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