Sany Truck Crane STC800S Safety Operation and Maintenance Manual

[Hyundai]

Download this document, you need 500 Gallons

Sany Truck Crane STC800S Safety Operation and Maintenance Manual
Size: 98.14 MB
Format: PDF
Language: English
Brand: Sany
Type of Machine: Truck Crane
Type of Manual: Safety Operation and Maintenance Manual
Model: Sany STC800S Truck Crane
Number of Pages: 460 Pages

Contents:
1 Introduction

1.1 About This Manual​

1.2 Contact Information​

1.3 Your Documentation Package​

1.4 Organization of This Manual​

1.5 Serial Number Location​

1.5.1 General​

1.5.2 Product Identification Plate​

1.5.3 Record of Serial Number and Distributor Information​

1.6 Correction Request Form​

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 Supervisor​

2.1.5 Owner and Other Authorized Personnel​

2.1.6 Operator​

2.1.7 Signal Person​

2.1.8 Job Site Safety​

2.1.9 Job Safety​

2.1.10 Wind​

2.1.11 High Altitude​

2.1.12 Electrocution Hazard​

2.1.13 High Voltage Areas​

2.1.14 Transmitter/Communication Towers​

2.1.15 Fire Safety​

2.1.16 Dust Hazards​

2.1.17 Environmental Precautions​

2.2 Product-Specific Safety​

2.2.1 Authorized Use of the Machine​

2.2.2 Unauthorized Use of the Machine​

2.2.3 Driving Precautions​

2.2.4 Crane Stability and Structural Integrity​

2.3 Operational Aids​

2.3.1 General​

2.3.2 Escape Tool​

2.3.3 Seat Belt​

2.3.4 Load Charts Manual​

2.3.5 Load Moment Indicator (LMI) Systems​

2.4 Personal Protective Equipment​

2.5 Personnel Handling​

2.6 Safety During Operation​

2.6.1 Cold Weather Operation​

2.6.2 Keeping the Cabs Clean​

2.6.3 Mounting and Dismounting the Machine​

2.6.4 Inside the Operator’s Cab​

2.6.5 Start-Up Safety​

2.6.6 Hoisting a Load Safely​

2.6.7 Wire Rope Safety​

2.6.8 Swingaway Boom Extension Safety​

2.6.9 Counterweight​

2.7 Interruption of Crane Work​

2.8 Taking Up Crane Operation Again​

2.9 Ending Crane Operation​

2.10 Parking the Vehicle​

2.11 Lockout/Tagout Procedures​

2.11.1 General​

2.11.2 Locking Out of Service​

2.11.3 Returning to Service​

2.12 Maintenance Safety​

2.12.1 General​

2.12.2 Cold Weather Maintenance​

2.12.3 Preparing for Maintenance​

2.12.4 Using the Correct Tools​

2.12.5 Rotating Parts​

2.12.6 Jacking Up the Machine​

2.12.7 Optional Attachments​

2.12.8 Weld, Drill, Cut or Grind on the Machine​

2.12.9 High-Pressure Fluid Lines​

2.12.10 Accumulator​

2.12.11 Refueling​

2.12.12 Adding Fluids to the Machine​

2.12.13 Battery Safety​

2.13 Towing or Lifting the Machine​

2.14 Decals​

3 System Functions

3.1 Directional Positions of Truck Crane​

3.2 General Description of Truck Crane​

3.2.1 Introduction​

3.2.2 General Description of Carrier​

3.2.3 General Description of Superstructure​

3.3 Description of the Carrier​

3.3.1 Overview of the Operating and Display Instruments​

3.3.2 Functional Description of the Display and Operating Instruments​

3.3.3 Functional Description of Adjustable Driver’s Seat​

3.3.4 Functional Description of Transmission Shift Lever​

3.3.5 Functional Description of Outrigger Control Levers​

3.3.6 Functional Description of Steering​

3.4 Description of the Superstructure​

3.4.1 Overview of the Operating and Display Instruments​

3.4.2 Functional Description of the Display and Operating Instrume​

3.4.3 Functional Description of Left/Right Joystick Controls​

3.4.4 Load Moment Indicator (LMI) System​

3.4.5 Functional Description of Adjustable Operator’s Seat​

3.4.6 Functional Description of the Operator Aids​

4 Operation

4.1 Basic Lifting Terminology​

4.2 Using a Load Chart​

4.2.1 General​

4.2.2 The Principle of Lift Weights​

4.2.3 The Principle of Radius​

4.2.4 Load Chart Understanding​

4.3 New Machine Run-In​

4.4 Pre-Start Checks​

4.4.1 General​

4.4.2 Manuals​

4.4.3 Maintenance Record Before Start​

4.4.4 Exterior​

4.4.5 Interior​

4.5 Engine Procedures​

4.5.1 General​

4.5.2 Cold-Weather Operation​

4.5.3 Engine Start Procedure​

4.5.4 Idle the Engine​

4.5.5 Engine Shutdown Procedure​

4.5.6 Engine Emergency Shutdown​

4.6 Operation of Power Take-off Device​

4.6.1 General​

4.6.2 Power Takeoff Device Activate Procedure​

4.6.3 Power Takeoff Device Deactivate Procedure​

4.7 Operation of outrigger​

4.7.1 General​

4.7.2 Outrigger Cribbing Support​

4.7.3 Outrigger Placement​

4.7.4 Operation of Outrigger Levers​

4.8 Operation of Movable Counterweight​

4.8.1 Operation of Movable Counterweight​

4.8.2 Counterweight Assemble Procedure​

4.8.3 Counterweight Disassemble Procedure​

4.9 Operation of Hoist​

4.9.1 General​

4.9.2 Operation of Main Hoist​

4.9.3 Operation of Auxiliary Hoist​

4.10 Operation of Booms​

4.10.1 Raise and Lower the Boom​

4.10.2 Extend and Retract the Boom​

4.10.3 Operation of Slewing the Boom​

4.11 Operation of Crane Preparation​

4.11.1 Preload Check​

4.11.2 Disconnect and Attach Main Hook Block​

4.11.3 Install Wire Rope onto a Hoist​

4.11.4 Reeving Wire Rope​

4.12 Operation of Swingaway Boom extension​

4.12.1 General Warnings​

4.12.2 Erect Swingaway Boom Extension​

4.12.3 Rig Swingaway Boom Extension​

4.12.4 Stow Swingaway Boom Extension​

4.12.5 Adjust the Offset (From Lesser to Higher)​

4.12.6 Adjust the Offset (From Higher to Lesser)​

4.13 Operation of Travel​

4.13.1 General Precautions​

4.13.2 Prepare to Travel​

4.13.3 Move the Machine​

4.14 End-Of-Driving Operations​

4.14.1 End-of-workday Checks​

4.14.2 End-of-workday Operation​

4.15 Storage the Machine​

4.15.1 Short-Term Storage​

4.15.2 Long-Term Storage​

4.16 Transport​

4.16.1 General​

4.16.2 Load the Machine​

4.16.3 Unload the Machine​

4.16.4 Towing the Machine​

4.16.5 Lift the Machine​

5 Maintenance

5.1 Maintenance Information​

5.1.1 General​

5.1.2 Checks Before Maintenance​

5.1.3 Checks After Maintenance or Repairs​

5.1.4 Hours and Mileage Reading​

5.1.5 Genuine Sany Replacement Parts​

5.1.6 Sany-Approved Lubricants​

5.1.7 Weld, Drill, Cut or Grind on the Machine​

5.1.8 Inventory Your Tools and Parts​

5.1.9 Covers and Locks​

5.1.10 Hydraulic Fluid Inspection​

5.1.11 Inspection and Maintenance in Adverse Environments​

5.1.12 Environmental Protection​

5.2 Maintenance Overview​

5.2.1 Maintenance Intervals​

5.2.2 Lubricants and Fluids​

5.2.3 Secure Machine for Maintenance​

5.3 Description of Maintenance Work on the Carrier​

5.3.1 General​

5.3.2 Carrier Overall Condition​

5.3.3 Maintenance for Engine​

5.3.4 Maintenance for Axles​

5.3.5 Maintenance for Wheels and Tires​

5.3.6 Maintenance for Steering System​

5.3.7 Maintenance for Clutch​

5.3.8 Maintenance for Transmission​

5.3.9 Maintenance for Drive Shaft​

5.3.10 Maintenance for Brake System​

5.3.11 Carrier Electrical System​

5.3.12 Maintenance for Air Condition​

5.3.13 Other Maintenance Work​

5.4 Description of Maintenance Work on the Superstructure​

5.4.1 General​

5.4.2 Wire Rope​

5.4.3 Hook Blocks​

5.4.4 Main Boom and Boom Extension​

5.4.5 Swing Mechanism​

5.4.6 Hoist​

5.4.7 Hydraulic System​

5.4.8 Superstructure Electrical System​

5.4.9 Air Conditioner​

5.4.10 Other Maintenance Work​

5.5 Tightening Torques​

5.5.1 General Torque Values​

5.5.2 Key Parts Tightening Torques​

6 Troubleshooting

6.1 Emergency Operation​

6.1.1 Emergency Troubleshooting During Crane Operation​

6.1.2 Towing the Truck Crane​

6.1.3 Jump-Start the Engine​

6.2 Wheel Change​

6.2.1 Remove the Damaged Wheel​

6.2.2 Mounting the Wheel​

6.3 Oil and Fluid​

6.3.1 Hydraulic Noise​

6.3.2 Oil and Fluid Leaks​

6.4 Motors Repair​

6.4.1 Hoist Motor​

6.4.2 Swing Motor​

6.5 Wiper and Washer Repair​

6.5.1 Windshield Wiper​

6.5.2 Windshield Washer​

6.5.3 Skylight Wiper​

6.6 Third Wrap Protector​

6.6.1 Check​

6.6.2 Removal​

6.6.3 Installation​

6.6.4 Adjustment​

7 Specifications

7.1 Outline and dimensions of truck crane​

7.2 Technical Parameters of Truck Crane​

7.2.1 Technical Parameters of Truck Crane in Driving Status​

7.2.2 Technical Parameters of Truck Crane in Operating Status​