Page 1 Operation & Maintenance Manual Original Instructions SWTC5D CRAWLERCRANE Improper use of this machine can lead to  serious accidents. Before operating/inspecting/maintaining  machine, operator maintenance personnel must read carefully this manual and completely understand its contents. Sunward Intelligent Equipment Co.,Ltd.
Page 2: Foreword
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.
Page 3: Manufacturer  Authorized Representative Established Within The Eu
(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 □ SUNWARD INTELLIGENT EQUIPMENT CO.,LTD. Manufacture’s Name No.16 Lixiang Road(M), Xingsha, Changsha, Hunan 410100, Manufacturer’s Address: P.R. China Authorized Rep’s Name...
Page 4: Information On The Serial Number And Your Sales Service Agency
Information on the serial number and your sales service agency Machine Serial Number Engine serial number Agency Name Address Telephone Service person in Charge...
Page 5: Table Of Contents
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 ..............................
Page 6 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 .............................
Page 7 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 S ..........................24 AFETY MAINTENANCE INFORMATION 1.3.1 Use warning signs ............................
Page 8 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 M ..........................38 ODEL NUMBER AND ITS MEANING 3.2 S ..............................38 ERVICE ENVIRONMENT 3.3 P ............................
Page 9 3.9.1 Constitution of safety device ........................63 3.9.2 Function of safety device ..........................64 ......................... 65 3.10 E LECTRICAL MONITOR METER 3.10.1 Construction Vehicle Monitor Meter ......................66 3.10.2 Moment-limiter monitor Meter ......................... 68 4 OPERATION AND USAGE OF CRAWLER CRANE ....................68 ...............................
Page 10 AILURE AND SOLUTIONS OF RAWLER CRANE 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 ...................
Page 11: Safety Rules
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.
Page 12: General Safety Rules
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...
Page 13 Operation &Maintenance Manual of SWTC5D 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.
Page 14 Operation &Maintenance Manual of SWTC5D 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.
Page 15 Operation &Maintenance Manual of SWTC5D...
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Page 18 Operation &Maintenance Manual of SWTC5D...
Page 19: Emergency Protection
Operation &Maintenance Manual of SWTC5D 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.
Page 20: Check Before Starting Operation
Operation &Maintenance Manual of SWTC5D 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 ...
Page 21: Adjusting Operator's Seat
Operation &Maintenance Manual of SWTC5D  Do not jump on or off the machine. 1.1.10 Adjusting operator’s seat A comfortable posture can alleviate operator’s fatigue. You may adjust seat for your comfort in relation to your weight, height and arm length.
Page 22: Prohibit Passenger
Operation &Maintenance Manual of SWTC5D available in the left-back side of seat. And use it as an alternative exit way for emergency. 1.1.15 Prohibit passenger  When machine is in the process of operation or traveling, do not allow anyone to ride on the machine except the operator. Because there is a hazard that passengers may fall off or get hit by foreign objects.
Page 23: Be Away From Power Lines
Operation &Maintenance Manual of SWTC5D loosened ground. Provide a flagman if necessary. Operator must pay much attention to caution plates and follow flagman’s instruction.  Use only one flagman to instruct.  Make sure all signals and gestures are understood by the personnel prior to operation.
Page 24: Stay Away From Driven Parts
Operation &Maintenance Manual of SWTC5D  The engine oil, gear oil, hydraulic oil will get hot when the machine is working, and engine, hose, pipe and other parts will get hot too, please pay attention to scalds prevention. 1.1.21 Stay away from driven parts ...
Page 25: Prevent Fly-Out Or Falling Object
Operation &Maintenance Manual of SWTC5D 1.1.24 Prevent fly-out or falling object  Wear protection glasses or goggles to avoid injury resulting from fly-out and falling object(such as metal particles or sand rock)  When hitting object, make sure nobody is around and clear the working area so as to avoid accidents ...
Page 26: Safety Rules For High Pressurized Fluid
Operation &Maintenance Manual of SWTC5D 1.1.28 Safety rules for high pressurized fluid  High pressurized fluid can penetrate skin which leads to severe injury  Always release pressure before separating fluid or other pipelines  You may release pressure by means of operating control lever ...
Page 27: Safe Disposal Of Waste Material
1.1.32Prohibit unauthorized modification to machine  Any unauthorized modification to machine may involve hazards.  SUNWARD disclaim any responsibility for the damages, injuries or accidents caused by unauthorized modification. 1.1.33 Noise reduction  When the machine is running, it will generate a certain level of noise at nearby.
Page 28: Proper Engine Start
Operation &Maintenance Manual of SWTC5D Check seat belt or mounting clamp if it is damaged or worn out.  Check meters to ensure they are functioning properly. Check working lamp angle. Make sure control levers are at neutral position.  Check safe lock control levers to ensure they are in LOCK (UP) position before starting engine.
Page 29: 4Safety Evaluation Before Operation The Machine
Operation &Maintenance Manual of SWTC5D different power source to start the engine, which may cause battery to be ignited.  Melt battery electrolyte and check electrolyte in case of leakage or freezing before charging battery or using different power source to start machine.
Page 30: Operation On Slopes
Operation &Maintenance Manual of SWTC5D and overhead barrier.  Some kind of combined movements is permitted, the others are prohibited. For example, hoisting the load, at the same time swing the platform. You must be careful when conduct combined movements of crane. You need operate the machine slowly in case of accident.
Page 31: 8Avoid Tipping Over
Operation &Maintenance Manual of SWTC5D 1.2.8Avoid tipping over Do not attempt to jump off a tipping over machine. This may cause severe accidents of injury and death. Machine will tip over before you jump off the machine. Fasten seat belt.
Page 32: Avoid Runaway Accident
Operation &Maintenance Manual of SWTC5D  Understand all flags ， signs and signals being used during operation. Select the person who is in charge of sending signals.  Keep windows, mirrors and lights fittings clean and in good condition.  In case of improper visibility arising from dust, rain, or fog etc., use appropriate lighting devices.
Page 33: Parking Machine
Operation &Maintenance Manual of SWTC5D  Before traveling or swinging, ring the horn and alert other people.  Bypass any obstacles during traveling.  When traveling, swinging, operating boom in confined area, set a signalman and define the meaning of the signals beforehand.
Page 34: Safety Maintenance Information
Operation &Maintenance Manual of SWTC5D 1.3 Safety maintenance information 1.3.1 Use warning signs During maintenance or service procedure, any attempt to start the engine, have access or to operate control lever of working device can result in serious injury or damage.
Page 35: Use Hammer
Operation &Maintenance Manual of SWTC5D  Keep body away from reaching driven parts of the machine.  If the maintenance procedure has to be carried out when engine is running, set a person in operator seat to stop the engine at any moment.
Page 36: Welding And Grinding Precautions
Operation &Maintenance Manual of SWTC5D 1.3.5 Welding and grinding precautions  Welding operation can generate flame and gas. Therefore, operation must be carried out in well-ventilating area with complete preparation.  Store flammable substance in safe place prior to welding operation.
Page 37: Accessories
Operation &Maintenance Manual of SWTC5D  Carry out painting operation outdoors or in ventilating area. Dispose of paint solvent properly.  Remove paints prior to welding or heating operation.  When using grinder or sand paper to remove paints, always wear proper respirator to avoid inhaling dust.
Page 38: Safety Rules For High Pressure Oil
If you find any loosed bolts, stop working and tighten the bolts to the specified torque. If you find any damaged hoses, stop operations immediately and contact your SUNWARD distributor. Such as: Damaged hose, deformed mouthpiece, damaged o-ring. ...
Page 39: Prevent Accumulator Explosion
 Do not drill holes, weld or welding torch on accumulator.  Do not hit or roll accumulator to avoid any shock on it.  When handling accumulator, bleed the air.  Please contact SUNWARD dealer to get assistance with these works. 1.3.14 Prevent accumulator explosion ...
Page 40: Waste Disposal
Operation &Maintenance Manual of SWTC5D oil shooting up. Tighten, repair, or replace any loosen clamps, pipes, hoses, oil cooler, and flange bolts of oil cooler. Don’t twist or knock on high-pressured pipe. Don’t assemble twisted or damaged pipeline or hose.
Page 41 Operation &Maintenance Manual of SWTC5D Related laws and codes should be obeyed when discharging  harmful sewage such as oil, fuel, coolant, solvent, filters, and batteries.
Page 42: Transportation And Storage
Operation &Maintenance Manual of SWTC5D 2 Transportation and Storage General transportation instruction  During mounting and dismounting process, erection process, and maintenance process, except the working personnel, other person is not permit enter the working area, otherwise may cause accident.
Page 43: Assembly And Disassembly
Operation &Maintenance Manual of SWTC5D 2.3 Assembly and disassembly 2.3.1 Dimension and weight of main parts Item Dimension (mm) Weight (t) Quantity Remarks Boom width 365mm Hook 0.07 Cabin 0.43 1535 1028 Derrick 0.206 Height cylinder 2178 Hoisting 0.176 reducer...
Page 44: Steps Of Hoisting The Machine
Operation &Maintenance Manual of SWTC5D 2.3.2 Steps of hoisting the machine 2.3.2.1 Evaluating the condition 1.Parking the crane at flat and firm ground, ensure there is enough space for assembly, disassembly and hoisting. 2. Ensure the wind speed is less than 13.8 m/s.
Page 45: Hoisting Method
Operation &Maintenance Manual of SWTC5D 2.3.4 Hoisting method Hang the hook over the hooking wire rope and move the boom so that it adopts the posture shown in the figure on the right. Secure the hook and boom to vehicle main body.
Page 46: Storage
Operation &Maintenance Manual of SWTC5D 2.4 Storage If the machine will be out of use over half a year, should be kept in proper position, you‘d better keep it in garage, if the machine has to be stored outdoors, should be covered with a sheet, and with a wooden block under the track.
Page 47 Operation &Maintenance Manual of SWTC5D drainage. 2 Monitor systems and the indicator of crane must be rainproof and damp-proof. Each joystick must be coated with butter to avoid rusting. 3 When store crane in the rainy season or damp area, please start-up crane every other 15 to...
Page 48: Machine Illustration
SWTC5D is a kind of self –propelled crane whose ground contact area is wide, with good capability and adaptability, ideal for rugged area, such as oil field, construction building site, goods site and dock and so on, especially for swamp and desert area where wheel crane cannot work, this crane exert its special efficiency.
Page 49: Performance Parameter
Operation &Maintenance Manual of SWTC5D than 13.8m/s, please stop working immediately and keep boom parallel to ground, The crane may only be operated, while the allowed maximum wind speed given in the capacity chart is not exceeded. When wind speed increases, the crane has to be brought into a safe position by either laying the boom down or moving into a parking position.
Page 50 Operation &Maintenance Manual of SWTC5D Max.line speed(m/min) Temperature of working environment（° ） -20～+40°C X-structure Chassis form Min. ground clearance（mm） A10V074 Main pump Main pump displacement（ml/r） FDNB12V-53-49/26-30-01 Travel mechanism FDNB12V-53-49/26-30-01 Travel motor 26/48.5 Motor displacement（ml/r） QBZX25B20 i=21.5 Lifting mechanism A2FE45/6.1WVZL2 Lifting winding motor Lifting motor displacement（ml/r）...
Page 51: Lifting Weight And Height Parameter Chart
Operation &Maintenance Manual of SWTC5D 3.3.2 Lifting Weight and Height Parameter Chart SWTC5D Main Boom Lifting Weight and Height Parameter Chart Boom length Lifting capacity of Lifting capacity of Lifting capacity of Lifting capacity of Lifting capacity of 4.63m boom 7.38m boom...
Page 52 Operation &Maintenance Manual of SWTC5D Jib 1 + 2 Main Boom ⁰ Offset Angle (Deg) 80⁰ 75⁰ 70⁰ 65⁰ 60⁰ ₋ ₋ 55⁰ ₋ ₋ 40⁰ ₋ ₋ ₋ ₋ Notice: 1. Rated lifting weight values shown in the chart are based on firm and hard ground.
Page 53: 3Lifting Height Curve
Operation &Maintenance Manual of SWTC5D 3.3.3Lifting height curve Liftingheight curve Working radius (m)
Page 54: Outline Dimension
The vibration data are determined according to EN ISO 5349-1 and EN ISO 5349-2. 3.4 Design features SWTC5D crawler crane consists of specified chassis, swing bearing, turntable assembly and working devices. Power device ， hydraulic driven system, lifting mechanism and swing mechanism etc.
Page 55: Chassis
Operation &Maintenance Manual of SWTC5D 3.4.1 Chassis The chassis of crawler crane consists of frame, travel motor, embedded planetary reducer, driving wheel, guide wheel, tension device, thrust wheel, carrier roller and track, as the following picture: 1 guide wheel 2 thrust wheel 3 carrier roller4 track assembly...
Page 56 Operation &Maintenance Manual of SWTC5D automatically when stops, aiming at locking and preventing slipping on slope. Travel motor is driven by variable piston pump, controlled by big flow high pressure direction control valve, pump can automatically adjust travel speed, and speed range is 0-2.5/4.6Km/h.
Page 57: 2Turntable Assembly
Operation &Maintenance Manual of SWTC5D 3.4.2Turntable assembly Turntable is welded by high intensity low alloyed steel plate, it adopts integral loading construction. Power device, transmission system, winch, control mechanism, counterweight, hood, cab and so on are fixed on the turntable.
Page 58: 4Swing Bearing
Operation &Maintenance Manual of SWTC5D 3.4.4Swing bearing The structure of swing bearing sees as the following picture. An internal gear and single-row ball type swing bearing which is made up of housing washer, ball bearing, inner race and sealing device. Housing washer is connected with turntable while inner race is connected with bearing support of chassis, and all bolts are high strength bolts.
Page 59: Lifting Hook Assembly
Operation &Maintenance Manual of SWTC5D 3.4.6 Lifting hook assembly Lifting hook assembly is made up of hook, beam, pulley block, plywood. The multiply factor of lifting pulley block is 4 and the rated load is 5 ton. 3.4.7 Boom 3.4.7.1...
Page 60 Operation &Maintenance Manual of SWTC5D 3.4.7.2 Main technical parameters of boom Description Units Value Length of basic boom 4630 Length of full extending boom 15630 Max. torque of basic boom kN·m Max. lifting force of full extending boom kN·m Max. lifting load of boom 5000（working range is 2.1m）...
Page 61 Operation &Maintenance Manual of SWTC5D Note: 1. The lifting load illustrated in the above table includes the weight of hook (70kg); 2. When the length of boom is between two values of the above table, you should refer the capacity in the longer length column.
Page 62 Operation &Maintenance Manual of SWTC5D 3.4.7.4 Maintenance of boom The daily maintenance of boom is very important to improve the working efficiency of machine, prolong the machine life and ensure the safety in work. You need to inspect the boomperiodic as required and make record in detail.
Page 63: Auxiliary Jib
Operation &Maintenance Manual of SWTC5D 3.4.7.4.2 Maintenance of boom 1）The first 100 hours of using time is running-in state. This state is critical to a new boom. During this state, we suggest that the lifting load don’t excess the 80% of rated load. When the boom pass the running-in state, need to examine all parts of the boom in time, clean or replace the hydraulic filter;...
Page 64 Operation &Maintenance Manual of SWTC5D The installation and use methods are as follows: 1. Mounting auxiliary boom Mounting auxiliary boom STEP1 Open pin shaft 1.STEP2 With pin shaft 2 for axial roating auxiliary boominstallation diagram pin shaft 3. STEP3Open pin shaft 2,horizontalrotating auxiliary boom to the working poision of thediagram,install another pin shaft 3,and secure auxiliary boom.STEP4 Lifiting rope to...
Page 65: Hydraulic System
Operation &Maintenance Manual of SWTC5D the positioning pin hole 1 poistioning. Whe using thefull extension boom , the two-section boom is pulled out to the positioning pin hole2 poistioning to achieve full extension of the workong condition. 3.Fixed auxiliary boom angle：...
Page 66: 1Travel System
Operation &Maintenance Manual of SWTC5D The system consists of variable pump, multiple valve, motor, cylinder, relief overflow valve, balance valve, fuel tank, oil filter and so on. Features: the high pressure oil of double plunger pump flows via multi-way valve to central swivel joint, then to travel motor, and drive machine to move;...
Page 67: Lifting Structure
Operation &Maintenance Manual of SWTC5D oil is distributed by multiple direction valve to operate the control handle，carry out platform swinging, boom telescoping, boom derricking and hook lifting. The working hydraulic system adopts loading sensitive system, it has two features: A. It can do all kinds of compound actions, such as lifting and telescoping, lifting and derricking and others.
Page 68: Telescopic Mechanism
Operation &Maintenance Manual of SWTC5D 3.5.4 Telescopic mechanism Telescopic mechanism is made up of two cylinders which have double function, steel wire and pulley block .Use pin to fix the end of piston rod of the first cylinder to root of the basic boom, and use pin to fix the end of piston rod of the secondary cylinder to root of the secondary boom, via the telescopic cylinder driving steel wire to drive boom stretch out and draw back.
Page 69: Derricking Structure
’ SWTC5D Operator Manual 3.5.5 Derricking structure Derricking structure is made up of double-acting single cylinder. Check the following picture. The flexing of cylinder rod changes the elevation of boom, making the distance between hook and swing center of crane changed, and to realize derricking. Balance valve is installed on amplitude cylinder to make sure the stability of boom and prevent accidents from the falling down of boom when hose is cracked.
Page 70 ’ SWTC5D Operator Manual P and P1 port are the pressure oil inlet of combination valve, and connected with port of variable main pump of hydraulic system. T port is return opening of combination valve, connected with hydraulic oil tank.
Page 71: Power System
It is made up of monitoring meter, accumulator, start-up motor, generator, illumining system, caution warning system, horn, electrical wiper, radio, moment limiter, sensors, relay, wane switch, fuse box, wiring harness and so on. The followings are the schematic charts of electric system (2 pages in total): SWTC5D Electrical schematic diagram...
Page 72: Air Conditioning System
’ SWTC5D Operator Manual 3.8 Air conditioning system Air conditioner is split type and cold or warm type. Power comes from engine. It is made up of evaporator, compressor, condenser, and dehydrator. Evaporator consists of refrigeration evaporator (the following is short for evaporator), heating exchanger (the following is short for heat exchanger), and blast blower and so on.
Page 73: Constitution Of Safety Device
’ SWTC5D Operator Manual will change, too. Moment limiter can provide some information about length of boom, angle of boom, height, working radius, rated load and actual lifting load. If the operations of crane exceed its rated range, the moment limiter HC2902 will warn operator, the warning light will flash, together with electrical system cutting off operations which can cause damage of crane.
Page 74: Function Of Safety Device
’ SWTC5D Operator Manual The moment limiter includes host machine(include display),compulsory key switch box, controller of moment limiter, rotary encoder, approach switch, trichromatic warining lights, three ring protection switch, length/angle sensor, height limiter switch, pressure sensor(B0,B1) and connecting cable.The detailed information about usage and configuration of moment limiter,Please refer to Annex HC2902 Crane information center instruction manual.
Page 75: Electrical Monitor Meter
This machine includes construction vehicle monitor meter and moment-limitmonitormeter. Main parameters that shown on SWTC5D are: water temperature, fuel quantity, working hours, rev. Besides,indicated light are used to display decades of warning signal and status indicator, such as: pressure warning, temperature warning, fuel quantity warning, air filter jammed warning, system voltage warning and so on.
Page 76: Construction Vehicle Monitor Meter
’ SWTC5D Operator Manual Crane electrical monitor meter is designed to ensure safe and effective operation and enable operator to monitor the working conditions of main parts. It indicates the working status of engine, hydraulic system, air pressure device and other parts via collecting signals from sensors which are installed on various parts of crane, displaying the working status of engine, hydraulic system, air pressure device and other partsby liquid crystal, indicator light on the meter.
Page 77 ’ SWTC5D Operator Manual 1.fuel-level meter 2.cooling water thermometer 3.system voltage 4.clock5.menu 6.maintenance 7.parameter view 8.ECU 9.help/buzzer 10.working hour 11.malfunction indication 12.Preheating indication 13. air filter block indication 14.high pressure warning of engine oil 15.system charging indication 16. maintenance indication 17.engine speed display...
Page 78: Moment-Limiter Monitor Meter
’ SWTC5D Operator Manual along with buzz and malfunction recording. (8)Charging indication When generator is idle, the symbol shines, along with text information. (9)Preheating indication There is 12V on the input, the preheating light goes on, along with text information.
Page 79: Notice For Operator
’ SWTC5D Operator Manual The crane assembly shall be part of the pre-lift inspection and shall be checked when the boom is on ground. In addition to the thorough inspection, a detailed examination prior to each lift job is recommended. Such examination is a visual inspection combined with functional tests. a functional test in real conditions but without load is advisable;...
Page 80 ’ SWTC5D Operator Manual · The operating wind speed must not exceed 13.8 m/s. · Overload lifting is not allowed, ensure loading adjustment comply with permitted loading during lifting process, prevent machine overturn and structure parts damaged from overloading. · Rotation movements with loading have to be smooth, do not turn and stop sharply.
Page 81: Operation Notes
’ SWTC5D Operator Manual person, operator should follow the stop signal all the time. Operator should refuse to implement instructions that against the operation regulation. · Never allowed to operate crane when the operator is ill. Forbid operating crane after drinking.
Page 82: Control Device
’ SWTC5D Operator Manual stucked or the track board may be broken. ·Please idle the machine before operating, make sure machine works normal before start. · Avoid suddenly lifting and dropping , speed up and speed down slowly. · Keep slow and uniform speed when lowering with load.
Page 83 ’ SWTC5D Operator Manual check machine parts before operating. Operation parts drawing of cab (1) Fuel adjustment dial (10) Winch two-speed switch (2)Air conditioner control panel (11) EMO switch (3) Safety lock lever (12) Right control lever (4) Left control lever...
Page 84: Start-Up Engine
’ SWTC5D Operator Manual EMO Switch (Emergency Stop Switch)  Emergency stop If a problem such as an abnormal operation occurs, press the EMO switch to stop the engine. Then, switch the starting key to OFF position to turn off electric system and pull the key out. Then set the safety lock lever to locked position.
Page 85: Flameout The Engine
’ SWTC5D Operator Manual 0 degree. · Forbid running engine with high speed accelerograph on cold machine, increase rotation speed gradually when starting up . · Please slowly throttling acceleratograph, avoid sharply movements. · Forbid idling engine for more than 10 minutes, long term idling would cooling combustion chamber, cause incomplete burning.
Page 86: 5Operation In Cold Weather
’ SWTC5D Operator Manual All movements of machine will stop when each handle is positioned in the middle. Crane will operate and travel when you push and pull handspike. The speed and degree of operation actions is directly proportional to the push and pull speed and flight route of joystick. On the limit position of each operation action, do make sure be careful and reduce the speed and flight route when push and pull joystick as well as concussion.
Page 87 ’ SWTC5D Operator Manual  Make sure antifreeze is stored in the container with remarkable mark and sealing cover. Always keep it away from children.  If antifreeze spatters into eyes, please wash eyes with water 10 to 15 minutes, then go for doctor immediately.
Page 88: Safety Device Operation
’ SWTC5D Operator Manual 4.4.5.3 Others Clean the mud and sludge that stick on the machine after work.Park crane on dry and firm ground. If not, place wooden board on the ground and park machine on the board. This is to avoid deposit builder and travel device from freezing on road.
Page 89 ’ SWTC5D Operator Manual whether displayed magnification is Press set-up key, choosemagnification that consistent with actual magnification 按设置建，选择 consistent with actual magnification Retract boom, checkwhether Adjust according 5.6.2, displayed length is consistent makedisplay length consistent with withactual length actual length...
Page 90: Electronic Switch Operation
’ SWTC5D Operator Manual 4.4.7 Electronic switch operation This is the description of devices necessary for the operation of the machine. The proper understanding of the operations and display details of these devices is critically important for proper, safe and comfortable operations.
Page 91 ’ SWTC5D Operator Manual 4.4.7.2 EMERGENCY STOP SWITCH WARNING • Emergency stop If a problem such as an abnormal operation occurs, press the EMO switch at the top left of the operator’s seat to stop the engine. Then, switch the starting key to the OFF position to turn off the electric system and pull the key out.
Page 92 ’ SWTC5D Operator Manual 4.4.7.3 Starter switch This switch (1) starts/stops the engine. OFF position You can insert/remove the starter switch key. All the switches for the electrical system except for room lamp and service meter turn off and the engine stops.
Page 93 ’ SWTC5D Operator Manual 4.4.7.4safety lock lever As figure 4.4.7.4a lock， and figure 4.4.7.4b unlock。 The engine will not start if the safety lock lever is not in the lock LOCK position. Check that the safety lock lever is at lock position before operating Figure 4.4.7.4a...
Page 94 ’ SWTC5D Operator Manual turned fully leftward (counterclockwise). (b) High gear: where the dial is turned fully rightward (clockwise). 4.4.7.6 Horn button 喇叭 Horn 自由回转 Free swing 自由回转 Free swing Figure 4.4.7.6 Note: This picture is a schematic diagram of the universal handle function, The machine is not equipped with the above functions.
Page 95 ’ SWTC5D Operator Manual 4.4.7.8Cigarette lighter Use this lighter to light a cigarette. Push in this cigarette lighter and it returns to its original figure 4.4.7.8 position in a few seconds. Pull out the lighter and use. With cigarette lighter removed, this can be used as a power supply.
Page 96 ’ SWTC5D Operator Manual （from left）：1 boom light switch, 2 platform light switch, 3 former wiper switch, 4 former window washer switch, 5 top wiper switch, 6 top window washer switch,7slow mode switch,8 high speed travel switch 4.4.7.9.1 Boom light switch ...
Page 97 ’ SWTC5D Operator Manual front window is dry. 4.4.7.9.4 Window washer switch  Window washer switch is used for controlling spray water with washing solution on the glass and washing.  The window washer switch can reset by itself. Press the switch and hold it will start the window washer.
Page 98 ’ SWTC5D Operator Manual Realization of hand throttle foot throttle switching Engine Diagnostic Switch 4.4.7.10 发动机故障/排气管温度报警再生请求/再生请求应答指示板 Engine failure/Exhaust pipe Regeneration request/Regeneration temperature alarm request response indicator board DPF 再生请求互锁开关 DPF 再生请求开关 DPF Regeneration Request DPF Regeneration Request Engine diagnostics include DPF regeneration...
Page 99: Electronic Monitor Meter Operation
’ SWTC5D Operator Manual 4.4.8 Electronic monitor meter operation It includes two monitors: construction vehicle monitor and moment-limitmonitorin this craneelectronic monitoringinstrument. The instruction is as following for the construction vehicle monitor. 4.4.8.1Construction vehicle MonitorPrinciple and Function Construction vehicle monitorcalculates and processes signals sampling by sensors,then display analog variable 、...
Page 100 ’ SWTC5D Operator Manual Figure 4.4.8.1 Figure 4.4.8.2 Turn the starter-switch key to the “ON” position, internal parametersare initialized, after 3s, the working interfaceis on the screen,asshown Figure 4.4.8.1. The monitor working interface is displayed on the screen as figure 4.4.8.2 while engine working without abnormal.
Page 101 ’ SWTC5D Operator Manual Options Menu InterfaceMaintenance Fault Interface Parameters Interface Engine Fault Code Query Interface 4.4.8.4 Options Menu Interface In the menu interface, you can operate buttons in case of the message at the bottom of the screen. you can do “User Setting, System Setting, GPS Setting, Light...
Page 102 ’ SWTC5D Operator Manual  User Settings Select the button F1/F2 to scroll up/down to “User Setting”, press F5 to enter the user setting interface. The system prompts the user input password, the interface is as follows: After enter password, in the User Setting interface,user can adjust Time, change user password, Clear phase hours.
Page 103 ’ SWTC5D Operator Manual  System Setting Select the button F1/F2 to scroll up/down to “System Setting”, press F5 to enter the system setting interface. Note: This is a mainframe manufacturers set, the user can notset secretly, so we do not descript in details.
Page 104 ’ SWTC5D Operator Manual prolong the life of the electric control system of crane. During product transportation、 installation、use，please pay attention to the following matters:  Environmental parameters - electronic monitoring instruments work normally: Working temperature: -20℃~65℃; Storage temperature: -40℃~85℃; Relative humidity: (5 ~ 95)%RH;...
Page 105: Air Conditioner
’ SWTC5D Operator Manual Meter(HC2902) instruction manual . 4.4.8.8 Notice for maintenance of electrical system of crane  Please read operating instruction manual carefully before using this combined meters.  This combined meter has micro controller as its core, adopts a great deal of precise electronic components, so it requires professional maintenance.
Page 106: Special Operations
’ SWTC5D Operator Manual Refrigeration Operation (1) Choose proper wind speed and direction according to the “aeration operation”. (2) As figure 4.5.1 shows, clockwise turn the main switch to a proper position. (Clockwise turn make lower temperature. Turning to the most right makes the lowest temperature.
Page 107 ’ SWTC5D Operator Manual speed increasing button” to choose the highest wind speed, press “set increasing button” to choose the lowest temperature. Weak refrigeration operation When it is slightly hot, especially the period of time after turning on air conditioner, the indoor temperature is suitable or even a little cool, you should choose this operation.
Page 108: Other Instructions
’ SWTC5D Operator Manual 4.5.4 Other instructions (1) Machine set up: As long as you change the system operation pattern, the system will close the extrinsic cycle air door automatically (enter internal circulation pattern). If operator has to use the extrinsic cycle after changing the operation pattern or just...
Page 109 ’ SWTC5D Operator Manual cooling fluid from freezing and causing the radiator or the water tank cracks, please use the prescribed cooling fluid by the main engine plant. You’d better effuse the cooling fluid if the engine stops for a long time in winter, or it will freeze.
Page 110 ’ SWTC5D Operator Manual √ dust screen dirty or jammed Note: (1) As figure 4.9.5 (left) shows, when check the tautness of the belt, press it by force in 15N. The sinkage between 5mm to 7mm (4~5mm) is appropriate. (2) As figure 3.8.4 (right) shows, when check the quantity of the refrigerant, please judge it according to the bubble in the fluid-inspection lens.
Page 111 ’ SWTC5D Operator Manual pressure at both sides high (especially high pressure side) Fluid inspection lens is clear with bubble, Slightly bubble appears at much start minutes after shut down. Fluid inspection Air outlet is cold, lens is clear with...
Page 112 ’ SWTC5D Operator Manual many Air outlet is not bubbles appear cold enough, during work condenser inlet is not hot enough, condenser outlet like Extremely environment insufficient temperature, intake duct warm pressure of high pressure side is very low. Check,...
Page 113 ’ SWTC5D Operator Manual (9) Cautions while disassembling the pipeline system 1. The joints disassembled from the pipelines must be sealed in time to make the inner system exposed to air for a short time as possible, avoiding the wet air from entering the system.
Page 114: Radio
’ SWTC5D Operator Manual 4.6 Radio 4.6.1 Functions of panel Figure 2.4.1 a) Power switch b) Sound mode c) Automatic storage d) Upward select e) Downward select Wave select g) Mute h) Volume Play/Pause Fast backward/Forward k) Radio prestore 3/Repeat play...
Page 115: Performance Index
’ SWTC5D Operator Manual 4.6.2 Performance index FM wave R a n g e o f f r e q u e n c y … … … … … … … … … … … … … 8 7 . 5 ~ 1 0 8 . 0 M H Z Utility sensitivity………………………………………………………..12dB...
Page 116 ’ SWTC5D Operator Manual Sound storage（AMS）： Shortly press,select among BAS,TRE and VOL. Channel selection/musical selection: The upward selections ( ), shortly press, radio frequency descending direction mode to automatic station search, playback mode switch to the next song. Long press, enter into the manual station search, then each short by...
Page 117 ’ SWTC5D Operator Manual (10) Radio prestorage 5/F-： Radio: short press, broadcasting radio station number 5 storage, long press, the currently playing station to the 5 station. When playing a MP3, short press, play the next folder. (11) Radio prestorage p6/F+：...
Page 118: Maintenance And Service
’ SWTC5D Operator Manual 5 Maintenance and service Regularly, strict maintenance is very important for your safety, correct operation and prolonging service life of machine. Qualified spare parts are essential to ensure the reliability and safety of machine. The inspector must be trained and be familiar with the structure and operation of machine.
Page 119: Every 500 Working Hours Maintenance
’ SWTC5D Operator Manual with every 50 working hours’ maintenance at the same time. 1 Check the crawler traveling device. 1) Check and adjust tension of crawler (first at 50 working hours). place a ruler on two chain wheels to test the biggest droop of track, the normal droop is about 40～...
Page 120: 9Maintenance For Long-Term Parking
’ SWTC5D Operator Manual 5.1.9Maintenance for long-term parking 1. Clean the whole machine, especially the traveling parts. 2. Filling-up grease oil to hinge joints, especially grease the parts which are easily rust such as the track. 3. Disassemble accumulator, drain out coolant of engine to avoid rusting.
Page 121: Lubrication
’ SWTC5D Operator Manual Swing bearing Check grease Air filter Replace filter core 5.2 Lubrication Machine lubrication chart is as follow, chart 5-2 is code and position. Chart 5-2 SWTC5 B Hydraulic crawler crane lubrication periodical table Lubrication Lubrication Mark...
Page 122: Hydraulic System Maintenance
’ SWTC5D Operator Manual fastened. Check whether the tension of tensioner is proper, whether the connecting bolts of link joint are loosened. 2. Whether the binding post of accumulator is reliable. 3. Whether the meters, lights, signal and wiper is normal.
Page 123: Refuel Types And Criteria
’ SWTC5D Operator Manual other components in non-dust room, make parts clean and no collision, prevent incorrect and misassemble. If possible, test and adjust them before fixing on crane. 3 Replace hydraulic oil every year (or after 2000 working hours), (or can be proper longer if oil does not go bad);...
Page 124: Safety Device Maintenance And Adjustment
’ SWTC5D Operator Manual wheel、riding wheel curve industry gear curve industry gear hole Notice: 1 After charging oil, the level of hydraulic oil must over mid-position of oil leveler. 2 Specified capacities in this table are theoretical value. Just for reference. Actual capacity depends on the judging criteria.
Page 125: Overload Test
’ SWTC5D Operator Manual retraction, it might caused by less pre-tightening force of winding reed of the winding box or length-measuring cable of winding box is out of socket. Pre-tightening some circles can solve this problem. The operation steps are as follows：...
Page 126 ’ SWTC5D Operator Manual element 3. Broken pipeline 3. Repair welding or renewal 4. Cracked welding 4. Repair welding or renewal slot Oil pressure is low 1. Start pressure 1. Adjust overflow valve overflow valve is too 2. Examine oil pump and replace sealing element 2.
Page 127 ’ SWTC5D Operator Manual Oil is yellowing and has air 1 Air in , oil suction pipe Repair and fasten bubble has air leakage Oil pump is hot 1. Needle bearing 1. Strip inspection damaged replacement 2. Suction pipe clogged 2.
Page 128 ’ SWTC5D Operator Manual When lifting weight, derricking 1. The inside 1. Inspect and repair cylinder and telescopic cylinder balance valve 2. Inspect and repair，replace automatically retract leaking sealing elements of piston 2. The inside cylinder is leaking Oil pressure is too high when 1.
Page 129: Manufacturer Information
’ SWTC5D Operator Manual 6 Manufacturer Information Company：Sunward Intelligent Equipment Co., LTD. Trade mark： Add：NO.16 Lixiang Road(M), Xingsha, Changsha, Hunan410100, P.R. China Tel：0086-0731-83572565 Distributor information Distributor : Add: Tel: Fax: Email: Contact: Machine model...
Page 130: Annex A Spare Parts List Of Swtc5D
’ SWTC5D Operator Manual Annex A Spare Parts list of SWTC5D Spare Parts list of SWTC5D No. Code Description Quantity 730603000107 O-ring 125X3.55 GB/T 3452.1 730603000090 O-ring G65 (A90) 9-5509 N552-90 730603000898 O-ring 16X1.9 730603000899 O-ring 11X1.9 730603000104 O-ring G100 (A70) 9-5516 N674-70 730603000436 O-ring 91.67X3.53 (A90) 2-239 N552-90...
Page 131 ’ SWTC5D Operator Manual 730403000123 Oil filter 119005-35151/R010001 730405010005 Oil-water separation filter 119A00-55700 730402000132 Air filter (outer)129935-12520 730402000131 Air filter (inner)119160-12570 730403000052 Diesel filter 129907-55800/R010002 730401000006 Filter WU-250X80-J-348 730401000029 Return fuel filter RFA-400X20 730402000020 Preloading air filter TM278B4P2 750603000001 Reflecting mirror 136# 720211000010 Safety piece BX2011C-20A 720412000062 Platform light 1GA 996.522-057...
Page 132: Annex B Certificate For Stretching Wire Rope
’ SWTC5D Operator Manual Annex B Certificate for Stretching Wire Rope...
Page 133: Annex C Technical Specification Of Hook Block
’ SWTC5D Operator Manual Annex C Technical Specification of Hook Block...
Page 134: Annex D Tool List
’ SWTC5D Operator Manual Annex D Tool list Orde Code Name Quantity 740505000120 Tool Box 410X200X210 740104000019 Allen WrenchS3 GB/T 5356-85 740104000003 Allen WrenchS4 GB/T 5356-85 740104000004 Allen WrenchS5 GB/T 5356-85 740104000005 Allen WrenchS6 GB/T 5356-85 740104000006 Allen WrenchS8 GB/T 5356-85...
Page 135: Annex E Typical Shapes And Corresponding Cw Values
’ SWTC5D Operator Manual Annex E Typical shapes and corresponding Cw values...
Page 136: Annex F Wind Speed As A Function Of Elevation
’ SWTC5D Operator Manual Annex F Wind speed as a function of elevation...
Page 137: Annex G Common Bolts Tighten Torque
’ SWTC5D Operator Manual Annex G Common bolts tighten torque Width Tighten torque（N·m） Bolt Order screw head Grade 8.8 Grade 10.9 Grade 12.9 type （mm) 10±1 13.2±1.4 20±2 31±3 49±5 66±7 74±7 88±9 113±10 127±12 137±14 177±19 205±20 270±30 317±30 294±30...

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