1 qndTIdIoOoOTmTIsoIc oso ast as as tat aed SCCS00D Hydraulic Crawler Crane Maintenance Manual SCC500D-0&M wn ~~ Shanghai SANY Science and Technology Co., Ltd. JAN. 2007a & SOC500DHydraulic Crawler Crane Maintenance Manual Content SCCS500D Hydraulic Crawler Crane. 1.Properties and parameters of the main components. 2. Sketch for various systems 2.1 THE STRUCTURE DIAGRAM OF THE CRANE... 2.2 PRINCIPLE DIAGRAM OF THE HYDRAULIC SYSTEM (APPENDIX 1) .. 2.3 PRINCIPLE DIAGRAM OF ELECTRIC SYSTEM (APPENDIX 2).. 3. Check, maintenance of the crane... 3.1 SCHEDULE FOR THE CRANE’S CHECK, MAINTENANCE WORK, 3.2 REQUIREMENTS OF REPAIR AND MAINTENANCE. 3.4. THE MAINTENANCE WORK OF THE ENGINE ASSEMBL) 15 3.6 MAINTENANCE WORK ON THE HYDRAULIC DEVICES. 19 3.7 TIGHTEN THE BOLTS, NUTS AND HYDRAULIC PIPES 4.Instruction on judging and eliminating the usual failure 5. Usual fuel, oil and grease recommendation.g a ‘SCC500Dliydraulic Crawler Crane Maintenance Manual Preface Distinguished customers: Shanghai SANY Science & Technology Co., Ltd. sincerely welcomes you to be the owner of SCC series Hydraulic Crawler Crane! We would do our utmost to provide you with “HIGH-CLASS products, HIGH-CLASS quality, and HIGH-CLASS service”. After being operated for a long term, the components would be worn naturally, get loosened and damaged. Therefore checking, maintaining and repairing the crane regularly is an important means to guarantee that the crane can bring its performance into full play, work safely and reliably and extend its service life. We provide you, our distinguished customers, with this maintenance manual so that you can check, maintain and repair the crane very conveniently. The manual has made detailed regulations and instructions on the check, repair and maintenance work of the crane. It also provides judgment methods and related handling methods on the usual faults of the crane. Im order to keep the crane work normally, bring its performance into full play and extend its service life, and also guarantee others’ as well as your safety, be sure to read the operation manual, maintenance manual and other documents carefully before operating the crane. At the same time, be sure to conduct the operations in conformity with the operation manual, maintenance manual and other documents. When performing the maintenance work, detaching or adjusting the hydraulic ‘components is definitely prohibited! When the hydraulic components are faulty or damaged, be sure to contact us promptly! Shanghai SANY Science and Technology Co., Ltd.a ‘SOC5ODDHYdraulic Crawler Crang Maintenance Manual. 1.Properties and parameters of the main components Table 1.1 Performance Parameters of the engine assembly ‘Sequence number Name Mass (kg) ‘Working parameter Power: 127KW 1 2000r/mnin ; Diesel engine “3 oe (6BTAS.9-C167) 395 Nem 2000 r/min Characteristic curve: Shown in fig 1-1 a Oil radiator 0s Oiflow: 250L/min | - (air cooled type ) Heat exchange area_+ 13.3m" : “Heat dissipating area isnot less > Radiator 0 than 35.582 Air filter 4 . 15 (model AH19225) 5 Fuel tank. - 20 Volume: 2001. TORQUE a CONTINUOUS RATING Ces 00 40 23) +000 469 (46) ‘100 sz (285) +00 006 tan 1500 est (400) : 1700 ou (475) i =z: & = 2000 $95 (4291 POWER OUTPUT oe a “9 1000 “0 5) i ‘100 0 @ 3 130 6 awn 5 1500 se aan 170 15 154 1609 1 164 2000 124 en aT ie 200 28 (404) q 100 Ey (389) ) 20 1100 zi ory ‘300 24 (5) 1500 207 (40) 1700 nor (340) 1800 a (a) 2000 25 (35 Fig 1-1 Engine characteristic Curve 3a ‘SCC500Dliydraulic Crawler Crane Maintenance Manual ‘Table 1.2 Performance parameters of pump group : Name Max. flux ‘Working pressure/Flooding valve No. : : ‘Main pump X 107m (K3V12DP-126R-9P_ oe a P7. ui Servo pump: 10mM/r 45 ZX1OLSLZ6-06E ‘Swing pump 44.7mVr 20.5 2 SGP2A44FIHI-RIS2 Table 1,3 Performance parameters of drum ‘ Length of steet_| Diameter of steel No. Name | Welght(kg).| Diameter(mm) ‘ ” “ wire rope(m) wire rope(mm) Main hoisting 1 450 “AN 20 drum Aux. hoisting 450 120 20 drum ‘ Loffing drum 404 aaa 16 .| Mwp325s2c542 Main valve MWP3252SC541A, ‘Swing W125P5198 Laffing main winch servo handle TH40KC1323A & ‘SCC500DHydraulic Crawler Grane Maintenance Manual 4 | swing aux. winch | 6.9 | Highest pressure 9.8Mpa, Rated flix 20L/min servo handle wh 7 7 THAOKC1323, 7 5. | Pedal valve | 9.6 | Highest pressure 9.8Mpa, Rated flux-10L/min ReVsccHt °6- | Soleniod valve 1.2 | Working pressure « P.-Ax/B~31SMPa__T=-16MPa ‘Table 1.5 Performance parameters of reducer&motor Weight Cg)” Main winch. reducer ‘Amrester Main winch motor Balance valve hutch ‘Aux. winch reducer Arrester Aux. winch motor Balance valve Luffing reducer Laffing motor i Balance valve Arrester ‘Swing reducer Swing motora — ‘SOC500DHydraulic Crawler Crane Me ‘Traveling reducer ‘Traveling motor ‘Max. output rotate speed 10.5¢/min e Balance valve 400 Pressure enactment: 28Mpa ‘Static state trig moment: 560N +m Arrester Unlock oil pressure: 1.8MPa Max. compression resistance: 5.0MPa Table 1.6 Performance parameters of other hydraulic element No. lame ‘Type Working parameter Filtration ‘precision 20m, Air flux 1.0 1 | Oil tank air filter QUQ2-20X1.0 . “ m/min 2 | Oil circle fiter RFA.630%10F __| Filtration precision 101m, Flux 63L/min, 3._| Main oil-suction oil filter XNI-630%100 Filtration precision 180 m, Flux SO0L/min LPF BN/HC 240 GE10B1 4 | Pipeline filter (HYDAC) : x/-B6 7] eae 3 Liquid ‘Temperature +-20 C 35 +100 °C , Pressure YWZ-150T ee oe level&temperature meter O1~0, 16M: : au ie sak apa ea | 260k fee Center swing system wy.32 Se ‘| Accumulator (HYDAC) $B0210-0.75E1 112 A9-210AB 1453/0-6.0BF MPa/PSI& SCC500DHydraulic Crawler Crane Maintenance Manual Manual 10 | direction-commutation SGIW-A valve _ 2. Sketch for various systems 2.1 The structure diagram of the crane a steel rope of Amplitude-changi th main drum - amplitude-changing, ng, steer ‘upper boom —pull-rope a septine co 3g, steel rope, A-shape frame / Hydraulic pump Engine assembly ‘Traveling device radiator track frame Fig2-1 The structure diagrain of the crane‘sCC500Dliydraul ic Crawler Crane Maintenance Manualaw ‘& ‘SCC500DHiydraulic Crawler Crane Maintenance Manual sanv 2.3 Principle diagram of electric system (appendix 2) 3. Check, maintenance of the crane 3.1 Schedule for the crane’s check, maintenance work Check, maintenance work of the crane must be conducted every day, every month and every year. Fuel. Oil and components replacement should be conducted according to the service schedule. Table 3.1 Schedule for the Related Check, Maintenance Items Check and nce number coos ‘maintenance item Time for conducting these work Interval ( hours) Daily check and ‘maintenance ‘Before and after the daily operation (the ‘work should be conducted according totable 3.1.1) 5-10 Monthly check and maintenance ‘Once per month (the related work should bbe conducted according to table 3.12) 150-250 Yearly check and ‘maintenance ‘Once per year (the related work should be conducted according to table 3.1.3) About 1000 4 Overhaul Disassemble the whole crane to conduct the ‘maintenance work 3000-4000 ‘Notes: please refer to the enginé operation manual concerning the engine part maintenance ‘Table 3.1.1 Table on Daily Check and Maintenance of the Crane ‘Name Check items Remark 1, Whether the engine oil quantity is sufficient 2. Whether the water quantity in the radiator is sufficient 3. Whether the color of the exhaust gas of the e Engine is normal, whether there is abnormal sound or abnormal smell 4, Whether various meters, electric equipments are normal. ‘Whether they have been damaged or worn ‘The main body of | 1. Whether there is fuel in the fuel tanka a SCC500DHydraulic Crawler Crane Maintenance Manual the crane 2, Whether there is sufficient oil in the hydraulic oil tank, | Whether there is oil leakage 3. Whether the operations of various control handles and pedals are in normal state ‘4, Whether the operations of brakes and locking devices are normal 5. Whether the gear oil quantity in the drum reducer is sufficient ‘6. Whether there is oil leakage from pipes or hoses. Whether the pipeline ‘or hoses are damaged. "7._Whether various instruments are damaged 1 Whether the tension condition of the crawler is proper 2. Whether there is leakage with the upper support rollers. the lower ‘Traveling device | rollers. The idler, the driving wheel and the reducer. 3. Whether there is leakage and damage with pipes, hydraulic components. Whether their clamps are loose Whether the main boom, the sheave and the hook block are damaged or deformed Working devices _| Whether the steel rope is won or deformed ‘Whether various working devices can work normally Whether various safety devices, alarm devices and wires or hamess in various part are abnormal Other equipments | Bolts and nuts in various parts are loosened or lost, ‘Whether various devices are fully grease filled. ‘Table 3.1.2 Schedule for Monthly Check and Maintenance ‘Name Check item Whether the oil filter is dirt, _ whether the filter is clogged 2Whether the fuel filter is dirt, whether the filter is clogged whether water drainage has been done. 3. Whether the air filter is dirt, whether the filter is clogged or broken. Engine 4Replace coolant in the radiator, whether the radia tor ,oil Cooling radiator are clogged or deformed or broken... ‘5. Whether the specific gravity and quantity of electrolyte in battery are normal, whether the terminal are loosened or corroded : Whether fuel/ oil quantity in fuel/ oil tanks is proper, whether there is fuel/ oil leakage, dirt, abnormal smell, or foreign matter in various fuel oil tanks ‘The main body of the cranew@ el SOC500DHydraulic Crawler Crane tenance Manual 2. Whether hydraulic oil is dirt, whether the oil filter is clogged, or broken, Whether water drainage has been done 3.Whether various drums are in abnormal conditions such as fissure - 4.Whether the hydraulic devices can work normally, whether they are damaged or rusted ‘5. Whether there is fissure or deformation on various parts of the swing platform, 1.The components of the traveling device are normal, oil quantity in reducer is proper ‘Traveling device 2.Whether there is deformation, fissure on the crawler, the swing form and the protection device | 3. Whether the operation of the hydraulic devices are in normal state, whether itis scratched or rusted 1.Whether there is deformation or fissure on the main boom or hook block 2.Whether the steel rope (its full length) is abnormal, treatment on the steel rope end is reliable, whether the steel rope is Working devices connected soundly 3.Whether various mechanisms of working devices can work normally ‘4.Whether prevention devices of the steel rope slide out from sheave or hook block is deformed or broken. 1, Whether the indication on the angle meter is correct 2. the upper limiting device and the over-hoisting prevention. device and the alarm device on the main boom can work normally Safety device 3. Whether the back stop post is deformed or bent. 4.Whether the switches for safety devices are perfect, whether various meters can indicate the operation condition normally ‘5.Whether various nameplates, warning labels are dirt or damaged ‘1.Whether various wires ,hamess are loosened, or short-circuited, or overlapped or worn oan 2.Whether bolts or nuts are loosened or lost 3.Whether the function of the crane is abnormal ‘Table 3.1.3 Schedule for Yearly Check and Maintenance on Main Items ceqwocemmnbr | Name | Someta 7A ‘SCC500DHydravlic Crawler Crane Maintenance Manual ————— eer Crater Crane Maintenance Manual repair 1 Fuel filter element | Replacement nie ee 2 Air filter Replacement Model: Al19225 Wash, clean and | Na6 antiewear Hydraulic oil tank 3 mene replace hydraulic oil | hydraulic oil ‘clean and 4 Drum reducer Nes LS2 industrial gear oil replace gear oil ‘swing reducer, Boom Wash, clean and 7 5 hoist and traveling ‘ 1.82 industrial gear oil replace gear oil Model and length 6 ‘Steel rope Check and replace refer to the spare parts catalog Model and length | 1 ‘Suspended steel rope | Check and replace _| refer to the spare parts Identify leakage oil ‘and length 8 ‘Hydraulic hose and damaging | refer to the spare parts condition catalog 3.2 Requirements of repair and maintenance 3.2.1 Instructions on check and maintenance of the crane: ‘After being operated for a long period of time, some components of the crane would be wom naturally and some connection parts would be loosened. Therefore, it is necessary to perform regular check ‘and maintenance work on the crane. Appropriate check as well as maintenance work can extend its service life. Operating the crane under severe badness conditions in particular, the related terms on the check and ‘maintenance work of the crane should be more strictly abided by. 3.2.2 Points for attention on check and maintenance work of the crane: 3.2.2.1Check and maintenance work of the crane should be performed on the solid flat ground and at fine days. 3.2.2.2 Then checking and maintaining the hydraulic components, the work should be done indoors or at a clean place with litle dust as far as possible. 3.2.2.3 It is very dangerous to conduct check or adjustment when itis loaded, Be sure to shut off the engine first, and then conduct it when the hook is unloaded. hanging a sign “under check and maintenance” ‘on the door ofthe cab during the whole process. 3.2.24 Disassembling or adjust hydraulic components such as pumps, valves and motors are definitely prohibitedaw sanv: ‘SOC500DHydraulic Crawler Crane Maintenance Manual 3.3 Maintenance of Lubricating Grease 3.3.1 Maintenance of lubricating grease should be carried out according to figure 3-1 and table 3.2; (il filling port ofthe main lifting mechanism Main lifting mechanism (il filling port ofthe sub- lifting mechanism Sub- lifting mechanism Juffing mechanism Ol filling port ofthe luffing mechanism Sketch Map of Oil Filling Port of the Main, Auxiliary and Luffing Drum& ‘ScC500Diiydraulic Crawler Crane Maintenance Manual ‘Sketch Map of Swing Support Lubricating ‘Sketch Map of A-framed Support Oil Filling Opening ‘Table 3.2 Time Interval Table of Lubricating Grease Filling ‘S/ |.- Lubricating N-| © Components ‘ 8 2000 Main, Auxili and 1 uy x Laffing Drum ce 2. | A-framed Support 3 | Swing Support Internal Gear of Swing 4 . * Rolling Dise 4. | Lower Pin of Boom % ‘ 6 | Central Swivel Joint |p: * 2 Note: + indicating that the one need inspection 3.3.2 Attention Points of Lubricating Grease ‘W) All the grease should be high quality mineral grease that is able to be pressed in oil pistol, without liquefaction in case of temperature rising and frozen in case of freezing point below. (@) Lubricating should be carried out before cleaning up the nozzle tip, and the lubricating grease and oil pistol should be kept clean. ) For the position without nozzle tip, such as manipulation lever, fork etc., should also be lubricated on time, @) Unified brand of grease should be used; and being mixed with other brands of grease is not allowed. ©) Lubrication should always be performed to prevent steel wire cable rustiness. Lubrication method is as follows in Fig. 3-2: m ih SS rahing by hand Banting by coton ‘rusting by coton yarn Fig. 3-2 “a ‘sC0500DHiydraulic Crawler Crane Maintenance Manual © Special tools are needed when lubricating the lifting drum, pulley block, drive/driven wheel and upper block, thrust wheel where with no need for regular lubrication. ( Grouser bar can be poured with waste oils regularly. (8) Electrical devices absolutely can not be soiled with grease. 34.1 3.4 The maintenance work of the engine assembly.. specified by table 3.3. Table 3.3 Schedule for Checking and replacement of the engine component. Please conduct the maintenance work ofthe engine assembly according to the requirements Seanenee | jsinienance content aa Remark 2000 i Checking the fuel quantity in the fuel tank 2 Replacing the engine oil : Replacing the oil filter ofthe engine 1: Drain the water from the * fucl-water separator 3 Drainage of the fuel tank 6 Replacing the fuef filter 7 7 Cleaning the filter sereen of the fuel tank 8 ‘Cleaning the air filter > Replacing the components of oe the air filter the standard 10 _| Checking the coolant quantity in the radiator a 11 __ | Cheek the tension force ofthe fan belt 2 Replacing of the coolant 13 __| Cleaning the ouside surface ofthe radiator = 14 _ | ‘leaning the inside surface of the radiator Notes: % means the related components needs checking. ‘The detailed work on the check and maintenance of the engine should be conducted according to the requirements specified in the Cummins engine series C operation and maintenance manual‘SCC500DHydraulic Crawler Crane Maintenance Manual 3.4.2.1 Soft water with very little impurity should be chosen as cooling water. 3.4.2.2 Filling the fuel tank with its volume being 200L after finishing the daily operation. 3.4.2.3. Never attempt to take off the cap of radiator from the hot engine. When water temperature drops to below 50 " C, then take off the cap of the radiator.. Be sure not to use sealing additive to prevent the leakage of cooling system. 3.4.2.4 To be sure to avoid human skin from contacting the used lubrication oil of the engine for a long time and repeatedly. The skin should be thorough cleaned after contacting it. Moreover, the lubricant should be put in places where children cannot reach. 3.4.2.5 Drainage of the lubricant should be done only when the lubricant is not too hot state and the impurity are in floating state. 3.4.2.6 Anti-freezing liquid is needed under all weather conditions for it can both lowering the freezing point and rise the boiling point of the coolant, thus widening the operation temperature scope. ‘When replace the coolant of the engine, the coolant filter should be also replaced at the same time. Coolant can be confected by 50% glycol base Anti-freezing liquid mixed with 50% soft water. This coolant is suitable to the ambient temperature : -32° C~0" C. 3.42.7 Confirmation of the water quantity in the radiator: open the cap of the radiator to confirm. whether the water level is between the highest and the lowest water line. If the water level is under the lowest waterline, Soft water should be filled into the radiator until it meets the above requirements. 3.4.2.8 When replacing water for the engine, Drain all the water both in the engine and in the radiator, then filling in new coolant. 3.4.2.9 When the color of the anti-reezing liquid has been changed because of being rusty, the ‘cooling system should be thoroughly cleaned. Then new anti-freezing liquid can be filled into the cooling system, 3.4.2.10 when replacing whole coolant, filling new coolant to specified quantity, Running the engine at idle speed for 30 seconds or 60 seconds, then take off the cap of radiator Observe the level of coolant If itis not sufficient, filling it again. 3.5 Maintenance and Upkeep of Planetary Reducer 3.5.1 The maintenance and upkeep of planetary reducer should be carried out according to Fig. 3-3 and Table 3.4: Fig. 3-3 Lubrication Drawing of Planetary Reducer 16Aa ‘SCC500DHydraulic Crawler Crane Maintenance Manual Table 3.4 Time Interval Table of Inspection and Oil Change of Planetary Reducer E 7 on Inspection intervals (hours) SIN | Lubricating Components - Remark * ‘Mass |g | so | 250 | 500 | 1000 | 1250 | 2000 Mae ting |e oe * Redvcer inspection il change |" 4L * Oil mass = ‘Swing Reducer | inspection a Oilchange | 6 * ‘haveing [OH a8 A Rabo inspection ~_[oitchange [8.5L x ‘ Oil mass Subsiting | Oe econ * Reducer 1 Oillchange | 4L * Luffing ee * Ret: [inspection Oil change [1.5L * 3.5.2 Inspections and Replacements (D Oil mass inspection for traveling reducer should be performed every 250 hours, and oil change for that should be performed every 1000 hours. Oil filler plug should be disassembled at first, and then the oil drain plug should be disassembled, that is to say, the oil can be drained now. The oil drain plug should be fixed at first, and then 8.75 L 220LS2 gear oil should be filled into from the oil filling port, finally, the oil filler plug should be well installed. Keep the machine flat on the ground, then disassemble the oil level plug. Oil mass is adequate if the oil level is visible. er a rive she) O11 80g pore OH Ie a 011 drain port Fig. 3-4 Lubrication Drawing of Traveling Reducer 2) Oil mass inspection for luffing reducer should be performed every 250 hours, and oil change for that should be performed every 1000 hours. Air plug and oil filler plug should be disassembled at first, and then the oil drain plug should be disassembled, that is to say, the oil can be drained now. The oil drain plug should be fixed at first, and then 1.5 L 220LS2 industrial gear oil should be filled into from the oil filling port, finally, the oil filler plug and air plug should beL) a SCC500DHydraulic Crawler Crane Maintenanc well installed. Keep the machine flat on the ground, then disassemble the oil level plug. Oil mass is adequate if the oil level is visible. Manual, Fig. 3-5 Lubrication Drawing of Luffing Reducer (3) Oil mass inspection for swing reducer should be performed every 250 hours, and oil change for that should be performed every 1000 hours. Oil filler plug and oil level plug on the reducer should be disassembled at first, and then the oil drain plug should be disassembled, that is to say, the oil can be drained now. The oil drain plug should be fixed at first, and then 6 L 220LS2 industrial gear oil should be filled into from the oil filling port, finally, the oil filler plug and oil level plug should be well installed. Keep the machine flat on the ground, then disassemble the oil level plug. Oil mass is adequate if oil level is visible. ott drain port SISTER oss sxrtine vort Fig. 3-6 Lubrication Drawing of Swing Reducer () Oil mass inspection for main and sub-lifting reducer should be performed every 250 hours, and oil change for that should be performed every 1000 hours. Oil filler plug and oil level plug on the reducer should be disassembled at first, and then the oil drain plug should be disassembled, that is to say, the oil can be drained now. The oil drain plug should be fixed at first, and then 4 L 220LS2 industrial gear oil should be filled into from the oil filling port, finally, the oil filler plug and oil level plug should be well installed. Keep the machine flat on the ground, then disassemble the oil level plug. Oil mass is adequate if oil level is visible. 18Fig. 3-7 Lubrication Drawing of Main and Sub-lifting Reducer 3.5.3 Precautions: (1) When oil changing, the drained oil should be filtered through a clean cloth before flowing into containers, observing whether there is any metal powder. (2) When oil checking, new oil should be filled timely in case of oil shortage. (3) When oil changing, new gear oil must be filled after all the residual oils being drained out. 3.6 Maintenance work on the hydraulic devices 3.6.1 The maintenance work on the hydraulic devices should be conducted according to the requirements specified by fig 3-12 and table 3.5. Fig 3.12 Diagram on Checking the Hydraulic Oil Tank ‘Table 3.5 Table on the Check Items and Check Interval for the Hydraulic Devices Sewence| sme on Check interval (hour) aes volume | 8 | 50 | 250 | 500 | 1000 | 1250 | 2000 1 Hydraulic oil quantity Check * 2 | Hydraulic oil tank deposition Check a 3 | Replacing components of pipeline oe 19A Soc500bHydraulic Crawler Crane Maintenance Manual filter Replacing filter components of the - * pillot system 7 5 Replacing hydraulic oil 200L 6 Cleaning the suction ol filter Replacing breatherdevice | u * components Notes: mieans the related components needs checking 3.6.2 Check items and steps 3.6.2.1 Oil quantity of the hydraulic oil tank should be checked every 8 hours; and refer to table 3.7 ‘conceming to the check work of the state of the hydraulic oil 3.6.2.2 Check before starting the engine: before the engine started, be sure to check oil quantity in the hydraulic oil tank. Ifthe oil in the tank is reduced too fast, it indicates that there is leakage in its pipeline or in its hydraulic components. Then you should tighten the pipeline connectors or replace some hydraulic components. In addition, too low (less than 20 * C) hydraulic oil temperature means bad oil fluidity. If ‘you conduct rapid operation under this circumstance, the hydraulic components may be damaged; too hot hydraulic oil (above 80 * C),lts deteriorating speed will be promoted. As a result, the service life of the hydraulic components would be shortened. Therefore, After starting the engine in cold environment, the engine should be preheated fully to get the engine oil temperature rise to about 20 ° C.. 3.6.2.3 Check after the engine started. (Refer to table 3.6 to conduct concrete check) ‘Table 3.6 Table on the Check After the Engine Started Check items Check method Judgment Purpose ‘When the speed of the a aera = Find out the abnormal condition Hydraulic oil Normal temperature: | ofthe hydraulic Tepenee [Seer pem 6 30MPR| se ore | armed ete of ste touch the hydraulic ol tank ° ————— ae yydraulic component No leakage is il Leake Visual estimati Find out the leakage ear il leakage sual estimation a out the leakage early Its temperature is 5 Pump Touch by hands oruse | higher than that of | Fitd Out the abnormal condition temperature | surface temperature m Sf prance meter | aa i an of the pump early Pay attention | Filt#out abnormal changes ofthe ¥ hydraulic oil, find out whether it | Senseits sound volume and | possible abnormal |" Pump noise : is mixed with air, whether the quality sound orto the . i ee pump is worn, whether its filter shia! screen is blocked Motor Pay attention to ‘Touch by hand, sense its Peel Find out the abnormal condition temperate eee ncerdeeatity | Possible abnormal the meron eat and noise amalty | sound orto the sesereananeenst 2A SOc500DHydraulic Crawler Crane Maintenance Manual filter Replacing filter components of the - * pillot system —_ tt 5 Replacing hydraulic oil 200L 6 Cleaning the suction oil filter Replacing breather device | u * components Notes: means the related components needs checking 3.6.2 Check items and steps 3.6.2.1 Oil quantity of the hydraulic oil tank should be checked every 8 hours; and refer to table 3.7 concerning to the check work of the state of the hydraulic oil. 3.6.2.2 Check before starting the engine: before the engine started, be sure to check oil quantity in the ‘hydraulic oil tank. Ifthe oil in the tank is reduced too fast, it indicates that there is leakage in its pipeline or in its hydraulic components. Then you should tighten the pipeline connectors or replace some hydraulic components. In addition, too low (less than 20 * C) hydraulic oil temperature means bad oil fluidity. If ‘you conduct rapid operation under this circumstance, the hydraulic components may be damaged; too hot hydraulic oil (above 80 * C),lts deteriorating speed will be promoted. As a result, the service life of the hydraulic components would be shortened. Therefore, After starting the engine in cold environment, the engine should be preheated fully to get the engine oil temperature rise to about 20 ° C.. 3.6.2.3 Check after the engine started. (Refer to table 3.6 to conduct concrete check) ‘Table 3.6 Table on the Check After the Engine Started Check items Check method Judgment Purpose When th th cntine ie aren = Find out the abnormal condition Hydraulic ot | eo pensre 3 ona, | NOMA temperate: | ofthe hydraulic system early s0 temperate | ee tice way | COC % 80°C) | as a te service a 7 aa yydraulic component No leakage is il Leake Visual estimati Find out the leakage ear il leakage fisual estimation es ox ge early Its temperature is 5 Pump Touch by hands or use | higher than that of | Fitd Out the abnormal condition temperature | surface temperature m Cf perature meter | | rate il nk of the pump early Pay attention w | Fld out abnormal changes ofthe y ae ____ | Sense its sound volume and | possible abnormal | ¥4rsulie oll find out whether it Pump noise : is mixed with air, whether the quality sound or to the . i aaa pump is worn, whether its filter Saou screen is blocked Motor Pay attention to “Touch by hand, sense its Perel Find out the abnormal condition temperate eee need eatity | Possible abnormal he menor eat and noise amalty | sound or to the sesereaneaneen 2»a Crane Maintenance Manual Remark il cannot permanently use , It will e replaced if it mixed with impurity or be deteriorated to certain degree. : ‘Table 3.7 Checking of hydraulic oil is mixed with foreign substances and deteriorated condition Spare material | Judgment | Judging method Dust or metal | Testing tbe Under the engine's starting condition, take powder | (transparent), | Appearance | some oil sample from the hydraulic oi intruding | new hydraulic | comparison | tank or from the pipeline, make a fiom the oil comparison on the turbidity with new oil outside Check on “Oil in the hydraulic oll tank is opacifying, — Heat the opacifying ol slightly, precipitate - —— water can be seen atthe bottom, Take out ‘Testiig tube | Appearance | opacified oil sample and iasert in red-hot Moisture | °ttansparent | comparison, | iron bar, sound like "ps-ps” would be container, new | Judging after | heard. Drip it onto the heated iron plat, hydraulic oi! | heated | sound like "pts-pts” would be also heard. : Before stating the engine, open the ol drain valve to take out oil sample, observe the precipitate water condition “Take out oil sample from the hydraulic oil ‘Testing ube or | Appearance | tank or from the pipeline, filling it into a - : . transparent | judgment | container. Make a comparison on the Deteriorate condition | container, new | Judging by | color and sell with new oil Oil which is hydraulic oi! | sense deteriorated seriously would emit - rmalodorous smell. 3.6.3 Waste oil in the hydraulic oil tank is drained according to the following method. 3.6.3.1 When draining waste oil, first detach the screw plug at the bottom of cut off valve, then open cut off valve, The oil will be drained. ARer finishing drain work, close the cut off valve, then screw in the screw plug and tighten it.g & SOC500DHydraulic Crawler Crane Maintenance Manual Stan a hee setter tempter on hi ie “platform it ve Fig3-13 Diagram of the Hydraulic Oil Tank 3.6.4 The filter element of the return oil filter should be replaced every 500 hours Its type : RFA-63 10F, delivered as a spare part. Replacing steps are shown in fig 3-13. 3.64.1 Disassemble: tum the red big bolt on the return oil filter, .pull out the whole filter element from the oil tank. ( hydraulic oil would not flow out when pulling out the filter element because the return oil filter is self-sealed ). 3.6.4.2 Cleaning: take out the outside cover and clean the inside part of the cover thoroughly, especially the bottom of the cover. 3.6.4.3 Replacement: replace the filter element. 3.6.4.4 assembling: when assembling the filter element, be sure to assemble it in the right place, not tilt. When assembling the cover, the tighten torque of the installed bolt is 50. Nm 3.6.5 The hydraulic oil should be replaced every 1500 hours; the same hydraulic oil should be replaced with the previous one. (The hydraulic oil that the producer provides for the first time is N46 anti- ‘wear hydraulic oil). Oil volume for each replacement is 2001 or so. ‘The concrete steps for each replacement is as follows: 3.65.1 Detach the screw, , take off the upper cover of the air filter, and through the filter screen, filling hydraulic oil until the oil level reaches the standard oil level line. 3.6.5.2 I the hydraulic oil is found out to be abnormal according to the check result, no matter how long the machine has been running, the hydraulic oil should be replaced. If the hydraulic oil is contaminated or deteriorated too soon , replace the oil ater searching the reason. 3.6.5.3 the following points should be paid attention to when replacing the hydraulic oil: specified hydraulic oil should be used to prevent dust and sand from being mixed into the oil tank; clean the oil tank and the filter; ifthe hydraulic oil for replacement is not the same as the original one, the oil tank should be cleaned thoroughly and at the same time, the hydraulic oil in the pipeline and the hydraulic components should also be replaced. 3.6.5.4 The following points should be paid attention to when supplementing the hydraulic oil: during, the maintenance period, the hydraulic oil should be supplemented to the required volume when the oil is found out to be insufficient. The oil brand for supplement should be the same as the original one. 3.6.6 The suction oil filter should be cleaned every 1500 hours; the process for cleaning is as follows: ‘The suction oil filter is installed in the hydraulic oil tank. First detach the air breather, and then you 2a SCC500DHydraulic Crawler Crane Maintenance Manual can see the suction oil filter. Take out the suction oil filter from the hole of the air breather. The filter element is made of metal, so it can be used after being cleaned. Because there is magnet in the handle of the suction oil filter, metal powder on the handle that is absorbed by the magnet should be cleared out while the filter element is cleaned. 3.6.7 the element of air filter with its type QUQ2-20 x 1.0 should be replaced every 1500 hours. 3.6.8 The pipeline filter for the servo system with its type LPF BN/HC 240 GE10B1 X/-B6 should be replaced every 500 hours. The concrete process shown in fig 3-14 is as follows: rome sem se, se TMI we Fig 3-14 Diagram of pipeline filter of Servo system ‘Tum the hexagonal head under the shell with a wrench. Pull down while tum, pull out the filter ‘element together with the shell. Replace the O- ring and the protection grommet while replacing the filter element. And clean the inner part of the shell. 3.6.9 Cleaning and replacing of the hydraulic pipeline: 3.6.9.1 Check daily whether there is leakage or is damage with the hydraulic pipeline; new hose should be replaced in time in case of cracks or aging with the hydraulic hose to avoid danger caused by use of the expired hose. 3.6.9.2 No scratch is permitted for the O- ring used in the pipeline. When assembling it, be sure to scratching it. 3.6.9.3 After detaching olive type tube union, replace the olives and unions and use new one. 3.6.9.4 Components of the hydraulic pipeline system should be assembled after being cleaned. 3.7 Tighten the bolts, nuts and hydraulic pipes. ‘When conducting daily check and monthly check, we should check whether bolts and nuts in all parts are loosened or lost, then tighten the loosened ones and complement the lost ones according to the check results. 2BTable 3.8 Table on bolts’ checking and tighten ‘SCC500Dliydraulic Crawler Crane Maintenance Manual Tighten | Check se Diameter of Center torque eal sequence : wo] im Bolt Position bolt distance ‘number 7 * omy (eo Em | a 50 | 500 i its for sw : installation bolts for swing roll ” 7 nae disk _ Engine installation bolts 12 18, 100 * ° Engine installation bolts 12 6 100 * oO ation bolt upper 4 Installation bolts for the uppe 12 8 90 «lo support rollers 5 Installation bolts for the lower 20 a 400 x|o rollers Installation bolts for the main 20 0 650 6 lifting drum (type 1) s ae Installation bolts for the main 16 4 330 */ Oo lifting drum (type IL) Installation bolts for the 20 37 650 x) Oo 7 auxiliary lifting drum (type 1) Installation bolts for the 20 40, 650 *) oO auxiliary lifting drum (type II) | lssliton bots for the swing | 5 = so alo device Installation bolts for the Boom 9 20 c 650 Oo hoist device a i To | lesion bois forte] ‘s 0 ae traveling device A Installation bolts for the Cab 20 140 650 * 12 _ | lasliton bots forthe motors | sso xlo ofthe main _/ aux, dram ation bol 7 B insall ition bolts for the swing 16 350 «lo Installation bolts for the Boom 4 16 50 hoist drum motor a | 2 15 Installation bolts for the 2» 155 650 «lo traveling motor ts for 16 Installation bolts for the A-shape 16 250 «lo frame post 17 Counterweight installation bolts 30 46 750 * oO 18 Pump-engine connection bolts 10 16 50 * [ec] 19 Bolts on the hydraulic pipelines * oO Notes: sx means preliminary tighten & Means checka owe ler Crané Maintenance Manual O Means tighten again ‘Table 3.9_ Tighten Torque Table of the Hydraulic Pipes I 1/4 | 3/8 | V 4 y | Nominal diameter MB) WA) 3B) V2) 34) | 14 | 12 Pipe connector tubular thread Tighten . " — | so | 70 | 95 | 180 | 210 | 350 | sso Torque (N.m) (High pressure) os (Low pressure) 15 | 20 | 30 | 50 | 70 | 110 | 160 | 200 3.7.1 Points for attention 3.7.1.1Due to too large tighten torque, an auxiliary wrench with extension pipe should be applied to increase the torque by 4 times. 3.7.1.2 Carry out the required daily, monthly and yearly check and tighten work strictly. 3.7.1.3 The tighten torque on the hydraulic pipe must conform with the torque listed in table. Tighten torque greater than the above tables will deform the pipe unions at its sealing interface position. Especially when the casting partis tightened, it may crack 3.7.14 No scratch on the junction surface of the hydraulic components is permitted. These ‘components should be cleaned carefully, and avoid dust and powder from entering in, 3,8 The maintenance of the battery AAs the power source for starting the engine, the electric control system, the illuminating system and the auxiliary electric devices, the battery plays a very important role. The technical properties of the battery are all in conformity with the standards of the PRC specified in the lead acid battery GB5008-91 for hoisting use. Therefore, the battery should be maintained properly to keep it in normal condition. 3.8.1 Maintenance work while operating: 3.8.1.1 The battery should be checked and maintained every 50 hours of operation. 3.8.1.2 Check whether the batteries connecting terminal is tightened to avoid affecting its normal use due to electric sparkling. 3.8.1.3 The surface of the battery should be kept clean. The surface the connecting terminal can be ‘pasted with some dry grease or Vaseline to avoid its being corroded. 3.8.1.4 The breather plug of the battery should be tightened firmly to avoid the acid liquid splashing out. 3.8.1.5 The height of the electrolyte level should be strictly controlled within the prescribed limit when checking the electrolyte. The electrolyte level should be kept 15mm to 20mm higher than the pole plate. Distilled water instead of electrolyte should be filled into the battery when the liquid level declines due to the electrolyte's evaporation. 3.8.1.6 Check the charge circuit once a day, and observe whether the instructions of the electronic ‘monitor in the Cab are normal. 3.8.1.7 Charge it normally under the following conditions: 3.8.1.7. the density of the electrolyte drops to less than 1.17g/em3 ( below 25°C) 3.8.1.7.2 The light is dim and the electric voltage is not sufficient. The tested electric voltage per cell is less than 1.8V when discharging. 3.8.2 Maintenance work when it is stored (not to use) 3.8.2.1 when it is not in use, the battery should be detached and preserved in a clean, dry and ‘well-ventilated storehouse with the temperature being 5°C to 40°C. The battery should not be preserved with the electrolyte init. Ifit should be preserved with the electrolyte in it under special conditions or after 2sA itis discharged, the battery should be charged once a month and be totally discharged every three months. 3.8.2.2 To be sure not to confect electrolyte with river water, well water or water with impurity. 3.8.2.3 When the battery is not in use after being installed on the crane, be sure to detach the earth rope end and check it once @ month; be sure to charge it in time. When itis put into use once again, it must be charged first. 3.8.2.4 The electrolyte in the battery contains sulfuric acid which may corrode people's skin, eyes or clothes, Therefore great attention must be paid to prevent the electrolyte from being splashed out. The following methods can be adopted in case of an accident occurs 3.8.2.4.1 Wash the skin immediately if itis splashed with the electrolyte. 3.8.2.4.2 Gargle the mouth immediately, drink a lot of water or milk and go to the hospital to consult the doctor after the electrolyte is splashed into one’s mouth. 3.8.2.4.3 Be sure to keep the vent hole on the breather plug well ventilated for very little inflammable ‘gas (hydrogen )may be produced in the battery. Be sure to keep it far away from open flame when using fr storing it to prevent the occurrence of accidental explosion hazard caused by the meeting of the inflammable gas and open flame.. 3.9 Adjustments on the Crawler Tensioning Device. ‘The adjustment on the tensioning of the crawler should be conducted when the crane is parking on the flat ground. The body of the crane should be moved forward a little bit before the adjustment so as to concentrate the loose part of the crawler above the driving wheel, thus making it more convenient to be adjusted. SCC500DHydraulic Crawler Crane Maintenance ManualA Crawler Crane Maintenarice Manual Hydraulic jack. Fig 3-15 Diagram of adjusting the crawler tension condition Adjustment steps: 3.9.1 Detach the right, left sides bolts and the protective hoods; 3.9.2 Align two hydraulic jacks to the related shaft respectively; 3.9.3 Two persons press the handles of the hydraulic jacks slowly to push the shaft and the idler forward. There will be space between the track frame and group A shims. 3.9.4 Terminate the movement of the jacks after the tensioning state of the crawler is adjusted proper. Selecting proper thickness group B shims, tuck them into the space between track frame and group A shims, ‘Then install the protective hoods. 3.10 Check and replace ofthe steel rope ‘The service life of the steel rope is different referring to different operation conditions of the crane. ‘The steel rope which is used either for lifting or Boom hoist should be strictly-checked regularly, once it is confirmed to have been damaged, it must be replaced immediately. 3.10.1 Check: 3.10.1.1 Daily check: any visible part of the steel rope should be checked on each working day so as to identify its damaged and deformed condition in time. Special attention should be paid to the position where the steel rope is connected with the crane. Any obvious change ofthe steel rope that is been found ‘out should be reported and the reasons for the change should be investigated and proper measures should be taken to cope with it. 3.10.1.2 Check position: 3.10.1.2.1 The whole length of steel rope 3.10.1.2.2 Moving part of the steel rope and the initial and the end part of the steel rope where it is fixed. 3.10.1.2.3 The part that crosses or through the sheave group. 3.10.1.2.4 During the lifting period, the part that crosses the sheave should be paid great attention to under the circumstance thatthe mechanism is in repeated operation. 3.10.1.2.5 The part where for balance of sheave and the part that may be worn because of external factors 3.10.1.2.6 Inspect for its inner corrosion and fatigue. 3.10.2 Replacement: replacing the steel rope should be determined by its broken, corroded and fatigued condition. If one of the following conditions occurs, the steel rope should be replaced immediately. ~ 7A ‘S0C500DHydraulic Crawler Crane Maintenance Manual 3.10.2.1 Broken wires: 10% or above of the single wires (stuffing wire excluded) have been broken in one spiral lift stroke of the steel rope.. 3.10.2.2 Broken wires: even in very small numbers at the steel rope end or the near part of it shows that the stress it bears there is very high. If its length is enough, the part of the broken wires should be cut off and be assembled properly. 3.10.2.3 Concentration of the broken wires: if broken wires are concentrated in the part which length is tess than 6 times of the diameter of the steel rope or concentrated in any one of the strands, even the number of the broken wires is small. 3.10.24 Increase of the broken wires: broken wires begin to appear after the steel rope is put in use for a period of time and the broken wires are increasing gradually with its interval being shorter and shorter. 3.10.2.5. Wom out: the cross-sectional area of the stecl rope is reduced caused by worn out, thus causing the reduce of its strength. When the worn out diameter of the outside layer of the steel rope reaches 4% of its diameter or the nominal diameter of the steel rope is reduced by 7% . 3.10.2.6 Broken strands: the diameter of the steel rope is reduced due to broken strands. 3.10.2.7 Blasticity reduce: when the diameter is reduced, or the spiral lift stroke of the steel rope is. extended, all parts of the steel rope are pressed firmly or the space between wires or between strands is very small. all these listed above are called elasticity reduce.. Though there is no new broken wires, the steel rope can not be easy-bent obviously, which may be broken suddenly when it is loaded with dynamic load. Therefore it should be scraped immediately 3.10.2.8 Corrosion: when the steel rope is corroded gravely both outside and inside. 3.10.2.9 Deformation: when the steel rope is lost in normal shape, such as it has visible wave or cage shape distortions, or strands were forced out, or the wires were extrude out, or the diameter of the steel rope is increased partial or decreased partial or part of the steel rope is deformed gravely as below: flattened, twisted, loosened, or bent. Besides the items listed above, fatigue is the major reason that the steel rope is damaged under many operation circumstances. Sometimes no defect can be found from its appearance, there may be broken wires inside.. Therefore even though the check results conducted according to the items listed above is up to standard, if the actual working hours of the steel rope has reached 2000 hours, the steel rope should be replaced by a new steel rope in time. 3.11 maintenance work under special working conditions 3.11.1 Operation under muddy or rainy or snowy environment: 3.11.11 Maintenance work before operation: check whether plugs or pins are loosened. 3.11.1.2 Maintenance work after operation: clean the crane, check whether bolts or nuts are loosened ‘oF lost. Filling in oil and grease in needed position. 3.11.2 Seaside operation: 3.11.2.1 Maintenance work before operation: check whether plugs or pins are loosened. Smear grease at rusty positions, especially at the connecting rod and the control rod. 3.1.2.2 Maintenance work after operation: Flushing the track frame to take off the salt content, smear grease at rusty places and conducting maintenance work on the electric components carefully To prevent the corrosion 3.11.3 Maintenance work under dusty environment. 3.11.3.1 Maintenance work on the ar filter: clean the filter element and the dust collector in advance. 3.11.3.2 Maintenance work on the radiator: clean the central part of the radiator frequently to avoid it from being clogged. 28A em. SCC500DHydraulic Crawler Crane Maintenance Manual 3.1.3.3 Maintenance work on the fuel system: clean the components of the fuel filter in advance. 3.11.3.4 Maintenance work on the electric components: clean the contact surface of the starter and the 3.11.4 Maintenance work under rocky environment: the crawler should be looser compared with the ordinary environment, Pay attention to whether the traveling device is damaged, o cracked, or worn, or scratched, whether bolts or nuts are loosened or lost. 3.11.5 Maintenance work under the stone-falling site: the top of Cab should be installed the protective hood. 3.11.6 Maintenance works in cold areas: low viscosity lubricant should be applied, and the battery * should be charged in advance. 3.11.7 Maintenance work under other working conditions 3.11.7.1: conduct daily check on the wear condition of the sheaves for if the sheave on the A-shape frame, the tensioned device and the working device is installed in different positions, their wor state is different. Replace them in time when necessary. : 3.11.72 When maintenance of lower rollers, install them again, It should be tured 180° $0 as to extend the track surface life of the crawler. 3.12 Points for attention when the crane would be stored for a long time If the crane would not be in use for a long time (more than two weeks), the following maintenance ‘work should be done in order not to affect its property when the machine is ptt into use again. 3.12.1 Cleaning: clean the machine thoroughly and check whether the traveling device is abnormal. 3.12.2 Lubricating: smear a thin layer of grease at the surface of the parts that may be corroded easily. 3.12.3 Maintenance work on the battery: detach it and store it after being fully charged, detach the earth cable. 3.3124 Dust prevention and moisture prevention: Drain all the coolant and hanging a “No water” sign ‘onthe hood.. Store the machine in the storehouse; cover the diesel engine with a plastic film to prevent ‘moisture. 3.12.5 Tools: store them after checking .and cleaning. 3.12.6 Operating the machine after lubricating: run the engine at low speed once a month regularly in order to avoid the engine from being over-wom caused by the broken oil film or rusty over the next actual running. During the actual running period, please pay great attention to the temperature change of the cylinder head of the engine. Notes: Doperating the machine after lubiicating means performing repeated and continuous ‘operation such as traveling, slewing, lifting etc after the machine gets preheated. @when operating the machine again, pay attention to the quality of the lubricant for the lubricant gets bad easily owing to less operation 29aw ‘SCC500DHydraulic Crawler Crane Maintenance Manual 4.Instruction on judging and eliminating the usual failure. Table 4.1 Trouble shooting of the engine —— Failures Possible reasons Eliminating methods Teonnectors for the starting “The engine can nt | EE evi are loosened or| 1. Check and tighten the connectors rae eae ae ne | conodeds firmly; are 2.The battery is not charged | 2. Check the voltage of the battery sufficiently; 3. Replace the starter. 3.Failure on starter. 1. Check or repair or replace the | ‘The engine can not | 1. Because ofthe cold weather, | THHATY starting device under cold be started or it is | 2.There is air in the fuel = 2. breed the air from the fuel_system 2 | Yay difficult to start | system; and check whether the suction pipe (omoke is exhausted | 3. Theres impurity inthe fuel. | Eas the east | Ate tenidon switch i) 3 The fuel should be fitted. or replaced 4.Replace the ignition switch The engine can) | There is no fuel in the fuel} rotate but can not | Filling fuel. 3 | be started (no smoke , 2.Drain the water from fuel-water is exhausted from sae oate nee ¥Y | separator or replace the fuel filter. the exhaust pipe) 1.Breed air from the fuel system and There is air in the fuel | check whether there is leakage with . system. the suction pipe. 4 ones S a 2.The fuel filter is clogged. | 2.Drain the water from the fuel-water ecpming 3:The fuel gets waxy because | separator or replace the fuel filter. cold weather Filling the fuel tha is specified for 4.There is impurity in the fuel. | cold weathers. = 4 Filtrte or replace the fuel The fuel level in the fuel | 1.Refuel the fuel tank. 5 _| Teil speed ofthe tanks too ow. 2.breed the air from the fuel system engine isnot stable | 2.There is ir in the fuel | and check whether there is leakage system. with the suction pipe. 1The oil level ofthe engine oil | 1.Filling or drain the engine oil is not correct. 2.Check whether the rain proof cover ‘The engine oit | 2THE emit ol is diluted by | or the cap of the engine oi filing 6 water port orthe oil dipstick are lost. pressure is too low 3.The specification of the engine oil is not proper. 4:The oil filter is blocked 3.Replace the engine oil, Replace the engine oil and the oil filter. 30$0c500DHydraulic Crawler Crane Maintenance Manval 1.The specification of the 1. Replace the lubricant ‘The lubricant | lubricant isnot proper. , 7 | rsaureiatootigh | 2 Satay vahe oft pump is | 282 WE safey vale of oi clogged Eee | 1-Filling the coolant 1. The coolant level if 0°) 5 Check the radiating fin of the low 3 radiator, clean and repair it. a ——r—C—r—C—“ “=$E—s— 8 | the coolant is too | radiator is damaged or blocked | oe Serine isto eneg |THE themestat should be opened Ae therm ie damagen | Woemtem. 82" ~83" CIE it is damaged, replace it. 1. Check the radiator, the heater, hose eee oe or unions to find out | Cootant consumed | radiator orwith tbe bester | eT ine and ie too much 2.There is leakage with the sate pateftiecagne, | components and contin wheter there is leakage caused by the seal ring or the seal gasket. There is rusty scale in the Tere is impury | C200 THe proper mixture | Drain and ish the cooling sytem, wo | eee of the filing in proper mixture of the ‘Antisfreeder and water is not | antifreezer and water. ny : " ema ‘Tere oo much sediment | Replace the lubricant othe ol filter - 1. The engine is with too heavy ee | Had 1 Reduce the load ofthe crane 2 | smoke exhausted | 2. There is, air in the fuel 2 Breed the sir fom the ful system, system. 3.Clean or replace the air filter. ee 3. The air filter is colgged The rated speed of | 1. The machine is overloaded. | ILReduce its load or use low traveling 13 | the engine can not | 2. There is failure with the | speed. reach when lotded | tachometer 2. Check the tachometer 1. Reduce its load or use low 1. The machine is overloaded. | traveling speed 2. The oil level of the lubricant | 2. Drain the Iubricant to proper oil 14__| Tie output power is | is too high. level. too low 3. ‘There is air in the fuel | 3. Breed the sir from the fuel system . system. and check whether there is leakage 4. The fuel quality is poor. | with the sution pipe. 4. Use high quality fuel 1.,Use high quality fuel. ts | T__ engine is | 1. There is impurity inthe ful. | 9° Sh i fom the fuel system misfire 2.there is air in the fuel system and check whether there is leakage 31a& SCC500DHydraulic Crawler Crane Maintenance Manual ‘With the suction fuel pipe Lm Toadea, | 1 Reduce the load of erane othe a a onde) 2. Use high quality fuel. The fuel quality is poor 3. Breed the air from the fuel system Knock of the | 3.There is air i fuel 16 2eTee is air in the el) and check whether there is leakage ae an atv 44 angle of fuel | “th the suetion fuel pipe. fedingittes hte | 4Adiust the advanced angle of fuel : feeding more early. 1. Check and repair the leaking position. ; fuel leakage. vy [Foo much foe is | Ther is vei fatats” | 2. Usehigh quality ue consumed 3 Theopention ioneeony 3. Conduct the operation such as os Proper. | gearshift, deceleration and : idle-running propery. Tighten ing belt and confirm The tension ofthe driving belt | TEM the driving belt and con : : Whether the operation of the. water The noise of the | is not sufficient or its operation 18 Weieo loud | is sbecrnal hon it av teeraty | Pump, the belt pulley , the fan shat een er when its Reavily | sg fan shield and alternator are loaded. normal, 1. The battery connector is The battery isn 1. Clean an of the ery it not | dee ‘ id tighten the clamp eager ee tre ematoe ie | bate cable connector 19 | charged fully by the a of the altemator 18 9. Check and adjust the bet idle. alternator : 3 Tighten the fixed screw of the belt 3. The belt pulley on the shaft ie of the alternator is loosened, e ‘Table 4.2 Table ofthe hydraulic system trouble shooting — Failures Possible reasons | Eliminating methods | Remark 1. Pilot pump failure. | 1. Check or replace the 2. Pilot overflow valve | pilot pump. ‘The engine can run | failure (only for 2. Check and adjust s ee 1 normally, but no pilot | B-type) the pressure of the ms pressure, 3.Suctionfiteris | over flow Valve —_ blocked. 3.Clean or replace the | immediately. suction filter 7 1. Pilot system 1. Search for the leakage. leakage place ‘The engine can run| 2. The suction fteris | 2. Clean or replace the 2 | normally, but the pilot | blocked oil filter, pressure is too low 3. Pilot over flow valve faiture (only for B-type) 3. Check and adjust the over flow valve pressure. 32a 2 S0C500DHydraulic Crawler Cran 1. Hydraulic pump | 1. Check or replace the . failure. main pump. ie ae 2. Pilot conto valve _| 2. Check the pilot 3 [eer Ranate te ecu (8S: control valve. on 3. Valve or pipeline | 3. Clean the blocked. components of the pipeline 1. swing pumpis | 1. Repair or replace failure. the swing pump. 2. swing brake isnot | 2. Move the swing : opened. handle, check whether bs 4 | Noswing movement | 3. Suction oil filter is | there is hydraulic oil at | StP the blocked P port of the swing | machine ee immediately. 3. Clean the filter sereen ofthe filter. + T: Inner leakage ofthe | L. Inspect or replace swing motor the motor. 5 | Te swing movement is | 21tis overloaded. | 2. Reduce its load * powerless 3. Valves and 3. Clean the pipeline Pipelines of the swing. | and the components system blocked : 1The telescopic shift} 1. Pull out the rod of the track | telescopic rod tothe frame at the traveling position. «¢__| Te let traveling device | telescopic position. | 2. Clean the telescopic can not move 2.The telescopic valve | valve. of the track ofthe track frame Frame is blocked. 1. There is toomuch 1. Slow down its resistance on the _| traveling speed. traveling device. 2.Clean the central | yc 2.The central swivel | swivel jointorthe | The traveling device can | joint or the pipeline is_| hydraulic pipeline of | 5 7 |not move or its | blocked. the traveling device. movement is powerless. | 3. There is leakage | 3. Check or replace the with the traveling | motor. motor. 4. Check or replace the 4, There is faiture with | main pump. ____| the hydrautie pump. ‘The speed of the| 1. Thereis leakage | 1. Check or replace the 8 | actuated components are | with the pump or the | pump or the moter. slow motor. 2. Clean the pipeline. 3Aa ‘scc500Diydraulic Crawler Crane Maintenance Manual 2. The hydraulic pipeline is blocked. 3. The filter is blocked. 4. The pilot handle is not pulled to the right position. 3. Clean the oil filter. 4, Adjust the pilot handle to the right position, The main or auxiliary 1. The main safety valve fails to work. 2. There is failure with 1. Adjust the pressure ofthe main safety valve. the hydraulic pump. | 2. Check or replace the lifting drum can not Seance noncnenris |3:THebalance valve | main pump. rowers fails to work, 3. Adjust the pressure 4. The hydraulic | ofthe balance valve. pipeline is blocked. | 4. Ctean the pipeline. S.Itis overloaded, | 5. Reduce the load. the telescopic shift} 1. Put the telescopic rod ofthe tack | shift rod at its frame is atthe telescopic postion. 10 | stretched out or drawn s the left traveling | device. device is closed. __ 3. Cheek the telescopie 3:There is failure with | valve forthe track the track frame fame. telescopic valve 1. The pilot pumps | 1. Check or replace the failure pilot pump. 2The pilot overflow | 2. Check and adjust The brakes for the min | ive future (only for | the pressure of Wer auriliary TRIOS | ype B) overflow valve Gee eeeea. | | athe peeline af hep | a1 Cias Getecie! pilot system is blocked 1. The pilot overflows | 1. Check and adjust valve failure (only for | the overflow valve type B). pressure, 2. The hand-operated | 2. Check the The clutch of the main | direction valve failure | hand-operated 12 | titing drum is not | and the hydraulic | direction valve or the separated controlled valve hydraulic controlled failure ofthe clutch. | valve. 3. The pipeline of the clutch system is blocked. 3. Clean the pipeline. 34a 1. The filter is 1. Clean the oil filter. blocked, 2. Replace the ‘There is - poise in | THE oil viscosity is | hydraulic oi. 3 to0 low. 1. Preheat the hydraulicsystem * 3. The hydraulic oil | hydraulic system. ‘temperature is too low. 1. The radiator or | 1. Wash and clean the the pipeline is radiator or the blocked. pipeline. 2.The hydraulic oil | 2. Replace the | brand isnotcorrect | hydraulic oil se |e toda Seta | 3 Reps deteriorated hydraulic oi. 4. The oil quantity in | 4. Filling the oil into the hydraulic oil tank | the hydraulic oil tank isnot sufficient. to the specified oil level. 1. There is airin the | 1.Breed the air hydraulic system. 2. Tighten the clamp 2. The fixed pipe of pipeline. clamp of the pipeline | 3. Wash the valve part 15 _ | The hydraulic pipeline is | is loosened. 4. Inspect or replace vibrated violently 3. The over flow valve | the pump, or the ‘or the safety valve is | motor, or the valve. blocked. 4, Pump, motor, valve failure. Hydrate ol is leakage | E™B€ union o# 1. Tighten the union or or pemmesting, at the | OmmCCOr are not connector 16 | ior or connector or | iehtened 2. Replace the sealing ae 2.The sealing parts are | parts damaged 1. The working ‘| 1. Replace witha pressure of the hose is | suitable hose. not conform with | 2. Replace the hose. 17 | Hose explosion and | rated pressure. 3.Wash the hose and cracked 1. Thehose is | unions or connectors aging or scratched 2. There is blocked atthe hose union Notes: when there is failure with the components marked with % , it is prohibited to disassemble or adjust the related components, and contact the manufacturer of the crane. 35& ‘SCC500Dliydraulic Crawler Crane Maintenance Manual operating, poking fork are rusty. _ Tabled 3 Trouble sho uence = Failures number _ 7 1. The tightness for the - ; 1. Adjust its tightess of the two ‘The traveling device is | le and the right sides 1 sides to the same. deviation crawler are different. 2. Adjust and tighten the crawler. | 2. The crawler is loose. 1. The crawler is tightened too much 1. Adjust its tightness sen sane [2 THE wounds son, | AONE TE = © is t00 “Filling, leveling a > 7 oe | 3 There is hard soil or iregthening the eect resistance on strengthenin nn ee ened corre (eee eeaeaeeaneas traveling device. 3. Take out the hard sil or rock. the track —plate( shoe) and the driving wheel or the idler. 1. The crawler is loose. 2. The pin hole of the 1. Adjust and tighten the crawler. track plate is wor out 3 | The crawleris slipping 2. Replace the track pate. 3. The inner gear surface 3. Replace the driving wheel. of the driving wheel is wor out 1. There is faifure with the planetary reducer. 2. The locking device for the pawl isnot a 1. Maintain the planetary reducer. ‘The r hates 2. Dis the pawl of th main or aunitary or | “SOE . Disengage the pawl of the OY T 3 The brake for the ee 4 | Boom hoist drum can locking device. main or auxiliary drum not rotate. 3.Release the brake are not released 4. Puton the cutch 3. The clutch for the main or auxiliary drum are not put 7 on “The brakes for the The brake plate in the 5 Swing, Boom hoist and | reducer is worn out. | Maintain or replace the brake plate traveling are slipping. ‘The pins or shafts of the = It is very difficult to Remove the rust, and filling in the 6 connecting rod or oil or grease. 36a& & SOC500DHiydraul ic. Crawler Crane Maintenance Manual ‘Table 4.4 Trouble shooting of the electrical system Sequence Failures Causes Eliminating methods number 1. The battery cables is not | 1.Check the eables connecting at connected properly the battery terminal ‘ No electricity supply | 2. The battery cables is | 2.Reconnect the cables. with the erane ‘wrongly connected 3.Charging the battery 3.No electricity in the battery. 1. No. 2 oF No. 6 circuit is | 1. Check the cable connection on 2 ‘The starter can not be | broken, battery terminals started 2. The K2 relay is no acting | 2. Check whether the K2 relay is damaged. The warer in| THE i NOT suficient | Check whether the battery is 3 electric power in the battery | fully recharged if not, recharges powerless tL ‘The tachometer, the wwater-thermometer : 4 and the engine Oil) reo fuse tube is faulty. | Replace the F9 fuse tube pressure gauge all fail to work, power indicator is on. The electric bell | 1. There is failure with the | 1. Check whether the $5, S6 : alarms abnormally. | S8 and $9 limiting switch. | limiting switch is normal, ‘The alarming light | 2. The circuit is broken. 2. Check whether the circuit is also shines. broken. ‘The waming buzzer | 1. The S7 limiting switch is | 1. Check whether the $7 limiting ‘ alarms abnormally, | faulty. switch is normal. ‘meanwhile the | 2. The circuit is broken. 2. Check whether the circuit is alarming light shines. broken. 1. The $10 releasing button | 1. Check the SII releasing js faulty button. Sia working | > The working indicating | 2. Replace the working indicating 7 indicating light does not shine. light is faulty. 3. The cireuit is broken. light. 3. Check whether the circuit is broken. aa 5. Usual fuel, oil and grease recommendation ‘Table 5.1 Recommendation table on the engine lubricant ‘SCC500DHydraulic Crawler Crane Maintenance Manual Suitable temp. re | © | 30 | 20 | to | o | | 2 | 30 | 4 | 50 Band SAEISI-40 I SABIOW-30 SAESW-30 < (1) Put the excellent CUMMINS blue-Brand lubricant as the first option, (@) Lubricant with high viscosity can improve lubricants’ consumption; it can improve the operation ability of the engine in cold weathers. While operating under high temperature, SAE1SW-40 lubricant is recommended under most weather conditions. Use the low-viscosity lubricant limitedly. Such as using the SAE1OW-30 under - 5 °C as the lubricant can help starting the engine and provide sufficient oil to flow. But using the low-viscosity lubricant continously fora long time would reduce the service life ofthe engine due to its wear increasing, ‘Table5.2 Fuel recommendation table for engine use aes Saye si exe a () \\ Caution: : (1) Under most operation circumstances, ASTH2 fuel and diesel with its minimum cetane number being 40 ‘can guarantee its optimum economical efficiency and properties. At high-altitude places or places of very Jow ambient temperature, fuel with its cetane number greater than 40 should be used to prevent it from misfire and exhaust too much smoke. (2) Low sulfur fuel with its cloud point at least lower than 10 °C (minimum expected fuel temperature) should be used. Cloud point represents the temperature under which waxy crystal begins to form in the diesel (3) Commercially universal brand diesel should be adopted with its sulfur content less than 0.5% 38a sanv: ‘SCC500DHydraulic Crawler Crane Maintenance Manual (4) When refueling, be sure to keep the fuel clean and free from moisture or impurity. ‘Table 5.3 Recommendation table on lubricating grease table Season Winter Name No.3 molybdenum disulphide > lithium base grease No.2 molybdenum disulphide as lithium base’ grease A\ caster: the highest working temperature of the lubricating grease is 20 to 30°C _ lower than its dropping point. ‘Table 5.4 Recommendation table on gear oil + Industrious gear off 20 | 30 | 40 | so > oil 30°F av: [30 Appendix: ‘Table 1 Judging method on the wind velocity Wind velocity (m/s) Condition (onthe ground) o~02 ‘Smoke can rise vertically Smoke can indicate wind o3~1s direction but the wind direction indicator can not rotate People can feel wild, leaves make Might sound and the 16-33 wind direction indicator can rotate, Leaves and slim branches 34~s4 Gentle breeze shake endlessly and flags waveA ‘ScC500bliydraulic Crawler Crane Maintenance Manual 5S~79 Moderate breeze ‘The ground dust and paper can be blown over and little branches can be shaken 8~10.7 Fresh breeze ‘Small trees with leaves are swaying and small riffle are formed in the inland water surface 108~13.8 Strong breeze Big trees are swaying, electric lines sound gravely. It is very difficult to open an umbrella 13.9~17.1 ‘Moderate gale ‘The whole tee is swaying and it is very inconvenient to walk facing the wind 17.2~20.7 Fresh gale ‘Small branches may be broken and big resistance can be felt when walking against with the wind 20.8~24.4 Strong gale "Avery small part of the building may be ruined (for example: the chimney cover and the earthenware tile may bbe removed) 245~28.4 Whole gale 10 It seldom appears on the land. Once it appears, trees may be pulled up by the roots and buildings may be severely damaged 28.5~32.6 ‘Storm gale n It seldom appears on the land. Once it appears on the land, it may cause in extensive damage 32.7~369 Hurricane 12 It rarely appears on the land. ‘Once it appears, it would cause in disastrous damage. Notes: the wind velocity listed in the table is measured at the place with 10 meters higher than the ground. Table 2 Table on the connection of the screw thread and tighten torque | (JG/T 5011.11-92) unit Nm Performance grade 46 48 68 10.9) 129) Guarantee stress MPA 230 310 440 830 970 Specifications |_M6 45 56 89 10-12 14-17 17-20 of the screw [M8 10-11 13-15 18:22 | 25-30 34-41 4-48 thread Mex [10-12 | 1417 20-23 | 27-32 37-43 B52a ‘SCC500DHydraulic Crawler Crane Maintenance Manual Mio 19-23 2631 31-36 36-43 49-59 68-81 81-96 Mioxt | 21-25 28-34 35-41 41-48 55-66 76-90 90-106 Miz | 3330 | 45-53 55-64 64-76 | 86-103 | 119-141 141-167 Mi2x1.5| 35-41 47-56 57-67 67-79 | 90-108 | 124147 | 147-174 Mi4_| 53-63 71-85__|_ 87-103 | 103-120 | 137-164 | 189-224 | 224-265 | Mi4x5 | _ 57-68 72 |_94ti0 | 10-131 | 149-179 | 206-243 | 243-289 Mie | 82-98 | 111-132 | 136-160 | 160-188 | 214-256- | 295-350 | 350-414 Mi6x1.5|_ 87-104 | 118-141 | 144-170 | 170-200 | 228-273 | 314-372 | 372-441 Mis | 113-135 | 152-182 | 186-219 | 219-259 | 204-353 | 406-481: | 481-570 isx1.s | 127-152 | 171-205 | 210-247 | 247-201 | 331-307 | 457-541 | 541-641 M20_| 160-192 | 216-258 | 264-312 | 312-366 | 417-500 | 576-683 | 683-808 20x15 | 178-213 | 239-287 | 294345 | 345-407 | 463-555 | 640-758 | 758-897 Mm22_| 218-261 | 293-351 | 360.431 | 416-499 | se8.680 | 786-941 | 918-1099 M22x1.5 | 239-286 | 322-386 | 395-473 | 45a-s48_| 624-747 | 863-1034 | 1009-1208 M24_| 277-331 | 373-446 | 457-547 | 529-634 | 722-864 | 998-1195 | 1167-1397 M24x2 | 301-360 | 406-486 | 497-595 | 576-589 | 785-940 | 1086-1300 | 1269-1520 m27_| 405-485 | 546-653 | 669-801 | 774-801 | 1056-1264 | 1461-1749 | 1707-2044 M27x2 | 437-524 | 589-706 | 723-865 | 837-1002 | 1141-1366 | 1578-1890 | 1845-2208 Mm30_| 550-658 | 741-887 | 908-1087 | 1052-129 | 1434-1717 | 1984-2375 | 2318-2775 M302 | 608-728 | 820-982 | 1005-1203 | 1164-1393 | 1587-1900 | 2196-2629 | 2566-3072 M36_| 961-1150 | 1295-1550 | 1587-1900 | 1838-2200 | 2500-3000 | 3466-4150 | 4051-4850 M36x3_| 1017-1218 | 1371-1641 | 1680-2011 | 1946-2529 | 2653-3176 | 3670-4394 | 4289-5135 =_Ma2_| 1536-1839 | 2071-2479 | 2538-3039 | 2939-3519 | 4008-4798 | 5544-6637 | 6479-7757 ‘M42x3_| 1653-1979 | 2228-2667 | 2731-3269 | 3162-3786 | 4312-5162 | 5965-7141 | 6921-8345 ‘Mag _| 2308-2763 | 3110-3723 | 3813-4364 | 4415-5285 | 6020-7207 | 8327-9969 | 9732-11651 ‘Magx3_| 2513-3008 | 3387-4055 | 4152-4970 | 5207-5777 | 6556-7848 | 9069-10857 | 10598-12688 Life (%) actual working pressure! 10 200 00D suggested working pressure % Fig 3 Relationship between the actual working pressure and its service ite or tne nyaraunic nose Figure 3 shows that when the actual working pressure is equal to 1.25 times that of the suggested * one, its service life is only half of the normal. 4