Sany All Terrain Crane SAC5000S Service Manual 2022

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Sany All Terrain Crane SAC5000S Service Manual 2022
Size: 67.31 MB
Format: PDF
Language: English
Brand: Sany
Type of Machine: All Terrain Crane
Type of Manual: Service Manual, Electrical and Hydraulic Pneumatic Diagrams
Model: Sany SAC5000S All Terrain Crane
Publication Date: 2022
Number of Pages: 736 Pages

Contents:
1 Introduction

1.1 Importance of This Manual​

1.2 How to Use This Manual​

1.3 Organization of This Manual​

1.4 Correction Request Form​

1.5 Contact Information​

1.6 General Repair​

1.6.1 General​

1.6.2 Cleanliness​

1.6.3 Removal and Installation​

1.6.4 Disassembly and Assembly​

1.6.5 Pressing Parts​

1.6.6 Locks​

1.6.7 Wires and Cables​

1.6.8 Shims​

1.6.9 Bearings​

1.6.10 Gaskets​

1.6.11 Batteries​

1.6.12 Hydraulic Systems​

1.6.13 Fatigue of Welded Structures​

1.6.14 Loctite​

1.6.15 Fasteners and Torque Values​

1.6.16 Lubricants and Fluids​

1.6.17 Wire Rope​

2 Safety

2.1 General Safety​

2.1.1 General​

2.1.2 Hazard Alerts in This Manual​

2.1.3 Machine Safety​

2.1.4 Operator Safety Information​

2.1.5 Operator is Important​

2.1.6 Operator Qualifications​

2.1.7 Job Site Safety​

2.1.8 Job Safety​

2.1.9 Surface and Underground Hazards​

2.1.10 Electrocution Hazard​

2.1.11 High Voltage Areas​

2.1.12 Transmitter/Communication Towers​

2.1.13 Pre-Operation Inspection​

2.1.14 Personal Protective Equipment​

2.1.15 Fire Safety​

2.1.16 Dust Hazards​

2.1.17 Repair Safety​

2.1.18 Electrical System​

2.1.19 Environmental Precautions​

2.1.20 Towing or Lifting the Machine​

2.1.21 Optional Attachments​

2.2 Product-Specific Safety​

2.2.1 Authorized Use of the Machine​

2.2.2 Unauthorized Use of the Machine​

2.2.3 Job Site Precautions​

2.2.4 Operational Aids​

2.2.5 Escape Tool​

2.2.6 Crush or Pinch-Point Precautions​

2.2.7 Crane Stability and Structural Integrity​

2.2.8 Wind​

2.2.9 High Altitude​

2.2.10 Load Charts Manual​

2.2.11 Counterweight​

2.2.12 Cold Weather Operation​

2.2.13 Load Moment Indicator (LMI) Systems​

2.2.14 Permissible Ground Pressure​

2.2.15 Personnel Handling​

2.2.16 Safety During Operation​

3 Electric system

3.1 Description​

3.1.1 General​

3.1.2 Alternator​

3.1.3 Batteries​

3.2 Carrier Fuse and Relay Panel​

3.3 Superstructure Fuse and Relay Panel​

3.4 Electric Service​

3.4.1 Preparations Before Electrical Parts Servicing​

3.4.2 Starter - Remove​

3.4.3 Starter - Install​

3.4.4 Alternator — Remove​

3.4.5 Alternator — Install​

3.4.6 Battery of Carrier Electric System — Remove​

3.4.7 Battery of Carrier Electric System — Install​

3.4.8 Anemometor​

3.4.9 Aircraft Light​

3.4.10 Anti-two Block Switch (A2B)​

3.4.11 Angle Sensor​

3.4.12 Height lamp​

3.4.13 Work Light of Boom​

3.4.14 Junction Box​

3.4.15 Cable Drum Outside Boom​

3.4.16 LMI Display​

3.4.17 Emergency Stop Switch​

3.4.18 Rocker Switch​

3.4.19 Operation Panel​

3.4.20 Joystick​

3.4.21 Hoist Monitor​

3.4.22 Pedals in Operator's Cab​

3.4.23 Windshield Wiper​

3.4.24 Windshield Washer​

3.4.25 Skylight Wiper​

3.4.26 Tricolor Light​

3.4.27 Work Light​

3.4.28 Slewing Encoder​

3.4.29 Third Wrap Protector​

3.4.30 Check Engine Error Codes​

3.4.31 Check Transmission Error Code​

3.5 Load Moment Indicating System​

3.5.1 E-touch Display Programming Procedure​

3.5.2 LMI Alarm Icons​

3.5.3 Parameter Setting​

3.5.4 Operation Parameter Setting​

3.5.5 LMI Calibration​

3.6 Troubleshooting​

3.6.1 General​

3.6.2 Multimeter​

3.6.3 How to Read Electrical Schematic Diagram​

3.6.4 No Display or Abnormal Display of Anemometer​

3.6.5 Boom Head Angle Sensor Error​

3.6.6 CAN Bus Error​

3.6.7 Carrier Bus Error​

4 Hydraulic system

4.1 Description​

4.1.1 General​

4.1.2 Special Attention on Hydraulic System​

4.1.3 Draining and Flushing Hydraulic Oil​

4.1.4 Removing Air From the Hydraulic System​

4.1.5 Parts Replacement​

4.2 Supply Pressure and Return Circuit​

4.2.1 General​

4.2.2 Hydraulic Filter​

4.2.3 Hydraulic Oil Cooler​

4.2.4 Hydraulic Pumps​

4.3 Valves​

4.3.1 General​

4.3.2 Pressure Setting Procedures​

4.3.3 Main Control Valve​

4.3.4 Hoist Counterbalance Valve​

4.3.5 Boom Tele Counterbalance Valve​

4.3.6 Boom Lift Counterbalance Valve​

4.3.7 Cab Tilt up/down Conterbalance Valve​

4.3.8 Auxiliary Operation Valve​

4.3.9 Hoist Brake Valve​

4.3.10 Swing brake valve​

4.3.11 Outrigger Directional Control Valve​

4.3.12 Emergency Valve​

4.3.13 Steering Governing Valve​

4.3.14 Rear Suspension Accumulator Valve​

4.4 Cylinders​

4.4.1 General​

4.4.2 Description​

4.4.3 Boom Lift Cylinder​

4.4.4 Boom Tele Cylinder​

4.4.5 Steering Cylinder​

4.4.6 Outrigger Beam Cylinder​

4.4.7 Outrigger Stabilizer Cylinder​

4.4.8 Suspension Cylinder​

4.4.9 Centering Cylinder​

4.4.10 Cab Tilt Cylinder​

4.4.11 Operator’s Footboard Cylinder​

4.5 Motors​

4.5.1 Hoist Motor​

4.5.2 Swing Motor​

4.6 Troubleshooting​

4.6.1 General​

4.6.2 Failure to Swing Right​

4.6.3 Fail to Swing Left​

4.6.4 Failure to Swing the Boom​

4.6.5 Erratic Swing Operation​

4.6.6 Main Hoist- Failure to Hoist Down​

4.6.7 Boom Lift Cylinder- Failure to Raise the Boom​

4.6.8 Boom Tele Cylinder - Failure to Extend the Boom​

4.6.9 Boom/Cylinder Pins - Failure to Pin out​

4.6.10 Oscillation Cylinder - Unintentional Action​

4.6.11 Auxiliary Steering and Centering Accumulators - Faulty Pressurekeeping​

4.6.12 Counterweight Cylinder - Unintentional Action​

5 Boom

5.1 Description​

5.2 Mechanical Principle​

5.2.1 Telescope Principle​

5.2.2 Boom Extend​

5.2.3 Boom Retract​

5.3 Main Boom - Remove​

5.3.1 Preparations for Removal​

5.3.2 Pivots - Disassemble​

5.3.3 Main Boom Assembly — Remove​

5.4 Main Boom - Disassemble​

5.4.1 General Description of Main Boom Disassembly​

5.4.2 Base Boom and Telescopic Cylinder - Disassemble​

5.4.3 Boom Telescope 1 Section - Disassemble​

5.4.4 Boom Telescope 2 Section - Disassemble​

5.4.5 Boom Telescope 3 Section - Disassemble​

5.4.6 Boom Telescope 4 Section - Disassemble​

5.4.7 Boom Telescope 5 Section - Disassemble​

5.4.8 Auxiliary Boom Nose Sheave - Remove​

5.5 Main Boom - Assemble​

5.5.1 General​

5.5.2 Boom Pins - Assemble​

5.5.3 Boom Tele 6 Section - Assemble​

5.5.4 Boom Telescope 5~6 Sections - Assemble​

5.5.5 Boom Telescope 4~6 Sections - Assemble​

5.5.6 Boom Telescope 3~6 Sections - Assemble​

5.5.7 Boom Telescope 2~6 Sections - Assemble​

5.5.8 Boom Tele 1~6 Sections - Assemble​

5.6 Main Boom - Install​

5.6.1 General​

5.6.2 Boom Pivots - Install​

5.6.3 Boom Accessories - Install​

5.6.4 Adjustment​

5.7 Main Boom - Inspect and Adjust​

5.7.1 Boom Inspection​

5.7.2 Wire Ropes Inspection​

5.8 Troubleshooting​

5.8.1 Boom Side Deflection​

5.8.2 Boom Telescoping Failure​

5.8.3 Boom Section Retracting by Itself​

6 Turntable

6.1 Description​

6.1.1 Hoist Assembly​

6.1.2 Swing System​

6.2 Parts Locatoin​

6.2.1 Description​

6.2.2 Turntable Frame Location​

6.2.3 Triple Hinge Location​

6.2.4 Counterweight Location​

6.2.5 Main Hoist Location​

6.2.6 Auxiliary Hoist Location (Optional)​

6.2.7 Superstructure Warm A/C Location​

6.2.8 Shelter Location​

6.2.9 Swing Bearing Location​

6.3 Repair​

6.3.1 Hoist​

6.3.2 Hoist Brake​

6.3.3 Swing Brake​

6.3.4 Swing Drive​

6.3.5 Swing Bearing​

6.4 Troubleshooting​

6.4.1 Main Hoist – Operation Erratic​

6.4.2 Swing – Operation Erratic​

7 Engine System

7.1 General​

7.2 Engine - Remove​

7.2.1 Preparations Before Removal​

7.2.2 Pipes and Drive Shafts - Remove​

7.2.3 Radiator Assembly - Remove​

7.2.4 Engine and Transmission Assembly - Remove​

7.2.5 Engine and Transmission - Separate​

7.3 Engine - Install​

7.3.1 Engine and Transmission — Install​

7.3.2 Radiator Assembly - Install​

7.3.3 Pipes and Drive Shafts - Install​

7.3.4 Engine Covers - Install​

7.4 Fuel System​

7.4.1 Description of Fuel System​

7.4.2 Fuel Tank - Remove and Install​

7.5 Air Intake System​

7.5.1 General Description of Air Intake System​

7.5.2 Air Intake System - Remove and Install​

7.6 Cooling System​

7.6.1 General Description of Cooling System​

7.6.2 Effects Of Cooling System Neglect​

7.6.3 Coolant​

7.6.4 Cooling System - Remove and Install​

8 Power Train

8.1 General Description of Power Train​

8.2 Transmission​

8.2.1 Structure and Function​

8.2.2 Transmission - Remove and Install​

8.3 Transfer Gearbox​

8.3.1 Structure and Function​

8.3.2 Transfer Gearbox - Remove​

8.3.3 Transfer Gearbox - Install​

8.4 Gear Oil Cooler​

8.4.1 Gear Oil Cooler - Remove​

8.4.2 Gear Oil Cooler - Install​

8.5 Emergency Steering Pump​

8.5.1 Emergency Steering Pump - Remove​

8.5.2 Emergency Steering Pump - Install​

8.6 Power Takeoff Device​

8.6.1 Power Takeoff Device - Remove​

8.6.2 Power Takeoff Device - Install​

8.7 Angle Transfer Gearbox​

8.7.1 Structure and Function​

8.7.2 Gear Oil Cooler for Lower Angle Gearbox - Remove​

8.7.3 Gear Oil Cooler for Lower Angle Gearbox - Install​

8.7.4 Gear Oil Cooler for Upper Angle Gearbox - Remove & Install​

8.7.5 Gear Oil of Lower Angle Gearbox - Drain & Change​

8.7.6 Lower Angle Gearbox - Remove​

8.7.7 Lower Angle Gearbox - Install​

8.7.8 Gear Oil of Upper Angle Gearbox - Drain & Change​

8.7.9 Upper Angle Gearbox - Remove​

8.7.10 Upper Angle Gearbox - Install​

8.8 Drive Shafts​

8.8.1 Structure and Function​

8.8.2 Notes and Warnings before Drive Shaft Removal​

8.8.3 Drive Shafts - Remove​

8.8.4 Drive Shafts - Install​

8.8.5 Drive Shafts - Check​

8.9 Troubleshooting​

8.9.1 Engine Oil Sludge​

8.9.2 Engine - Oil Pressure Too Low​

8.9.3 Engine - Excessive Oil Level Drop​

8.9.4 Engine - Coolant Temperature Too High​

8.9.5 Engine - Excessive Fuel Consumption​

8.9.6 Engine - Lacks Power or Stall​

8.9.7 Engine – Failure of Ignition​

8.9.8 Drive shaft - Too Much Noise on Drive Shaft​

9 Braking System

9.1 Brakes​

9.1.1 General information​

9.1.2 Brake Slack​

9.1.3 Brake Pad​

9.1.4 Brake Air Chamber​

9.1.5 Brake​

9.2 Air System​

9.2.1 Description​

9.2.2 Parts Location​

9.2.3 Repair​

9.2.4 Charge Air​

9.2.5 Air Pressure Inspection​

9.2.6 Leakage Inspection​

9.2.7 Moisture Draining/ Air Release​

10 Wheels and Tires

10.1 General Description of Wheels and Tires​

10.2 Tires - Exchange Position​

10.3 Tires - Remove​

10.4 Wheels on the Front Axle - Install​

10.5 Wheels on the Rear Axle - Install​

10.6 Tires - Disassemble​

10.7 Tires - Assemble​

11 Axle and Suspension

11.1 Non-driving steer axle​

11.1.1 General Description of Non-Driving Steer Axle​

11.1.2 Non-Driving Steer Axle - Remove​

11.1.3 Non-Driving Steer Axle - Install​

11.2 Driving Steer Axle​

11.2.1 General Description of Non-Driving Steer Axle​

11.2.2 Axle 1 - Remove and Install​

11.2.3 Axle 2 - Remove and Install​

11.2.4 Axle 4 - Remove and Install​

11.2.5 Axle 5 - Remove and Install​

12 Steering System

12.1 General Description of Steering System​

12.2 Power Steering Box - Remove​

12.3 Power Steering Box - Install​

12.4 Toe-in - Measure​

12.5 Toe-in - Adjust​

13 Outriggers

13.1 General Description of Outriggers​

13.2 Outriggers - Inspect​

13.3 Outrigger Assembly - Remove​

13.4 Outrigger Beam Cylinder - Remove​

13.5 Outrigger Stabilizer Cylinder - Remove​

13.6 Outrigger Stabilizer Cylinder - Install​

13.7 Outrigger Beam Cylinder - Install​

13.8 Outrigger Assembly - Install​

13.9 Troubleshooting: Outriggers Telescoping - Out of Synchronization​

14 Appendix

14.1 Hydraulic Schematics​

14.1.1 Superstructure Hydraulic Schematics​

14.1.2 Carrier Hydraulic Schematics​

14.2 Brake Schematics​

14.2.1 Brake Schematics​

14.3 Electrical Schematics​

14.3.1 Superstructure Electrical Schematics​

14.3.2 Carrier Electrical Schematics​