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Section 1 Maintenance

SCC1000C Crawler Crane — Maintenance Manual

TY 0210

Two Leg Chain Sling

TY 0211

Three Leg Chain Sling

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Table of Contents1
Maintenance Safety Instructions9
1�1 Overview10
1�2 Maintenance Personnel11
1�3 Risks During Maintenance11
Crushing/Impact Hazard11
Entangling and Dragging Hazard12
Slipping, Tumbling, and Falling Hazard12
Thermal Hazard13
Gas, Dust, and Smoke13
Risk from Pressure Remaining in the Hydraulic System13
1�4 Fire Prevention14
Preventive Measures against the Risk of Fire14
Other Checks and Replacement14
1�5 Precautions before Lubrication and Maintenance Work15
1�6 Precautions During Lubrication and Maintenance Work16
1�7 Repair Work Safety Instructions17
Fuel , Lubricating Oil, Lubricating Grease, Coolant and the Capacities20
2�1 Overview20
2�2 Table of Recommended Common Grease23
Lubrication and Maintenance Form of Various Components28
3�1 Precautions for Inspection and Maintenance28
3�2 Purpose of Crane Maintenance28
Check Status of the Crane28
Preventive Maintenance28
Tightening Connecting Bolts, Nuts and Hydraulic Pipes29
3�4 Lubrication and Maintenance Schedule30
Engine System (Tier Ⅱ)40
4�1 Engine40
4�2 Fuel System42
Draining Fuel-Water Separator42
Replacing the Fuel Filter43
Checking Fuel Tank44
Checking the Fuel System Pipelines44
Refilling the Fuel45
4�3 Cooling System45
Cooling System Diagram45
Checking the Coolant46
Refilling the Coolant46
Cleaning the Radiator and Replacing Coolant47
Checking Drive Belt48
4�4 Air Intake System49
Air Intake System Diagram49
Checking the Filter Element50
Cleaning And/Or Replacing the Filter Element of Air Filter51
Checking Air Intake Piping and Pipe Clamp53
4�5 Visual Check of the Exhaust System54
Checking the Oil Level55
Replacing Engine Oil55
4�7 Precautions for Serving the Engine56
Slewing Bearing58
5�1 Lubricating Inside of the Slewing Bearing58
Structure of the Slewing Bearing58
Lubrication Requirements59
5�2 Lubrication of the Slewing Bearing Pinion Surface61
5�3 Checking the Slewing Bearing Bolt62
Slewing Reducer (Kawasaki)64
6�1 Slewing Reducer - Checking the Oil Level64
6�2 Slewing Reducer - Changing Oil65
6�3 Slewing Reducer - Checking the Brake65
6�4 Slewing Reducer - Checking the Connecting Bolt67
Hoisting Winch (Kawasaki)70
7�1 Main Hoisting Winch (Without Free-Fall Function)70
Main Hoisting Winch - Checking the Oil Level70
Main Hoisting Winch - Replacing the Lubricating Oil72
Main Hoisting Winch - Lubricating Winch Drum Bearing72
Main Hoisting Winch - Checking the Brake73
Main Hoisting Winch - Checking the Connecting Bolts74
Adjustment Steps86
Hydraulic System90
10�2 Replacing Element of Pipeline Filter Element93
10�3 Checking and Replacing Hydraulic Oil94
Checking Hydraulic Oil94
Replacing Hydraulic Oil95
Hydraulic Oil Replacement Interval95
Drain Water from Hydraulic Oil Tank95
10�4 Checking the Hydraulic System for Leakage96
10�5 Checking the Pressure Hose96
10�6 Replacing the Pressure Hose97
Types of Hydraulic Hose97
Identification of Hydraulic Hose97
10�7 Hydraulic System - Checking the Initial Pressure in the Accumulator98
10�8 Precautions on Maintaining the Hydraulic System100
10�9 One-Way Valve & Oil Can101
10�10 Tightening the Connecting Bolt102
10�11 Precautions in Quick Coupling Maintenance103
Electrical System106
11�1 Checking the Lighting System106
11�2 Checking the Limit Switches106
11�3 Battery Maintenance106
11�4 Preventive Measures against Cable Fire106
Fault Reasons for Fire in Electrical Parts or Cable106
Measures to Prevent Fire in Electric Parts or Cable107
11�5 Check Crane after a Thunderstorm108
11�6 Fuse109
Air Conditioning Device112
Composition of Air Conditioning Device112
Checking Air Conditioning Device112
Checking Contents114
Maintenance of Air Conditioning Device115
During-Operation Precautions115
Operator's Cab118
13�1 Checking the Windshield Wiper118
Checking the Sliding Door119
Refill the Windshield Wiper Solution Reservoir119
13�4 Checking the Traveling Levers119
13�5 Checking the Slewing Brake and Lock119
13�6 Checking the Switches, Buttons and Control Levers119
Others122
14�1 Lubricating Pins on Boom122
14�2 Lubricating the Hook Blocks123
14�3 Wire Ropes124
Lubricating the Wire Ropes124
Cleaning the Wire Ropes125
Replacing the Wire Ropes127
General Instructions on Operation and Installation133
14�4 Pulleys140
Checking Bearings on the Pulleys140
Checking the Pulleys140
14�5 Riggings142
Chain Slings for Lifting Application142
Use and Maintenance of Chain Slings145
Operation Requirements and Inspection Criteria of Riggings147
14�6 Measures to Protect Exposed Shaft Surfaces152
Checking the Crane154
15�1 Visual Check154
15�2 Regular Check156
Checking Large Scale Steel Structure156
Checking Winches159
Checking the Hook Blocks160
15�3 Checking the Other Parts161
Ladder161
Guardrail161
Safety Device161
15�4 Check and Maintenance under Special Working Conditions162
Working in Mud, Water, Rain, and Snow162
Working at Seaside162
Dusty Circumstances162
Stony Circumstances162
Site with Falling Stones162
Other Working Conditions162
15�5 Storage of the Crane163
Troubleshooting Guide166

SANY SCC1000C - Page 143

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