SUNWARD SWTC5D Manual

Operation & Maintenance Manual
Original Instructions
SWTC5D
CRAWLERCRANE
Sunward Intelligent Equipment Co.,Ltd.

Improper use of this machine can lead to
serious accidents.

Before operating/inspecting/maintaining the
machine, the operator and maintenance
personnel must read carefully this manual and
completely understand its contents.

Foreword
Sunward works out this operator’s manual for effectively using and maintaining your
machine.
Read this manual carefully before operating the machine which helps to accomplish your
task, otherwise the machine will be damaged and unsafe.
This manual should be considered as a permanent part of your machine and should remain
with machine at all time. If this machine is transferred or sold, please transfer this manual
together.
This machine is designed by metric system, all the dimension in the manual is in line with
the metric system. Please only use the stated parts and tools.
The definition for left side and right side of the machine: Assuming the operator face the run
way of machine, the cab is on the left side of machine, right side is the symmetry parts. The
driving wheel of the carriage is at the backside.
Please fill in the “machine code” column of this manual. Correct code records will be
convenient for looking up in the future. The dealers also need those codes when ordering parts or
components. If you keep the manual in the machine, please keep those codes in the archive safely
at the same time.
Sunward guarantees the maintenance of the machine for clients. References are illuminated
from the certificate that you get from the dealers.
The guarantee certificate makes sure the machine purchased from Sunward will get free and
local service in normal situation. If the machine is abused by user, or has been changed beyond
the rules of Sunward, or been overloaded, guarantee will be invalid and local service will be
refused.
Only trained, qualified and experienced personnel shall be permitted to operate, inspect and
maintain this machine.
The important safety items has been contained in the “safety” part of this manual, users must
read them carefully and know the safety rules and suggestions, obey the safety rules of operation.
All data, charts and specifications are the latest information when they are published.
Sunward reserves the right to make modifications or amendments of any nature without prior
notification.

EC DECLARATION OF CONFORMITY
For the following machinery:
Product name: Crawler crane
Model/serial No.: SWTC5DS00131
is herewith confirmed to fulfill all the relevant provisions of Machinery Directive
(2006/42/EC) and the following harmonized standards have been complied with:
-EN 60204-32:2008;
-EN 13000:2010+A1:2014;
Responsible for marking this declaration is the:
Manufacturer Authorized representative established within the EU □
Manufacture’s Name
:
SUNWARD INTELLIGENT EQUIPMENT CO.,LTD.
Manufacturer’s Address:
:
No.16 Lixiang Road(M), Xingsha, Changsha, Hunan 410100,
P.R. China
Authorized Rep’s Name
:
Authorized Rep’s Address
:
Person responsiblefor compiling the technical files established within the EU
Name, Surname
:
Address
:
Person responsible for making this declaration
Name, Surname
:
Guo Qing
Position/Title
:
Certification Engineer

Information on the serial number and your sales service agency
Machine Serial Number
Engine serial number
Agency Name
Address
Telephone
Service person in Charge

CONTENTS
FOREWORD ..............................................................................................................................................................2
MANUFACTURER AUTHORIZED REPRESENTATIVE ESTABLISHED WITHIN THE EU □......................................3
MANUFACTURE’S NAME ..........................................................................................................................................3
AUTHORIZED REP’S NAME........................................................................................................................................3
AUTHORIZED REP’S ADDRESS ...................................................................................................................................3
PERSON RESPONSIBLE FOR COMPILING THE TECHNICAL FILES ESTABLISHED WITHIN THE EU..................................3
NAME, SURNAME.....................................................................................................................................................3
ADDRESS...................................................................................................................................................................3
PERSON RESPONSIBLE FOR MAKING THIS DECLARATION.........................................................................................3
NAME, SURNAME.....................................................................................................................................................3
POSITION/TITLE ........................................................................................................................................................3
INFORMATION ON THE SERIAL NUMBER AND YOUR SALES SERVICE AGENCY.................................................................................... 4
MACHINE SERIAL NUMBER.......................................................................................................................................4
ENGINE SERIAL NUMBER ..........................................................................................................................................4
AGENCY NAME .........................................................................................................................................................4
ADDRESS...................................................................................................................................................................4
TELEPHONE...............................................................................................................................................................4
SERVICE PERSON IN CHARGE ....................................................................................................................................4
1 SAFETY RULES ........................................................................................................................................................1
1.1 GENERAL SAFETY RULES.................................................................................................................................................. 2
1.1.1 Obey safety rules............................................................................................................................................ 2
1.1.2 Understand safety label................................................................................................................................. 2
1.1.3 Emergency protection.................................................................................................................................... 9
1.1.4 Protective articles........................................................................................................................................... 9
1.1.5 Safety Equipment........................................................................................................................................... 9
1.1.6 Keep machine clean ....................................................................................................................................... 9
1.1.7 Check before starting operation .................................................................................................................. 10

1.1.8 Instructions of cabin entry............................................................................................................................ 10
1.1.9 Mounting and dismounting ......................................................................................................................... 10
1.1.10 Adjusting operator’s seat........................................................................................................................... 11
1.1.11 Fasten safety belt....................................................................................................................................... 11
1.1.12 Secure perfect visibility............................................................................................................................... 11
1.1.13Leave operator’s seat.................................................................................................................................. 11
1.1.14 Emergency exit........................................................................................................................................... 11
1.1.15 Prohibit passenger ..................................................................................................................................... 12
1.1.16 Worksite safety .......................................................................................................................................... 12
1.1.17 Operation around loosened area............................................................................................................... 12
1.1.18 Signals and gestures from flagman........................................................................................................... 12
1.1.19 Be away from power lines ......................................................................................................................... 13
1.1.20Scalds Prevention ........................................................................................................................................ 13
1.1.21 Stay away from driven parts...................................................................................................................... 14
1.1.22 Prevent fire and explosion.......................................................................................................................... 14
1.1.23Fire management........................................................................................................................................ 14
1.1.24 Prevent fly-out or falling object ................................................................................................................. 15
1.1.25 Prevent fly-out parts .................................................................................................................................. 15
1.1.26 Avoid inhaling asbestos dust ..................................................................................................................... 15
1.1.27 Be cautious not to inhale exhaust gas....................................................................................................... 15
1.1.28 Safety rules for high pressurized fluid........................................................................................................ 16
1.1.29 Safe disposal of fluid .................................................................................................................................. 16
1.1.30 Chemical disposal....................................................................................................................................... 16
1.1.31 Safe disposal of waste material................................................................................................................. 17
1.1.32Prohibit unauthorized modification to machine ........................................................................................ 17
1.1.33 Noise reduction .......................................................................................................................................... 17
1.2SAFE OPERATION INSTRUCTIONS......................................................................................................................... 17
1.2.1 Check before starting engine. ...................................................................................................................... 17
1.2.2 Proper engine start....................................................................................................................................... 18
1.2.3 Start engine in cold weather........................................................................................................................ 18
1.2.4Safety evaluation before operation the machine......................................................................................... 19
1.2.5 Safe operation .............................................................................................................................................. 19
1.2.6 Operation on slopes ..................................................................................................................................... 20
1.2.7 Operation in snowy days.............................................................................................................................. 20

1.2.8Avoid tipping over ......................................................................................................................................... 21
1.2.9 Avoid accidents during swing and reversing ............................................................................................... 21
1.2.10 Avoid runaway accident............................................................................................................................. 22
1.2.11Machine movement.................................................................................................................................... 22
1.2.12 Parking machine......................................................................................................................................... 23
1.2.13Things not allowed during operation ......................................................................................................... 23
1.3 SAFETY MAINTENANCE INFORMATION............................................................................................................................. 24
1.3.1 Use warning signs ........................................................................................................................................ 24
1.3.2 Park the machine prior to service ................................................................................................................ 24
1.3.3 Safety maintenance rules............................................................................................................................. 24
1.3.4 Use hammer................................................................................................................................................. 25
1.3.5 Welding and grinding precautions .............................................................................................................. 26
1.3.6 Avoid heating pipeline containing flammable gas...................................................................................... 26
1.3.7 Avoid heating around hydraulic pressure pipeline...................................................................................... 26
1.3.8 Remove paint prior to welding or heating operation.................................................................................. 26
1.3.9 Accessories ................................................................................................................................................... 27
1.3.10 Maintenance precaution of track tension mechanism ............................................................................. 27
1.3.11 Safety rules for high pressure oil................................................................................................................ 28
1.3.12 Safe operation of high-pressure hoses ...................................................................................................... 28
1.3.13 Accumulator............................................................................................................................................... 28
1.3.14 Prevent accumulator explosion ................................................................................................................. 29
1.3.15 Fire prevention ........................................................................................................................................... 29
1.3.16 Waste disposal ........................................................................................................................................... 30
2 TRANSPORTATION AND STORAGE.......................................................................................................................32
2.1GENERAL TRANSPORTATION INSTRUCTION....................................................................................................... 32
2.2FIX MACHINE ......................................................................................................................................................... 32
2.3 ASSEMBLY AND DISASSEMBLY........................................................................................................................................ 33
2.3.1 Dimension and weight of main parts .......................................................................................................... 33
2.3.2 Steps of hoisting the machine...................................................................................................................... 34
2.3.3 Dimension..................................................................................................................................................... 34
2.3.4 Hoisting method........................................................................................................................................... 35
2.4 Storage ............................................................................................................................................................ 36
2.4.1 Park and storage of crane............................................................................................................................ 36

2.4.2 Park in the garage and its storage............................................................................................................... 36
2.4.3 Park in the open air and its storage............................................................................................................. 36
3 MACHINE ILLUSTRATION .....................................................................................................................................38
3.1 MODEL NUMBER AND ITS MEANING ............................................................................................................................... 38
3.2 SERVICE ENVIRONMENT................................................................................................................................................ 38
3.3 PERFORMANCE PARAMETER.......................................................................................................................................... 39
3.3.1 Main Performance parameter form............................................................................................................ 39
3.3.2 Lifting Weight and Height Parameter Chart ............................................................................................... 41
3.3.3Lifting height curve........................................................................................................................................ 43
3.3.4 Outline dimension ........................................................................................................................................ 44
3.3.5 Information Concerning Hand/Arm Vibration Level ................................................................................... 44
3.4 Design features................................................................................................................................................ 44
3.4.1 Chassis .......................................................................................................................................................... 45
3.4.2Turntable assembly....................................................................................................................................... 47
3.4.3 Cab................................................................................................................................................................ 47
3.4.4Swing bearing................................................................................................................................................ 48
3.4.5 Swing structure............................................................................................................................................. 48
3.4.6 Lifting hook assembly................................................................................................................................... 49
3.4.7 Boom............................................................................................................................................................. 49
3.4.7.1 Main Boom................................................................................................................................................ 49
3.4.7.5 Auxiliary jib............................................................................................................................................... 53
3.5HYDRAULIC SYSTEM .............................................................................................................................................. 55
3.5.1Travel system................................................................................................................................................. 56
3.5.2 Work system................................................................................................................................................. 56
3.5.3 Lifting structure ............................................................................................................................................ 57
3.5.4 Telescopic mechanism ................................................................................................................................. 58
3.5.5 Derricking structure...................................................................................................................................... 59
3.5.6 Central swivel joint....................................................................................................................................... 59
3.5.7 Combination control valve........................................................................................................................... 59
3.6POWER SYSTEM........................................................................................................................................................... 61
3.7 ELECTRIC SYSTEM ........................................................................................................................................................ 61
3.8 AIR CONDITIONING SYSTEM........................................................................................................................................... 62
3.9SAFETY DEVICE..................................................................................................................................................... 62

3.9.1 Constitution of safety device........................................................................................................................ 63
3.9.2 Function of safety device.............................................................................................................................. 64
3.10ELECTRICAL MONITOR METER ......................................................................................................................... 65
3.10.1 Construction Vehicle Monitor Meter......................................................................................................... 66
3.10.2 Moment-limiter monitor Meter................................................................................................................. 68
4 OPERATION AND USAGE OF CRAWLER CRANE ....................................................................................................68
4.1PREPARATION ....................................................................................................................................................... 68
4.2NOTICE FOR OPERATOR....................................................................................................................................... 69
4.3OPERATION NOTES............................................................................................................................................... 71
4.4CONTROL DEVICE................................................................................................................................................. 72
4.4.1 Start-up engine............................................................................................................................................. 74
4.4.2Run engine..................................................................................................................................................... 74
4.4.3 Flameout the engine .................................................................................................................................... 75
4.4.4Crawler crane operation ............................................................................................................................... 75
4.4.5Operation in cold weather ............................................................................................................................ 76
4.4.6 Safety device operation................................................................................................................................ 78
4.4.7 Electronic switch operation.......................................................................................................................... 80
4.4.8 Electronic monitor meter operation ............................................................................................................ 89
4.5 AIR CONDITIONER ....................................................................................................................................................... 95
4.5.1 Basic form..................................................................................................................................................... 95
4.5.2 Basic operations ........................................................................................................................................... 95
4.5.3 Special operations ........................................................................................................................................ 96
4.5.4 Other instructions......................................................................................................................................... 98
4.5.5 Warning........................................................................................................................................................ 98
4.6 RADIO .................................................................................................................................................................. 104
4.6.1 Functions of panel ...................................................................................................................................... 104
4.6.2 Performance index ..................................................................................................................................... 105
4.6.3 Operating instructions................................................................................................................................ 105
5 MAINTENANCE AND SERVICE ............................................................................................................................108
5.1MAINTENANCE FOR CRAWLER CRANE.............................................................................................................. 108
5.1.1 Every day or 8 working hours maintenance.............................................................................................. 108
5.1.2 Every week or 50 working hours maintenance ......................................................................................... 108
5.1.3 Every half month or 100 working hours maintenance.............................................................................. 108

5.1.4 Every month or 250 working hours maintenance..................................................................................... 108
5.1.5 Every 500 working hours maintenance ..................................................................................................... 109
5.1.6 Every six months or 1000 working hours maintenance ............................................................................ 109
5.1.7Every year or 2000 working hours maintenance ....................................................................................... 109
5.1.8Engine maintenance ................................................................................................................................... 109
5.1.9Maintenance for long-term parking........................................................................................................... 110
5.1.10 Maintenance after long-term parking..................................................................................................... 110
5.2LUBRICATION...................................................................................................................................................... 111
5.3EXAMINATION DURING OPERATION.................................................................................................................. 111
5.4HYDRAULIC SYSTEM MAINTENANCE................................................................................................................. 112
5.5REFUEL TYPES AND CRITERIA........................................................................................................................... 113
5.6SAFETY DEVICE MAINTENANCE AND ADJUSTMENT.......................................................................................... 114
5.6.1 Maintenance content................................................................................................................................. 114
5.6.2Adjustment of length sensor....................................................................................................................... 114
5.6.3Adjustment of angle sensor ........................................................................................................................ 114
5.6.4 Continuous ringing of buzzer ..................................................................................................................... 114
5.6.5Length-measuring cable retract unsmooth................................................................................................ 114
5.6.6 Overload test .............................................................................................................................................. 115
5.7FAILURE AND SOLUTIONS OF CRAWLER CRANE .............................................................................................. 115
6 MANUFACTURER INFORMATION.......................................................................................................................119
Annex A Spare Parts list of SWTC5D ................................................................................................................ 120
Annex B Certificate for Stretching Wire Rope.................................................................................................. 122
Annex C Technical Specification of Hook Block ............................................................................................... 123
Annex D Tool list............................................................................................................................................... 124
Annex E Typical shapes and corresponding Cw values ................................................................................... 125
Annex F Wind speed as a function of elevation............................................................................................... 126
Annex G Common bolts tighten torque........................................................................................................... 127

1
1 Safety rules
WARNING
Please thoroughly read and completely understand all
precautions described in this manual or safety labels. Follow all the
instructions when operating or servicing this machine.

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1.1 General safety rules
1.1.1 Obey safety rules
Thoroughly read, understand and follow all the safety
precautions and procedures stated in this manual.
Regularly fix, maintain and renew the safety labels to keep them
legible, conspicuous and firmly fixed all the time.
In case the safety label or manual is damaged or lost, please
contact with us or our authorized distributor to order new ones
(when ordering, please specify machine model, and serial No.)
Learn how to operate the machine and its controlling devices
properly and safely.
Only trained and qualified personnel shall be permitted to operate
this machine.
Keep machine in good working condition.
Unapproved modification on this machine can impair its function,
shorten the service life and jeopardize personal safety.
Note: all safety information described in this section covers only
the basic safety information of this machine. It is not possible to
predict every circumstance which might involves potential hazards.
It is necessary to ask for instructions from your superior or
Sunward, or appointed dealers before attempting any operations or
maintenance procedures.
1.1.2 Understand safety label
1.1.2.1 Safety mark
The right mark reminds operator of safety, when you see this mark
on the machine or in the manual book, it indicates that the human
body is in danger of injury.

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1.1.2.2 Safety label
Different safety labels containing safety messages are located in
different position. All messages of safety are identified by words
“DANGER”, “WARNING”and “CAUTION”(see fig).Their
significations are as follow:
DANGER ---indicates an imminent hazard, if not avoided, will
result in death or serious injury.
WARNING---indicates a potential hazard, if not avoided, could
result in death or serious injury.
CAUTION---indicates a potential hazard. If not avoided, may
result in minor or moderate injury.
Label of “DANGER”“WARNING”and “CAUTION”are
placed in specific position in which involves a possible hazard.
General safety related items are listed on “CAUTION”labels. In this
manual, “CAUTION”may also be used to remind the safety
instructions.
1.1.2.3Other Safety messages
There are several specific safety messages on this machine. The
exact location of the hazards and the description of the hazards are
reviewed in this section. Please become familiarized with all safety
messages.
Make sure that all of the safety messages are legible. Clean the
safety messages or replace the safety messages if you cannot read the
words. Replace the illustrations if the illustrations are not legible.
When you clean the safety messages, use a cloth, water and soap. Do
not use solvent, gasoline, or other harsh chemicals to clean the safety
messages. Solvents, gasoline, or harsh chemicals could loosen the
adhesive that secures the safety message. Loose adhesive will allow
the safety message to fall.
Replace any safety message that is damaged, or missing. If a

Operation &Maintenance Manual of SWTC5D
4
safety message is attached to a part that is replaced, install a safety
message on the replacement part. Any Caterpillar dealer can provide
new safety messages.

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1.
2.

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3.
4.
5.

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6.
7.
8.
9.

Operation &Maintenance Manual of SWTC5D
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10.
11.
12.

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1.1.3 Emergency protection
Be cautious of fire and accidents: make sure there are fire
extinguishers ready for emergency, thoroughly read and
understand all instructions on fire extinguisher and know how to
operate it.
Regular maintenance and inspection procedures to make sure fire
extinguisher are available at all times.
A first-aid kit should be ready for emergency. Be sure that all
drugs are in effective period.
Be well-prepared to have access to the contacts of doctor,
ambulance, hospital and fire brigade. Take notes of their
telephone numbers for emergency cases.

1.1.4 Protective articles
Do not wear accessories or loose clothing. Always wear tight
fitting clothing and protective articles suited for operation.
Include the following items:
Close fitting clothing
Hard hat
Thick gloves
Protective glasses, goggles or face shield.
Mask or filter face shield
Ear plug or ear shield
Safety belt and rainproof.
1.1.5 Safety Equipment
Make sure that all guards and covers are properly positioned.
Repair immediately if they are damaged.
Understand how to use safety devices properly.
Never remove any safety devices, keep them in good operating
condition.
1.1.6 Keep machine clean
Keep engine, radiator, accumulator, hydraulic pipe, fuel tank, cab
clean.
After stopping engine, the surrounding temperature of engine may
go up and cause fire. At this moment, you can open access door,
make engine cool and clean the engine room.
Do not use water or water vapor to flush electrical circuit or
connector of machine to avoid electrical system failure.
Remove all mud, oil dirt and other foreign matter in time. Keep
machine clean at all time.

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1.1.7 Check before starting operation
Inspection and refilling of cooling water
Inspection and refilling of oil in the engine oil pan
Inspection and refilling of fuel
Inspection and refilling of oil in the hydraulic oil tank
Inspection of dust indicator
Inspection of water separator
Inspection of electrical wires
Inspection of horn and headlight functions
Inspection of winch and boom operations
Inspection of moment limiting device
Above instructions for the relevant inspections also should be strictly
followed after a maintenance or repair.
1.1.8 Instructions of cabin entry
Remove all mud, oil adhered to your shoes prior to access into
cab. Or not, your foot may slip and cause serious accidents.
Do not leave parts or tools around operator’s console.
Do not store flammable and explosive items in cab.
Do not use radio or cell phone during operation.
Do not place transparent bottles and other convex stuff in cab to
prevent fire as a result of solar light focusing.
Do not leave lighter in cab. There is a possibility that the lighter
may explode along with the increase of temperature.
1.1.9 Mounting and dismounting
Always face the machine, maintain a secure three point contact to
mount or dismount machine by means of steps or handrails to
avoid falling off.
Do not grip any control levers as a substitute of handrails to
mount or dismount the machine.
Keep all handrails, gangway clean and free of oil and mud to
prevent slip.
Never mount or dismount the machine while it is swinging or
lifting cargo.
Do not mount or dismount machine while holding tools in your
hands.