. Icons Explanation

Ⅰ 1st gear of comprehensive brake

Ⅱ 2nd gear of comprehensive brake

1
Ⅲ 3rd gear of comprehensive brake

Ⅳ 4th gear of comprehensive brake

Normal road steering mode

Tight-turning radius mode

Anti-drifting mode
2
Rear axle locked mode

Crab walk mode

Rear axle independent steering mode

a Zero position of rear axle steering

3 + Adjustment of rear axle right turn angle

- Adjustment of rear axle left turn angle

Chassis operation 2-25

 XCA160H All Terrain Crane Operation Manual

No. Icons Meaning

H Expressway mode

C Town road mode

4
P Off-road mode

G Heavy load mode

5 Reserve

6 ABS ABS disable switch

7 Rearview mirror heating

8 ！ Retarder disable switch

9 Reserve

2-26 Chassis operation

 XCA160H All Terrain Crane Operation Manual

2-1-5 Air conditioner control panel

A/C AUTO

Figure 2-26 Air conditioner control panel

No. Name No. Name

1 Temperature adjusting knob 2 Fan speed adjusting knob
3 Air blow mode knob 4 A/C key
5 Internal and external circulation selector key 6 AUTO key

1. Temperature adjusting knob: adjust the setting temperature.

2. Fan speed adjusting knob: In manual mode, use the knob to adjust the fan speed.

3. Air blow mode knob: in manual mode, adjust the knob to change the air flow direction between
upper, lower, windshield and upper-lower.

4. A/C key: in manual mode, it is used to control compressor in the order of ON-OFF-ON; in

automatic mode, press the key to enter manual mode.

5. Internal/external circulation switch: in manual mode, press the switch to select internal circulation

or external circulation. In auto mode, press the switch to enter manual mode.

6. AUTO key: press the key to switch between auto and manual working modes.

In auto mode, the system will automatically adjust the fan speed, air blow mode, etc., according to

the temperature setting and temperature sensor.

Chassis operation 2-27

 XCA160H All Terrain Crane Operation Manual

2-1-6 Control mechanism

1. Transmission shift lever

Refer to Section 2-5-1 for transmission operation.

2. Parking brake/service brake/auxiliary brake

Refer to Section 2-5-3 for braking operation.

3. Combined switch

The combined switch is located below the steering wheel, and consists of lamp control switch (left)

and windshield washer switch (right). The combined switch is used to control the left and right turn

lamps, head lamps, small lamps, wipers, windshield washer, auxiliary brake, etc. See Figure 2-27.

Lamp control switch Windshield washer switch

HI

Figure 2-27 Location of combined switch

2-28 Chassis operation

 XCA160H All Terrain Crane Operation Manual

a. Operation of the left turn and right turn lamps is as shown in Figure 2-28.

Push forward, right turn lamp illuminates (R)

Neutral (N)

Push backward, left turn lamp illuminates (L)

Figure 2-28 Operation of the left turn and right turn lamps

b. Operation of head lamps and small lamps is as shown in Figure 2-29.

A. Rotate the switch 30° from the initial B. Further rotate the switch 30° to turn on
position to turn on the night travel lamps. the beam lamps.

Figure 2-29 Head lamps and small lamps

Note: the small lamps consist of clearance lamps, marker lamps and license lamps.

Chassis operation 2-29

 XCA160H All Terrain Crane Operation Manual

c. Switch between dim lamp and beam lamp is as shown in Figure 2-31.

A. With the lever in neutral, rotate the switch to

turn on the head lamps.

Move upward
Beam lamp (Down)

Move downward

Overtaking (Up) Automatic reset

B. Lift up the lamp control switch View A

Dim lamp (Mid)
C. Move it up and down to switch between dim lamp
and beam lamp.
Beam lamp (Down)

Figure 2-31 Switch between dim lamp and beam lamp

2-30 Chassis operation

 XCA160H All Terrain Crane Operation Manual

When overtaking a vehicle at night or in the dark, use the lamp control switch to switch

between the dim lamp and beam lamp for safety!

Overtaking is inevitable and dangerous during driving. Observe traffic regulations and use

correct overtaking methods as follows:

(1) Observe the rearview mirror at the driver’s side to ensure there are no other vehicles

intending to overtake.

(2) Before overtaking, switch between the dim lamp and beam lamp to alert vehicles in the

front. Do not overtake on a bend or at a junction.

(3) After the other vehicles give way, turn on the left turn lamp and prepare to overtake. Honk

if necessary;

(4) Accelerate to overtake. After the overtaking is done and the vehicle has traveled for at least

another 20 m, turn on the right turn lamp and return to the initial lane.

It's forbidden to overtake when safety could not be ensured in order to prevent accidents!

Chassis operation 2-31

 XCA160H All Terrain Crane Operation Manual

e. Operation of wiper switch is as shown in Figure 2-32.

A. Rotate the switch 30 ° , i.e. the arrow points B. Rotate the switch 60 ° , i.e. the arrow
to INT, to turn on the wiper for intermittent points to LO, to turn on the wiper for low
movement. speed movement.

C. Rotate the switch 90 ° , i.e. the

arrow points to HI, to turn on the wiper
for high speed movement.

Figure 2-32 Operation of wiper

2-32 Chassis operation

 XCA160H All Terrain Crane Operation Manual

f. Operation of windshield washer is as shown in Figure 2-33.

A. Press the washer switch to turn on the washer B. Release to reset the switch.

Figure 2-33 Operation of windshield washer switch

g. Operation of auxiliary brake switch is as shown in Figure 2-34.

Move it forward to turn off

向前拨，
auxiliary
关闭缓速制动 brake

Move
向后拨， it backward to turn on
auxiliary brake
打开缓速制动

Figure 2-34 Operation of auxiliary brake switch

Refer to Section 2-5-3 for the operation of auxiliary brake.

4. Starter switch

Refer to Section 2-4-1 for details.

Chassis operation 2-33

 XCA160H All Terrain Crane Operation Manual

2-2 Inspection before driving

Please strictly check the crane according to the following requirements before driving.

2-2-1 Driving conditions

National and local traffic regulations must be followed when the crane is traveling on a road. Before

traveling on roads, make sure that the total weight, axle load and overall dimensions do not exceed the

limits dictated by municipal and local traffic regulations.

The requirements about the travel configurations of the crane will be detailed in the Transporting

Manual.

Before traveling, the operator should confirm that the following is met:

a. Before traveling, secure all loose items on the crane;

b. The turntable must be in travel position and secured by the turntable lock pin, so as to prevent it

from slewing;

c. The boom must be in travel configuration and secured;

d. Outrigger beams must be retracted fully and secured by lock pins so as to prevent them from

extending out;

e. Anemometer is dismounted (if equipped);

f. Check and confirm that the parking brake is disengaged.

Do not forget to drain the water condensed in the air reservoir before traveling in cold winter.

2-34 Chassis operation

 XCA160H All Terrain Crane Operation Manual

2-2-2 Check the coolant level

The coolant level in the expansion tank can be detected with a probe. The low coolant level warning

lamp on the instrument panel in the driver's cab illuminates when the level is too low. When the engine

is running, the coolant temperature is shown on the coolant temperature gauge on the instrument panel or

the display screen in the driver's cab. If the temperature is too high, the coolant temperature warning lamp

on the main screen will illuminate.

N O.T 112317C
Filler port

N O.T 1133 C
内部机器运行，有被挤伤的
Hands can be crushed.

chine is running inside.

Keep hands away!
有挤伤的危险！
手可能会被挤伤

Crush hazard!

Crush hazard!
手勿靠近 !

危险！

N O.T 1133 3C
Fire or explosion may occur!
No flammable or explosive
烫伤危险！手勿靠近！
此处禁止放置易燃物品！
可能会导致火灾或爆炸！
urn hazard! Keep handsaway!

goods here !

N O.T 1133 3C
Fire or explos i on may occur!
No flammable or explosive
有烫伤危险！手勿靠近！
此处禁止放置易燃物品！
可能会导致火灾或爆炸！
urn hazard! Keep handsaway!

goods here !
N O.T 112317C

N O.T 1133 C
内部机器运行，有被挤伤的
Hands can be crushed.

chine is running inside.

Keep hands away!
有挤伤的危险！
手可能会被挤伤

Crush hazard!

Crush hazard!
手勿靠近 !

危险！

Figure 2-35 Check the coolant level

● Hot coolant and steam can burn and scald. Do not service the cooling system while the engine is

operating or when the coolant or vapor is hot.

● Only after the vehicle is parked, the engine is stopped and the temperature of engine coolant drops

below 40℃, can the coolant level be checked, so as to prevent injury caused by hot coolant and vapor.

Chassis operation 2-35

 XCA160H All Terrain Crane Operation Manual

Checking coolant level:

a. Slightly open the cap of expansion tank to release the superfluous vapor pressure;

b. Remove the cap of sight hole on the side of expansion tank to observe the coolant level;

c. Refill with coolant if necessary. Please refer to Table 2-1 in XCA160H All Terrain Crane

Maintenance and Service Manual for the specification of coolant.

Never refill with antifreeze coolant when the temperature of engine coolant exceeds 40℃.

Otherwise, it may cause engine explosion.

2-36 Chassis operation

 XCA160H All Terrain Crane Operation Manual

2-2-3 Check fluid levels and filters

1. Check the fuel level

After turning the starting key to the ON position, the fuel quantity remained in the fuel tank is

indicated. The icon at the left bottom of the fuel gauge illuminates when it is necessary to add fuel.

15 60
F1
10 20 2019/01/12 13:40 26℃ 40 80

F2
X 100rpm INT 1 km/h
！ P
底盘总线系统故障

5
CH
N
25 底盘转向系统失效 20 100 F3
正常公路行驶
81.9 h
RET
1885 km
F4
30 120
维护保养提醒
F5

Fuel gauge

Figure 2-36 Fuel gauge

● Stop the engine before refueling. Never leave the machine unattended when refueling.

● Keep open flames away from the machine, and do not smoke when refueling.

Always refuel before the fuel tank is empty. Otherwise, it will be necessary to re-bleed the fuel

circuit.

Chassis operation 2-37

 XCA160H All Terrain Crane Operation Manual

2. Check the engine oil level

a. Observe the engine rpm and oil pressure for proper readings after start-up. If the oil pressure is

below 100 kPa for Weichai engine (120 kPa for Hangzhou engine) after the engine is started for more than

10 seconds, stop the engine and correct the fault.

b. Check the dipstick when the engine is cool or after the engine is shut down for more than 30 min.

The oil level should be between the marks ADD and FULL. Add oil if the oil level is below ADD. Refer

to Table 2-1 in XCA160H All Terrain Crane Maintenance and Service Manual for the specification of

engine oil.

ADD
b

Dipstick

FULL

Fill to the FULL mark on the dipstick. Do not overfill. Otherwise, the engine will be damaged.

2-38 Chassis operation

 XCA160H All Terrain Crane Operation Manual

3. Check the hydraulic oil level

Check the hydraulic oil level by observing the sight glass. The hydraulic oil level should be between

the Max. and Min. marks.

Return oil filter

Air filter

C F
0 0

100
20
90
80 18
70 16
60 14
50 12
40 10
30 80
20 60
10 40
0 20
10
20 0

Min. mark WZ-400T

Sight glass with

thermometer Butterfly valve Drain plug

Figure 2-37 Sight glass with thermometer

When checking the oil level the crane must be in travel configuration. Make sure that the outrigger

cylinders, suspension cylinders and boom are fully retracted.

If the level is below the min. mark, refill immediately. Refer to Table 2-1 in XCA160H Truck Crane

Maintenance and Service manual for the specification of hydraulic oil.

Chassis operation 2-39

 XCA160H All Terrain Crane Operation Manual

4. Check the transmission oil level

Remove the screw plug at the sight hole and observe the oil level. The oil level should not be lower

than the lower edge of the sight hole. Refer to Transmission Operation Manual for details.

Scald hazard! Only after the vehicle has stopped for more than half an hour can the oil level of

transmission and transfer box be checked.

6. Check the filters

a. If a red line appears in the air filter negative pressure indicator (near the outlet of the air filter),

replace the filter element. Empty and clean the dust collector everyday if the vehicle operates in a dusty

environment.

b. Check the fuel filter (oil-water separator) and drain the water at the bottom of the oil-water

separator.

2-40 Chassis operation

 XCA160H All Terrain Crane Operation Manual

2-2-4 Check the tires

a. Check the tires (spare tire included) to make sure the tread depth of the tire crown is no less than 3.2

mm.

b. The tire pressure should be 0.9±0.05 MPa. Inflate the tires in time when the tire pressure is not

sufficient.

c. Check the tires for tightness. The bolt tightening torque is 650~700 N.m.

When inflating the tires, keep the area clear of bystanders.

2-2-5 Check the windshield cleaning solution

The container of windshield cleaning system is located at the left rear side of the driver's cab. Open

the access door and check the cleaning solution in the container. Keep enough cleaning solution in the

container.

2-2-6 Check the lamps and mirrors

a. Check and confirm all lamps are functional. Absence or fault will increase incident probability, so

never drive before maintenance is done.

b. Before driving, clean and adjust all mirrors to obtain the best view during driving.

● Defective lamps may lead to accidents.

● Prior to driving, have any defective lamps repaired by the professional.

Chassis operation 2-41

 XCA160H All Terrain Crane Operation Manual

2-3 Enter the driver’s cab

2-3-1 Seat and seat belt
1. Driver's seat

It adopts an air bag suspension seat, as shown in the figure.

Figure 2-39 Driver's seat

No. Name No. Name

1 Seat damper adjusting knob 4 Seat cushion rear section adjusting handle
2 Seat sliding control lever 5 Backrest angle adjusting lever
3 Seat cushion front section adjusting handle

Adjusting method:

a. Seat position: Pull up the lever No. 2 to slide the seat forward or backward. Release the lever once

the seat reaches the desired position.

b. Height: Move the handles (No. 3 and No. 4) upward to release the locking mechanism on the seat

height. The seat may then be lowered by the driver’s weight and the seat may rise up if nobody is sitting

on it. The seat height automatically locks when the handles are released.

c. Backrest angle: Move the handle No. 5 to release the locking of backrest angle. Release the handle

after the desired angle is obtained, then it will be locked automatically.

2-42 Chassis operation

 XCA160H All Terrain Crane Operation Manual

d. Rigidity: Turn the knob No. 1 to match the displayed number with the operator’s weight.

● Do not adjust the seat while the vehicle is traveling.

● Do not turn the red pointer beyond the range of 40~130.

2. Co-driver's seat

The co-driver's seat with a tool box integrated as shown in the figure can be unfolded and turn into a

simple sleeper.

Figure 2-40 Co-driver's seat

No. Name No. Name

1 Tool box 4 Passenger's seat belt
2 Tool box door lock 5 Locking lever of sleeper
3 Co-driver's seat belt anchorage 6 Backrest angle adjusting handle

Adjusting methods:

a. Adjusting the backrest angle: move the handle No. 6 to release the locking of backrest angle. The

backrest angle adjusting range is 0°~100°.

b. Opening the tool box door: turn the tool box door switch 90° clockwise to open the box door.

c. Unfold the sleeper

(1) Adjust the backrest of the driver's seat backwards to the max. angle according to the adjusting

method of the driver's seat.

Chassis operation 2-43

 XCA160H All Terrain Crane Operation Manual

(2) Unfold the sleeper as shown in the figure.

A. Pull the backrest angle adjusting B. The backrest is put down.

handle with one hand and put down the
backrest with the other hand.

D. Unfold the folded section to form a sleeper. C. Pull up the locking handle of the
folded section to release the locking.

Figure 2-41

Always adjust the backrest angle when the backrest angle adjusting handle is disengaged fully.

2-44 Chassis operation

 XCA160H All Terrain Crane Operation Manual

3. Seat belts

Driver's seat and co-driver's seat are equipped with 3-point seat belts. Passenger's seat is equipped

with 2-point seat belt.

See the figure below for the method of securing the belts.

A. Red anchorage B. Insert the buckle into its anchorage until a

click is heard.

Figure 2-42 Securing the seat belt

How to use the belt:

a. Pull out the belt slowly, insert the buckle into its anchorage until a click is heard, then the seat belt

is secured.

b. After the seat belt is secured, the passenger still can lean or move forward slowly. But in the event

of emergency brake or a sudden rapid pull of the belt, the seat belt will be stopped from extending off the

reel.

c. Press the red button on the anchorage to release the belt. After the buckle ejects, the seat belt will

be automatically retracted into the retractor.

●To ensure your safety, always wear the seat belt properly. Otherwise, it may result in unnecessary

injury in the event of a collision Make sure you and your passengers always wear the seat belt properly.

● Only when the seat belt is properly fitted can it provide protection. If it is loose, the protection

function will be greatly impaired.

● Be sure the seat belt is not twisted.

● Only one person should be strapped in each seat belt.

Chassis operation 2-45

 XCA160H All Terrain Crane Operation Manual

2-3-2 Steering wheel

1. Adjustment of steering wheel

With the vehicle parked, adjust the seat

first (see Section 2-3-1), then adjust the steering

column

a. Loosen the left knob to adjust the steering

column upward and downward.

b. Loosen the right knob to adjust the

steering column forward and backward, as shown

in the figure.

Figure 2-43 Adjustment of steering wheel

After adjustment is done, tighten the knobs

to prevent unexpected position changes of the

steering wheel during traveling.

Do not adjust steering column while

2. Use of horn switch
vehicle is in motion.
The vehicle is equipped with an air horn,

whose switches are located on both sides of

XCMG logo on the steering wheel. When the

vehicle is powered on, press the horn switch,

then it honks.

2-46 Chassis operation

 XCA160H All Terrain Crane Operation Manual

2-4 Operation of the engine

2-4-1 Start the engine

1. Operation of main power switch

The main power switch is initially in the OFF state, and the red switch is vertically positioned, as A

shown in Figure 2-44. When it is in the ON state, the red switch is horizontally positioned, as B shown in

Figure 2-44.

A. OFF state B. ON state

Figure 2-44 Main power switch

Chassis operation 2-47

 XCA160H All Terrain Crane Operation Manual

Operating method:

a. Prior to starting the engine, turn the main power switch 90° clockwise to turn on the main power,

as shown in Figure A below.

b. After the engine is stopped, turn the main power switch 90° counterclockwise to turn off the

main power, as shown in Figure B below.

A. Turn the switch 90°clockwise while B. Turn the switch 90°counterclockwise

pushing it in with a proper effort. while pulling it out with a proper effort.
Figure 2-45 Main power switch operation

● In the switch, there is a spring that makes sure the switch can only be turned 90° in either

direction.

● Turn the main power switch in the correct direction and with a proper effort. Otherwise, the
switch will be damaged.

Never turn off the main power while the engine is running normally! Battery can absorb and

restrain the high voltage generated in electric circuit. When the main power switch is turned off

suddenly, the current in the electric circuit will also change suddenly, resulting in high transient voltage,

and electrical components will be damaged eventually.

2-48 Chassis operation

 XCA160H All Terrain Crane Operation Manual

2. Operation of starter switch

Four positions, i.e. LOCK, ACC, ON and S (START) are available for selection after the key is

inserted into the starter switch as shown in the figure below.

O N S TA
C

LO C K A C

RT
Figure 2-46 Starter switch

No. Name Function

After the engine is stopped, turn the key to this position to turn off the
1 LOCK
main power supply. The key can be pulled out only at this position.

After turning the key to this position, audio device and cigarette lighter
2 ACC
are available although the engine is not started.

Turn the key to this position to turn on the power supply. Then
3 ON instrument panel, indicator lamps, windshield wiper, heater and horn,
etc. can work normally.

Turn the key to the S position to start the engine. Move your hand
4 S (START)
away, then the key will automatically return to ON position.

Never let the key in the ACC position for a long time! Otherwise, the service life of battery will

be reduced!

Chassis operation 2-49

 XCA160H All Terrain Crane Operation Manual

Operation of the starter key is as shown in the figure below.

A. Turn the key from ON to START and B. Move your hand away, then the key will
hold for 3~5 s. automatically return to the ON position.

Figure 2-47

● After turning the key to the ON position, the charging indicator lamp will illuminate. If the air
pressure of braking circuit is lower than 0.6 MPa, the low air pressure warning lamp will also illuminate.
● After the engine is started, the indicator lamps can be used as warning lamps of the
corresponding functions to convey the information if the vehicle is in the normal working condition
to the driver’s cab. If there is fault in the indicator lamp, please repair or replace the combined
instruments.
● After the engine is started, generator will work normally and charge the battery. At this time,
the charging indicator lamp will go out. If the charging indicator lamp does not go out, it means there is
fault in the system.

With the key in the START position, if the engine can’t be started within 10~12 seconds,
immediately return the key to the ON position. After 1~2 minutes, start the engine again. If the engine
fails to start 3 times in a row, stop and dial 400-001-5678 to contact the customer service.

2-50 Chassis operation

 XCA160H All Terrain Crane Operation Manual

2-4-2 Checklist after start-up

Pay attention to the following gauges and indicator lamps during traveling:

1. Engine oil pressure gauge;

2. Engine coolant temperature gauge

3. Engine stop indicator lamp

Immediately shut down the engine if any one of the following situations is found:

● Engine oil pressure is lower than 1.2 bar;

● Coolant temperature is higher than 100 ℃;

● Engine stop indicator lamp illuminates.

● Never turn the key to the START position while the engine is running.

● After start-up, let the engine run at idle for a while. Never immediately depress the accelerator:

● In winter, after start-up, let the engine run at idle for a while to reach the proper system pressure

and temperature.

● The crane is equipped with cold weather starting device. So never use starting liquid to start the

engine.

Chassis operation 2-51

 XCA160H All Terrain Crane Operation Manual

2-5 Driving operation

2-5-1 Transmission operation

ZF transmissioon

1. Gears

ZF transmission is equipped with an automatic transmission selector lever which consists of a knob

switch and a joystick, as shown in the figure below.

M A S

Joystick
变速杆

Knob switch
旋转开关

Figure 2-48 Transmission selector lever

2-52 Chassis operation

 XCA160H All Terrain Crane Operation Manual

There are five positions on the knob switch:

DM： Creep forward gear; D: Drive gear; N: Neutral gear; R: Reverse gear; RM: Creep reverse gear.

During reversing, R1 or R2 will appear on the display screen. R1 means reversing in low speed,

and R2 means reversing in high speed. No automatic mode is available for “R” gear, please change

reversing gear manually.

The joystick is used to select the gears and to change the gear-shifting mode.

Meaning of symbols on the joystick:

A/M: to select automatic mode or manual mode, by pushing the control lever to the left.

+
+: Up by one gear; : Up by two gears;
-: Down by one gear; —: Down by two gears;

S: automatically select the proper gears

2. Gear shifting operation

There are two transmission modes: manual and automatic. Push the selector lever to the left to shift

between manual mode and automatic mode. In automatic mode, transmission will automatically control

the driving speed. In manual mode, move the shift lever forward\backward to increase\decrease the

+
gear. Moving the selector lever towards“+/ ”or“–/—” also can shift to the manual mode from the
automatic mode.

Chassis operation 2-53

 XCA160H All Terrain Crane Operation Manual

3. Start to move

a. Turn the starter key to the ON position to turn on the power source;

b. After the system is powered on, it will perform self-inspection for 15 seconds. When the self-

inspection is finished, start the engine.

c. Turn the knob switch to "D" or "R" position. If don’t move the selector lever, the system will

automatically adopt the last selected mode (automatic or manual). Push the selector lever to the left to

enter the automatic mode, or push the lever again to return to the manual mode.

d. Depress the accelerator pedal while releasing the parking brake, then the vehicle starts to move.

Creep mode
When extreme low speed is required (e.g. when towing a trailer), creeping modes may be used. Turn

the knob switch to “DM” or “RM” to select the creep forward gear or creep reverse gear.

Adjust clutch engaging state with the accelerator pedal, then the vehicle can move slowly. Never

keep the vehicle in creeping modes for a long time, otherwise the clutch will be worn badly. Starting

several times in a short time or releasing the parking brake too slow during the starting may result in

clutch overload. Pay attention and reduce clutch sliding wear, so that further overload can be avoided.

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 XCA160H All Terrain Crane Operation Manual

● Only when the air pressure in the braking system reaches 0.6 MPa, the hand brake indicator

lamp and low air pressure warning lamp go out, and the parking brake is disengaged fully, can the truck

start to move.

● Before shifting the selector lever between D (drive gear) and R (reverse gear), stop the vehicle

first. And make sure the engine runs at idle speed.

● Automatic mode is recommended on normal roads.

● In the manual mode, engine over-speed protection function is not available. Pay attention to
avoid engine over-speed.

● To enter the creeping mode under drive gear 1 or reverse gear 1, the accelerator pedal should

be depressed less than 85% of its stroke, and the clutch be partially engaged. When the accelerator

pedal is depressed more than 85% of its stroke, the vehicle is out of the creeping mode automatically,

and the clutch will be fully engaged. Then shocks and sudden rises in engine rotation speed will occur.

Therefore, under the creeping modes, the accelerator pedal should be depressed less than 85% of its

stroke and care must be taken to prevent against any potential hazard.

● No automatic mode is available when reversing. Please change reversing gears manually.

● In drive gear 1, reverse gear 1, creep forward gear and creep reverse gear, the clutch is in half-

linkage state. Being in these gears for a long time will accelerate the wear of friction disc and even affect

normal traveling. So, it is not recommended to use these gears.

● When parking the vehicle, knob switch should be turned to "N" position.

● When driving on a long downhill, never coast with the selector lever in neutral or the engine

shutdown.

● When towing is necessary, remove the axle shaft, or disconnect the propeller shaft, or keep the

drive wheels off the ground.

Chassis operation 2-55

 XCA160H All Terrain Crane Operation Manual

2
3

6
5
4

Figure 2-48a Transmission shift lever

No. Name Function

1 F Function key
For selecting forward/reverse gear and for up-shifting/down-shifting (F key
2 Lever
can be pressed meantime)
3 N Neutral key. Pressing this key means the driver intends to shift to neutral.
4 L Low speed mode
5 E/P Economy/power mode selector key
6 M/A Auto/manual mode selector key

The keys are self-return type. Push the shift lever with proper effort.

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 XCA160H All Terrain Crane Operation Manual

The premise condition is that the vehicle is stationary with the engine at idle, and the air pressure is

above 8 bar. Depress the brake pedal, with the F key pressed, push the lever forward/backward to engage

forward/reverse gear;

When starting the vehicle for the first time, the default starting gear is F3, F4 or R1. After using

the vehicle for a period of time, the starting gear will be automatically selected among the low gears

according to the weight of vehicle.

The driver can select the starting gear manually: Press the F key and hold, then push the lever

forward/pull it backward will increase/decrease one gear each time. Directly push the lever forward/pull

it backward will increase/decrease two gears each time. Press the F key a few times, then push the lever

forward/pull it backward will increase/decrease a corresponding number of gears each time.

Release the parking brake, release the brake pedal and depress the accelerator pedal, then the vehicle

will start to move.

Chassis operation 2-57

 XCA160H All Terrain Crane Operation Manual

A. Hold the hand brake lever with

forefinger and middle finger gripping

the disc on the lever.

B. Slightly grasp the lever with your

right hand to pull it out to free the

locking mechanism.

Lever state after the parking

brake is released

C. Push the lever forward to

release the parking brake.

Figure 2-48b Operation of hand brake

2-58 Chassis operation

 XCA160H All Terrain Crane Operation Manual

3. Starting mode
There are three different modes for starting:
Mode 1: Shift the lever into the starting gear and depress the accelerator pedal. With the engine
running at idle speed, the clutch will be engaged. And the vehicle will start to move with engine idling.
(When the accelerator pedal is depressed harder, the starting process will be quicker.)
Mode 2: Shift the lever into the starting gear and depress the accelerator pedal to its utmost. When
the engine RPM is increasing, engage the clutch, namely depress the accelerator pedal and engage the
clutch at the same time. This mode is for starting with heavy weight.
Mode 3: L mode starting. Shift the lever into starting gear 1, then depress the accelerator pedal. After
the engine RPM increases to a certain level, engage the clutch. This mode is for starting under special
road conditions.
During the starting process, how much and how fast the accelerator pedal is depressed will influence
the starting mode and speed which further influence the starting performance and comfort level.

● If the selected starting gear is too high, when depressing the accelerator pedal for starting,

the engine may shut down.

● When starting on an uphill, if the power output is exceeded, the engine may shut down. At

this time, please select the manual mode, and you can switch to automatic mode after the vehicle

travels stably. When necessary, adjust the transfer box to low gears, and after the vehicle reaches the

level surface, stop the vehicle and switch to high gears.

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Traveling, accelerating/decelerating and stopping

Automatic mode <A>

In automatic mode, the transmission will automatically select and shift gears according to the
vehicle’s running condition. The driver can also intervene in gear selection at any time by using the shift
lever.
a. With the F key pressed, push forward/pull backward the lever to increase/decrease one gear each
time.
b. Directly push forward/pull backward the lever to increase/decrease two gears each time.
c. Press the F key multiple times in a row and release the key, then push forward/pull backward the
lever to increase/decrease multiple gears each time.
In automatic mode, the system will jump gears automatically when the condition allows.

Economy mode <E> and Power mode <P>

Economy mode <E> and Power mode <P> are available only under the Automatic mode <A>.

Economy mode (A+E shows on the display) provides a more fuel-efficient traveling. It is the default

mode and suitable for paved road with a gradient below 5%, such as the expressway. Power mode (A+P

shows on the display) provides a more powerful traveling and is suitable for paved road with a gradient

between 5% and 8%.

● The default mode of the system is automatic mode.

● During the automatic gear shifting, do not release the accelerator pedal, otherwise it may cause
unsmooth gear shifting.
● The manually selected gear will be executed only when it is suitable for the current running
conditions of the vehicle, and the manual intervention is only valid for a short time. If no signal is
received by the transmission during this time, the transmission will automatically select a suitable gear
for further traveling.
● The vehicle will not exit the automatic mode due to manual intervention.

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Manual mode <M>

In manual mode, the gear shift of the transmission is controlled by the driver:

a. With the F key pressed, push forward/pull backward the lever to increase/decrease one gear each

time.

b. Directly push forward/pull backward the lever to increase/decrease two gears each time.

c. Press the F key multiple times in a row and release the key, then push forward/pull backward the

lever to increase/decrease multiple gears each time.

d. Gear shifting and clutch are controlled automatically by the AMT system.

● If the gear selected by the driver is not suitable for the current running conditions of the

vehicle, the ATM will reject the gear shifting request or automatically shift to a proper gear.

● Manual mode is highly recommended when the vehicle is heavily loaded or the road conditions

are poor, such as sharp slopes, sharp turns, muddy roads and construction sites.

● In manual mode, it is necessary to wait until the current gear is shown on the display before

shifting again. Otherwise, the gear shifting may fail, especially when the vehicle is on a slope.

● When the road gradient exceeds 8%, manual gear-shifting is recommended.

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Acceleration, deceleration and stop

Depress the accelerator pedal to accelerate.

Release the accelerator pedal or depress the brake pedal to decelerate.

After the vehicle is stopped, engage the hand brake, place the transmission lever in neutral, and shut

down the engine.

After the vehicle is stopped, the driver can use the N button to shift to neutral gear. If the vehicle

is stopped and no operation is carried out within 90 seconds, the system will shift to neutral gear

automatically and engage the clutch.

After the vehicle is stopped, if the engine shuts down before transmission shifts to neutral gear, the

transmission will shift to neutral gear automatically, and the buzzer will sound as a warning.

The transmission can not predict the road condition ahead. Therefore, when there is significant

change in road condition, such as sharp uphill, continuous curves, etc., please switch to manual mode

in advance and select the gear properly. Otherwise, gear-shifting may fail, and unexpected engine shut-

down and sliding on slopes may occur.

● When traveling on a long downhill, please use the automatic mode. Otherwise, engine retarder

brake failure and engine over-speeding will occur, even leading to casualties and property losses.

● When shifting the transmission shift lever, check and confirm that the selected gear is shown

on the digital screen. For example, if the shift lever is in the N position, the letter "N” should

appear on the screen.

● Before shifting between D (forward gear) and R (reverse gear), make sure the vehicle has

been stopped and the engine runs at idle speed.

When the vehicle is traveling at low speed with low gear, if depress the brake pedal suddenly and

hard, the engine speed will decrease so fast that the clutch can not response in time, and unexpected

engine shut-down may occur.

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When the vehicle is traveling on a straight road with a gradient less than 3%, release the accelerator

pedal, and the transmission will down-shift according to the travel speed automatically. When the travel

speed is below 30 km/h, the transmission will shift to neutral gear automatically. When the driver steers,

or depress the accelerator pedal or brake pedal, the transmission will automatically exit the coasting mode

and shift to a proper gear.

When the vehicle needs to move very slowly, use the creep mode. Press the L button to enter the

creep mode. After the creep mode is activated, depress the accelerator pedal slightly, then the vehicle will

move very slowly.

Press the L button again to exit the creep mode.

This mode is for starting under extreme working conditions, such as when the vehicle is severely

overloaded, or driving on soft or muddy terrain.

When starting under this mode, the AMT system will wait until the engine speed increases to a

higher lever before engaging the clutch and starting the vehicle.

Press the L button and hold on for 5 seconds to activate this mode. This mode is only available when

reverse gear, neutral gear or low gears are used.

Press the L button again to exit this mode.

When starting the vehicle under this mode, the clutch will be worn more heavily when engaged

due to high engine speed. Therefore, use this mode only when necessary. Otherwise, the service life

of clutch will be greatly reduced.

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d. Traveling with engine running at low idle speed

Shift into gear 1 for starting, and press the L button two times quickly. When “L” flashes, the

vehicle has entered this mode (at this time, the vehicle will enter the manual mode). Then depress the

accelerator pedal slightly, the vehicle will start to move, and when the accelerator pedal is released, the

vehicle will continue moving. During traveling, the driver can use the accelerator pedal or brake pedal to

adjust the speed.

When the A/M or L button is pressed, the transmission will exit this mode.

When starting with low speed, great shocks may occur.

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e. Kick down function

This function is suitable for starting on a slope, starting with heavy load or quick starting. The

procedure is as follows:

1. Depress the accelerator pedal to the utmost very quickly.

2. The system will maintain the current gear or select a low gear.

3. When the desired speed is reached, release the accelerator pedal. Then the system will select a

proper gear again.

f. Overheating protection for clutch

Although there is no clutch pedal, when the vehicle is moving slowly or frequently starting on a

slope with heavy load, the clutch may slip or overheat. If the clutch is overheated, the system will send out

an audio warning and disengage the clutch for a while (about 70 seconds) to cool it down, and depressing

the accelerator pedal has no effect at this time. Pay attention to the travel speed to ensure safety. When

necessary, park the vehicle in a safe place. If the vehicle has to be started, depress the accelerator pedal

to its utmost and hold on, then the transmission will engage the clutch, but this operation will cause

irreversible damage to the clutch and greatly reduce its service life, even destroy it.
g. Engine over-speed protection

When the engine rotation speed is too high, the transmission will automatically up-shift to prevent

over-speeding.

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2-5-2 Steering operation

Mechanical steering plus hydraulic booster and electro-hydraulic proportional control steering

system are adopted. The steering type is 10×10. The 1st and 2nd axles adopt the mechanical steering plus

hydraulic booster, and the 3rd, 4th and 5th axles adopt the electro-hydraulic proportional control steering

system. The driver controls the driving direction with the steering wheel.

● Before steering, always observe the surroundings to ensure safety!

● The hydraulic oil tank provides hydraulic oil for steering operations, thus hydraulic oil in the

tank should be kept at the specified level during traveling.

● When the steering system fails due to faults in the oil pump or circuit, the steering gear may be

used as a mechanical steering gear until the vehicle reaches a repair station. But forced steering for a

long time may damage the steering gear.

● When steering, do not keep the steering wheel at its limit positions for more than 1 min.

Otherwise, the steering oil pump may be damaged.

The movement of the steering gear is realized through the steering pump activated by the engine.

Never coast with the engine shut down, otherwise it is heavy to steer and accidents may occur.

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To adapt for different travel speeds and jobsite conditions, six steering modes are available for the

chassis of XCA160H All Terrain Crane.

1. Normal road travel mode

a. Traveling speed v=（0～30）km/h, steering type is 10×10. All axles are involved in steering.

The 2nd and 3rd axles steer in the same direction as the 1st axle, while the 4th and 5th axles steer in the

reverse direction. The theoretical steering center is on the middle line of the 3rd and 4th axles.

Figure 2-49 All-wheel steering mode

b. Traveling speed v=(30～60) km/h, middle speed traveling, steering type is 10×6. The 1st, 2nd

and 5th axles are involved in steering. The 2nd axle steers in the same direction as the 1st axle, while the

5th axle steers in the reverse direction. The theoretical steering center is on the middle line of the 3rd and

4th axles. The 3rd and 4th axles are not involved in steering, locked at the middle position by the locking

cylinder.

Figure 2-50 Middle speed traveling mode

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c. Traveling speed V ≥ 60 km/h, high speed traveling, steering type is 10×4. The 1st and 2nd axles

are involved in steering and steer in the same direction. The 3rd, 4th and 5th axles are not involved in

steering, locked at the middle position by the locking cylinder.

Figure 2-51 High speed traveling mode

2. Rear axles locked at middle position mode

To adapt for diverse operating habits, steering mode can be changed manually at any speed. The 3rd,

4th and 5th axles can be locked at the middle position by the locking cylinder and excluded from steering.

Figure 2-52 Rear axles locked at middle position mode

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3. Tight-turning radius mode

Traveling speed v=(0～8) km/h, tight-turning steering mode, steering type is 10×10. All axles are

involved in steering. The steering center is 380 mm behind the middle line of the 3rd axle. The 3rd axle

steers in the same direction as the 1st axle, and the 4th and 5th axles steer in the reverse direction. At this

time, the smallest turning radius of 8972.3 mm is obtained.

Figure 2-53 Tight-turning radius mode

4. Crab walk mode

Traveling speed v=(0～8) km/h, all tires steer to the same side. The steering angle of the 3rd, 4th and

5th axles is identical with that of the 1st axle.

Figure 2-54 Crab walk mode

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5. Rear axle independent steering mode

Traveling speed v=(0～8) km/h, the 3rd, 4th and 5th axles can steer independently.

Figure 2-55 Rear axle independent steering mode

6. Anti-drifting mode

Steering type is 10×8. The 1st, 2nd, 3rd and 4th axles are involved in steering. The 3rd and 4th

axles steer in the same direction as the 1st axle. The 5th axle is excluded from steering. The steering

center is on the middle line of the 5th axle. Under the anti-drifting mode, drifting can be avoided as much

as possible.

Figure 2-56 Anti-drifting mode

In order to ensure safety, under the tight-turning mode, crab walk mode and rear axle independent
steering mode, some protective measures will take effect when necessary.
● When the traveling speed reaches 8 km/h, if continue to accelerate, "steering system pre-
warning" will appear on the steering monitoring screen.
● When the traveling speed reaches 12 km/h, "steering system fault" will appear on the steering
monitoring screen.
● Even if continue to accelerate, the traveling speed will be confined at 12 km/h without further
increase, thus the engine rotation speed is also confined.

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2-5-3 Braking operation

The braking system consists of service brake (foot brake), parking brake (hand brake) and auxiliary

brake (engine retarder brake, transmission retarder brake) and comprehensive brake.

Free stroke of brake pedal is in the range of 15 mm~20 mm, the range of brake friction pair is 41

mm~33 mm for brake disc, and 32 mm~11 mm for friction lining.

1. Service brake (foot brake)

The service brake is controlled by the foot pedal. Depress the pedal to decrease the travel speed.

Figure 2-57 Foot brake pedal

The braking system is equipped with ABS (anti-lock braking system). The ABS works along with

the service brake. It may prevent the brake from being locked suddenly. The service brake is dual-circuit

air pressure brake. The rated working pressure of air reservoir is 1.0 Mpa. In the service brake system,

the interval between the brake pedal is depressed and the braking force on the least favorably placed axle

reaches the level corresponding to the prescribed performance is 0.6 second.

Never repeatedly apply the brake in a short time, because it may cause the pressure to drop, which
will impair the braking efficiency.
The ABS is able to shorten the vehicle's braking distance on wet roads. However, after the service
brake is engaged, the vehicle will still coast for a short distance due to inertia. Therefore, the safety
distance should be properly determined.

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2. Parking brake (hand brake)

The parking brake is located at the right side of driver's seat, as shown in the figure below. The

parking brake is an air-release spring brake which acts on the 2nd, 3rd, 4th and 5th axles and gives effect

by the spring-loaded air chamber on each axle.

Figure 2-58 Parking brake lever

● For safety, before starting the engine, always move the hand brake lever to the position for

engagement.

● Only after the low air pressure warning lamp and parking brake indicator lamp go out, can the

parking brake be released.

● Always apply the hand brake lever while parking on a slope.

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A. Hold the hand brake lever

with forefinger and middle
finger gripping the disc on the
lever.

B. Slightly grasp the lever with

your right hand to pull it out to
free the locking mechanism.

Lever state after the parking brake is released

C. Push the lever forward to

release the parking brake.

Figure 2-59 Operation of parking brake

Before starting to move, release the parking brake.

The parking brake may be used as emergency brake. For example, when the service brake is

damaged and the vehicle has to be slowed down, use the parking brake as a substitute.

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3. Auxiliary brake

The auxiliary brake consists of engine retarder brake, transmission retarder brake and exhaust brake.

In order to prolong brake service life, when driving on a long downhill, press down the auxiliary

brake switch (as shown in figure 2-60) to activate the auxiliary brake. Applying the auxiliary brake can

prevent the vehicle from speeding up to a dangerous extent due to deadweight, reduce the use of brake

and protect the brake from being overheated.

Figure 2-60 Auxiliary brake switch

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Operating method:

(1) After moving the auxiliary brake switch backward to ON position, the auxiliary brake indicator

lamp illuminates. The auxiliary brake works when the accelerator pedal is released; the auxiliary brake is

invalid when the accelerator pedal is depressed.

(2) After moving the auxiliary brake switch forward to OFF position, the auxiliary brake stops

working and then the auxiliary brake indicator lamp goes out.

● Never shut down the engine or position the shift lever in neutral while using the auxiliary brake.

Otherwise, the auxiliary brake function will be invalid.

● Release the accelerator pedal before using the engine auxiliary brake. Never depress the

accelerator pedal before deactivating the engine auxiliary brake. Otherwise, the engine will be damaged.

● Never use auxiliary brake in emergency situation.

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Ⅱ Ⅲ

Ⅰ Ⅳ

Figure 2-61 Auxiliary brake gear selector switch

Operating methods:

a. During traveling, move the auxiliary brake switch backward to ON position, and the engine

retarder brake indicator and transmission retarder indicator will illuminate. The auxiliary brake will

be activated when release the acceleration pedal. You may depress the acceleration pedal to release

the retarder brake. The auxiliary brake gears can be changed when pressing the enable switch and

auxiliary brake gears selector switch simutaneously. The auxiliary brake force will increase from Gear I to

Gear IV.

b. Push the auxiliary brake switch forward to OFF position, the auxiliary brake will stop, and the

engine retarder brake indicator and transmission retarder indicator will be off.

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4. Emergency braking

Emergency braking means the proper measure the driver takes in emergency to stop a moving

vehicle within a distance as short as possible by using the brake properly.

● Emergency braking is a most dangerous braking operation which may easily cause accidents!

● Emergency braking will cause significant damage to the vehicle and tires, which may lead to

unbalanced braking and loss of control of the vehicle!

● Never apply emergency braking while traveling on a wet, icy or snowy road or on a long

downhill unless in emergency!

In case of emergency, do as follows:

● Keep clam and do not panic.

● Properly hold the steering wheel to keep the vehicle in control.

● Try your best to drive the vehicle to the emergency lane if you are driving on an expressway.

● Keep the vehicle away from pedestrians and non-motor vehicles if you are driving on a town

road.

Proper measures for emergency braking are as follows:

1. When there is a tire punctured while traveling on an expressway:

Hold the steering wheel with both hands and keep calm. Slowly release the accelerator pedal and

lightly depress the foot brake pedal while trying to keep the vehicle moving forward along a straight line.

Change to the Low gear as soon as possible, and decelerate by using the engine brake.

Do not brake abruptly. Otherwise, the vehicle can overturn!

2. In case of failure of the service brake:

Release the accelerator pedal and gradually decelerate the vehicle by downshifting. When the

traveling speed is lower than 20 km/h, pull up the parking brake lever to stop the vehicle.

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5. Usage of ABS

The braking system is equipped with ABS. When the service brake is engaged by pressing the brake

pedal, the system will automatically adjust the brake to buffer the locking effect caused by the service

brake, improving the steering controllability and decreasing the risk of drifting.

ABS is equipped in the service brake system. When the starter key is at the ON position and the

engine is not started, the ABS indicator on the display will illuminate, system self-checking will be

activated, and each solenoid valve will exhaust one time. If the ABS works normally or the engine is

started, the ABS indicator will go out within 3 s. If there is fault in the ABS, the indicator will remain

illuminated.

There is no additional operation required when driving on the expressway or cement concrete

road. If emergency braking is needed, the driver can depress the brake pedal continuously to ensure the

performance of the brake. If intend to drive on muddy roads, press the ABS disable switch (if available) to

switch ABS control logic, then ABS control program will be switched from road mode to off-road mode.

At this time, the ABS indicator will continuously flash, and further adjustment will be implemented by the

ABS to ensure the stability of the vehicle, which may increase the braking distance, so it is necessary to

leave a longer distance for braking.

● During traveling, if the ABS indicator remains illuminated, it means there is fault in the ABS

and anti-locking function is invalid, but the service brake is still valid. Be careful during traveling. When

emergency brake is required or wheel-locking occurs, intermittently apply the brake as far as possible.

● If the ABS is faulty, read the fault description according to the fault code. Non-professionals are

not allowed to repair the crane.

● The ABS is able to shorten the vehicle's braking distance on wet roads. However, after the

service brake is engaged, the vehicle will still coast for a short distance due to inertia. Therefore, the

safety distance should be properly determined.

● Although the ABS is equipped, the driver should still be careful when applying emergency

braking on wet, icy or snowy roads or on a curve.

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6. Other special operations

a. Release of self-braking

When self-braking happens due to leakage in the pipeline that connects to spring brake air chamber,

do the following to release:

1) Open the blocking cover at the tail of brake air chamber (see figure A below);

2) Let the bolt out by tightening the nut to release the braking (see figure B below).

A B

Figure 2-62 Release of spring brake

If the vehicle is parked on a slope, block the wheels to prevent the vehicle from slipping away

before releasing the spring brake.

b. Control of engine rotation speed

When driving on a long downhill, position the shift lever in the automatic mode, and keep the engine

rotation speed below 2200 r/min by depressing the brake pedal properly or moving the retarder brake

lever to a proper gear.

Overspeeding the engine can result in serious damage!

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2-5-4 Suspension operation

1. Suspension operation is divided into manual adjustment and automatic leveling
1) Manual adjustment:
a. Start the engine, and the transmission is in a neutral state.
b. Press the power take-off switch (No. 13 in the figure);
c. Press the suspension Up/Down switches to adjust the height and levelness of crane. (No. 1~8
in the figure respectively control the up/down movements of four suspension cylinders: left front, right
front, right rear, left rear.)
2) Automatic leveling:
The suspension should be in the unblocked state
a. Start the engine with the crane on a level ground, and the shift lever is adjusted to neutral;
b. Press the power take-off switch (No. 13 in the figure);
c. Press automatic leveling switch (No. 11 in the figure), and the automatic leveling indicator lamp
illuminates;
d. After the crane is leveled, press the auto leveling switch again to reset it.
Note: Press No.10 and No.13 and press and hold the enable switch No. 12 to activave No.10 and
No.13.

TEST

R RES/+ SET/-

Figure 2-63 Suspension operation control switch

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2. Suspension adjustment in different loading states

1) Adjustment of suspensions for driving on roads:
The suspension should be manually adjusted or automatically leveled in the unblocked state.2)

Adjustment of suspensions for heavy load job site transfer (with certain boom angle):

The suspensions should be manually adjusted in the blocked state.

Press No. 10 selector switch for blocking the suspension, the suspension enters the blocked state,

the indicator light on the switch lights up, and the blocked state indicator appears in the screen.

● After moving up and down of suspensions in the blocked state, the crane will shake when

the blocked state is switched to the unlocked state.

● After moving up and down of suspensions in the blocked state, when you extend the

outrigger jacks to support the crane, the suspension cylinder will extend simultaneously, causing

the tires to sink.

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2-5-5 Stopping and parking

The service brake or the parking brake

● Automatic mode is recommended on
can be used to stop the vehicle no matter which
normal roads.
gear the transmission selector lever is at. During
● In the manual mode, engine over-
temporary stops, the position of transmission
speed protection function is not available. Pay
joystick can remain unchanged. If the driver
attention to avoid engine over-speed.
is going to leave the vehicle for quite a while,
● Under drive gear 1 or reverse gear
the transmission joystick must be positioned in
1, the accelerator pedal should be depressed
neutral. When the vehicle needs to be parked,
less than 85% of its stroke, and the clutch be
apply the parking brake to avoid coasting.
partially engaged. When the accelerator pedal

is depressed more than 85% of its stroke, the

clutch will be fully engaged. Then shocks and

sudden rises in engine rotation speed will occur.

Care must be taken to prevent against any

potential hazard.

● No automatic mode is available when

reversing. Please change reversing gears

manually.

● Never let the vehicle coast with the

transmission selector lever positioned in neutral.

Otherwise, the transmission will be damaged.

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2-5-6 Operation of differentials

The inter-axle differential or inter-wheel differential should be engaged only when slipping occurs at

the drive wheel.

How to use the inter-wheel differential and inter-axle differential:

In case of a single wheel slipping, engage the inter-wheel differential;

In case of a single axle slipping, engage the inter-axle differential;

If the said two situations simultaneously occur, engage the inter-wheel differential and inter-axle

differential at the same time.

● Engagement and disengagement of differential must be done when the crane is stationary. After

the inter-wheel differential or inter-axle differential is engaged, keep the vehicle driving in a straight line

and do not steer.

● Once the wheels are out of the slipping area, immediately stop the vehicle and disengage the

inter-axle differential and (or) inter-wheel differential.

● If a wheel gets stuck in a pit, take proper measures to decrease the pit gradient and reduce the

driving resistance.

Before then, it is not allowed to engage the inter-wheel differential or the inter-axle differential.

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2-6 After travel

2-6-1 Stop the engine
After a full load operation, allow the engine to run at idle for 3 to 5 min before shutting it down. This

will allow the engine to cool gradually.

Press Engine stop switch to shut down the engine.

To ensure the safe and reliable running of entire machine, always use the Engine stop switch to shut
down the engine.
Before leaving the mobile crane out-of-service, the following aspects shall be considered:
——Out-of-service condition of the crane and lifting attachment (e.g. parking position);
——Stop the engine, cut off the power supply;
——Cab doors are closed and locked, and control devices are secured;
——Precautions against thunder strikes and storms.

2-6-2 Close and lock the door

After the door is closed, insert the key and rotate it clockwise. After the door is locked, remove the

key.

Figure 2-64

● Park the crane on a firm and level ground and in a safe place. Apply wedges under tires to secure
the crane if it has to be parked on a slope.
● Keep any part of body away the door frame while closing the door. Otherwise, there is pinching
risk.

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2-7 Towing operation

1. Operating method

a. If the engine/transmission/transfer box is damaged, disconnect the propeller shafts on the front and

rear output ends of the engine/transmission/transfer box.

b. If the steering system fails or front axle is damaged, raise up the front section of the vehicle for

towing.

c. If the drive axle is damage, disconnect the propeller shafts on the front and rear ends of the drive

axle.

d. If the service brake is damaged, the parking brake can be used as a substitute in emergency.

2. Observe the following rules during towing:

a. Release the parking brake;

b. The vehicle speed should not exceed 10 km/h;

c. Use professional towing tools;

d. Turn on danger warning lamp.

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2-8 Winter operation

1. Cooling system

Use only the recommended antifreeze coolant in the cooling system. Select antifreeze coolant

according to the local ambient temperature and actual situation. Refer to XCA160H All Terrain Crane

Maintenance and Service Manual for details.

● Replace the antifreeze coolant timely according to the ambient temperature.

● Do not use the antifreeze coolant made of “alcohol-water”.

● Never use sea water to cool the engine directly.

● Add antifreeze coolant according to the operation requirements of the engine. Use the antifreeze

coolant whose freezing point is 5℃ lower than the lowest temperature in the area where the crane is

operated.

● The coolant is toxic. If the coolant gets into your eyes or on your skin, immediately flush with

water and seek medical attention.

● After coolant replacement or radiator maintenance, do not pour the waste coolant into the sewer

or on the ground. Please contact XCMG dealers or professional companies to deal with it properly.

● Antifreeze coolant is flammable. Keep it away from the flames. Never smoke when dealing with

antifreeze coolant.

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2. Draining off the water in the air reservoir

Do not forget to drain the water condensed in the air reservoir after traveling.

3. Battery
A maintenance-free battery is used for the crane. There is a battery state indicator lamp on the top

surface of the battery. Determine battery status according to the color of the indicator lamp and take

proper measures.

1) Check the battery

Cautions for battery inspection:

a. Keep the battery clean and dry. Remove the terminals for cleaning if they are contaminated, then

lubricate them with clean, acid-free and acid-proof grease.

b. Do not rest tools on the battery.

c. Do not remove the battery cable while the engine is running.

d. When disconnecting the battery cables, remove the negative cable first, then the positive one.

e. The battery voltage can be known from the instrument. If the voltage is below 22 V after the key

is turned to the ON position, or the voltage is below 16 V after the key is turned to the START position,

the engine could not be started normally. If the engine is not started (i.e the generator is not working), it is

not allowed to use high-power automotive electrical appliances for a long time, such as air conditioning,

radio, lighting, etc., to prevent the battery from deep discharging. If fail to do so, the engine will be

unable to get started, and the battery be lack of electricity or damaged.

2) Maintain the battery

a. Turn off main power source if the crane is not used. Take measures to prevent the battery from

exposure to sunshine and rain.

b. When the crane is out of service for more than one week, turn off the starter switch and the main

power source switch, or disconnect the battery cables from electrical system, to prevent the battery from

discharging.

c. If the crane is out of service for more than one month, charge the battery until the voltage of each

unit is above 12.6 V; afterwards, weekly check the battery. If the voltage of any single battery unit is

lower than 12.6 V or the charging indicator lamp illuminates, recharge the battery in time.

Charge the battery with DC power only, and the current should not exceed 1/10 of the battery

capacity. For example, when charging a 180 Ah battery, the charging currency should not exceed 18 A.

See the notice on the battery for the charging state of the battery.

Chassis operation 2-87

 XCA160H All Terrain Crane Operation Manual

2-88
 XCA160H All Terrain Crane Operation Manual

Chapter 3 Crane operation

3-1 Operator's cab

The newly designed operator's cab is made of steel and provides better sealing and rust-proofing

performance. It is safe and comfortable. The fully enclosed cab adopts safety glass for the windshield

and sun shields for windows. A sliding door and a pull-out step are available to make it easy and safe to

enter and exit the cab. The operator’s seat reclines and the control levers are mounted on the hand rail at

both sides of the seats. In addition, the standard controls and indicators are designed ergonomically. The

well-positioned working lamp can provide illumination for a wider range and enhance safety during night

operations. Air conditioning system is equipped. Air conditioner is enclosed in coverings. A specially

designed manhole makes maintenance easy.

Never stand on the roof of the cab.

Crane operation 3-1

 XCA160H All Terrain Crane Operation Manual

Figure 3-1 External structure of operator's cab

No. Name No. Name

1 Working lamp 2 Tri colored light bar
3 Mirror 4 Front windshield wiper
5 Front step 6 Pull-out step
7 Sliding door 8 Roof window wiper
9 Protective grilles

Tri-colored light bar:

● Green: normal working state

● Amber: pre-warning state

● Red: warning or unloading working state

3-2 Crane operation

 XCA160H All Terrain Crane Operation Manual

Figure 3-2 Inside structure of operator's cab

No. Name No. Name

1 Instrument panel 2 Control lever
3 Seat 4 Slewing brake foot pedal
5 Accelerator pedal

Crane operation 3-3

 XCA160H All Terrain Crane Operation Manual

3-1-1 Instrument panel

MODE

SC N
L
BA

SE
N
D

1 2 RDM 3 USB SD 4 INT 5 6 A/C AUTO

VO L

Figure 3-3 Instrument panel

No. Name No. Name

1 Touch screen display 2 Emergency stop switch
3 Starter switch 4 Charging interface
5 Switches and indicator lamps 6 Air conditioner control panel
7 Control panel of radio

3-4 Crane operation

 XCA160H All Terrain Crane Operation Manual

Emergency stop switch, starter switch and cigarette lighter are shown in the following table.

No. Illustrations Name Function

Press this switch to stop the engine

Emergency
1 in case of emergency. Caution: this
stop switch
switch must be reset in time.

It is used to turn on the power source

Starter
2 of superstructure control system and
switch
start the engine.

When the battery of wireless remote

control device needs to be charged,
24 V insert its charger into this interface.
3 Charging
interface After charging is completed, remove
the charger and cover the interface
with the protective cap.

• If the chassis power is off, stop the engine by turning off the starter switch or pressing down the

stop switch on the control panel;

• If the chassis power is on, stop the engine by pressing the engine stop switch;

• In case of emergency, pressing the emergency stop switch on the instrument panel.

• After engine is stopped, reset the emergency stop switch in time.

● Emergency stop switch must be reset in time.

● The charging interface is only used for charging, never use it for electrical appliance with

power of over 120 W.

Crane operation 3-5

 XCA160H All Terrain Crane Operation Manual

3-1-2 Switches and indicator lamps

The icons and functions of the switches and indicator lamps in the operator's cab are shown as

follows. There is an indicator lamp under each switch icon.

No. Illustration Name Function

The switch has the same function as the enable

switch on each control handle. Before lifting
1 Pilot switch operation, it is necessary to press this switch (the
indicator lamp illuminates) or the one on the
related control handle.

The default state is telescoping working

Telescoping/ state. Press this switch to switch to auxiliary
2 auxiliary winch
winch working state, and its indicator lamp
selector switch
illuminates.

Auxiliary winch
3 Press this switch to activate auxiliary winch.
enable switch

Counterweight Switches No.7 and No.11 will only function

4
enable switch when this switch is also pressed.

It is used to control the brake of slewing

Slewing brake reducer. After the switch is pressed, the slewing
5
release switch brake is disengaged and slewing operation is
available.

Enable switch of Before using the wireless remote controller, it

6 wireless remote
is necessary to press this switch.
control

After pressing the counterweight enable

Counterweight Up
7 switch, press and hold this switch, and it is
switch
possible to lift counterweight slabs.

Cylinder pin In/Out Press this switch to insert or retract the cylinder
8
switch pin.

3-6 Crane operation

 XCA160H All Terrain Crane Operation Manual

No. Illustration Name Function

Boom pin In/Out

9 The switch is used to control the boom pin.
switch

10 Reserved Reserved

With the counterweight enable switch pressed,

Counterweight
11 press and hold this switch, and it is possible to
Down switch
lower counterweight slabs.

Self hold function activated if: control lever is

in neutral position and load is less than 110%
of the capacity chart, or no capacity chart can
be found by the rated capacity limiter (rigging/
derigging mode). Self hold function deleted if:
control lever has been in neutral position for
over 10 seconds, or load exceeds 110% of the
capacity chart, or the engine stops, or there is a
defect in LMI sensor, or this switch is pressed
again. When this function is activated, all
Selector switch
movements are free from limitations (except
12 for rigging/
for the anti-two block and lowering limiter). If
derigging of crane
a capacity chart cannot be found by the rated
capacity limiter (rigging/derigging mode):
All movements are free from limitations.
Therefore, all movements to erect the crane can
be done with full speed without limitations.
If a capacity chart can be found by the rated
capacity limiter (operation mode): All speeds
are reduced to 15%. The switch is used only
when rigging/de-rigging the crane. Never use
the switch in any other situations.

The switch is only used in maintenance

Override switch working condition or for further luffing out the
13
for luffing up boom with no load suspended. Never use the
switch in any other situations.

Crane operation 3-7

 XCA160H All Terrain Crane Operation Manual

No. Illustration Name Function

Press the selector switch for rigging/derigging

of crane and then this switch, then the hook
can continue to be raised. The operator should
Override switch
pay close attention to this operation and avoid
14 for the anti-two
dangers. This switch can only be used when
block
replacing or repairing hook block and fault
code E02 appears. Never use the switch in any
other situations.

Press down the Selector switch for rigging/

derigging of crane, and then press down this
switch, the hook lowering will be resumed. The
Override switch
switch can only be used when it is necessary
15 for lowering
to maintain or replace wire rope and fault code
limiter
E02 appears. Take care to avoid risk during
operation. Never use the switch in any other
situations.

Release accelerator pedal until the engine runs

Engine stop at idle speed. Stop all operations and press and
16
switch hold the stop switch. After 2～3 seconds, the
engine stops.

Engine start
17 It is used to start the engine.
switch

Hydraulic oil Press the switch to actuate the hydraulic oil

18
cooler switch cooler.

Half-extended
outrigger enable Pressing the switch enables half-extended
19
switch outriggers.
(optional)

3-8 Crane operation

 XCA160H All Terrain Crane Operation Manual

No. Illustration Name Function

Windshield Press and hold the switch to actuate the

20
washer switch windshield washer.

Windshield Press the switch to actuate the windshield

21
wiper switch wiper.

Roof window Press the switch to actuate the roof window

22
wiper switch wiper.

Press this button to turn on the working

Working lamp
23 lamps in operator's cab, at the turntable and
switch
on the boom.

Marker lamp Press the switch to turn on the superstructure

24
switch marker lamps.

Beacon lamp Press the switch to turn on the beacon lamp

25
switch on boom tip.

26 Horn switch Press this switch to sound the horn.

Instrument
Press the switch to turn on the instrument
27 panel lamp
panel lamp.
switch

Crane operation 3-9

 XCA160H All Terrain Crane Operation Manual

No. Illustrations Name Function

1) Amber indicator lamp solid: active regeneration.

2) Amber indicator lamp flashing: driver has to

park the crane on a safe place and press the DPF

regeneration switch on the instrument panel in
DPF regeneration
the driver's cab to start DPF regeneration. Do not
1 indicator lamp
release audible alarm before fault is removed.
3) Red indicator lamp solid: it is necessary for

driver to seek out a service station to perform DPF

regeneration. Do not release audible alarm before
fault is removed.

Red lamp solid: the DPF regenrationinhibit switch

on the instrument panel in the driver's cab is
DPF regeneration
pressed, and DPF regeneration is not performed
2 inhibit indicator lamp
temporarily.
It is not allowed to inhibit generation for a long
time if there is no special situation.

Refer to section 2-4-3 DPF regeneration operation guidance in this manual for DPF regeneration.

3-10
 XCA160H All Terrain Crane Operation Manual

Notes:

1. If amber DPF regeneration indicator lamp is flashing and audible alarm sounds:

——operator should stow the crane into travel configuration (i.e. load is lowered on the ground, boom is

fully retracted, outriggers are fully retracted and turntable is locked) within eight hours;
——park the crane in a safe and open place, and start DPF generation.

2. If red DPF regeneration indicator lamp is solid:

——operator should immediately stow the crane into travel configuration (i.e. load is lowered on the

ground, boom is fully retracted, outriggers are fully retracted and turntable is locked);
——it is necessary for driver to seek out a service station to perform DPF regeneration.

Caution:
XCMG is not responsible for any replacement and maintenance fees caused by damage of engine after-
treatment related parts due to nonobservance of the said requirements.

3-11
 XCA160H All Terrain Crane Operation Manual

3-1-3 Control mechanism

The control mechanism includes control levers, pedals and wireless remote controller, etc.

1. Control levers

Figure 3-4 Control levers

No. Name No. Name

1 Horn button 2 Free swing button

3 Electric proportional control handle enable button 4 Left control handle
5 Right control handle

3-12 Crane operation

 XCA160H All Terrain Crane Operation Manual

2. Pedals

Slewing brake foot pedal Accelerator pedal

Figure 3-5 Pedals

Crane operation 3-13

 XCA160H All Terrain Crane Operation Manual

3-1-4 Air conditioner control panel

A/C AUTO

Figure 3-6 Air conditioner control panel

No. Name Function

Turn the knob clockwise to increase the temperature in the

1 Temperature adjusting knob
cab and counter-clockwise to decrease the temperature.

2 Fan speed adjusting knob In manual mode, use the knob to adjust the fan speed.

In manual mode, adjust the knob to change the air flow

3 Air blow mode knob direction between lower, upper, windshield and lower-
windshield.

In manual mode, it is used to control compressor in the

4 A/C key order of ON-OFF-ON; in automatic mode, press the key to
enter manual mode.

In manual mode, press the switch to select internal

Internal and external circulation
5 circulation or external circulation. In auto mode, press the
selector key
switch to enter manual mode.

Press the key to switch between auto and manual working

modes.
6 AUTO key In auto mode, the system will automatically adjust the fan
speed, air blow mode, etc., according to the temperature
setting and temperature sensor.

3-14 Crane operation

 XCA160H All Terrain Crane Operation Manual

3-1-5 Control panel of radio

MODE

SCN
L

BA
SE

ND
1 2 RDM 3 USB SD 4 INT 5 6
VOL

Figure 3-7

Crane operation 3-15

 XCA160H All Terrain Crane Operation Manual

3-1-6 Other devices

1. Breaker

There is a breaker in the operator’s cab. In

case of an emergency, use it to break the window

for escape.

Figure 3-8 Breaker

2. Fire extinguisher

There is a dry powder fire extinguisher in

the operator’s cab. Refer to the instruction on

the fire extinguisher for cautions.

Figure 3-9 Fire extinguisher

3-16 Crane operation

 XCA160H All Terrain Crane Operation Manual

3-2 Safety devices

3-2-1 Load moment indicator

Prior to lifting operations, please read the LMI instructions carefully and be familiar with related

operations.

1. Load moment limiting system

The load moment limiting system (hereinafter called LMI) includes the main machine of load

moment limiter, display, angle sensor, oil pressure sensor and anti-two block, etc. It is installed in the

control box.

The LMI may carry out real-time monitoring of the boom length, boom angle, max. lifting height,

working radius, rated lifting load and actual lifting load, etc. upon which the load moment is calculated

out. When any operation is beyond the safe range, a warning icon will appear on the display and buzzer

will sound. At the same time, the controller will send a signal to stop all dangerous crane movements

(boom out, boom down, and hook up), and only safe movements (boom in, boom up and hook down) are

allowed.

Crane operation 3-17

 XCA160H All Terrain Crane Operation Manual

Figure 3-10 LMI system

No. Name No. Name

1 Boom angle sensor at boom head 2 Anemometer
3 Cable reel 4 Boom angle sensor on the side of boom
5 LMI 6 Lowering limiter
7 Display 8 Oil pressure sensor
9 Anti-two block

3-18 Crane operation

 XCA160H All Terrain Crane Operation Manual

2. Cable reel/angle sensor

The cable reel/angle sensor system is mounted at the side of boom. The cable is fixed on the head of

boom end section after going through the reel which rotates along with the movement of the boom. The

cable is also used to transfer signals from other sensors, such as the sensor of anti-two block. The luffing

angle of boom against the horizontal is measured by an angle sensor.

3. Anti-two block

The anti-two block consists of the height limiter switch on boom/jib tip and weight. It is used to

prevent the hook block from contacting with boom head sheave during lifting operations. When the

hook block approaches the boom head sheave (refer to lifting height curves), the height limit switch is

activated, which stops the extension of the boom and the raising of the hook block. At the same time, the

icon for the anti-two block on the display illuminates and buzzer sounds. Lowering the hook or pressing

anti-two block bridging switch may disable the limitation.

● Although the crane is equipped with a load moment limiter, it is still the operator’s responsibility
to maintain and ensure safety during all operations. Keep in mind that the load moment limiter can never
replace the judgment and practical experience of the human operator.

● Before performing operations, always know the weight of the load to be lifted and determine
whether or not the crane can lift the load by referencing the rated load charts;
● The LMI is a very important safety device.
● Never operate the crane with the LMI switched off, for example, do not extend the boom with a
suspended load.
● XCMG is not responsible for the damage caused by unauthorized modification.

● Serious damage to the crane and personal injury may be caused if do not properly use the LMI.
● Unauthorized installation of equipment or modifications of hydraulic and electrical lines will lead
to serious accidents such as boom breaking and crane tipping.

Crane operation 3-19

 XCA160H All Terrain Crane Operation Manual

4. LMI bridging switch

The LMI bridging switch is located outside the operator's cab, see the figure below.

In case of a component failure of the load moment limiter system or in an emergency situation, the

load moment limiter system can be temporarily turned off by using the load moment limiter bridging

switch outside the operator’s cab. This bridging switch may automatically reset.

Control levers in the cab must be in neutral and engine is running while the bridging switch is

engaged. Turning the switch can activate LMI bridging function to release all movement limitations.

The bridging switch is only used to release the lock state by the LMI. After the crane configuration is

adjusted into the designed range, lifting operation may continue. After turning the switch, the red of the tri

colored light bar flashes, audible alarm sounds continuously and data recorder is activated, recording real-

time working condition.

The LMI bridging switch is disengaged when:

a. the key is turned again; or

b. the engine stops.

Operator's cab

LMI bridging switch

Figure 3-11 LMI bridging switch

Although the LMI bridging switch is equipped to release LMI limitation, but this function only

can be used under the guidance of a service personnel designated by XCMG. XCMG will not take

responsibility for any damage to the crane or accident induced by using the switch without authorization.

3-20 Crane operation

 XCA160H All Terrain Crane Operation Manual

3-2-2 Lowering limiter

The lowering limiter, also called the counter, is equipped to prevent the rope from being let out

excessively. When only 3 turns of rope is left on the winch drum, hook lowering operation will be cut off

automatically, with a visual warning appearing on the display and the buzzer sounding.

Lowering limiter

Figure 3-12 Location of lowering limiter

Crane operation 3-21

 XCA160H All Terrain Crane Operation Manual

3-2-3 Electric control handle enable switch (pilot pressure switch)

The electric control handle enable switch is also called the pilot pressure switch. See the figure

below. It is equipped to avoid unintended crane operations caused by touching the control levers by

accident when entering or exiting the operator’s cab. Only after this switch is pressed, may the electric

proportional system work properly and the system pressure be built.

Control handle enable switch

Figure 3-13 Control handle

3-22 Crane operation

 XCA160H All Terrain Crane Operation Manual

3-2-4 Turntable locking device

3
4

Figure 3-14 Turntable locking device

No. Name No. Name

1 Pin 2 Flexible shaft controller
3 Gasket 4 Bolt

Always operate the turntable locking device slowly and keep the engine running at idle. The pin

must be applied to secure the turntable and frame during traveling.

● Always secure the turntable with the turntable lock pin before lifting and lowering the

counterweight slabs.

● Make sure the turntable is unlocked before slewing operations.

Crane operation 3-23

 XCA160H All Terrain Crane Operation Manual

3-2-5 Slewing brake foot pedal

It is equipped to stop slewing movement quickly in case of emergency. Depress the pedal to stop

slewing movement, and then slewing function is locked.

Figure 3-15 Slewing brake foot pedal

3-2-6 Rope guard

A rope guard is installed for the sheave block at both the boom head and the hook block. Rope guards

are used to prevent the rope from running out of the sheave groove.

Install the rope guard after the rope is installed; remove the rope guard before removing the rope.

3-24 Crane operation

 XCA160H All Terrain Crane Operation Manual

3-3 Inspection before crane operation

Check the crane strictly according to the following requirements before lifting operation.

3-3-1 Site condition

The crane operator must possess all necessary information before the crane arrives at the site,

especially:

1. Natural condition of working site, such as temperature and wind speed;

2. Site location (distance);

3. Height and side clearances;

4. Overhead electrical wires;

5. Movement and operation restrictions due to surrounding structures;

6. Weight and dimension of the load to be lifted;

7. Required lifting height and radius;

8. Load bearing capacity of the surface or foundation under the crane.

Only after the above information is provided, can the operator know the working condition and

decide what equipment should be installed, such as the hook block, jib, lifting/slinging tackle, supporting

pads and tools, etc.

Make sure the operator has all the necessary information before crane operations, so that the intended

task will be accomplished. Accidents may happen anytime due to poor preparation.

3-3-2 General items of inspection before lifting operation

1. Make sure the mirrors are adjusted in place for a clear view.

2. Make sure the seat is properly adjusted and all controls are easily accessible from the seat.

3. Make sure the fire extinguisher is placed at the designated position.

4. Set the air conditioner reasonably according to the ambient temperature.

5. Make sure all walking and working surfaces of the crane are clean, dry and not slippery.

6. Read the section about starting and stopping the engine in the Engine Operation Manual.

7. Check the hydraulic oil level in the tank and make sure it meets the requirement and the cap is

tightened.

Crane operation 3-25

 XCA160H All Terrain Crane Operation Manual

8. Check all structural members for defects and abnormalities. If any is found, it must be removed

before crane operations.

9. After the engine is started, run at a low speed to warm it up.

10. Before engaging the PTO, make sure all levers are placed in neutral and switches are off.

11. With no load applied, check all control levers and switches for malfunction. If any is found,

remove it immediately.

12. Pre-check the load moment indicator (refer to LMI Operation Manual)

13. Check all indicator lamps and safety devices (such as warning lamp) for abnormalities.

14. Turn on the power source switch in driver’s cab.

3-3-3 Inspection of safety devices

● Safety devices must be activated during crane operations.

● Defective safety devices must be repaired by the professional service personnel from XCMG.

1. Check the LMI

Run the test procedure, then check if there is any

a. error information indication;

b. pre-warning and warning indication;

c. continuous audible warning.

If any is found, stop and correct the fault before further operation.

2. Check the anti-two block

Raise the boom up, and then raise the hook block up slowly, until the hook block approaches the

weight of the anti-two block. Check:

a. if the warning lamp of the anti-two block is lit;

b. if all the movements that increase the load moment are still valid, namely hook up, boom down

and boom out operations.

If the warning lamp lights up and these movements are cut off, it means the anti-two block is

functional.

3. Check the emergency stop switch

Lower the load on the ground and release the two control levers. Press the emergency stop switch. If

the engine stops, it means this switch is functional.

3-26 Crane operation

 XCA160H All Terrain Crane Operation Manual

3-3-4 Inspection of wire rope

Refer to Section 4-4-3 in the Maintenance and Service Manual for details of wire rope inspection.

All running ropes in service should be visually inspected once each working day. A visual inspection

shall consist of observation of the section of rope that can reasonably be expected to be in use during the

day's operations. These visual observations should include the following:

1. Rope winding around sheave and drum.

2. Distortion of the rope such as kinking, crushing, unstranding, birdcaging, main strand

displacement, or core protrusion.

● Protective gloves should be worn when inspecting the rope.

● Care shall be taken when inspecting sections of rapid deterioration such as flange points,

crossover points, and repetitive pickup points on drums.

● Immediately take the wire rope out of service when the discard criteria is reached. The rope

should be replaced by professional maintenance staff.

Crane operation 3-27

 XCA160H All Terrain Crane Operation Manual

3-4 Operation of PTO

The PTO switch is located on the control panel in the driver's cab. PTO must be engaged before
extending outriggers and adjusting suspensions.

Engage the PTO:

Park the vehicle in a safe place. With the parking brake applied and the engine idling, position the

transmission selector lever in neutral. Press down the PTO switch and by-pass switch at the same time to

engage the PTO, and the PTO indicator lamp illuminates.

Disengage the PTO:

Press down the PTO switch and by-pass switch at the same time again to disengage the PTO, and the

PTO indicator lamp goes out.

● All controls must be positioned in neutral before pressing down the PTO switch.

● When the PTO is not used, the PTO switch must be turned off.

● During traveling, the PTO switch must be turned off.

● The PTO indicator lamp on the superstructure display has three colors. Red means PTO is not

engaged, yellow means PTO is engaging, and green means PTO has been engaged successfully.

● After the PTO switch is pressed, the system will normally take 10~30 seconds to conduct the

operation ( the PTO indicator lamp is yellow during this period). If the operation fails (the PTO indicator

does not turn green within 1 minute), please press the PTO switch again to exit the previous operation.

Then shut down the engine and cut off the power supply for the whole machine. After 1 minute, turn on

the power supply, start the engine, and repeat the PTO engaging operation again.

● After work and before leaving the driver’s cab, make sure to disengage the PTO first, then shut

down the engine, and turn off the power supply with the key at last. Only turning off the power supply

will lead to transmission faults, gear shifting failure and PTO engagement failure.

● If the PTO still can’t be engaged after three attempts in a row, please stop the vehicle, cut off

the power supply, and check if the transmission or engine is faulty. Try again after the fault is removed.

3-28 Crane operation

 XCA160H All Terrain Crane Operation Manual

3-5 Operation of outriggers

3-5-1 Preparation before operation

1. Check the job site

a. Make sure there is enough space for deploying outriggers

The crane should be set up at a place where outriggers can extend or move without obstacles. Always

extend the outriggers fully before carrying out crane operation.

● Keep all personnel away from the working area when extending or retracting the outrigger.

● Before any crane operation, verify that the LMI set-up matches the crane configuration and that

the corresponding load charts are used.

b. Selection of supporting ground

The most essential prerequisite for safe operation is to set up the crane on a firm and level supporting

surface. Make sure there is no risk of sinking during operating.

● If the crane has to be set up on soft or slant ground with outriggers, make sure it is level.

● The crane inclination should be no more than 1%. Each outrigger float must be placed at the

center of its supporting steel plate or wood block to avoid uneven load distribution.

It should be noted that sometimes the ground seems to be solid, but its internal structure can not bear

the weight of the crane and the load. Pay special attention to the following:

1) simply paved road;

2) pavement or other roadways paved by stones;

3) backfilled soil;

4) uncompacted fill;

5) area in the vicinity of road shoulder or excavations.

Crane operation 3-29

 XCA160H All Terrain Crane Operation Manual

OK

OK

OK

Figure 3-17

3-30 Crane operation

 XCA160H All Terrain Crane Operation Manual

When any factor that reduces crane stability occurs, lower the load and retract the boom. After
potential risk is removed, set up the crane once more according to requirements. Factors that may reduce
crane stability are rain, snow or other water source, which can lead to changing ground conditions.
Excessive oil leakage in addition to being an environmental concern could cause ground conditions to
change.

● If outriggers are supported on the improper ground, tipping may occur!

● It is forbidden to place supporting pads over man made or natural hollow structures.
● It is not allowed to use deformed supporting pad.
● Never set up the supporting pads on a slope.
● Only when the outrigger beams have been extended in place stipulated in the load charts can the
crane be supported.

c. Supporting outriggers on special ground

When the crane has to be set up near a river or road shoulder, utmost attention should be paid.
Soil near a river or road shoulder is loose, and it’s very dangerous to set up the outriggers near these
places. In this case, the ground that outriggers will be supported upon should be strengthened. Piling
reinforcement piles and backfilling rubble or flag stone may increase the supporting area, and timbers
may be used if necessary.
2. Check the shut-off valve
There is a shut-off valve installed near the suction port of the hydraulic oil tank. The shut-off valve
must be open before the hydraulic system begins to work. The shut-off valve is as shown in the figure
below.

Closed Open
state state

Figure 3-18 Shut-off valve

Crane operation 3-31

 XCA160H All Terrain Crane Operation Manual

3. Check the hydraulic oil level

Prior to lifting operation, check the hydraulic oil level from the sight glass. If the hydraulic oil

level is lower than the Min. mark, check the hydraulic system for leakage according to instructions in

XCA160H All Terrain Crane Maintenance and Service Manual. After the problem is removed, open the

end cover of air filter located on the upper surface of the hydraulic oil tank, then add the same brand of

hydraulic oil through the air filter screen. For the hydraulic oil brand, please refer to the Maintenance and

Service Manual.

4. Check the outrigger pins

Two kinds of outrigger pin are available, pin 1 and pin 2.

Prior to extending outrigger beams, make sure the outrigger pins are unlocked, as shown in the figure

below.

B. Locked A. Unlocked

Figure 3-19 Status of outrigger lock pin 1

3-32 Crane operation

 XCA160H All Terrain Crane Operation Manual

After extending the outrigger beams, apply the outrigger pins, as shown in the figure below.

Chassis operation

A. Unlocked B. Locked

Figure 3-20 Status of outrigger lock pin 2

Crane operation 3-33

 XCA160H All Terrain Crane Operation Manual

5. Check the outrigger floats

Prior to extending outriggers, pull the outrigger floats out in place from travel configuration (as

shown in Figure 3-21 A). Firstly, remove the fixed pin (as shown in Figure 3-21 B) and pull out the float

(as shown in Figure 3-21 C), and then insert the fixed pin into adjacent pin hole (as shown in Figure 3-21

D). Before traveling, stowed the outrigger floats in the reverse procedure.

A. A float in travel configuration B. Remove the fixed pin

D. Insert the fixed pin into the adjacent pin hole

C. Pull out the float in place

Figure 3-21 Adjustment of outrigger float

When the crane is supported on the outrigger jacks, make sure all outrigger floats are in complete

contact with the ground and all tires are off the ground. Apply steel plate or wood block under the floats if

necessary.

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 XCA160H All Terrain Crane Operation Manual

3-5-2 Outrigger structure and outrigger control panel

1. Outrigger structure is as shown in the figure below.

Figure 3-22 Outrigger structure

No. Name No.

1 Outrigger beam lock pin 2 Lock pin hole
3 Jack cylinder 4 Outrigger float

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 XCA160H All Terrain Crane Operation Manual

2. Control panel of outriggers

There is an outrigger control box located on the covering on each side of the chassis. In each

outrigger control box there is an outrigger control panel, see the figures below.

TEST

{0}°
{0}°

-{0}°
-{0}°

Figure 3-23 Outriggers control panel at right side of the crane

No. Name No. Name

1 Rear left jack cylinder Down switch 15 Rear right jack cylinder Up switch
2 Rear left jack cylinder Up switch 16 Rear right jack cylinder Down switch
3 Outrigger enable switch 17 Rear right extension cylinder Out switch
4 Outrigger illuminator switch 18 Rear right extension cylinder In switch
5 Rear left outrigger pressure indicator 19 Four jacks simultaneously Up switch
6 Unused 20 Four jacks simultaneously Down switch
7 Unused 21 Electronic level gauge
8 Outrigger enable indicator 22 Engine stop switch
9 Unused 23 Speed-down switch
10 Front left outrigger pressure indicator 24 Front right extension cylinder In switch
11 Engine start switch 25 Front right extension cylinder Out switch
12 Speed-up switch 26 Front right jack cylinder Up switch
13 Front left jack cylinder Up switch 27 Front right jack cylinder Down switch
14 Front left jack cylinder Down switch

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 XCA160H All Terrain Crane Operation Manual

3. Function of outrigger control box

a. There are two outrigger control boxes, which are located at the left and right side enclosures

between the 3rd and 4th axle. Outrigger control panels are fixed in the control boxes. The two control

panels have the same functions, but their layouts are different.

b. No.4 is the outrigger lamp switch. During night operations, press this switch to turn on the

outrigger working lamp.

c. No.11 is the engine start switch; No.22 is engine stop switch; No.12 and No.23 are accelerator

control switches. Press No.12 switch to increase the rotation speed of engine and press No.23 to decrease

the rotation speed of engine.

d. There is an electronic level gauge installed inside each outrigger control box. When the indicator

lamps at horizontal and vertical directions go out and the center indicator lamp illuminates, it means the

crane is leveled. Otherwise, adjust by the outrigger control switches until the crane is leveled. Secure

outrigger beams with lock pins before lifting operations.

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 XCA160H All Terrain Crane Operation Manual

3-5-3 Extend the outriggers

● Incorrectly extended outriggers can not ensure safety during operations. Extend the outrigger

beams according to the rated load charts. Use the fully extended outriggers as much as possible, even if

half-extended outriggers are allowed.

● Sometimes a crane can be leveled when it is supported by only three outrigger jacks. However,

it is forbidden to carry out lifting operations under this condition. After the outriggers are out, make sure

all floats are in complete contact with the ground. If any outrigger float is afloat, lower it down until it is
in complete contact with the ground.

● If a crane is not leveled on the ground, the working radius will gradually increase while the load

lifted is moving to the lower side of the crane. In the worst case, the crane may tip over. After outriggers

are out, confirm that the crane has been leveled by observing the level gauge.

● When operating the crane on outriggers, any tire in contact with the ground will reduce the crane

stability. If necessary, apply wood blocks under outrigger floats to raise all tires off the ground.

● The outrigger beams may unexpectedly retract during crane operations if they are not locked by

the lock pins. Secure the outrigger beams with the lock pins after the outrigger beams are fully extended.

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 XCA160H All Terrain Crane Operation Manual

To fully extend the outrigger beams:

1. Make sure the parking brake lever is engaged;

2. Make sure that each outrigger float aligns with its matching jack cylinder. Refer to Section 3-4 for

engagement of PTO;

3. Remove all outrigger beam lock pins;

4. Press the switches of extension cylinders on your side of the crane to fully extend the outrigger

beams on this side;

● Operation of outrigger beams is single-sided, i.e. use the left outrigger control box to extend or

retract the front left and rear left outrigger beams, and use the right outrigger control box to extend or

retract the front right and rear right outrigger beams.

● If it is necessary to extend four outrigger beams simultaneously, make sure it is safe to extend

the outrigger beams on the opposite side of the operator before such operation. During such operation, a

helper is needed on the opposite side to monitor and ensure safety.

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 XCA160H All Terrain Crane Operation Manual

5. Insert lock pins to secure the extended outrigger beams;

6. Walk to the other side of the crane, and press the switches of extension cylinders on this side to

fully extend the outrigger beams on this side;

7. Insert lock pins to secure the extended outrigger beams;

Figure 3-24 Fully-extended outriggers

8. Press the four jacks simultaneously Down switch to fully extend four jack cylinders;

9. Make sure the crane is leveled through observing the electronic level gauge. If the crane is not

leveled, refer to Section 3-5-4 How to level the crane to level it.

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 XCA160H All Terrain Crane Operation Manual

To half extend the outrigger beams:

1. Take the same method as stated in Step 1~6 above, but only extend the outrigger beam to the

middle position mark (2.5 m);

2. Insert four outrigger lock pins into pin holes to secure the outrigger beams;

Figure 3-25 Half-extended outrigger

3. Take the same method as Step 8 above to fully extend all jack cylinders.

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 XCA160H All Terrain Crane Operation Manual

3-5-4 How to level the crane

Level the crane by retracting (extending) the jack cylinders on the higher (lower) side of the crane.

For example, when the right side is higher (lower):

1. Press the speed-down switch, then press the front right and rear right jack cylinder Up (Down)

switches to retract (extend) the jack cylinders on the right side of the crane little by little;

2. If the red light in the middle of the electronic level gauge is on, it means the crane is leveled;

3. Make sure four outrigger floats are in complete contact with the ground.

When the crane is supported on the outrigger jacks, make sure all outrigger floats are in complete

contact with the ground and all tires are off the ground. Apply steel plate or wood block under the floats

if necessary.

3-6 Enter the operator’s cab

3-6-1 Open and close the door

Turn the key 90° clockwise and it will spring back, indicating that the door is locked. Turn the key

90° counterclockwise and it will spring back, indicating that the door is unlocked. Pull or push the door

handle to open or close the door.

Always use the front step, the pull-out step and handholds to access the operator’s cab.

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 XCA160H All Terrain Crane Operation Manual

3-6-2 Adjustment of seat

There is a seat equipped in the operator's cab as shown in the figure below. The seat travels up or

down by 60 mm, and it travels forward or backward 170 mm. The backrest is adjustable up to 120°. The

seat damper adjusts according to body weight (40 kg~130 kg), the maximum movement is 50 mm. The

headrest moves up or down by 40 mm.

120 o

30 o

Figure 3-26 Operator’s seat

No. Name No. Name

1 Headrest height locking switch 2 Seat damper adjusting knob
3 Seat height adjusting lever 4 Backrest angle adjusting lever
5 Armrest switch 6 Seat cushion adjusting lever
7 Seat sliding control lever

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 XCA160H All Terrain Crane Operation Manual

Adjusting methods:

a. Headrest: adjust the headrest to the proper position after the headrest switch is turned on.

b. Suspension: turn the damper adjusting knob so the displayed number matches the operator’s

weight.

c. Height: Move the switch (No.3) upward to release the locking mechanism on the seat height. The

seat may then be lowered by the driver’s weight and the seat may rise up if nobody is sitting on it. The

seat height automatically locks when the switch is released.

d. Seat backrest angle: Move the switch (No.4) upward to release the locking of the seat backrest

angle. Release the switch after the proper angle is reached, and then it will lock automatically.

e. Armrest switch: Move the switch (No.5) upward to release the locking of the armrest, which may

be lifted up by the gas spring.

f. Seat cushion: Pull the lever (No.6) upward to release the locking of the seat cushion. Release the

lever once the cushion reaches the proper position.

g. Seat position: pull the lever (No.7) upward to release the locking of the seat position. Release the

lever once the seat reaches the proper position.

Always lock the adjusting levers in place after adjusting the seat forward or backward and after

adjusting the backrest angle. Make sure the levers are locked in place before operating the crane.

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 XCA160H All Terrain Crane Operation Manual

3-6-3 Operation of PTO

Before engaging the PTO, make sure the vehicle is stationary, outriggers are extended, the frame is

leveled, hand brake is engaged, transmission is in neutral, retarder control lever is in the OFF position,

and air pressure is above 6.0 bar. Then press the PTO switch. After the system inspection is finished, the

PTO icon turns green and the engine RPM increases to 700 r/min, the PTO is engaged successfully.

With the PTO engaged, press the PTO key on the screen again, and when the key
turns gray, the PTO is disengaged.

● In winter, after the PTO is engaged, let the hydraulic pump run for a while so as to warm up the

hydraulic oil.

● Before shutting down the engine, make sure to disengage the PTO first.

● The PTO indicator lamp on the superstructure display has three colors. Red means PTO is not

engaged, yellow means PTO is engaging, and green means PTO has been engaged successfully.

● After the PTO switch is pressed, the system will normally take 10~30 seconds to conduct the

operation ( the PTO indicator lamp is yellow during this period). If the operation fails (the PTO indicator
does not turn green within 1 minute), please press the PTO switch again to exit the previous operation.

Then shut down the engine and cut off the power supply for the whole machine. After 1 minute, turn on

the power supply, start the engine, and repeat the PTO engaging operation again.

● After work and before leaving the driver’s cab, make sure to disengage the PTO first, then shut

down the engine, and turn off the power supply with the key at last. Only turning off the power supply

will lead to transmission faults, gear shifting failure and PTO engagement failure.

● If the PTO still can’t be engaged after three attempts in a row, please stop the vehicle, cut off

the power supply, and check if the transmission or engine is faulty. Try again after the fault is removed.

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 XCA160H All Terrain Crane Operation Manual

3-6-4 Power switch

Turn on the main power switch at chassis. Turn the starter switch to the ON position to turn on the

power source for superstructure electric system.

• If the chassis power is off, stop the engine by turning off the starter switch or pressing down the

stop switch on the control panel;

• If the chassis power is on, stop the engine by pressing the engine stop switch;

• In case of emergency, pressing the emergency stop switch on the instrument panel;

• After engine is stopped, reset the emergency stop switch in time.

Figure 3-28 Switches

No. Name No. Name

1 Main power switch 2 Starter switch

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 XCA160H All Terrain Crane Operation Manual

● Turn the main power switch in correct direction. Turn the main power switch with proper

effort. Otherwise, the switch will be damaged;

● Always turn the starter switch to the OFF position after operation is completed and before

leaving the cab.

● Always turn off the main power switch if do not use the crane and before leaving the the crane.

Never turn off the main power switch while the engine is running normally! Battery can absorb

and restrain the high voltage generated in electric circuit. If cutting off the main power switch, the

current in the electric circuit will suddenly change, resulting in high transient voltage, successively

damaging electrical components.

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 XCA160H All Terrain Crane Operation Manual

3-6-4 Operation of accelerator

1. Notes on operation

a. Never depress the pedal abruptly during operation, otherwise unexpected accidents and crane

damage may occur. Smooth operation of the accelerator will not only ensure safety and steadiness but also

prolong engine service life and reduce oil consumption.

b. Max. engine torque is gained when it is running at 1000~1400 r/min. Use the lever in combination

with the accelerator pedal to reach the desired speed.

c. The accelerator pedal has been calibrated before delivery, so no further regulation is needed. Reset

it only when bad return or lumpy movement of accelerator pedal is found.

Accelerator pedal

Figure 3-28 Accelerator pedal

2. Operating method

Engine speed is controlled from the crane operator's cab by either the throttle pedal on the floor or

the knob on the right arm rest. Depress the accelerator pedal in the operator’s cab to increase the engine

speed, leading to faster slewing, boom luffing, boom telescoping and winching operations. Release the

accelerator pedal, then it will be reset under spring force, and the engine will return to the idling state.

Never abruptly depress the accelerator pedal.

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 XCA160H All Terrain Crane Operation Manual

3-7 Operation of crane control levers

3-7-1 Winch operation

1. Notes on operation

a. Do not abruptly move the winch control lever. Always lift or lower the load smoothly.

b. Before lifting operation, check and make sure the winch brake is functional. Always lift a load off

the ground by winch rather than by raising or telescoping the boom.

c. Select proper number of parts of line according to the rated load charts.

d. If the winch rope twists and the hook block rotates, fully untwist the rope before lifting loads.

e. At least three wraps of rope must always be maintained on the winch drum.

f. Always lift the load in a vertical direction. Avoid side-loading or dragging a load on the ground.

● Prior to operation, make sure that the crane is set up on level and firm ground.

● Prior to operation, ensure that there are no obstacles in the crane's working area and no persons in

the danger area. Give a short warning signal (honk) before starting a crane movement. Otherwise, injury

or death may be caused.

● Never extend your hand or head out of window during crane operation, otherwise casualty may be

caused.

● Overloading is very dangerous and may result in injury or death. When lifting a load off the

ground, the working radius will increase due to boom deflection, which may lead to overloading. When
the load is just off the ground, stop the lifting operation and make sure there is no overloading, then

resume the lifting operation.

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 XCA160H All Terrain Crane Operation Manual

2. Operation of main winch (right lever)

Load (or main hook) up: pull the lever backward;

Load (or main hook) down: push the lever forward;

Stop: position the lever to neutral.

The speed of main winch system is controlled by the lever and accelerator pedal.

Ma
in h
ook
dow
n

Ma
in h
ook
up

Figure 3-29

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 XCA160H All Terrain Crane Operation Manual

3. Operation of auxiliary winch (left lever)

Press the telescoping/auxiliary winch selector switch and auxiliary winch switch on the human-

machine interaction control panel to enable auxiliary winch operation.

Load (or auxiliary hook) up: pull the lever backward;

Load (or auxiliary hook) down: push the lever forward;

Stop: position the lever to neutral.

The speed of auxiliary winch is controlled by the left lever and accelerator pedal.

Telescoping/auxiliary winch selector switch Auxiliary winch switch

wn
k do
oo
yh
iliar
Aux

up
ok
ho
y
ar
xili
Au

Figure 3-30

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 XCA160H All Terrain Crane Operation Manual

4. Free swing operation

In order to avoid side loading while the boom is lifting a load, press and hold the free swing button

on the control lever to activate the free swing function, and the free swing indicator lamp illuminates.

Then the boom will slew until its center of gravity aligns with that of the load. When the load is off the

ground, release the button, and the free swing indicator lamp goes out. Take the right control lever as an

example.

During lifting operation, press the free When the load is off the ground,
swing button to align the gravity center release the button.
of boom with that of the load.

SLIDE

Free swing indicator lamp

Figure 3-31 Free swing operation

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 XCA160H All Terrain Crane Operation Manual

3-7-2 Boom telescoping operation

1. Notes on operation

a. The hook block will rise or lower when the boom is extended or retracted. Compensate for this

by simultaneously letting out or taking in the winch rope to adjust the height between the hook block and

ground.

Do not increase the hydraulic oil temperature excessively.

b. Sufficiently lower the hook block before extending the boom.

c. Before extending the boom, make sure that the length of fully retracted boom shown on the

indicator of LMI is in the specified range.

● Prior to operation, ensure that there are no obstacles in the crane's working area and no persons in

the danger area. Give a short warning signal (honk) before starting a crane movement. Otherwise, injury

or death may be caused.

● Never extend your hand or head out of window during crane operation, otherwise casualty may be

caused.

e. Boom lateral bending due to sun exposure

If one side of boom is exposed to sunlight and the other side is not, the temperature difference

between the two sides will cause lateral bending of the boom, resulting in a decrease in lifting capacity.

When the crane lifts the max. load, especially under jib working condition, before lifting load, first check

the boom lateral curvature due to the sun exposure.

f. Before extending or retracting the boom with boom of 72.9 m + extension of 16 m + jib of 18.5

m and 30° offset angle, the boom should be raised to about 78°, and E01 fault alarm may occur when

luffing up, but it will not hinder the luffing up operation.

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 XCA160H All Terrain Crane Operation Manual

2. Operating method (left lever)

Prior to operation, make sure the “Telescoping/auxiliary winch selector switch” on the instrument

panel has not been pressed.

Figure 3-32 Telescoping/auxiliary winch selector switch

Before operating the lever, confirm that auxiliary winch working indicator lamp goes off. Failing to

do so will result in danger.

Boom out: push the lever forward;

Boom in: pull the lever backward;

Stop: position the lever to neutral.

The speed of boom extending and retracting is controlled by the lever and the accelerator pedal.

Boom extending and retracting operations are allowed only when no load is applied.

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 XCA160H All Terrain Crane Operation Manual

New single cylinder pinning telescoping system is adopted. Automatic and manual modes are

available for telescoping the boom.

a. Automatic mode

For the automatic mode, you only need to select a boom length telescoping code on the display, then

when you move the lever, the boom will extend or retract as configured automatically.

t
ou
m
Boo

in
om
Bo

Figure 3-33 Automatic telescoping mode

● When the automatic mode is adopted for extending or retracting the boom, observe the text

shown on display screen constantly. If the message “Telescopic cylinder pressure sensor fault, please

switch to manual mode” or “Telescopic cylinder pressure is too low, please switch to manual mode”

appears, it means that pressure sensor or the telescoping system is faulty, and automatic telescoping

operation will be stopped. At this time, please stop engine to check and remove trouble. Otherwise, there

is a risk of boom retracting or telescoping cylinder damage or other potential safety hazard.

● Extending the cylinder manually for building pressure is for emergency operation, which must

be done by a professional worker in such way that the safety of equipment and personnel is ensured.

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 XCA160H All Terrain Crane Operation Manual

Operating procedures under automatic mode:

1) The OM confirmation screen will be shown once the starter switch is turned on.

A screen for confirming OM is shown on the display after the display is powered on (see the

following figure). If the actual working condition is consistent with the one shown on the display, click

"√" to enter the main screen, click "×" to enter OM selection screen to reset.

Figure 3-34 OM confirmation screen

No. Name No. Name

1 Boom OM 2 Weight of counterweight
3 Outrigger span 4 OM code
5 Boom length 6 Boom telescoping combination
7 Parts of line 8 Code of boom telescoping combination
9 Buttons

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2) Main screen (crane monitoring screen)

The working conditions and crane state information while the crane is working are shown on the

main screen. On the left side of the screen, current crane operation information is shown: maximum lifting

capacity, actual lifting load, wind speed, boom length, radius, angle, height, etc. On the right side of the

screen, the cylinder pin/boom pin state, the actual and target telescoping percentage of each boom section

are shown.

Figure 3-35 Main screen

Area Function

1 Crane state information: indication of warning information

2 Operation data: indication of important parameters when crane is working

3 Lifting state information: indication of crane state information during lifting operation
Telescoping/outrigger/air conditioner: information for telescoping state, engine, outrigger state
4
and air conditioner, etc.
Buttons: from left to right, menu, mute, help, OM setting, telescoping combination, virtual
5
keyboard

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 XCA160H All Terrain Crane Operation Manual

3) Screen selection menu

Click at the lower left corner of the main screen, the screen selection menu will pop up.
Click the button to enter a related screen.

Figure 3-36 Screen selection menu

No. Function No. Function

1 Crane monitoring screen 2 OM setting
3 Professional diagnosis 4 Control interaction setting
5 Maintenance and service 6 Panel parameter adjusting
7 Intelligent boom 8 Help screen
9 System setting 10 Factory settings
11 Fault inquiry

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4) OM setting screen

Select OM setting screen in the screen selection menu or click the icon “×” on the OM

confirmation screen to enter the OM setting screen. Or click “ " on crane monitoring screen to
enter OM setting screen. As shown in the following figure.

Figure 3-37 OM setting screen

No. Explanation No. Explanation

1 OM information 2 OM code
3 Parts of line 4 Code of boom telescoping combination
5 Boom length 6 Boom telescoping combination
7 Graphic indication of OM 8 Telescoping combination selection
9 Load chart inquiry 10 Recommended OM

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 XCA160H All Terrain Crane Operation Manual

5) Parts of line setting screen

Click " " on OM setting interface to enter the following setting interface. The operator should click
numbers to set parts of line, and then click "OK" to exit.

Figure 3-38 Parts of line setting screen

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6) Telescoping combination selection screen

Click the icon “ ”on the crane monitoring screen to enter the screen for selecting
telescoping combination and telescoping mode, refer to the following figure.

Figure 3-39 Telescoping combination selection screen

Click needed telescoping combination in this interface, the code of combination selected may be
shown in the right column, manual telescoping is default; click "automatic boom extending" in the inferior

column, window information about whether it is automatic telescoping may pop up, click "confirm" to

enter automatic telescoping mode, and click “cancel” to exit.

When the setting of automatic telescoping is completed and the joystick is not in the neutral, the

automatic telescoping will start.

• Pull out the cylinder pin, select the position of boom that located at outermost layer, then insert

cylinder pin;

• Pull out the boom pin after inserting the cylinder pin. Extend or retract the boom to the required

position.

• The operation of other boom section is the same with above.

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 XCA160H All Terrain Crane Operation Manual

b. Manual mode

When the manual telescoping mode is selected, the cylinder pin and boom pin operations should be

done slowly and cautiously. After manual telescoping mode is selected, boom length telescoping code on

the display should be selected too. With the aid of “Cylinder/boom pin selector switch”, “Cylinder/

boom pin situation indicator lamp”, “Boom position indicator lamp”, “Indication of boom section

telescoping ratio”, and “Left lever”, the manual operation can be completed. Pull the left control lever

backward to retract the boom; push the left control lever forward to extend the boom.

Cylinder pin In/Out switch

Boom pin In/Out switch

Figure 3-40 Cylinder pin/boom pin selector switch

No. 1 cylinder head

(front cylinder head)

No. 2 cylinder head

(rear cylinder head)

Figure 3-41 Cylinder pin/ boom pin state

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 XCA160H All Terrain Crane Operation Manual

● Remove and insert the cylinder pins and boom pin slowly and cautiously.
● When extending the boom, first extend the last boom section (count from boom tail), and then
successively extend the rest boom sections.
● When retracting the boom, first retract the second boom section (count from boom ), and then
successively retract the rest boom sections.

The telescoping cylinder adopts double cylinder heads type. The rear cylinder head is the No.2
cylinder head and can extend the boom from 0% position to 46% position. The front cylinder head is the
No.1 cylinder head, which is located in the middle of the telescoping cylinder and can extend the boom
from 46% position to 92% or 100% position. The boom extending and retracting procedure is as shown in
Table 3-1.

Table 3-1 Boom extending and retracting procedure

Current Current Desired

Boom extending and retracting procedure
percentage cylinder head percentage

Extend the boom section to 46% position after the boom pin
0% No. 2 46% is retracted.
Extend each boom section to 46% position after the boom
pin is retracted, and then retract the cylinder pins and switch
0% No. 2 92% or 100% to the No.1 cylinder head to locate the current boom position,
and extend the boom section to 92% or 100% position after
the boom pin is retracted.

92% or 100% Extend the boom section to 92% or 100% position after the
46% No. 1 boom pin is retracted.
First retract the cylinder pins and switch to the No.1 cylinder
46% No. 2 92% or 100% head to locate the current boom position, retract the boom pin
and then extend the boom section to 96% or 100% position.
Extend the boom section to 100% position after the boom pin
92% No. 1 100% is retracted.
Retract each boom section to 46% position after the boom
pin is retracted, and then retract the cylinder pins and switch
92% or 100% No. 1 0% to the No.2 cylinder head to locate the current boom position,
and retract the boom section to 0% position after the boom
pin is retracted.
Retract the boom to 46% position after the boom pin is
92% or 100% No. 1 46% retracted.
First retract the cylinder pin and switch to the No.2 cylinder
46% No. 1 0% head to locate the current boom position, retract the boom
pin and then retract the boom to 0% position.
Retract the boom to 0% position after the boom pin is
46% No. 2 0% retracted.
Retract the boom to 92% position after the boom pin is
100% No. 1 92% retracted.

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 XCA160H All Terrain Crane Operation Manual

Extend boom sections:

a. Locate boom position in the forward direction: retract cylinder pins→extend cylinder to locate

boom position→insert the cylinder pins→retract boom pin→extend the boom section→insert the boom

pin

b. Locate boom position in the backward direction: retract cylinder pins→retract cylinder to locate

boom position→insert the cylinder pins→retract boom pin→extend the boom section→insert the boom

pin

Retract boom sections:

a. Retract the non-current boom section: retract cylinder pins→locate boom position→insert the

cylinder pins→retract boom pin→retract the boom section→insert the boom pin

b. Retract the current boom section: retract boom pin→retract the boom section→insert the boom pin

Example: assume the telescoping cylinder and boom are fully-retracted, the desired telescoping code

is "111000", i.e. the telescoping percentage of each boom section is as follows: T2:46%, T3:46%, T4:46%,

T5:0%, T6:0% and T7:0%.

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① First locate boom position in forward direction, and extend the 4th boom section from 0% position

to 46% position by using the No. 2 cylinder head:

Check the indication of cylinder Left and right cylinder pin indicator
pin and boom pin state lamps go off (cylinder pins unlocked)
Press the cylinder pin in/out switch
Pull out cylinder pin

T4 lamp comes on Move the left lever forward

Return left lever to neutral
Press the cylinder pin in/out switch

Locate boom position T4

0
46

Move the left lever Left and right cylinder pin indicator
forward/backward slowly lamp come on (cylinder pin locked)
Press the boom pin in/out switch
Insert cylinder pin Pull out boom pin

Boom telescoping ratio Boom pin indicator lamp goes

Move the left lever
Move the left lever forward off (boom pin unlocked)
is approaching 43% forward/backward slowly
45% 92%100%

Pull out T4
43 boom pin
Manual
T2 T3 T4 T5 T6 T7
Act 0 0 43 0 0 0
Aim 46 46 46 0 0 0

Move the left lever Boom pin indicator lamp comes on

forward/backward slowly (boom pin locked)

Press the boom pin in/out switch 46% of T4 boom

extending is
Insert boom pin finished. Locate
boom position
in backward
direction to
extend 46% of
T3 boom

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② Then locate boom position in backward direction. Locate the position of 3rd boom section by

using the No. 2 cylinder head and extend the 3rd boom section from 0% position to 46% position.

Left and right cylinder

Check the indication of cylinder pin indicator lamps go off
pin and boom pin state (cylinder pins unlocked)
46% of T4 boom Press the cylinder pin in/out switch
extending is
finished. Locate
boom position in
backward direction
to extend 46% of
T3 boom

Pull out cylinder pin

T3 lamp comes on Move the left lever backward

Return left lever to neutral

Press the cylinder pin in/out switch Locate boom

position T3
0
46

Move the left lever Left and right cylinder pin indicator
forward/backward slowly lamp come on (cylinder pin locked)

Insert cylinder Pull out boom pin Press the boom pin in/out switch
pin

Boom telescoping ratio Boom pin indicator lamp goes Move the left lever
is approaching 43% Move the left lever forward
off (boom pin unlocked) forward/backward slowly
45% 92%100%
Pull out T3
43 boom pin
Manual
T2 T3 T4 T5 T6 T7
Act 0 43 46 0 0 0
Aim 46 46 46 0 0 0

Move the left lever Boom pin indicator lamp

forward/backward slowly comes on (boom pin locked)

Press the boom pin in/out switch

Insert boom pin 46% of T3
boom extending
is finished

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③ Locate the position of 2nd boom section by using the No. 2 cylinder head and extend the 2nd

boom section to 46% position.

④ Retract 2nd boom section (assume cylinder pin/boom pin is located on 2nd boom section):

Boom pin indicator

Move the left lever lamp goes off (boom
forward/backard slowly pin unlocked)
T2 boom is Press the boom pin in/out switch Pull out
retracted first,
Assume cylinder boom pin
pin/boom pin is
located on T2 boom
section

Pull out T2 boom pin

Boom telescoping ratio
is approaching 2% Move the left lever backward
2% 92%100%
Press the boom pin in/out switch
2

Manual
T2 T3 T4 T5 T6 T7
Act 2 43 46 0 0 0
Aim 0 46 46 0 0 0

Move left lever forward/ Boom pin indicator lamp comes

backward slowly on (boom pin locked)

Insert boom pin Retraction of

T2 boom is
finished

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 XCA160H All Terrain Crane Operation Manual

⑤ Retract 2nd boom section (assume cylinder pin/boom pin is not located on 2nd boom section):

Check the indication Left and right cylinder

of cylinder pin and pin indicator lamps go off
boom pin state (cylinder pins unlocked)
T2 boom is
retracted first, Press the cylinder in/out switch
Assume cylinder
pin/boom pin is
not located on
T2 boom section

Pull out cylinder pin

T2 lamp comes on Move the left lever backward
Return left lever to neutral

Press the cylinder in/out switch Locate boom

position T2
0
0

Left and right cylinder

Move left lever forward/ pin indicator lamp come
backward slowly on (cylinder pin locked)
Pull out
Insert cylinder pin boom pin Retraction of
Repeat the
movements T2 boom is
in Step 4 finished

⑥ Repeat step 5 to retract 3rd and 4th boom sections.

During manual operation of removing pin, if "Telescoping cylinder pressure sensor failure,

insufficient telescopic cylinder pressure will likely cause boom damage! Do you use manual cylinder to

build pressure?” shown on display, please select "Y" and move left lever slightly so as to supplement

pressure for the large chamber. When the pressure setting is reached, the system is restored and the

operation of manually removing pin may be done. "N" may be selected in case of emergency. And it

must be done by a professional worker in such way that the safety of equipment and personal is ensured.

Otherwise, there is a risk of boom retracting or telescoping cylinder being damaged or other potential

safety hazard.

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3-7-3 Boom luffing operation

1. Notes on operation

a. Observe the boom angle limit.

b. Move the right lever slowly when starting and stopping boom motions.

● Prior to operation, ensure that there are no obstacles in the crane's working area and no persons

in the danger area. Give a short warning signal (honk) before starting a crane movement. Otherwise,

injury or death may be caused.

● Never extend your hand or head out of window during crane operation, otherwise casualty may

be caused.

2. Operating method (right lever)

Boom up: move the right lever leftward to raise the boom up;

Boom down:move the right lever rightward to lower the boom down;

Stop: position the lever to neutral.

The speed for raising the boom is jointly controlled by the lever and accelerator. The speed for

lowering the boom is controlled only by the lever, and the engine speed is irrelevant.

3. Relationship among boom angle, total rated load and working radius

When the boom is lowered, the working radius increases and the value of the total rated load

decreases; when the boom is raised, the working radius decreases and the value of the total rated load

increases.

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 XCA160H All Terrain Crane Operation Manual

n
m dow
Boo

p
mu
Boo

Figure 3-42 Boom luffing operation

● When the boom is lowered, the working radius will increase and overloading may occur.

Therefore, pay close attention and avoid overloading during boom luffing down.

● The boom must not be raised or lowered beyond the limits stated on the range diagrams or into

areas of the load chart where no capacities are listed, otherwise forward or backwards tipping may occur.

● Before lowering the boom for jib erection and rope re-reeving, extend the outriggers fully first.

Then fully retract the boom and luff down. After the required work is completed, raise the boom and

extend it to the desired length.

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3-7-4 Slewing operation

1. Notes on operation

a. Before slewing operation, check and make sure that the lateral span of outriggers is within the

specified value shown in the rated load charts.

b. Make sure there is enough space for operation.

c. Before slewing operations, release the turntable locking device and press the slewing brake release

switch.

d. Move the control lever slowly when starting and stopping slewing operation.

e. Turn off the slewing brake release switch when slewing operation is not to be performed.

● Prior to operation, ensure that there are no obstacles in the crane's working area and no persons in

the danger area. Give a short warning signal (honk) before starting a crane movement. Otherwise, injury

or death may be caused.

● Never extend your hand or head out of window during crane operation, otherwise casualty may be

caused.

● Never drag a load through slewing operations. Otherwise, crane damage or accidents may happen.

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2. Operating method (left lever)

● Prior to operation, make sure that the turntable locking device has been unlocked and slewing

brake release indicator lamp illuminates.

● When the control lever is returned to neutral to stop the slewing operation, the turntable will

continue to rotate due to inertia. Therefore, slow down in advance when approaching the intended

position.

Figure 3-43 Slewing brake release switch

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 XCA160H All Terrain Crane Operation Manual

Slew rightward: move the left lever rightward;

Slew leftward: move the left lever leftward;

Stop: position the lever to neutral.

The slewing brake foot pedal may be used for braking.

The slewing speed is controlled by the control lever and accelerator pedal.

Slew
ing to
the le
ft

Slew
ing to
the ri
ght

Slewing operation (left lever)

Figure 3-44 Slewing operation

Never move the control lever fast or abruptly start or stop the slewing operation. Otherwise, the hook

block and the load will swing out of control. Always smoothly start or stop the slewing operation. Move

the control lever slowly to keep the load in control.

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3-7-5 Simultaneous movements

Simultaneous movements listed in the table below are permissible. During crane operation, various

permissible combined movements should be done carefully. Always operate the crane in the permissible

ranges. The following must be observed:

1. Simultaneous movements are permissible only when the load applied to one part of line is less

than 30% of designed single line capacity and the total load is less than 15 t.

2. Slewing operation may be carried out simultaneously with main or auxiliary winch, or luffing

operation.

3. Main winch may be operated simultaneously with luffing or telescoping operation. During

telescoping operation, no load is allowed to be applied.

4. Auxiliary winch may be operated simultaneously with luffing operation.

5. Telescoping operation may be carried out simultaneously with main winch (no load). Never

perform telescoping operation simultaneously with other movements under any other working conditions.

6. It is not allowed to simultaneously operate the main winch and auxiliary winch.

Movements Main winch Auxiliary winch Luffing Telescoping Slewing

Main winch √ √ √
Auxiliary winch √ √
Luffing √ √ √
Telescoping √
Slewing √ √ √ √

● During simultaneous operation, move the control levers slowly, otherwise there are danger and

potential safety hazard.

● Switching of simultaneous operation should be done when the engine runs at idle speed. If it is

done while accelerating, it is easy to generate pressure shock.

● Make sure that the turntable lock pin has been released before performing simultaneous

movements that involve the slewing operation.

● During simultaneous movements, the pressure required by every movement varies. When the

pressure difference is large (greater than 8 MPa), it will lead to unstable movements, or simultaneous

operation is impossible.

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● Never press high speed switch during simultaneous operation, otherwise, simultaneous operation

is impossible or abrupt speed change will cause the crane to shake.

● Telescoping operation may only be carried out simultaneously with main winch. Never perform

telescoping operation simultaneously with other movements. Otherwise there is risk of overturning.

● If the load applied to one part of line is more than 30% of designed single line capacity or the

total load is more than 15 t, performing combined movement may result in engine shutdown or crane

shaking due to too large load power required.

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3-7-6 Operation of turntable locking device

The turntable locking device consists of a locking pin and the turntable. It is the safety device to

fix superstructure by the lock pin when the turntable is at 0°(forward direction of crane) and 180°

positions.

1. Notes on operation

a. Prior to traveling, secure the turntable and frame with the turntable locking device.

b. Slowly move the control lever of the turntable locking device, and it is better to move the control

lever with the engine at idle.

2. Operating method

The turntable lock pin is controlled through a flexible shaft.

Control lever of turntable locking device

Position limit slot

Figure 3-45 Turntable locking device

The control lever of turntable locking device is located in the operator's cab. Pull the control lever of

turntable locking device backward to lock the turntable with the frame. Push the control lever forward to

unlock the turntable.

● Always secure the turntable with the turntable lock pin before lifting and lowering the

counterweight slabs.

● Make sure the turntable is unlocked before slewing operations.

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3-7-7 Tilt the operator’s cab

1. Notes on operation

a. Tilt the operator's cab slowly, and keep the engine running at idle speed.

b. The operator's cab should be in level state during traveling.

2. Operating method

On the main screen, press " " to enter the screen selection menu, then press " Virtual
虚拟面板 panel " to

enter virtual panel, use "Operator's cab tilting up" and "Operator's cab tilting down" switches to control

the operator's cab, as shown in the figure.

The operator’s cab has a maximum tilting angle of 20°.

Operator's cab tilting up

Operator's cab tilting down

Figure 3-46 Operator's cab tilting up and down switches

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