H545sannyhTechnical Manual

Quality Changes the World
Reach Stacker
SRSC45C30
SRSC45C2
SRSC45H1
SRSC45H2
SRSC45H2A
SRSC45H3
SRSC45H4
SRSC4535H1
SRSC4540H2-70
SRSC4545C2
SRSC4545H1
SRSC1009-6E
SRSC1009H5-6E
SRSC0808-6EH
SRSC3515-3
Safety, Operation & Maintenance Manual
BO3T01ENAQ4
Reach Stacker
Safety, Operation & Maintenance Manual - August 2019 I

Reach Stacker
Reach Stacker
Safety, Operation & Maintenance Manual
WARNING
Read and follow the safety precautions and instructions in this manual and on
the machine labels. Failure to do so can cause serious injury, death or damage
to property. Keep this manual along with the machine for reading and future
reference.
II Safety, Operation & Maintenance Manual - August 2019

Reach Stacker
Sany Port
SANY Marine Heavy Industry Co.,LTD
SANY Industrial Park, Gaolan Port Economic and
Development Zone, Zhuhai City, Guangdong Province, China
Tel: 0086-756-7266945
Fax: 0086-731-84031999-149
Website: www.sanyhi.com
Service hotline: 0086 4006098318
© 2018 by Sany Port. All rights reserved. No part of this publication may be reproduced,
used, distributed or disclosed except for normal operation and maintenance of the
machine as described herein. All information included within this publication was accurate
at the time of publication. Product improvements, revisions, etc., may result in differences
between machines and what is presented here. Sany Port assumes no liability. For more
information, contact Sany Port.
Safety, Operation & Maintenance Manual - August 2019 III

Reach Stacker
SPECIFIC DECLARATION
SANY reach stacker is applicable for transferring containers, steel coils, steel pipes, wood, etc.
Different spreaders can be installed on the reach stackers for different applications. Any other
usage or operations beyond the specified working range are not authorized. SANY expressly
bears no liability for any consequences due to unauthorized uses.
Information on this manual is used to guide certified operators to operate and maintain reach
stackers correctly. SANY expressly bears no liability for any consequences due to the violation of
following rules:
• The personnel should observe the information on this manual.
• It is prohibited to modify the machine without authorization.
• When cracks or electrical failures on the machine occur, please contact SANY instead of
conducting welding or making changes without permission.
• Use genuine SANY spare parts instead of non genuine or unauthorized spare parts or tools.
• Machine failures or damages due to force majeure of natural disasters (earthquake, typhoon)
and wars are not the responsiblity of SANY.
SANY cannot predict every circumstance that might involve a potential hazard in operation or
maintenance. Operators and owners should attach high importance to safety. Local specific
safety rules of the countries may be stricter. If they differ from the regulations on this manual,
observe the stricter one.
Duty of SANY
• Be responsible for providing quality products and correct documentations.
• Fulfill the promises on after-sales service, and document all maintenance and repair work
done by after-sales service personnel.
• Train the operator and maintenance personnel based on their needs.
Duty of Owners or Other Authorized Personnel

• Only after each personnel involved in the product’s operation, maintenance and repair is
trained and fully understands the Parts Book & Safety, Operation & Maintenance Manual, can
they operate and maintain the container reach stacker.
• Ensure the operation and maintenance personnel are qualified and know their related
responsibilities.
• Periodically check related personnel's safety consciousness during working.
• If any failure which would lead to unsafe conditions occurs, stop the machine immediately.
• If necessary, SANY service personnel have the right to check the machine for safety.
• Except for checking items regulated by SANY, please do the related inspections according to
local laws and regulations.
• Ensure timely maintenance and repair on this machine.
• Carefully plan the use of this machine.
IV Safety, Operation & Maintenance Manual - August 2019

Reach Stacker
Duty of All Working Personnel

• If there is any abnormality which may cause the failure of this machine or a potential hazard,
please report to your manager. If possible, eliminate the failure in time.
• All personnel working close to the machine must observe all warning signals and take care of
their own and others' safety.
• All personnel should know their work tasks and procedures.
• Watch out for high voltage wire, unrelated personnel and poor ground for potential danger, or
report to the operators and signalmen.
Duty of Managers
• Ensure the operators are trained and fully understand the Safety, Operation & Maintenance
Manual supplied by SANY. Ensure they are in good health and have the certification of
operation. Otherwise, it is prohibited to operate this machine.
• Ensure the operators have good judgment ability, teamwork consciousness and psychological
quality. Otherwise, it is prohibited to operate or repair this machine.
• Ensure the signalmen have good vision and sound judgment as well as master standard
command signals. At the same time, they should have enough experience in recognizing
dangers correctly and informing the operators of dangers to avoid them in time.
• Ensure assistant workers can identify the operation and working condition to choose the
correct machine.
• Publicize safety consciousness to working personnel, and make them aware of safety
precautions and their related responsibilities.
Safety, Operation & Maintenance Manual - August 2019 V

Reach Stacker Table of Contents
Table of Contents
1. Introduction
1.1 Overview�� 1-3
1.2 Application Range�� 1-5
1.2.1 Intended use�� 1-5
1.2.2 Unintended use�� 1-6
1.3 Machine Authorizations��1-7
1.4 Your Documentation Package�� 1-8
1.4.1 CD system requirements�� 1-8
1.4.2 Recommendations on using the documentation�� 1-9
1.4.3 Documentation storage��1-10
1.4.4 Manual organization��1-10
1.5 Terminology��1-12
1.6 Machine Information��1-14
1.6.1 Machine nameplate��1-14
1.6.2 Engine nameplate��1-14
1.6.2.1 VOLVO engine nameplate��1-14
1.6.2.2 CUMMINS engine nameplate��1-15
1.6.2.3 YUCHAI engine nameplate��1-15
1.6.3 Spreader nameplate��1-16
1.6.3.1 SANY spreader nameplate��1-16
1.6.3.2 ELME spreader nameplate��1-16
1.6.3.3 BROMMA spreader nameplate��1-17
1.6.4 Transmission case nameplate��1-18
1.6.4.1 DANA transmission case nameplate��1-18
1.6.4.2 ZF transmission case nameplate��1-18
1.7 Running in a New Machine ��1-19
1.8 Machine Serial No. and Distributor Info.�� 1-20
1.9 Correction Request Form��1-21
1.10 Contact Information�� 1-22
2. Safety
2.1 Safety Information�� 2-4
Safety, Operation & Maintenance Manual - August 2019 I

Table of Contents Reach Stacker
2.1.1 Signal words�� 2-4

2.1.2 Examples of using signal words �� 2-5
2.1.3 Other signal words�� 2-5
2.1.4 Safety labels�� 2-6
2.1.4.1 Safety labels - location�� 2-8
2.1.4.2 Safety labels - content�� 2-9
2.2 General Precautions��2-15
2.2.1 Basic safety instructions��2-15
2.2.2 Personal protective equipment��2-16
2.2.3 Never operate while in bad health��2-19
2.2.4 No passenger in the cab��2-19
2.2.5 Hand signals�� 2-20
2.2.6 Preparing safety items�� 2-23
2.2.7 Checking safety equipment�� 2-23
2.2.8 Precautions in high voltage areas��2-24
2.2.9 Precautions in thunderstorm��2-27
2.2.10 Precautions in wind��2-27
2.2.11 Abnormal cases��2-28
2.2.12 Unauthorized modification�� 2-29
2.3 Safety During Operation�� 2-30
2.3.1 Work area safety�� 2-30
2.3.1.1 Work area requirements�� 2-30
2.3.1.2 Work area indications�� 2-30
2.3.2 Checks before operation��2-31
2.3.3 Keeping machine clean�� 2-33
2.3.4 Climbing on or off the machine safely�� 2-33
2.3.5 Start-up safety �� 2-35
2.3.5.1 Inside the operator cab�� 2-35
2.3.5.2 Adjusting the seat�� 2-35
2.3.5.3 Checking the seat belt�� 2-36
2.3.5.4 Machine starting precautions�� 2-36
2.3.5.5 Jump-start the engine, precautions�� 2-38
2.3.5.6 In cold weather�� 2-39
2.3.5.7 After starting the engine�� 2-39
2.3.6 Requirements for safe operation�� 2-40
2.3.6.1 Ensuring good visibility �� 2-40
II Safety, Operation & Maintenance Manual - August 2019

2.3.6.2 Safety rules for traveling�� 2-40

2.3.6.3 Precautions while operating on slopes�� 2-42
2.3.6.4 Avoiding injury from reversing �� 2-42
2.3.6.5 Precautions while operating on snow or frozen surfaces�� 2-43
2.3.6.6 Preventing control failure�� 2-44
2.3.6.7 Never hoist a load except container�� 2-45
2.3.6.8 Never hoist the load over people�� 2-45
2.3.6.9 Never stand under the load�� 2-45
2.3.6.10 Precautions for operating emergency stop button�� 2-46
2.3.6.11 Precautions for operating safety bypass switch�� 2-46
2.3.7 Parking the machine securely�� 2-47
2.3.7.1 Parking requirements�� 2-47
2.3.7.2 Turning off the engine �� 2-48
2.4 Safety During Maintenance�� 2-49
2.4.1 Preparation for the work area�� 2-49
2.4.2 Warning label is important�� 2-50
2.4.3 Lockout/tagout procedures�� 2-50
2.4.4 Self-preparation before maintenance��2-51
2.4.5 Using tools correctly ��2-51
2.4.6 Regular replacement of safety-related parts��2-51
2.4.7 Removing attachments carefully�� 2-52
2.4.8 Adding fluids to the machine�� 2-52
2.4.9 Towing or lifting the machine�� 2-53
2.4.10 Keep clear of moving machinery�� 2-54
2.4.11 Preventing hydraulic hazards �� 2-55
2.4.11.1 Checking rubber hose regularly�� 2-55
2.4.11.2 Releasing the pressure before maintenance�� 2-56
2.4.11.3 Replacing rubber hose regularly�� 2-57
2.4.11.4 Prevent heat near the hydraulic pipeline�� 2-58
2.4.11.5 Filling accumulator�� 2-58
2.4.11.6 Selecting oils and fuel�� 2-59
2.4.11.7 Handling hydraulic oil �� 2-59
2.4.12 Preventing burn and scald�� 2-60
2.4.12.1 Burn by high temperature liquid�� 2-60
2.4.12.2 Chemical burn�� 2-61
2.4.13 Preventing fire and explosion�� 2-63
Safety, Operation & Maintenance Manual - August 2019 III

2.4.13.1 Handling inflammables safely�� 2-63

2.4.13.2 Removing inflammables�� 2-63
2.4.13.3 Checking oil leakage�� 2-64
2.4.13.4 Checking short circuit�� 2-64
2.4.13.5 Checking ignition key�� 2-65
2.4.13.6 Preventing battery explosion�� 2-65
2.4.13.7 Evacuating from the machine�� 2-66
2.4.14 Preventing poisoning and asphyxiation�� 2-68
2.4.14.1 Handling chemicals safely�� 2-68
2.4.14.2 Preventing poisoning by paint �� 2-68
2.4.14.3 Preventing poisoning by off-gas�� 2-69
2.4.15 Preventing dust hazard��2-70
2.4.16 Working under machine��2-71
2.4.17 Precautions in welding��2-71
2.4.18 Safe maintenance of air conditioning system��2-72
2.4.19 Precautions in maintaining the engine��2-73
2.4.20 High voltage precautions�� 2-74
2.4.21 Precautions after maintenance�� 2-74
2.4.22 Handling waste properly�� 2-74
2.5 Tag��2-76
3. System Functions
3.1 Main Components of Machine�� 3-3
3.2 Cab �� 3-5
3.2.1 Steering controller�� 3-6
3.2.1.1 Steering panel�� 3-7
3.2.1.2 Gear selector��3-10
3.2.1.3 Direction indication controller��3-11
3.2.1.4 Adjusting the angle of steering controller ��3-14
3.2.2 Pedal��3-14
3.2.3 Joystick��3-15
3.2.4 Right operation panel��3-16
3.2.4.1 Ignition switch��3-17
3.2.4.2 Emergency retraction / lowering switch��3-18
3.2.4.3 Emergency stop switch��3-19
3.2.4.4 Safety bypass switch��3-19
IV Safety, Operation & Maintenance Manual - August 2019

3.2.4.5 Cab moving switch�� 3-21

3.2.4.6 Counterweight moving switch (optional)�� 3-21
3.2.4.7 Parking switch�� 3-22
3.2.4.8 Fuel heating switch (optional)�� 3-22
3.2.4.9 Hydraulic oil preheating switch (optional)�� 3-22
3.2.5 Front operation panel�� 3-23
3.2.5.1 Spreader light switch�� 3-23
3.2.5.2 Boom light switch�� 3-24
3.2.5.3 Rear light switch�� 3-24
3.2.5.4 Front wiper switch�� 3-25
3.2.5.5 Top wiper switch�� 3-26
3.2.5.6 Rear wiper switch�� 3-26
3.3 Display�� 3-28
3.3.1 Menu introduction�� 3-28
3.3.2 Introduction and operation of display area�� 3-29
3.3.2.1 Start menu�� 3-29
3.3.2.2 Main menu�� 3-29
3.3.2.3 Language setting menu�� 3-32
3.3.2.4 Engine information menu�� 3-33
3.3.2.5 Gear information menu�� 3-34
3.3.2.6 Hydraulic information menu�� 3-35
3.3.2.7 Digital analogy menu�� 3-36
3.3.2.8 Function set menu�� 3-38
3.3.2.9 Help System�� 3-39
3.4 Air Conditioning System�� 3-39
3.4.1 Control panel�� 3-39
3.4.1.1 Power switch�� 3-40
3.4.1.2 Fan speed switch�� 3-40
3.4.1.3 Temperature or Paging switch�� 3-41
3.4.1.4 Mode switch�� 3-41
3.4.1.5 Fresh air switch�� 3-42
3.4.2 Operation�� 3-43
3.4.3 Precautions�� 3-44
3.4.4 Troubleshooting�� 3-45
3.5 Electric Control Cabinet�� 3-46
3.6 Fuse�� 3-48
Safety, Operation & Maintenance Manual - August 2019 V

3.7 Fire Extinguisher�� 3-49
4. Operation
4.1 Before the Starting of Engine�� 4-4
4.1.1 Operator responsibility�� 4-4
4.1.2 Checks before operation�� 4-5
4.1.2.1 Wiper water level, checking�� 4-6
4.1.2.2 Coolant level, checking�� 4-6
4.1.2.3 Engine oil level, checking�� 4-7
4.1.2.4 Transmission oil level, checking�� 4-7
4.1.2.5 Hydraulic oil level, checking�� 4-7
4.1.2.6 Fuel level, checking�� 4-7
4.1.2.7 Brake oil level, checking�� 4-8
4.1.2.8 Tyres, checking�� 4-8
4.1.2.9 Electrical components, checking�� 4-9
4.1.2.10 Working light, checking��4-10
4.1.2.11 Horn, checking��4-10
4.1.3 Adjustment before operation��4-11
4.1.3.1 Seat, adjusting�� 4-11
4.1.3.2 Rearview mirror, adjusting��4-13
4.1.3.3 Safety belt, adjusting��4-14
4.2 Starting the Machine��4-15
4.2.1 Start in normal weather��4-15
4.2.2 Start in cold weather��4-18
4.2.3 Start with booster batteries or starting generators��4-19
4.3 Stopping the Machine��4-21
4.3.1 Engine shutdown procedures��4-21
4.3.2 Emergency shutdown�� 4-23
4.4 Driving�� 4-24
4.4.1 How to drive�� 4-24
4.4.2 Driving forward�� 4-25
4.4.3 Driving backward�� 4-26
4.4.4 Turning around�� 4-26
4.4.5 Parking�� 4-27
4.5 Load Handling �� 4-28
4.5.1 Operation switches�� 4-28
VI Safety, Operation & Maintenance Manual - August 2019

4.5.2 Boom, operation�� 4-29

4.5.3 Spreader, operation�� 4-34
4.5.4 Hook, operation�� 4-37
4.5.5 Load capacity diagram�� 4-38
4.5.5.1 Load capacity diagram of SRSC45C30 / SRSC45C2 / SRSC45H1 /
SRSC45H2 / SRSC45H2A / SRSC45H3 / SRSC45H4 container reach stackers�� 4-39
�� 4-39
4.5.5.2 Load capacity diagram of SRSC4535H1 heavyweight container reach
stacker�� 4-42
4.5.5.3 Load capacity diagram of SRSC4540H2-70 heavyweight container reach
stacker�� 4-43
4.5.5.4 Load capacity diagram of SRSC4545C2 / SRSC4545H1 container
heavyweight reach stacker�� 4-41
4.5.5.5 Load capacity diagram of SRSC1009-6E / SRSC1009H5-6E empty
container reach stacker�� 4-40
4.5.5.6 Load capacity diagram of SRSC0808-6EH empty container reach stacker
�� 4-41
4.5.5.7 Load capacity diagram of SRSC3615-3 lightweight container reach stacker
�� 4-45
4.5.5.8 Load capacity diagram of steel coil reach stacker�� 4-46
4.5.5.9 Load capacity diagram of steel pipe reach stacker�� 4-47
4.5.6 Picking up a container from the stack�� 4-48
4.5.7 Depositing a container on the stack�� 4-51
4.5.8 Transferring the steel coil�� 4-53
4.5.9 Transferring the steel pipe�� 4-54
4.6 Store the Machine�� 4-55
4.6.1 Overnight storage�� 4-55
4.6.2 Short-Term Storage�� 4-55
4.6.3 Long-term storage�� 4-56
4.6.3.1 Preparations�� 4-56
4.6.3.2 During storage�� 4-57
4.6.3.3 Return to service�� 4-57
4.7 Transportation and Assembly�� 4-58
4.7.1 Guidelines�� 4-58
4.7.2 Disassembling the machine�� 4-59
4.7.2.1 Disassembling principles�� 4-59
Safety, Operation & Maintenance Manual - August 2019 VII

4.7.2.2 Disassembly list �� 4-60

4.7.2.3 Hoisting points of parts�� 4-61
4.7.3 Packing requirements�� 4-63
4.7.4 Transportation�� 4-64
4.7.4.1 Transporting by platform lorry�� 4-64
4.7.4.2 Transporting by container�� 4-64
5. Maintenance
5.1 Scheduled Maintenance, General Information �� 5-7
5.2 Tightening Torques ��5-11
5.2.1 General tightening torques��5-11
5.2.1.1 Fastener torque value��5-11
5.2.1.2 Hydraulic coupling torque values��5-12
5.2.1.3 Tapered connections��5-12
5.2.1.4 O-ring and flange connections��5-13
5.2.1.5 Low pressure hose clamps��5-14
5.2.2 Specific tightening torques ��5-15
5.3 Recommended Fuel, Coolant and Lubricant��5-16
5.3.1 Specification��5-16
5.3.2 Capacity of oil��5-18
5.3.3 Hydraulic oil, description�� 5-21
5.3.4 Quality of hydraulic oil, check�� 5-22
5.3.5 Urea�� 5-23
5.4 Lubricating Points�� 5-24
5.4.1 Lubricant�� 5-24
5.4.2 Lubricating points of complete machine�� 5-25
5.5 Scheduled Maintenance�� 5-27
5.5.1 Maintenance every day�� 5-27
5.5.2 Maintenance every 50 hours�� 5-28
5.5.6 Maintenance 1500 hours�� 5-31
5.6 Engine�� 5-33
VIII Safety, Operation & Maintenance Manual - August 2019

5.6.1 General engine inspection �� 5-34

5.6.1.1 Charge air pipe, checking�� 5-34
5.6.1.2 Drive belt, checking�� 5-35
5.6.1.3 Drive belt, replacing (engine option VOLVO)�� 5-36
5.6.1.4 Alternator belt, replacing (engine option VOLVO)�� 5-37
5.6.1.5 Air filter, checking / changing�� 5-38
5.6.1.6 Air filter, cleaning�� 5-39
5.6.1.7 Engine mounting pad, checking�� 5-39
5.6.1.7 Diesel fuel cleaner, changing�� 5-40
5.6.2 Lubrication system�� 5-41
5.6.2.1 Oil level, checking and topping up �� 5-41
4..The oil level is only measured before the time the ignition is turned on.�� 5-41
5.6.2.2 Engine oil, changing�� 5-42
5.6.2.3 Oil filter / Bypass filter, changing (engine option VOLVO)�� 5-43
5.6.2.4 Oil filter, changing (engine option CUMMINS)�� 5-44
5.6.3 Fuel system�� 5-45
5.6.3.2 Draining condensate, fuel system (engine option VOLVO)�� 5-46
5.6.3.3 Draining condensate, fuel system (engine option CUMMINS)�� 5-46
5.6.3.4 Fuel filter, replacing (engine option VOLVO)�� 5-47
5.6.3.5 Fuel filter, replacing (engine option CUMMINS)�� 5-48
5.6.3.6 Fuel pre-filter, changing�� 5-49
5.6.3.7 Fuel system, bleeding�� 5-49
5.6.4 Cooling system�� 5-50
5.6.4.1 Coolant, mixing�� 5-51
5.6.4.2 Water quality�� 5-52
5.6.4.3 Coolant level, checking and topping up�� 5-52
5.6.4.4 Filling a completely empty system�� 5-53
5.6.4.5 Coolant, draining�� 5-54
5.6.4.6 Radiator, cleaning�� 5-55
5.6.4.7 Radiator fan, checking�� 5-55
5.6.4.8 Cooling system, cleaning�� 5-56
5.6.4.9 Coolant filter, replacing (engine option CUMMINS)�� 5-57
5.6.5 Air intake and exhaust system�� 5-58
5.6.5.1 Air leaks, checking �� 5-58
5.6.5.2 Turbocharger and blast pipe, checking�� 5-59
Safety, Operation & Maintenance Manual - August 2019 IX

5.6.6 Urea filter element, changing�� 5-60

5.7 Transmission�� 5-61
5.7.1 Gearbox, function description�� 5-61
5.7.2 Mounting bolts of propeller shaft, checking�� 5-61
5.7.3 Speed sensor, checking�� 5-62
5.7.4 Mounting bolts and mounting pad, checking�� 5-62
5.7.5 Propeller shaft, lubricating�� 5-63
5.7.6 TE Transmission calibration�� 5-63
5.7.7 Transmission oil, changing�� 5-64
5.7.8 Transmission oil level, checking�� 5-65
5.7.9 Transmission oil filter, changing�� 5-65
5.8 Drive Axle�� 5-66
5.8.1 Mounting bolts of drive axle to the frame, checking�� 5-66
Check the drive axle’s attachment to the frame so that there is no corrosion of
structural elements (e.g. mounting bolts).�� 5-66
5.8.2 Mounting bolts of drive axle to the propeller shaft, checking�� 5-66
5.8.3 Oil leaking of drive axle and brake components, checking�� 5-66
5.8.4 Drive axle oil, changing�� 5-67
5.8.5 Breather, cleaning�� 5-68
5.8.6 Brake pedal, checking and adjusting�� 5-69
5.8.7 Parking brake pads, changing�� 5-69
5.8.8 Brake oil filter, changing�� 5-70
5.9 Steering Axle��5-71
5.9.1 Daily check��5-71
5.9.2 Steering axle, lubricating�� 5-72
5.9.3 Stub axle, maintaining�� 5-72
5.9.4 Steering axle cradle, checking�� 5-73
5.9.5 Steering pressure, checking�� 5-73
5.10 Tyres and rims��5-74
5.10.1 Tyre, description��5-74
5.10.2 Tyre, inflating�� 5-76
5.10.4 Wheel rim, description�� 5-77
5.10.3 Tyres, checking�� 5-77
5.10.5 Rim, checking�� 5-78
5.10.6 Wheel rim, installing and removing�� 5-80
5.10.6.1 Wheel rim, installing�� 5-80
X Safety, Operation & Maintenance Manual - August 2019

5.10.6.2 Wheel rim, removing��5-81

5.10.7 Drive axle yre, removing and installing�� 5-82
5.10.7.1 Drive axle tyre, removing�� 5-82
5.10.7.2 Drive axle tyre, installing�� 5-83
5.10.8 Steering axle tyre, removing and installing �� 5-84
5.10.8.1 Steering axle tyre, removing�� 5-84
5.10.8.2 Steering axle tyre, installing�� 5-85
5.11 Boom�� 5-86
5.11.1 Basic boom, checking�� 5-87
5.11.2 Wear pads, checking�� 5-88
5.11.3 Wear pads of the fixed arm, replacing�� 5-89
5.11.4 Wear pads of the telescopic arm, replacing�� 5-89
5.11.5 Pitching cylinder, checking��5-91
5.11.6 Cylinder piston rod, maintaining��5-91
5.12 Spreader�� 5-92
5.12.1 Container spreader�� 5-92
5.12.1.1 Twistlock, checking�� 5-92
5.12.1.2 Twistlock, lubricating�� 5-93
5.12.1.3 Sensor / Indicator of twistlock, checking�� 5-93
5.12.1.4 Fixed bolts of spreader rotating gearbox, checking�� 5-94
5.12.1.5 Wear pads of spreader, checking�� 5-94
5.12.2 Steel coil spreader�� 5-96
5.12.2.1 Spreader, lubricating�� 5-96
5.12.2.2 Wear pads, maintaining�� 5-96
5.12.2.3 Slewing mounting and small gear, maintaining��5-97
5.12.2.4 Reducer, maintaining��5-97
5.12.3 Steel pipe spreader�� 5-98
5.12.3.3 Slewing mounting and small gear, maintaining�� 5-99
5.12.3.4 Reducer, maintaining�� 5-99
5.13 Air Conditioning System��5-100
5.13.1 General recommendations ��5-100
Authorization is required to perform repairs on the climate control unit.��5-100
5.13.2 Air conditioning, checking / performance test�� 5-101
5.13.3 Refrigerant quantity, checking ��5-102
Safety, Operation & Maintenance Manual - August 2019 XI

5.13.4 Refrigerant, filling��5-103

5.13.5 Cleanness of heat-exchanger plate in evaporator and condenser, checking
��5-104
5.13.6 Leaking or lack of oil in condenser, checking��5-104
5.13.7 Radiator, cleaning��5-105
5.13.8 Maintenance table for air conditioner��5-105
5.14 Hydraulic System��5-107
5.14.1 Hydraulic oil level, checking��5-107
5.14.2 Air filter element, changing��5-107
5.14.3 Hydraulic oil, changing��5-108
5.14.4 Oil return filter element, replacing��5-109
5.14.5 Hydraulic oil tank, cleaning�� 5-110
5.14.6 Parking brake unit, checking and adjusting�� 5-111
5.14.7.1 Brake system accumulator, checking�� 5-112
5.14.7 Accumulator�� 5-112
5.14.7.2 Accumulators, charging with nitrogen gas�� 5-113
5.14.8 Hydraulic oil circuit, checking�� 5-115
5.15 Electrical System�� 5-116
5.15.1 Battery�� 5-117
5.15.1.1 Battery, cleaning�� 5-117
5.15.1.2 Battery, checking�� 5-118
5.15.1.3 Battery, detecting�� 5-119
5.15.1.4 Battery, charging��5-120
5.15.1.5 Battery, using��5-123
5.15.1.6 Battery cables, checking��5-125
5.15.1.7 Battery, scheduled maintenance ��5-126
5.15.2 Fuses, changing��5-126
5.15.3 All working lights and indicators, checking ��5-127
6. Troubleshooting
6.1 Precautions�� 6-2
6.2 Troubleshooting Procedures�� 6-3
6.3 Common Troubleshooting Methods�� 6-5
6.3.1 Troubleshooting the engine system�� 6-5
6.3.2 Troubleshooting the transmission system�� 6-8
6.3.2.1 Overview�� 6-8
XII Safety, Operation & Maintenance Manual - August 2019

6.3.2.2 Troubleshooting procedures�� 6-9

6.3.2.3 Troubleshooting table��6-11
6.3.3 Troubleshooting the drive axle and brake system��6-12
6.3.4 Troubleshooting the steering system��6-13
6.3.5 Troubleshooting the spreader system��6-13
6.3.6 Troubleshooting the boom system��6-15
6.3.7 Troubleshooting the air conditioning system��6-16
6.3.8 Troubleshooting the hydraulic system��6-17
6.3.9 Troubleshooting the electrical system��6-18
6.3.9.1 Troubleshooting the cable harness��6-19
6.3.9.2 Troubleshooting table�� 6-20
6.4 Engine Error Codes �� 6-27
6.4.1 VOLVO engine error codes�� 6-27
6.4.2 CUMMINS engine error codes�� 6-36
6.4.3 YUCHAI engine error codes�� 6-42
6.5 Transmission Error Codes �� 6-47
6.5 Machine Error Codes �� 6-55
7. Specifications
7.1 Technical Specifications��7-2
7.1.1 Basic parameters��7-2
7.1.2 Technical parameters��7-9
7.1.3 System configuration�� 7-12
7.1.3.1 Power system configuration�� 7-12
7.1.3.2 Spreader configuration�� 7-15
7.2 Unit Conversion�� 7-16
7.2.1 Unit abbreviation explanation�� 7-16
7.2.2 Conversion table, SI units �� 7-17
7.2.3 Conversion table, length�� 7-18
7.2.4 Conversion table, area �� 7-18
7.2.5 Conversion table, volume�� 7-18
7.2.6 Conversion table, weight �� 7-19
7.2.7 Conversion table, pressure�� 7-19
7.2.8 Conversion table, temperature�� 7-19
Safety, Operation & Maintenance Manual - August 2019 XIII

8. Optional Parts
8.1 Fire Detection and Alarm System / Automatic Extinguishing Device�� 8-3
8.1.1 Fire detection and alarm system�� 8-3
8.1.1.1 Function description�� 8-4
8.1.1.2 Precautions�� 8-6
8.1.1.3 Troubleshooting�� 8-7
8.1.1.4 Maintenance and repair�� 8-7
8.1.2 Automatic fire extinguishing device �� 8-9
8.1.2.2 Technical parameters��8-10
8.1.3 Electrical diagrams��8-11
8.2 Loudspeaker and Controller Kit��8-14
8.2.1 Control panel��8-14
8.2.2 Operations��8-14
8.2.3 Electrical wiring diagram��8-15
8.2.4 Precautions��8-16
8.3 Engine Idle Protection Function��8-16
8.4 Engine Preheating Protection Function��8-17
8.5 Engine Hour Meter��8-17
8.6 Twistlock Counter��8-17
8.7 Reversing Radar Display��8-18
8.8 Operator Presence System��8-18
8.9 Radio��8-19
8.9.2 Mute (Silence)�� 8-20
8.9.3 Sound�� 8-20
8.9.4 Audio setting�� 8-20
8.9.5 Radio�� 8-21
8.9.6 Radio troubleshooting�� 8-23
8.10 Automatic Lubrication System�� 8-24
8.10.1 Operation precautions�� 8-24
8.10.2 Time setting�� 8-25
8.11 CCTV System�� 8-27
8.11.1 Safety precautions�� 8-27
8.11.2 Major parts�� 8-28
8.11.3 Installation�� 8-29
XIV Safety, Operation & Maintenance Manual - August 2019

8.11.4 Shift switch�� 8-30

8.11.5 Troubleshooting the CCTV system�� 8-31
8.11.6 Wiring diagram�� 8-32
8.12 Flowmeter�� 8-33
9. Schematics
9.1 Symbol Explanation�� 9-2
9.2 Hydraulic Schematic Diagrams�� 9-3
9.3 Electrical Schematic Diagrams�� 9-7
9.3.1 C /H type container reach stacker�� 9-7
9.3.2 Empty container reach stacker�� 9-24
9.4 Schematic Diagrams of Spreader System�� 9-37
9.4.1 Hydraulic schematic diagram of spreader system�� 9-38
9.4.1.1 SDJ450 Spreader�� 9-38
9.4.1.2 SJD450F-R3 / SDJE100-R1 Spreader�� 9-39
9.4.1.3 SJD450E-R1 / SJD450F-R1 Spreader�� 9-40
9.4.1.4 ELME817 Spreader�� 9-41
9.4.1.5 BROMMA RSX40 Spreader�� 9-42
9.4.2 Electrical schematic diagram of spreader system�� 9-43
9.4.2.1 SDJ450 Spreader�� 9-43
9.4.2.2 SDJ450F-R1 Spreader�� 9-45
9.4.2.3 SDJ450E-R1 Spreader�� 9-47
9.4.2.4 SDJ450F-R3 Spreader�� 9-49
9.4.2.5 SJE100-R1 Spreader�� 9-51
9.4.2.6 ELME817 Spreader�� 9-53
9.4.2.7 BROMMA RSX40 Spreader�� 9-59
Safety, Operation & Maintenance Manual - August 2019 XV

XVI Safety, Operation & Maintenance Manual - August 2019

Reach Stacker Introduction
Introduction
1. Introduction
1.1 Overview�� 1-3
1.2 Application Range�� 1-5
1.2.1 Intended use�� 1-5
1.2.2 Unintended use�� 1-6
1.3 Machine Authorizations��1-7
1.4 Your Documentation Package�� 1-8
1.4.1 CD system requirements�� 1-8
1.4.2 Recommendations on using the documentation�� 1-9
1.4.3 Documentation storage��1-10
1.4.4 Manual organization��1-10
1.5 Terminology��1-12
1.6 Machine Information��1-14
1.6.1 Machine nameplate��1-14
1.6.2 Engine nameplate��1-14
1.6.2.1 VOLVO engine nameplate��1-14
1.6.2.2 CUMMINS engine nameplate��1-15
1.6.2.3 YUCHAI engine nameplate��1-15
1.6.3 Spreader nameplate��1-16
1.6.3.1 SANY spreader nameplate��1-16
1.6.3.2 ELME spreader nameplate��1-16
1.6.3.3 BROMMA spreader nameplate��1-17
1.6.4 Transmission case nameplate��1-18
1.6.4.1 DANA transmission case nameplate��1-18
1.6.4.2 ZF transmission case nameplate��1-18
Safety, Operation & Maintenance Manual - August 2019 1-1

Introduction Reach Stacker
1.7 Running in a New Machine ��1-19

1.8 Machine Serial No. and Distributor Info.�� 1-20
1.9 Correction Request Form��1-21
1.10 Contact Information�� 1-22
1-2 Safety, Operation & Maintenance Manual - August 2019

1. INTRODUCTION
Thank you heartedly for choosing our
SRSC45C30 / SRSC45C2 / SRSC45H1 /
SRSC45H2 / SRSC45H2A / SRSC45H3 /
SRSC45H4 / SRSC4535H1 / SRSC4540H2-70
/ SRSC4545C2 / SRSC4545H1 / SRSC1009-
6E / SRSC1009H5-6E / SRSC0808-6EH/
S R S C 3 6 1 5 - 3 R e a c h S t a c k e r. We a r e
commited to provide you with good quality
machine and superior after-sales service.
1.1 Overview WARNING

WARNING
This Safety, Operation & Maintenance Manual Before starting operation and maintenance,
is a guide to handle the machine correctly. personnel should observe the following
It provides technique and safety information items:
necessary for operation and maintenance of • O n l y q u a l i f i e d a n d e x p e r i e n c e d
the machine. Please make sure to read every operators with official license
parts of this manual in detail. (according to the local laws) are allowed
to operate the machine.
• Always operate your machine according
to national, provincial, prefectural and
municipal laws and regulations.
• Read and understand the complete
manual.
• Read and understand safety notices in
this manual and safety labels on the
machine.
• Do not operate the machine under any
circumstances or in a manner that is
prohibited in this manual.
Failure to do this would result in personal

injuries or possibly death.

Information, specifications, and illustrations

in this publication are based on the
latest available information. Continuous
improvements in the design of the machine
can lead to changes which may not be
covered in this manual. SANY reserves the
right to change the information at any time
without prior notice. Please consult SANY
authorized distributors to obtain the latest
information if you have any question on the
information in this manual.
Modifying the machine without any approval

o r abusing it mi ght r isk t he mac hine’s
performance, or result in potential hazard.
Incorrect operation may cause personal injury
or damage. SANY assumes no liability for
such losses.
NOTE:
• This manual should be regarded as a
permanent component of the machine. If
the machine is sold to a third party, give
this manual to the new owner.
• SANY products are in line with all
spec if ic ations and st andards of the
country of destination. If the machine is
purchased from another country or a third
country, it might lack some safety devices
or technical requirements necessary for
using in your country.
• If you are not sure whether the machine is
in accordance with the specifications and
standards of your country, please contact
SANY authorized distributors before
operating the machine.
• Machines covered by this manual are
used for various operations under normal
conditions. If you are not sure about the
safety of some procedures, please contact
SANY directly.

1.2 Application Range
1.2.1 Intended use
Reach stacker is a type of auxiliary equipment

for transferring containers, steel coils, steel
pipes, wood, etc.
Never hoist or transport heavier load than

Fig. 1-1 Container Reach Stacker
the max. lifting capacity of the machine. (For
detailed information, see: “Load capacity
diagram“ on page 4-38.)
The rules for intended and approved uses

of the machine must be followed under all
circumstances by the responsible person,
more importantly by the operator and service
personnel.
The user is responsible for any danger arising

from applications not authorized by the
manufacturer.
Fig. 1-2 Steel Coil Reach Stacker
NOTE:
Numerous spreaders are provided for your
options, including container spreader, steel coil
spreader, steel pipe spreader, etc.
This manual mainly introduces the safety,
operation and maintenance information of
reach stackers with container spreader. The
rules and steps of other reach stackers are of
the same.
Fig. 1-3 Steel Pipe Reach Stacker

1.2.2 Unauthorized use
If any procedures or actions not specified,

recommended or allowed in this manual are
performed, you must be sure that you and
others can perform such procedures and
actions safely without damaging the machine
or injuring yourself and other personnel.
Unauthorized uses include:

• Transporting people. No people may be
transported;
• Tr a n s p o r t i n g p e o p l e i n s i d e o r o n
containers;
• Adding load to the machine;
• Using c ables, chains or other items
attached to the boom to transport or lift
objects;
• Pulling or pushing vehicles, trailers or
containers;
• Operating, driving and crossing on roads;
• Starting, retracting and operating in public
areas with risks of explosion;
• Overloading the machine beyond its max.
lifting capacity listed in the load capacity
diagram on page 4-38;
• Transporting non-centered loads;
• Leaving the machine with the load hanging
on the spreader.
NOTE:
SANY assumes no liability for damage to
people, the environment or the machine due to
unauthorized uses.

1.3 Machine Authorizations
S A N Y p o r t m a c h i n e s h ave a l l p a s s e d
European CE authoriaztion, North America
ANSI authorizatin and Customs Union CU-TR Address: Sany Industry Town,
authorization. Economic and Technological
Development Zone, Changsha,
1417
Hunan, China
All machines and equipment manufactured by

SANY Port Machinery Company are labeled
with CE, which certifies their conformity to the
European Union machine safety instructions. Fig. 1-4 CE Label

1.4 Your Documentation Package
Several documents will be packed along with

the machine, as listed below:
• Safety, Operation & Maintenance Manual:
this manual must always remain in the cab
when not being used.
• Parts Book: this publication consists of
list of parts and their matching drawings
for ordering spare parts as needed. If not
shipped with the machine, it is available
directly from SANY.
• CD: all the above data are stored on a CD
either already shipped with your machine
or available directly from SANY.
NOTE:
When the machine is sold, these
documentations must be provided to the new
owner.
1.4.1 CD system requirements
The requirements of computer configuration

are listed below for the use of SANY CD.
Hardware:
• Intel® Pentium II® at 500 MHz or above
• At least 128 MB RAM
• CD-ROM drive
• Minimum screen resolution of 800 x 600
pixels, high-color depth
Software:
• Windows 2000, XP, Vista or Windows 7
operating system
• Internet Explorer 6.0 or later version (pop-
up blocker disabled)
• Acrobat Reader 7.0 or later version

1.4.2 Recommendations on using the

documentation
• This documentation applies only to the

machine and should not be used for any
range of machine.
• Ensure that the documentation is always
complete and up to date.
• Keep all sequential pages inside its binder
(if loose leaves are shipped).
• Use the CD to print and replace any
missing pages or those unreadable due to
damage, grease, dirt, etc.
• Replace the old versions of some
pages with SANY replacement pages if
necessary. Destroy the old ones.
• Replace outdated CDs with new ones.
Destroy the old ones to prevent any
confusion in the future.
• This manual is marked with corresponding
page numbers.
1. Page number of the Table of Contents part

is marked with roman letters, for example:
Ⅰ、Ⅱ、Ⅲ、Ⅳ ......
2. Page number of the Content part is marked
as below:
3 -20
chapter 3, page 20
chapter 3
3. Edition number of Safety, Operation and

Maintenance Manual is marked as below:
Safety, Operation & Maintenance Manual - July 2012
updated month of this edition

updated year of this edition

1.4.3 Documentation storage
• Always keep this manual in the operator

cab.
• Keep the parts book either in the workshop
area or of f ice to be available to the
maintenance personnel when needed.
• The above documents can be printed out
from the CD.
1.4.4 Manual organization
CHAPTER 1: INTRODUCTION
This section provides a general outline of what
is covered in this manual, including machine
nameplates and SANY contact information.
CHAPTER 2: SAFETY
This section covers basic safety information
related to the machine. Make sure that you
fully understand all the precautions described
in this manual and the safety labels on the
machine before operating or maintaining the
machine. Failure to do so may result in serious
injury or death.
CHAPTER 3: SYSTEM FUNCTIONS

T h i s s e c t i o n p r ov i d e s a n ove r v i e w o f
control and operating system, as well as all
mechanisms. It is important to study and
become familiar with all systems before any
operations.
CHAPTER 4: OPERATION
T h i s s e c t i o n p r ov i d e s b a s i c o p e r at i n g
procedures for the machine. Study and
know all operating procedures before any
operations. This section also introduces the
information about transportation / assembly/
disassembly of the machine.

CHAPTER 5: MAINTENANCE
This section provides all general maintenance
and repair procedures. (Detailed adjustment /
replacement / repair information are covered
in a separate shop manual.) Study and know
all repair and maintenance procedures before
performing any repair or maintenance.
CHAPTER 6: TROUBLESHOOTING
This section includes all the common faults
and error diagnostic procedures, as well as
the general troubleshooting methods for faults
in mechanical, hydraulic and electrical system.
CHAPTER 7: SPECIFICATIONS
This section provides general specifications
of the machine. Note that this can vary in
different design.
CHAPTER 8: OPTIONAL PARTS

SANY has provided lots of optional parts for
the customer to install on the machine. This
section mainly introduces the functions and
operations of these optional parts.
CHAPTER 9: SCHEMATICS
This section provides the hydraulic and
electrical schematic diagrams of reach stacker.
Besides, the hydraulic and electrical diagrams
of spreader are included.

1.5 Terminology
Table 1-1 Terminology

Term Description
Accumulator Reservoir that stores (accumulates) pressure for i.e. hydraulic functions
Anti-corrosion compound Prevents oxidation, in simple terms, rust-proofing
Attachment Part of the machine that grabs the load when lifting
Axle distance Distance between drive axle and steering axle
Bar Unit to express pressure
Battery disconnector Cuts off current from battery
Boom Lift beam moveable vertically and in-out. Bracket for attachment
Buzzer Acoustic alarm to alert the operator
Valves that can be used to control hydraulics, for example, to release pressure
Control valve
and thus lower the boom
The actions that should be performed daily to ensure the machine’s
Daily inspection
functionality
Display “Window” showing digital information on steering wheel panel in cab
Drive axle Receives torque from the drive train
Parts in machine including engine, torque converter, transmission, propeller
Drive train
shaft and drive axle with differential and hub reduction
The air filter collects the coarsest particles in a dust reservoir, emptied
Dust reservoir
automatically during operation
Electrolyte level Fluid level in battery cells
Used oils, filters, etc., must be handled according to governing national laws
Environmental waste
and regulations
Expansion tank Tank for coolant
Fixed displacement Pump with fixed pump volume
Hanging load Lifted load
Hub reduction Final drive that reduces rpm and increases torque from the drive train
Hydraulic oil Oil for hydraulic system
Hydraulic oil pump Pump in hydraulic system
Hydraulic system System that uses oil pressure to transfer power to different functions
Manual “sensor”, for example, shows that a filter is clogged and needs to be
Indicator
changed
Load capacity Indicates machine’s max. load capacity
Hoisting point Attaching point for lift device when lifting an object
Engine with low emissions of hazardous substances. Manufactured according
Low-emission engine
to regulations
Machine model Machine type indicated
Main fuse Located by the battery. Relays current to all systems in machine

Term Description
Maintenance Periodic maintenance actions so that machine functions safely and for long
life.
OP Overload protection. Overloading system to warn when machine is overloaded
Operating hours Number of hours machine has been in operation, shown on hour meter in cab
Optional Optional equipment for machine
Overloading system See OP
Planetary gear Gears in constant engagement
Product option One of several options is selected for a machine, i.e. engine alternative
Proportional valve An electro-magnetically controlled valve. If a current is applied, the valve is
activated in proportion to the current’s amplitude. In simple terms, infinitely
variable valve, as opposed to on/off valve. For example, on transmission’s
valve housing
Reach stacker Machine with special top lift attachment for containers
Refrigerant Fluid/gas in air conditioning. May only be handled by authorized trained person
S e c u r i n g m a c h i n e f o r Actions before transporting machine
transport
Serial number Unique machine designation. On machine nameplate
Service position How machine should be safely positioned before service may be started
Servo pressure A low control pressure to control a higher pressure, for example, to a valve
Side-shift Parallel sideways movement of attachment
Solenoid valve An electro-magnetically controlled valve
Spreader Widening attachment
Start-up Start procedure for control and monitoring system (from powerless to supplied
with voltage)
Steering axle Wheel axle with steering
Tilting Load is leaned forward or backward
Torque converter Hydraulic, variable clutch
Transmission oil Oil for transmission and torque converter
Twistlock Four lock pins, one in each corner of the attachment, pushed down in
corresponding holes in container and twisted to lock the container when lifting
Variable displacement Adjustable volume (capacity) of a pump
Variable pump Pump with adjustable flow rate
Wet brakes Brake discs in oil-bath

1.6 Machine Information

Please inform SANY authorized distributors of the following information when ordering
replacement parts or requiring assistance for your equipment.
1.6.1 Machine nameplate
SANY Marine Heavy Industry Co., Ltd
Fig. 1-5 Machine Nameplate
1.6.2 Engine nameplate

1.6.2.1 VOLVO engine nameplate
Fig. 1-6 VOLVO Engine Nameplate

1.6.2.2 CUMMINS engine nameplate
Fig. 1-7 CUMMINS Engine Nameplate
1.6.2.3 YUCHAI engine nameplate
Development code
Displacement code
Power code
Serial Code
Code of cylinder amount
Enterprise Code
Fig. 1-8 YUCHAI Engine Nameplate

1.6.3 Spreader nameplate
1.6.3.1 SANY spreader nameplate
SANY Marine Heavy Industry Co., Ltd
Fig. 1-9 SANY Spreader Nameplate
1.6.3.2 ELME spreader nameplate
Type Year
Cap Weight
Voltage Ser.No.
Elme Spreader AB
P O Box 174 S-343 33 AL MHULT
Phone +46 475 558 90 Fax +46 478 558 99
www.elme.com Made in Sweden
Fig. 1-10 ELME Spreader Nameplate

1.6.3.3 BROMMA spreader nameplate
Spreader type RSX40

Serial No: 12810-12815
General Assy No: 1031900
Container Range 20´and 40´
Fig. 1-11 BROMMA Spreader Nameplate

1.6.4 Transmission case nameplate
1.6.4.1 DANA transmission case nameplate
SPICER OFF-HIGHWAY
BRUGES
BELGIUM
MODEL XX.XXXXXXXX-XXX
SERIAL XXXXXXXXXX XX/XX
Fig. 1-12 DANA Transmission Case Nameplate
1.6.4.2 ZF transmission case nameplate
ZAHNRADFABRIK PASSAU
G.m.b.H.
MADE IN GERMANY
TYPE / SERIAL NO.
PARTS LIST NO. TOTAL RATIO
OPERATING PRESS. (bar)
TORQUE CONVERTER
PARTS LIST NO. TYPE
OEL-LEVEL
CHECK AT IDLING SPEED
USE OIL ONLY ACCORDING TO

ZF SPEC. TE-ML 03
Fig. 1-13 ZF Transmission Case Nameplate

1.7 Running in a New Machine
NOTICE
NOTICE
Yo u r m a c h i n e h a s b e e n t h o r o u g h l y
adjusted and tested before shipment.
However, initial operation of the machine
under severe conditions can adversely
af fect its per formance or shor ten its
service life.
Therefore, SANY recommends that you

allow a running-in period of 100 operating
hours for a new machine (according to the
indication of the hour meter).
Make sure that you have understood the

complete manual, and pay attention to the
following points during the running-in period:
• Start engine at idle for 3-5 minutes. Do not
operate the joystick during this time. Then
adjust the throttle switch to 1500 RPM,
and operate slowly until the temperature of
water reaches around 60 ℃ .
• Avoid operating with severe load or at high
speed.
• Avoid sudden start or fast movement or
stop.

1.8 Machine Serial No. and

Distributor Info.
The table below is for you to record information

relating to your machine. It is required that
you keep this manual with your machine at all
times for reference.
Machine Serial No.
Engine Serial No.
Distributor Name
Address
Tel /Fax

1.9 Correction Request Form
If you f ind a problem with this manual,

please make a copy of this page, fill out the
information and send it to us. For detailed
information, see: “Contact Information” on
page 1-22.
Date of this Request
Your Name
Company Name
Your Department
Street Address
City, State & ZIP
Phone
E-mail
Machine Model & Serial No.
Description of Problem
(wrong information, unclear or
erroneous procedure, etc.)

1.10 Contact Information
Address: SANY Industrial Park, Gaolan Port Economic and Development Zon, Zhuhai City,
Guangdong Province, China
Tel: 0086-756-7266945
Fax: 0086-731-84031999-149
Email: sanyport@sany.com.cn
Service hotline: 0086 4006098318

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Reach Stacker Safety
Safety
2. Safety
2.1 Safety Information�� 2-4
2.1.1 Signal words�� 2-4
2.1.2 Examples of using signal words �� 2-5
2.1.3 Other signal words�� 2-5
2.1.4 Safety labels�� 2-6
2.1.4.1 Safety labels - location�� 2-8
2.1.4.2 Safety labels - content�� 2-9
2.2 General Precautions��2-15
2.2.1 Basic safety instructions��2-15
2.2.2 Personal protective equipment��2-16
2.2.3 Never operate while in bad health��2-19
2.2.4 No passenger in the cab��2-19
2.2.5 Hand signals�� 2-20
2.2.6 Preparing safety items�� 2-23
2.2.7 Checking safety equipment�� 2-23
2.2.8 Precautions in high voltage areas��2-24
2.2.9 Precautions in thunderstorm��2-27
2.2.10 Precautions in wind��2-27
2.2.11 Abnormal cases��2-28
2.2.12 Unauthorized modification�� 2-29
2.3 Safety During Operation�� 2-30
2.3.1 Work area safety�� 2-30
2.3.1.1 Work area requirements�� 2-30
2.3.1.2 Work area indications�� 2-30

Safety Reach Stacker

2.3.3 Keeping machine clean�� 2-33
2.3.4 Climbing on or off the machine safely�� 2-33
2.3.5 Start-up safety �� 2-35
2.3.5.1 Inside the operator cab�� 2-35
2.3.5.2 Adjusting the seat�� 2-35
2.3.5.3 Checking the seat belt�� 2-36
2.3.5.4 Machine starting precautions�� 2-36
2.3.5.5 Jump-start the engine, precautions�� 2-38
2.3.5.6 In cold weather�� 2-39
2.3.5.7 After starting the engine�� 2-39
2.3.6 Requirements for safe operation�� 2-40
2.3.6.1 Ensuring good visibility �� 2-40
2.3.6.2 Safety rules for traveling�� 2-40
2.3.6.3 Precautions while operating on slopes�� 2-42
2.3.6.4 Avoiding injury from reversing �� 2-42
2.3.6.5 Precautions while operating on snow or frozen surfaces�� 2-43
2.3.6.6 Preventing control failure�� 2-44
2.3.6.7 Never hoist a load except container�� 2-45
2.3.6.8 Never hoist the load over people�� 2-45
2.3.6.9 Never stand under the load�� 2-45
2.3.6.10 Precautions for operating emergency stop button�� 2-46
2.3.6.11 Precautions for operating safety bypass switch�� 2-46
2.3.7 Parking the machine securely�� 2-47
2.3.7.1 Parking requirements�� 2-47
2.3.7.2 Turning off the engine �� 2-48
2.4 Safety During Maintenance�� 2-49
2.4.1 Preparation for the work area�� 2-49
2.4.2 Warning label is important�� 2-50
2.4.3 Lockout/tagout procedures�� 2-50
2.4.4 Self-preparation before maintenance�� 2-51
2.4.5 Using tools correctly �� 2-51
2.4.6 Regular replacement of safety-related parts�� 2-51
2.4.7 Removing attachments carefully�� 2-52
2.4.8 Adding fluids to the machine�� 2-52
2.4.9 Towing or lifting the machine�� 2-53

2.4.10 Keep clear of moving machinery�� 2-54

2.4.11 Preventing hydraulic hazards �� 2-55
2.4.11.1 Checking rubber hose regularly�� 2-55
2.4.11.2 Releasing the pressure before maintenance�� 2-56
2.4.11.3 Replacing rubber hose regularly�� 2-57
2.4.11.4 Prevent heat near the hydraulic pipeline�� 2-58
2.4.11.5 Filling accumulator�� 2-58
2.4.11.6 Selecting oils and fuel�� 2-59
2.4.11.7 Handling hydraulic oil �� 2-59
2.4.12 Preventing burn and scald�� 2-60
2.4.12.1 Burn by high temperature liquid�� 2-60
2.4.12.2 Chemical burn�� 2-61
2.4.13 Preventing fire and explosion�� 2-63
2.4.13.1 Handling inflammables safely�� 2-63
2.4.13.2 Removing inflammables�� 2-63
2.4.13.3 Checking oil leakage�� 2-64
2.4.13.4 Checking short circuit�� 2-64
2.4.13.5 Checking ignition key�� 2-65
2.4.13.6 Preventing battery explosion�� 2-65
2.4.13.7 Evacuating from the machine�� 2-66
2.4.14 Preventing poisoning and asphyxiation�� 2-68
2.4.14.1 Handling chemicals safely�� 2-68
2.4.14.2 Preventing poisoning by paint �� 2-68
2.4.14.3 Preventing poisoning by off-gas�� 2-69
2.4.15 Preventing dust hazard�� 2-70
2.4.16 Working under machine��2-71
2.4.17 Precautions in welding��2-71
2.4.18 Safe maintenance of air conditioning system�� 2-72
2.4.19 Precautions in maintaining the engine�� 2-73
2.4.20 High voltage precautions��2-74
2.4.21 Precautions after maintenance��2-74
2.4.22 Handling waste properly��2-74
2.5 Tag�� 2-76

2. SAFETY
2.1 Safety Information
This manual provides detailed information

on basic safety precautions and preventive
measures during operation and maintenance
of this machine.
Before conducting operation and maintenance,
you must read and understand all safety
labels on the machine. Strictly follow the
safety rules and suggestions in this manual.
Take precautions to reduce the risk of injury
or death, the damage of machine caused
by incorrect service, and the risk of unsafe
factors, to the minimum.
2.1.1 Signal words

The following (ANSI/ISO) signal words are
used to inform you that there is a potentially
hazardous situation that may lead to damage,
personal injury or even death.
DANGER It indicates an imminent

hazard which, if not avoided, will result in
serious injury or death.
WARNING It indicates a potentially

hazardous situation which, if not avoided,
could result in injury or possibly death.
CAUTION It indicates a possible

potential hazardous situation which, if not
avoided, could result in minor or major
injury.
NOTICE
NOTICE It indicates a situation
which can cause damage to the machine,
personal property and/or the environment,
or cause the equipment to be operated
incorrectly.

This hazard alert symbol appears

with most (Danger, Warning & Caution)
hazard alerts. It means attention, become
alert, your safety is involved! Please read
and abide by the message that follows the
hazard alert symbol.
2.1.2 Examples of using signal words
CAUTION
CAUTION
Do not open the filler cap when the engine

is hot, except in emergencies. Steam or hot
fluid could spray out.
2.1.3 Other signal words

Other than the above, the following signal
words indicate matters to be observed for
protecting your machine, or provide you with
very useful information.
NOTE is the term used whenever information

requires additional emphasis beyond the
standard text.
REMARK is the term used whenever

information requires special attention to
procedures to ensure proper operation or to
prevent possible equipment failure.

2.1.4 Safety labels

Safety labels, fixed on the machine, are used
to warn the operator or maintenance personnel
of potential dangers.
The operator and all other personnel involved

with this machine must be aware of the label
contents and locations.
• All safety, alert and warning labels must

be in place and always clean, undamaged,
and clearly visible.
• The use of organic solution or gasoline to
clean the labels is not allowed, the labels
may scale off.
• Additional safety or warning labels may be
added to your machine if necessary.
• SANY can supply you with new
replacement labels if needed. Never modify
or change existing label information unless
authorized by your SANY distributors.
• When replacing labels, be sure that they
are placed in the proper locations.
NOTE:
SANY cannot accept any liability for damage/
injury as a result of the user’s failure to order
replacement labels in due time.

a. Safety label example 1
WARNING
Keep clear of moving machinery

Death or serious injury can occur
Fig. 2-1 Safety Label 1
b. Safety label example 2
Fig. 2-2 Safety Label 2

2.1.4.1 Safety labels - location
6 4 5
4 3 2
1
14
7
8
9
10
11 12
13
4
3 2 1 5
4
16
17
8 6 7
15
Fig. 2-3 Safety Labels of Whole Machine

2.1.4.2 Safety labels - content
1. Warning label, spreader
Never stand close to the spreader. There is

danger of being hit by it.
For its location on machine, see position 1 in

Fig. 2-3.
Fig. 2-4 Attachment Warning
2. Warning label, overhead danger
Never stand beneath swinging load. There is

danger of being hit by it.

Fig. 2-3.
Fig. 2-5 Overhead Danger
3. Warning label, caution for electricity
Keep the machine away from power lines.

Fig. 2-3.
Fig. 2-6 Caution for Electricity

4. Warning label, head injury
Stay clear from the machine in the operation

process and be cautious of the hanged
objects.

Fig. 2-3.
Fig. 2-7 Head Injury
5. Label, no passengers
Only the operator is allowed in the cab if not

otherwise indicated when the machine is
traveling.
For its location on machine, see position 5 in No passengers allowed

Fig. 2-3.
Fig. 2-8 No Passengers
6. Label, no climbing
Never climb on the place placed with this no

climbing label.

Fig. 2-3.
Fig. 2-9 No Climbing

7. Warning label, tyre precautions
Observe the precautions listed in the right

illustration when repairing or maintaing the
tyres.

Fig. 2-3.
Fig. 2-10 Tyre Precautions
8. Label, stay clear of moving machine
Never stand in places where there is a label

as shown in the right figure.

Fig. 2-3.
Fig. 2-11 Stand Clear of Moving Machine
9. Warning label, no ether
To avoid explosion and severe injury, do not

use ether.

Fig. 2-3.
Fig. 2-12 No Ether

10. Label, battery disconnect
Disconnect the battery before servicing the

machine.

Fig. 2-3.
Fig. 2-13 Battery Disconnect
11. Warning label, chemical hazard
The battery contains corrosive and hazardous

materials. Do not pucture the battery.

Fig. 2-3.
Fig. 2-14 Chemical Hazard
12. Warning label, electrical hazard
Always disconnect the power before servicing

the machine.

Fig. 2-3.
Fig. 2-15 Electrical Hazard

13. Warning label, fire is prohibited
Do not smoke or use any open fires, as fire

disaster or explosion may occur.

Fig. 2-3.
Fig. 2-16 Fire is Prohibited
14. Warning label, crushing hazard
Take care of your hand. There is a danger of

being crushed.

Fig. 2-3.
Fig. 2-17 Crushing Hazard
15. Warning label, stay clear
Death or serious injury may occur if you are hit

by the machine. Stay clear from the machine.

Fig. 2-3.
Fig. 2-18 Stay Clear

16. Warning label, caution for disassembling

counterweights
Do not stand under or on counterweights when

assembling or disassembling them.

Fig. 2-3.
Fig. 2-19 Caution for Disassembling

Counterweights
17. Warning label, stay clear
Please stay clear from the machine with a

distance of at least 8m.

Fig. 2-3.
Fig. 2-20 Stay Clear

2.2 General Precautions
WARNING
WARNING
Negligence by maintenance or on-site

personnel will lead to injuries, serious
damages of machine and property loss.
2.2.1 Basic safety instructions
• Only appointed and trained personnel

are allowed to operate and maintain this
machine.
• A l w a y s ke e p t h e m a c h i n e i n g o o d
condition.
• The safety information in this manual does
not substitute for any rules and laws in
your country. Know the local safety rules
and laws. Make sure that equipment fitted
to your machine abide by these rules and
laws.
WARNING
WARNING
Read and follow all safety precautions
before operating or maintaining machine.
Failure to do so could result in equipment
damage, serious injury or possibly death.
Protective equipment should contain:

2.2.2 Personal protective equipment
Protective equipment ensures only the proper

protection but not complete protective effects.
Therefore, stay alert ever and again.
Always wear protective equipment when

operating, maintaining, or repairing the
machine. Take protective tools necessary for
tasks.
Fig. 2-21 Protective Equipment
CAUTION
CAUTION
Operator and maintenance personnel are

not allowed to:
• work without putting on safety helmet.
• wear loose clothing, including rings,
earrings or similar accoutrement.
• wear music earphone while operating.
Failure to do so may result in injuries.
Responsibilities:
• wear protective equipment
• clean and maintain personal protective
equipment at regular intervals
• change damaged or inapplicable protective
equipment

• Safety Helmets:
Safety helmets can protect head from injury.
B e s u r e t o we a r s a f et y h e l m et s w h i l e
operating, maintaining, repairing the machine.
Fig. 2-22 Safety Helmet

• Safety Shoes
Safety shoes can decrease foot injuries
caused by following reasons:
1. hitting hard objects
2. stepping on sharp objects
3. heavy objects falling down
Be sure to wear safety shoes while operating,

maintaining, repairing the machine.
Fig. 2-23 Safety Shoes
• Safety Goggles and Mask
Safety goggles can protect eyes from harm.
Put on safety goggles while hammering or

grinding parts, splashing objects such as
dust, sand or metal scraps can cause serious
injuries.
Hold a protective mask in hand while welding.
• Ear-muffle
Fig. 2-24 Safety Goggle

Ear-muffle can protect you from loud noises.
Noise louder than 85 dB(A) that lasts for

longer than 8 hours is considered to be a
hearing hazard. In more severe cases, hearing
hazard can become permanent.
Use hearing protection. Make sure that it is

tested and protects personnel against the
hazardous noise level.
Fig. 2-25 Ear-muffle
• Dustproof Mouth-muffle
Put on a dustproof mouth-muffle when welding

or working in the area surrounded with harmful
gases or dusts.
Fig. 2-26 Dustproof Mouth-muffle
• Protective Gloves
Protective gloves can protect you from hand

injuries. Make sure to put on protective gloves
under below circumstances:
• during the repair:
• when handling hot, freezing, corrosive,
wood materials;
• when handling steel cables or metals with
sharp edges.
• when the environment temperature is
extremely low;
• when using impact tools for a long time.
Fig. 2-27 Protective Glove
• Protective Clothes

Be sure to wear protective clothes while

operating, maintaining, repairing the machine.
It could effectively reduce the danger caused
by fire, freezing, corrosion, stab, or scratch,
etc.
Do not wear clothes with wide sleeves, wide

pants, etc, since the not suitable garments
may hook on the control lever or protrusion of
machine and thus lead to injuries.
Clothes should be in good condition and Fig. 2-28 Protective Clothes

without oil dirt, or it may catch fire.
2.2.3 Never operate while in bad health
Distracted attention may lead to the danger of

injuries.
Do not operate the machine when you are:
• exhausted
• ill
• after drinking
• after taking medicine, etc.
2.2.4 No passenger in the cab
No other passenger except the operator is

allowed to stay in the cab. Passengers may
block the operator’s sight, which may result in
an unsafe situation.
Fig. 2-29 No Passenger

2.2.5 Hand signals
DANGER
DANGER
Operation without signals and instructions

may result in machine damage or injuries
even death.
Clear and precise communication between

the operator and the signalman is a must for
safe and efficient machine operation. Both
personnel must know proper hand signals for
each movement of the machine or load.
RAISE LOAD
With forearm vertical and index finger pointing
up, move the hand in a small horizontal circle.
RAISE
LOAD
Fig. 2-30
LOWER LOAD
With arm extended downward and index finger
pointing down, move hand in a small horizontal
circle.
LOWER
LOAD
Fig. 2-31

RAISE LOAD SLOWLY

Use one hand pointing upward to give a motion
signal and place the other hand motionless
above the hand giving the motion signal.
RAISE
LOAD
SLOWLY
Fig. 2-32
LOWER LOAD SLOWLY

Use one hand pointing downward to give
a motion signal and place the other hand
motionless below the hand giving the motion
signal.
LOWER
LOAD
SLOWLY
Fig. 2-33
NORMAL STOP
Use one hand starting at the waist and move it
outward.
STOP
Fig. 2-34

EMERGENCY STOP
Use both hands starting at the waist and move
them outward.
EMERGENCY
STOP
Fig. 2-35
Tips for safe signaling
• A new machine operator or signalman
should brief each other to ensure
understanding.
• Never begin operations until all signals are
clearly understood. If non-standard signals
are to be used, be sure that the operator
and signalman agree on them before
operations.
• If communication with the signalman is
obstructed in any way, all movements
of the machine must be stopped until
communications are restored.
• There should be only one designated
person at a time giving machine signals.
• An operator should move loads only based
on signals from a designated signalman
who wears distinctive clothing.
• The signalman must have a clear view of
the load and machine at all times.
• The signalman must keep all personnel
outside the machine’s operating area.
Any requests or questions should only be
addressed to the signalman.
• The signalman should never direct a load
over people.

2.2.6 Preparing safety items
To prevent injury or fire, observe the following

precautions:
• Fire extinguisher and first aid kit should be
available.
• Read and understand the instruction label
on fire extinguisher. Use fire extinguisher
correctly. Fig. 2-36 Safety Items
• Do regular inspection and maintenance
to ensure proper f unc tioning of f ire
extinguisher at any time.
• Check the f irst aid kit regularly and
replenish it when necessary.
• Prepare and implement emergency plan to
deal with fire and accidents.
CAUTION
CAUTION
Firefighters should put on a fire-fighting

mask to prevent injury when extinguishing
the fire with CO2, foam, dry-powder fire
extinguisher.
2.2.7 Checking safety equipment

To protect all, your machine may be fitted with
the following safety equipment. Ensure that
each item is securely in place and in operating
condition.
• Guard against falling objects
• Handrail
• Lights
• Safety labels Fig. 2-37 Check Safety Signs
• Horn
• Reverse alarm buzzer
• Rearview mirrors
• Fire extinguisher
• First aid kit
• Wipers
Be sure that the above devices are ready for
operation. Never remove or disconnect any
safety devices.

2.2.8 Precautions in high voltage areas
Operating machine near high frequency towers

(for instance, cell phone towers) or working
around overhead electrical lines may pose an
electrical hazard.
A minimum distance of 5 meters should be

maintained irrespective the voltage is. During
operation no part of the load, machine or Fig. 2-38 Electricity strike
additional equipment used should exceed this
limit. If in doubt, contact your local Electrical
Power Utility Company FIRST!
DANGER
DANGER
• NEVER operate the machine under

electrical power lines. Electrical energy
under high voltage can discharge to
ground through the machine without
direct contact with the machine’s
structure. It will result in serious injury
or death.
• If the power line is discharging
electricity, operator should stay in the
cab and prevent others from touching
the machine.
• Machine is not insulated!
• High voltage charge of machine could
result in equipment damage and
personal injury. Avoid direct contact
with power supply while operating the
electrical equipment. Do not work in
the areas of high-voltage cables or near
high-voltage power supply.

To address these risks:

• Identify overhead power lines and mark
safe routes where the equipment must
operate.
• Ask the local Electrical Power Utility
Company to shut this system down until
your work is completed.
• Operate the equipment at a slower-than-
normal speed in the vicinity of power lines.
• When working under overhead power
lines, de-energize and ground them, or
take other protective measures such as
guarding or insulating the lines.
• If the power lines are not shut down, Table. 2-1 Safety Distance
operate the equipment in the area ONLY if
a safe minimum clearance (see Table 2-1) Cable Voltage Safety Distance
is maintained. 6,600 V about 2m (7ft)
22,000 V about 3m (10ft)
66,000 V about 4m (14ft)
154,000 V about 5m (17ft)
187,000 V about 6m (20ft)
275,000 V about 7m (23ft)
500,000 V about 12m (38ft)
• If maintaining safe clearance by visual

means is difficult, designate a person
to obser ve the clearance and to give
immediate warning when the equipment
approaches the limits of safe clearance.
• All personnel should keep well away from
the equipment whenever it is close to
power lines.
• Do not touch the equipment until the
signalman indicates that it is safe to do so.
• The use of electrocution hazard devices is
not a substitute for de-energizing lines, or
maintaining safe clearance.

If the equipment or any of its components

does contact an energized power source, you
must:
1. Remain calm.
2. Immediately warn personnel in the vicinity
to stay away.
3. Attempt to move the equipment away from
the power source.
4. If in the cab, stay there until the power
company has been contacted and the
power source has been shut down.
5. NO ONE must attempt to come close to
the equipment until the power has been
turned off.
6. If it is absolutely necessary to leave the
cab, jump completely clear of the vehicle.
Maintain balance and land with both feet,
legs, arms and hands still together. Your
hands, arms or any part of your body
should not touch the equipment during the
jump.
7. Once on the ground continue to jump away
from the affected area as far as possible.
DO NOT walk or run as this will cause an
electrical arc resulting in serious injury or
death.
NOTE:
• If the machine is c ontacted with an
energized electrical source, the local
authorized SANY distributors must be
immediately advised of the incident and
consulted on necessary inspections and
repairs.
• The equipment must not be returned to
service until it is thoroughly inspected for
any damage and all damaged parts are
repaired or replaced as authorized by
SANY or your local SANY distributors.

2.2.9 Precautions in thunderstorm
If the thunderstorm occurs, operator and

others around may be caught in danger. Some
parts of the machine could be damaged.
• Make sure to stop operating if there is the
possibility of thunderstorm.
• Lower the load to ground and stop the
engine.
• Leave the machine and hide in secure
areas.
• After the thunderstorm, check all parts Fig. 2-39 Thunderstorm
of the machine before operating it. If any
defects found, contact the local SANY
distributors to troubleshoot and fix the
problem.
Check the defects:

• whether the machine is burnt or damaged
• whether the electrical equipment are
working normally
• whether all the functions are in good order
2.2.10 Precautions in wind
Wind can have a significant effect on loads

lif ted by the mac hine. Wind forc es ac t
differently on the machine, depending upon
the direction from which it is blowing.
SANY recommends that operation of this

machine in wind speeds over 30 mph (48 km/
h) be prohibited. To assist you in determining
prevailing wind c onditions, refer to the
following table.

Table 2-2 Wind speeds and Their Effects
Wind Force Wind

Visible Indicator
Beaufort Velocity
Designation Effects of wind as observed on land
Scale km/h (mph)
Zero (0) Calm <2 (<1) No wind: smoke rises vertically
1 Light air 2-5 (1-3) Wind direction seen by smoke but not by wind vanes
2 Light breeze 6-11 (4-7) Wind felt on face: leaves rustle: wind vane moves slightly
3 Gentle breeze 13-19 (8-12) Leaves/small twigs in constant motion: wind extends flag
4 Moderate breeze 21-29 (13-18) Raises dust & loose paper: moves small branches
Reduce machine load ratings and operating parameters at 32 km/h (20 mph)
Small trees in leaf begin to sway: on ponds, crested
5 Fresh breeze 31-39 (19-24)
wavelets form
Large branches in motion: telegraph cables whistle:
6 Strong breeze 40-50 (25-31)
umbrellas used with difficulty
Cease all craning operations at 48 km/h (30 mph); lower & retract spreader
7 Moderate gale 52-61 (32-38) Whole trees in motion: walking against wind is inconvenient
2.2.11 Abnormal cases
In case of any defects found during operation

and maintenance, such as noise, vibration,
odor, incorrect gauge display, smoke, or
oil leakage, you are obligated to report to
the person in charge and take necessary
measures. Do not operate the machine before
the fault is attended to.

2.2.12 Unauthorized modification
• Installation of optional parts or attachments

may involve safety or legal compliance.
Contact SANY in this regard.
• Do not use attachments that are not
authorized by your SANY distributors.
Uses of unauthorized attachments could
create a safety problem and adversely
affect proper operation and service life
of the machine. Any injuries, accidents,
product failures resulting from the use of
unauthorized attachments will not be the
responsibility of SANY.
• Always read and follow the instructions of
attachments in this manual when installing
and using optional attachments.
• O p e r at i o n of di f fe r e nt o r c o m b i n e d
attachments may result in unsafe working
conditions or component failure. Before
operating the attachments that you are not
familiar with, check for the possibility of
collision and operate carefully.

2.3 Safety During Operation
2.3.1 Work area safety
When working on port, wharf, freight station

or yard where power lines or other obstacles
exist, the driver should pay special attention.
It is preferred that a person is assigned on the
site to give commands.
2.3.1.1 Work area requirements
• The machine should be driven on

substantially f irm, smooth, level and
prepared ground.
• There is a possibility of tipping when the
machine works on whar f or yard with
poor operating conditions, this can lead
to serious injury or death. It is essential to
check the operating surface condition in
advance to avoid accidents.
• Design a work plan and select the machine
that is suitable for such work or site.
Fig. 2-40 Do not Work on Uneven Ground
• When working on a narrow site, try to
operate the machine in a small working
radius, and assign a signalman when
necessary.
• Pay special attention to avoid slipping
when working on frozen ground.
• It is prohibited to perform any operations
on uneven road or muddy road. Drive the
machine only on even and firm ground.
• Reinforce the ground prior to work when it
is too loose or soft.
2.3.1.2 Work area indications
Do not start working before the area has

been indicated by a “blue flag” or some other
recognizable indications.
Fig. 2-41 Indicate the Work Area

2.3.2 Checks before operation
Check the machine carefully before starting it

daily or at the start of the shift:
• Check whether the air pressure in tyres is

correct. The correct tyre pressure should
be 0.95-1.05 MPa.
Fig. 2-42 Check Tyre Pressure
• Check whether the attaching bolts of tyre,

driving axle, transmission shaft, mast and
frame are secure.
Fig. 2-43 Check Attaching Bolts
• Check whether the lubrication points of

connecting shaft of boom pitching cylinder
and boom telescopic cylinder, steering
cylinder and its connecting plate, hinge
point of spreader cylinder, and sliding
Fig. 2-44 Check Lubrication Points

blocks are adequately lubricated.

• Check if the hydraulic pipes are in good
condition, also if the electric wirings are
secured.
Fig. 2-45 Check Hydraulic Pipe
• Check whether the engine oil level, fuel

level, hydraulic oil level, brake oil level and
coolant level are correct.
Fig. 2-46 Check Oil Level
• Check whether the spreader movements

are in good condition.
• Check for alarms.

2.3.3 Keeping machine clean
• Clean the windshields, mirrors and lights

daily before starting your work.
• Make sure that the operating area, steps
and handrails are free from oil, grease,
snow, ice or mud, this can cause slipping.
Remove all mud, oils or any debris from
the soles of your shoes before climbing the
steps to the operator cab.
• Never use caustic soaps, high-pressure
water or steam cleaners to clean the
electrical system, for these could damage
the system or cause intermittent system
failures.
Fig. 2-48 Avoid Cleaning the Electrical System

with High-pressure Water
• Never leave any tools, personal items or
any other objects in the operator cab. Keep
these items in the tool box rather than in
the cab.
• Never bring dangerous objects or fluids
into the operator cab, for these may spill,
ignite or explode.
2.3.4 Climbing on or off the machine

safely
To avoid personal injury from slipping or falling
from the machine, do the following requests:
• Always be sure that the machine is at a full

stop before attempting to access it. Never
jump onto or out of the machine.
• Always keep handrails, steps and walkway
c lean and c lear of mud, oil, grease
or similar debris. If these areas are
damaged, have them repaired or replaced

immediately. Tighten any loose bolts.

• Always maintain both feet and one hand or
one foot and both hands with the handrails,
steps, walkway and platforms to ensure
that you can support yourself properly.
• Wear shoes with a high slip-resistant sole
material. Clean any mud or debris from
shoes before entering the machine cab or
climbing onto the machine superstructure.
• Do not mount or dismount the machine
when you are carrying tools or supplies.
• Never leave tools or similar objects on the
Fig. 2-49 Climb on the Machine
machine walkway or service areas. These
could drop and get stuck in the machine
operating systems.
• Do not climb on the engine hood, cover,
covering parts or counterweight with the
antislip sticker.
• Do not step on surfaces of the machine
that are not approved or suitable for
walking and working. You could lose your
balance, slip and fall from the machine.
• Never exit or enter the machine cab or
deck by any other means than the access
system’s provided steps and grab handles.
• Never modify machine’s access system in
any way that has not been evaluated and
approved by SANY.
Fig. 2-50 Slipping Hazard

WARNING
WARNING
• Always face the machine when climbing

on or off it.
• Never attempt to climb on a moving
machine.
• Never jump onto the machine and try to
stop it.
• The cab must be at an appropriate
position for you getting on or off.
Failure to do this may result in serious
injuries.

2.3.5 Start-up safety
2.3.5.1 Inside the operator cab
Once inside the operator cab, observe the

following:
• Never allow other personnel inside the
operator cab regardless of the situation
and never bring objects into the operator
cab that could restrict your movement or
vision in any manner.
• Close or latch all doors or windows in
place.
• Check the work area to ensure that all
personnel and equipment are clear from
your machine. Before starting the machine,
Sound the horn to warn others that you are
about to start the machine.
• Check all gauges and allow ample warm-
up time for the engine before traveling or
performing any operations.
2.3.5.2 Adjusting the seat
Incorrect seat position can lead to operator

fatigue and operating mistake. Therefore,
operators should observe the following:
• Seat in a comfortable position before
operating the machine.
• Adjust the seat and console so that you
can easily access all controls from a
seated position and be sure that your
vision is clear in all directions as viewed
from the seated position. Fig. 2-51 Adjust the seat

2.3.5.3 Checking the seat belt
In case of tipping accident, the operator can

be injured or thrown out of the cab, or crushed
by the tipping machine. Operators should
observe the following:
• Before operating, carefully check the
strap, buckle and fastener of the seat belt.
If any abrasion or damages are found,
replace the seat belt or its components
immediately.
• When the machine is traveling, always
Fig. 2-52 Check the Seat Belt
sit in the seat and fasten the seat belt to
minimize the probability of injury resulted
from accident.
• To reduce the danger, it is preferred to
replace the seat belt every three years.
2.3.5.4 Machine starting precautions
DANGER
DANGER
Prior to operation, be sure that you can

properly control the speed, direction,
braking, and turning of the machine.
Understand the control mode of work
equipment before operating. Machine out
of control can cause serious injury or
death.
To understand proper starting steps of the

machine, see “Starting the Machine” on
page 4-15 for instructions.

WARNING
WARNING
Never start the machine by tampering with

or shorting the starter terminals. Accidental
movements of the machine could lead to
injury or possibly death.
Never use starting aids to start the engine.
Starting aids are explosive and will damage
the engine. Possible injury could occur.
Before star ting operations, obser ve the

following:
• Ask for inspection and maintenance
records and verify that the appropriate
safety, operation & maintenance manual is
inside the cab.
• Walk around the machine and check for
nearby and unauthorized personnel and
objects.
• Do not start the machine if warning plates
have been attached to the control levers.
• Sound the horn to warn others in the
area before starting the engine, moving
the machine or star ting any machine
operations.
• Always use the ignition switch to start the
machine from a seated position in the
driver’s seat.
• Become familiar with all warning devices,
gauges and operation controls.
• Never allow anyone else inside the cab or
on the machine during operation.
• Check your view. Be sure you can see all
work areas around your machine clearly.
• Ample ventilation must be guaranteed if
you have to start the engine or operate the
machine in an enclosed environment.

2.3.5.5 Jump-start the engine, precautions
The use of jumper cable to start the engine

must be carried out according to instruction of
the operation section (For detailed information:
see: “Star t with booster bat teries or
starting generators” on page 4-19). Incorrect
operation can lead to battery explosion and
machine out of control, hence personal injury
and death.
• Never use jumper cable to star t the

engine without permission. Contact SANY
authorized distributor when necessary.
• Two personnel should work together to
start engine with jumper cable (One is
seated in the operator's seat and the other
handles the battery).
• Wear goggles and rubber gloves before
starting the engine with jumper cable.
• When jumper cable is used to connect
a mechanically machine with a faulty
machine, main power switch of both
machines should be turned off.
Fig. 2-53 Main Power Switch
• Never use a welder or equipment with a 2
1
higher voltage system to jump-start the
machine, because it may damage the
machine’s electrical system or cause an
unexpected explosion or fire. Always jump-
start the engine with equal voltages.
• When connecting jumper cable, connect
the positive (+) (position 1 in Fig. 2-54)
first. When disconnecting jumper cable, 1
disconnect the grounding or negative (-) 2
(position in Fig. 2-54) first.

• Prevent the clips of jumper cable from
touching each other or the machine when
removing the jumper cable.
Fig. 2-54 Booster Battery

2.3.5.6 In cold weather
Cold weather operation requires additional

caution:
• Check operating procedures in this manual
or the engine manual for cold weather
starting. (For detailed information: see:
“Start in cold weather” on page 4-18).
• Do not touch metal surfaces that could
cause you to be frozen by them.
• Keep the machine clear of all ice and
snow.
• Allow time for the hydraulic oil to warm up.
• Park the machine in an area where it
cannot be frozen to the ground.
• Sufficient warm-up operation is necessary
before starting engine in cold weather.
Incomplete warming up may result in slow
reaction and accidents.
• In cold weather, check the battery before
the starting to see if its electrolyte is frozen
or leaking. In case of frozen electrolyte,
do not charge the battery or use another
power source to start the engine. The
electrolyte of battery should be melted, or
it has the danger of catching on fire.
2.3.5.7 After starting the engine
Run the enigne at idle for 3-5 minutes after

its starting. Observe the pressure gauges,
instrument and warning lights to ensure they
are properly functioning, with all readings
within specific ranges.

2.3.6 Requirements for safe operation
2.3.6.1 Ensuring good visibility
Observe the following items when operating

or driving the machine in a place with poor
visibility.
• Check rearview mirrors, remove debris
and adjust the view before operation.
• Pr i o r to o p e r at i o n, b e su r e t h at a l l
personnel understand the signals and
gestures.
• Turn on working lights and headlights of
Fig. 2-55 Ensure Good Visibility
the machine when working in a dark area.
Set up auxiliary illumination in the work
area if necessary.
• Stop operation if clear visibility cannot be
guaranteed in days with fog, snow, rain or
sand storm, etc.
• Road shoulder or soft ground should
be marked. In case of poor visibility, a
signalman should be available. Operator
shall pay special attention to the marks
and follow the instructions of signalman.
2.3.6.2 Safety rules for traveling
• Do not operate machine over the max

acceptable load or performance parameter.
• When traveling or operating, keep a safe
distance from people, building or other
machines so as to avoid collision.
• Speed must be adjusted according to
personnel, visibility, surface and load of
the site.
• When traveling on a road, contact the
relevant departments and follow their
instructions.
• When traveling on rough ground, operate
the machine at low speed and avoid
sudden change of direction.

• Avoid traveling over a barrier if possible.

If you have to do that, lower the work
equipment close to ground and drive
slowly.
• Before passing through a br idge or
building, check first its structural strength
to see whether it could support the weight
of machine.
• Operate slowly when you are working in
a tunnel, under bridge or power cables or
under where working height is limited. Pay
special attention to not damage anything
with work equipment.
• Under all circumstances, the machine must
be operated at a speed which enables it to
be brought to a stop in a safe manner.
NOTICE
NOTICE
Slow down the machine before changing

gears, or damage may occur to the
transmission.
WARNING
WARNING
When operating the machine on uneven

ground, always drive the machine slowly,
retract the spreader fully and lower the
load as close to the ground as possible .
If not done, this could result in injury or

possibly death.

2.3.6.3 Precautions while operating on

slopes
When operating on slopes, obser ve the

following rules:
1. The machine must move up and down
slopes slowly.
2. Do not turn the machine on slopes, nor
drive across slopes.
3. The load must fac e uphill when the
machine is driving up or down gradients of Fig. 2-56 Operate on Slope
over 10%.
2.3.6.4 Avoiding injury from reversing
In the reversing process, personnel around the

machine may be knocked down or crushed.
In order to avoid accidents:

• Look around to make sure that nobody
is standing close to the machine before
reversing. Keep the traveling alarm device
in working order. Always stay alert whether
someone enters the work area. Fig. 2-57 Avoid Injury from Reversing
• Keep the windows, rearview mirrors and
lights clean and in good condition.
• Before moving the machine, warn others
with horn or other signals.
• In the reversing process, if your sight is
blocked, assign a signalman. Always keep
the signalman within your visual field.
• The machine can’t be moved until both
signalman and operator understand the
meaning of all flags, signals and marks.
• Avoid sudden acceleration or braking in
reversing. In addition, the driver should
adjust the speed properly when reversing
to avoid slippage or tipping.
Fig. 2-58 Avoid Injury from Reversing

2.3.6.5 Precautions while operating on

snow or frozen surfaces
Be careful when traveling or operating the

machine on frozen or snowy surfaces. Snow-
covered or frozen surfaces are slippery. The
ability to maneuver the machine is seriously
affected. The machine may not respond as
expected when turning:
• Always travel at a slow speed and gently
operate the controls.
• Avoid any rapid movement, acceleration
or quick stopping. Always be aware of the
increased stopping distance required on
these surfaces. Allow ample distance to
stop the machine.
• Avoid deep snow or frozen bodies of water.
The machine could easily get stuck in
these areas.
• Keep in mind, even a slight slope may
cause the machine to slide out of control.
Be extra careful when working on a sloped
surface covered with snow or ice.
• When traveling or moving the machine on
a snow-covered slope, slow down gently.
To reduce the speed, use the engine to
slow the machine down.

2.3.6.6 Preventing control failure
Injury may be caused by loosing control. In

order to avoid control failure, you should:
• Do not lif t a c ontainer whith weight

exceeding the max. load capacity of the
machine.
• Make the unloaded engine run idle for 3~5
minutes to make it cool down. Then shut
down the engine and pull the ignition key
out.
• Park the machine on a horizontal ground Fig. 2-59 Signalman
rather than on a slope. Maintain a proper
distance from other machines.
Operation on a slope has tipping hazard,

which can result in serious injury or death. In
case of the machine tipping, never try to jump
out of the machine. Otherwise, serious or fatal
crush damage can occur. The tipping speed
of machine is much higher than your jumping
speed.
Fig. 2-60 Go to Hospital
In case of tipping accidents, always stay in the

cab holding the steering wheel tight. Never try
to jump out of the cab.
Fig. 2-61 Never Jump Down

2.3.6.7 Never hoist a load except container
The machine must not hoist any load except

for containers. For instance, never tighten
a sling on spreader for lifting other load.
Personnel may be seriously injured.
SANY number
Fig. 2-62
2.3.6.8 Never hoist the load over people
The load hoisted over people may fall down

and result in injuries.
Never hoist the load over people. And do not
let any person stand under the load.
Fig. 2-63
2.3.6.9 Never stand under the load
Personnel under the load may be seriously

hurt if the load falls down. Do not let any
person stand under the load.
Fig. 2-64

2.3.6.10 Precautions for operating

emergency stop button
The emergency stop button can also be used

to brake the machine in emergency cases.
However it can only be used when the brake
system fails in a real emergency situation.
NOTE:
It is prohibited to use the emergency stop
button when the brake pedal is still working
normally or in good conditions.
Fig. 2-65 Emergency Stop Button

If the emergency stop but ton has been
used twice, replace the brake lining block
immediately. Be sure to readjust it for a good
parking brake effect if the parking brake has
been separated from the machine.
2.3.6.11 Precautions for operating safety

bypass switch
OPERATING RULES OF SAFETY BYPASS

All safety protection functions are canceled
after the safety bypass switch is turned on. Its
operating rules are set as below:
• The key of safety bypass switch must

be kept by a special technician. Only in
special cases can it be used after approval
by the principals of relevant departments.
• When using this function, note to find out
the condition of work area to ensure the
safe operation. Fig. 2-66 Safety Bypass Switch
• SANY will assume no responsibilities
for any accidents caused by incorrect
operation of the safety bypass function.

2.3.7 Parking the machine securely
2.3.7.1 Parking requirements
After operating, always park the machine in a

safe area away from tracks and truck lanes.
Fig. 2-67 Safe Area to Park the Machine
The ground on which the machine is parked

or traveling must have sufficient carrying
capacity. It should be hard and horizontal with
even supporting distribution.
Fig. 2-68 Park Ground
It is not allowed to park the machine on uneven

and loose ground.
Fig. 2-69 Avoid Parking on Uneven Ground

If the machine is parked on a slope, wedge the

front and rear wheels with blocks to prevent
sliding.
Fig. 2-70 Caution for Parking on Slope
2.3.7.2 Turning off the engine
1. Park the machine on solid and even

horizontal ground.
A B
2. Retract the spreader and lower it to its
lowest position.
3. Turn the gear selector to neutral position.
Run engine idle for 3 - 5 minutes to cool it
down.
4. Turn the ignition key to ON position (B
in Fig. 2-71). Move the joystick forward,
back ward, lef t ward and right ward
respectively t wo or three times to
Fig. 2-71 Ignition Switch
depressurize the hydraulic system.
5. Turn the key to OFF position (A in Fig. 2-71)
to stop the engine.
6. And remove it from the switch.
7. Close all the doors and windows in cab.
8. Dismount the machine safely. Never jump
out of it. For detailed information, see:
“Climbing on or off the machine safely”
on page 2-31.
9. Put blocks under the wheel to avoid the
machine from moving.
Fig. 2-72 Secure the Wheel

2.4 Safety During Maintenance
For correct and safe maintenance of machine,

below rules should be followed:
• Only approved and qualified personnel can
conduct the maintenance or repair.
• Comprehend fully all the maintenance
information covered in this manual prior to
maintenance.
Fig. 2-73 Read the Manual
• Maintenance personnel shall be physically
suited for this work, especially their health
and eyesight.
• Do not spray water or steam in the cab.
• N e v e r a d d l u b r i c a n t s o r p e r f o r m
maintenanc e when your mac hine is
moving.
• Keep your hands, feet and clothing away
from rotating parts.
2.4.1 Preparation for the work area
Before maintenance, you should:

• Choose a clean and even area with
enough space, light, and good ventilation
to conduct the maintenance.
• Clean the working surface. Wipe away the
fuel, lubrication oil and water. Spread sand
or other absorbing materials on sliding
surface.
• Do not leave any tools in work area.
Fig. 2-74 Prepare for the Work Area

2.4.2 Warning label is important
If anyone have started the engine or operated

the joystick during the maintenance, serious
ac cidents would happen. Before any
maintenance work on the machine, be sure to:
• Set the WARNING LABEL of “Shut down!
Under maintenance!” on the steering wheel
SHUT DOWN
UNDER MAINTENANCE
or ignition switch.
• If necessary, place a warning label around
the machine.
Fig. 2-75 Warning Label
2.4.3 Lockout/tagout procedures
The following steps must be followed in

sequence when the machine is to be locked-
out and tagged-out for service or repair.
1. Notify all personnel who may be potentially

affected by the repair or maintenance of
the machine.
2. Secure the machine in a safe position.
3. Identify, remove or disconnect all power
or energy sources and be sure to install a Fig. 2-76 Lock
lockout / tagout device to them.
4. Attach the warning lable to the machine.
5. If the ser vic e personnel is issued a
lock and key, he/she shall not share the
lock or key with other personnel until all
maintenance procedures are complete
and the machine is ready to put back into
service.
6. Be sure all personnel involved in the
maintenance have installed their own locks
on the power source before performing.
Each one who completes his/her work
must remove his/her own lock and not
access the machine further.

2.4.4 Self-preparation before

maintenance
For detailed information, see: “Personal

protective equipment” on page 2-16.
Fig. 2-77 Protective Equipment
2.4.5 Using tools correctly
• Only use appropriate tools in a correct

manner. Using damaged, inferior, defective,
temporary tools or misusing the tools could
result in serious accidents.
• Keep your tools clean and take inventory
of the tools you were using to confirm no
tools were left in the machine when the job Fig. 2-78 Tools
is complete.
• Always put shop tools back in their proper
storage location when finished.
2.4.6 Regular replacement of safety-

related parts
For the consideration of operating the machine

safely in a long term, make sure to:
• Replace regularly the safety-related parts
such as hoses, fan belt, etc.
• Replace those parts exceeding specific
time limit.
• Replace worn or damaged parts at regular
intervals.
• Replace or repair the defective safety parts
or components immediately.

2.4.7 Removing attachments carefully
• When removing large and heav y

attachments, always be sure to use the
correct lifting equipment rated for the
capacity of the load you will be lifting.
• After the attachment or part has been
removed, store it where it cannot fall or
move. Always be sure that the attachment
is stable on a solid surface and clear of all
walkways or fire exits.
• W h e n i n st a l li n g a n d u s i n g o pt i o n a l Fig. 2-79 Crushed by Removed Attachments
attachments, read and follow Chapter 8 for
the instructions.
• Do not use attachments that are not
authorized by SANY. Use of unauthorized
attachments could result in hazards and
adversely affect proper operation and
useful life of the machine. Any injuries,
accidents, product failures resulting from
the use of unauthorized attachments will
not be the responsibility of SANY.
2.4.8 Adding fluids to the machine
Before adding fluids, shut down the engine

and allow the systems to cool to outdoor
ambient temperature before removing any
caps. Failure to do so may result in serious
burns or a sudden loss of fluid. Read and
understand the following:
• Refueling the machine could pose some
hazards.
• Grease, fuel, oil or coolant spills pose a Fig. 2-80 Refueling
hazard if not cleaned up immediately.
• When refueling or adding any fluids to
the machine, be sure you are in a well-
ventilated area.
• Never smoke or allow open flames near
while refueling the machine.
• Never mix gasoline with diesel or fuel.

Gasoline is extremely flammable and could

cause an explosion.
• Always allow room for the fuel to expand
when filling the fuel tank.
CAUTION
CAUTION
If fluids must be added to the equipment

during operation, always be aware that
these systems are under high pressure and
hot. It can lead to injury.
2.4.9 Towing or lifting the machine
Serious injury or death could result if a faulty

machine is towed or lifted incorrectly or if the
wrong cables or towing points are selected.
Adhere to the following:
• Use only the designated lift points to lift the
machine and designated tow points to tow
the machine. Be sure that the lift and tow
points are in good working order.
• Always tow or lift in the direction indicated
by the label. If the label is missing or
damaged, contact your SANY distributors
for the proper procedures. Fig. 2-81 Hoisting Point
• Always wear leather gloves when handling
cables.
• During the towing operation, never stand
between the towing machine and the
machine being towed.
• Never tow a machine on a slope.
• Never use towing equipment that is
damaged, stretched or overstressed.
•
CAUTION
CAUTION
Only tow or lift the machine after you have

confirmed that everybody is clear of the
machine. Or, they could be hurt.

2.4.10 Keep clear of moving machinery
Death or serious injury could result if you are

WARNING
hit by moving parts of this machine.
Barricade the entire area where the machine is

Keep clear of moving machinery
working and keep all unnecessary personnel Death or serious injury can occur
out of the work area.
Never allow anyone to stand or work near the

machine while the machine is in operation.
Fig. 2-82 Keep Clear of Moving Machinery

2.4.11 Preventing hydraulic hazards
2.4.11.1 Checking rubber hose regularly
CAUTION
CAUTION
Contact with coolant of high temperature

and high pressure could result in serious
injuries.
Check the conditions of rubber hose regularly:

• C h e c k w h e t h e r t h e hy d r a u l i c h o s e
connection is in good condition.
Fig. 2-83 Check the Rubber Hose
• Check whether the housing of hydraulic
hose is in good condition.
• Check whether the external surface of
hose do not expand.
• Check whether the hose do not bend or
flat.
• Check whether the external bracket of
hose is in place.
WARNING
WARNING
In case of any damage on the rubber hose,

replace it immediately after the pressure is
released.
Damage on rubber hose could result in

2.4.11.2 Releasing the pressure before

maintenance
1. Park the machine.

2. Retract the spreader and lower it to its
lowest position.
3. Stop the engine.
4. Release the pressure in hydraulic system.
5. Turn the ignition key to ON position (B in
A B
Fig. 2-84).
If there is pressure in the hydraulic system,
a clear sound of “hiss-hiss” would be
heard.
Then start the pitching, telescoping and
side-shif ting function of spreader for
several times.
Turn the ignition key to OFF position (A in
Fig. 2-84).
Turn off the main power. Fig. 2-84 Ignition Key
• Open the pressure-releasing valve on the

accumulator charging valve to release the
pressure in brake system.
Fig. 2-85 Release the Brake Pressure

2.4.11.3 Replacing rubber hose regularly
Due to aging, fatigue and wear, rubber hose

containing flammable liquid may rupture under
high pressure. Its aging and degree of wear
can’t be judged only by visual inspection.
Failure to replace the rubber hose regularly

can result in accidents such as fire disaster,
splashed liquid onto skin, or fallen work device
Fig. 2-86 Replace the Rubber Hose
on personnel, etc. These could lead to serious
burn, necrosis or other injuries or death.
Fig. 2-87 Avoid Hydraulic Injury 1
Fig. 2-88 Avoid Hydraulic Injury 2

2.4.11.4 Prevent heat near the hydraulic

pipeline
Heating near the hydraulic pipeline can

generate flammable spray, which can result
in serious burn to you and personnel around.
Therefore, personnel should follow below
rules:
• Avoid heating pipes or hoses conveying
flammable liquid:
• Do not perform welding or air-cutting on Fig. 2- 89 Do not Create Heat near the
the pipe or hose conveying flammable Hydraulic Pipe
liquid.
• Before welding or air-cutting the pipeline,
clear off the flammable liquid thoroughly
with nonf lammable solvent. Set a
temporary fireproof shield to protect the
hose or other materials.
2.4.11.5 Filling accumulator
The accumulator is f illed with nitrogen.

Incorrect operation will lead to explosion
causing machine damage and personal injury.
Pay attention to the following when dealing
with accumulators:
• Do not dismantle the accumulator.
• Keep the accumulator away from fire.
• D o n o t d r i l l h o l e s i n o r w e l d t h e
accumulator.
• Do not crash or roll the accumulator. Avoid Fig. 2-90 Caution for Filling Accumulator
any shock of accumulator.
• Drain the air before dealing with the
accumulator. Please contact SANY to
conduct this operation.

2.4.11.6 Selecting oils and fuel
Pay attention to the following when selecting

oils and fuel:
• Select the allowable highest viscosity oil
for the corresponding temperature.
• For the machine already running for a long
time, select the lubrication oil with higher
viscosity on its final drive to try to keep the
thickest oil film.
• The fuel may become frozen and starting
the engine becomes dif f icult in cold
weather. Therefore, fuel should be selected
according to the weather and temperature.
• Use antifreeze specified by SANY. It is
prohibited to fill tap water or coolant of
other brands without permission.
• Use the hydraulic oil specified by SANY. It
is not recommended to fill hydraulic oil of
other brands without permission.
• The optimum temperature of hydraulic oil
is above 50 ˚C (not higher than 80˚C ).
• Be sure to warm up the machine when the
temperature is lower than 25˚C. It this is
not done, the machine may be unable to
start.
2.4.11.7 Handling hydraulic oil
Hydraulic oil contains harmful and toxic

substances. When handling the waste oil,
observe the following to protect personal
safety:
• Do not touch hydraulic oil. Before handling
the waste oil, smear protective oil on the
skin.
• Wash the contaminated skin with water
and soap. It is preferred to use nail
brush. Wash your hands with special oil
dissolvent.
• It is prohibited to wash the contaminated

skin with gasoline, diesel or coil oil.

• Keep the oil contaminated clothing away
from the skin.
• Do not put the dirty oil stained cloth in the
pocket.
• Wash the dirty clothes thoroughly before
wearing them. Dispose oily shoes as
required.
CAUTION
CAUTION
Always keep the lubrication oil out of the

reach of children. It is prohibited to store
the lubrication oil in an uncovered or
unmarked container. Or possible injuries
would happen.
2.4.12 Preventing burn and scald
2.4.12.1 Burn by high temperature liquid
Hot water and steam exist in the hot water

h o s e s o f t h e e n g i n e, r a d i a t o r a n d a i r
conditioner. Skin contact with overflowing hot
water or steam can result in serious burn.
Be sure to observe below rules to prevent

scald by splashed hot water:
• Do not open the filler cap before the
engine cools down.
• Turn the cap slowly when opening it. Fig. 2-91 Caution for Burn
Remove the cap after the pressure has
fully released.
• Start the check or maintenance after the
oil and parts cooled down.
In case of burn or scald:

• Wrap the injured with wet carpet; make
him/her roll on the ground.
• Do not try to tear off the substances like

fiber attached on the skin.

• In case of scald by liquid, take off the wet
clothes immediately. Special attention must
be paid when taking off the clothes.
• The wound should be wrapped or bound
with protective bandage.
• If serious, go to the hospital immediately.
2.4.12.2 Chemical burn
Some oil seals and repair kits used on the

machine are made of elastic materials like
fluorinated rubber and fluoride. In case of
high temperature, these elastic materials will
release many corrosive acids.
WARNING
WARNING
It is prohibited to burn fluorinated rubber

materials or related parts, for toxic gases
or substances may be generated. They
will bring pollution to the environment and
When the parts made of elastic materials are

used at a temperature that exceeds 300˚C, the
following measures should be taken:
• Wear thick rubber gloves and special
protective glasses; then, remove the parts
and put them into plastic bags.
• Wash the burnt part with 10% Ca (OH)2
solution (limewater) or other alkaline
solution. Wash away the residues attached
on the metal surface. Then, wash this part
again with the mixture of fresh water and
detergent.
• Place all residues into a proper container.
Dispose them in a proper method
according to the local laws and regulations.

In case of burn caused by battery electrolyte,

the following measures should be taken:
1. Take off the clothes carefully.
2. Wash the burnt part with fresh water.
Prevent the mixture of the fresh water and
the acidic substances on the skin from
flowing to the uninjured skin.
3. Consult a doctor immediately.
In case of eye injury caused by electrolyte,

lubric ation oil and diesel, the following
measures should be taken:
1. Wash the eyes with fresh water for at least
20 min. Keep the eyes open to wash the
eyeballs with fresh water. Roll the eyeballs
in different directions.
2. Consult a doctor immediately.
Fig. 2-92 Go to Hospital

2.4.13 Preventing fire and explosion
2.4.13.1 Handling inflammables safely
If the inflammables are ignited, explosion or

fire may occur. Pay attention to below items:
• Handle fuel carefully, because it is a highly
flammable substance.
• Never Fill fuel to the machine while
smoking, or near a naked fire and sparks.
• Shut down the engine before refilling fuel.
• Always Fill fuel outdoors.
• Store the flammable liquid (all fuels, most Fig. 2-93 Avoid Fire
lubricants and some coolants) in a place
away from fire hazard.
• Do not burn or puncture the pressured
container.
• Do not store oily cloth. They can be ignited
or combusting spontaneously.
2.4.13.2 Removing inflammables
Splashed fuel, oil, waste, grease, scrap,

accumulated coal dust and other inflammables
can result in fire.
Check and clean the machine daily. Remove

the splashed or accumulated inflammables
immediately to prevent fire.
Fig. 2-94 Remove Inflammable

2.4.13.3 Checking oil leakage
Leakage of fuel, hydraulic oil and grease can

result in fire. Personnel should observe the
following regulations to prevent fire:
• Check whether the clamp is in place and
secure.
• Check whether the hose is not twisted.
• Check whether the hose and pipeline do
not rub each other.
• Check whether the oil c ooler is not
Fig. 2-95 Check Oil Leakage
damaged .
• Check whether the flange bolt of oil cooler
is not secure.
• Che c k w het h e r t h e h o se s and hi gh
temperature par ts (e.g. turbocharger,
exhaust pipeline, silencer) have the contact
protection.
• Check whether the pipe connectors of
high temperature parts (e.g. turbocharger,
exhaust pipeline, silencer) are secured and
not leaking.
• Tighten, repair or replac e all loose,
damaged or lost clamps, pipelines, hoses,
oil coolers, or flange bolts.
• Do not bend or strike high pressure
pipelines.
• Do not install any bent or damaged
pipelines, tubes, or hoses.
2.4.13.4 Checking short circuit
Short circuit can result in fire. Pay attention to

take below measures:
• Clean and tighten all circuit connections.
• Check whether the cable or wire is secure,
not twisted, hardened or cracked before
shift or after 8-10h operation.
• Check whether the terminal end cover is
in place and not damaged before shift or
after 8-10h operation.
• Do not operate the machine if the cable or
wire is secure and not twisted.

2.4.13.5 Checking ignition key
If the engine is shut down when the machine

is on fire, the fire would spread and it will
become difficult to put out. Therefore, you
should:
• Check the function of ignition key before
operating the machine daily.
• Start the engine and make it run at an idle
speed.
• Turn the key switch to OFF position (see
the arrow in Fig. 2-96) to confirm whether Fig. 2-96 OFF Position
the engine shuts down.
• In case of any abnormality, make sure to
fix it before operating the machine.
2.4.13.6 Preventing battery explosion
Battery electrolyte contains corrosive sulfuric

ac i d w hi c h may c re ate f lammab l e an d
explosive hydrogen. Incorrect operation could
result in personal injury or fire hazard. Be sure
to follow below regulations:
• Keep the battery away from children.
• Do not smoke near the battery.
Fig. 2-97 Battery Explosion
• Avoid open fires and kindling materials
while charging or using the battery.
• Never put the battery under direct sunlight
in hot seasons.
• Avoid battery terminals contacting with
tools and other metal objects.
• Switch the main power switch to of f
position before operating the battery.
• Wear protective goggles and rubber gloves
during battery operation.
• Never discharge or charge the battery too
much.
• Connect the battery with proper cables.
Connect plus-cable (red) first and then
Fig. 2-98 Cables

minus-cable (black). Make sure that all the

terminals are firmly fixed.
• Disconnect the battery approx. one minute
after the engine is turned off. Remove
minus-cable (black) first and then plus-
cable (red).
• If c harging a bat ter y removed f rom
machine, put it in a ventilated place before
opening the battery cover.
• If the battery temperature exceeds 45°C,
stop charging until the battery temperature
reaches room temperature. Reduce half of
the electric current and continue charging.
• If the battery starts to splash sulfuric acid,
stop charging immediately.
• If the battery magic eye shows green,
the battery has been fully charged. Stop
charging it.
• Fit the battery cover after charging. And
install it in the correct position.
• If electrolyte splashes on bare skin, wash
with soap and a lot of water immediately.
• If electrolyte has gotten into eyes, rinse
immediately with water and contact a
doctor immediately.
2.4.13.7 Evacuating from the machine
1. Emergency escape procedure in case of

fire
If the engine is not stopped when a fire disaster

happens, the fire would become intense and
thus obstruct the rescue. Therefore, be sure
to check the function of ignition key before
running the machine.
If it is permitted to fight the fires preliminarily, Fig. 2-99 Evacuate

you may evacuate from the fire as long as you
are able to evade the danger anytime.

In case of fire, you must:

• switch the ignition key to OFF position (see
the arrow in Fig. 2-100) and make sure that
the engine is stopped. Evacuate from the
machine.
• call the fire agency.
• if time permits, put the gear selector to
neutral position and press brake button to
keep it in the “P” position.
• if time permits, use the fire extinguisher.
2. Emergency evacuation Fig. 2-100 OFF Position
In case that distorted windows and doors

in cab cannot be opened due to the high
temperature, or the cab is stuck into cylinders,
open the back window and evacuate from the
machine as below methods:
CAUTION
CAUTION
Always wear protective goggles before

breaking the windows. Otherwise, you may
get hurt.
NOTE:
There is an emergency exit label placed to the
back window.
Fig. 2-101 Emergency Exit Label

2.4.14 Preventing poisoning and

asphyxiation
2.4.14.1 Handling chemicals safely
Direct contact with harmful chemicals can

result in serious injury to human body. The
chemicals used in this machine (such as
lubricant, coolant, coat and agglutinate) may
be harmful. Personnel should observe the
following rules while handling chemicals:
• Dispose of the chemicals according to
related national and local regulations.
• A l ways we a r p r ote c t i ve g l ove s a n d
goggles.
• Avoid direct contact of chemicals with skin.
• Never smoke or take diet when handling
chemicals.
• If chemicals are splashed on bare skin,
wash with a lot of fresh water immediately.
Go to hospital if serious.
• If chemicals have gotten into eyes, rinse
the eye with water and contact a doctor
immediately.
2.4.14.2 Preventing poisoning by paint
Harmful gases can be generated when paint

is heated in fusion welding, soft welding
or torch welding. Inhalation of these gases
can be nauseating. Pay attention to prevent
generating potentially toxic gases and dust.
• Properly handle the paint and solvent

before welding or heating.
• Remove the paint outdoors or in ventilated
Fig. 2-102 Respirator
place.
• If sand paper and grinding wheel are used
to remove the paint, prevent inhaling dust
by wearing a qualified respirator.
• If solvent or paint remover is used, wash

away the paint remover with soap and

water before welding. Clear up the solvent
or paint remover container and other
flammables in the work area. Wait for at
least 15 min. before welding or heating to
make the volatile gases go away.
• Never put the paint, solvent or paint
remover near the combustion source.
• Dispose of the paint or solvent according
to related national and local regulations.
2.4.14.3 Preventing poisoning by off-gas
Gases exhausted from the machine contain

carbon monoxide which is an odorless,
colorless and toxic gas. In order to prevent
poisoning, personnel should observe the
following rules:
• Stay well ventilated if the machine is

st ar te d o r o p e r ate d in an enc l o se d
environment. Fig. 2-103 Avoid Poisoning by Off-gas
• If a person is poisoned by off-gas in the
enclosed environment, open the doors
and windows first to reduce the level of
harmful gases before conducting the first
aid treatment.
• Put the poisoned person in a ventilated
place or outdoors. If the poisoned person
is unconscious, make him/her lie sideways.

2.4.15 Preventing dust hazard
Dust in air at the work area is harmful to the

lung if inhaled. If there is a danger of inhaling
the dust when operating on the work area,
always observe the following:
• If there is possibly asbestos dust or similar
dust in the air, always operate the machine
from an upwind position. All personnel
should use qualified respirators.
• Spray water to keep down the dust when
cleaning. Do not use compressed air for
cleaning.
• Always obser ve the national or local
rules and regulations for work site and
environmental standards.
NOTE:
SANY machines do not contain asbestos,
but there is a possibility that ingenuine or
aftermarket parts may contain asbestos.
Always use genuine SANY replacement parts.

2.4.16 Working under machine
Always perform the following when working

under the machine:
• Be sure to lower the spreader to its lowest
position before going under the machine.
• Never per form maintenance or repair
under the machine before the machine is
firmly supported by blocks or supports.
• Always use blocks or supports that are
strong enough to support the machine or
work equipment. Never use slag bricks, Fig. 2-104 Work under Machine
empty tyres or stands to suppor t the
machine. These things may collapse under
continuous load. Never use only one jack
to support the machine.
2.4.17 Precautions in welding
Fire or electricity hazard may occur if the

welding is performed incorrectly. Observe the
following:
• O n l y q u a l i f i e d w e l d e r w i t h p r o p e r
equipment is approved to weld on the
machine.
• Welding must be performed in correct
procedures to prevent damaging the
electronic control device and bearing.
• Before welding on the machine or engine
equipped with electronic control device,
you should turn the main power switch to
off position first. Then remove the positive
and negative cables from the battery.
• Prevent wire harness from contacting
with the sparks generated in the welding
process.
Follow standard procedures in welding:
Fig. 2-105 Main Power Switch

1. Clamp the parts to be welded with ground

clamp of the welding machine.
2. Make the clamp as close as possible to the
welding point, ensuring that current from
the ground wire to the parts will not pass
through any bearing.
3. This could increase the possibility of
damaging the parts such as transmission
bearing, hydraulic parts, electrical parts,
other mechanic parts.
2.4.18 Safe maintenance of air

conditioning system
Make sure to observe below items:

• Keep fire source away when servicing air
conditioning system.
• In maintenance of air conditioning system,
observe the instructions on refrigerant
container and use it correctly. The type of
refrigerant is R134a. Other refrigerants are
not allowed to be used, which may damage
the air conditioning system otherwise.
• Avoid refrigerants from getting into eyes or
splashing onto skin.
• R e f r i g e r a n t R13 4 a w i l l c r e a t e t h e
greenhouse effect. 1kg emission of R134a
(af ter t wenty years) equals to 3400g
emission of CO2. Obey local material
disposal regulations of refrigerants. Never
discharge refrigerant directly into the air.
DANGER
DANGER
Refrigerant R134a is a harmless gas under
room temperature. It will change into highly
toxic gas when burning. Handle it properly
to prevent personal injury or even death.

2.4.19 Precautions in maintaining the

engine
To prevent injury, no maintenance shall be

carried out when the engine is running. If
maintenance has to be done on a running
engine, there should be at least two personnel
handling the maintenance according to the
following rules:
• One person should always be seated in
operator’s seat and ready to shut down
the engine at any time. All personnel must Fig. 2-106 Caution for Fan
keep communicate.
• Always lock the machine and fix its wheels
with wedges to prevent it from moving or
operating.
• Never enter into the movable places of
machine, as you may be clamped or
crushed.
• Pay special attention to rotating parts like
fan and fan belt, you may get caught by
them when standing close to.
Fig. 2-107 Be Clamped by the Rotating Parts
• Do not leave or insert any tools or other

objects in fan or fan belt, which may cause
the parts to break or fly.
• Do not touch any control levers. If one

of the control levers must be used, send
signal to others and warn them to move
quickly to a safe area.
Fig. 2-108 Parts Flying to Hurt Personnel

2.4.20 High voltage precautions
When the engine is running or has just been

shut down, high voltage can occur in fuel
injector and engine controller. Personnel
should observe the following to prevent the
danger of electricity strike:
• Do not touch the fuel injector or the engine
controller, it might cause electrocution.
• Contact SANY authorized distributors if
you have to access the fuel injector or the
engine controller. Fig. 2-109 Caution for High Voltage
2.4.21 Precautions after maintenance
Personnel should observe the following after

maintenace or repair:
• Tighten all fasteners and connectors with
recommended torque.
• Install all guards, covers and hoods after
repair and service. Check if there are
missing pins, gaskets and nuts.
• Start the engine and check for leakage of
hydraulic system. Check whether all liquid
levels are correct.
• Operate all control devices to be sure of
their proper functioning. Make road test if
necessary.
2.4.22 Handling waste properly
The potential harmful substances used in this

machine include oil, fuel, coolant, brake fluid,
filter and battery etc. Incorrect disposal of
waste can negatively impact the environment
and ecosystem. Therefore, pay attention to the
below items:
• Always abide by the national or local
regulations, rules and environmental
standards. Do not pour the waste liquid on Fig. 2-110 Disposal of Waste

the ground, in the sewer or into any water

source.
• Consult the local environmental protection
organization or recovery center for the
correct method of recovering or handling
the waste.
• Use a leakage -proof container when
draining the liquid. Do not use food or
beverage container, this might mislead
somebody to drink accidentally.
• Leakage of refrigerant into the air can
damage the atmosphere. For detailed
information, see: “Safe maintenance of
air conditioning system” on page 2-72.
NOTE:
The following substances and liquids must be
delivered to a certified waste treatment facility
for disposal:
• Starter battery
• Waste lubricating oil
• Lubricating grease
• Mixture of water and anti-freezing fluid
• Filter element
• Waste tyre
• Other auxiliaries (such as grease or oily
Fig. 2-111 Do not Drop Waste Randomly
duster cloth etc.).
NOTICE
NOTICE
Pay attention to the following to prevent

environmental problems:
• Strictly observe laws and regulations of
the region/country where the machine
is operating. Any actions that violates
these laws and regulations can and will
lead to prosecution.
• It is prohibited to drop waste product,
waste oil and relevant washing goods
without permission. The waste should
be handled according to the local laws
and regulations.

2.5 Tag
SANY cannot predict every circumstance

that might involve a potential hazard in
o p e r at i o n o r m a i nte n a n c e. T h e s a f et y
chapter in this manual may not include every
possibly dangerous circumstance. But the
safety measures and regulations you have
understood could help you to make positive
judgments when encountering danger.
Our aim is to help you get into the habit of safe

operation and to make you a better operator of
machine.
Safety is your career and responsibility.

Wish you work pleasantly!

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Reach Stacker System Functions
System Functions
3.1 Main Components of Machine�� 3-3
3.2 Cab �� 3-5
3.2.1 Steering column�� 3-6
3.2.1.1 Steering panel�� 3-7
3.2.1.2 Gear selector��3-10
3.2.1.3 Direction indication controller��3-11
3.2.1.4 Adjusting the angle of steering controller ��3-14
3.2.2 Pedal��3-14
3.2.3 Joystick��3-15
3.2.4 Right operation panel��3-16
3.2.4.1 Ignition switch��3-17
3.2.4.2 Emergency retraction / lowering switch��3-18
3.2.4.3 Emergency stop switch��3-19
3.2.4.4 Safety bypass switch��3-19
3.2.4.5 Cab moving switch�� 3-21
3.2.4.6 Counterweight moving switch (optional)�� 3-21
3.2.4.7 Parking switch�� 3-22
3.2.4.8 Fuel heating switch (optional)�� 3-22
3.2.4.9 Hydraulic oil preheating switch (optional)�� 3-22
3.2.5 Front operation panel�� 3-23
3.2.5.1 Spreader light switch�� 3-23
3.2.5.2 Boom light switch�� 3-24
3.2.5.3 Rear light switch�� 3-24
3.2.5.4 Front wiper switch�� 3-25
3.2.5.5 Top wiper switch�� 3-26

System Functions Reach Stacker
3.2.5.6 Rear wiper switch�� 3-26

3.3 Display�� 3-28
3.3.1 Menu introduction�� 3-28
3.3.2 Introduction and operation of display area�� 3-29
3.3.2.1 Start menu�� 3-29
3.3.2.2 Main menu�� 3-29
3.3.2.3 Language setting menu�� 3-32
3.3.2.4 Engine information menu�� 3-33
3.3.2.5 Gear information menu��3-34
3.3.2.6 Hydraulic information menu�� 3-35
3.3.2.7 Digital analogy menu�� 3-36
3.3.2.8 Function set menu�� 3-38
3.3.2.9 Help System�� 3-39
3.4.1.1 Power switch�� 3-41
3.4.1.2 Fan speed switch�� 3-41
3.4.1.3 Temperature or Paging switch�� 3-42
3.4.1.4 Mode switch�� 3-42
3.4.1.5 Fresh air switch��3-43
3.4.2 Operation��3-44
3.4.4 Troubleshooting��3-46
3.5 Electric Control Cabinet�� 3-47
3.6 Fuse��3-49
3.7 Fire Extinguisher�� 3-51

3. SYSTEM FUNCTIONS
3.1 Main Components of Machine
Reach stacker is composed of power drive NOTE:

system (1), steer ing system (2), f rame Numerous spreaders are provided for your
assembly (3), boom assembly (4), spreader options, including container spreader, steel coil
assembly (5), cab and operation console spreader, steel pipe spreader, etc.
assembly (6), hydraulic system (7), electrical
system (8), and lubrication system (9), etc.
4
7
5
3
9
1
Fig. 3-1 Main Components of Reach stacker

Table 3-1
No. Item Function
Engine and transmission case constitute the power drive
1 Power drive system system of reach stacker, which supplies power for traveling,
braking, stacking and picking up loads..
Steering system controls the direction of machine during
2 Steering system
traveling and operation.
3 Frame assembly Frame is the mounting base as well as the support for all parts.
Boom is to raise the load. It is composed of a fixed boom, a
4 Boom assembly moving boom and a telescopic cylinder which is located in the
fixed boom.
Spreader is the main working mechanism which is capable of
5 Spreader assembly rotating, pitching, telescoping, as well as locking and unlocking
a container.
Cab and operation console Cab is the work area for the operator, where operation of the
6
system machine is performed.
Hydraulic system includes: braking/steering hydraulic system
and working device hydraulic system. It supplies power for
7 Hydraulic system
steering and braking of the machine, as well as motion of the
working mechanism such as boom and spreader.
Electrical system consists of control circuits of traveling,
8 Electrical system driving, and working mechanisms. Working mechanism are
controlled through the circuits.
Lubricating system is an auxiliary system. Centralized and
9 Lubrication system
decentralized lubrication types are included.

3.2 Cab
NOTE:
To operate correctly and safely, it is important
to fully comprehend the methods to operate
the control devices and the meaning of display
items.
Cab is composed of steering column (1), brake

pedal (2), accelerator pedal (3), joystick (4),
right operation panel (5), front operation panel
(6), display (7), air conditioner panel (8) and so
on.
8 7
6 4
2 3
Fig. 3-2 Control Device

3.2.1 Steering column
Steering column is composed of steering

panel (1), gear selector (2), direction indication
6 3
controller (3), steering wheel angle adjusting
handle (4), steering column angle adjusting 2
pedal (5) and steering wheel (6).
1
Fig. 3-3 Steering controller

3.2.1.1 Steering panel
There are four indic ator lights and t wo

switches on the steering panel, including left
steering indicator light (1), fault indicator light
(2), parking indicator light (3), right steering
indicator light (4), warning light switch (5) and
headlight switch (6).
Fig. 3-4 Steering panel
Left steering indicator light (1 in Fig. 3-4)
The left steering indicator light would

blink if the left steering light is turned
on.
Fault indicator light (2 in Fig. 3-4)
The fault indicator light would illuminate

to alert the operator if there is any fault
in the machine.
Parking indicator light (3 in Fig. 3-4)
The parking indicator light would

illuminate if the parking brake is
engaged.
Right steering indicator light (4 in Fig. 3-4)
The right steering indicator light would

blink if the right steering light is turned
on.

Warning light switch (5 in Fig. 3-4)
The switch is used to turn on or off the

warning light.
Fig. 3-5 Warning Light Switch
Press down the warning light switch. The

warning light on the boom and warning
indicator light in the cab will begin blinking.
NOTE:
For some machines, the warning light is
installed on the rear counterweight.
Fig. 3-6 Warning Light
Press down the warning light switch. The

width lights, fitted on the flank of front and rear
mudguards, will light up.
Fig. 3-7 Width Light

Headlight switch (6 in Fig. 3-4)
The switch is used to turn on or off the

headlight.
Fig. 3-8 Headlight Switch
Headlight is located in the center front of front

wheel arches.
Fig. 3-9 Standard Headlight
Some machines have the option for installing

eight headlights.
RS-1407028-1
Fig. 3-10 Optional Headlight

3.2.1.2 Gear selector
Gear selector (2 in Fig. 3-3) can be moved

forward or backward. Three letters “F, N, R”
are marked on the gear selector.
Driving direction of machine (flip the gear 2

1
selector in the direction of arrow):
3
• F: Forward gear (flip forward) 1
2
3
Fig. 3-11 Flipping Forward

• N: Neutral gear (in the middle)
1
2
3
1
2
3
1
2
3
Fig. 3-12 Flipping
• R: Reverse gear (flip backward)
The rear light illuminates when gear selector is

placed at the R mark. And the reversing alarm 1
will soon make a sound. 2

3
1
2
3
Fig. 3-13 Flipping Backward

Gear selector can also be rotated towards 3

positions respectively signifying 1st gear, 2nd
gear, and auto gear.
Driving speed of machine (turn the gear

selector in the direction of arrow):
• 1: 1st gear
• 2: 2nd gear
• 3: auto gear
• With the controller at the neutral position,

the engine can be started.
• In switching over between the forward Fig. 3-14 Rotating
and reverse positions, stop the machine
completely to avoid overload on the
gearbox or transmission system.
3.2.1.3 Direction indication controller
Direction indication controller (3 in Fig. 3-3)

can be moved forward or backward to turn on
or off the left / right steering indicator lights.
Left / right steering
Steering light is used to warn the nearby

personnel that the machine is about to change
its driving direction. Steering indicator lights
are used to remind the driver whether the Fig. 3-15 Flipping Forward/backward
steering light turns on normally.
Push the direction indication controller forward.

The left steering light on front mudguard and
on the upper counterweight as well as the
left steering indicator light in cab will begin
blinking.
Fig. 3-16 Left Steering Indicator Light

Push the direction indic ation c ontroller

backward. The right steering light on front
mudguard and on the upper counterweight as
well as the right steering indicator light in cab
will begin blinking.
Fig. 3-17 Right Steering Indicator Light
Front steering lights are fitted together with

headlights.
Fig. 3-18 Front Steering Light
Rear steering lights, located at the end of main

frame, are fitted together with tail lights.
Fig. 3-19 Tail Light

Horn button
Horn buttons are located at the ends of

both gear selector and direction indication
controller.
Hold this button, and the horn will alarm

continuously.
Fig. 3-20 Horn button
Washer button
Direction indication controller is equipped with

a washer button.
• Press down the button as shown in the

right figure, water would be sprayed out.
• Hold this button, and water would be
sprayed out continuously.
• Release it. The switch will automatically
retur n to its or iginal plac e and stop
Fig. 3-21 Washer button
spraying out water.
The controller can be rotated to four positions,

O, J, I and II, to control the operation of wipers.
• O-stop, stop wiping.
• J-intermittent wiping
• I-continuous wiping at selection 1
• II- continuous wiping at selection 2

3.2.1.4 Adjusting the angle of steering

controller
The angle of the steering wheel and steering

column can be adjusted to the desired angle.
Steering wheel angle adjusting handle (1)

1. Loosen the handle.
2. Adjust the steering wheel to a desired
position.
3. Tighten up the handle after the adjustment.
1
Steering column angle adjusting pedal (2)
1. Step on the pedal.
2. Adjust the steering column to a desired
2
position.
3. Release the pedal.
Fig. 3-22 Adjustment Handle and Pedal
3.2.2 Pedal
Brake pedal (3)

Brake pedal is used to reduce the machine
speed or stop it completely.
Accelerator pedal (4)

Accelerator pedal is used to speed up the
machine.
3 4
Fig. 3-23 Washer button

3.2.3 Joystick
2
3
Joystick is located at the right of cab seat. It 6
can be swayed in different directions to control
telescopic and pitching of the boom. 1 4
7
5
With the joystick on / off switch on right 8
operation panel pressed down, the joystick
can be switched and thus realize the singal
operation of boom to four directions without
pressing the joystick enable switch at the back
of joystick. 1. Spreader locking
2. Spreader unlocking
NOTE: 3. Spreader rotating anti-clockwise
To avoid incorrect operation, the driver should 4. Spreader rotating clockwise
turn off the joystick on / off switch on right 5. Spreader side-shifting leftward
operation panel before leaving the cab. 6. Spreader side-shifting rightward
7. Vertically lifting/lowering enable
When a combination operation is needed, 8. Joystick enable
push the joystick directly. Fig. 3-24 Joystick
NOTE:
Reaction speed of all operations (except
vertical operation) is directly related to the
joystick angle. When the joystick remains at its
neutral position, all operations will be ceased.

3.2.4 Right operation panel

5
Right operation panel is composed of the 6
following switches (see Fig. 3-25): 7
8
9
1. Ignition key switch 11
2. Safety bypass switch 12
3. Buzzer
13
14
4. Emergency stop switch 2
4
5. Cab moving switch
6. Boom emergency retraction switch
7. Counterweight moving switch 10
8. Boom emergency lowering switch 1
9. Joystick on / off switch 3
10. Spreader extending switch
11. Spreader retracting switch
12. Moving enable switch
13. Alarm resetting switch
14. Parking switch
Fig. 3-25 Right Operation panel

3.2.4.1 Ignition switch

A B
Ignition switch (position 1 in Fig. 3-26) is used
to start or shut down the engine.
C
A: OFF position
The key can be plugged in or pulled out. Turn
off all the electrical equipment.
B: ON position
The key stays at position B during engine
operation.
C: HEAT position Fig. 3-26 Ignition Switch
This is the position to preheat the engine.
Plug in the key. Turn it clockwise to position C
and keep it there to preheat the engine.
NOTE:
Some engines have the function of preheating
automatically.
D: START position
This is the position to start the engine.
Plug in the key. Turn it clockwise to position D
and keep it there to start the engine.
Release the key after the engine has started,
and it will automatically return to position B.
E: PARK position
The key can be plugged in or pulled out.
When it is at position E, the engine is shut
down.
NOTICE
NOTICE
Stopping engine on high speed would

shorten the service life of engine. Unless in
emergency, never stop the machine when
the engine is running at high speed. Doing
this can result in machine faults such
as wear crack on cylinder cover, burnt
bearings of turbocharger, etc.

3.2.4.2 Emergency retraction / lowering

switch
Buzzer would begin alarming to alert the

operator of current danger if the Load
percentage is larger than a certain value
(90%) in boom operation. Thus, be sure to
operate joystick to retract the boom as soon
as possible. After the danger is eliminated,
press down the reset button (13 in Fig.
3-25) to cancel the alarm. If the safety value
decreases further due to the mis-operation or
inertia until the Load percentage is larger than
another value (100%), the program would lock
the boom operation of pitching and extension
(except for the retraction). Fig. 3-27 Boom Emergency Retraction
In some emergency cases, press down the

emergency retraction button to retract the
boom. After the boom retracts to its min.
length, press down the emergency lowering
button to lower the boom. Be sure to retract
the boom first and lower the boom next,
for when the boom is lowered in a hurry,
the suspended load would move forward
horizontally, which would cause a danger of
overturning.
When the joystick is operated to move the

boom, the system program will give alarm
and lock the current operation if the forward-
overturning sensor is triggered to send tilting
signal. The boom then can only be retracted. Fig. 3-28 Boom Emergency Lowering
NOTE:
If the controller fails to work normally, it will
reset automatically 3 seconds after its power
supply is disconnected as long as the danger
is eliminated.

3.2.4.3 Emergency stop switch
Emergency stop switch (1) is located on the 1

operation panel. Press down this switch, and
the engine is stopped. The entire electrical
system has no power and all actions stop.
After the fault is eliminated, turn the switch in
the arrow direction as shown in Fig. 3-29 to
cancel the emergency stop. Parking brake can
be used for emergency brake.
This switch can be also used to brake the

machine in emergency cases. However it can
only be used when the brake system fails
in a really emergency circumstance. When Fig. 3-29 Emergency Stop Switch
driving this reach stacker, it is forbidden to use
this emergency stop switch when the brake
pedal is still working normally or in not really
emergent cases.
3.2.4.4 Safety bypass switch
When the working system can’t work normally

due to one operation protection caused by
some unexpected factors, you can cancel this
protection by the safety bypass function.

OPERATING STEPS OF SAFETY BYPASS:

2
1. Conf irm that this protection can’t be
canceled without using the safety bypass
function.
2. Before using the safety bypass function,
make sure the machine is in the safe
status.
3. Insert the key into the safety bypass switch
(2).
3
4. Turn the key clockwise to activate the
safety bypass function. Meanwhile, the
buzzer (3) near the safety bypass key
would begin to make alarm and the screen
would display “Safety Bypass Switch Fig. 3-30 Safety Bypass Button
Activated”. The protection is canceled.
5. When safety bypass switch is turned on,
the operator can only control the joystick
to lift / lower the boom and to side-shift /
rotate / telescope the spreader after the
machine is confirmed to be in the safe
status. When the machine is unloaded,
the safety bypass enables the locking and
unlocking of speader if the mechanical
lock pin of spreader twistlock mechanism
is released.
6. When the reach stacker is adjusted to the
normal status, make sure to proceed with
the next operation after this safety bypass
function is canceled, the fault indicator
light stops giving alarm and the “Safety
Bypass Function Activated” displayed on
the screen disappears.
7. After the operation, take away the key
and pass it to the special personnel for
keeping.
Fig. 3-31 Fault Indicator Light

3.2.4.5 Cab moving switch
After the moving enable switch (1) is engaged,

the cab would move forward when the cab 2
moving switch (2) is pressed forward, and
move backward when this switch is pressed
backward. The moving stops as soon as the
1
switch (2) is released. When the cab reaches
its limit positions, it will not move any more
even if the switch (2) is pressed down.
When the moving enable switch (1) is not

engaged, the cab would not move even if the
cab moving switch (2) is pressed down.
Fig. 3-32
3.2.4.6 Counterweight moving switch

(optional)
After the moving enable switch (position 1

in Fig. 3-32) is engaged, the counterweight
would move forward when the counterweight 3
moving switch (3) is pressed forward, and
move backward when this switch is pressed
backward. The moving stops as soon as the
switch (3) is released. When the counterweight
reaches its limit positions, it will not move any
more even if the switch (3) is pressed down.
When the moving enable switch (1) is not

engaged, the counterweight would not move
even if the counterweight moving switch (3) is
pressed down.
Fig. 3-33 Counterweight Moving Button

3.2.4.7 Parking switch
This switch is used to turn the parking

brake on or off.
Fig. 3-34 Parking Brake Switch

Press the parking brake switch, and the
parking indicator light will be turned on.
Fig. 3-35 Parking Indicator Light
3.2.4.8 Fuel heating switch (optional)
Press the fuel heating switch (1) when the fuel

temperature is too low, and the fuel heater
would be started to heat the fuel. 1
3.2.4.9 Hydraulic oil preheating switch 2

(optional)
Press the hydraulic oil preheating switch (2)

when the temperature of hydraulic oil is too
low, and the hydraulic oil would be preheated.
Fig. 3-36 Heating Switches (Optional)

3.2.5 Front operation panel
The switches on front operation panel consist

of three working light switches including
spreader light switch (1), boom light switch (2),
rear light switch (3) and three wiper switches
including front wiper switch (4), top wiper
switch (5), and rear wiper switch (6). See Fig.
3-37.
The three working light switches can be used

together as a combination light. Fig. 3-37 Front Operation Panel
3.2.5.1 Spreader light switch
This switch is used to turn on or off the

spreader light.
Fig. 3-38 Spreader Light Switch
There is respectively one spreader light at

both ends of spreader telescopic beam.
Fig. 3-39 Spreader Light

3.2.5.2 Boom light switch

boom light.
Fig. 3-40 Boom Light Switch
There are respectively two boom lights at both

sides of the middle of boom.
Fig. 3-41 Boom Light
3.2.5.3 Rear light switch

rear light.
Fig. 3-42 Rear Light Switch

There are respectively two rear lights at both

sides near the end of boom telescopic cylinder.
Fig. 3-43 Rear Light
3.2.5.4 Front wiper switch

front wiper.
Fig. 3-44 Front Wiper Switch
The front wiper is located at the front of cab.
Fig. 3-45 Front Wiper

3.2.5.5 Top wiper switch

top wiper.
Fig. 3-46 Top Wiper Switch
The top wiper is located at the top of cab.
Fig. 3-47 Top Wiper
3.2.5.6 Rear wiper switch

rear wiper.
Fig. 3-48 Rear Wiper Switch

The rear wiper is located at the back of cab.
Fig. 3-49 Rear Wiper

3.3 Display
Display is composed of menu display area (1),

function display area (2), and operation buttons
F1-F6 (3). See Fig. 3-50.
1 2 3
Fig. 3-50 Display
3.3.1 Menu introduction
Menu display area (position 1 in Fig. 3-50)
This area displays system parameters.
Fig. 3-51 Menu Display Area

Operation buttons (position 3 in Fig. 3-50)
By pressing relevant buttons, the desired

menu can be displayed.
Fig. 3-52 Operation Buttons

3.3.2 Introduction and operation of
display area
3.3.2.1 Start menu
When the ignition key is turned to position O,

the screen would display start menu as shown
in the right figure.
Fig. 3-53 Start Menu

3.3.2.2 Main menu
A b o ut 2 s e c o n ds af te r t h e st a r t m e nu
is displayed, main menu will be shown
automatically as the right illustration under
normal circumstances. Or you can press F1
directly to enter main menu.
Main menu displays engine rotation speed,

vehicle speed, fuel level, urea level, spreader
light, load percentage, container weight,
boom length, boom angle, timing information,
maintenance tips, and alarm area. Fig. 3-54 Main Menu

Below are the explanations of information

shown on main menu.
indicates the fuel level and urea level.
blue. heavy container..

grey. empty container.
light on. parking state.
light on. break pressed.

light off. break released.
light on. emergency stop..
light on. not on the seat.

light off. sit on the seat.
light on. CAN bus fault.
light on. twist lock.

light off. twist lock forbided.
green. sensor positioning..

grey. sensor not in place..

1. Engine rotation speed

The right instrument indicates the actual
rotation speed of engine.
Displayed speed on instrument alters within
the range of 0-25. It signifies the rotation
speed of 0-2500 rpm/min.
RS-1510029-1
Fig. 3-55 Engine Speed Instrument
2. Vehicle speed
The right instrument indicates the actual

traveling speed of machine.
Displayed speed on instrument alters within
the range of 0-30. It signifies the vehicle speed
of 0-3000 km/h.
Fig. 3-56 Vehicle Speed Instrument
3. Load percentage
Load percentage is aimed at protecting the

machine.
• Load percentage≤90%: safe for lifting load
• L o a d p e r c e n t a g e > 9 0 % : a l a r m f o r
dangerous working condition
• Load percentage=100%: impossible to
extend and lower the boom
Fig. 3-57 Load Percentage

4. Spreader indicator lights
Three spreader indicator lights on this menu

signify the conditions of spreader twistlocks.
• G (green) indicates the locking condition;

• Y (yellow) indicates the seating condition;
• R (red) indicates the unlocking condition.
Only the main menu of reach stackers with

container spreader shows these indicator
lights.
Fig. 3-58 Spreader Indicator Lights
5. Boom length, boom angle, gear, load

weight
• Boom length: the retracted or extended

length of boom
• Boom angle: the angle is shown as 0
degree when the spreader is lowered to its
lowest position. And it will change along
with the lifting of boom.
• Load weight: the weight is shown as 0
when the machine is unloaded. And it will
change according to the weight of load.
Fig. 3-59 Load & Boom Information
3.3.2.3 Language setting menu

Language
It is able to select the program language from

Chinese, English, French and Russian
Fig. 3-60 Language Setting Menu

3.3.2.4 Engine information menu
Press F1 to enter engine information menu.
indicates the engine water temperature

Fig. 3-61 Engine Information Menu
indicates the fuel level
indicates the engine oil pressure
indicates the engine rotation speed
indicates the engine working hours
indicates the system voltage

3.3.2.5 Gear information menu
Press F2 to enter gearbox information menu.
Gearbox parameters:
indicates the gearbox temperature
Fig. 3-62 Gear Information Menu

indicates the gearbox oil pressure
indicates the gearbox rotation speed
indicates the driving speed
Traveling gear information:
indicates respectively 1st gear, 2nd

gear, and auto gear
indicates respectively forward, neutral, and

reverse gear
indicates actual gear 1/2/3/4.

3.3.2.6 Hydraulic information menu
Press F3 to enter hydraulic information menu.

Hydraulic parameters:
L indicates the pressure of left lifting

cylinder non-rod chamber
R indicates the pressure of right lifting
cylinder non-rod chamber
O indicates the pressure of lifting
cylinder rod chamber
Length indicates the boom length
Angle indicates the boom angle

LoadWeight indicates the load weight
Total twistlock indicates the counting of

twistlock
Total container indicates the counting of
container
Fig. 3-63 Hydraulic System Menu

3.3.2.7 Digital analogy menu
Digital input menu
When a specific signal is “1” (activated), the

light at the left of the words changes into red.
Fig. 3-64 Digital Input Menu
Digital output menu

Fig. 3-65 Digital Output Menu

Analogy input menu
Fig. 3-66 Analogy Input Menu
Analogy output menu
4 output status of PWM valve:

• The valve opening is 0 when the value is
1526.
• The smaller the value is, the larger the
valve opening becomes.
• When the joystick is pushed and pulled to
its limit positions, the accordant value is
around 762.
Fig. 3-67 Analogy Output Menu
Spreader input menu

Fig. 3-68 Spreader Input Menu

Spreader output menu

Fig. 3-69 Spreader Output Menu
3.3.2.8 Function set menu
Function: 1 is “YES“, 0 is “NO.“

Gear Test is only useful for TE Gearbox, 0 is
normal use, other is force the other gear.
Fig. 3-70 Function set menu

3.3.2.9 Help System
When a failure occurs as showen in the

help imformation, enter the relevant help
information page to check the internal state of
the program.
Fig. 3-71 Help System
Fig. 3-72 Help System

3.4 Air Conditioning System
3.4.1 Control panel
AIR CONDITIONER
1 4
OUT
2 C
MODE(模式) 5
O3 AUTO
3 6
SANY HEAVY INDUSTRY CO.,LTD.
1. Fresh air switch 5. Mode switch

2. Fan speed switch 6. Temperature down or Page down switch
3. Power switch 7. LCD display
4. Temperature up or Page up switch
Fig. 3-73 Control Panel

3.4.1.1 Power switch
The power switch is used to start or stop

the functions of air conditioner (refrigeration, Fig. 3-74 Power Switch
dehumanization, ventilation, heating).
• Press the power switch when the fan is

working to start the air conditioner, and
the indicator light above this switch would
illuminate. Press it again to stop the air
conditioner, and the indicator light would
go out.
• Air conditioner cannot function while the
fan is turned off (no indication of fresh air
mode on the display).
3.4.1.2 Fan speed switch
This switch is used to adjust the air volume by

circulating from low-speed to medium-speed Fig. 3-75 Fan Speed Switch
and then to high-speed gear. Air volume can
be seen on the LCD display.
• Press this switch, and the set fresh air

volume increases gradually.
• Press this switch when the system reaches
its highest air volume, and the air volume
would return to its original condition.
• Air volume automatically transits among A B C
the gears during the automatic operation
of air conditioner.
Fig. 3-76 Air Volume Indication

Indications of air volume on display screen:

• A: it indicates low air volume
• B: it indicates medium air volume
• C: it indicates high air volume
3.4.1.3 Temperature or Paging switch
This switch is used to control the temperature

inside the operator cab.
Fig. 3-77 Temperature or Paging Switch
The temperature can be set between 16°C

(60.8°F) and 32°C (89.6°F).
• Press once to increase 1°C of the set

temperature.
• Press once to reduce 1°C of the set
Display Temperature (℃ ) Set Temperature (℃ )
temperature.
16.0 Max. refrigeration effect
• No operation for 5 seconds, temperature
18.5-31.5 Adjust the temperature
returns to the original display condition.
• The temperature is 32.0
generally set at 25°C Max. heating effect
(77°F).
Table 3-2 Temperature Reference
3.4.1.4 Mode switch
Mode switch is used to change the modes

bet ween refrigeration, dehumanization,
ventilation and heating. Fig. 3-78 Mode Switch
indicates that air conditioner is in

refrigeration mode.


ventilation mode.

heating mode.

dehumidification mode.
3.4.1.5 Fresh air switch
Fresh air switch is used to change the modes

Fig. 3-79 Fresh Air Switch
between fresh air, ozone sterilization, and
automation. Press this switch, and above
modes circulate in proper sequence.
NOTE:
• Mode, Fresh Air, Set and Fan Speed have
the memory function after power-off.
• Memory function after power-off means
that the operation mode, the fresh air
status, the set temperature, and the fan
speed when the controller is turned on this
time remain the same condition as that
before the system is powered off last time.
• Condenser starts within 30 seconds after
the fan begins working.

3.4.2 Operation
Press power switch after starting of

engine, the evaporator fan starts to operate.
Due to the memory function of controller after
power-off, the air conditioner may be under
the original condition of ventilation, fresh
air, refrigeration mode. Do the adjustments
according to your needs.
1. Press mode switch to choose the
operation mode of air conditioner. For
example, begins blinking when the

mode is set to be refrigeration. 30 seconds
later, the air conditioner starts to refrigerate
and keeps on. If the set temperature
is higher than c ab temperature,

would blink all the time. Then the idling
lifter would start to work if the engine is Fig. 3-80 Mode Switch
equipped with idling lifting device.
2. Press or one time to raise or
reduce 1℃ of the set temperature. The set

temperature can be adjusted between 16℃
to 32 ℃ . Generally, human body could
adapt to the temperature between 22℃ to
28 ℃ . As soon as the cab temperature is
lower than the set value, the sensor would
send signals to controller. And the air
conditioner will stop refrigerating.
Fig. 3-81 Temperature or Paging Switch

3. Press to adjust the air volume.
Fig. 3-82 Fan Speed Switch

fresh air mode.

ozone sterilization mode.

automation mode.
3.4.3 Precautions
1. As an electric c omponent, once the

c ont ro ller is damage d by water, air
conditioner would fail to function. Pay
particular attention to following:
• Remember to close the windows when
parking and cleaning the machine in case
that rain splashes and thus ruins the
controller.
• The operator should keep liquids away
from the controller while driving to avoid
splashing and thus ruining the controller.
2. Do not turn on the air conditioner until the

engine starts.

NOTICE
NOTICE
Turning on air conditioner before the

operation of engine would make the clutch
engage with the driving disc of condenser.
Starting engine at this time could create
large torque of engine and make the
clutch fraction with the driving disc.
Consequently, the clutch can be worn out
in a short time. (When the air conditioner
is stopped because the cab temperature
reaches the set temperature, instant
friction of disc arisen is normal.)
3.4.4 Troubleshooting
Fault light blinks when the machine broke
down. Press or once, and the screen

displays the corresponding error code. 5
seconds later, the display would return to show
cab temperature.
Table 3-3 Troubleshooting the Air Conditioner
Displayed code Fault

High / low pressure of air conditioning system
Open circuit of temperature sensor
Open circuit of defrosting sensor
The power voltage is below +20V
NOTE:
Do not operate compressor and condenser
when faulty.

3. Do not use the air conditioner when the

lights indicating air conditioner fault or
insufficient pressure light up.
4. Close windows, doors and ventilation
devices (except fresh air device) during the
operation of air conditioner.
5. Do not close all the air outlets. Keep at
least one thirds of air outlets open.
3.5 Electric Control Cabinet
The electric control cabinet is located behind
the operator’s seat, and the junction box is
installed on the right side of the machine, next
to the cab. The inner layouts are shown in the
below figures. When an electrical component
is burned, replace it with a new one of the
Reserved
Expansion
module
Central electric boxZN211A
GND
Fig. 3-83 Cab Electric Control Cabinet

5V PCB
SYMC controller
Large
current
relay
Fig. 3-84 Frame Electric Control Cabinet

3.6 Fuse
Fuses are located in the electric control

cabinet in cab. Fuse protector is a protection
electrical element of high generality. When
burned, it can be replaced with a new one of
the same specification easily.
Below fuse table has listed the necessary data

of each fuse.
same specification. Electrical diagnosis requires professional techniques and must be conducted
by a qualified and specific personnel. When important parts like a breaker or a relay are
damaged, please refer to the Parts Book and find out the relative material code, then purchase
them from SANY.
Table 3-4 Specifications of the upper electric control cabinet
Code Fuse Function

FU1 10A Expansion module
FU2 20A Boom lamp, Fog light
FU3 10A Emergency stop
FU4 10A
FU5 10A Bypass
FU6 20A Service light
FU7 10A Rear light
FU8 10A Alarm light
FU9 5A Top wiper
FU10 5A Rear wiper
FU11 20A Talkie walkie
FU12 20A Front wiper
FU13 5A Joystick
FU14 10A Counterweight
FU15 20A
FU16 5A Parking
FU17 10A Reverse camera
FU18 10A Expansion module
FU19 20A Reserved

Table 3-4 Specifications of the lower electric control cabinet
Code Fuse Function Code Fuse Function

FU1 10A Cab FU19 25A
FU2 10A FU20 10A
FU3 10A FU21 10A
FU4 20A FU22 10A
FU5 10A FU23 10A
FU6 10A FU24 10A APC controller
FU7 10A Front lamp FU25 25A Brake oil fan
FU8 10A FU26 20A Boom lamp
FU9 10A Lubrication FU27 10A Boom extension
FU10 10A Middle relay FU28 20A
FU11 10A Spreader FU29 10A
FU12 10A Spreader FU30 20A
FU13 10A Horn FU31 15A Controller power supply
FU14 10A Rear horn FU32 15A Controller power supply
FU15 10A Sensor power supply FU33 10A Emergency stop
FU16 10A FU34 5A Spreader delay
FU17 10A FU35 10A OEM1
FU18 10A Sensor FU36 10A OEM2

3.7 Fire Extinguisher
There are two fire extinguishers in the cab,

respectively located at both sides of cab.
In case of the fire hazard, be sure to observe

the following items:
NOTE:
• Make sure to put fire extinguishers in
cab and read carefully the instructions.
Understand its usage under emergency Fig. 3-85 Fire Extinguisher
circumstances.
• Check whether the lead wire and shell
of fire extinguisher are in good condition
daily. If damaged, change it immediately.
Check the electrical wiring of circular
fire extinguisher and change the wires if
damaged.
• Be sure that the fire extinguisher is in the
guarantee period. If the fire extinguisher
exceeds the guarantee period, you must
change it in time.
• Change the fire extinguisher at least every
two years.

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K
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N
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L
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Reach Stacker Operation
Operation
4. Operation
4.1 Before the Starting of Engine�� 4-4
4.1.1 Operator responsibility�� 4-4
4.1.2.1 Wiper water level, checking�� 4-6
4.1.2.2 Coolant level, checking�� 4-6
4.1.2.3 Engine oil level, checking�� 4-7
4.1.2.4 Transmission oil level, checking�� 4-7
4.1.2.5 Hydraulic oil level, checking�� 4-7
4.1.2.7 Brake oil level, checking�� 4-8
4.1.2.8 Tyres, checking�� 4-8
4.1.2.9 Electrical components, checking�� 4-9
4.1.2.10 Working light, checking��4-10
4.1.2.11 Horn, checking��4-10
4.1.3 Adjustment before operation��4-11
4.1.3.1 Seat, adjusting��4-11
4.1.3.2 Rearview mirror, adjusting��4-13
4.1.3.3 Safety belt, adjusting��4-14
4.2 Starting the Machine��4-15
4.2.1 Start in normal weather��4-15
4.2.2 Start in cold weather��4-18
4.2.3 Start with booster batteries or starting generators��4-19
4.3 Stopping the Machine�� 4-21
4.3.1 Engine shutdown procedures�� 4-21

Operation Reach Stacker
4.3.2 Emergency shutdown�� 4-23

4.4 Driving�� 4-24
4.4.1 How to drive�� 4-24
4.4.2 Driving forward�� 4-25
4.4.3 Driving backward�� 4-26
4.4.4 Turning around�� 4-26
4.4.5 Parking�� 4-27
4.5 Load Handling �� 4-28
4.5.1 Operation switches�� 4-28
4.5.2 Boom, operation�� 4-29
4.5.3 Spreader, operation�� 4-34
4.5.4 Hook, operation�� 4-37
4.5.5 Load capacity diagram�� 4-38
4.5.5.1 Load capacity diagram of SRSC45C30 / SRSC45C2 / SRSC45H1 /
SRSC45H2 / SRSC45H2A / SRSC45H3 / SRSC45H4 container reach stackers�� 4-39
�� 4-39
4.5.5.2 Load capacity diagram of SRSC4535H1 heavyweight container reach
stacker�� 4-42
4.5.5.3 Load capacity diagram of SRSC4540H2-70 heavyweight container reach
stacker�� 4-43
4.5.5.4 Load capacity diagram of SRSC4545C2 / SRSC4545H1 container
heavyweight reach stacker�� 4-41
4.5.5.5 Load capacity diagram of SRSC1009-6E / SRSC1009H5-6E empty
container reach stacker�� 4-40
4.5.5.6 Load capacity diagram of SRSC0808-6EH empty container reach stacker
�� 4-41
4.5.5.7 Load capacity diagram of SRSC3615-3 lightweight container reach stacker
�� 4-45
4.5.5.8 Load capacity diagram of steel coil reach stacker�� 4-46
4.5.5.9 Load capacity diagram of steel pipe reach stacker�� 4-47
4.5.6 Picking up a container from the stack�� 4-48
4.5.7 Depositing a container on the stack�� 4-51
4.5.8 Transferring the steel coil�� 4-53
4.5.9 Transferring the steel pipe�� 4-54
4.6 Store the Machine�� 4-55
4.6.1 Overnight storage�� 4-55

4.6.2 Short-Term Storage�� 4-55

4.6.3 Long-term storage�� 4-56
4.6.3.1 Preparations�� 4-56
4.6.3.2 During storage�� 4-57
4.6.3.3 Return to service�� 4-57
4.7 Transportation and Assembly�� 4-58
4.7.1 Guidelines�� 4-58
4.7.2 Disassembling the machine�� 4-59
4.7.2.1 Disassembling principles�� 4-59
4.7.2.2 Disassembly list �� 4-60
4.7.2.3 Hoisting points of parts�� 4-61
4.7.3 Packing requirements�� 4-63
4.7.4 Transportation�� 4-64
4.7.4.1 Transporting by platform lorry�� 4-64
4.7.4.2 Transporting by container�� 4-64

4. OPERATION
4.1 Before the Starting of Engine
4.1.1 Operator responsibility
The machine operator must do the following:

• Reject the work site if there is doubts
regarding safety.
• Become familiar with the work area and
surroundings before beginning work.
• Read and completely understand the
instructions in this manual prior to first-time
operation.
• Know and obey the operating procedures,
relevant laws and regulations.
• Know and follow the requirements for safe
operation.
• K n o w a n d u s e t h e r e q u i r e d s a f e t y
precautions and protective devices.
• Know basic information about the systems
of this machine.
• Know and use the correct hand signals
between the machine operator and a
signalman.
• The operator must c oncentrate only
on machine operation when using the
machine.
• Stop machine operations in case any
defects endangering safety are found.
• The operator must control the machine to
protect the personnel or other facilities in
the vicinity of the machine.
• Ensure that all control devices are set to
neutral or idle position before supplying
power to the drive components.
• Ensure that the control devices are set
to neutral or idle position and the power
supply is shut of f before leaving the
operator cab.
• The operator must give warning signals
when necessary.

• The operator must be provided with

necessary personal protective equipment.
WARNING
WARNING
The operator must never leave the machine

while a load is on the machine. Failure to
follow this warning could result in death,
serious injury or equipment damage.
WARNING
WARNING
A l w ay s o p e r a t e t h e m a c h i n e s l ow l y
and cautiously, avoiding sudden, rapid
movements.
Failure to follow this warning could result
in death, serious injury, loss of control of
the machine or equipment damage.
4.1.2 Checks before operation
Every time before starting the machine or

changing shift, the driver should check wiper
water level, coolant level, engine oil level,
gearbox oil level, hydraulic oil level, fuel level,
brake oil level, tyre, electrical components,
working lights, and horn to ensure that the
machine is in good condition and ready for
operation.

4.1.2.1 Wiper water level, checking
The wiper water tank is located behind the

driver’s cab. Fill it when necessary.
Fig. 4-1 Wiper Water Tank
4.1.2.2 Coolant level, checking
The expansion water tank, located behind the

driver’s cab, is directly connected to the engine
radiator. The water level in this tank indicates
the amount of coolant in the radiator.
Steps to fill coolant into expansion tank:

1. C oolant level should be maint ained
between the MAX and MIN markings on
tank when the engine is operating. If the
coolant level is below the MIN marking, it Fig. 4-2 Expansion Water Tank
is time to fill in coolant through the filling
port (1) until it reaches the MAX marking. CAUTION
CAUTION
Tighten up the cap after filling in coolant.
2. If the tank is empty, the coolant may be Never start the machine when the coolant
leaking. Check the coolant pipelines for is insufficient. Never open the tank cap
leakage. If so, fix the trouble immediately (1) when the engine is running or touch
Top up the tank if the coolant level is low. it within 10 minutes after the engine is
3. Clean the expansion tank when it is too turned off. Coolant temperature and the
dirty to see the level. pressure in tank are still high even if the
engine is stopped. Removing the cap to
REMARK: check the coolant level at this time may
Tank capacity: 35 - 50L lead to personal scald.
For detailed information, see: “Capacity of Therefore, firstly loosen the cap 1/4 turn to
the tanks” on page 5-18. check whether the expansion tank is under
high pressure. If so, open the cap after the
pressure is lower.

4.1.2.3 Engine oil level, checking
Always check the engine oil level prior to

starting the engine. This will help you to
quickly notice if any abnormal conditions have
occurred or are occurring.
For detailed information, see “Oil level,

checking and topping up” on page 5-40.
4.1.2.4 Transmission oil level, checking
Check oil level daily with engine running at

500-600 RPM and oil at 180 to 200° F (82.2-
93.3° C). Maintain oil level to H marking.
For detailed information, see “Transmission

oil level, checking” on page 5-53.
4.1.2.5 Hydraulic oil level, checking
Hydraulic oil directly determines whether the

hydraulic system will work normally. Be sure to
check the level daily.
For detailed information, see “Hydraulic oil
level, checking” on page 5-106.
4.1.2.6 Fuel level, checking
Insufficient fuel can lead to the ineffectivity

of engine. Check fuel level everytime before
operation.
For detailed information, see “Fuel level,

checking” on page 5-44.

4.1.2.7 Brake oil level, checking
The brake oil level can be indicated by level-

temperature indicator mounted on the tank.
The oil level must be maintained between the
Max and Min markings. You can also check
the quality of brake oil by its color. When the
oil level is lower than the Min marking, refill the
tank up to the Max marking. Change the oil
when it is necessary.
Fig. 4-3 Brake Oil Tank

REMARK:
Tank capacity: 195 - 250L
For detailed information, see: “Capacity of
the tanks” on page 5-18.
4.1.2.8 Tyres, checking
2
Carry out a visual inspection of the tyre. Make
sure that the rim and hub cover (1) are not
damaged, both sides of the tyres (2) and the
wheel tread (3) are not damaged. In case
of faults, the tyre will have to be carefully 3
inspected by the maintenance personnel
before being used.
Fig. 4-4 Check Points of Tyre
Tyre pressure should be 0.95-1.05 Mpa.
DANGER
DANGER
A exploding lock ring or exploding tyre can

be deadly to anyone close to the tyre.
O nly p rop er ly t rained p er sonnel are

allowed to service the tyres. Failure to do
this could result in serious injury or death.
Fig. 4-5 Tyre Explosion

4.1.2.9 Electrical components, checking
Check the following electrical components:

• Check if the fuses are not blown and
conforms to the subscribed volume.
• Check for open circuit or short circuit in
cables, and if the cover of cables is not
damaged.
• Check if the terminals are secure. If loose,
tighten them up.
• Also, pay particular attention to the cables
when checking the battery, engine, starter
motor, and alternator. Be sure to check if
there are flammable materials accumulated
around the battery. If so, clear them away
immediately.
NOTE:
• If the fuses are burnt out frequently or there
is a sign of short circuit in cables, please
contact SANY authorized distributors to
find the reasons and repair it.
• Keep the top surface of battery clean and
check the air vent on battery cover. If it is
clogged by dirt or dust, wash the battery
cover and clean the air vent.

4.1.2.10 Working light, checking
Start the machine. And turn on the working

light switch.
• Check if the working light can be turned on
normally.
• Check for dirt or damage of the working
light.
• Check whether the working light is on.
• If the working light is off, maybe the bulb is
burnt out or the electricity is disconnected. Fig. 4-6 Working Light
Please contact SANY authorized
distributors to repair it.
4.1.2.11 Horn, checking
Start the machine. And press down the horn

switch.
• Check whether the horn can sound.
• Check whether the horn sound is normal.
• If the horn does not sound or the horn
sound is abnormal, please contact SANY
authorized distributors to repair it.
Fig. 4-7 Horn

4.1.3 Adjustment before operation
4.1.3.1 Seat, adjusting
NOTE:
Adjust the seat before operation or after
changing the driver.
Adjust the seat until the driver can freely and
conveniently operate the joystick, brake pedal
and switches while seated.
1. Adjustment of headrest 1
Lift the headrest to a desired position, and

then release it to get it locked.
Distance: 120mm
2
3
4
4
5
4
6
Fig. 4-8 Headrest

2. Adjustment of armrest
Turn the handle (2) clockwise, and the height

of armrest is increased; Turn it anticlockwise,
and the height is decreased.
2
Angle range: -50°to 50°
Fig. 4-9 Handle to Adjust the Armrest

3. Adjustment of backrest
When adjusting the inclination of backrest,

firstly pull the handle (3) upward and tilt the
backrest to a desired position, then loosen the
handle to get the backrest locked properly.
3
Angle range: 75°to 140°
Fig. 4-10 Handle to Adjust the Backrest
4. Adjustment of safety belt
For detailed information, see: “Safety belt,

adjusting“ on page 4-14.
5. Adjustment of suspension
Turn the handle (5) to left, and the suspension

becomes firm to accommodate the drivers of
large weight.
Turn this handle to right, and the suspension
becomes soft to accommodate the drivers of
5
small weight.
Weight range: 50 to 130 KG
Fig. 4-11 Handle to Adjust the Suspension
6. Adjustment of seat height
The first hearing of “snip-snap” after the

handle (6) is lifted means that the seat is lifted
up for 30mm. Continue to lift this handle, and
the seat is lifted up for another 30mm after the
second hearing of “snip-snap”. Lift it another
time, and the seat is lowered to its original
position. 6
Height range: 0-60 mm

Fig. 4-12 Adjust the Seat Height

4.1.3.2 Rearview mirror, adjusting
CAUTION
CAUTION
Always adjust the rearview mirror before

operation.
Failure to do this can result in injuries to

you or others due to the blocked view.
Adjust the rear view mir ror s to make it

convenient for the driver to see the situation at 2
the back of machine.
Steps to adjust the rearview mirrors:

1
1. Rotate the rearview mirrors to a correct
angle.
2. If the mirror cannot move smoothly when
the angle is being adjusted, loosen the
fixing bolts of mirror and the bolts in fixing
lever of mirror.
3. Take the view of machine’s profile in mirror
Fig. 4-13 Rearview Mirror
as the standard while adjusting the angle
of rearview mirror.

4.1.3.3 Safety belt, adjusting
NOTE:
• Check whether the safety belt and its
mounting base are in good condition
before using it. Change it if worn or
damaged.
• Change the safety belts every three years
even if they are in good condition. Date
of manufacture is marked on the back of
safety belt.
• A l ways we ar t h e s afet y b e lt dur in g
operation.
• Do not bend the safety belt while wearing
it.
Fixing and disassembling

An intertwist device is attached to the safety
belt. Therefore, it is unnecessary to adjust the
length of safety belt.
Safety belt, fixing

1. Hold the safety belt clamp (2).
2. Pull the safety belt out of the intertwist
device (1). Make sure that the safety belt is
4，5 3 2 1
not bent.
3. Plug the lock tongue (3) in the shackle (4).
4. Pull slightly the safety belt to check if it is
fastened.
Safety belt, disassembling

1. Press down the button (5) on shackle (4).
2. Pull out the lock tongue (3) from the
Fig. 4-14 Safety Belt
shackle (4).
3. Safety belt will automatically roll back to
the intertwist device (1).
4. Hold the safety belt clamp (2) and Make
the safety belt roll back slowly to intertwist
device (1).

4.2 Starting the Machine
4.2.1 Start in normal weather
WARNING
WARNING
• Do not start the engine until you are in

the driver’s seat.
• D o n o t s t a r t t h e e n g i n e by sh o r t
circuiting the engine, because this
could result in severe personal injury
or fire disaster.
• Make sure that there is no one or no
obstacles around the machine. Then
press down the horn and star t the
engine.
• Do not use starting auxiliary liquid that
could cause explosion.
• Exhaust air is poisonous. Pay particular
a t t ent i o n to t h e vent il a t i o n w hil e
starting engine in a closed space.
1. Insert the main power key into the main

circuit switch and turn it clockwise.
Fig. 4-15 Main Power Key

2. Put the gear selector (1) in neutral position.

Make sure that the emergency parking
switch is released. 2
1
2
3
3. Insert the ignition key into the ignition 1
1
2
3
switch (2), and turn it to position I (see Fig.

1
2
I II
0
3
P
4-17) to electrify the entire system.
III
Fig. 4-16 Gear Selector
4. Turn the key to start position (III) and
hold for 3-5 seconds until the engine has
started successfully.
NOTE:
Do not operate the starter motor for longer
than 15 seconds. In case of start failure, wait
for 10 seconds between one start attempt and
another.
The ignition key should not stay at position

III for more than 10 seconds. If the engine
continuously fails to start for three times,
make sure to find the reason and solve the
problem before attempting to start it again, so
as to avoid damaging the engine.
In order to protect the battery, an interval of 1-2

minutes should be kept between starts. Only
start the engine after the system is powered
on and the start menu displays.

NOTE:
• When the temperature of engine is low, do
not run it at a high speed.
• Before the temperature of engine rises to
60˚C, do not run it at high acceleration or 60°c
at full load.
0°c
- 5°c
Fig. 4-18 Temperature Gauge
The following conditions must be met to start

the engine. 0 ℃ SPN 0
• Observe if there is any alarm information
0.0 L
showing on the display. If there is, correct
and clear the fault accordingly. 0.0 Bar
• Check if relevant parameters on Engine
0 RPM
Information Menu conform to correct
standards. 0 H
• Put the gear selector in the neutral 0.0 V
position.
• Release the emergency stop button.
• S te p o n t h e ac c e l e r ato r p e da l w i t h
observation on the parameters of the Fig. 4-19 Engine Information Menu
engine.
CAUTION
CAUTION
Emission of the diesel engine contains

substances harmful to personal health.
• Always operate the machine in a well
ventilated area.
• Discharge the exhaust gas outdoors
while operating in a closed space.

4.2.2 Start in cold weather
NOTE:
When the temperature is below 50°F (10°C),
special care should be taken to start the
engine. A start in cold weather may require
some assistant devices, but the operations in 35°c
the driver’s cab are identical to a normal start.
0°c
- 5°c
For maximum engine protection and easier
start at low temperature, observe the following
precautions:
• Keep the batteries fully charged.
• Keep the fuel clean and free of water. Fig. 4-20 Temperature Gauge
• Use lubricating oil with correct viscosity for
the ambient temperature range where the
engine has to be operated.
A hydraulic oil heater should be used when

the machine is operating in cold environment
(temperature below 0˚C). A preheating light
will illuminate to inform the driver that the
preheating is in process and go out when the
preheating is finished after about 1 minute.
If a normal start fails in cold environment, wait

for 2 minutes before trying to start again. If the
engine continuously fails to start for several
times, do not attempt starting it again before
finding out the reason and solving the problem.
Ask the maintenance personnel to check the
air intake preheating system.

4.2.3 Start with booster batteries or

starting generators
WARNING
WARNING
Booster batteries should only be

connected by personnel who have been
specially trained on their proper use.
Failure to connect the booster battery

correctly could result in injury or possibly
death.
2
If the battery of machine is barely charged,
1
use booster batteries or a starting generator to
start the engine.
1. Make sure that parking brake is engaged
and all electrical controllers are turned off.
2. Connect the booster batteries or starting
generator in the following procedures
to prevent sparks near the battery, or
explosion may happen: 1
• a. Connect a jumper cable with the positive 2
(+) terminal of the booster battery at one

end and with the positive (+) terminal of the
battery on machine at the other end.
• b. Connect another jumper cable with the
negative (-) terminal of the booster battery
and with the grounding connector (the one
away from the battery) on the machine
frame at the other end. Fig. 4-21 Booster Battery
3. Start the engine in a normal manner.
4. After the engine has been started, first
disconnect the negative (-) jumper cable
from the frame, then remove the positive (+)
jumper cable.
NOTE:
Never attempt to start the machine by towing
or pushing it.

WARNING
WARNING
Batteries produce explosive gases when

being charged or discharged. ALWAYS
wear safety goggles when using booster
bat teries and/or star ting generators.
Batteries can explode if a spark or flame
comes near the battery, and could result in
ANTIDOTES Recommended by Batter y

Manufacturers:
• EXTERNAL: flush with water. Flush eyes
for at least 15 minutes.
• INTERNAL: drink large quantities of water.
Do not induce vomiting. Go to hospital
immediately!

4.3 Stopping the Machine
4.3.1 Engine shutdown procedures
1. Release the accelerator pedal (3) to slow

down the machine.
2. Step on the brake pedal (2) to disconnect

the gearbox and the transmission shaft.
2 3
WARNING
WARNING
Fig. 4-22 Brake Pedal
When the machine is loaded with extended
boom, do not brake it suddenly. If not
avoided, this could result in injur y or
possibly death.
4
3. When the machine is totally still, press
down the parking switch (4), and the
parking indicator light (5) will illuminate.
Fig. 4-23 Parking Switch
Fig. 4-24 Parking Indicator Light

4. Put the gear selector (1) in the neutral

position.
5. Allow the engine to run idle for a few 2

1
minutes if it has been running constantly
3
with loads. 1
1 2
3
1
2
3
Fig. 4-25 Gear Selector
6. Turn the ignition key to position P in order

to stop the engine.
7. Remove the key from ignition switch when

leaving the machine.
8. Turn off the electricity with the main power

key if the machine is left unsupervised.
DANGER
DANGER
NEVER leave the machine with a load

suspended. It could inadvertently lower,
possibly causing serious injury or death.
Fig. 4-27 Main Power Supply Switch

4.3.2 Emergency shutdown

1
Emergency stop switch, located on the right
operation panel, can shut down the engine
and stops all machine operation. This switch
can also be used to stop the machine in an
emergency if the brake system should fail
while the machine is in motion.
After the failure is eliminated, turn the switch in

the arrow direction as shown in right illustration RS-1406049-1
to cancel the emergency stop.
Fig. 4-28 Emergency Stop Switch
If the emergency stop but ton has been
used twice, replace the brake lining block
immediately. Be sure to readjust it for a good
parking brake effect if the parking brake has
been separated from the machine.
NOTE:
It is prohibited to use the emergency stop
button when the brake pedal is still working
normally or in not really emergency cases.

4.4 Driving
4.4.1 How to drive
Only authorized operators who are familiar

with the functional features, load limits and
safety rules of the machine are allowed to
operate this machine.
F
1
2
N
1. Adjust the operator’s seat to a comfortable 3
and suitable position.

R
2. Run the engine idle and select driving

direction and traveling gear with the gear 1 3
selector (1).
3. Release the parking brake (2), and step on
the accelerator pedal (3).
Fig. 4-29 Driving
4. Before changing the gear, release the
accelerator pedal first, and then speed up
normally after the desired gear has been
selected.
5. Keep stepping on the accelerator pedal 2
when driving.
WARNING
WARNING
NEVER drive the machine when there is a

tipping alarm. Check if all safety facilities
work normally before operating.
Failure to follow this could result in injury

or possibly death. Fig. 4-30 Parking Switch
SPEED
• Adjust the speed according to personnel,
visibility, surface and load of the work area.
• Special care must be taken on wet and
slippery surfaces, such as snow or ice.
• Under all circumstances, the machine
must be operated at a speed that enables
it to be stopped in a safe manner.

WARNING
WARNING
Do not lift the load too high or too low

when operating the machine on uneven
ground. If not avoided, this could result in
OPERATING ON GRADIENTS (SLOPES)

When operating on slopes, obser ve the
following rules:
• The machine must move up and down the
slopes slowly.
• Do not turn the machine on slopes, nor
drive across slopes.
• The load must face uphill when driving up
or down gradients of over 10%.
NOTICE
NOTICE
Slow the machine down before changing

gears, or unexpected damage may occur
to the transmission shaft.
4.4.2 Driving forward
1. Push the gear selector (1) forward. 1

2. Release the parking switch (see Fig. 4-30).
3. Step on the accelerator pedal (3) slowly so
that the machine starts gently.
NOTE:
When accelerating up a hill, do not release the
brake pedal (4) until the machine has sufficient
pulling power.
4 3
Fig. 4-31 Driving Forward

4.4.3 Driving backward
1. Turn the gear selector (1) backward.

2. Step on the accelerator pedal (3) to speed 1
up the machine slowly.
WARNING
WARNING
Before driving backward, make sure that

no personnel is near the machine. If not
avoided, this could result in injur y or
3
possibly death.
Fig. 4-32 Driving Backward
4.4.4 Turning around
With the help of a hydraulic assisted system,

the machine can turn with a relatively small
turning torque.
To minimize unnecessary tyre wear, do not
turn the steering wheel when the machine is
stationary.
Do not continue turning the steering wheel
when it has reached its turning limit.
O t he r w i se, ste e r ing c o mp o nent s m ay
overheat.
WARNING
WARNING
Fig. 4-33 Turning Around
To maintain machine stability and prevent
possible tipping, do not turn around the
machine abruptly, especially:
• when the machine is traveling at a high
speed;
• with spreader elevated higher than its
mid-point;
• on uneven ground.
If not avoided, these could result in injury
or possibly death.

4.4.5 Parking
1
The parking brake switch (1) is located on the
left of front operation panel. Press the parking
brake switch, and the parking indicator light
will be turned on.
Do not use this parking brake switch for a

short-time stop, unless in emergency.
If the driver leaves the seat without pressing

the parking brake switch, the machine will give
off an alarm. Fig. 4-34 Parking
NOTE:
T h e p a r k i n g sy s te m i s l o c a te d o n t h e
transmission shaft. Switch on the parking
brake, and the transmission shaft will be
locked. Do not use the parking brake to stop
the machine unless in emergency.

4.5 Load Handling
4.5.1 Operation switches
9
2 10
3
11
A 6
12
D 13
14
1 15
4
C 16
7 B 17
5 18
19
8 20
21
24
25
22
23
A. Boom lowering B. Boom lifting C. Boom retraction D. Boom extension

2. Spreader 3. Spreader rotating 4. Spreader rotating 5. Spreader
1. Spreader locking
unlocking anti-clockwise clockwise shifting leftward
6. Spreader shifting 7. Vertically lifting /
8. Joystick enable
rightward lowering enable
12. Boom
10. Boom emergency 11. Counterweight 13. Joystick on /
9. Cab shifting emergency
retraction shifting (optional) off
lowering
15. Spreader 17. Alarm resetting 18. Fuel heating
14. Spreader extending 16. Shifting enable
retracting button switch (optional)
20. Fire detection
19. Hydraulic oil heating
alarm switch 21. Parking switch
switch (optional)
(optional)
24. Safety bypass 25. Emergency stop
22. Ignition key switch 23. Buzzer
switch switch
Fig. 4-35 Joystick

4.5.2 Boom, operation
To avoid improper operation and elevate the F

security of machine, this reach stacker has A
been equipped with a joystick on / off button
“F“ on the right operation panel and a joystick B
enable button “B” at the back of joystick.
To realize the vertically shifting function of

boom, there is a button “A” at the back of
joystick.
See the functions of enable buttons in below

table. Fig. 4-34 Enable Buttons
Table 4-1
Key Function Category

Vertically shifting
A Inching button
enable switch
Joystick enable
B Inching button
switch
Joystick on / off Two-position rocker
F
switch switch

Boom, lifting:
1. Press down switch B and hold it.
2. Pull the hydraulic joystick backward.
Fig. 4-37 Boom Lifting
Boom, lowering:
2. Push the hydraulic joystick forward.
Fig. 4-38 Boom Lowering

Boom, extension:
2. Turn the hydraulic joystick rightward.
Fig. 4-39 Boom Extension
Boom, retraction:
2. Turn the hydraulic joystick leftward.
Fig. 4-40 Boom Retraction

Boom, lifting vertically:

1. Press down switch A and hold it.
2. Pull the hydraulic joystick backward.
Fig. 4-41 Boom Lifting Vertically
Boom, lowering vertically:

1. Press down switch A and hold it.
2. Push the hydraulic joystick forward.
Fig. 4-42 Boom Lowering Vertically

Vertically lifting/lowering the boom can only

be applied when the torque percentage is less
than 85%. Otherwise, the machine will give off
an alarm and stop the boom operation.
The buzzer will be activated when the ma-

chine is in low safety level. In this case, retract
the boom quickly by manually operating the
joystick, and press down the alarm resetting
button until the danger is eliminated.
The vertically lifting/lowering speed of boom is

decided by a system program, and unrelated
to the angle of joystick. To shift from vertically
lifting to vertically lowering, release the joystick
and hold it for 2-3 seconds.
Vertical boom operations can only be applied

when the extended length of boom is short.
Operate the boom vertically as little as pos-
sible. Manual boom operation is preferable for
safety reasons.

4.5.3 Spreader, operation
WARNING
WARNING
Never continue side-shifting the spreader

after the container is lifted and tilted.
Personal injuries or possibly death could
happen.
When light A turns green, it indicates that the

twistlock is LOCKED;
When light B turns yellow, it indicates that the
crown bar is SEATED;
A B C
When light C turns red, it indicates that the
twistlock is UNLOCKED. Fig. 4-43 Spreader Light
Spreader, locking:
1. When the spreader is seated, light B will

turn yellow.
2. If the operator has set up the automatic
locking program, the controller will send
a locking signal and thus realize the
automatic locking of spreader. Then, light
A will turn green.
3. If the operator has not set up the automatic
locking program, spreader will be locked
and light A will turn green after the locking
switch on joystick is pressed down. Fig. 4-44 Spreader Locking Button
Spreader, unlocking:
1. When the spreader is seated, press down

the unlocking switch and joystick enable
switch to unlock the spreader.
2. Then light C turns red and light A goes out.
WARNING
WARNING
NEVER press the spreader unlocking but-

ton when the load is suspended, as the
load may fall down accidently. If not avoid-
ed, this could result in injury or possibly
Fig. 4-45 Spreader Unlocking Button
death.

Spreader, side-shifting (leftward):

When the spreader is not seated, press down
the side-shifting button (left), and the spreader
will shift leftward.
Fig. 4-46 Spreader Side-shifting Leftward
Spreader, side-shifting (rightward):

When the spreader is not seated, press
down the side-shifting button (right), and the
spreader will shift rightward.
Fig. 4-47 Spreader Side-shifting Rightward

Spreader, rotating (anti-clockwise)

Press down the spreader anti-clockwise
rotating button, and the spreader will rotate
anti-clockwise.
Fig. 4-48 Spreader Rotating Anti-clockwise
Spreader, rotating (clockwise)

Press down the spreader clockwise rotating
button, and the spreader will rotate clockwise.
Fig. 4-49 Spreader Rotating Clockwise

4.5.4 Hook, operation
The spreader is installed with four hooks for

loading bulk.
Observe the following rules when operating

the hooks:
• Make sure to connect ropes and tooling of
sufficient load capacity to the hooks.
• All the four hooks should be used at the
same time.
• Retract the spreader to be 20ft before
loading. Fig. 4-50
• The four ropes should be of the same
length.
The angle between the rope and the normal of

spreader corner parts is α.
• Angle range: 0°≤ α ≤ 30°
• Max. spreader load G should not exceed
the curve in right figure when α is different.
For example: G should be less than 20T
when α is 30°.
Fig. 4-51
Spreader tooling should be adopted to hoist

load by hooks. The size of tooling is as below:
• A≤5560 mm
• B≤2260mm
• 1≤ A/B ≤2.5
Fig. 4-52

4.5.5 Load capacity diagram
WARNING
WARNING
Overload is absolutely prohibited during

the operations, for it could result in injury
or possibly death.
Pay attention to transfer load according to the

load capacity diagram.
Unit of the unmarked sizes in the diagram is
mm.

4.5.5.1 Load capacity diagram of

SRSC45C30 / SRSC45C2 / SRSC45H1 /
SRSC45H2 / SRSC45H2A / SRSC45H3 /
SRSC45H4 container reach stackers
6000
Fig. 4-53 Load Capacity Diagram


SRSC4535H1 heavyweight container reach
stacker
15100
1965
3815 6500
6315


SRSC4540H2-70 heavyweight container
reach stacker
15250(15100)
1965 7000
3815
5800(6315)


SRSC4545C2 / SRSC4545H1 container
heavyweight reach stacker
13600
2100
3900 8000
6400


SRSC1009-6E / SRSC1009H5-6E empty
container reach stacker
16200
1965
5000
3815
6315


SRSC0808-6EH empty container reach
stacker
306
1435
17880
983
1535
1907 2500
3158


SRSC3615-3 lightweight container reach
stacker
256
9200
2896

4.5.5.8 Load capacity diagram of steel coil

reach stacker

4.5.5.9 Load capacity diagram of steel pipe

reach stacker

4.5.6 Picking up a container from the

stack
WARNING
WARNING
Overload is absolutely prohibited during

the operations, for it could result in injury
or possibly death.
This reach stacker is only used to lift 20′
and 40′ containers. Lifting other containers
1. Approach the container to be lifted.

2. Carefully move the machine so that the
container is centered to it.
3. Lift the spreader until it is right ahead of
the container.
NOTE:
The right light (red) is lid, indicating that the
spreader is unlocked.
Fig. 4-62
4. Drive the machine forward as close to the
stack as possible.
5. Apply the parking brake if desired, or stop
the machine by stepping on the brake ped-
al.
6. Adjust the position of spreader by side-
shifting and rotating it, making the twist-
locks align with the four holes at the con-
tainer corners.
NOTE:
The right light (red) is lid, indicating that the
spreader is unlocked.
Fig. 4-63

7. Put the spreader on the container.

NOTE:
The middle light (yellow) is lid, indicating that
all four corners are correctly aligned.
Fig. 4-64
8. Press the spreader unlocking button to

lock the twistlocks (if the automatic locking
program is not set).
NOTE:
The right light (red) goes out when the twist-
locks begin operating.
The left light (green) lights up when the twist-
locks finish operating.
WARNING
WARNING
Never lift the spreader during the locking

Fig. 4-65
moment! Otherwise the container could be
locked loosely and fall, possibly causing
personal injuries.
9. Ready to lift the container.

10. As soon as the container is lifted, the mid-

dle light (yellow) goes out and the twistlock
function is interrupted.
11. Lift the container only as much as needed
to ensure that its clearance from the lower
container (A) is approx. 20 to 40 cm.
12. Reverse the machine carefully to a position
where the lifted container is away from the
lower container. Reverse it only as much
as needed to ensure that the clearance
between the stack and the lifted container
(B) is less than 20 to 40cm. Then stop the
machine.
Fig. 4-66
13. Retract the boom as much as possible.
Then the lifted container will be lowered.
The system will alarm and interrupt the re-
traction of the boom when it is too far back.
14. Be sure to keep a certain distance from
the stack in front while retracting the boom,
because the container will move forward
horizontailly at the same time when it is
lowered vertically.
15. Continue retracting the boom and lowering

the container until the safe traveling posi-
tion is reached.
16. Retract the boom all the way back.
17. Lower the container as much as possible
without obstructing the visibility (not below
C).
18. Center the container by moving the
Fig. 4-67

spreader horizontally until the container is

right ahead of the machine.
19. Drive the machine with a suspended con-
tainer away from the stack carefully and
slowly.
Fig. 4-68
4.5.7 Depositing a container on the

stack
1. Approach to the stack.

2. Carefully move the machine so that the
container is centered to the machine.
3. Lift the container until it is right above the
stack.
4. Drive the machine forward as close to the
stack as possible.
5. Apply the parking brake if desired, or stop
the machine by stepping on the brake ped-
al.
6. Center the container over the stack by
Fig. 4-69

side-shifting and rotating the spreader.

7. Lower the container onto the stack.
Fig. 4-70
8. The middle light (yellow) illuminates when

the spreader is seated.
9. Then it is able to unlock the spreader.
10. The left light (green) goes out when the
twistlocks begin unlocking.
11. The right light (red) only lights up when the
twistlocks are fully unlocked.
12. Remove the spreader from the container.
And the machine can now begin picking up
or stacking a new container.
Fig. 4-71
WARNING
WARNING
Never lift the spreader during the locking

moment! Otherwise the container could be
locked loosely and fall, possibly causing
personal injuries.

4.5.8 Transferring the steel coil
NOTICE
NOTICE
The hook of steel coil spreader can plug in

or draw out the steel coil in the transverse
direction. Never load or unload the steel
coil in the lengthways direction. Otherwise,
the steel coil may drop from the spreader
when the machine is traveling.
The sideshift distance of hook is 2000mm.

This distance can only allow the machine to
hoist steel coil from the side. After the steel
coil is hoisted, reduce the sideshift distance to
below 500mm. Otherwise, the hook may be
unable to unload the steel coil.
NOTICE
NOTICE Fig. 4-72
Never sideshift the hook beyond 2000mm.

In this case, the gravity center of load will
deflect too much from the gravity center
of boom, thus resulting in the distortion of
boom.
When the spreader sideshift to the extreme of

left side, the gravity center of spreader will de-
flect from the spreader center. If the spreader Steel coil
is rotated at this time, the whole spreader will
Fig. 4-73
lean to one side and the rotation of spreader
will be influenced. Therefore, do not rotate the
spreader after the spreader is sideshifted.
1. Sideshift the spreader to the side of steel

coil.
2. Align the hook with the inner loop of steel
coil.
3. Sideshift the spreader to plug in the steel
coil.
4. Hoist the spreader and move the machine. Steel coil
Fig. 4-74

4.5.9 Transferring the steel pipe
Clamping sensors are installed on the left and

right telescopic beams. The working conditions
of sensors can be indicated by the spreader
indicator lights. These lights are installed on
the main beam which can be easily seen from
the operator’s front view.
• When the signals of both sensors are not

received, the right indicator light (see Fig.
4-74) lights up. The machine is ready to
pick up the steel pipe.
Fig. 4-75
• When the signals of both sensors are

received, the lef t indicator light (see
Fig. 4-75) lights up. The machine has
successfully loaded the steel pipe and is
ready to lift up the spreader.
Fig. 4-76
• When the signal of only one sensor is
received, the yellow indicator light (see Fig.
4-76) lights up. Do not lift up the spreader
at this moment. Extend the spreader and
try again to pick up the steel pipe. It is also
able to cancel the protection by turning on
the safety bypass switch.
Fig. 4-77

4.6 Store the Machine
4.6.1 Overnight storage
1. Park the machine on a flat, level, stable

surface away from people, traffic or other
machines.
2. Lower the attachment.
3. Run the engine at idle speed for 3 - 5
minutes to allow for heat dissipation.
Extend this cool-down time in hot weather.
4. Shut down the engine.
5. Remove the ignition switch when the
engine comes to a complete stop.
RS-1406021-1
NOTICE
NOTICE
Fig. 4-78
Always remove the ignition switch and
take it with you, even if you are leaving
the machine for only a moment. Keep
i t w i t h yo u t o p r eve n t u n a u t h o r i z e d
operation of the machine. Failure to follow
this notice can cause damage to the
machine, personal property and / or the
environment.
6. Close and lock the windows.

7. Exit the cab and lock the cab door.
8. Fill the fuel tank to the maximum level.
4.6.2 Short-Term Storage
Complete the “Overnight Storage” procedure

and then:
1. Clean the machine.
2. Keep it dry.
3. Keep it fully lubricated.
4. Cover it to protect from dust.
NOTE:
Short-term storage is defined as a storage
period of 30 days or less.

4.6.3 Long-term storage
Proper preparations for long-term storage

will reduc e the chanc es for damage or
deterioration of the machine.
NOTE:
Long-term storage is defined as a storage
period of more than 30 days.
4.6.3.1 Preparations
1. Park the machine on a flat, level, stable

surface away from people, traffic or other
machines.
2. Lower the attachment completely.
3. Run the engine at idle speed for 3 - 5
minutes to allow for heat dissipation.
Extend this cool-down time in hot weather.
4. Shut down the engine.
5. Remove the ignition key when the engine
comes to a complete stop. TY-1509015-1
Fig. 4-79 Ignition Key

NOTICE
NOTICE
Always remove the ignition switch and

take it with you, even if you are leaving
the machine for only a moment. Keep
i t w i t h yo u t o p r eve n t u n a u t h o r i z e d
operation of the machine. Failure to follow
this notice can cause damage to the
machine, personal property and / or the
environment.
6. Close and lock the windows.

7. Exit the cab and lock the cab door.
8. Fill the fuel tank to the maximum level.
9. Apply spray lubricant to any exposed
piston rods.
10. Change the engine oil.
11. Turn the main power switch to the off
position and remove the handle. Fig. 4-80 Main Power Switch

4.6.3.2 During storage
WARNING
WARNING
When operating the machine inside a

building and to prevent asphyxiation, it
is necessary to open doors and windows
to provide adequate ventilation. Failure
to observe and follow this warning could
result in death or serious injury.
Once a month:
1. Start the machine (For detailed information,

see: “Starting the Machine” on page
4-15).
2. Drive the machine a short distance.
3. Cycle each cylinder a few times to coat
piston rods with oil and exercise the seals.
4. Coat the exposed parts of the piston rods
with spray lubricant to prevent corrosion.
5. Turn on the air conditioner and allow it
to run for 3 to 5 minutes to lubricate the
compressor and related parts.
6. Return the machine to the proper storage
location and condition.
4.6.3.3 Return to service
1. Check the fuel and engine oil for water

contamination. Drain water or replace
fluids as necessary.
2. Examine the exterior of the machine for
signs of rust or damage and repair as
necessary.
3. Start the machine and test all operations
(For detailed information, see: “Starting
the Machine” on page 4-15).

4.7 Transportation and Assembly
4.7.1 Guidelines
Reach stacker is a specific kind of vehicle

used in ports, wharfs and stacking yards etc.
NOTE:
Reach stacker can’t be directly driven on road,
therefore in order to get the machine to the
clients’ designated wharfs or stacking yards
etc, the reach stacker has to be disassembled
before transported by road or sea.
A reach stacker is disassembled to: main

frame, boom, spreader, upper counterweight,
rear counterweight, and pitching cylinder.
Other small parts are packed in two or three
wooden cases based on their properties. All
these parts should be fixed and protected to
avoid paint damage.
Our professional transpor ting team will

disassemble and pack the machine before it is
delivered. If you wish to transfer this machine
to another work area, the machine should be
disassembled first.
As the disassembling is very abstract, SANY

provides you with some instructions of this
operation in a CD. So please refer to “CD for
Disassembling and Packing” for detailed
information.

4.7.2 Disassembling the machine
4.7.2.1 Disassembling principles
Observe the following rules while dismounting

the machine:
• Mark the plug-in parts and connectors of
wiring to be removed. Pack and seal them
with a plastic bag to prevent short circuit
due to water or dust.
• A l l hydr au li c h o s e s a n d c a b l e s n ot
removed should be bound and fastened on
the main frame, and the fastening positions
should be covered, protected and marked
to avoid confusion when reassembling.
• All the removed bolts should be fastened to
the corresponding parts and packed with
plastic bag. Put the bolts into the wooden
case.
• Plug the removed hydraulic connectors
with plugs. Pack and seal them with plastic
bags to prevent dust and water.

4.7.2.2 Disassembly list

Before transportation, the reach stackers
S R S C 4 5 H1/ S R S C 4 5 H 2 / S R S C 4 5 H 2 A /
SRSC45H3/SRSC45H4/SRSC45H8A /
SRSC45R5/SRSC3615 -3 should be first
dis as sembl e d into sever al par t s: main
frame (1), boom (2), spreader (3), upper
counterweight (5), rear counterweight (6) and
lights (7).
Before transportation, the reach stackers
SRSC1009-6E/SRSC1009H5-6E/SRSC0808-
6 EH /S RS 4 5 3 5 H1/S RSC 4 5 4 0 H 2-70 /
SRSC4545C2/SRSC4545H1 should be first
disassembled into several parts: main frame
(1), boom (2), spreader (3), pitching cylinder (4),
upper counterweight (5), rear counterweight (6)
and lights (7).
2
3 5
7
1
Fig. 4-81

4.7.2.3 Hoisting points of parts
Label, hoisting point:

Please choose suitable hoisting points before
using hoisting equipment.
NOTE:
It is the machine owner’s responsibility to
ensure all hoisting chain cables, hangers and
hook blocks are in good condition and with
sufficient capacity rating to hoist the attached Fig. 4-82 Hoisting Point Label
load.
1. Hoisting points of main frame
There are 4 hoisting points on the main frame,

each two at both sides of machine (position 1
and position 2 in Fig. 4-82).
Fig. 4-83 Hoisting Points of Main Frame

2. Hoisting points of boom

There are 6 hoisting points on the boom, each
three at both sides of boom (position 1, 2 and
3 in Fig. 4-83).
2
3
Fig. 4-84 Hoisting Points of Boom
3. Hoisting points of spreader

There are 4 hoisting points on the spreader;
each two at both sides of spreader (position 1
and position 2 in Fig. 4-84).
Fig. 4-85 Hoisting Points of Spreader

4.7.3 Packing requirements
• Pack all the stripped parts except main

frame, boom, spreader, counterweight
and cylinderss with plastic film of bubbles.
Fasten them with paper tapes.
• Rubber plates or cloth strips should be
placed under all used binding iron wires
and ropes.
• Pack the scattered bolts, screws, nuts
and gaskets in the plastic bag with buckle.
Mark the bag and put it into the spare
wooden case.
• Smear the exposed bearing, shaft pin and
assembling holes with grease and seal
them with oil papers.
• Plug the connectors of hydraulic oil hoses
with plugs. Bind the oil hoses with nylon
ropes or steel wires to the reliable places.
• Pack and seal all the cable connectors
with plastic bags to prevent rain or dust.
• All fragile parts (e.g. lights, reflective
m i r r o r s, etc .) s h o ul d b e b o un d a n d
fastened with plastic film of bubbles.
• Pack the exposed cylinder piston rod with
plastic films.
• Never paste the tapes directly to the
surface of parts.
• Label all the standard par ts with
information including name, amount, etc.
Load them into a big plastic bag.

4.7.4 Transportation
4.7.4.1 Transporting by platform lorry
If the machine is to be transferred to a nearby

yard by road, it can be disassembled into
several parts and bound to three platform
trucks for transportation. Weight of the parts
should not exceed load capacity of the platform
truck. Binding positions should be protected
to avoid paint damage. Load the main frame
to a platform truck whose load capacity is
33t. Load the boom, rear counterweight and
pitching cylinders to a platform truck whose
load capacity is 23t. Load the spreader, upper
counterweight and wooden cases to a platform
truck whose load capacity is 22t.
4.7.4.2 Transporting by container
If the machine is to be transferred to a distant

place by sea, three containers should be
prepared. Encase the main body in a 40 feet
frame container. Then, load the boom, pitching
cylinder, and rear counterweight in a 40 feet
standard container, and the spreader, upper
counterweight, other small parts in another 40
feet standard container. All the parts should be
fixed inside the containers to avoid moving.

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Reach Stacker Maintenance
Maintenance
5.1 Scheduled Maintenance, General Information �� 5-7
5.2 Tightening Torques ��5-11
5.2.1 General tightening torques��5-11
5.2.1.1 Fastener torque value��5-11
5.2.1.2 Hydraulic coupling torque values��5-12
5.2.1.3 Tapered connections��5-12
5.2.1.4 O-ring and flange connections��5-13
5.2.1.5 Low pressure hose clamps��5-14
5.2.2 Specific tightening torques ��5-15
5.3 Recommended Fuel, Coolant and Lubricant��5-16
5.3.1 Specification��5-16
5.3.2 Capacity of oil��5-18
5.3.3 Hydraulic oil, description�� 5-21
5.3.4 Quality of hydraulic oil, check�� 5-22
5.3.5 Urea�� 5-23
5.4 Lubricating Points�� 5-24
5.4.1 Lubricant�� 5-24
5.4.2 Lubricating points of complete machine�� 5-25
5.5 Scheduled Maintenance�� 5-27
5.5.1 Maintenance every day�� 5-27

Maintenance Reach Stacker

5.6 Engine�� 5-33
5.6.1 General engine inspection �� 5-34
5.6.1.1 Charge air pipe, checking�� 5-34
5.6.1.2 Drive belt, checking�� 5-35
5.6.1.3 Drive belt, replacing (engine option VOLVO)�� 5-36
5.6.1.4 Alternator belt, replacing (engine option VOLVO)�� 5-37
5.6.1.5 Air filter, checking / changing�� 5-38
5.6.1.6 Air filter, cleaning�� 5-39
5.6.1.7 Engine mounting pad, checking�� 5-39
5.6.1.7 Diesel fuel cleaner, changing�� 5-40
5.6.2 Lubrication system�� 5-41
5.6.2.1 Oil level, checking and topping up �� 5-41
4..The oil level is only measured before the time the ignition is turned on.�� 5-41
5.6.2.2 Engine oil, changing�� 5-42
5.6.2.3 Oil filter / Bypass filter, changing (engine option VOLVO)�� 5-43
5.6.2.4 Oil filter, changing (engine option CUMMINS)�� 5-44
5.6.3 Fuel system�� 5-45
5.6.3.2 Draining condensate, fuel system (engine option VOLVO)�� 5-46
5.6.3.3 Draining condensate, fuel system (engine option CUMMINS)�� 5-46
5.6.3.4 Fuel filter, replacing (engine option VOLVO)�� 5-47
5.6.3.5 Fuel filter, replacing (engine option CUMMINS)�� 5-48
5.6.3.6 Fuel pre-filter, changing�� 5-49
5.6.3.7 Fuel system, bleeding�� 5-49
5.6.4 Cooling system�� 5-50
5.6.4.1 Coolant, mixing�� 5-51
5.6.4.2 Water quality�� 5-52
5.6.4.3 Coolant level, checking and topping up�� 5-52
5.6.4.4 Filling a completely empty system�� 5-53
5.6.4.5 Coolant, draining�� 5-54
5.6.4.6 Radiator, cleaning�� 5-55
5.6.4.7 Radiator fan, checking�� 5-55
5.6.4.8 Cooling system, cleaning�� 5-56
5.6.4.9 Coolant filter, replacing (engine option CUMMINS)�� 5-57

5.6.5 Air intake and exhaust system��5-58

5.6.5.1 Air leaks, checking ��5-58
5.6.5.2 Turbocharger and blast pipe, checking��5-59
5.6.6 Urea filter element, changing��5-60
5.7 Transmission��5-61
5.7.1 Gearbox, function description��5-61
5.7.2 Mounting bolts of propeller shaft, checking��5-61
5.7.3 Speed sensor, checking��5-62
5.7.4 Mounting bolts and mounting pad, checking��5-62
5.7.5 Propeller shaft, lubricating��5-63
5.7.6 TE Transmission calibration��5-63
5.7.7 Transmission oil, changing��5-64
5.7.8 Transmission oil level, checking��5-65
5.7.9 Transmission oil filter, changing��5-65
5.8 Drive Axle��5-66
5.8.1 Mounting bolts of drive axle to the frame, checking��5-66
Check the drive axle’s attachment to the frame so that there is no corrosion of
structural elements (e.g. mounting bolts).��5-66
5.8.2 Mounting bolts of drive axle to the propeller shaft, checking��5-66
5.8.3 Oil leaking of drive axle and brake components, checking��5-66
5.8.4 Drive axle oil, changing��5-67
5.8.5 Breather, cleaning��5-68
5.8.6 Brake pedal, checking and adjusting��5-69
5.8.7 Parking brake pads, changing��5-69
5.8.8 Brake oil filter, changing�� 5-70
5.9 Steering Axle�� 5-71
5.9.1 Daily check�� 5-71
5.9.2 Steering axle, lubricating�� 5-72
5.9.3 Stub axle, maintaining�� 5-72
5.9.4 Steering axle cradle, checking�� 5-73
5.9.5 Steering pressure, checking�� 5-73
5.10 Tyres and rims�� 5-74
5.10.1 Tyre, description�� 5-74
5.10.2 Tyre, inflating�� 5-76
5.10.4 Wheel rim, description�� 5-77
5.10.3 Tyres, checking�� 5-77

5.10.5 Rim, checking��5-78

5.10.6 Wheel rim, installing and removing�� 5-80
5.10.6.1 Wheel rim, installing�� 5-80
5.10.6.2 Wheel rim, removing�� 5-81
5.10.7 Drive axle yre, removing and installing�� 5-82
5.10.7.1 Drive axle tyre, removing�� 5-82
5.10.7.2 Drive axle tyre, installing�� 5-83
5.10.8 Steering axle tyre, removing and installing �� 5-84
5.10.8.1 Steering axle tyre, removing�� 5-84
5.10.8.2 Steering axle tyre, installing�� 5-85
5.11 Boom�� 5-86
5.11.1 Basic boom, checking�� 5-87
5.11.2 Wear pads, checking�� 5-88
5.11.3 Wear pads of the fixed arm, replacing�� 5-89
5.11.4 Wear pads of the telescopic arm, replacing�� 5-89
5.11.5 Pitching cylinder, checking�� 5-91
5.11.6 Cylinder piston rod, maintaining�� 5-91
5.12 Spreader�� 5-92
5.12.1 Container spreader�� 5-92
5.12.1.1 Twistlock, checking�� 5-92
5.12.1.2 Twistlock, lubricating�� 5-93
5.12.1.3 Sensor / Indicator of twistlock, checking�� 5-93
5.12.1.4 Fixed bolts of spreader rotating gearbox, checking�� 5-94
5.12.1.5 Wear pads of spreader, checking�� 5-94
5.12.2 Steel coil spreader�� 5-96
5.12.3 Steel pipe spreader�� 5-98
5.13.1 General recommendations ��5-100

Authorization is required to perform repairs on the climate control unit.��5-100

5.13.2 Air conditioning, checking / performance test��5-101
5.13.3 Refrigerant quantity, checking ��5-102
5.13.4 Refrigerant, filling��5-103
5.13.5 Cleanness of heat-exchanger plate in evaporator and condenser, checking
��5-104
5.13.6 Leaking or lack of oil in condenser, checking��5-104
5.13.7 Radiator, cleaning��5-105
5.13.8 Maintenance table for air conditioner��5-105
5.14 Hydraulic System��5-107
5.14.1 Hydraulic oil level, checking��5-107
5.14.2 Air filter element, changing��5-107
5.14.3 Hydraulic oil, changing��5-108
5.14.4 Oil return filter element, replacing��5-109
5.14.5 Hydraulic oil tank, cleaning�� 5-110
5.14.6 Parking brake unit, checking and adjusting�� 5-111
5.14.7.1 Brake system accumulator, checking�� 5-112
5.14.7 Accumulator�� 5-112
5.14.7.2 Accumulators, charging with nitrogen gas�� 5-113
5.14.8 Hydraulic oil circuit, checking�� 5-115
5.15 Electrical System��5-116
5.15.1 Battery�� 5-117
5.15.1.1 Battery, cleaning�� 5-117
5.15.1.2 Battery, checking�� 5-118
5.15.1.3 Battery, detecting�� 5-119
5.15.1.4 Battery, charging��5-120
5.15.1.5 Battery, using��5-123
5.15.1.6 Battery cables, checking��5-125
5.15.1.7 Battery, scheduled maintenance ��5-126
5.15.2 Fuses, changing��5-126
5.15.3 All working lights and indicators, checking ��5-127

WARNING
WARNING
Always read and understand the Safety section before attempting to service this machine.
Failure to do this could result in injury or possibly death.

5. MAINTENANCE
5.1 Scheduled Maintenance,

General Information
Do not perform any maintenance or repair not

authorized in Safety, Operation & Maintenance
Manual of this machine. Always obser ve
and follow all safety precautions and use the
correct tools when performing any repair or
maintenance operation. Pay special attention
to Chapter 2 SAFETY.
HOUR METER READINGS

Always take note of the hour meter reading on
a daily basis. Confirm meter readings with the
required maintenance schedule listed in this
manual.
GENUINE SANY QUICK-WEAR PART

Please replace the worn parts with genuine
SANY parts stipulated in Parts Book.
GENUINE SANY OILS AND GREASES

Please use SANY recommended lubrication
oils and greases. Choose oils and greases
of appropriate viscosity in accordance with
ambient temperature.
WINDSHIELD WASHER FLUID

Use automotive windshield washer fluid only.
Do not mix concentrates into the detergent.
CLEAN OILS AND GREASES

Please use clean oils and greases. Always
keep them clean and avoid impurities into oils
and greases.
OIL AND FILTER INSPECTION

Always inspect the drained oils and old filters
for signs of metal particles and impurities. Re-
port to the person responsible if any abnormal-
ity is found in the filter or oil.

FUEL STRAINER
Fuel strainer should be installed when fuel is
filled.
WELDING INSTRUCTIONS
• Disconnect the negative terminal of battery
approx. one minute after turning off the
engine.
• Connect the ground cable no further than
3.3 ft (1 m) away from the place being
welded.
• If the ground cable is to be connected
to an electrical component (instrument,
connector, etc.), this component may be
damaged.
• Avoid welding near bearings, bushings,
seals or sliding surfaces. Choose another
ground point away from these parts.
• Never use hydraulic cylinder components,
cables or hydraulic hoses as a ground
point.
• Never apply more than 200V continuously.
AVOID DROPPING OBJECTS INSIDE THE

MACHINE
• After performing maintenance or repair to
the machine, always take time to inventory
your tools, parts used and nuts and bolts to
be sure none of these items were left on or
inside the machine. Failure to do so could
result in unexpected failure or damage to
the machine.
• Do not put unnecessary objects inside
your pocket other than those required for
maintenance.
DUSTY WORK AREA CONDITIONS

Observe the following items before working in
a dusty environment.
• Park the machine in a dustless place to
prevent dust from getting into oil when

checking the machine or changing oils.

• Frequently clean the radiator fins and other
heat-exchanger parts to avoid clogging.
• Clean or replace the fuel filter and air filter
frequently.
• Check and clean any electrical
components especially the starter motor
and alternator to avoid any accumulated
corrosion.
AVOID MIXED OILS

Never mix lubricants of different brands. If
necessary, make sure to drain out the old oils
and change with the new ones.
COVERS AND LOCKS

When servicing the machine with the covers
open, be sure they are properly supported in
place and the lock (if exists) is properly latched
for security.
BLEED THE HYDRAULIC SYSTEM

If any hydraulic components have been
replaced or removed, always bleed the air
from the system before resuming operation.
Be sure there are no leakings and the hoses
or lines do not rub on other components.
INSTALLATION OF HYDRAULIC TUBE

• When disassembling the parts at the place
sealed by o-rings or sealing gaskets,
pay attention to clean the surface before
changing with the new parts. Do not forget
to install the o-ring and sealing gasket.
• Do not distort or bend the tube during its
installation, because this would damage
the tube and shorten its service life.
SECURING OF ENGINE BONNET

W h e n c l o s in g t h e e n gin e b o nn et af te r
maintenance and repair, hold the handle and
slightly lift up the bonnet to examine if the pin
has been locked. It is dangerous to start the
engine without the bonnet secured.

CLEANING PARTS OF THE MACHINE

• Never clean the machine with caustic
chemicals or steam cleaners to avoid
damages to the paint or operating system.
• Instead, use mild soaps and a pressure
washer to clean the machine. Always
protect electrical parts when cleaning the
machine.
• Never flood or pressure-wash the inside of
the operator’s cab as this will damage the
electrical system.
• Use only nonflammable cleaning solvents.
Never use caustic or flammable liquids to
clean parts or systems.
CHECKS AFTER MAINTENANCE OR

REPAIRS
Always do the following after performing any
maintenance or repairs to the machine.
Check during operation
• Check if the maintained or repaired part is
working normally.
• Check for any leaking or overheating in the
system after you have completed repairs or
maintenance.
• Be sure there are no abnormal sounds
coming from the engine or hydraulic
system and nothing is loose.
Check after operation (when the engine is

stopped)
• Be sure you have completed all the steps
in the maintenance or repair of the machine
you have worked on.
• Check if ever y item is examined and
maintained correctly.
• Check that no tools or parts have fallen
inside the machine.
• Check if the water or oil is leaking, and all
the bolts are secured.

5.2 Tightening Torques
Premature component failure could occur if

fasteners or couplings are not torqued to the
specified torque value. All fasteners, hose or
pipe couplings on this machine have a torque
value.
5.2.1 General tightening torques
If a value is not specificity listed for the

fastener or coupling, always refer to the charts
below in this section for a torque value.
5.2.1.1 Fastener torque value
Table 5-1 All Types of Fasteners
Wrench Wrench (A) Socket, Open or Boxed end

(B) Allen Wrench
Diameter Bolt Type Type Wrench
(A) (B) lbf•ft kgf•m N•m lbf•ft kgf•m N•m
M6 10.9 10 4 9.74 1.37 13.2 9.74 1.37 13.2
M8 10.9 13 6 22.87 3.16 31 22.87 3.16 31
M10 10.9 17 8 48.7 6.73 66 48.7 6.73 66
M12 10.9 19 10 83.39 11.53 113 83.39 11.53 113
M14 10.9 22 12 130.6 18.06 177 130.6 18.06 177
M16 10.9 24 14 205.9 28.47 279 205.9 28.47 279
M18 10.9 27 14 281.9 38.98 382 281.9 38.98 382
M20 10.9 30 17 405.16 56.02 549 405.16 56.02 549
M27 10.9 41 19 974.16 134.7 1,320 974.16 134.7 1,320
M10 12.9 17 6 57.76 7.96 78 57.76 7.96 78
M12 12.9 19 8 101.1 13.98 137 101.1 13.98 137
M16 12.9 24 14 250.18 34.6 339 250.18 34.6 339
M20 12.9 30 17 490 67.75 664 490 67.75 664
B
A A A
10.9 8.8 12.9

5.2.1.2 Hydraulic coupling torque values
Table 5-2 “M” and “G” Couplings
Port Tightening Torque Value Tube Tightening Torque Value

Fitting lbf•ft N•m Fitting lbf•ft N•m
M14 25 ± 4 34.3 ± 5 G1/8 (148 ± 18) 16.7 ± 2
M16 40 ± 4 54 ± 5 G1/4 27.1 ± 2 36.7 ± 2.5
M18 52 ± 7 70 ± 10 G3/8 54 ± 4 73.5 ± 5
M20 69 ± 7 93 ± 10 G1/2 80 ± 6 107.8 ± 7.8
M22 92 ± 7 125 ± 10 G3/4 119 ± 10 161.7 ± 14
M24 105 ± 15 142 ± 20 G1 162 ± 18 220 ± 25
M24 51 ± 7 68.6 ± 10
M26 133 ± 15 180 ± 20
M20 36 ± 4 49 ± 5
G3/8 51 ± 15 68.6 ± 20
G3/4 (A) 1.226 ± 10 1,661.7 ± 14
5.2.1.3 Tapered connections

o
30
Table 5-3 Male Coupling
Wrench Tightening Torque Value
Union lbf•ft kgf•m N•m Female end

19 44 6 59
22 72 10 98
27 87 12 118
36 173 24 235
41 218 30 295
50 316 50 490
60 494 68 670
Fig. 5-1
70 723 100 980
Table 5-4 Female Coupling

o
Wrench Tightening Torque Value 30 Male end
Union lbf•ft kgf•m N•m
19 32 4.5 44
22 44 6 59
27 87 12 118
36 173 24 235
41 218 30 295
50 361 50 490
Fig. 5-2

5.2.1.4 O-ring and flange connections
• Never reuse the O-ring when disconnecting 1 O-ring 2

hose end fittings. Always replace it with a
new O-ring.
• Always check the condition of the O-ring
retaining groves or flanges, replace the
fitting or flange if the groves are damaged
or worn.
• Be sure the O-ring fits into the groves
properly and is not too small or too large
for the fitting or flange. Fig. 5-3
• Always torque the fitting, flange or hose
end to the value listed below.
Table 5-5 O-ring Fittings
Wrench Wrench Tightening Torque Value
Fitting (1) Hose Nut (2) lbf•ft kgf•m N•m

19 17 44 6 59
22 19 72 10 98
27 22 87 12 118
36 30, 32 173 24 235
41 36 218 30 295
50 46 361 50 490
Table 5-6 Split Flange Bolts
Bolt Thread Width Across Tightening Torque

Diameter Flats lbf•ft kgf•m N•m
10 14 44 to 55 6.0 to 7.5 5 9 to 74
12 17 72 to 90 10.0 to 12.5 98 to 123
16 22 173 to 210 23.5 to 29.5 235 to 285

5.2.1.5 Low pressure hose clamps
The tightening torque for a low pressure hose

clamp will differ depending on the type of
clamp being used. Never over tighten a hose A B
clamp, damage to the hose will result. If a
specific torque value is listed for a hose clamp
always use the listed value. If it is not listed,
use the torque value listed below:
Fig. 5-4
Table 5-7
Type lbf•in N•m

A T-bolt type 39 4.4
B Worm type 52 - 61 5.9 - 6.9

5.2.2 Specific tightening torques
CAUTION
CAUTION
If the nuts, bolts or other parts are not

secured to regulated torques, it will result
in machine malfunction or operation
failures.
Pay particular attention when tightening
bolts and nuts.
Before starting the machine, please carefully

check critical bolts for tightness. Loose bolt
has a great possibility to result in dramatic
vibration of the machine, component damage
or weakened function of bolts, etc.
Periodical check can avoid unexpected results.
The following bolts must be checked:
Table 5-8 Recommended Tightening Torque of Bolts on Main Components
Bolt Recommended tightening torque(N·m)

Mounting bolts of engine and frame M22 650±35
Mounting bolts of transmission case M20 540±30
Bolts coupling engine and transmission case M10×1.25 70±5
Bolts coupling propeller shaft and drive axle M14×1.5 220±15
Mounting bolts of drive axle M36 1600±100
Mounting bolts of steering cylinder M30×2 1400±100
Mounting bolts of upper and lower counterweights M36 1600±100
Nuts of drive axle pressure plate M18 430-460
Nuts of steering axle pressure plate M22 550-600

5.3 Recommended Fuel, Coolant

and Lubricant
Fuel, hydraulic oil, and coolant recommend

by SANY in this manual must be used. The
quality and quantities of all functional liquids
should be periodically checked. Only when
their quality and quantities are up to standard
can the machine be put in operation.
NOTE:
Oils produced by different manufacturers
have different properties. It is best use the oils
recommended by SANY.
Be sure to drain out all the oil in tank before
filling in new oils.
5.3.1 Specification
If the environment temperature exceeds the

range listed in the below table, use the oil of
higher standard.
For the oil standard, refer to the below table for
information.
NOTE:
Before starting the engine, preheat the oil to
the min. temeprature meeting the requirement
of oil adherence.
Table 5-9 Oil Specifications

Recommended Oil Adherence Under Different
Temperature
Filling Position Oil Quality
°C -30 -20 -10 0 +10 +20 +30 +40 +50
°F -22 -4 +14 +32 +50 +68 +86 +104 +122
Engine Engine oil
VOLVO series SAE 5W-30
CUMMINS series API CI-4 SAE 10W-30
YUCHAI series SAE 15W-40
Transmission case Transmission oil
DEXRON-II or
DANA HR32000 series DEXRON II
equivalent *
Caterpillar TO-4
DANA HR36000 series SAE 10
Allison C-4

Recommended Oil Adherence Under Different

Temperature
Filling Position Oil Quality
°C -30 -20 -10 0 +10 +20 +30 +40 +50
°F -22 -4 +14 +32 +50 +68 +86 +104 +122
DANA TE17 series
DEXRON-III only DEXRON III
DANA TE32 series
Drive axle Transmission oil
SAE 75W-140
KESSLER series API GL-5 SAE 80W-90
SAE 85W-140
Spreader reductor Transmission oil
ISO 6743-6
Reggiana MOBIL gear 629 ISO-L CKC150
recommended
Hydraulic system Hydraulic oil
ISO-L HV32
ISO 6743-4 ISO-L HV46
ISO-L HV68
Brake system Hydraulic oil
DONAX TD **
Travel brake and outer
HV(94%) + DONAX TD 5W-30
cooling system only
LZ9990A(6%)
Light diesel for vehicle meeting EN590 or GB/ T 19147 standard. It is

Fuel recommended to use 0# diesel in summer and -35# diesel in winter. Machine
equipped with stage IV engines should apply ultra-low sulfur diesel.
Grease 2# or general lithium-based grease
Anti-freezing fluid of ethylene glycol or propylene glycol (For the information of
Engine coolant mixing proportion, see: “Coolant, mixing” on page 5-40.). VOLVO engines
adopt the VOLVO anti-freezing fluid VCS.
Freezing oil (air
PAG100
conditioning system)
Refrigerant (air
R134a
conditioning system)
Urea (Stage IV engines
AUS32 specific urea solution meeting ISO 22241-1 standard only
only)
* If the friction disc contains graphite, do not NOTICE

NOTICE
use this oil.
** No addictive Never replace oil with that of other types,
DEXRON is the regristed brand of US GM or machine damage could be resulted.
Co., LTD

5.3.2 Capacity of oil
Values in the below tables are only used for

reference.
Oil level indicator is installed on the side of oil
tank for oil level checking.
Oil capacity of SRSC45C30 / SRSC45C2 /

SRSC4540H2-70 reach stackers
Table 5-10
Items Oil Capacities (unit: L)

Hydraulic oil tank 800 Hydraulic oil tank capacity: 650L
Fuel tank 550 Fuel tank capacity: 650L
Brake oil tank 150 Brake oil tank capacity: 195L
Engine oil 40
Engine coolant 50
Gearbox and torque converter 65
Main reducer of drive axle 73.5
Reduction hub 11 X 2
Oil capacity of SRSC45H1 / SRSC45H2

/ SRSC45H2A / SRSC45H3 / SRSC45H4
reach stacker
Table 5-11

Engine oil 40 (21L for SRSC45H4) Oil change interval: 500h
Engine coolant 50
Urea 35

Oil capacity of SRSC4535H1 reach stackers
Table 5-12

Engine oil 40
Engine coolant 50
Oil capacity of SRSC4545C2 / SRSC4545H1

reach stacker
Table 5-13

Engine oil 40
Engine coolant 50

Oil capacity of SRSC1009 - 6E /

SRSC1009H5 - 6E/SRSC0808 - 6EH reach
stacker
Table 5-14

Engine oil 23
Engine coolant 45
Reduction hub 2.3 X 2
Oil capacity of SRSC3615-3 reach stacker
Table 5-15
Engine oil 27
Engine coolant 35
Reduction hub 5.6 X 2

5.3.3 Hydraulic oil, description
Hydraulic oil, a very important part of hydraulic

system, is used to realize the transition and
control of power. It is rust-proof and anti-
corrosive, able to lubricate and cool the
system.
The cleanness of hydraulic oil does influence
the performance of hydraulic system and
service life of hydraulic components. It directly
determines whether the hydraulic system
would function normally.
Check the hydraulic oil in tank every six
months with the means of visual inspection
and oil analysis.
The malfunction of hydraulic system is mainly
due to the bad management of hydraulic
oil. Therefore, make sure to improve the
management of hydraulic oil:
• Do not mix concentrates into oil.
• Replace the oil immediately when the oil is
of bad quality.
• Change the filter as regulated.
• Ensure the capacity and quality of oil in
tank.
• Keep the oil cooler ventilated to prevent
the abnormal increase of oil temperature.
• Block off the oil filling port with screw plug
(or wrap it with clean plastic bag) after the
hydraulic components (pump, valve, rubber
hose, etc.) are stripped.

5.3.4 Quality of hydraulic oil, check
The common way to evaluate the pollution

degree of hydraulic oil is to compare the tested
oil with the clean oil. Check whether the oil
color is different, or if there is dust or sediment
in the oil.
1. Each month take about one liter of oil
sample out of the oil tank.
2. Inject them into numerous clean test tubes.
3. Keep those test tubes respectively for ten
days and one month.
4. Compare them with new oils and examine
their color, transparency, impurities and
sediments, etc.
5. Use the filter paper to filtrate the impurities
out of the hydraulic oil.
Below table is a simple way to evaluate the oil

quality on the spot:
Table 5-17 Evaluation Method of Oil Quality
Color Odor Pollution Status Measures

Transparent Normal No pollution Keep using
Keep using if the viscosit y is
Thin transparent Normal Different oil mixed
qualified
Transparent but gleamy Normal Metal particles mixed Filter or change the oil
Transparent with macula Normal Impurities mixed Filter or change the oil
Black brown Stinky Oxidated materials mixed Change all the oils
Seperate water from oil or change
Milky white Normal Air or water mixed
the oil
More strictly, check the viscosity, oxidation,

water content, sediment, specific gravity, color
and flash point of oils in accordance with the
standards of hydraulic oil manufacturer. It is
better to plan for changing oils based on the
examination result and sample time.

5.3.5 Urea
Vehicle urea solution is colorless, transparent,

and clear. This f luid, whose strength is
bet ween 31. 8% and 3 3. 2% , is use d to
deoxidize the nitrogen oxide.
Sany port machines equipped with stage 4

engines are required to fill vehicle urea to
reduce the emission of nitrogen oxide and thus
to meet the environment-friendly needs.
This machine can only be filled with AUS32

urea which is conformed with standard ISO Fig. 5-5 Urea Jar
22241-1.
To reduce its decomposition, the urea solution

should avoid the long-term storage as far
as possible. Besides, it is better not to store
the urea solution in the environment whose
temperature is higher than 25°C.
Table 5-18
Urea Storage
Temperature (°C) Storage term (month)

≤10 36
11-25 18
26-30 12
31-35 6
>35 Detect before usage

5.4 Lubricating Points
5.4.1 Lubricant
Lubricant is used to ensure the smooth rotation

and sliding of all parts. Insufficient lubrication
will lead to the seizing of components and
excessive wear. Lubricant is critical for the
lubrication of the engine to ensure smooth
operation.
This machine should adopt lithium-based

grease. Never use lubricants not specified by
SANY.
Application method of lubricants (grease):

Please clean the grease nipple before applying
grease. Lubricate into the nipple with grease
gun until old grease is extruded. Remove the
excessive grease.
NOTE:
As for sliding surface, remove the old grease
and apply grease on the contact surface of
sliding block.

5.4.2 Lubricating points of complete

machine
The movable connecting shafts, boom and

spreader are key positions to be lubricated.
Refer to below figure and table for details.
Fig. 5 - 6 Lubricating Points for Complete

Machine

Table 5-19 Lubricating Interval of Machine (Corresponded to Fig. 5-6)
No. Position Number Oil change intervals

1 Steering axle 13
2 Lower hinge supporting point of pitching cylinder 2
3 Boom pin shaft 4
4 Lubricating block of telescopic boom 14
5 Telescopic surface of spreader 6
6 Hinge of spreader and boom 2
7 Damping cylinder lug of spreader 4
Every 60 hours or weekly
8 Sideshift cylinder lug of spreader 4
9 Sideshift surface of spreader 4
10 Telescopic cylinder lug of spreader 4
11 Twistlock of spreader 8
12 Upper rotary platform slewing bearing of spreader 4
13 Propeller shaft 3
14 Parking brake 1
15 Diesel engine 1 Every 250 hours
16 Brake oil tank 1 Every 500 hours or a half year
17 Reduction hub of drive axle 2 Every 1000 h or 1 year
18 Differential of drive axle 1 Every 1000 h or 1 year
19 Hydraulic tank 1 Every 2000 h or 1 year
20 Torque converter 1 Every 1000 h or 1 year
21 Engine radiator 1 Every 1000 h or 1 year

5.5 Scheduled Maintenance
5.5.1 Maintenance every day

Table 5-20
System Maintenance Item Reference
Check the drive belt. See “Drive belt, checking” on page 5-35
See “Air filter, checking / changing” on
Check the air filter indicator.
page 5-38
See “Coolant level, checking and topping
Engine Check the coolant level.
up” on page 5-52
Check the engine oil level. null
See “Radiator fan, checking” on page
Check the engine radiator fan.
5-55
See “Transmission oil level, checking” on
Check the transmission oil level.
page 5-65
Check the gearbox for oil leaking. null
Transmission See “Mounting bolts of propeller shaft,
Check the mounting bolts of propeller shaft.
checking” on page 5-61
Check if the mounting bolts and mounting See “Mounting bolts and mounting pad,
pad is secured. checking” on page 5-62
Steering Axle Check and tighten the hub bolts. null
Check the basic boom. See “Basic boom, checking” on page 5-87
Check and lubricate wear pads of boom. See “Wear pads, checking” on page 5-88
Load Handling
See “Pitching cylinder, checking” on
Equipment Check the pitching cylinder.
page 5-91
Check the twistlock. See “Twistlock, checking” on page 5-92
Hydraulic Check the hydraulic oil for leaking. null
System Check the hydraulic hoses and connectors. null
Check if all the working lights and indicator See “All working lights and indicators,
Electrical
lights are working normally. checking” on page 5-127
System
Clean the battery. null
Check the tyre pressure. null
Others
Fill in lubricants. null

5.5.2 Maintenance every 50 hours
Table 5-21

Check the drive axle and brake components See “Oil leaking of drive axle and brake
Drive Axle for oil leaking. components, checking” on page 5-66
Clean the breather. See “Breather, cleaning” on page 5-68
See “Steering axle, lubricating” on page
Steering Axle Lubricate the steering axle.
5-72
Check the fixed bolts of spreader rotating See “Fixed bolts of spreader rotating
gearbox. gearbox, checking” on page 5-94
Load Handling Lubricate the bearing of lifting cylinder. null
System Lubricate the wear pads of boom. null
Lubricate the bearings of sideshift cylinder. null
Lubricate the bearings of telescopic cylinder. null
S e e “A i r c o n d i t i o n i n g , c h e c k i n g /
Check the performance of air conditioner.
performance test” on page 5-101
See “Refrigerant quantity, checking” on
Check the quantity of refrigerant.
page 5-102
See “Leaking or lack of oil in condenser,
Check the air condenser for oil leakge.
Check the pipeline. null
Air
Check the cables. null
Conditioning
Check if the fixing bolts of air compressor
System null
are secured.
Check if the fixing bolts of air conditioner are
null
secured.
See “Cleanness of heat-exchanger plate
Check the cleanness of heat-exchanger
in evaporator and condenser, checking”
plate.
on page 5-104
Check the filter screen of evaporator. null

Table 5-22
Clean the engine surface. null

Clean the air filter. See “Air filter, cleaning” on page 5-39
Replace the engine oil. See “Engine oil, changing” on page 5-43
See “Oil filter / Bypass filter, changing
Replace the engine oil filter.
(engine option VOLVO)” on page 5-42
Engine See “Coolant filter, changing (engine option
Replace the coolant filter.
CUMMINS)” on page 5-57
See “Diesel water separator filter, changing”
Replace the diesel water separator filter
on page 5-40
Check the air intake system and exhaust
See “Air leaking, checking” on page 5-58
system for air leaking.
Check the mounting bolts of drive axle to See “Mounting bolts of drive axle to frame,
frame. checking” on page 5-61
Check the mounting bolts of drive axle to S e e “ M o u n t i n g b o l t s o f d r i v e a x l e t o
Drive Axle
propeller shaft. propeller shaft, checking” on page 5-62
See “Brake pedal, checking and adjusting”
Check and adjust the brake pedal.
on page 5-69
Check if the steering shaft is worn. null
Check the stub axle. See “Stub axle, maintaining” on page 5-72
Steering Axle
See “Steering pressure, checking” on page
Check the steering pressure.
5-73
See “Sensor / Indicator of twistlock,
Check the sensor/indicator of twistlock.
Load checking” on page 5-93
Handling Lubricate the twistlock. See “Twistlock, lubricating” on page 5-93
System See “Wear pads of spreader, checking” on
Check the wear pads of spreader.
page 5-94
Hydraulic See “Hydraulic oil level, checking” on page
Check the hydraulic oil level.
System 5-107
Clean and tighten the wiring posts. null
Check the cables for tightness. null
Check the movements of emergency stop
Electrical null
device.
System
Check the electrolyte level. null
Check the battery for charging. See “Battery, charging” on page 5-120
Check and adjust the wiper. See “Wiper, adjusting” on page 5-127
Check if the lubrication system is working
Others null
normally.

Table 5-23
Check the charge-air pipes. See “Charge air pipe, checking” on page 5-34
See “Drive belt, replacing (engine option
Replace the drive belt.
VOLVO)” on page 5-36
See “Alternator belt, replacing (engine option
Replace the alternator belt.
VOLVO)” on page 5-37
See “Air filter, checking / changing” on page
Change the air filter.
5-38
See “Draining condensate, fuel system” on
Drain the condensate.
Engine page 5-46
Replace the fuel pre-filter. See “Fuel pre-filter, changing” on page 5-49
Clean the ventilation pipe of crankcase. null
Bleed the fuel system. See “Fuel system, bleeding” on page 5-49
Adjust the valve. null
See “Turbocharger and blast pipe, checking”
Check the turbocharger.
on page 5-59
Change the engine oil. null
See “Transmission oil filter, changing” on page
Replace the transmission oil filter.
5-65
Transmission
Check the speed sensor. See “Speed sensor, checking” on page 5-62
Check and lubricate the propeller shaft. See “Propeller shaft, lubricating” on page 5-63
Drive Axle Replace the brake oil and brake oil filter. See “Brake oil filter, changing” on page 5-70
Check and tighten the bolts. null
Check the steering axle components. null
Steering Axle
See “Steering axle cradle, checking” on page
Check the steering axle cradle.
5-73
Inflate the tyre. See “Tyre, inflating” on page 5-76
Tyre System
Check the rim. See “Rim, checking” on page 5-78
Check the oil pipes and suppor ting
null
bracket.
Hydraulic See “Air filter element, changing” on page
Replace the filter.
System 5-107
See “Oil return filter element, replacing” on
Replace the oil return filter element.
page 5-109
Check the harness of cab steering
null
Electrical mechanism for abnormality.
System Check the cables. See “Battery cables, checking” on page 5-125
Replace the fuses. See “Fuses, changing” on page 5-126

Table 5-24
See “Fu el f il t er, replacing (engine opt ion
Engine Replace the fuel filter. VOLVO)” on page 5-47 and “Fuel filter, replacing
(engine option CUMMINS)” on page 5-48
Replace the transmission oil. See “Transmission oil, changing” on page 5-64
Transmission
Check the manual brake function. null
Change the parking brake pads. See “Parking brake pads, changing” on page 5-69
Check and replace the differential
Drive axle null
oil.
Check and replace the drive axle oil. See “Drive axle oil, changing” on page 5-67
Others Clean the complete machine. null
Table 5-25

Check and repair the oil injection nozzle. null
Check and set the turbocharger. null
Engine
Check and set the supercharger. null
Check and adjust the valve opening. null
See “ B r a ke sys t e m a c c u m ul a t o r,
Check the accumulator.
Hydraulic
Check the volume and pressure of hydraulic motor. null
System
See “Hydraulic oil circuit, checking”
Check the hydraulic oil circuit.
on page 5-115
Check the overload control system and adjust it if
Others null
necessary.

Table 5-26

Engine Clean the radiator. See “Radiator, cleaning” on page 5-55
Transmission Test the transmission oil. null
See “Hydraulic oil tank, cleaning” on page
Clean the oil tank.
Hydraulic 5-110
System Test the pressure from hydraulic system. null
Replace the hydraulic oil. See “Hydraulic oil, changing” on page 5-108
Electrical
Replace the wiper. See “Wiper, replacing” on page 5-128
System
Clean fuel tank for possible impurities null
Others
Test the brake system pressure. null
Table 5-27
Clean and adjust the fuel injection pump. null

Clean and adjust the engine fuel injector. null
Check the water pump. null
S e e “ Fi l l i n g a c o m p l e t e l y e m p t y
Replace the coolant. system” on page 5-53 and “Coolant,
Engine draining” on page 5-54
See “Radiator fan, checking” on page
Check the radiator fan.
5-55
See “Cooling system, cleaning” on
Clean the cooling system.
page 5-56
See “Engine mounting pad, checking”
Check the engine mounting pad.
on page 5-39
See “Wheel rim, installing and
Replace the wheel rim.
removing” on page 5-80
Tyre See “Drive axle tyre, removing and
Replace the drive axle tyre.
System installing” on page 5-82
See “Steering axle tyre, removing and
Replace the steering axle tyre.
installing” on page 5-84
Load
Handling Replace the twistlock. null
System

5.6 Engine
WARNING
WARNING
Always observe the following items to

prevent machine damage, personal injuries
or possibly death.
• Maintenance and service work shall be
performed on a stopped engine if not
otherwise indicated.
• Stop the engine before the engine cover
/ hood is opened or removed.
• Make accidental start-up impossible
by removing the ignition key and
disconnect the power by using the main
switch.

5.6.1 General engine inspection
Get in the habit of giving the engine and

engine compartment a ”visual” inspection
before starting the engine and after operation
when the engine has stopped. This will help
you to quickly realize if something unusual has
happened or is happening.
Check especially for oil, fuel and coolant leaks,
loose screws, worn or loose drive belts, loose
connections or damaged hoses and wires.
The inspection only takes a few minutes but Fig. 5-7 Check Oil Leaking
can mean that serious service interruptions
and costly repairs can be avoided.
DANGER
DANGER
If you discover a leaking of oil, fuel or

coolant, investigate the cause and fix the
fault before you start the engine.
Deposits of fuel, oils and grease on the
engine or in the engine bay are a fire
hazard and must be removed as soon as
they are discovered.
Failure to do so could result in personal
injuries or even death.
5.6.1.1 Charge air pipe, checking
Inspect the condition of the charge air pipe,

pipe connections and clamps for cracks and
other damages. Change them if necessary.
NOTE:
Tighten the clamps with a torque of 9±2Nm
(6.6±1.5lbf.ft.).
Fig. 5-8 Charge Air Pipe

5.6.1.2 Drive belt, checking
Inspections must be carried out af ter

operations, while the belts are hot.
You should be able to depress the alternator
belt and the drive belt about 3-4 mm between
the pulleys. The alternator belts and drive belts
have automatic belt tensioners and do not
need to be adjusted.
Check the condition of the drive belts. Replace

as necessary.
Fig. 5-9 Drive Belt -VOLVO TAD1151
Fig. 5-10 Drive Belt -CUMMINS QSM11

5.6.1.3 Drive belt, replacing (engine option

VOLVO)
1. Disconnect the main switch(es) and check

that the engine is not connected to system
voltage.
2. Remove the fan guard and fan ring round
the cooling fan.
3. Remove the belt guard.
4. Place a 1/2" square wrench in the belt
tensioner (1). Lift the wrench and remove
the drive belt.
5. Thread the drive belt round the fan and
remove it.
6. Check that the pulleys are clean and
undamaged.
7. Thread the new drive belt over the fan.
8. Lift the 1/2" wrench and install the new
drive belt. Fig. 5-11 Replace Drive Belt
9. Install the belt guards.
10. Install the fan guard and fan ring round the
cooling fan.
11. Start the engine and perform a function
check.

5.6.1.4 Alternator belt, replacing (engine

option VOLVO)
NOTE:
Always replace a drive belt that seems worn or
is cracked.
1. Disconnect the main switch(es) and check

that the engine is not connected to system
voltage.
2. Remove the fan guard and fan ring round
the cooling fan.
3. Remove the belt guard.
tensioner (1). Lift the wrench up and lift the
water pump drive belt off.
tensioner (2). Press the wrench down and
remove the alternator belt. Fig. 5-12 Replace Generator Belt
6. Check that the pulleys are clean and
undamaged.
7. Press the 1/2" wrench in the belt tensioner
(2) down and install the new alternator
drive belt.
8. Lift the 1/2" wrench in the belt tensioner (1)
and reinstall the water pump drive belt.
9. Install the belt guards.
10. Install the fan guard and fan ring round the
cooling fan.
11. Start the engine and perform a function
check.

5.6.1.5 Air filter, checking / changing
NOTE:
• T h e m a i nt e n a n c e a n d r e p l a c e m e nt
intervals is just for reference.
• The service life of filter core is 200 working
hours (working in desert) and 1600 working
hours (on clean operation surface).
• Replace the main filter every 800 working
hours.
• Replace the filter at least once a year
under any circumstances. Replace a worn, Fig. 5-13 Air Filter
bent or damaged filter immediately.
The engine is equipped with electronic air filter

indicator. When the indicator (see Fig. 5-13)
turns red as a warning of pressure drop, the
filter element must be checked and possibly
changed. Reset the indicator after replacing
the filter element.
Fig. 5-14 Indicator
If the indicator turns red, clean the filter core in

following steps:
1. Loosen the cover clamp (2).
2. Remove the filter core cover (3).
2
3. Drag out the filter core (1) and clean it
(For detailed information, see: “Air filter,
cleaning” on page 5-39.
NOTE: 1
3
Pay attention not to let dust into the filter seat
(or filter net, if installed) when cleaning the
filter core.
1. Filter core 2. Cover clamp 3. Cover
Fig. 5-15

5.6.1.6 Air filter, cleaning
NOTE:
Before replacing the filter element, be sure
to clean the inside of filter housing. In event
of emergency, the main filter element must
be cleaned and reinstalled. Do not use
compressed air to clean the filter element.
1. Clean the filter element with pressurized

air.
2. Pressurize the air to 3 Bar. Put the nozzle
at 5 cm around the filter element and start Fig. 5-16 Cleaning Air Filter
to clean it from the inner to the outer.
3. Never knock the filter element with the
hard surface of nozzle.
NOTE:
Never clean the filter element for more than 6
times. If done, replace it.
5.6.1.7 Engine mounting pad, checking
Functions of engine mounting pad (1):

• Fix the engine on the frame
• Absorb the shock when the engine is
started, running and stopped.
NOTICE
NOTICE
Silicone oil in the engine mounting pad
would turn solid if it is used for a long time.
Thus the ineffectiveness of the engine 1
TY-1610004-1
mounting pad would occur, and result
in serious engine fault or transmission Fig. 5-17 Engine Mounting Pad
malfunction.
• Check whether there is no silicone oil in

engine mounting pad.
• Check if the engine mounting pad is
shaking.
• Check the depth of engine mounting pad.
• Check if the cover plate of engine mounting
pad is deformed.

5.6.1.7 Diesel water separator filter,

changing
1. Close the fuel pipeline ball valve.

2. Turn the knob(1).
3. Open the cover(2).
4. Replace the filter(3).
Fig. 5-18 Diesel fuel cleaner

5.6.2 Lubrication system
Oil change intervals may vary according to the

lubrication oil grade, fuel sulfur content and
running conditions. The oil change interval
may under certain conditions be increased.
NOTE:
The oil change intervals shall never exceed a
period of 12 months.
5.6.2.1 Oil level, checking and topping up

1
The oil level must be inside the marked area

on the dipstick and must be checked daily
before the first start.
1. Top up with oil via the filler opening (1).
2. Check that the correct level has been
achieved. If the engine is stationary, wait
for a few minutes to allow the oil to run
down into the oil pan.
3. Do not fill above the maximum oil level.
Only use a recommended grade of oil.
4. The oil level is only measured before the
time the ignition is turned on.
Fig. 5-19

5.6.2.2 Engine oil, changing
CAUTION
CAUTION
Hot oil and hot surfaces can cause burns.

Oil changes must be done when the engine
is cool.
1. Connect the drain hose to the oil drain

pump and check that no leaking can occur.
2. Pump the oil out (or remove the bottom
drain nipple and drain the oil).
3. Collect all the old oil and old filters, and
hand them to a re-cycling station for
destruction.
4. Remove the drain hose (or install the
bottom drain nipple). Fig. 5-20
5. Fill with engine oil. For change volume,
refer to “Capacity of the tanks“ on page
5-18.

5.6.2.3 Oil filter / Bypass filter, changing

(engine option VOLVO) 2
CAUTION
CAUTION
Hot oil can cause severe burns.
1. Clean the oil filter housing (2).

2. Remove all oil filters with a suitable oil filter
extractor (1). 4
3. Clean the mating surface of the oil filter
housing. Make sure that no remnants of
old oil seal are left behind. Carefully clean
round the inside of the protective rim on 3
3
the oil filter housing. 1
4. Put a thin layer of engine oil on the seal
rings of the new oil filters.
5. Install the new oil filters (4). Tighten the
two full-flow filters (on the right of the
illustration) 1/2–3/4 of a turn after they Fig. 5-21 Oil Filter and Bypass filters
bottom. Tighten the bypass filter (3) 3/4– 1
turn after it bottoms.
6. Top up with engine oil, start the engine and
let it run for 20-30 seconds.
7. Stop the engine, check the oil level and top
up as required.
8. Check the sealing round the oil filters.
Pay attention to the following points when

replacing the engine oil filter:
Table 5-21 Engine oil Pollution Phenomena
No. Phenomena Causes

Engine oil level Water or coolant enters
1
increase into the lubricating system
Metal particle in Serious damage of engine
2
engine oil parts
The piston ring is worn,
Dramatic engine oil enters into
3 decrease of combustion chamber and
engine oil engine oil leaks from the
connection and edge.

5.6.2.4 Oil filter, changing (engine option

CUMMINS)
CAUTION
CAUTION
Avoid skin contact with the oil, use

protective gloves.
Hot oil may cause burns, rashes and
irritation!
1. Run the engine until warm.

2. Remove the protective plates over the oil
filling point for the engine and transmission.
3. Place a receptacle underneath the engine.
4. Remove the drain nipple on the engine and
drain the engine of oil.
5. Place a receptacle under the oil filters.
6. Clean the area around the oil filters.
Remove the oil filter.
7. Fill the new filter with new engine oil and
1. Shut-off valve
lubricate the O-ring on the filter with engine
2. Coolant filter
oil.
3. Oil filter
8. Fit t he new f ilte r. T i ghten t he f ilte r
Fig. 5-22
according to the instructions on the filter.
9. When the oil has drained, install the oil
plug. Torque with 88 Nm.
10. Fill with engine oil. For change volume,
refer to “Capacity of the tanks“ on page
5-18.
11. Start the engine, let it idle and check that
the drain nipple and filters do not leak.
12. Turn off the engine and check the oil level,
see “Oil level, checking and topping
up” page 5-40. Top up if needed.
13. Remove the receptacle, handle the engine
oil as environmentally hazardous waste.

5.6.3 Fuel system
5.6.3.1 Fuel level, checking
WARNING
WARNING
Do not splash or outflow the fuel. Failure

to do this could result in fire disaster.
If the fuel is splashed out, wipe it away
completely. If the fuel is dripped on ground
or sand, make sure to clean it.
Fuel is flammable and dangerous. Keep the
fuel away from open fire.
Do not weld around the fuel tank and avoid
spark splashing.
1. Turn the ignition switch to position I and

check the fuel level shown on display (1). 0 ℃ SPN 0
After the check, turn the switch back to

1 0.0 L
position O.
0.0 Bar
0 RPM
0 H
0.0 V
Fig. 5-23
2. If the fuel level is low, release the cap of
filling port (see the right illustration) on fuel
tank, and fill in fuel through the filling port
until oil floater reaches its highest point.
NOTE:
For the fuel volume, see: “Capacity of the
tanks” on page 5-18.
RS-1406096-1
Fig. 5-24

5.6.3.2 Draining condensate, fuel system

(engine option VOLVO)
1. Put a collection container under the fuel

filter to collect the condensate and fuel.
2. Open the drain nipple (1) in the base of the
fuel prefilter.
3. Tighten the drain nipple (1) when fuel
without water starts to run out.
5.6.3.3 Draining condensate, fuel system Fig. 5-25

(engine option CUMMINS)
Fuel from the tank line (1) is passed through

the filter, water being denser than fuel, will
sink to the bottom of the filter preventing water
being passed into the fuel injection system 1
through the feed line (2).
2
1. Unscrew the drain nipple (A) in the bottom 3
of the unit by two or three turns.
2. Drain the condensate until clean fuel runs
from the drain nipple.
3. Then retighten the screw by hand pressure
only.
35702_10-05
Fig. 5-26

5.6.3.4 Fuel filter, replacing (engine option

VOLVO)
WARNING
WARNING
●● To avoid the risk of fire due to spilled

fuel on hot surfaces, please change the
fuel filter when the engine is cold.
●● Fire hazard. When carrying out work on
the fuel system make sure the engine
is cold. A fuel spill onto a hot surface
or an electrical component can cause a
fire. Store fuel soaked rags so that they
cannot cause fire.
●● Do not fill the new fuel filter with fuel
before assembly. There is a risk that
dust could get into the system and
cause malfunctions or damage.
Fig. 5-27
1. Clean round the fuel filter.
2. Remove the filter with a suitable filter
remover. Collect any spilled fuel in a
collection container.
3. Clean the filter mating surface on the filter
housing.
4. Lubricate the seal with diesel fuel and
install the new fuel filter. Tighten the fuel
filter in accordance with the instructions on
the fuel filter.
5. Where necessary, bleed the fuel system.
6. If a water trap is installed, change the filter
in it at the same time as the fuel filter, and
clean the water trap in the plastic bowl
under the filter with a soft rag.
NOTICE
NOTICE
Do not fill the new fuel filter with fuel before

assembly. There is a risk that dust could
get into the system and cause malfunctions
or damage.

5.6.3.5 Fuel filter, replacing (engine option

CUMMINS)
WARNING
WARNING
●● Pay attention to the fire hazard when

working on the fuel system.
●● Avoid changing the fuel filter when the
engine is hot. Fuel may spill on hot
surfaces and may ignite.
●● Avoid skin contact with fuel, use gloves.
Fuel on hands may cause rashes and TY-1610011-1
irritation.
Fig. 5-28
1. Place a receptacle under the fuel filter.

2. Clean the area around the fuel filter.
3. Disconnect the wiring from the sensor for
water in fuel.
4. Remove the fuel filter with filter tool.
5. Change the seal by the filter's threaded
connection on the f ilter housing and
lubricate it with engine oil.
6. Fill the new fuel filter with pure fuel.
7. Lubricate the seal on the new fuel pre-filter
with engine oil.
8. Fit the new fuel filter. Tighten the fuel
filter to contact and then another half to
threequarter turn.
9. Turn on the main electrical power and start
the engine. Check that the fuel filter seals
tight.
10. Tu r n o f f t h e e n g i n e a n d r e m o v e
t h e r e c e pt a c l e. H a n d l e t h e f u e l a s
environmentally hazardous and
inflammable waste.

5.6.3.6 Fuel pre-filter, changing
1. Undo the cable from the water trap sensor.

2. Remove the water trap filter from the
filter housing. Collect any spilled fuel in a
collection container.
3. Remove the lower part of the water trap
from the filter.
4. Clean the lower part of the water trap with
a soft rag. Check that the drain hole in the
lower part is not blocked.
5. Install a new seal on the lower part and
lubricate the seal with diesel fuel. Re-
install the lower part of the filter.
6. Lubricate the seal with diesel fuel. Screw
the filter onto the filter housing by hand
until the rubber seal just touches the
mating surface. Then tighten a further half
turn, no more.
7. Connect the cable to the water trap sensor. Fig. 5-29
8. Where necessary, purge the fuel system.
5.6.3.7 Fuel system, bleeding
The system does not need to be bled unless it

has been run completely dry. Purging is then
done with the hand pump on the fuel filter
housing.

5.6.4 Cooling system
The cooling system ensures that the engine

operates at the right temperature. It is a closed
system and must therefore always be filled
with a mixture of at least 40 % concentrated
coolant and 60 % water to prevent interior
corrosion, cavitation and frost rupture.
The coolant should contain ethylene glycol

of a good quality with a suitable chemical
consistency that of fers complete engine
protection. Using an anti-corrosion mixture
exclusively is not permitted in engines. Never
use water only as the coolant.
NOTE:
• Coolant with a suitable chemical formula
must be used all year round. This also
applies in areas where there is a risk
of frost to give the engine full corrosion
protection.
• War rant y c laims on the engine and
ancillaries may be rejected if the incorrect
coolant has been used or if the instructions
concerning coolant mixing have not been
adhered to.
• The anti-corrosive distributors become
less effective in time, which means that
the coolant must be replaced.

5.6.4.1 Coolant, mixing
WARNING
WARNING
All glycol is dangerous to human health

and ecologically damaging. Shall not be
consumed!
Glycol is flammable.
Ethylene glycol should not be mixed with
other types of glycol.
Mix: Fig. 5-30 Mix Coolant

40 % conc. coolant
60 % water
T h i s m i x t u r e p r ote c t s a g a i n s t i nte r n a l
corrosion, cavitation and frost damage down
to -28 °C (Using 60 % glycol lowers the
freezing point to -54 °C.). Never mix more than
60 % concentrate coolant in the cooling liquid,
since this would reduce the cooling effect
and increase the risk of overheating and frost
damage.
NOTE:
• Coolant shall be mixed with pure water
or distilled – de-ionized water. The water
must fulfill the requirements specified by
SANY, see “Water quality” on page 5-51.
• It is extremely important that the correct
concentration of coolant is added to the
system. Mix them in a separate clean
vessel before filling the cooling system.
Make sure that the liquids mix.
NOTE:
VOLVO engine adopts the VOLVO anti-
freezing fluid VCS which does not need to be
mixed.

5.6.4.2 Water quality
Total solid particles ......................... < 340 ppm

Total hardness .................................... < 9.5° dH
Chloride ............................................... < 40 ppm
Sulfate ............................................... < 100 ppm
pH value ................................................. 5.5-9
Silica (acc. to ASTM D859) ..... < 20 mg SiO2/l
Iron (acc. to ASTM D1068) ........... < 0.10 ppm
Manganese (acc. to ASTM D858) ...... < 0.05
ppm
Conductivity (acc. to ASTM D1125) ....< 500
Fig. 5-31 Water
μS/cm
Organic content, CODMn (acc. ISO8467) ......
< 15 mg KMnO4/l
5.6.4.3 Coolant level, checking and topping

up
1
CAUTION
CAUTION
Do not open the coolant filler cap (1) when

the engine is warm. Steam or hot coolant
can squirt out as pressure is released.
Coolant filling must be performed with the

engine stopped. Check the coolant level daily
before starting.
Fig. 5-32 Check Coolant Level
1. Open the filler cap (1).

2. Check that the coolant level is above the
MIN mark on the expansion tank.
3. Top up with coolant as required, so that the
level is between the MIN and MAX marks.
Fill slowly, to allow air to flow out.
NOTE:
Only use the coolant recommended by SANY.
Top up with the same type of coolant as
already used in the system. Different types of
coolant must not be mixed.

5.6.4.4 Filling a completely empty system
NOTE:
Mix the correct amount of coolant in advance, 1
to ensure that the cooling system is completely
filled.
1. Check that all drain points are closed.

2. Open filler cap (1).
3. Fill with coolant, so that the level is
between the MIN and MAX marks. Fill
slowly, to allow air to flow out.
Fig. 5-33 Filler
NOTE:
Do not start the engine until the system is
completely filled and bled.
4. Start the engine when the cooling system

has been completely filled and bled. Open
any bleeding nipples a short while after
starting, to allow trapped air to escape.
5. If a heating unit is connected to the engine
cooling system, the heat control valve
must be opened and the installation vented
during filling.
6. Stop the engine af ter about an hour
and check the coolant level. Top up as
necessary.

5.6.4.5 Coolant, draining
On engines which are to be put in storage, the 1

engine cooling system must be drained.
1. Stop the engine.

2. Remove the filler cap (1).
3. Open all drain points. Drain the coolant
from the radiator and engine block, using
the drain hose. The drain nipples are
situated under the radiator on the right side
of the engine block.
Fig. 5-34 Filler Cap
4. Check that all coolant drains out. Deposits
may be found inside the drain nipple/tap,
and need to be cleared away. There is
always a risk that coolant could remain
and cause damage due to freezing.
5. Check whether the system has any further
taps or plugs at the lowest points of the
cooling water pipes.
6. Shut all taps and check that the spring-
loaded c over s on the nipples c lose
completely. Install the rubber plugs.
CAUTION
CAUTION
Stop the engine before draining the cooling

system and remove the expansion tank
cap.
Do not open the filler cap when the engine
is hot, except in emergencies. Steam or hot
fluid could spray out.
On engines which are to be laid up or put in
storage, the engine cooling system should
not be drained. The coolant contains
corrosion-inhibiting additives.

5.6.4.6 Radiator, cleaning
Clear away the impurities off the surface of

radiator at regular intervals to ensure the
maximum air through engine radiator for the
best cooling effect.
Perform the following steps to clear away the

impurities:
1. Remove the radiator cover.
2. Wipe away all the dirt and dust on the
radiator fins.
3. Clean the radiator with special detergent.
4. Check the radiator fins and rubber sealing Fig. 5-35 Radiator
parts for damage. If necessary, replace it.
NOTICE
NOTICE
Never flush the radiator with high-pressure
water. Or it may be damaged.
5.6.4.7 Radiator fan, checking

1
CAUTION
CAUTION
• Do not start the engine by dragging or

prying the radiator fan.
• Do not rotate the curve shaft when
working on the radiator fan.
• Do not bend the fan blades.
Dam aged or be nt fa n bla des c a n n o t 2
function normally, even resulting in
personal injuries or property loss.
1. Check the radiator fan everyday. Fig. 5-36 Radiator Fan

2. Check if the fan blade (1) is cracked, if the
bolts (2) are secured, and if the blade is
bent or secured.
3. Check the fan and make sure that it is
firmly fitted.
4. If necessary, tighten the bolts (2).

5.6.4.8 Cooling system, cleaning
NOTE:
Never clean the cooling system if there is any
risk of freezing, since the cleaning solution
does not have any frost prevention ability.
Cooling performance is reduced by deposits in

the radiator and cooling galleries. The cooling
system should be flushed when the coolant is
changed.
1. Empty the cooling system. For detailed

information, see: “Coolant, draining” on
page 5-53.
NOTE:
To prevent suspended materials from settling
back in the system, emptying should be done
rapidly within 10 minutes after the engine has
not been stopped. Remove the filler cap and
possibly the lower radiator hose to increase
the speed of draining.
2. Put a hose into the expansion t ank

filling hole and flush with clean water as
specified by SANY until the draining water
is completely clear.
3. If there is still some contamination left after
flushing for a long time, clean the system
with coolant. Alternatively, continue as in
item 8 below.
4. Fill the cooling system with 15 -20 %
mixture of concentrated coolant. Use only
SANY recommended concentrated coolant
mixed with clean water.
NOTE:
It is extremely important that the correct
concentration and volume of coolant is put
in the system. Mix them in a separate clean
vessel before filling the cooling system. Make
sure that the liquids mix.

5. D r ain t he c o o lant af ter 1-2 days of

operation.
6. F l u s h t h e sy s t e m i m m e d i a t e l y a n d
thoroughly with clean hot water to prevent
dirt from settling in the inner areas. Flush
until the water that runs out is completely
clean. Make sure that any heater controls
are set to full heating during emptying.
7. If contamination should still be left after
a long period of flushing, you can do a
clean-out with radiator cleaner, followed
by finishing-off with neutralizer. Otherwise,
continue as in item 8 below.
8. When the cooling system is completely
free from contamination, close the drain
taps and plugs.
9. Fill up with SANY recommended coolant,
following the instructions in the chapters
entitled “Coolant , mixing” on page
5-50 and “Filling a completely empty
system” on page 5-52.
5.6.4.9 Coolant filter, replacing (engine

option CUMMINS)
CAUTION
CAUTION
Ensure that the engine is cool before

working on the cooling system. Danger of
burning or scalding.
1. Switch the valve on the filter head (1) to the

off position.
2. Use a filter wrench (2) to remove the filter
(3).
Fig. 5-37 Coolant Filter
3. Before fitting the new filter clean the filter
head and smear the rubber seal on the
filter with clean engine oil.
4. Screw the new filter on until the rubber
seal is in contact with the filter head then
tighten the filter by a further ½ to ¾ turn.

5.6.5 Air intake and exhaust system
5.6.5.1 Air leaks, checking
1. Check weekly that there is no ruptured

pipe or damaged / loose clamp in the inlet
pipeline.
2. If necessary, replace the damaged pipe
and tighten all loose clamps to ensure that
the air intake system is sealed.
Torque: 8 N.m
3. Check if the inlet pipeline is not corroded, Fig. 5-38 Inlet Pipe
because it will lead to the corrosive
materials and dirt into air intake system.
4. Dismantle if necessary and clean the inlet
pipeline.
Noise can be created due to the air leaking

from below parts:
• C o n n e c t i n g p a r t s b e t w e e n t h e
turbocharger and exhaust air pipe.
1. Check if there are any damages.
2. Tighten all loose clamps. Torque: 8 N.m
• Sealing gaskets between the turbocharger

and exhaust manifold pipe.
1. Change the sealing gaskets.
2. Tighten the V-band clamped screw of air
compressor housing.
NOTICE
NOTICE
Air should be filtered before flowing into

the engine to avoid impurities and scraps
into engine. If the inlet pipe is damaged or
loose, dirty unfiltered air would enter into
the engine and lead to early wear or failure
of engine.

5.6.5.2 Turbocharger and blast pipe,

checking
Before starting the engine, check if there is

leaking of oil pipes in the turbocharger and of
all the blast pipe connectors. If so, replace all
the damaged sealing ring, connecting pipes
and couplings where the leaking occurs. If
the ventilation hole in crankcase is blocked,
increasing pressure will lead to the entrance
of oil into the air-intake system of turbocharger
and engine.
Fig. 5-39
Turbocharger, checking:
1. Tighten the mounting nut of turbocharger.
Torque: 61 N.m
2. Check if there is any air leaking in sealing
surface of turbocharger housing. If so,
tighten the V-band clamped nut.
Torque: 9 N.m
3. Check if there is any air leaking in sealing
surface of air compressor housing. If so,
tighten the V-band clamped nut.
Torque: 9 N.m
Check the turbocharger every 6000 hours:

1. Remove the inlet and exhaust pipe, and
then check the turbocharger.
2. Check if there are any damage or rupture
in the air compressor or turbine blades.
3. Check if the king pin of turbocharger can
rotate freely.
4. If any problem occurs, please contact
SANY to repair it.

5.6.6 Urea filter element, changing
1. Use a 27mm spanner to unscrew the urea

filter cover (1).
2. Take out the filter balance tube (2). 3
3. Take out the used filter element(3) and plug 2
the new one into the urea supply module. 1
4. Tighten up the filter cover again after
changing the filter element with a torque of
20 n.m [177 in-lb].
Notes: Its change interval is 4500h or 3 years.
NOTE:
Fig. 5-40
1. Check if the inner screw thread of filter
cover is damaged when changing the filter
element. If so, replace it with a new filter
cover.
2. It is unnecessary to seal the urea filter
cover with O-rings.
3. Change the urea filter element every 4500
hours.
CAUTION
CAUTION
Never let the urea inject into your eyes,

otherwise you may get you hurt. In this
case, rinse your eyes with water for 15
minutes.

5.7 Transmission
5.7.1 Gearbox, function description
Gearbox converts the engine power to drive

axle via the propeller shaft and also the power
to drive hydraulic oil pumps for hydraulic
system and brake system.
The gearbox is fully automatic with torque

converter. It has four forward gears and four
reverse gears.
NOTICE
NOTICE
High modulation (that is, soft operation /

intensive slipping between gear positions)
results in high gearbox wear and high oil
temperature.
NOTE:
• The sensor for oil temperature generates
a warning when the oil gets warmer than
100 °C.
• If the oil temperature sensor indicates 125
°C, the gearbox declutches.
5.7.2 Mounting bolts of propeller shaft,

checking
Loose bolts will easily rupture under load and

vibration. Fixed bolts of propeller shaft should
be checked carefully before torque force is
transmitted.
1. Check if the mounting bolts of propeller

shaft are secured;
TY-1405119-1
Fig. 5-41 Mounting bolts of Propeller shaft

2. Check if the universal joint bearing is in

good condition;
3. Tighten the loose bolts of propeller shaft

with a torque of 75 N.m.
TY-1405120-1
Fig. 5-42 Universal Joint
5.7.3 Speed sensor, checking
Speed sensor is located at the connecting

parts between gearbox and propeller shaft (2).
Check if the speed sensor (1) or its bearing
is not damaged to ensure that speed signals
of the machine can be transmitted to relative
control system exactly. Thus, drive can be 1
carried out only in low speed, and transmission 2
device can be protected.
Fig. 5-43 Speed Sensor

5.7.4 Mounting bolts and mounting pad,
checking
Functions of mounting pad and damping pad:

• Fix the transmission on the frame;
• Absorb the shock in the start, operation,
and stop of transmission.
Check:
• if damage exists on mounting pad (2) and 2
damping pad (1);
• if bolts are tight. 1
Fig. 5-44 Mounting bolts and Mounting Pad

5.7.5 Propeller shaft, lubricating
1. Inject the grease into lubrication points (see

arrow in Fig. 5-44) with manual lubrication
gun (not with high pressure lubrication
gun).
2. S to p inj e c t ing grease i f t he grease
squeezes out.
NOTE:
Manually lubricate the propeller shaft even
if the machine is equipped with a central Fig. 5-45
lubrication system.
DANGER
DANGER
Always turn off the engine before operating

the propeller shaft.
Never touch the running propeller shaft, or
serious injuries or even death could occur.
Fig. 5-46
5.7.6 TE Transmission calibration
Apart from calibrating the analog input signals,

the TCON.H f ir mware also c ontains an
automatic transmission calibration procedure,
which is able to optimize the shift quality of the
transmission. An automatic calibration has to
be done:
• When the machine is built at the OEM
• When an overhaul of the transmission is
done
• When the transmission is repaired
• When the TCON.H is replaced
• Recommended after each 2000 hours
d r i v i n g i n g e a r (f o r wa r d o r r eve r s e
selected)

5.7.7 Transmission oil, changing
1. Let the engine run idle.

2. Check the transmission oil level. For
detailed information, see: “Transmission
oil level, checking” on page 5- 64. If
necessary, fill transmission oil through the
oil filler (1).
NOTE:
Wipe off the dipstick before checking.
The oil dipstick is long. Use gloves.
NOTE: 1
Make sure that the drain nipple’s washer seal
is removed. Place a container under the drain
nipple to receive the drained oil. Fig. 5-47 Change Transmission oil 1
3. R e m o v e t h e d r a i n n i p p l e ( 2 ) f o r
transmission oil and let the oil drain into
the container.
4. Check the transmission oil prefilter (3).
If the filter core is damaged, replace it
immediately.
5. When the transmission oil has drained,
fit the drain nipple (2). Make sure that the
washer for the oil plug is included.
6. Remove the gearbox dipstick and fill new 3
transmission oil through the dipstick’s hole
to the correct level.
2
7. Turn on the main electric power and start
the engine. Let the engine run idle for at
Fig. 5-48 Change Transmission oil 2
least two minutes.
8. Check the transmission oil level with the
engine running at idle and top up to the
marking for correct level.
9. Check the drain nipple’s sealing.
10. Operate and warm up the gearbox until the
operating menu shows oil temperatures
between 60-65 ℃ .
11. Let t h e e n g i n e r u n i d l e. C h e c k t h e
transmission oil level.

5.7.8 Transmission oil level, checking
The oil level must be maintained between the

H and L markings. The oil level should be at
the H marking.
1. Check the oil level with the engine at
idle, gearbox in neutral position and at
operating temperature (approx. 60-65 °C).
2. Fill transmission oil if needed.
3. I t i s r e c o m m e n d e d t h a t t h e o i l b e
filled when the gearbox is at operating
temperature. Fill----wait a moment----
Fig. 5-49 Check Transmission oil Level
check the oil level with dipstick.
NOTICE
NOTICE
Work carefully when filling transmission

oil to prevent other fluids or particles from
contaminating the oil, which means risk of
gearbox damage.
5.7.9 Transmission oil filter, changing

NOTE:
The gearbox does not need to be emptied of
oil before the filter is changed.
If the transmission oil is to be changed,
change the transmission oil before starting the
engine.
1. Park the machine in service position.

2. Remove the oil filter with the filter tool.
3. Lubricate the O-ring on the new oil filter
with transmission oil.
4. Install the new filter on the gearbox.
Tighten to contact and then another 2 / 3
turn.
5. Turn on the main electric power and start Fig. 5-50 Transmission oil Filter
the engine. Let the engine run at idle.
6. Check the transmission oil filter’s sealing.
7. Check the transmission oil level, see
“Transmission oil level, checking” on
page 5-64.

5.8 Drive Axle
5.8.1 Mounting bolts of drive axle to the

frame, checking
Check the drive axle’s attachment to the frame

so that there is no corrosion of structural
elements (e.g. mounting bolts).
• Loose bolts tend to rupture shen machine
is loaded and vibrating.
• Ruptured mounting bolts will lead to 2
serious damage to machine, or even 1
personal injuries.
• Tighten the mounting bolts (2) with 1600 Fig. 5-51 Mounting bolts of Drive Axle to the
N.m (oiled bolt). Frame
5.8.2 Mounting bolts of drive axle to the

propeller shaft, checking
Tighten the mounting bolt (3) with 75 N.m (oiled

bolt).
Fig. 5-52 Mounting bolts of Drive Axle to the

Propeller shaft
5.8.3 Oil leaking of drive axle and brake
components, checking
Check the oil-immersion disc brake and its

connecting pipe, parking brake system and its
connecting pipe, reducer, driving wheel and
driving axle for oil leaking.

5.8.4 Drive axle oil, changing
NOTICE
NOTICE
1
Dirt and impurities in the drive axle oil can
cause breakdown. Pay particular attention
to cleanliness when working on the drive
axle.
1. Place the machine in position so that the

2
hub’s drain nipple (2) is at the lowest point
vertically.
NOTE:
This applies to both drive wheels.
• Wheel 1: move forward or backward to Fig. 5-53 Filler Plug and Drain nipple
obtain the correct position.
• Wheel 2: lift the wheel from the ground
(raise the machine under the drive axle)
and rotate the wheel into the correct
position.
2. Place a drainage receptacle at every hub.

Place a piece of sheet metal or similar in
the wheel to lead the oil to the receptacle.
3. Remove the hubs’ drain nipples on both
sides. Also remove the hub lever and filter
plugs to facilitate draining. Both sides shall
be drained separately.
4. Remove the differential’s drain nipple. Also
remove the differential lever and filter plugs
to facilitate draining.
5. Clean the drive axle’s breather while the oil
is draining.
6. Install the drain nipples on the hubs and
the differential.
7. Fill oil until the oil level is at level with the
filter and lever holes.
8. Install the hub lever and filler plug (1) on
the differential.
9. Fill oil in the differential until the oil is

flushed with the filter and lever holes.

10. Install the lever and filter plug on the
differential.
11. Turn on the main electric power.
12. Check the sealing and the oil level in the
drive axle after a short test-drive.
NOTE:
Make sure that the seals are in place.
NOTE:
The oil is of high visocity and filling should be
slow. Level check should be done in stages so
that the oil has time to distribute itself.
5.8.5 Breather, cleaning
Clean the breather to release pressure from

the drive axle. If the pressure is too high in the
drive axle, there is a possibility of oil leaking in
fragile parts, like oil seal.
Fig. 5-54 Breather

5.8.6 Brake pedal, checking and

adjusting
1. Clean the floor around brake pedal and

check that nothing restricts the movement
of brake pedal.
2. Check that the brake pedal springs return
adequately and that the clearance between
brake pedal and brake valve is 1-1.5 mm. If
needed, adjust the stop bolt of brake pedal
to correct the clearance. TY-1407020-1
3. Check that the pedal’s travel is smooth.
Fig. 5-55 Brake Hinge
4. Grease the pedal hinges with grease.
5. Check that the rubber on the pedal is intact
and that the tread pattern isn’t worn out.
Change it if necessary.
5.8.7 Parking brake pads, changing

2. Remove the cover from the brake caliper.
3. Loosen the lock nut.
4. Loosen the adjusting screw so that the
brake pads become loose.
5. Remove the split pin and loosen the nut
on the mounting bolt holding the parking
brake caliper.
6. Pull out the mounting bolt so that the brake
pads can be twisted out and removed.
Fig. 5-56 Parking Brake Pads

NOTE:
The bolt does not have to be removed.
7. Remove the parking brake pads.

8. Clean the brake disc with methylated spirit.
9. Fit the new parking brake pads.
10. Press back the mounting bolt.
11. Fit the nut and fit a new split pin.
12. Adjust the parking brake.

5.8.8 Brake oil filter, changing
NOTE:
The filter protects the brake system from
impur ities. It is ver y impor t ant that no
impurities enter the brake system when
changing the filter.

2. Depressurize the hydraulic and brake
system.
DGH-1703002-1
NOTE: Fig. 5-57 Brake Oil Filter

Leave the valves open when changing.
3. Remove the drain nipple on the underside

of the filter. Let the oil drain. Wait a while
as the oil drains slowly.
4. Remove the filter housing.
NOTE:
The filter housing is heavy. Loosen it carefully.
5. Remove the filter insert.
NOTE:
Note the position of O-rings.
6. Clean the filter housing.

7. Fit the O-rings on the filter cartridge and
filter housing. Lubricate the O-rings with
hydraulic oil.
8. Fit the new filter insert to the filter housing.
9. Fit the filter housing and the drain nipple.
10. Close the valves that were opened to
release the pressure in the hydraulic
system.
11. Start the engine and check that the filter
housing does not leak.

5.9 Steering Axle
5.9.1 Daily check
3 4
5
6 1
1. Steering axle beam 4. Link arm

2. End cover of king pin 5. Interlocking mechanism
3. Steering cylinder 6. Stub axle
Fig. 5-58 Main Components of Steering Axle
1. Check the wear condition of king pin (2).

Inject with grease every 50 hours.
2. Check steering cylinder (3) for leaking.
Check piston rod for deformation. Replace
or repair damaged parts.
3. Check whether the link arm (4) is worn. If
worn, it must be replaced immediately.
4. Check whether the steering joints of
interlocking mechanism (5) can rotate
smoothly. Lubricate onto the connecting
pin shafts at both ends every 50 hours.
5. If the machine has driven for a long
distance with insufficient tyre pressure,
stop the machine immediately, and remove
the wheels. Then check the condition of
stub axle (6).

5.9.2 Steering axle, lubricating
1. Clean the grease nipple.

2. Use the grease gun to lubricate into the
nipple until grease pushes out.
3. Clear the redundant grease. Lubricate
the lubrication points after scraping the
remained grease on sliding surface.
4. Smear grease on the lubrication point.
Fig. 5-59 Lubricate Steering Axle
5.9.3 Stub axle, maintaining
1. Remove the hub cover (1).

2. Check the stub axle (2) for deformation,
fatigue and damage as early as possible;
replace it with a new one if there is
damage.
3. If the hub bearing (3) is loose, adjust
the hub nut (4) to adjust its clearance.
Per for m c or rect pre - load set ting, to
prevent accelerated the damages of other
components.
4. Lubricate through the grease nipple (5) to
lubricate the king pin (6) until it is difficult to
inject further.
Fig. 5-60 Stub Axle

5.9.4 Steering axle cradle, checking

2. Check that the bushings in the suspension
are intact.
3. Measure the distance between the frame
and the steering axle cradle. Note down
the measurement.
4. L i f t t h e m a c h i n e u n d e r t h e r e a r
counterweight.
NOTE:
Do not lift under the steering axle. Fig. 5-61 Take the Measurement
5. Re-measure the distance between the

frame and the steering axle cradle. Note
the measurement.
6. Calculate the difference between the two
measurements. The difference must not
be more than 3 mm.
5.9.5 Steering pressure, checking
1. Operate and warm up the machine so

that the oil in the brake system reaches
operating temperature (at least 50°C).
3. Connect a pressure gauge (0-25 MPa) to
the measuring exhaust on the hydraulic oil
pump for steering and load handling.
4. Start the engine and increase engine
speed to approx. 1200 rpm.
5. Turn the steering wheel fully and read
pump pressure during the steering wheel
movement. Compare this to the steering
pressure on the hydraulic plate.
6. Turn the ignition key to position 0 and turn
off the main electric power.
7. Remove the pressure gauge and fit the
protective cap on the measuring exhaust.

5.10 Tyres and rims
As an important component of wheel vehicles,

tyre technology decide the performances
of traction, transition, smoothness, safety,
comfor t, and economy. Do remember to
maintain and change the tyre according to this
technical guide.
WARNING
WARNING
Fitting and changing of tyre for reach

stacker is extremely dangerous. At least
two professional technicians are needed,
and high alert is required during the work.
Failure to do this could result in injury or

possibly death.
5.10.1 Tyre, description
Tyres are the points of contact between the

machine and the ground, and they absorb
unevennesses and provide suspension.
Generally, specification of tyres in C and F
type reach stacker is 18.00-25-40PR-E-4J.
NOTE:
Tyre specification of special reach stackers:
Heavyweight container handler
(SRSC4535H1): 18.00-33 36PR E-4J
Heavyweight container handler (SRSC4545C2

Fig. 5-62 Tyre
/ SRSC4545H1 / SRSC4540H2-70): 21.00-35-
36PR E-4 no inner tube
Empty container handler (SRSC1009- 6E/

SRSC1009H5-6E/SRSC0808-6EH): 14.00-24-
28PR E-3
Lightweight container handler (SRSC3615-3):

16.00-25-32PR-E-3J

CAUTION
CAUTION
Type of the tyre should be the same or

have the same performance of the original
tyre. Unmatched tyre and wheel rim will
cause damage to the tyre lip, or explosion
of the tyre and personal injuries.
NOTE:
Tyres on the same axle should be of the same
brand, type, structure, and wear. The wear
limit of tyres should be the same to ensure the
identical outer radius. Tyre should be replaced
when the tread at 1/4 of the tyre edge is worn
to a depth of 2-3 mm.
NOTE:
Before starting the machine, check if crack,
corrosion, excessive or uneven wear exists
on the tyre surface. Replace tyres that are
seriously worn in time. Check and clean
impurities such as glass from the tyre. Check
the air pressure of tyre, and charge air in
time when the pressure is low, because low
pressure reduces stability and load capacity of
the overall machine.
DANGER
DANGER
Stop the machine when the tyre

temperature is too high. Park the machine
in a cool place to let it cool down. Never
discharge the air to release pressure or
splash water on the tyre to cool it down,
for these could cause tyre explosion and
personal injuries.
Replace the tyre timorously when it

reaches it max. wear limit. Otherwise, tyre
explosion and personal injuries or even
death can occur.

5.10.2 Tyre, inflating
Always follow the instructions for inflating tyres

to avoid the risk of accidents.
• Only use approved rim components.
• If the tyre has been completely deflated,
the tyre must be dismantled and the rim
checked for damage.
• Never install rim components by striking
with a hammer during inflating. Never
strike fully or partly inflated tyres or rim
assemblies.
Fig. 5-63 Inflate the Tyre
• Never inflate tyres before all parts are in
place.
• Wheels shall be inflated on the machine
or in a protective device, designed and
dimensioned so that it can handle or
dissipate a shoc k wave f rom a t yre
explosion as well as catch the ejected
parts.
• Do not exceed prescribed tyre pressure
that is to be checked at ambient
temperature.
• Never stand directly opposite the tyre
when deflating or inflating. The lock ring
and retainer ring may release and shoot off
when the pressure changes.
• Check that all parts are in place when the
tyre pressure is 0.95-1.05 Mpa.
Steps to inflate the tyre:

1. Make sure that the lock ring and retainer
ring are in the correct position before
inflating.
2. Connect the compressor with the air valve
of tyre.
3. Stand to the side of the tyre while the
inflation is in progress.
4. Inflate the tyre to the prescribed level of
0.95-1.05 Mpa.
Other tyre pressure may apply when changing
tyre or rim version, contact SANY.

5.10.3 Tyres, checking
• Check for uneven and accelerated wear

which is caused by mechanical problems
such as uneven brake action. Make sure
that such malfunctions are attended to
immediately.
• Remove penetrating objects such as
crushed glass, wood pieces, metal fillings,
etc.
If the tyre is damaged, dismantle the wheel

and change the tyre in time.
If the tyres have no defects, check and tighten

the wheel nuts with a torque of 650 N.m (oiled
bolt).
5.10.4 Wheel rim, description
W heel r im f its direc tly on hub, and its

dimensions must be the same to that of the 6
hub. Only use the wheel rim that is approved
by SANY. 5
4
Our reach stacker applies five-element-type
wheel rim with no spoke. The wheel rim is
composed of wheel rim body, retainer ring,
seat ring, and lock ring.
1. Retainer ring 4. Retainer ring

2. Wheel rim 5. Seat ring
3. Tyre 6. Lock ring
Fig. 5-64 Wheel Rim

5.10.5 Rim, checking
Perform the following checks to minimize the

risk of accidents for all split rims.
• Always use the correct tyre dimension and
design corresponding to the manufacturer’s
rim type and dimension. Oversize tyres
may not be used.
• Replace all damaged, worn or corroded
rims or mounting parts.
• Check the rim in connection with tyre
change or once a year.
1. Dismantle the rim.

2. Carefully clean the outside of the rim edge
with a steel brush.
3. Measure the wear condition of lock ring.
• The lock ring’s wearing on the tyre bead
often results in a mark A in the figure. The
mark shows up between the lock ring’s
ends.
• Measure the depth of this wearing with a
steel ruler and sliding gauge. If the wear A
exceeds 0.5 mm, scrap the rim, lock ring
and the tapered rim course and replace Max 0.5 mm
them with new parts when necessary.
Fig. 5-65 Measure Wear

4. Check the rim’s diameter.
• Measure the rim edge’s circumference (O)
with a measuring tape and calculate the
diameter (D). (D=O/3.14)
• Compare the value of the diameter with
the specified min. measurement. If the D
O
diameter is smaller, the rim, lock ring and
the tapered rim course be discarded and
replaced with new parts.
O. Circumference D. Diameter
Fig. 5-66

5. Check for damage in the areas with high

stress concentration. Checking is done in
two steps:
• The magnetic particle method is used to
determine if there’s a crack or not, and
where it is.
• Confirmed cracks are investigated further
with penetrating fluid.
• Typical rim damages are circumference
cracks, corrosive damage, rust, warping
and wear.

5.10.6 Wheel rim, installing and

removing
5.10.6.1 Wheel rim, installing 6
5
1. Follow the procedures indicated by the
arrowhead in Fig. 5-66 to mount the tyre. 4
2. L ay t h e w h e e l r i m (2) ve r t i c a l l y o n
the ground with a 100 mm high block
underlaying. Put the retainer ring (1) in
wheel rim. Then fit valve core and ensure
that it is closely connected with wheel rim.
3. Put the tyre (3) in wheel rim with a lifting
device such as a traveling vehicle. Put an 3
O-ring in the wheel rim. Put the retainer
ring (4) inside the tyre, and knock the seat
ring (5) into space between wheel rim and 2
retainer ring. Then knock the lock ring (6)
1
into space between wheel rim and shelter
ring, and lock the tyre ring.
Fig. 5-67 Wheel Rim
NOTE:
When knocking the seat ring (5) and lock ring
(6), equalize the force around the ring rather
than knock only at one place. Check if retainer
ring seat laps over with the whole 45° surface
of lock ring. If not, mount the rim again.
WARNING
WARNING
• If any crack or deformation exists in

relative parts of wheel rim, replace the
part immediately.
• Welding cannot be used as repair if the
wheel rim is damaged.
Failure to follow the above instructions

5.10.6.2 Wheel rim, removing
CAUTION
CAUTION
Be sure to work according to the correct 1

procedure while installing or removing the
tyre from rim. If the sequence is wrong, the
tyre may rupture and thus lead to personal
injury.
2
NOTE:
If the personnel has insufficient experience, or
the appropriate tools for work are not enough,
do not install or remove the tyre. Under such
circumstances, contact the authorized and
professional personnel related to tyres to deal
with the tyre.
3
Wheels can be disassembled horizontally and

vertically. Before disassembly, take down the
valve core and let all the air out.
1. Take down the tyre ring on the side of

wheel rim gutter with correct tools. Be
careful not to damage the tyre ring (1).
2. Take down the lock ring with correct tools 4
(2).
3. Take down the O-ring and diacard it (3).
4. Take down the seat ring of tyre ring (4).
5. Take down the rim from wheel rim seat.
Loosen the rear tyre ring and take down
the shoe from wheel rim (5).
Fig. 5-68 Remove the Wheel Rim

5.10.7 Drive axle tyre, removing and

installing
Most load of the machine is on drive axle, and

the tyre pressure may increase under different
working conditions. When the machine is
lifting containers, drive axle loads almost total
weight of the machine.
WARNING
WARNING
Discharge the air before replacing tyre. If

the valve core is blocked, use a saw blade
to saw a notch with a depth of about 1/3 of
the diameter.
In replacing, always lay blocks under the
steering axle before lifting the drive axle,
otherwise personal injuries will be caused
by unexpected move of the machine.
Failure to follow this could result in injury
or possibly death.
5.10.7.1 Drive axle tyre, removing
1. Put two jacks of 20t under the drive axle.

They should be placed symmetrically
around the centerline of frame, with their
centers 1.6m away from each other. After
all the positions have been checked to be
right, lift the drive axle until the tyres are
50mm clear from the ground.
2. Screw out the air valve cover and turn it
round. Insert the cover in the air valve and
turn it for 2-3 circles after it sticks to the
valve core. Then discharge air of the inner
and outer tyres. Fig. 5-69 Drive Axle Tyre
3. Loosen all nuts symmetrically.
4. Remove all nuts except three proportionally
spaced ones.
5. Support the outer tyre with a forklift or

other reliable lifting devices.

6. Remove the rest three nuts and displace
the outer tyre (1).
7. Take down the spacer ring (3) between 1
tyres. 3
8. Displace inner tyre (5) safely with a forklift
2
or other lifting device.
4
5
Fig. 5-70
5.10.7.2 Drive axle tyre, installing
1. Remove the dust and impurities on hub

surface and in inner ring of wheel rim.
2. Fit the inner tyre (5) to drive axle with a
forklift or other lifting devices, with the lock
ring outwardly.
3. Fit the spacer ring (3).
4. Fit the outer tyre (1) to drive axle with a
forklift or other lifting devices, with the lock
ring inwardly.
5. Fit the open end thimble (4).
6. Fit the pressure plate (2) symmetrically and
tighten the nuts with a torque of 430 - 460
N.m.
7. Rotate the tyre for several circles and
ensure that swing range at the max. radius
do not exceed 3 mm.
8. Char g e t h e t y re w it h a p re s sure of
0.95~1.05MPa.
9. During 200 hours after the machine is
started for the first time or the new tyre
is replaced, be sure to re-torque the hub
screw every 50 hours.

5.10.8 Steering axle tyre, removing and

installing
WARNING
WARNING
Discharge the tyre before replacing. Failure

to follow this could result in injury or pos-
sibly death.
NOTE:
If the valve core is blocked, use a saw blade
to saw a notch with a depth of about 1/3 of the
diameter.
5.10.8.1 Steering axle tyre, removing

1. Put two jacks of 20t under the steering
axle. They should be placed symmetrically
around the centerline of frame, with their
centers 1.4m away from each other. After
all the positions have been checked to be
right, lift the drive axle until the tyres are
50mm clear from the ground.
2. Rotate the tyres to make nozzle jets
upwards. Discharge the tyres.
3. Remove nuts of shor t pressure plate
interlacedly and symmetrically, and take
out the short pressure plate.
4. Loosen the nuts of long pressure plate for
2-3 circles with a torque spanner.
5. Check if crack exists in wheel rim, shelter
ring, or lock ring. Fig. 5-71 Remove the Steering Axle Tyre
6. Lift the tyre with a forklift or other lifting
device.
7. R e m o v e t h e l o n g p r e s s u r e p l a t e
symmetrically.
8. Displace tyres with a forklift or other lifting
device.
NOTE:
If serious crack exists in shelter ring or lock
ring, first knock the wheel rim to discharge
force of the cracked shelter ring or lock ring
under the retaining of long pressure plate, then
take down the long pressure plate.

5.10.8.2 Steering axle tyre, installing
1. Remove the dust and impurities on hub

surface and in inner ring of wheel rim.
2. Fit the tyre to steering axle with a forklift
or other lifting devices, with the lock ring
outwardly.
3. Fit the long pressure plate symmetrically
and tighten the nuts with a torque of 550
N.m. (The tightening torque for SRSC1009-
6E / SRSC1009H5-6E/SRSC0808-6EH is
600 N.m.)
4. Fit the short pressure plate symmetrically Fig. 5-72 Steering Axle Tyre
in group and tighten the nuts with a
torque of 550 N.m. (The tightening torque
for SRSC1009-6E / SRSC1009H5-6E/
SRSC0808-6EH is 600 N.m.)
5. Rotate the tyre for several circles and
ensure that swing range at the max. radius
do not exceed 3mm.
6. Char g e t h e t y re w it h a p re s sure of
0.95~1.05MPa.
7. Within 200 hours after the initial operation
or tyre replacement, the nuts of hub should
be secured once per 50 hours.
NOTE:
A group consists of a long pressure plate and
two short pressure plates.

5.11 Boom
Boom system of reach stacker is composed

of basic arm (1), pitching cylinder (2), drag
chain (3), telescopic cylinder (4), wear pad (5),
telescopic arm (6), etc.
4 1 2 3 5 6
Fig. 5-73 Boom
Its function is to adjust the pitching angle of

boom by telescoping pitching cylinder, and to
adjust the extending length of telescopic boom
by telescoping oil cylinder, so as to realize
the lifting operation for container at different
positions through combination of both above
actions.

5.11.1 Basic boom, checking
Check if the mounting pad and pin shaft on

basic boom are secured or worn
The mounting pad and pin shaft on the basic

boom are the main components coupling the
frame and spreader. The structure and welding
of mounting pad, pin shaft, pin-hole bearing
and mounting bolts should be periodically
checked. If needed, conduct dye check.
Fig. 5-74 Check of Boom
Visually check for crack
Boom is an important element to directly lift

the container. The stability of its structure
directly influences the reliability and safety of
this machine. Frequently check the important
components to find the crack on spreader
timely and take appropriate actions. By doing
this, the further abrasion can be avoided.
Fig. 5-75 Crack of Boom

5.11.2 Wear pads, checking
• Fully retract the boom and lower it to its

lowest position.
• Check the abrasion of side-mounted wear

pads at the rear end of telescopic arm.
1. The min. thickness of wear pads is 25mm.
Replace it if necessary.
2. Adjust the clearance between telescopic
arm and sliding block. The clearance of
one side should be 2-3mm. Smear grease
on the friction surface of wear pads and
the corresponding sliding groove on the
boom.
• Check the abrasion of upper wear pads at

the rear end of telescopic arm.
2. Smear grease on the friction surface of
wear pads and the corresponding sliding
groove on the boom.
• Check the abrasion of upper and lower

wear pads at the front end of fixed arm.
Fig. 5-76 Sliding Block
2. Smear grease on the friction surface of
wear pads and the corresponding sliding
groove on the boom.
• Check the abrasion of side-mounted wear

pads at the front end of fixed arm.
2. Adjust the clearance between fixed arm
and sliding block. The clearance of one
side should be 2-3mm. Smear grease on
the friction surface of wear pads and the
corresponding sliding groove on the boom.

5.11.3 Wear pads of the fixed arm,

replacing
Replace every 1500 work hours, proceeding

as follows (see Fig. 5-76):
1. Rest the arm with spreader on a container,

without raising the load.
2. Loosen the screws (1 and 2) and remove
the wear pad support (3).
4
3. Loosen the lock nuts (4) and remove the
worn wear pads.
4. Before fitting the new sliding block, make
sure there is no dirt in the housing that 1
could impair the perfect alignment of the 2
3
wear pad itself.
5. Correctly position the wear pad and tighten Fig. 5-77 Wear pad of Fixed Arm
the screws.
5.11.4 Wear pads of the telescopic arm,

replacing
Replace every 1500 work hours, proceeding

as follows (see Fig. 5-77):
1. Rest the arm with spreader on a container,

without raising the load.
2. Loosen the screws (1 and 2) and remove
the wear pad support (3).
3. Loosen the lock nuts (4) and remove the
worn wear pads.
4. Before fitting the new sliding block, make
sure there is no dirt in the housing that
could impair the perfect alignment of the
wear pad itself.
5. Correctly position the wear pad and tighten
the screws.
6. The wear of side wear pads (5) is less than
that of the upper and lower wear pads. It is
nonetheless best to replace them.
7. After replacement, grease the wear pads

as previously described, pull out the arm

and apply a slight film of grease on the
surfaces indicated in the illustration below.
4
3
1
5 2
3
Fig. 5-78 Wear pad of Telescopic Arm

5.11.5 Pitching cylinder, checking
Check the attaching seat and pin shaft on the

pitching cylinder.
Check the adjacent area of mounting pad for
crack. If needed, conduct dye check.
Fig. 5-79 Pitching Cylinder
5.11.6 Cylinder piston rod, maintaining
Perform the following maintenance during

transporting, installing and operating the
cylinder piston rod:
• After coating or assembling the cylinder,
seal the exposed section of piston rod with
anti-rust oil or grease to prevent corrison.
• During the long transportation or ocean
shipping, seal and pack the exposed
section of piston rod with anti-rust oil or
hydraulic oil.
• If the machine installed with cylinder will be
parked for more than half month, coat the
exposed section of piston rod with antirust
oil or hydraulic oil. Besides, check and
maintain the cylinder weekly.
• When operating the machine, keep the
surface of piston rod clean. Clear the
piston rod off mud or dust. Pay attention
not to bump, cut or damage the piston rod.

5.12 Spreader
5.12.1 Container spreader
1. Slewing table assembly 4. Sideshift mechanism

2. Hydraulic system 5. Cross beam assembly
3. Twistlock mechanism
Fig. 5-80 Spreader
5.12.1.1 Twistlock, checking
• Check if the t wistlock (1) is in good

condition. Replace it when needed.
• Check if the coupling rod (2) of twistlock is
located correctly and stably.
• Check if all sensors are secured. Adjust
the tightness when needed. 2
Fig. 5-81 Twistlock and Coupling Rod

5.12.1.2 Twistlock, lubricating
Spreader is an impor tant par t for lif ting

containers. Lubricating the twistlock can
reduce its wear and extend its service life.
Fill lubricants in oil filler (3) every 200 hours.
If the twistlock is seriously worn, i.e. horizontal

cross section dimension is less than 25mm,
replace the t wistlock; it also should be 3
replaced after being used for more than 5000
hours.
Fig. 5-82 Oil Filler of Twistlock
NOTE:
It is very important to check the twistlocks and
related components, as they can facilitate the
lifting of container.
5.12.1.3 Sensor / Indicator of twistlock,

checking
Check:
• if the sensor (4) and its wiring are good.
• if all sensors (4) are secured properly or
damaged.
• if the clearance between sensor and wear 4
pad is normal.
• if the indicator can work normally.
Fig. 5-83 Twistlock Sensor

5.12.1.4 Fixed bolts of spreader rotating

gearbox, checking
To avoid the rupture of loose bolts, damage of

components and unmanagement of spreader
rotation, make sure to check the par ts
fastened by fixed bolts at regular intervals.
Components of rotating motor are composed

of hydraulic motor, disc brake and planet gear.
They are all connected by fixed bolts.
Hydraulic motor, above the disc brake, Fig. 5-84 Fixed Bolts of Spreader
provides power for rotating. Disc brake is used
to avoid accidental rotation. Release the brake
while the hydraulic motor is rotating, and the
planet gear of spreader is driven to rotate.
Thus strengthen the output of motor and disc
brake.
5.12.1.5 Wear pads of spreader, checking
There are two types of wear pad on spreader:

sideshift wear pad and telescopic wear pad of
20/40 feet, both of which can bear and guide
related sliding elements.
1. Sideshift wear pads
Lubricating 1
When the surface of wear pad has little sliding
effect, be sure to smear grease on the surface
in time. No need to consider the lubrication 2
interval.
3
Replacing
Replace the wear pad if its worn depth
exceeds 3mm. Follow the below steps:
1. Screw out the bolts (2) at both ends.
Remove the end baffle (3). Fig. 5-85 Sideshift Sliding Block

2. Install a new wear pad (1). Adjust the

clearance between horizontal wear pad
and main tube of spreader to 2mm by
adding or reducing the adjusting gaskets
or pads.
3. Reinstall the end baffle and tighten the
bolts with a torque of 90 N.m. Spread anti-
loosing glue on the bolt before installing it.
4. Smear lubricants on the surface of sliding
block.
5. If all the bolts are secured, replace them
immediately. Spread anti-loosing glue on
them and re-tighten them with a torque of
560 N.m.
2. Telescopic wear pads
Lubricating
in time. No need to consider the lubrication
interval.
Replacing
exceeds 3mm. Follow the below steps:
1. Screw out the bolts (3) at both ends.
Remove the end baffle (2). 1
2. Install a new wear pad (1) or lower wear
4 3 2
pad (4). Adjust the clearance between
horizontal wear pad and main tube of
spreader to 2mm by adding or reducing the Fig. 5-86 Telescopic Sliding Block
adjusting gaskets or pads.
3. Reinstall the end baffle and tighten the
bolts with a torque of 70 N.m. Spread anti-
loosing glue on the bolt before installing it.
4. Smear lubricants on the surface of sliding
block.

5.12.2 Steel coil spreader
5.12.2.1 Spreader, lubricating

1 2
Fill the lubricating oil in oil cups until the oil
flows out every 200 hours.
Fig. 5-87 Oil Cups
5.12.2.2 Wear pads, maintaining

interval.

exceeds 3mm.
1
Fig. 5-88 Oil Cups

5.12.2.3 Slewing mounting and small gear,

maintaining
1
Filling grease in the rolling way of slewing
mounting should be done when the bearing
is rotating. After the first 50 working hours,
fill grease in the slewing mounting. Then fill it 2
every 100 hours until the grease squeezes out
from the sealing part. Lubricate the bearing 3
with grease Mobilux EP2 in the temperature
within -20°C and +120°C.
Before starting the system, make sure that
the gear teeth are totally covered by grease.
Lubricate the gear with grease Mobiltac 81 in
the temperature within -20°C and +120°C. 1. Reducer
Fill gear oil in the reducer in time. 2. Small gear
3. Slewing mounting
Fig. 5-89
5.12.2.4 Reducer, maintaining
Tighten the reducer bolts (1) with the torque

of 120N•m. Circle bolts should be secured
diagonally instead of be secured roundly.
Tighten the fixing bolts of pressure plate (2)

with the torque of 70Nm.
Fig. 5-90

5.12.3 Steel pipe spreader
5.12.3.1 Spreader, lubricating

1 2
Fill the lubricating oil in oil cups until the oil
flows out every 200 hours.
Fig. 5-91
5.12.3.2 Wear pads, maintaining

interval.

exceeds 3mm.

5.12.3.3 Slewing mounting and small gear,

maintaining
Filling grease in the rolling way of slewing 1

mounting should be done when the bearing
is rotating. After the first 50 working hours,
fill grease in the slewing mounting. Then fill it
every 100 hours until the grease squeezes out 2
from the sealing part. Lubricate the bearing
with grease Mobilux EP2 in the temperature 3
within -20°C and +120°C.
Before starting the system, make sure that
the gear teeth are totally covered by grease.
Lubricate the gear with grease Mobiltac 81 in
the temperature within -20°C and +120°C. 1. Reducer
Fill gear oil in the reducer in time. 2. Small gear
3. Slewing mounting
Fig. 5-92
5.12.3.4 Reducer, maintaining
Tighten the reducer bolts (1) with the torque

of 120N•m. Circle bolts should be secured
diagonally instead of be secured roundly.
Tighten the fixing bolts of pressure plate (2)

with the torque of 70Nm.
Fig. 5-91

5.13 Air Conditioning System
5.13.1 General recommendations

Authorization is required to perform repairs on
the climate control unit.
• If there is a rupture in the cooling coils or
a leaking on the attachment – immediately
switch off the unit.
• It is dangerous to allow refrigerants to
come in contact with skin or eyes.
• Never release refrigerant in a closed
room; the gas can cause asphyxiation, for
example, pits.
• Never weld on, or in the vicinity of, a
closed cooling system.
• Drain the refrigerant during repairs on the
air conditioning.
• Work may only be per formed on the
r ef r i g e r ant c ir c uit by an ac c r e dite d
company.
WARNING
WARNING
Electric fans can cause injury to hands.

Risk of personal injury.
Avoid placing hands near the cooling fans
when the engine is running.

5.13.2 Air conditioning, checking /

performance test
NOTICE
NOTICE
If the pressure in the refrigerant circuit

gets too low, the low-pressure monitor
p o w e r s u p p l y t o t h e c o m p r e s s o r ’s
magnetic clutch would break down, which
causes the air conditioning unit to stop
functioning.
Please check the air conditioning system

during continuous operation weekly from early
spring to late autumn as well as during long
periods of high humidity in winter.
In winter, the compressor should be run for a
few minutes weekly so that the rubber hoses,
couplings, gaskets and axle seals are well
lubricated.
1. Check that the condenser is not clogged –

clean condenser flanges with compressed
air as needed.
2. Check that the compressor turns on and
off without error.
3. Check that the drain for the cooling
element’s mixture water is not clogged.
4. C h e c k t h a t t h e r e i s n o l e a k i n g o f
refrigerant. Leaking often causes oil and
gas to form a dusty and dirty stain.
5. Start the engine and turn on the cooling
function set to maximum cooling. With
EEC: Choose Cool mode with temperature
on minimum.
Let the engine run at at least 1500 r/min.
(At temperatures below approx. 0 °C, the
cooling function will not start due to low
pressure in the system.)
6. Set the fan to intermediate speed.
7. After running for 10 minutes, check that

there are no bubbles visible in the receiver

dryer’s sight glass. (Bubbles should occur
only when the compressor starts and
stops.)
8. Place a thermometer at the exhaust
nozzle nearest the evaporator. After 5-10
minutes, the temperature should be under
10 °C. (Deviations in the measurement
result can occur if the performance test is
conducted when the ambient temperature
is under approx. 18 °C.) If bubbles occur,
subsequent filling should be done by an
expert.
5.13.3 Refrigerant quantity, checking
Check the refrigerant condition from the 1

o b s e r va t i o n w i n d o w (1) o n c o n d e n s e r
refrigerant container (2) when the engine is sufficient injection
running at high speed and air conditioner is
refrigerating at maximum.
2
Sight glass inspection
insufficient injuection
2. Start the engine and let it run idle.
3. Switch on the air conditioning at max. Fig. 5-93 Check Refrigerant Quantity
cooling and fan.
4. Check that a few bubbles are visible in the
sight glass on the receiver dryer.
5. Bubbles in the glass means that the
quantity of refrigerant is incorrect or that
the condenser is defective, clogged by e.g.
dust, or that the ambient temperature is
very high.
It is the easiest way to detect bubbles by

examing the sight glass while the compressor
is being star ted. Visible bubbles should
not normally be noticeable when the air
conditioning system is in operation. Bubbles

can occur if the system contains the incorrect

quantity of refrigerant, in connection with the
compressor stopping and starting, and if the
condenser is defective or at very high ambient
temperatures.
NOTE:
Reliable checking of refrigerant quantity
through the sight glass can only be made
when the ambient temperature is above
approx. 15 °C.
5.13.4 Refrigerant, filling
The type of refrigerants and freezing oil should

be up to the requirements of air conditioning
system. Choose the refrigerant of genuine
quality.
Check the system for leaking.

1. Fill 150cc of cooling lubricants. Make sure
that no water or dirty oil enters into the
system.
2. Vacuum the system for no less than 40
minutes.
3. Fill the refrigerants according to the
specified quantity of system. Too much or
too little refrigerants will effect the cooling
effect.
4. Check the condition of system and if it is
leaking air.
Run the air conditioning system for no less

than 30 minutes when filling refrigerants.
During that period, check the system pressure
of pipeline, condenser fan, circulating fan
to ensure that the air conditioning system is
properly installed for use.

5.13.5 Cleanness of heat-exchanger

plate in evaporator and condenser,
checking
Clean the evaporator and condenser at least

once every year by below means:
• Use high-pressure hydraulic nozzle and
detergent to clean the outer surface of
condenser and evaporator core.
• Use high-pressure pneumatic gun to
clean the outer surface of condenser and
evaporator core.
Fig. 5-94 Evaporator
NOTE:
High-pressure hydraulic nozzle and pneumatic
gun pressure should be adjusted before
cleaning. Do not punch down the fin. As to
those dirty cores, especially the evaporator
core with dust strainer mesh unwashed for
a long time, use fin detergent special for air
conditioner to wash after diluted because the
fins are covered with lots of dust and dirt.
5.13.6 Leaking or lack of oil in

condenser, checking
Observe the leaking of condenser through

the shaft seals. The running-in period of
condenser is 250 hours, when leaking is
normal. After 250 hours, leaking amount per
hour should be less than 0.05 cm3.
Obser ve the flatness of refrigerant oil in

condenser through the observation window:
check oil level 10-15 minutes after starting the
condenser. The condenser can be installed
in different places (tilt place). Therefore, it is
better to check oil level through the two glass
holes, then through one glass hole.

5.13.7 Radiator, cleaning
Follow below steps to clear away the impurities

off the surface of radiator at regular intervals:
1. Remove the radiator cover.
2. Wipe away all the dirt and dust on the
radiator fins.
3. Clean the radiator with special detergent.
4. Check the radiator fins and rubber sealing
parts for damage. If necessary, replace it.
NOTICE
NOTICE
Never flush the radiator with high-pressure

water as the radiator may be damaged.
5.13.8 Maintenance table for air conditioner
Table 5-27 Maintenance Table for Air Conditioner
Maintenance
Item Condition Requirements
interval
Before / after Make sure that 2/3 of air exhausts are opened and well
Air exhaust Daily the start of ventilated when the air conditioner is running. Check
engine whether the air volume of two sides are proximal.
Clean the air return grid filter screen (sponge block)
Air return grid Before the start
Weekly with clean water. Clean in advance the machine
filter screen of engine
running in areas surrounded by lots of dust.
Clean the filter screen of evaporator core with clean
Filter screen of Before the start
Monthly water. Clean in advance the machine running in areas
evaporator core of engine
surrounded by lots of dust.
Check whether the condensed water is drained
from the condenser water pipe one hour after the air
Condenser water After the start of
Daily conditioner has started. The volume of drained water
pipe engine
is relatively high at the south or inshore areas of high
humidity or in the rainy season.
Before the start Check the tightness and abrasion condition of belt.
Weekly
Transmission of engine Adjust or change it if necessary. Impose vertically the
belt Before the start pressure of 10Kg (approx. 98 N) on the belt between
Daily
of engine the two belt wheels with thumb.

Maintenance
Item Condition Requirements
interval
Check the oil quantity of compressor. The flatness
of compressor cooling oil can be seen from the
observation window. Compressor oil should exceed
4
/ 5 of the total oil quantity 30 minutes after the air
Before / after
Oil quantity of conditioner is stopped and be within the range of 1/4 to
Daily or weekly the start of 3
compressor /4 when the air conditioner is running.
engine
If the oil is less than the above standard in the 250
hours of running-in period, change the felt and fill
cooling oil; if the oil is less than the above standard
after the running-in period, replace the shaft seal.
Chec k t he nosie of c lutc h bear ing befo re t he
Before / after
Electromagnetic electrification. Check after the electrification whether
Daily the start of
clutch the electromagnetic clutch can occlude and separate
engine
quickly and whether it is slippy.
Before the start Check if the bolts on fixing bracket of compressor are
Yearly
of engine secured.
If the compressor will be unused for a long time, run
it once for several minutes weekly. Check if all parts
Compressor
After the start of are functioning normally. (If the compressor cannot be
Weekly
engine started due to low temperature, you can warm up the
machine by opening the warm wind firstly and then run
the air conditioner.)
After the start of
Blower Yearly Check for excessive noises while the blower is running.
engine
Change it. (Note: If the test paper does not turn yellow
After the start of
Dryer Yearly and the system is refrigerating normally, there is no
engine
need to change the dryer.
Plug-in parts, Before the start Check whether the wires of compressor clutch and
Monthly
terminals of engine terminals of generator are secured.
Check whether the main fuse of power supply, blower
Before the start
Fuse Monthly fuse, and inserting fuse are normal. Check whether
of engine
two ends of fuse and fixed bolts of seat are secured.

5.14 Hydraulic System
5.14.1 Hydraulic oil level, checking
NOTE:
The oil level is checked with the boom lowered
and the spreader retracted completely.

2. Check the oil level in the hydraulic tank
and brake oil tank. The oil level should be
visible from the level glass. Top up with oil
when needed.
REMARK: Fig. 5-95 Hydraulic Oil Tank Level

Hydraulic oil tank capacity: 650 - 1270L
For detailed information, see: “Capacity of
the tanks” on page 5-18.
NOTICE
NOTICE
Do not overfill!
Leaking and environmental damage!
5.14.2 Air filter element, changing
NOTICE
NOTICE
Ensure cleanliness around the filter and

filling point when working on the hydraulic
tank.
Dirt particle may cause damage to

machine.

1. Turn off the engine and main electric

power.
2. Remove the cover plate over the air filter.
3. Lift up the filter unit and place it in a
receptacle. Let the hydraulic oil drain.
4. Part the filter unit and remove the filter
element. Dispose the filter element as
environmentally hazardous waste. Note
the conditions of these parts.
5. Clean the filter housing’s parts.
6. Fit the new filter and assemble the filter
unit.
7. Install the filter unit and the cover. Tighten
the screws crosswise.
8. Check the oil level with dipstick in the
hydraulic oil tank. The oil level shall be
Fig. 5-96 Hydraulic Oil Tank
at the top of the level glass. Top up as
needed.
5.14.3 Hydraulic oil, changing
NOTICE
NOTICE
Ensure cleanliness around the filter and

filling point when working on the hydraulic
tank.
Dirt particles may cause damage to the
machine.
1. Turn off the engine and main electric

power.
2. Remove the filler cap and pump out the
hydraulic oil in a receptacle.
3. When most of the oils have been pumped
out, place a receptacle under the hydraulic
oil tank’s drain nipple (position 3 in Fig.
5-92) and drain the hydraulic oil.
4. Fit the drain nipple when the oil has been
drained completely.

NOTE:
Make sure that the seal washer is installedl.
5. If necessary, change the filter before filling

the tank with oil, see “Air filter element,
changing” on page 5-106.
6. Fill new hydraulic oil through the filler hole
on the filter’s cover. Then the oil can be
filtered and the hydraulic system can be
protected from impurities.
NOTICE
NOTICE
Do not overfill!
Leaking and environmental damage!
5.14.4 Oil return filter element, replacing
The oil return filter element is located at the

oil inlet of hydraulic oil tank. Blocked filter
element will effect the flow of oil, resulting in
high pressure at the oil exhaust of pump and
bursting of oil pipe.
Steps to replace the filter element:

1. Dismantle the hydraulic oil return filter from
the hydraulic oil tank.
2. Loosen the fixed screws in the filter.
3. Take out the filter element.
4. Replace with a new filter element.
WARNING
WARNING
Hot, pressurized oil!

Personal injury, burn injury!
Always depressurize the hydraulic system
before operation. Avoid skin contact with
the oil, and use protective gloves.
Failure to follow the above instructions

5.14.5 Hydraulic oil tank, cleaning

Be sure to clean the oil tank every six months.
The steps to clean the oil tank are as follows:

1. Remove the oil drain nipple at the bottom
of hydraulic oil tank. Drain the hydraulic oil
in the tank and pipeline.
2. Remove the cleaning hole cover.
3. Clean the oil tank with cleanout fluid (diesel,
etc.).
4. Af ter the tank is cleaned, install the
cleaning hole cover.
5. Open the air filter cover on the tank. Fill
filtered hydraulic oil into the tank until the
oil reaches the “H” marking as shown on
dipstick.

5.14.6 Parking brake unit, checking and

adjusting
WARNING
WARNING
The machine may start to roll.

Risk of crushing!
Block the wheels so that the machine
cannot start to roll when the parking brake
is released.
Fig. 5-97 Parking Brake Unit

1. Start the engine and run up hydraulic
pressure until the accumulators are fully
charged and the accumulator charging
valve switches to cooling.
2. Turn off the engine and turn the ignition
switch to position I.
3. Release the parking brake.
4. Check that the parking brake caliper can
move on the bracket.
5. Check that the brake disc is clean from oil
and dirt.
6. Remove the cover from the brake caliper.
Check that there is no oil inside the cover.
7. Loosen the lock nut.
8. Adjust the adjustment screw so that the
brakes are applied.
9. Turn back the adjusting screw so that the
clearance between pad and disc becomes
0.5±0.1 mm.
10. Tighten the lock nut.
NOTE:
To avoid turning the adjustment screw as well,
the lock nut must be held still when tightening
it.
11. Refit the cover on the caliper.

12. Check the function of parking brake.

5.14.7 Accumulator
There are two accumulators in the hydraulic

system: Brake System Accumulator, and
Control System Accumulator.
Usually the pressure of c ontrol system

accumulator conforms to the requirements of
control system.
WARNING
WARNING
• Hydraulic oil-way remains pressurized.

Do not stand in oil spraying direction
when dismantling the hydraulic
devices. Only loosen the screws.
• Do not dismantle the accumulator.
• Keep the accumulator away from fire.
• Do not drill holes on or weld on the
accumulator.
• Do not crash or roll the accumulator.
Avoid any shock of accumulator.
• Drain the air before dealing with the
accumulator. Please contact SANY to
conduct this operation.
Failure to follow above items may lead to
serious personal injuries or even death.
5.14.7.1 Brake system accumulator,

checking
The accumulator is f illed with nitrogen.

Improper operations will lead to explosion
causing machine damage and personal
injuries. Pay attention to the following items
when dealing with accumulators:

1. Start the engine (position 1 in Fig. 5-97);

let it run until the accumulator is fully 2
pressurized.
2. Stop the engine, and turn the ignition key

1
to position 2 in Fig. 5-97. Step on the brake
pedal (position 3 in Fig. 5-98) to its bottom
and hold it there for a short interval, then
repeat this operation several times.

3. Make sure that at least 5 brakes can be
realized before the alarm light turns on.
4. S t a r t t h e e n g i n e t o p r e s s u r i z e t h e
accumulator, and then repeat step 2
several times.
NOTE:
If the brake cannot function normally for 5
times before the alarm light turns on, it means
that there is a failure of the accumulator. Find
out the cause and eliminate the failure as 3
soon as possible. The accumulator should be
charged again. Fig. 5-99 Brake Pedal
5.14.7.2 Accumulators, charging with

nitrogen gas
T h e a c c u m u l a t o r s h ave a l r e a d y b e e n
precharged with nitrogen gas before the
installation.
NOTE:
• As the precharging pressure changes
along with the temperature, recheck the
accumulator pressure approx. 2 minutes
af ter charging. Correct the possible
deviation of pressure.
• Tighten the accumulator pressure tighten-

ing screw to 25 N.m, and c lose the

nitrogen exhaust valve. Open the bleed
valve of charging device to discharge the
gas. Remove the charging device, and
check the tightening valve for tightness
with, for example, soap liquid. Repair it if
air leaking occurs.
• Seal the tightening screw with sealing
lacquer. The pressurized accumulator is
now ready to be installed.
Steps to charge the accumulator:

1. M easure t he hydr auli c ac c umulato r
before charging to confirm that there is no
pressure in the system.
2. Precharge the accumulator with a special
charging device and check its pressure.
3. Remove the cap and clear away the
sealing lacquer around.
4. Clean the sealing surface and external
thread at the accumulator opening.
5. Loosen the tightening screw just a little
with a hexagon spanner.
6. C o n n e c t t h e c h a r g i n g d e v i c e t o Fig. 5-100 Charging Device
accumulator and the hose to a nitrogen
gas bottle.
7. Make sure that the O –ring is properly
positioned between the charging device
and accumulator sealing surface.
8. Open the accumulator pressure tightening
screw with a square spanner and auxiliary
tools of charging device until it is just
enough to see the readings on pressure
gauge.
NOTE:
If the precharging pressure is too high, please
open the bleed valve of charging device to
reduce the pressure. Note that the bleed valve
must be closed to check the correct reading.

5.14.8 Hydraulic oil circuit, checking
By observing and touching, check for loose

bolts or oil leaks on installation of hydraulic
oil circuit. If so, contact SANY authorized
distributors to replace the parts.
Fig. 5-101 Hydraulic Oil Hose

5.15 Electrical System
The normal voltage of electrical system is 24

VDC.
The whole electrical system adopts only
one type of conductor, while the electrical
frame acts as the other conductor. For the
convenience of detecting failures, all wires are
numbered according to the markings specified
in the circuit diagrams.
SAFETY
T h e i n su l at i o n m ate r i a l o ut s i d e of t h e
conductor is oil resistant. However, please
avoid the contact of lead with oils or other
solvent fluids. Make sure that the insulation
layer of the lead close to the engine and other
hot surfaces are not damaged. If necessary,
replace the lead.
WARNING
WARNING
Risk of short-circuit and fire!

The blowing of a fuse always indicates a
fault in the electric system. Eliminate the
fault prior to fitting a new fuse.
Failure to follow the above instruction

5.15.1 Battery
WARNING
WARNING
Risk of fire and explosion! Avoid contact

with flames or sparks.
Never confuse the positive terminal with
the negative one.
Battery electrolyte contains corrosive
sulphuric acid.
Avoid contact with skin, eyes, and clothes
when handling the batteries. Use gloves
and protective glasses. If electrolyte
splashes on bare skin, wash with soap and Fig. 5-102 Precautions for Battery
a lot of water immediately. If electrolyte
has gone into eyes, rinse with water and
contact a doctor immediately.
5.15.1.1 Battery, cleaning
Keep the battery clean and dry. Dirt and

oxidated materials on battery and battery
connector may cause electrical leaking,
decreased voltage and discharge, especially
in wet weather.
Use copper wire brush to clean the oxidated

materials off battery connector. Tighten the
cable connector and lubricate with protective
grease or vaseline. Fig. 5-103 Clean the Battery

5.15.1.2 Battery, checking
CAUTION
CAUTION
Battery electrolyte is very caustic. Avoid

any contact with battery electrolyte.
• If electrolyte comes into contact with
clothing, skin or eyes, flush the areas
immediately with water.
• In case of eye contact, rinse with plenty
of water and see a doctor at once!
The battery is fitted in the battery compartment

on the left side of machine.
• Check the battery for cracks in the casings,
and leaked electrolyte.
• Remove any corrosion on battery terminals
and check the connections for tightness.
• Tighten up the terminals and coat with
non-acidic grease.

5.15.1.3 Battery, detecting
Due to improper usage or maintenance, the

battery may be unable to be charged. Assess
the battery as follows.
1. Common assess equipment

• Multimeter
• Electric conductometer
• Gravimeter
2. Assessment measures
Estimate the service condition of battery
through magic eye or with the multimeter.
Through magic eye:

• Green magic eye signifies the normal
battery.
• Black magic eye signifies lack of voltage.
Charge the battery immediately.
• W h i t e m a g i c e y e s i g n i f i e s l a c k o f
electrolyte. Change the batter y
immediately.
With the multimeter:
• If the battery voltage is higher than 12.5V,
the battery is normal.
• If the battery voltage is between 11.5V and
12.5V, the battery lacks of voltage. Charge
the battery and check its voltage again.
• If the battery voltage is lower than 11.5V,
the battery discharges too much or there
is malfunction of this battery. Charge the
battery and check its voltage again.

5.15.1.4 Battery, charging
DANGER
DANGER
Danger of explosion!
Hydrogen will be released when the battery
is being charged. If the hydrogen mixes
with air, explosive gas will be created.
Short circuit, flame or sparks shall result in
severe explosion. Keep ventilated.
TY-1406004-1
Fig. 5-104 Charge the Battery
Principles of charging common batteries:
1. The current and time for charging the

battery can be referred to below table:
Table 5-28 Battery Charging Current & Time

Charging the new battery
Model
Current (A) Time (H)
6-QA-180 18 6-10
Charging the battery daily
Model
Current (A) Time (H)
according to the
6-QA-180 18
battery status
NOTE:
The correct charging time can vary a lot
according to the battery status. (The voltage
should be above 12.56V and the specific
gr avit y of ele c t ro ly te should b e ab ove
1.28+0.05)
2. Charge the battery in a well ventilated

place with the temperature of 10-30°C.
If the temperature of electrolyte exceeds
45°C, reduce the current value by half and
then recharge it until the volts is full.

3. The anode of battery should be connected

with that of DC charging equipment, and
the same rule applies to the cathode.
The connections should be firm and well
contacted. Do not connect the anode
with the cathode, or the battery will be
damaged.
4. If the battery is fully charged, the following
phenomenon would appear:
• The voltage of anode and cathode exceeds
12.56V (as to the measurement of battery
assessment equipment), and it would not
change in three hours;
• The density of electrolyte is above 1.275 g/
cm3 (25°C) and that of each cell should be
the same. The density would not change
in three hours;
• The bubble is close and well distributed in
battery.
NOTE:
Only when all the above three phenomenon
appear it can be assumed that the battery is
fully charged.
Principles of charging maintenance-free

batteries:
Precautions of charging batteries:

• Assess the battery before charging (For
detailed information, see: “Bat ter y,
detecting” on page 5-118). Only if the
batter y needs to be charged can the
charging be started.
• Do not charge the batteries with broken
cover, with white magic eye or whose
electrolyte is frozen.
• Always charge the battery in a ventilated
area.

• If the battery temperature exceed 50°C

during the charging procedure, reduce
the charging voltage or stop the charging.
If acid fluid sprays out from the exhaust
hole or the magic eye is white, stop the
charging immediately and discard the
battery as useless.
Charging procedures:
1. Select proper charging equipment.
2. Connect the terminals of battery when the
charging equipment is turned off.
3. Connect the plus cable (normally red)
of generator with the positive terminal of
battery. Connect the minus cable (blue
or black) of generator with the negative
terminal of battery. Make sure they are well
connected.
4. Turn on the charging switch of generator.
Slowly adjust the charging voltage or
cur rent from small to large with the
generator adjuster.
5. When the magic eye turns green, the
battery is finished charging.
6. Af ter charging, turn of f the charging
switch of generator first. Then disconnect
the cables of battery (never remove the
charging cables during the charging).

5.15.1.5 Battery, using
1. Check the electrolyte level weekly. If it is

low, fill in adequately purified water (Avoid
filling mineral water, tap water, etc.). Do
not fill any sulfuric fluid or other fluids, as
well as avoiding impurities into the battery.
Clean water drips on the battery cover
after filling water. Keep the surface of
battery dry.
NOTICE
NOTICE
Prevent the electrolyte level from

descending to expose the pole group, or
the battery will be damaged.
2. Battery should be charged under below

circumstances:
• If the battery on machine will not be used
for a long time (more than half month), you
should store the battery after dismantling
and charging it. Also, recharge the battery
every two months, or remove the lead of
cathode to prevent the battery from over-
discharging.
• If the battery being used, alarms for low
voltage, charge it.
• When the machine is parked for more than
five days, fully charge the battery before
using it.
3. Check the charging voltage of engine

every month and control it in the regulated
range.
4. Keep the surface of battery clean and dry.

If there is dust and acid on the surface,
wipe it away with a cloth soaked with soda
water immediately. And then wash it with
clean water. Check whether the battery is
clean twice a month .

5. Clean the breather bolt with distilled water

frequently. Keep it well ventilated.
6. When the engine is not functioning, do not
use the electrical equipment of high power
such as lights, air conditioner to prevent
the battery from over-discharging.
7. Make sure to turn off the main power
immediately after parking the machine.
This could prevent the battery from over-
discharging and the poles from acidating.
8. It is difficult to prevent natural creepage
caused by machine load. If the machine is
to be stored for more than 10 days, be sure
to remove the cable connected to negative
terminal to avoid serious discharge of
battery.
9. The start time of machine is 3-5 seconds.
The interval between two starts should be
no less than 15 seconds. If the machine
cannot be started, check the battery and
its start circuit. This usually happens in
winter.
10. Improper disposal of battery can result in
envirionmental pollution. It is suggested
to handle the used batteries to Recycling
Centers.

5.15.1.6 Battery cables, checking
WARNING
WARNING
Check that the battery cables are correctly

clamped and free from damage.
Fire hazard! Risk of serious injury!
Repair or replace damaged clamps and
check that no machine parts wear or chafe
against battery cables. Replace damaged
battery cables.
The following battery cables must be checked

for clamping, risk of chaf ing and c able
damages. Rectify incorrect clamping and risks
of chafing. Replace battery cables that show
signs of damage.
• Plus-cable between battery and battery
disconnector
• Plus-cable between battery and starter
motor
• Plus-cable between starter motor and
alternator
• Plus-cable between battery disconnector
and main fuses
• Plus-cable between starter motor and
preheating relay
• Plus-cable between preheating relay and
preheating coil
• Ground cable between battery and frame
• Ground cable between engine and frame

5.15.1.7 Battery, scheduled maintenance
Table 5-29 Scheduled Maintenance of Battery
Items Standards Schedule

Tighten the positive and negative terminals of
Check if the terminals are
battery at regular intervals to avoid loosening. per week
secured
Smear adequate vaseline to avoid corrosion.
Check if the fastening iron Check if the screws at two ends of the iron plate
per 15 days
plate is loose fixing the battery are secured.
Clean the dirt away from the battery surface. Use
Check if the battery surface is
distilled water to clean the breather bolt. Keep per 15 days
clean
the battery ventilated.
Add electrolyte to meet the max. marking. Fill
Check the electrolyte per week
electrolyte when it is below the min. marking.
Stop the machine immediately when the battery
Check the voltage alarms for difficult start or low voltage. And everyday
charge it.
Turn off the main power if the battery is unused
Maintenance for long-time
for over half month. Charge the battery every per month
unused
month.
Deposit the battery alone. Keep ventilated and
Check the battery storage avoid sunshine. Charge immediately as soon as every second month
the opening voltage is less than 12.55 V.
5.15.2 Fuses, changing
WARNING
WARNING
Risk of cable damage and fire in cable

harnesses! Always use fuses with the
correct ampere rating.
1. Turn off the main power supply (battery

disconnector).
2. Remove the cover from the fuse holder.
3. Check if the fuse is intact, and change it if
needed.

5.15.3 All working lights and indicators,

checking
Check whether working lights are in good

condition.
Check for dirt or damage.
If the lights do not illuminate, bulbs may burn
out or short circuit occurs. Please contact
SANY authorized distributor to repair.
1. Turn the ignition switch to position I.

2. Turn on working lights to check whether
they illuminate normally. Fig. 5-105 Working Light
5.15.4 Wiper, adjusting
1. Adjust the angle of wiper blade by hand to

vary its covering range.
1
2. If there is dust on the wiper blade, lift the
blade up and clean it, then place it back
to its original position so as to reduce the
wiping resistance.
3. Adjust the tightness of fixed screws (1) to
make the motor run the wiper blade easily.
4. If there is damage on the wiper blade,
loosen the screw, dismantle the old wiper
blade from the arm, and replace it with a Fig. 5-106 Fixed Screw of Wiper
new blade.

5.15.5 Wiper, replacing
The wiper arm is fixed on the motor axle with

a tapered spline. When installing the wiper,
tighten the screw enough to make the spline
squeezed into the connector as the supporting
frame.
Wiper, dismantling
1. Loosen the screw, and knock it.
2. Swing the wiper arm with care to take it
down.
Wiper, installing
1. Make sure that no soft materials on the
wiper connector are dropped onto the
spline of motor axle. If so, clean the spline
to make it fully squeezed into the connector
of wiper arm.
2. Install the wiper arm onto motor axle, and
tighten the screw with a torque of 16-20
Nm.
3. When tightening, fix the wiper arm to make
it bear the torque pressure. Do not let the
torque transfer to the motor, or it will be
damaged.

5.16 Maintenance Record List
Machine
Model
Serial No.
Table 5-30
Finished Maintenance
Working Maintenance
Strategies Working hours Signature
hours Date
50
250
500
750
1000
1250
1500
1750
2000
2250
2500
2750
3000
3250
3500
3750
4000
4250
4500
4750

Finished Maintenance
Working Maintenance
Strategies Working hours Signature
hours Date
5000
5250
5500
5750
6000
6250
6500
6750
7000
7250
7500
7750
8000
8250
8500
8750
9000
9250
9500
9750
10000

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A
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K
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N
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A
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L
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B
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Reach Stacker Troubleshooting
Troubleshooting
6. Troubleshooting
6.1 Precautions�� 6-2
6.2 Troubleshooting Procedures�� 6-3
6.3 Common Troubleshooting Methods�� 6-5
6.3.1 Troubleshooting the engine system�� 6-5
6.3.2 Troubleshooting the transmission system�� 6-8
6.3.2.1 Overview�� 6-8
6.3.2.2 Troubleshooting procedures�� 6-9
6.3.2.3 Troubleshooting table��6-11
6.3.3 Troubleshooting the drive axle and brake system��6-12
6.3.4 Troubleshooting the steering system��6-13
6.3.5 Troubleshooting the spreader system��6-13
6.3.6 Troubleshooting the boom system��6-15
6.3.7 Troubleshooting the air conditioning system��6-16
6.3.8 Troubleshooting the hydraulic system��6-17
6.3.9 Troubleshooting the electrical system��6-18
6.3.9.1 Troubleshooting the cable harness��6-19
6.3.9.2 Troubleshooting table�� 6-20
6.4 Engine Error Codes �� 6-27
6.4.1 VOLVO engine error codes�� 6-27
6.4.2 CUMMINS engine error codes�� 6-36
6.4.3 YUCHAI engine error codes�� 6-42
6.5 Transmission Error Codes �� 6-47
6.5 Machine Error Codes �� 6-55

Troubleshooting Reach Stacker
6. TROUBLESHOOTING
6.1 Precautions
If two or more personnel are engaged in the

repair or maintenance at the same time, they
should agree on the operation procedures
before starting the work. Prior to the repair or
maintenance, they should firstly notify other
personnel that is involved.
Troubleshooting is aimed to find out the

causes of failures and repair the machine to
avoid further damage. The key to detect the
failures is to understand the structure and
functions of machine.
Asking the operators about the possible

reasons of failures is a shor tcut for
troubleshooting.

6.2 Troubleshooting Procedures
You can perform the following 6 basic steps

to find out the failure cause and work out the
corresponding sollution:
1. Read this manual in detail to get a general

knowledge about related system and its
operating principle as well as the structure,
function and technical specification of
system components .
2. Consult the driver

Before checking, you should consult relevant
personnel (the driver) for all the failure details.
• The current operation condition of the
machine (Does the machine operate
properly)
• When is the failure found and what was
the machine operation at that time
• The failure development. Does the failure
get worse or occur for the specific time
• What other failures did the machine have
before
For example, which components have
been repaired or replaced
• What have been done and what was the
result after the failure occurred
• Can the failure be repeated
3. Check before starting

• Before per forming trouble diagnosis,
check the running record and operation
maintenance record for any irregular or
incorrect operation or maintenance.
• Check if any part of the machine is faulty
such as: the lack of or leaking of oil and
water; loose pipes, wire or circuit; cracks,
etc.
• In addition, check the electrical system
such as battery voltage. Check whether

power wire connecting end is not loose or

burnt. Use multi-meter to check whether
fuse is burnt or not.
4. Operate machine yourself (trial run)

• After making sure that there is no failure in
the above three items, start the machine
according to standard operating procedure
to inspect and confirm the cause of failure.
If the failure cannot be confirmed, stop the
engine and get further failure details from
the driver.
5. Perform trouble diagnosis

• Review the information in this manual
NOTE:
It should be noticed that displayed error code
may not indicate the current machine failure
due to temporary electrical failures stored in
the controller. Therefore, “failure simulation” is
required to erase the error codes accumulated
in the controller memory and confirm whether
the error code is displayed after “ failure
simulation”. In other words, this failure can be
repeated.
6. Find the possible causes

• Before coming to a conclusion, check
the most possible cause again and try to
confirm the real cause of the failure. Make
a proper repair schedule according to your
conclusion.

6.3 Common Troubleshooting

Methods
6.3.1 Troubleshooting the engine

system
Table 6-1
Failure Symptom Possible Causes Suggested Actions Reference

Too low temperature
Completely preheat the
Insufficient preheating time of -
engine.
engine
Hard to start the Blocked air filter or air intake Check the air intake system
-
engine pipe of engine for blockage.
see “Fuel system”
Fault in oil circuit of fuel system Check the fuel system.
on page 5-45
Insufficient starting voltage Check the voltage of battery. -
The engine is over The EDC fuel control unit is
Check the fuel control unit. -
rewing faulty
The corrugated pipes
have cracks and air The quality of pipe itself Replace it. -
leakage
The rotation speed of The EDC fuel control unit is
Check the fuel control unit. -
engine is not stable faulty
No fuel in tank Check if fuel is used up. -
Check if fuel oil circuit is
Blockage in fuel pipe -
Engine cuts out blocked.
Check if air enters into the
Air entering in fuel pipe -
fuel pipe.
see “Coolant
Insufficient coolant in water Check if the coolant of water level, checking
tank tank is sufficient. and topping up”
on page 5-52
Engine over-heating
Malfunction of thermostat Check the thermostat. -
or running hot
see “Drive belt,
The fan belt is loose Check if the fan belt is loose. checking” on page
5-35
The water pump is damaged Check water pump. -
There is oil in water The engine oil cooler is Check if engine oil cooler is
-
but no water in oil damaged damaged. If yes, replace it.


The quality of cylinder head Replace the cylinder head. -
see “Coolant
The cylinder head has
C h e c k i f t h e c o o l a n t i s level, checking
crack Insufficient coolant
sufficient. and topping up”
on page 5-52
The lubrication oil The cylinder head or cylinder Check if cylinder head or
-
level in oil pan rises body has crack cylinder gasket has crack.
unexpectedly and Check if the cylinder liner is
The cylinder liner is damaged -
water enters oil damaged.
The oil level is too low Refill the lubrication oil. -
see “Oil filter /
Bypass filter,
The oil filter is blocked Replace the filter. chaging (engine
Lubrication oil
option VOLVO)”
pressure is too low
on page 5-43
see “Engine oil,
The lubrication oil is too thin Replace the lubrication oil. changing” on page
5-42
The water tank has refer to “Shop
The water tank is damaged Replace it.
leak Manual”
The engine oil cooler The engine oil cooler is refer to “Shop
Replace it.
has leak (gearbox) damaged Manual”
Check if the fuel oil circuit is
The fuel supply is insufficient -
not blocked.
The diesel quality cannot meet
Use accepted fuel. -
The power of engine requirements
is not sufficient see “Turbocharger
Check if the air intake pipe is and blast pipe,
The air intake pipe is damaged
not blocked. checking” on page
5-58
The speed of engine
Check if the fuel oil circuit is
is automatically The fuel supply is not smooth. -
not blocked.
decreased
The pre-filter and filter The fuel is too dirty Chang the fuel. -
elements for engine
The fuel tank is dirty Clean fuel tank. -
fuel are blocked
The exhaust pipe is damaged Replace the pipe.
The exhaust pipe of
The flange of exhaust pipe is
engine has leak Tighten the flange. -
loose


see “Drive belt,
replacing (engine
The engine fan belt is The quality of belt itself Replace belt.
option VOLVO)”
broken
on page 5-36
The belt is too tight Adjust the tension of belt. -
The wear clearance between
The engine has blue valve and valve sleeve Replace the valve. -
smoke becomes large
The oil rings are worn Replace piston rings. -
It is hard to speed up The EDC fuel control unit is
Check EDC fuel control unit. -
the engine faulty
The engine
The seal of supercharge is
supercharger has oil Replace the seal. -
damaged
leakage
The indication of fuel The fuel gauge or oil level Check the fuel gauge and oil
-
gauge is incorrect sensor is damaged level sensor.
The oil seal at the
front end of engine The quality of seal itself Replace it. -
crankshaft

6.3.2 Troubleshooting the transmission

system
6.3.2.1 Overview
When troubleshooting a “ transmission”

problem, it should be kept in mind that the
transmission is only the central unit of a
group of related power-train components.
Proper operation of the transmission depends
on the condition and correct functioning of
other components of the group. Therefore,
to properly diagnose a suspected problem in
the transmission, it is necessary to consider
the transmission fluid, charging pump, torque
converter, transmission assembly, oil cooler,
filter, connecting hoses, and controls, including
the engine, as a complete system.
Torque converter transmission troubles fall

into three general categories: mechanical,
hydraulic and electrical problems. In addition
to the mechanical and electrical components,
all of which must be in the proper condition
a n d f u n c t i o n i n g c o r r e c t l y, t h e c o r r e c t
functioning of the hydraulic circuit is most
important. Transmission fluid is the “life blood”
of the transmission. It must be supplied in an
adequate quantity and delivered to the system
at the correct pressures to ensure converter
operation, to engage and hold the clutches
from slipping, and to cool and lubricate the
working components.

6.3.2.2 Troubleshooting procedures
Step 1: Stall test

Use a stall test to check for transmission,
converter, or engine problems.
1. Park the machine against a solid barrier,
such as a wall, and / or apply the parking
brake and block the wheels.
2. Put the gear selector at for ward (or
reverse, as applicable) gear.
3. Select the highest speed.
4. With the engine running, slowly increase
engine speed to approx. 1/ 2 throttle and
hold until transmission (converter outlet) oil
temperature reaches the operating range.
NOTICE
NOTICE
Do not operate the converter at stall

condition longer than 30 seconds at
one time, shift to neutral for 15 seconds
and repeat the procedure until desired
temperature is reached. Excessive
temperature (120°C/250°F maximum)
will cause damage to the transmission
clutches, fluid, converter, and seals.
Step 2: Transmission pressure checks

Transmission problems can be isolated by
the use of pressure tests. When the stall test
indicates slipping clutches, measure clutch
pack pressure to determine if the slippage
is due to low pressure or clutch plate friction
material failure.
In addition, converter charging pressure and
transmission lubrication pressure may also be
measured.

Step 3: Mechanical and electrical checks:

Prior to checking any part of the system for
hydraulic function (pressure testing), perform
the following mechanical and electrical checks:
• Check the parking brake for correct
adjustment.
• Be sure all lever linkage is properly
connected and adjusted in each segment
and at all connecting points.
• The controls are actuated electrically.
Check the wiring and electrical
components.
• B e sure t hat all c o mp o nent s of t he
cooling system are in good condition and
operating correctly. The radiator must
be clean to maintain proper cooling and
operating temperatures for the engine
and transmission. Air clean the radiator, if
necessary.
• The engine must be operating correctly.
Be sure that it is correctly tuned and
adjusted to the correct idle and max. no-
load governed speed specifications.
Step 4: Hydraulic check
Before checking the transmission clutches,

torque converter, charging pump, and hydraulic
circuit for pressure and rate of oil flow, it is
important to make the following transmission
fluid check.
Check oil level in the transmission. The

transmission fluid must be at correct level. All
clutches and the converter as well as its fluid
circuit hoses must be fully charged (filled) at all
times.
NOTE:
Be careful that the machine does not move
unexpectedly when the engine and converter
are operating at stall RPM.

6.3.2.3 Troubleshooting table

Table 6-2

Low oil pressure see "Transmission
oil level,
Check the oil level.
Insufficient oil checking" on page
Slipping of clutch 5-65
Worn charge pump Check the charge pump. -
Wear of the clutch abrasion refer to “Shop
Replace the clutches.
sheet Manual”
see "Transmission
oil level,
Low or high oil level Check the level of lubrication oil.
checking" on page
5-65
High oil temperature
Worn of charge pump Check the charge pump. -
Step the clutch in braking and
The clutch does not release
check if the clutch switch is -
when braking
operating.
Abnormal meshing of gear Check the meshing of gear. -
Too much noise Abrasion or damage of Replace the damaged or abraded
-
bearing bearing.
see "Transmission
oil level,
Low oil level Check the oil level.
Inadequate oil checking" on page
pressure displayed 5-65
Worn charge pump Check the charge pump. -
by oil pressure
Damage of the clutch Check the presssure-adjusting
gauge -
pressure-adjusting valve valve.
Damage of the clutch oil-
Replace the damaged sealing part. -
sealing part
Check the signal of control unit of
-
gearbox.
The gearbox can Fault in control unit of
Check if the solenoid coil of
not switch gears gearbox -
gearbox solenoid valve is blown.
Check if the valve core is blocked. -
The gear cannot be
shifted manually
The contact is faulty Check the contact. -
Faulty of control
lever
see "Mounting
Excessive vibration The mounting bolts are bolts of propeller
Tighten the mounting bolts.
and noise in cab loose shaft, checking"
on page 5-60

6.3.3 Troubleshooting the drive axle

and brake system
Table 6-3

Oil pressure of braking system see “Oil leakage
is low of drive axle
Check if the brake oil has leak.
The force of service Braking oil circuit has air and brake
brake is not sufficient components,
The brake components are checking” on page
Check the brake components.
worn out 5-66
Check if the fan of cooling
The oil temperature of braking system can rotate or fan flanks refer to “Shop
Too much noise
system is high are damaged. Replace it if Manual”
necessary.
Adjust the distance of brake
Failure of brake valve -
valve.
Check the clearance of brake
Failure of brake -
sheet.
Failure of pressure relay Clean or replace it. -
No service brake or see “Brake system
the service brake accumulator,
Failure of accumulator Check the accumulator.
functions bad checking” on page
5-112
refer to “Shop
Failure of gear pump Replace it.
Manual”
refer to “Shop
Failure of brake valve group Clean or replace it.
Manual”
Failure of parking brake Clean the parking brake. -
Clean the solenoid valve or
No parking brake or Failure of solenoid valve -
replace it.
the parking brake
High oil return back pressure Check the oil return pipe. -
functions bad
refer to “Shop
Failure of brake valve Clean or replace it.
Manual”

6.3.4 Troubleshooting the steering

system
Table 6-4

refer to “Shop
Insufficient oil supply Check the system pressure.
Manual”
Failure of hydraulic steering
Clean and replace it. -
Defective or gear
impossibble to steer Serious leakage of steering
Replace the sealing parts. -
cylinder
Damping hole of flow amplifier
Clean it. -
is clogged
6.3.5 Troubleshooting the spreader

system
Table 6-5

Damaged overflow valve or relief Replace the overflow valve or
-
valve relief valve.
No pressure in the
Valve core is blocked Clean it. -
system
Check the oil pump feed to oil
No output of oil pump -
circuit.
Electrical failure Replace the circuit. -
No spreader
Solenoid valve is damaged Replace the solenoid valve. -
functions
The valve core is blocked Clean the valve core. -
Bad connection caused by wiring
Check and fix the fault. -
fault
The corresponding solenoid valve
Clean the solenoid valve. -
is clamped
Only a few of
The coil of solenoid valve is
spreader functions Replace the coil. -
damaged
are effective
The controller of spreader is Replace the spreader refer to “Shop
damaged controller. Manual”
Check and repair it. Replace
Fault in button of joystick -
the joystick if necessary


see “Fuses,
The power supply fuse of spreader
Replace the fuse. changing” on
control device is blown
page 5-126
The hoses of general oil supplying
Inspect and fix it. -
No movement of valve have some malfunction
the spreader Check and resume it. Replace
General oil supplying valve has
the general oil supplying valve -
some malfunction
if necessary.
refer to “Shop
Spreader controller is damaged Replace it.
Manual”
The yellow indicator Wrong induction distance of
Adjust the distance. -
light blinks or seated sensor
illuminates all the Seated sensor is damaged Replace the sensor. -
time when the
The yellow indicator light is refer to “Shop
spreader is not Replace the indicator light.
damaged Manual”
seated
The red indicator Wrong induction distance of
light does not blink unlocked sensor
or illuminate when Unlock sensor is damaged Replace the sensor. -
the spreader is refer to “Shop
The red indicator light is damaged Replace the indicator light.
unlocked Manual”
The green indicator Wrong induction distance of
light does not blink locked sensor
or illuminate when Lock sensor is damaged Replace the sensor. -
the spreader is The green indicator light is refer to “Shop
Replace the indicator light.
locked damaged Manual”

6.3.6 Troubleshooting the boom system
Table 6-6

Boom shakes while
Clogged solenoid valve Clean it. -
being retracted
Leakage of telescopic and Check and replace the sealing
-
Boom retracts or pitching cylinder parts.
lowers automatically Malfunction of self-locking
Check it. -
function of logic valve
Check, adjust the pressure
Low oil pressure -
No pitching or valve in pump and main valve.
telescopic movements Malfunction of logic valve Check it. -
of boom Only one movement of Check the electrification
-
differential solenoid valve situation of the valve.
Low oil level Fill oil into the tank. -
Boom is not extended Too large protecting distance
Reduce the distance. -
completely of telescopic cylinder
Insufficient system pressure Increase the pressure. -
The fuse of boom control see “Fuses,
return circuit power supply is Replace the fuse. changing” on
blown page 5-126
see
No movement of boom "Troubleshooting
Circuit failure Check and recover the circuit. the cable
harness" on page
6-19
Safe protection Check it. -
Too much interference signal Check and adjust it. -
Signal line of joystick is
Check the joystick. -
Boom movement is damaged
refer to “Shop
out of control The joystick is damaged Replace it.
Manual”
Electric proportional valve is
Replace it. -
damaged
The ignition switch is turned off Turn on the ignition switch. -
The boom cannot be Failure of emergency lowering Check and repair the valve. -
solenoid valve
lowered in emergency
The connector is loose or the
Check the connector and wire. -
wire is dropped

6.3.7 Troubleshooting the air conditioning system
Table 6-7
Failure
Possible Causes Suggested Actions Reference
Symptom
Cab temperature is lower
Set a lower temperature. -
than the set temperature
Turn on the refrigeration mode
High temperature changes
after the temperature is getting -
during one day
higher.
Belt is loose Tighten the belt. -
Check if the inserting fuse in
see “Fuses, changing”
electric cabinet is blown. If yes,
on page 5-126
change the fuse.
Fuse of condenser burns out Check if the fuse is fixed. -
Check if the plug-in part of
No refrigeration
controller and condenser coil -
effect
has good contact effect.
Plug-in part of condenser
Insert the plug-in part again. -
clutch coil is loose
Coil is too tight or plug-in part
Fix the coil terminals. -
has poor contact effect
Turn off the refrigeration mode. -
see “Leakage or lack
Check the condenser for of oil in condenser,
Refrigerant is leaking
leakage. checking” on page
5-104
Inform SANY to deal with it. -
Some of the air outlets are Adjust the cab temperature.
-
Poor blocked Open all the air outlets.
refrigeration Bad sealing of cab Close all the windows and doors. -
effect see “Refrigerant,
Refrigerant is not enough Fill in refrigerant.
filling” on page 5-103
Check the output, grounding and
Connecting wire to engine is
connecting wire of conditioner. -
loose or ruptured
Small air Connect the wire again.
volume or no see “Fuses, changing”
Fuse is blown Change the fuse.
air on page 5-126
Speed governing resistance
Inform SANY to deal with it. -
of evaporator is damaged
L o w a i r
pressure and
Filter is dirty Clean the filter. -
the refrigeration
effect is poor

6.3.8 Troubleshooting the hydraulic system
Table 6-8
Failure
Symptom
refer to “Shop
Failure of cooler Replace it.
Manual”
Hydraulic motor of cooling circuit is refer to “Shop
Replace the hydraulic motor.
damaged Manual”
High oil Fuel supply of loop feed pump is not Replace the back pressure
-
temperature enough spring.
Inter drainage of reversing valve is
Replace the reversing valve. -
faulty
Low flow of cooler Clean the cooler. -
Outer radiator fins are too dirty Wash the outer radiator fins. -
Hydraulic oil of substandard quality see "Hydraulic oil,
Replace the hydraulic oil. changing" on page
Hydraulic oil of substandard viscosity
5-108
Long-term use of hydraulic oil
Periodical filtration. -
without filtrating or replacing it
see "Oil return filter
The constant entrance of dust, sand Replace the filter core
Hydraulic oil is element, replacing"
and other debris periodically.
polluted and on page 5-109
deteriorated High temperature; oxidation
see "Hydraulic oil,
metamorphism
Replace the hydraulic oil. changing" on page
Entry of water and air, as a result of
5-108
cavitation, erosion, etc.
see "Air filter
Clogged filter Clean it or replace it. element, changing"
on page 5-107
Leaking of Damaged or distorted sealing parts Replace the sealing parts. -
hydraulic oil Joints and pipelines are loose Tighten the loose parts. -
see “Fuses,
The fuse of cooling system is burnt Replace the fuse. changing” on page
The hydraulic
5-126
or brake
The temperature switch is damaged Replace the switch. -
cooling system
The contact of relay controlling the
does not cool Replace the contact. -
cooling system is fused
automatically
Failure of cooler solenoid valve Replace it. -
Failure of radiator motor Replace it. -

6.3.9 Troubleshooting the electrical

system
The causes for faults in electrical control

system are generally complicated. The real
causes for faults should be diagnosed only
based on careful obser vation, research,
experiments and good practical experiences.
When the causes are diagnosed, eliminate
them in sequence from easy to difficult.

6.3.9.1 Troubleshooting the cable harness
NOTE:
Perform troubleshooting for all cables in the
same way to avoid damage to control units,
components or measuring equipment.
1. Study the circuit diagram in question.

Check where the suspected cable is
connected and if so where it is spliced.
2. Turn off the main power supply.
3. Unplug the connector at the control unit or
component in question.
4. Check if there is open circuit.
NOTE:
Some components cannot be checked without
power supply to the components. In such an
event, proceed to point 5.
• a. M easure the resist anc e bet ween

connections for the component in the
c onnec tor at the c ontrol unit or the
component in question.
• b. The resistance must correspond with
the component. As there may be an open
circuit or short circuit in cable harness and
/ or the component.
5. Check if there is short circuit to frame:

• a. Unplug the connector at both the control
unit and the component in question.
• b. Measure the resistance of one lead at
a time. Measure between the lead and a
frame-connected part of the machine.
• c. The multi-meter should show endless
resistance.

6.3.9.2 Troubleshooting table
Table 6-9
Failure
Symptom
see
"Troubleshooting
Open circuit or short circuit Check and fix it.
the cable harness"
on page 6-19
Non-operation of
Magnet rusted Scrub the magnet. -
magnetic valve
Replace the spool or seal
Spool abrasion or seal-ring aging -
ring.
Severe oil carbon pollution in the valve Scrub the magnet. -
Failure of deflection spring Replace the spring. -
Air ejection from
Failure of magnetic valve Replace the valve. -
magnetic valve
see
"Troubleshooting
Open circuit Check and fix it.
Water level the cable harness"
switch alarms for on page 6-19
full tank Fault of structure of water level switch Replace the switch. -
The water level switch is reversely
Reinstall the switch. -
installed
see
"Troubleshooting
Open circuit Check and fix it.
No indication of the cable harness"
fuel level on page 6-19
Reverse connection of power line and
Reconnect the lines. -
signal line
Line abrasion, there is contact
Inaccuracy
resistance between signal line and Check and fix it. -
of fuel level
power line
indication
Failure of sensor Replace the sensor. -
see
Non-operation "Troubleshooting
Failure of circuit Check and fix it.
of temperature the cable harness"
switch on page 6-19
Switch damaged Replace the switch. -
Faulty Adjusted value of temperature switch
Replace it. -
temperature is inaccurate
switch The temperature switch is defective Check and fix it. -


see
"Troubleshooting
Non-operation of Failure of circuit Check and fix it. the cable
pressure switch harness" on page
6-19
Switch damaged Replace the switch.
Adjusted value of pressure switch
Readjust it. -
Faulty pressure switch is inaccurate
The pressure switch is defective Replace it. -
see
"Troubleshooting
Open circuit Check and fix it. the cable
No signal of pressure
harness" on page
sensor
6-19
Reverse connection of signal line
Reconnect the lines. -
and power line
Line abrasion: there is contact
resistance between signal line and
Faulty pressure sensor Check and fix it. -
its housing, or power line and its
signal
housing
The sensor is defective Replace it. -
Incorrect signal of
throttle. Start the engine
and run it at its max. Reverse connection of power line
Check and fix it. -
speed. Step on the of pedal and ground wire
throttle, but the rotation
speed decreases
The rocker switch is damaged Replace it. -
see
No operation of rocker "Troubleshooting
switch The lead is broken Check and fix it. the cable
harness" on page
6-19
The bulb is damaged Replace the bulb. -
see
"Troubleshooting
No indicator light
Failure of circuit Check and fix it. the cable
harness" on page
6-19


The contact spring is too soft Adjust the elasticity of spring. -
The connection iron
The bottom plate is eneven Remove the protruding part. -
of contactor does
The connection iron or
not fall when the Fix it to be flexible. -
mechanical part is clamped
power is off
The contacts are fused together Replace the contact. -
The contact of
cotactor does not
The contact spring is too soft Adjust the elasticity of spring. -
close fully when the
power is on
Its load exceeds the max. Find out the reason and eliminate
-
volume the failure.
Contact of relay is The contact moves too much Replace the contact. -
hot The contact is serious burnt Replace the contact. -
The contact pressure is
Replace the contact. -
inadequate
The contact is covered with Find out the reason and eliminate
-
P o o r c o n t a c t o f dust, dirt or is blown the failure.
relay Adjust the elasticity of spring.
The contact spring is too soft -
Replace it as necessary.
The contact is incorrect Replace the contacts. -
There is sparks on Adjust the elasticity of spring.
The contact spring is too soft -
the contact when Replace it as necessary.
the relay is closed The contact is burnt, poor
Replace it. -
contact
Pool connection of armature
Clean the connection surface. -
Abnormal noise of and iron core
DC contactor Large pressure of contact Replace the contact spring and
-
pressure contactor if necessary.
Battery switch The contacts are fused together Replace the contacts or switch. -
cannot be
The mechanical part is clamped Repair it to make it flexible. -
disconnected
see
"Troubleshooting
N on - operation of Open circuit Check and fix it. the cable
preheater harness" on page
6-19
Heater damaged Replace it. -


see
"Troubleshooting
Short circuit of horn power wire
The horn alarms all Check and fix it. the cable
and control power line
the time when the harness" on page
power is on 6-19
The contact of relay controlling the
Replace the relay. -
horn is fused
The contact head is loose Retighten the contact. -
see “Fuses,
The fuse of control circuit is blown Replace the fuse. changing” on
Press down the wiper page 5-126
The positive wire is not connected Re - connect the positive
button, but the wiper -
in the control circuit wire.
motor is not starting
Check the relay, and
The start relay is damaged -
replace it as necessary.
Check the button, and
The wiper button is defective -
see
"Troubleshooting
Sound & light alarm The lead is broken or open circuit Check and fix it. the cable
does not work harness" on page
6-19
The alarm is damaged Replace it. -
see
"Troubleshooting
Open circuit Check and fix it. the cable
harness" on page
6-19
see “Fuses,
The fuse of power supply is blown Replace the fuse. changing” on
Non-operation of
page 5-126
display when the
see
system is powered
"Troubleshooting
Failure of circuit Check and fix it. the cable
harness" on page
6-19
Check and recover the
Endless loop of program -
program.
The controller is damaged Replace the controller. -


The contact head is loose Retighten the contact. -
see “Fuses,
The fuse of control circuit is blown Replace the fuse. changing” on
page 5-126
Turn the key in
The gear selector is not at neutral Rotate the gear selector to
ignition switch, but the -
engine does not start position neutral position.
Check the relay, and
The start relay is damaged -
Check the switch, and
The ignition switch is defective -
Find out the reason and
Poor contact of ignition switch -
eliminate the failure.
see “Fuses,
Turn the key in Replace the fuse body after
The fuse of control circuit is blown changing” on
ignition switch, but the inspection.
page 5-126
start relay and start The lead and contact head are Find out the reason and
-
contractor do not work loose, poor contact eliminate the failure.
The contact head of relay or
Find out the reason and
contactor is loose, the loop is -
eliminate the failure.
defective
The brake pedal is blocked and
Make the pedal to move
unable to be stepped to its release -
smoothly.
position
Engine speed cannot
Make the output signal to
reach needed speed Incorrect throttle output signal -
be 1.6-3.8V.
The connector is loose or the wire Check the connector and
-
is dropped wire.
After the engine The brake pedal is blocked and
Make the pedal to move
is started, and the unable to be stepped to itsrelease -
smoothly.
gear is selected, the position
machine cannot move Press down the parking
There is parking signal -
with the gear signal button.
see
"Troubleshooting
Failure of the ground wire Check and fix it. the cable
The travelling speed
harness" on page
is not displayed and
6-19
the machine can only
The speed sensor is damaged Replace it. -
travel in 1st gear
Replace the channel, or
The circuit board is damaged if necessary, replace the -
frequency divider.


Reverse connection of rod
and rodless chamber pressure Reconnect them. -
Inaccurate sensors
measurement of Pressure sensor is damaged Replace it. -
weight The connector is loose or the
wire is dropped
Uneven road Make the road even. -
F a u l t y a l a r m o f Wrong distance of proximity Adjust the distance. -
switch
forward over-turning
Proximity switch is damaged Replace it. -
protection
The connector is loose or the
wire is dropped
Cab cannot be Solenoid valve is damaged Check the solenoid valve. -
moved The connector is loose or the
wire is dropped
Counterweight Solenoid valve is damaged Check the solenoid valve. -
cannot be moved The connector is loose or the
wire is dropped
The menus cannot Too much redundancy data Refresh the page. -
be displayed The screen is disturbed by Eliminate the interference
-
normally with magnetism source.
distorted figures The screen is damaged Replace the screen. -
see
"Troubleshooting
CANBus failure Check and recover the wire. the cable
harness" on page
6-19
The data displayed
CANBus terminal resistance is
on the screen is Replace the resistance. -
damaged
abnormal
see
"Troubleshooting
The lead is broken Check and recover the wire. the cable
harness" on page
6-19


see “Fuses,
The fuse of power supply is
blown
page 5-126
Failure of controller Check it. -
Failure of program -
No operation of program.
controller Controller damaged Replace the controller. -
see
"Troubleshooting
Failure of input or output circuit Check the circuit. the cable
harness" on page
6-19
see “Fuses,
The fuse of power supply is
No operation of blown
page 5-126
extended block
Failure of extended block -
communication circuit.
Communication fault Check if the circuit is
Failure of the communication
between engine and disconnected or if there is -
circuit
controler water in circuit.
Communication fault Check if the circuit is
between controller disconnected or if there is -
circuit
and I/O water in circuit.
Check if the circuit is
disconnected or if there is -
circuit
Communication fault water in circuit.
between controller Check if the terminal resistor
and display is burnt or poorly connected.
Failure of terminal resistor -
Check if the terminal resistor is
on its plug.
Check if the circuit is
disconnected or if there is -
circuit
Communication fault water in circuit.
between controller Check if the terminal resistor
and length & angle is burnt or poorly connected.
sensor Failure of terminal resistor Check if the terminal resistor -
is in its plug, or replace the
sensor.

6.4 Engine Error Codes
6.4.1 VOLVO engine error codes
For the detailed information, see: “VOLVO

ENGINE MANUAL”.
Table 6-10 Engine Error Codes

Code SPN
Description Possible Causes Failure Symptom Suggested Actions
No. Code
1.1 No faults
2.1 97 Water in fuel Water in fuel None Empty the primary fuel filter
1. Check the coolant level.
2.2 111 Coolant level Low coolant level Engine stopped 2. Check the function of coolant
level monitor.
1. Check that the coolant level
1. Short circuit to
Coolant level sensor cable is not damaged.
2.3 111 positive (+) None
sensor 2. Check the function of coolant
2. Fault in sensor
level sensor.
1. Check that the sensor
1. No signal connector is correctly installed.
2. Abnormal 2. Check that the engine speed
Engine is very
frequency sensor cable is not damaged.
Flywheel difficult to start and
2.4 637 3. “Intermittent” 3. Check that the engine speed
speed sensor runs roughly when it
signal from the sensor is correctly installed in
starts.
sensor the flywheel housing.
4. Fault in sensor 4. Check the function of engine
speed sensor.
1. Check that the engine speed
sensor connector is correctly
installed.
Engine takes
1. No signal 2. Check that the engine speed
Camshaft longer to start than
2. Abnormal sensor cable is not damaged.
2.5 636 drive speed normal. Engine
frequency 3. Check that the engine speed
sensor runs normally when
3. Fault in sensor sensor is correctly installed in
running.
the upper timing gear cover.
4. Check the function of engine
speed sensor.
After the engine has stopped,
Engine speed too
2.6 190 Engine speed None look for the reason for the high
high
speed.

Code SPN
No. Code
1. Engine goes to
idle 1. Check that the potentiometer
2. If you release the has been connected correctly.
Speed
1. Shorted to positive accelerator first and 2. Check that the cable harness
potentiometer
2.8 608 (+) or negative (-) then press it down to the potentiometer has not
connected to
2. Fault in sensor again, the engine been damaged.
CIU
can be forced to 3. Check the potentiometer
run using the idle function.
contact.
1. Check the indicator cables for
1. Short circuit breaks and short circuits.
Indicator for
2.9 97 2. Open circuit None 2. Check the function of
water in fuel
3. Fault in indicator indicator. Change it as
necessary
1. Short circuit 1. Check that the oil pressure
Oil pressure to positive (+) or sensor cable is not damaged.
3.1 100 None
sensor negative (ground) (–) 2. Check that the oil pressure
2. Open circuit sensor is correctly connected.
1. Check that the boost
temperature sensor connector is
correctly installed.
2. Check that the boost
1. Short circuit
Boost temperature sensor cable is not
to positive (+) or
3.2 105 temperature None damaged.
negative (ground) (–)
sensor 3. Check that the boost
2. Open circuit
temperature sensor is correctly
installed.
4. Check the function of boost
temperature sensor.
1. Check that the coolant
temperature sensor connector is
correctly installed.
2. Check that the coolant
1. Short circuit
Coolant Preheating is also temperature sensor cable
to positive (+) or
3.3 110 temperature activated when the is not damaged.
negative (ground) (–)
sensor engine is hot. 3. Check that the coolant
2. Open circuit.
temperature sensor is correctly
installed.
4. Check the function of coolant
temperature sensor.

Code SPN
No. Code
1. Check that the boost pressure
installed.
1. Short circuit Engine smokes
Boost 2. Check that the boost pressure
to positive (+) or more than normally
3.4 106 pressure sensor cable is not damaged.
negative (ground) (–) during acceleration /
sensor 3. Check that the boost pressure
2. Open circuit load increase.
sensor is correctly installed.
4. Check the function of boost
pressure sensor.
Engine control
module reduces
1. Check the function of
engine power
turbocharger compressor.
Boost Boost pressure too (unless the
3.5 106 2. Check the function of boost
pressure high protection has been
pressure sensor.
shut off with the
3. Check fuel volume / injector.
VODIA diagnostic
tool).
1. Check that the fuel pressure
installed.
1. Short circuit
Fuel pressure to positive (+) or
3.6 94 None sensor cable is not damaged.
sensor negative (ground) (–)
2. Open circuit
sensor is correctly installed.
4. Check fuel pressure sensor
function.
1. Check that the cable harness
1. Short circuit to the oil temperature sensor
Oil
to positive (+) or has not been damaged.
3.7 175 temperature None
negative (ground) (–) 2. Check that the oil temperature
sensor
2. Open circuit sensor has been connected
correctly.
1. Check if it is possible to
increase pressure with the hand
3.8 94 Fuel pressure Low supply pressure None pump.
2. Check the fuel filter.
3. Check the fuel pre-filter.
1. Faulty alternator
Battery Check the supply voltage from
3.9 158 2. Faulty battery, None
voltage, EMS the control unit.
battery cables

Code SPN
No. Code
1. The engine 1. Check that connections to
1. Short circuit
cannot be started. the ignition key have not been
Start output to positive (+) or
2. The engine starts damaged.
4.6 677 / Start motor negative (–)
immediately when 2. Check that the cable harness
relay 2. Activated for too
the ignition is turned to the ignition key has not been
long
on. damaged.
1. Short circuit to Engine can only be
520 Stop input Check that the starter switch
4.8 negative (-) stopped with the
195 EMS connections are not damaged.
2. Open circuit auxiliary stop.
1. The engine 1. Check that connections to
1. Short circuit to cannot be started. the ignition key have not been
520 Starter input negative (-) 2. The engine starts damaged.
5.2
194 CIU 2. Activated for too immediately when 2. Check that the cable harness
long the ignition is turned to the ignition key has not been
on. damaged.
1. Engine can only
be stopped with the
auxiliary stop.
2. Engine stops. A
1. Short circuit to
fault is displayed for 1. Check that the starter switch
negative (-)
Stop input 40 seconds and the connections are not damaged.
5.3 970 2. Open circuit
CIU engine can not be 2. Check that the ignition switch
3. Activated for too
started during this cable is not damaged.
long
time. When a fault
is active, the engine
can be started but
not stopped.
1. Preheating can
1. Short circuit
not be activated. 1. Check that the relay input
Preheating to positive (+) or
5.4 626 2. Preheating cable is not damaged.
relay negative (ground) (–)
relay is constantly 2. Check the function of relay.
2. Open circuit
connected.
5.7. 98 Oil level Oil level is too low Warning indication Check the oil level.
1. Warning
indication.
2. The engine
1. Check the oil level.
control module
Oil Oil temperature is 2. Check the oil temperature.
5.8 175 limits engine output
temperature too high 3. Check the function of oil
(unless protection
temperature sensor.
has been turned off
with the diagnosis
tool VODIA).

Code SPN
No. Code
1. Short circuit
to the oil level sensor has not
Oil level to positive (+) or
5.9 98 None been damaged.
2. Check the function of oil level
2. Open circuit
sensor.
2. Check the intercooler
Engine control
(cleanliness).
module reduces
3. Check if there is air in the
engine power
cooling system.
Coolant Coolant temperature (unless the
6.1 110 4. Check the pressure cap on
temperature is too high protection has been
the expansion tank.
shut off with the
5. Check the function of coolant
VODIA diagnostic
temperature sensor.
tool).
thermostat.
Engine control
module reduces
2. Check the intercooler
engine power
(cleanliness).
Boost Boost temperature is (unless the
6.2 105 3. Check boost temperature
temperature too high protection has been
sensor the function of.
shut off with the
VODIA diagnostic
thermostat.
tool).
1. Check that the 8-pin
connector is not damaged.
Data link Instruments and
Faulty data link 2. Check that the cables
6.4 639 (CAN), warning lights stop
(CAN), CIU between the CIU and the engine
CIU working.
management unit are not
damaged.
Internal fault in
control module.
Engine not
2. Check that the cables
operating: engine
between the CIU and the engine
2017 / PSID Data link (CAN), can not be started.
6.5 639 management unit are not
201 EMS 2 Engine operating:
damaged.
engine idles and can
3. Check that sleeves 11 and 12
only be stopped with
in the connector on the CIU are
the auxiliary stop
not damaged.
(AUX-stop).

Code SPN
No. Code
Engine control 1. Check the oil level.
module reduces 2. Check that the air filters are
engine power not blocked.
Oil pressure is too (unless the 3. Check system pressure
6.6 100 Oil pressure
low protection has been valves and safety valves in the
shut off with the oil system.
VODIA diagnostic 4. Check the function of oil
tool). pressure sensor.
Engine stopped. The
Check that the oil pressure in
520 Piston cooling Piston cooling fault is de-activated
6.7 the engine exceeds 175 kPa
192 pressure pressure is too low at engine speed
(25.4 psi).
below 1000 rpm.
1. Check that the piston cooling
pressure sensor contact is
1. Short circuit correctly installed.
Piston cooling
520 to positive (+) or 2. Check that the cable harness
6.8 pressure None
192 negative (ground) (–) to the piston cooling pressure
sensor
2. Open circuit sensor has not been damaged.
3. Check the function of piston
cooling pressure sensor.
1. Short circuit to 1. Check the supply voltage
negative (-) from the control unit.
Battery Problems in engine
6.9 158 2. Faulty alternator 2. Check the battery.
voltage, CIU starting.
3. Faulty battery or 3. Check the alternator.
battery cables 4. Check the 8-pin contact.
1. Check that the injector cables
are not damaged.
1. Engine runs on 5
1. Electrical fault 2. Check that the injector
cylinders.
Injector, 2. Faulty connections are not damaged.
7.1 651 2. Abnormal sound.
cylinder #1 compression or 3. Check fuel supply pressure.
3. Reduced
injector 4. Check the valve clearance.
performance.
5. Do a compression test and
check cylinder #1.
are not damaged.
1. Engine runs on 5
cylinders.
3. Reduced
performance.
check cylinder #2.

Code SPN
No. Code
are not damaged.
1. Engine runs on 5
cylinders.
3. Reduced
performance.
check cylinder #3.
are not damaged.
1. Engine runs on 5
cylinders.
3. Reduced
performance.
check cylinder #4.
are not damaged.
1. Engine runs on 5
cylinders.
3. Reduced
performance.
check cylinder #5.
are not damaged.
1. Engine runs on 5
cylinders.
3. Reduced
performance.
check cylinder #6.
Crankcase The engine is 1. Check whether the crankcase
ventilation shut down (if the ventilation is blocked.
Crankcase ventilation
7.7 153 pressure protection has not 2. Check whether cylinder liner,
pressure too high
(TAD950- been shut off by the piston or piston rings
952VE) parameter tool). are worn or damaged.

Code SPN
No. Code
1. Check that the crankcase
ventilation pressure
sensor contact is correctly
Crankcase
installed.
ventilation 1. Short circuit
pressure to positive (+) or
7.8 153 None to the crankcase
ventilation pressure sensor has
(TAD950- 2. Open circuit
not been damaged.
952VE)
crankcase ventilation pressure
sensor.
1. Fault in cable
Internal EGR harness (boost Engine control 1. Check the cable harness
8.5 2791 (TAD950- pressure sensor) module reduces (boost pressure sensor).
952VE) 2. Mechanical fault engine power. 2. Check the IEGR.
on the IEGR
1. Faulty values in oil
pressure and boost
pressure sensors.
2. Fault for oil 1. Check that the cable harness
620/ pressure and boost to oil pressure and boost
1079/ Power supply 1. Shortcut pressure sensor. pressure sensor has not been
9.3
1080 to sensor 2. Fault in sensor 3. Low engine damaged.
output. 2. Check the oil pressure and
4. The instrument boost pressure sensors.
displays zero oil
pressure and boost
pressure.
Faulty data 2. Check that the cables
9.2 608 Faulty data link None.
link (J1587) between the CIU/DCU and the
engine management unit are not
damaged.

Code SPN
No. Code
1. Faulty values in oil
pressure and boost
pressure sensors.
2. Fault for oil 1. Check that the cable harness
pressure and boost to oil pressure and boost
620/ Power supply 1. Shortcut pressure sensor. pressure sensor has not been
9.3
1079 to sensor 2. Fault in sensor 3. Low engine damaged.
output. 2. Check the oil pressure and
4. The instrument boost pressure sensors.
displays zero oil
pressure and boost
pressure.
Data set 1. Internal fault in 1. Re-program the control
memory control module Engine does not module.
9.8 630
EEPROM, 2. Programming start. 2. If the fault remains, change
CIU faulty the control module.
1. Faulty EEPROM, 1. CIU returns to
CIU factory setting.
Fault in
2. Faulty flash 2. Engine goes to 1. Re-program the unit.
9.8 629 control unit,
memory, CIU idle. 2. Change the CIU unit.
CIU
3. Fault in control 3. Engine can not be
module, CIU started.
Memory fault in
Engine might not
9.9 639 Memory fault engine management Re-program the unit.
start.
system
Data set 1. Internal fault in 1. Re-program the control
memory control module Engine does not module.
9.9 630
EEPROM, 2. Programming start. 2. If the fault remains, change
EMS faulty the control module.
1. Engine misfires.
Control Internal fault in
9.9 629 2. Engine does not Change the control unit.
module EMS control module
start.

6.4.2 CUMMINS engine error codes
For the detailed information, see: “CUMMINS

ENGINE MANUAL”.

Code
Description Failure Symptom Suggested Actions
SPN / FMI
Engine speed limited to
1. Check the cabling between
Vehicle Speed Sensor max. engine speed. Road
84 / 2 control unit and component.
Circuit - data incorrect speed gover ner will not
2. Check the sensor.
work.
Engine speed limited to
Vehicle Speed Sensor 1. Check the cabling between
max. engine speed. Road
84 / 10 Circuit - tampering has control unit and component.
speed gover ner will not
been detected 2. Check the sensor.
work.
SAE J1939 Multiplexing Engine may only idle or
Use diagnostic menu to find the
91 / 19 Accelerator Pedal Sensor engine will not accelerate to
incorrect segment.
System Error full speed.
A c c e l e r a t o r P e d a l S evere der ate in p ower 1. Check the cabling between
91 / 3 Position Sensor Circuit - output of the engine. Limp control unit and component.
shorted high home capability only. 2. Check the sensor.
A c c e l e r a t o r P e d a l S evere der ate in p ower 1. Check the cabling between
91 / 4 Position Sensor Circuit - output of the engine. Limp control unit and component.
shorted low home capability only. 2. Check the sensor.
N o n e o n p e r f o r m a n c e . 1. Check the cabling between
Wate r i n Fu e l S e ns o r
97 / 3 No water-in-fuel warning control unit and component.
Circuit - shorted high
available. 2. Check the sensor.
N o n e o n p e r f o r m a n c e . 1. Check the cabling between
Wate r i n Fu e l S e ns o r
97 / 4 No water-in-fuel warning control unit and component.
Circuit - shorted low
available. 2. Check the sensor.
Water in Fuel Indicator Possible white smoke, loss
97 / 15 Drain water from the fuel.
High – Maintenance of power, or hard starting
Progressive power derate
Engine Oil Pressure Low Check the engine oil level, top up as
100 / 1 increasing in severity from
– critical needed.
time after alert.
Engine Oil Pressure None on performance. No 1. Check the cabling between
100 / 2 Sensor Circuit - data engine protection for oil control unit and component.
incorrect pressure. 2. Check the sensor.
100 / 3 Sensor Circuit - shorted engine protection for oil control unit and component.
high pressure. 2. Check the sensor.
100 / 4 Sensor Circuit - shorted engine protection for oil control unit and component.
low pressure. 2. Check the sensor.

Code
SPN / FMI
Engine Oil Pressure Low Check the engine oil level, top up as
100 / 18 None on performance.
– warning needed.
Intake Manifold Pressure 1. Check the cabling between
102 / 2 S e n s o r C i r c u i t - d a t a Engine power derate. control unit and component.
incorrect 2. Check the sensor.
Derate in power output of
102 / 3 Sensor #1 Circuit - control unit and component.
the engine.
shorted high 2. Check the sensor.
Derate in power output of
102 / 4 Sensor #1 Circuit - control unit and component.
the engine.
shorted low 2. Check the sensor.
1. Check the coolant level in the
engine, top up as needed.
Intake Manifold Progressive power derate
2. Check that the charge-air cooler
105 / 0 Temperature #1 High - increasing in severity from
is clean, clean as needed.
critical time after alert.
3. Check that fan belts are intact.
Intake Manifold Possible white smoke. No 1. Check the cabling between
105 / 3 Temperature Sensor #1 engine protection for intake control unit and component.
Circuit - shorted high manifold air temperature. 2. Check the sensor.
I n t a k e M a n i f o l d Possible white smoke. No 1. Check the cabling between
105 / 4 Temperature Sensor #1 engine protection for intake control unit and component.
Circuit - shorted low manifold air temperature. 2. Check the sensor.
A mbi ent A ir Pre s sure 1. Check the cabling between
108 / 2 S e n s o r C i r c u i t - d a t a Engine power derate. control unit and component.
108 / 3 Sensor Circuit – shorted Engine power derate. control unit and component.
high 2. Check the sensor.
108 / 4 Sensor Circuit – shorted Engine power derate. control unit and component.
low 2. Check the sensor.
2. Check that the radiator is clean.
3. Check if there is air in coolant
Engine Coolant Progressive power derate
system.
110 / 0 Temperature High – increasing in severity from
4. Check the cap on the expansion
critical time after alert.
tank.
6. Check the thermostat.

Code
SPN / FMI
Engine Coolant Possible white smoke. No 1. Check the cabling between
110 / 3 Temperature Sensor engine protection for engine control unit and component.
Circuit - shorted high coolant temperature. 2. Check the sensor.
Engine Coolant Possible white smoke. No 1. Check the cabling between
110 / 4 Temperature Sensor engine protection for engine control unit and component.
Circuit - shorted low coolant temperature. 2. Check the sensor.
2. Check that the radiator is clean.
3. Check if there is air in coolant
Engine Coolant Progressive power derate
system.
110 / 16 Temperature High – increasing in severity from
4. Check the cap on the expansion
warning time after alert.
tank.
6. Check the thermostat.
Progressive power derate 1. Check the coolant level in the
Engine Coolant Level Low
111 / 1 increasing in severity from engine, top up as needed.
- critical
time after alert. 2. Check the sensor.
Electrical Charging Warning lamp illuminated
167 / 1 System Voltage Low - until very low battery voltage Check batteries and alternator.
critical level condition is corrected.
Amber warning lamp
Electrical Charging
illuminated until high 1. Check fuses.
167 / 16 System Voltage High -
battery voltage condition is 2. Check batteries and alternator.
warning level
corrected.
Electrical Charging Amber lamp will light until
167 / 18 System Voltage Low - low battery voltage condition Check batteries and alternator.
warning level is corrected.
Battery #1 Voltage High - Possible electrical damage 1. Check fuses.
168 / 16
warning to all electrical components. 2. Check batteries and alternator.
Battery #1 Voltage Low - Engine may stop running or 1. Check fuses.
168 / 18
warning be difficult to start. 2. Check batteries and alternator.
Fuel injection disabled until
En gin e S p e e d H i gh – Ease off throttle or select higher
190 / 0 engine speed fails below the
critical gear.
overspeed limit.
Engine can exhibit misfire
as control switches from
Engine Speed / Position
the primary to the backup 1. Check the cabling between
Sensor Circuit - lost both
190 / 2 speed sensor. Engine power control unit and component.
of two signals from the
is reduced while the engine 2. Check the sensor.
magnetic pickup sensor
operates on the backup
speed sensor.
Real Time Clock - power
251 / 2 None on performance. -
interrupt

Code
SPN / FMI
Accelerator Pedal Idle 1. Check the cabling between
558 / 2 Validation Circuit - data Engine will only idle. control unit and component.
558 / 4 V a l i d a t i o n C i r c u i t - Engine will only idle. control unit and component.
shorted low 2. Check the sensor.
558 / 13 Validation Circuit - out of Engine will only idle. control unit and component.
calibration 2. Check the sensor.
Possible no noticeable
performance effects
Fuel Pump Control or engine dying or har
1. Check fuses.
627 / 2 Module, Electronic starting. Fault information,
2. Check batteries and alternator.
Calibration Code Error trip information, and
maintenance monitor data
can be inaccurate.
Engine Control Module –
629 / 12 Engine may not start. Check the control unit.
critical internal failure
Possible no noticeable
performance effects
or engine dying or har
Engine Control Module – Re-program the software in control
630 / 2 starting. Fault information,
data lost unit engine.
trip information, and
maintenance monitor data
can be inaccurate.
One or more multiplexed
SAE J1939 Multiplexing devices will not operate Use diagnostic menu to find
639 / 9
PGN Timeout Error properly. One or more incorrect segment.
symptoms will occur.
At least one multiplexed
SAE J1939 Multiplexing Use diagnostic menu to find
639 / 13 d ev i c e w i l l n o t o p e r a t e
Configuration Error incorrect segment.
properly.
External Speed
Input (Multiple Unit Primary or secondary
644 / 2 control unit and component.
Sychronization) - data engines may be shut down.
incorrect
The fan may stay on 1. Check the cabling between
Fan Clutch Circuit -
647 / 4 continuously or not run at control unit and component.
shorted low
all. 2. Check the sensor.
Injector Solenoid Valve 1. Check the cabling between
Engine can misfire or
651 / 5 Cylinder #1 Circuit - open control unit and component.
possibly run rough.
circuit 2. Check the sensor.

Code
SPN / FMI
651 / 7 Cylinder #1 Circuit – out Engine will shut down. control unit and component.
of adjustment 2. Check the sensor.
652 / 5 Cylinder #2 Circuit – open control unit and component.
possibly run rough.
possibly run rough.
possibly run rough.
654 / 7 Cylinder #4 Circuit - out Engine will shut down. control unit and component.
possibly run rough.
Injecto r Solenoid Valve 1. Check the cabling between
656 / 5 Cylinder #6 Circuit - open control unit and component.
possibly run rough.
656 / 7 Cylinder #6 Circuit - out Engine will shut down. control unit and component.
Auxiliary Equipment 1. Check the cabling between
Possible engine power
703 / 11 Sensor Input # 3 (OEM control unit and component.
derate.
Switch) 2. Check the sensor.
Remote accelerator will not
Remote Accelerator 1. Check the cabling between
operate. Remote accelerator
974 / 3 Pedal Position Sensor control unit and component.
position will be set to zero
Circuit - shorted high 2. Check the sensor.
percent.

Code
SPN / FMI
Remote accelerator will not
Remote Accelerator 1. Check the cabling between
operate. Remote accelerator
974 / 4 Pedal Position Sensor control unit and component.
position will be set to zero
Circuit - shorted low 2. Check the sensor.
percent.
The engine will not respond
SAE J1939 Multiplexing to the remote throttle. 1. Check the cabling between
974 / 19 Remote Throt tle Dat a Engine may only idle. The control unit and component.
Error primary or cab accelerator 2. Check the sensor.
may be able to be used.
Engine Speed/Position
Sensor #1 (Crankshaft)
1043 / 3 Engine will only idle. control unit and component.
Supply Voltage Circuit -
shorted high
Engine Speed/Position
Sensor #1 (Crankshaft)
1043 / 4 Engine will only idle. control unit and component.
Supply Voltage Circuit -
shorted low
Sensor Supply Voltage #1
1079 / 3 Engine power derate. control unit and component.
Circuit -shorted high
Sensor Supply Voltage #1
1079 / 4 Engine power derate. control unit and component.
Circuit - shorted low
Engine will run poorly but
High Fuel Pressure
will be severely derated.
1347 / 3 Solenoid Valve #1 Circuit -
Fuel pressure will be higher
- shorted high
than commanded.
Engine will run poorly at
High Fuel Pressure
idle. Engine will have low
1347 / 4 Solenoid Valve #1 Circuit -
power. Fuel pressure will be
- shorted low
higher than commanded.
Fuel Pumping Element
Engine will not run or
1347 / 7 #1 (Front) - mechanically -
possible low power.
stuck

6.4.3 YUCHAI engine error codes
For the detailed information, see: “YUCHAI

ENGINE MANUAL”.

SPN
Description Possible Causes Suggested Actions
Code
1. Check if the plug of fuel pressure sensor is
connected correctly.
2. Check if the circuit of fuel pressure sensor is in
1. Short circuit of positive good condition.
pole (+) or negative pole (-) 3. Check if the fuel pressure sensor is installed
Fuel pressure
94 2. Open circuit correctly.
sensor
3. Low pressure of fuel 4. Check the function of fuel pressure sensor.
supply 5. Check if the manual pump can be used to
increase the pressure.
6. Check the fuel pre-filter.
7. Check the fuel filter.
1. Drain the main fuel filter.
1. Water in fuel
Water in fuel 2. Check if the cable of indicator is short circuit or
2. Short circuit
97 or indicator open circuit.
3. Open circuit
malfunction 3. Check the function of indicator. Replace it if
4. Indicator error
necessary.
1. Low lubricating oil level 1. Check the lubricating oil level.
Lubricating
2. Short circuit of positive 2. Check if the harness to lubricating oil level
98 oil level and
pole (+) or negative pole (-) sensor is in good condition.
sensor
3. Open circuit 3. Check the function of lubricating oil level sensor.
1. Check if the harness to lubricating oil pressure
sensor is in good condition.
2. Check if the lubricating oil pressure sensor is
connected correctly.
Lubricating 1. Short circuit of positive
3. Check the lubricating oil level.
100 oil pressure pole (+) or negative pole (-)
4. Check if the lubricating oil filter is clogged.
sensor 2. Open circuit
5. Check the pressure valve and safety valve of
lubrication system.
6. Check the function of lubricating oil pressure
sensor.

SPN
Code
1. Check if the plug of supercharged air pressure
sensor is connected correctly.
2. Check if the circuit of supercharged air pressure
1. Short circuit of positive
Supercharged pole (+) or negative pole (-)
3. Check if the supercharged air pressure sensor
102 pressure 2. Open circuit
is installed correctly.
sensor 3. High supercharged
4. Check the function of supercharged air pressure
pressure
sensor.
5. Check the function of turbocharger.
6. Check the fuel amount / pump nozzle.
2. Check the intercooler.
3. Check the function of coolant temperature
sensor.
1. High supercharged air 4. Check the function of thermostat.
Supercharged temperature 5. Check if the plug of supercharged air
105 air temperature 2. Short circuit of positive temperature sensor is connected correctly.
and sensor pole (+) or negative pole (-) 6. Check if the circuit of supercharged air
3. Open circuit temperature sensor is in good condition.
7. Check if the supercharged air temperature
sensor is installed correctly.
8. Check the function of supercharged air
temperature sensor.
1. Check if the plug of air filter is connected
correctly.
Air filter 2. Check if the circuit of air filter is in good
107 pole (+) or negative pole (-)
pressure condition.
2. Open circuit
3. Check if the air filter is installed correctly.
4. Check the function of air filter.

SPN
Code
2. Check the intercooler.
3. Check if there is air in the cooling system.
4. Check the pressure cap on expansion water
tank.
1. High coolant temperature 5. Check the function of coolant temperature
Coolant
2. Short circuit of positive sensor.
110 temperature
pole (+) or negative pole (-) 6. Check the function of thermostat.
and sensor
3. Open circuit 7. Check if the plug of coolant temperature sensor
is connected correctly.
8. Check if the circuit of coolant temperature
9. Check if the coolant temperature sensor is
installed correctly.
1. High coolant temperature 1. Check the coolant level.
Low coolant
2. Short circuit of positive 2. Check the function of coolant level sensor.
111 level or sensor
pole (+) 3. Check if the circuit of coolant level sensor is in
malfunction
3. Sensor malfunction good condition.
1. Short circuit of negative
pole (-) 1. Check the power supply voltage of control unit.
Battery voltage 2. Malfunction of charging 2. Check the battery.
158
(SPN) generator 3. Check the charging generator.
3. Malfunction of battery or 4. Check the 8-pin plug.
battery cables
1. Check if the cable harness of lubricating oil
temperature sensor is in good condition.
2. Check if the lubricating oil temperature sensor is
pole (+) or negative pole (-)
Lubricating oil installed correctly.
175 2. Sensor malfunction
temperature 3. Check the lubricating oil level.
3. High lubricating oil
4. Check the lubricating oil temperature.
temperature
5. Check the functions of lubricating oil temperature
sensor.
High engine Stop the machine to check the causes of high
190 High engine rotation speed
rotation speed engine rotation speed.

SPN
Code
1. Check if the potentionmeter is installed correctly.
Malfunction
2. Check if the cable harness to potentionmeter is
of engine 1. Short circuit of positive
in good condition.
rotation speed pole (+) or negative pole (-)
608 3. Check the function of potentionmeter.
potentionmeter 2. Sensor malfunction
4. Check if the 8-pin plug is in good condition.
to CIU or data 3. Data line malfunction
5. Check if the cable harness betweeen CIU and
line
engine control unit is in good condition.
1. Check if the cable harness of lubricating oil
pressure sensor and supercharged air pressure
Power supply of 1. Short circuit
620 sensor is in good condition.
sensor 2. Sensor malfunction
2. Check the lubricating oil pressure sensor and
supercharged air pressure sensor.
1. Short circuit of positive 1. Check if the cable of relay input is in good
Power supply of
626 pole (+) or negative pole (-) condition.
relay (SPN)
2. Sensor malfunction 2. Check the function of relay.
1. Inner malfunction of
control unit
2. Malfunction of electrical
removable read-only
Control unit 1. Re-programme the control unit.
629 memorizer (EEPROM)
malfunction 2. Replace the CIU unit.
3. Malfunction of flash
memory, CIU
4. Malfunction of control
unit, CIU
Data collection 1. Inner malfunction of
1. Re-programme the control unit.
630 memorizer control unit
2. Replace the control unit when necessary.
(SPN) 2. Program malfunction
1. Check if the plug of engine rotation speed
2. Check if the cable of engine rotation speed
Camshaft 1. No signal
636 speed sensor 2. Abnormal frequency
3. Check if the engine rotation speed sensor is
malfunction 3. Sensor malfunction
installed correctly.
4. Check the function of engine rotation speed
sensor.

SPN
Code
1. Check if the plug of engine rotation speed
1. No signal
2. Check if the cable of engine rotation speed
Flywheel 2. Abnormal frequency
637 rotation speed 3. Sensor sends out
3. Check if the engine rotation speed sensor is
sensor “interval” signals
installed correctly in the flywheel cover.
4. Sensor malfunction
4. Check the function of engine rotation speed
sensor.
1. Reprogramme the control unit.
2. Check if the 8-pin connector is in good condition.
Memorizer 3. Check if the cable harness between CIU and
639 Memorizer malfunction
malfunction engine control unit is in good condition.
4. Check if the plug hole 11 and 12 on CIU plug are
in good condition.
Cylinder 1
651
(SPN)
Cylinder 2 1. Check if the cable of pump nozzle is in good
652 condition.
(SPN)
Cylinder 3 1. Electrical malfunction 2. Check if the connector of pump nozzle is in
653
(SPN) 2. Difference of compressed good condition.
Cylinder 4 pressure or malfunction of 3. Check the fuel supply pressure.
654
(SPN) pump nozzle 4. Check the clearance of air valve.
Cylinder 5 5. Test the compressed pressure and check the
655
(SPN) cylinder.
Cylinder 6
656
(SPN)
1. Check if the power supply switch is connected
Start motor well.
677 pole (-)
(SPN) 2. Check if the cable of power supply switch is in
2. Too long operating time
good condition.
1. Short circuit of negative 1. Check if the power supply switch is connected
Stop input to pole (-) well.
970
CIU 2. Too long operating time 2. Check if the cable of power supply switch is in
3. Open circuit good condition.
1. Check if the power supply switch is connected
Start input to well.
520194 pole (-)
CIU 2. Check if the cable of power supply switch is in
good condition.
Stop inout to
520195 pole (-) Check if the power supply switch is connected well.
EMS

6.5 Transmission Error Codes
For the detailed information, see: “DANA

TRANSMISSION MANUAL”.
Table 6-13 Tranmission Error Codes

Code No. Description Limitation Suggested Actions
Memory error in control Transmission in locked Contact SANY distributors for more
00.50
unit transmission neutral position information.
00.51
00.52
00.53
Signal from sensor oil
1. Check cabling to sensor oil pressure.
pressure indicates low Transmission in locked
20.60 2. Check sensor oil pressure (with
oil pressure when there neutral position
engine on / off).
should be pressure
Signal from sensor oil
pressure indicates low Transmission in locked
20.61 2. Check sensor oil pressure (with
oil pressure when there neutral position
engine on / off).
should be pressure
Electrical malfunction Perform checks according to error code
20.62 Control unit activates
sensor oil pressure 50.XX.
Electrical malfunction Transmission in locked
20.63 -
solenoid valve drive neutral position
Electrical malfunction Transmission in locked
20.64 -
solenoid valve drive neutral position
Solenoid valve drive reacts Transmission in locked
20.65 -
too slow neutral position
Control unit saves stored
1. Check cabling to control unit.
information to flash
30.04 Low battery voltage 2. Check alternator, battery and cabling
memory and restarts to
between battery and alternator.
clear memory
Control unit receives
reduced proportional 1. Check voltage feed.
30.05 High battery voltage control precision 2. If auxiliary start equipment is
depending on reduced connected, disconnect it.
PWM work cycle
Reference voltage to Control unit receives 1. Check voltage feed.
31.00
sensors is too low reduced sensor signals 2. Check control unit.
Reference voltage to Control unit receives 1. Check voltage feed.
31.01
sensors is too high reduced sensor signals 2. Check control unit.


Incorrect direction from Control unit locks Check cabling to gear selector with
40.06
gear selector transmission in neutral regards to forward and reverse signal.
Control unit does not
Incorrect gear selection allow change of range, Check cabling to gear selector with
41.06
from gear selector however, operation of regards to signal range.
machine is possible
1. Check transmission with purpose to
Control unit indicates that understand if and, if that is the case,
42.04 Actual gear ratio too low one or several clutches which clutch is slipping.
are slipping 2. Check the set transmission ratio for
the control unit.
1. Check transmission with purpose to
Control unit indicates that understand if and, if that is the case,
42.05 Actual gear ratio too high one or several clutches which clutch is slipping.
are slipping 2. Check the set transmission ratio for
the control unit.
Signal from sensor engine 1. Check cabling to sensor temperature
rpm and oil temperature Control unit indicates the torque converter.
43.03
transmission outside valid error 2. Check sensor temperature torque
range converter.
Control unit indicates the 1. Check cabling to sensor temperature
Torque converter error to make operator torque converter.
43.07
temperature exceed 100°C aware of the warning's 2. Check sensor temperature torque
level converter.
The control unit protects
the transmission and does
not allow the temperature
1. Check cabling to sensor temperature
in the torque converter
Torque converter torque converter.
43.08 to exceed the limit value.
temperature exceed 125°C 2. Check sensor temperature torque
The control unit locks the
converter.
transmission in neutral,
engine is restricted to
50% of max. rpm
Sensor oil pressure short-
50.00 Control unit activates 2. Check sensor oil pressure (with
circuited to ground
engine on / off).
Sensor oil pressure not
50.01 Control unit activates 2. Check sensor oil pressure (with
connected or open circuit
engine on / off).


The control unit limits
the transmission's
temperature 1. Check cabling to sensor oil sump
Sensor engine rpm and oil
measurement to the temperature transmission.
51.00 temperature transmission
lowest value in its 2. Check sensor engine rpm and oil
short-circuited to ground
settings, which results temperature transmission.
in poor temperature
compensation
the transmission's
Sensor engine rpm and oil temperature 1. Check cabling to sensor oil sump
temperature transmission measurement to the temperature transmission.
51.01
not connected or short- highest value in its 2. Check sensor engine rpm and oil
circuited to ground settings, which results temperature transmission.
in poor temperature
compensation
the transmission's
temperature
1. Check cabling to sensor oil sump
Sensor oil temperature measurement to the
52.00 temperature transmission.
short-circuited to ground highest value in its
2. Check sensor oil temperature.
settings, which results
in poor temperature
compensation
the transmission's
temperature
1. Check cabling to sensor oil sump
Sensor oil temperature measurement to the
52.01 temperature transmission.
short-circuited to ground highest value in its
2. Check sensor oil temperature.
settings, which results
in poor temperature
compensation
Analogue input 3 short-
53.00 - -
circuited to ground
Analogue input 3 not
53.01 - -
connected
54.00 - -
circuited to ground
54.01 - -
connected
55.00 - -
circuited to ground


55.01 - -
connected
56.00 - -
circuited to ground
56.01 - -
connected
When only one rpm signal
which is not the engine 1. Check cabling between control unit
Sensor drum rpm short-
60.00 rpm signal is incorrect, and component.
circuited to ground
the control unit calculates 2. Check component.
the missing rpm.
Sensor drum rpm not
connected
the missing rpm.
Sensor rpm output shaft
the missing rpm.
Sensor rpm output shaft
not connected
the missing rpm.
Sensor engine rpm short-
circuited to ground
the missing rpm.
Sensor engine rpm not
connected or open circuit
the missing rpm.
Sensor rpm turbine short-
circuited to ground
the missing rpm.


Sensor rpm turbine not
connected
the missing rpm.
Electric malfunction
solenoid valve forward,
cables are short circuited
70.00 to each other, signal cable Control unit activates Check cabling to solenoid valve forward.
short-circuited to voltage
or positive cable short-
circuited to ground
Electric malfunction 1. Check cabling to solenoid valve
70.01 solenoid valve forward or Control unit activates forward.
short-circuited voltage 2. Check solenoid valve forward.
1. Check cabling to solenoid valve
solenoid valve forward,
70.02 Control unit activates forward.
control current above
2. Check solenoid valve forward.
1400mA
solenoid valve forward, 1. Check cabling to solenoid valve
70.03 control current outside Control unit activates forward.
approved interval. 2. Check solenoid valve forward.
Incorrect impedance
Electric malfunction gear 2
/ 4, cables short-circuited
to each other, signal cable
71.00 Control unit activates Check cabling to solenoid valve gear.
circuited to ground
Electric malfunction gear
1. Check cabling to solenoid valve gear.
71.01 2 / 4, open circuit or short- Control unit activates
2. Check solenoid valve gear 2/ 4.
circuited voltage
Electric malfunction gear 1. Check cabling to solenoid valve gear
71.02 2 / 4,control current above Control unit activates 2 / 4.
1400mA 2. Check solenoid valve gear 2/ 4.
solenoid valve gear 1. Check cabling to solenoid valve gear
71.03 2 / 4,control current Control unit activates 2 / 4.
outside approved interval 2. Check solenoid valve gear 2/ 4.
(incorrect impedance)


solenoid valve reverse,
cables are short circuited
72.00 to each other, signal cable Control unit activates Check cabling to solenoid valve reverse.
circuited to ground
72.01 Control unit activates reverse.
open circuit or short-
2. Check solenoid valve reverse.
circuited voltage
72.02 Control unit activates reverse.
control current above
2. Check solenoid valve reverse.
1400mA
solenoid valve reverse, "1. Check cabling to solenoid valve
72.03 control current outside Control unit activates reverse.
approved interval. 2. Check solenoid valve reverse.
Incorrect impedance
Electric malfunction gear 1
/ 3, cables short-circuited
to each other, signal cable Check cabling to solenoid valve gear 1 /
73.00 Control unit activates
short-circuited to voltage 3.
circuited to ground
73.01 1 / 3, open circuit or short- Control unit activates 1 / 3.
circuited voltage 2. Check solenoid valve gear 1 / 3.
73.02 1 / 3,control current above Control unit activates 1 / 3.
1400mA 2. Check solenoid valve gear 1 / 3.
solenoid valve gear 1. Check cabling to solenoid valve gear
73.03 1 / 3,control current Control unit activates 1 / 3.
outside approved interval 2. Check solenoid valve gear 1 / 3.
Analogue output signal 4
74.00 related error; output signal - -


74.01 not connected or short- - -
circuited to voltage
Analogue output signal
74.02 4 control current above - -
1400mA
4 control current outside
74.03 - -
approved interval
75.00 5 output signal short- - -
circuited to ground
75.01 not connected or short- - -
75.02 5 control current above - -
1400mA
5 control current outside
75.03 - -
approved interval
Electric malfunction brake,
Control unit indicated the
76.00 cable short-circuited to Check cabling to solenoid valve brake.
error, no limitation
ground
Electric malfunction brake,
76.01 cable not connected or Check cabling to solenoid valve brake.
Electric malfunction brake, 1. Check cabling to solenoid valve
76.02 control current above brake.
1400mA 2. Check solenoid valve brake.
brake, control current Control unit indicated the
76.03 brake.
outside approved interval error, no limitation
2. Check solenoid valve brake.
Electric malfunction drive,
Transmission in locked 1. Check cabling to solenoid valve drive.
80.00 cable short-circuited to
neutral position 2. Check solenoid valve drive.
ground
80.01 cable not connected or


Electric malfunction gear 1. Check cabling to solenoid valve 2 / 4.
81.00 selection 2 / 4, cable Control unit activates 2. Check solenoid valve gear selection
short-circuited to ground 2 / 4.
1. Check cabling to solenoid valve 2 / 4.
selection 2 / 4, cable
81.01 Control unit activates 2. Check solenoid valve gear selection
not connected or short-
2 / 4.
Electric malfunction gear 1. Check cabling to solenoid valve 1 / 3.
82.00 selection 1 / 3, cable Control unit activates 2. Check solenoid valve gear selection
short-circuited to ground 1 / 3.
1. Check cabling to solenoid valve 1 / 3.
selection 1 / 3, cable
82.01 Control unit activates 2. Check solenoid valve gear selection
not connected or short-
1 / 3.
83.00 cable short-circuited to
ground
83.01 cable not connected or
90.XX-99. Transmission in locked Contact SANY distributors for more
System error
XX neutral position information.

6.6 Machine Error Codes
Table 6-14 Machine Error Codes
No. Name Possible Causes Suggested Actions Reference

1. Check if there is leakage
Fuel level is too low,
in fuel tank.
01 FuelLevel_L checked to be lower than -
2. Check sensors and
50L.
wires.
1. see “Engine oil,
1. Fill engine oil. changing” on page 5-42
Engine oil pressure is too
2. Change oil filter. 2. see “Oil filter /
02 Eng_OilPre_L low, checked to be lower
3. Check oil level sensor Bypass filter (engine
than 80kPa.
and their wires. option VOLVO),
changing” on page 5-44
1. Check if there are
impurities in engine radiator. 1. see “Radiator,
Engine temperature is too
If yes, clean it. cleaning” on page 5-56
03 Eng_Tem_H high, checked to be higher
2. Check coolant tank and 3. see “Radiator fan,
than 98 °C.
pipes. checking” on page 5-55
3. Check fan and bulleys.
1. Check if the coolant level
is really too low.
2. Check all the components
Engine coolant level is too with a multi-meter. 1. see “Coolant level,
04 Eng_Coolant_L low; signal of water level 3. Check if the switch is too checking and topping
switch is with error. dirty. up” on page 5-52
4. Check if the outlet
w ire s of t h e sw itc h are
disconnected.
Battery voltage error,
1. Check the generator.
05 Voltage_L checked to be lower than -
2. Check battery volume.
23V.
Signal line: 1010
1. Check if the temperature
is too high.
Gearbox temperature is 2. Check if the radiator
06 GearboxTem_H too high, checked to be temperature control switch, -
higher than 90 °C. motor and radiator blade
are too dirty.
3. Check the parallel
resistance circuit.


Oil pressure of the
Unscrew the sensor and
gearbox is too low,
07 GearboxPre_L check if it is blocked, -
checked to be lower than
defective and disconnected.
16bar.
Brake oil temperature is Signal line: 1048
BrakeOil_Tem_
08 too high; the temperature Check components, circuits -
H
switch acts. and fan.
Signal line: 1012 and 1049
Brake oil pressure is too
Check hydraulic pressure
09 BrakeOil_Pre_L low; the parking pressure -
and circuits of parking
low switch acts.
valve, etc.
System oil pressure is too Chec k if the system oil
10 Sys_Pre_H high, checked to be higher pressure is higher than -
than 27MPa. 27MPa.
Signal line: 1046
1. Check the sensor plug.
2. Check if the sensor is
defective.
Hydraulic oil temperature
3. Check if the radiator is 5. see “Radiator fan,
11 Hyd_OilTem_H is too high, checked to be
working. checking” on page 5-55
higher than 65 °C.
4. Check the temperature
control switch on it.
5. Check if the radiator
blade is too dirty.
1. Check if the machine is in
The front lean protection critical state of tipping over.
12 Tilting_Protect approach switch is with 2. Check whether the -
error. approach switch is
damaged.
Leaning back is forbidden,
L o a d e d _To o _ The center line of the load
13 please retract or lower the -
Back moves to tyres.
boom.
Spreader approach switch Check the approach switch
14 Lock_Alarm -
is with error. of the spreader.
W e i g h t _To o _ The load is detected to be
15 Lower the boom. -
High too high.
Lower driving speed when
L o a d _
16 Run overspeed with load. t h e m a c h i n e i s h e av i l y -
OverSpeed
loaded.
T his is an alar m of t he
Safe_ Bypass_ Use the safety bypass key
17 safety bypass key. Check if -
On now.
it is used.


No time before receiving
Check if the engine CAN is
18 CAN2_Alarm any information from -
normal.
engine.
1. Retract the boom first if
the load percentage is too
large.
2. Check the approach
Overloaded or has a
19 Danger_Area switch for overturning -
danger of over-turning.
protection.
3. Check if wires of
the approach switch is
damaged.
First retract the boom and
Load more than rated lower it by using the safety
20 Load_Over_45T -
weight of 45t. bypass key; overload is
forbidden.
1. see “Engine oil,
Engine stops running due 1. Fill the engine oil. changing” on page 5-42
to too low engine oil. It 2. Change the oil filter. 2. see “Oil filter /
21 Flam_Out
can only be started after 3. Check the oil level sensor Bypass filter (engine
10 minutes. and its wires. option VOLVO),
changing” on page 5-43
Observe the actual
machine speed and turbo
speed. This happens
Difference between shaft
mostly because of faults
22 Gearbox_slip speed and turbocharger -
inside the gearbox. When
speed is too large.
this fault is repeated, check
the gearbox as soon as
possible.
Check if the CAN line of the
Long time before receiving
23 Angle_Sen_Err length & angle sensor is -
any length&angle signal.
connected properly.
1. Check whether power
supplying wires and
Signal of left rodless
Oilpre_L_Sen_ signal lines are connected
24 chamber sensor is -
Err normally.
incorrect.
2. Check if there is a fault in
sensor itself.


supplying wires and
Signal of right rodless
Oilpre_R_Sen_ signal lines are connected
25 chamber sensor is -
Err normally.
incorrect.
sensor itself.
supplying wires and
Oilpre_O_Sen_ Signal of rod chamber signal lines are connected
26 -
Err sensor is incorrect. normally.
sensor itself.
1. Check if the filter is too
dirty. If yes, clean or change
Ctr_Filter_ it.
27 Filter signal error. -
Blocking 2. Check switch
components with a
multimeter.
1. see “Air filter
H y d _ F i l t e r _ Hydraulic oil filter is it.
28 element, changing” on
Blocking blocked. 2. Check switch
page 5-107
components with a
multimeter.
B r a ke _ F i l t e r_ it. 1. see “Brake oil filter,
29 Brake oil filter is blocked.
Blocking 2. Check switch changing” on page 5-70
components with a
multimeter.
The declutch switch is
There is a signal of defective or stuck. If it is
30 FootSwitch_Err declutch detected for a not pressed down for a -
long time. long time, please check the
signal line.
1. Check the relay and its
The boom angle increases wires.
31 Vacumm_Pump after the down valve is 2. Check the if -
powered. electromagnetic plug is
loose.


The machine speed is
1. Check if the sensor is
detected to be lower than
32 Speed_Sen_Err defective and loose. -
0.3 km/h at 1st or 2nd
2. Check the power supply.
gear.
This is a engine internal
The engine SPN is not
33 SPN_Err fault, please refer to -
detected to be 0.
relevant SPN code.
see "Troubleshooting
M a g n e t i c _ Gear solenoid valve open Check if the circuit of gear
34 the cable harness" on
Alarm circuit or short circuit solenoid valveis normal.
page 6-19
N o s i g n a l f r o m g e a r Check if the signal of gear
35 Joy_Alarm -
selector selector is normal.
5MPa pressure difference
H o i s P r e s _ b e t w e e n l e f t n o - r o d Sideshift the spreader to
36 -
Alarm chamber and right no-rod reduce its deflection.
chamber
Contact the service
37 GPS_L_Fi GPS level 1 lock engineer to unlock the -
machine.
Contact the service
38 GPS_L_Sec GPS level 2 lock engineer to unlock the -
machine.
GPS no installed. The GPS
39 GPS_EN GPS set -
protection is not active.
GPS no installed. The GPS
40 GPS_Set GPS not set -
protection is not active.
Extend or lower the
41 Moment 90% Moment reaches 90% sp r e ad e r s l ow ly. Tr y to -
retract the spreader.
42 Moment 105% Moment reaches 105% Retract the spreader. -
43 Undercharge Low battery volume Charge the battery. -
C a n _ E r r _ G e a r b o x C A N B u s Check the gearbox error
44 -
GearBo malfunction codes.
GearBox_SPN_ Check the gearbox error
45 Gearbox malfunction -
Alar codes.
Check the engine indicator
QSL9_Status_ T h e e n g i n e s i t u a t i o n
46 lights to prevent the engine -
Alarm indicator light is in alarm
from damaging.
1. Check if the urea level is
D EF_Ta nk _ L _ The urea level is lower too low.
47 -
Alarm than 30L 2. Fill in urea to prevent
abnormality.

NOTE:
Only the reach stackers equipped with stage
IV engines can display alarm information item
44-47.

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Reach Stacker Specifications
Specifications
7. Specifications
7.1 Technical Specifications��7-2
7.1.1 Basic parameters��7-2
7.1.2 Technical parameters�� 7-9
7.1.3 System configuration�� 7-12
7.1.3.1 Power system configuration�� 7-12
7.1.3.2 Spreader configuration�� 7-15
7.2 Unit Conversion��7-16
7.2.1 Unit abbreviation explanation��7-16
7.2.2 Conversion table, SI units �� 7-17
7.2.3 Conversion table, length�� 7-18
7.2.4 Conversion table, area �� 7-18
7.2.5 Conversion table, volume�� 7-18
7.2.6 Conversion table, weight ��7-19
7.2.7 Conversion table, pressure�� 7-19
7.2.8 Conversion table, temperature�� 7-19

Specifications Reach Stacker
7. SPECIFICATIONS
7.1 Technical Specifications
7.1.1 Basic parameters
Table 7-1
F
D E
A B
SRSC45C30 / SRSC45C2 / SRSC45H1 / SRSC45H2

Item Unit / SRSC45H2A / SRSC45H3 / SRSC45H4 Container
Reach Stacker
Machine weight kg 72000
A Overall length mm 11258
B Width of front wheel mm 4188
C Overall height mm 4770
D Wheel base mm 6000
E Width of rear wheel mm 3380
F Min. ground clearance mm 350
G Overall width mm 6042-12175
mm Load center 1965

Line 1 1-4 layer 45000
Kg
5 layer 43000
mm Load center 3815

Load
capacity
Kg 5 layer (8”6”) 30000
mm Load center 6315

Kg 4 layer (8”6”) 14000

Table 7-2
F
D E
A B
Item Unit SRSC4535H1 Heavyweight Container Reach Stacker

mm Load center 1965

Line 1 1st - 4th layer 45000
Kg
5th layer 43000
mm Load center 3815

Load
capacity
Kg 5th layer (8”6”) 3100
mm Load center 6315

Line 3 1st - 3rd layer 19000
Kg 4th layer (8”6”) 15000

Table 7-3
F
E
D
B
A
SRSC4540H2-70 Heavyweight Container Reach
Item Unit
Stacker
mm Load center 1965

Kg
5th layer 40000
mm Load center 3815
Load Line 2 1st - 3th layer 40000
capacity Kg
4th layer 37000
mm Load center 6315
Line 3 1st - 2rd layer 31000

Kg
3th layer 30000

Table 7-4
F
E
D
B
A
SRSC4545C2 / SRSC4545H1 Heavyweight Container
Item Unit
Reach Stacker
mm Load center 2100

Kg
5th layer(8’6”) 45000
Load mm Load center 3900
capacity Line 2
Kg 1st - 4th layer 45000
mm Load center 6400
Line 3
Kg 1st - 3rd layer 40000

Table 7-5
F
D E
A B
SRSC1009-6E / SRSC1009H5-6E Empty Container

Item Unit
Reach Stacker
mm Load center 1965
Line 1
Kg 1st - 6th layer (8”6”) 10000

Line 2
capacity Kg 1st - 5th layer 9000
mm Load center 6315

Line 3

Table 7-6
F
D E
A B
Item Unit SRSC0808-6EH Empty Container Reach Stacker

G Overall width mm 6053
mm Load center 1965
Line 1
Kg 1st - 6th layer (8”6”) 8000

Line 2
capacity Kg 1st - 5th layer 8000
mm Load center 6315

Line 3

Table 7-7
F
D E
A B
Item Unit SRSC3615-3 Lightweight Container Reach Stacker

mm Load center 1965
Line 1
Load Kg 1st - 3rd layer 35000
capacity mm Load center 3815
Line 2
Kg 1st - 2nd layer 15000

7.1.2 Technical parameters
Table 7-8 Technical Parameters

Model Technical Parameters
Max. Lifting Height 15100mm
Boom
Angle 0-60°
SRSC45C30 Max. Lifting Speed (unloaded/loaded) 480/250mm/s
/ SRSC45C2 Max. Lowering Speed (unloaded/loaded) 360/300mm/s
/ SRSC45H1 /
Max. Travel Speed (unloaded/loaded) 25/21 km/h
SRSC45H2 /
Gradeability (unloaded/loaded) 39/32 %
SRSC45H2A
/ SRSC45H3 / Min. Turning Radius 8000mm
SRSC45H4 Container Brake distance
8.5/2.0m
Reach Stacker (unloaded/loaded 31t, 10km/h)
Overall Displacement 210 ml/r
Max. Working Pressure 260 bar
Boom
Angle 0-60°
Max. Lifting Speed (unloaded/loaded) 420/250mm/s
Max. Lowering Speed (unloaded/loaded) 360/300mm/s
SRSC4535H1
Heavyweight
Container Reach
Min. Turning Radius 8800mm
Stacker
Brake distance
8.5/2.0m
(unloaded/loaded 31t, 10km/h)
Boom
Angle 0-57°
SRSC4540H2-70
Heavyweight
Container Reach
Stacker
Brake distance
1.6/2.4m


Boom
Angle 0-50°
SRSC4545C2 / Max. Lowering Speed (unloaded/loaded) 360/280mm/s

SRSC4545H1 Max. Travel Speed (unloaded/loaded) 20/15 km/h
Heavyweight Gradeability (unloaded/loaded) 26/17 %
Container Reach Min. Turning Radius 10000mm
Stacker
Brake distance
1.6/2.4m
Boom
Angle 0-64.5°
SRSC1009-6E /
SRSC1009H5-6E
Empty Container
Reach Stacker
Boom
Angle 0-64.5°
SRSC0808-6EH Max. Lowering Speed (unloaded/loaded) 400/300mm/s
Empty Container Max. Travel Speed (unloaded/loaded) 28 km/h
Reach Stacker Gradeability (unloaded/loaded) 38/31 %


Boom
Angle 0-46°
SRSC3615-3 Max. Travel Speed (unloaded/loaded) 29/24 km/h
Lightweight Container Gradeability (unloaded/loaded) 36/21 %
Reach Stacker Min. Turning Radius 7500mm
Brake distance
8.5/13m
(unloaded/loaded)

7.1.3 System configuration
7.1.3.1 Power system configuration
Table 7-9 Power System Configuration
Model SRSC45C30
Model No. VOLVO TAD1340VE

6 In-line Cylinders, 4 Strokes, Turbo Pressured, Centralized
Type
Air- Air Cooling, Electric Control, etc.
Engine Rated power 256kw/2100rpm
Max. torque 1745Nm/1260rpm
Exhaust gas standard EU Stage II
Average fuel consumption rate 197g/kWh
Gearbox Model No. DANA 15.5HR36000
Drive axle Model No. Kessler D102PL341
Model SRSC45H1 / SRSC4535H1
Model No. VOLVO TAD1151

Type
Exhaust gas standard EU Stage III
Gearbox Model No. DANA 15.7TE32418
Model SRSC45C2 / SRSC45H2 / SRSC4540H2-70
Model No. Cummins QSM11
Type
Exhaust gas standard Tier 3

Model SRSC45H2A
Type
Gearbox Model No. DANA 15.7TE32418
Model SRSC45H3
Type
Engine Rated power 177kW/2300rpm
Exhaust gas standard EU Stage IV
Model SRSC45H4
Model No. Cummins QSL9
Type
Exhaust gas standard Tier 4F
Gearbox Model No. DANA TE32
Model SRSC4545H1
Type


Model SRSC4545C2
Type
Model SRSC1009-6E/SRSC0808-6EH
Model No. Cummins QSB6.7
Type
Model SRSC1009H5-6E
Model No. Yuchai YC6M240-30
Type
Exhaust gas standard China Stage III

Model SRSC3615-3
Model No. VOLVO TAD852VE

Type
Gearbox Model No. DANA 340TE17000
7.1.3.2 Spreader configuration
Table 7-10 Spreader Configuration
Model Technical Parameters

Rotating Angle +105°/-195 °
SDJ450 / SDJ450F-R2 Side-shifting Distance ±800 mm
/ SDJ450H-R1 Max. Loading Capacity 45000 Kg
Applicable Range 20ft - 40ft International Standard Container
Side-shifting Distance ±800 mm
SDJ450F-R5 Max. Loading Capacity 45000 Kg
20ft, 30ft, 35ft, 40ft International Standard
Applicable Range
Container
SDJE100-R1
Max. Loading Capacity 10000 Kg
ELME817
BROMMA RSX40


Side-shifting Distance 2000 mm
STG320
Applicable Range Steel coil
Side-shifting Distance ±800mm
Swinging Angle ±5°
STP250
Weight ≤25T
Steel Pipe
Inner span ≥400mm
Capacity
Length 7900-13500mm
7.2 Unit Conversion
7.2.1 Unit abbreviation explanation

Table 7-11 Unit Abbreviation Explanation
Name Abbreviation
Newton metre N.m
Kilo pound metre kpm
Kilo pascal kPa
Mega pascal MPa
Kilowatt kW
Kilojoule kj
British termel unit Btu
Calorie ca
Inch in
Feet ft
Yard yd
Mile mile
Centimetre cm
Metre m
Kilometre km

7.2.2 Conversion table, SI units
Table 7-12 SI Units Conversion Table
SI-unit Recalculation factor Non-SI Recalculation factor SI

Torque
N.m x 10.2 = kg·cm x 0.8664 =lb·in
N.m x 0.74 =lbf·ft x 1.36 =Nm
N.m x 0.102 =kg·m x 7.22 =lb·ft
2
Pressure (Pa=N/m )
kPa x 4.0 =in.H2O x 0.249 =kPa
kPa x 0.30 =in.Hg x 3.38 =kPa
kPa x 0.145 =psi x 6.89 =kPa
bar x 14.5 =psi x 0.069 =bar
2
kp/cm x 14.22 =psi x 0.070 =kp/cm2
N/cm2 x 145.04 =psi x 0.069 =bar
MPa x 145 =psi x 0.00689 =MPa
Power (W=J/s)
kW x 1.36 =hp (cv) x 0.736 =kW
kW x 1.34 =bhp x 0.746 =kW
kW x 0.948 =Btu/s x 1.055 =kW
W x 0.74 =ft·lb/s x 1.36 =W
Energy (J=Nm)
kJ x 0.948 =Btu x 1.055 =kJ
J x 0.239 =calorie x 4.19 =J
Speed and acceleration
m/s2 x 3.28 =ft/s2 x 0.305 =m/s2
m/s x 3.28 =ft/s x 0.305 =m/s
km/h x 0.62 =mph x 1.61 =km/h
Horsepower/torque
Bhp x 5252 rpm = TQ(lb·ft) TQ x rpm 5252 = bhp
Temperature
℃ =（ -32)/1.8 =（℃ x 1.8) +32
Flow factor
l/min (dm3/min) x 0.264 = US gal/min x 3.785 = liter/min

7.2.3 Conversion table, length
Table 7-13 Length Conversion Table
Unit cm m km in ft yd mile
cm 1 0.01 0.00001 0.3937 0.03281 0.01094 0.000006
m 100 1 0.001 39.37 3.2808 1.0936 0.00062
km 100000 1000 1 39370.7 3280.8 1093.6 0.62137
in 2.54 0.0254 0.000025 1 0.083333 0.02777 0.000015
ft 30.48 0.3048 0.000304 12 1 0.3333 0.000189
yd 91.44 0.9144 0.000914 36 3 1 0.000568
mile 160930 1609.3 1.6093 63360 5280 1760 1
1 mm = 0.1 cm - 1mm = 0.001 mm
7.2.4 Conversion table, area

Table 7-14 Area Conversion Table
Unit cm2 m2 km2 a ft 2 yd2 in2

cm2 1 0.0001 - 0.000001 0.001076 0.000012 0.155000
2
m 10000 1 0.000001 0.001 10.764 1.1958 1550.000
2
km - 10000000 1 10000 1076400 1195800 -
a 0.01 100 0.0001 1 1076.4 119.58 -
2
ft - 0.092903 - 0.000929 1 0.1111 144.000
2
yd - 0.83613 - 0.008361 9 1 1296.00
2
in 6.4516 0.000645 - - 0.006943 0.000771 1
2 2
1 ha = 100a - 1 mile = 259 ha = 2.59 km
7.2.5 Conversion table, volume
Table 7-15 Volume Conversion Table
Unit cm3 = cc m3 l in3 ft3 yd3

cm3 = ml 1 0.000001 0.001 0.061024 0.000035 0.000001
3
m 1000000 1 1000 61024 35.315 1.30796
3
dm (l) 1000 0.001 1 61.024 0.035315 0.001308
3
in 16.387 0.000016 0.01638 1 0.000578 0.000021
3
ft 28316.8 0.028317 28.317 1728 1 0.03704
3
yd 764529.8 0.76453 764.53 46656 27 1
3 3
1 gal (US) = 3785.41 cm = 231 in = 0.83267 gal (UK)

7.2.6 Conversion table, weight
Table 7-16 Weight Conversion Table
Unit g kg t oz lb
g 1 0.001 0.000001 0.03527 0.0022
kg 1000 1 0.001 35.273 2.20459
t 100000 1000 1 35273 2204.59
oz 28.3495 0.02835 0.000028 1 0.0625
lb 453.592 0.45359 0.000454 16 1
1 ton (metric) = 1.1023 ton (US) = 0.9842 ton (UK)
7.2.7 Conversion table, pressure
Table 7-17 Pressure Conversion Table
Unit kp/cm2 bar Pa=N/m2 kPa lbf/in2 lbf/ft2

kp/cm2 1 0.98067 98066.5 98.0665 14.2233 2048.16
bar 1.01972 1 100000 100 14.5037 2088.6
Pa=N/m2 0.00001 0.001 1 0.001 0.00015 0.02086
kPa 0.01020 0.01 1000 1 0.14504 20.886
lbf/in 2
0.07032 0.0689 6894.76 6.89476 1 144
lbf/ft2 0.00047 0.00047 47.88028 0.04788 0.00694 1

kg/cm2 = 735.56 Torr (mmHg) = 0.96784 atm
7.2.8 Conversion table, temperature
Table 7-18 Temperature Conversion Table
°F °C °F °C °F °C °F °C °F °C °F °C
-90 -67.78 -40 -40 10 -12.22 60 15.56 110 43.33 160 71.11
-80 -67.22 -30 -34.44 20 -6.67 70 21.11 120 48.89 170 76.67
-70 -56.67 -20 -28.89 30 -1.11 80 26.67 130 54.44 180 82.22
-60 -51.11 -10 -23.33 40 -4.44 90 32.22 140 60 190 87.78
-50 -45.56 -0 -17.78 50 -10 100 37.78 150 65.56 200 93.33
t°C = 5 (T°F-32) / 9, T°F = (9*t°C+160) / 5

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.

Reach Stacker Optional Parts
Optional Parts
8. Optional Parts
8.1 Fire Detection and Alarm System / Automatic Extinguishing Device�� 8-3
8.1.1 Fire detection and alarm system�� 8-3
8.1.1.1 Function description�� 8-4
8.1.1.3 Troubleshooting�� 8-7
8.1.1.4 Maintenance and repair�� 8-7
8.1.2 Automatic fire extinguishing device �� 8-9
8.1.2.2 Technical parameters��8-10
8.1.3 Electrical diagrams��8-11
8.2 Loudspeaker and Controller Kit��8-14
8.2.2 Operations��8-14
8.2.3 Electrical wiring diagram��8-15
8.3 Engine Idle Protection Function��8-16
8.4 Engine Preheating Protection Function��8-17
8.5 Engine Hour Meter��8-17
8.6 Twistlock Counter��8-17
8.7 Reversing Radar Display��8-18
8.8 Operator Presence System��8-18
8.9 Radio��8-19
8.9.2 Mute (Silence)�� 8-20

Optional Parts Reach Stacker
8.9.3 Sound�� 8-20

8.9.4 Audio setting�� 8-20
8.9.5 Radio�� 8-21
8.9.6 Radio troubleshooting�� 8-23
8.10 Automatic Lubrication System�� 8-24
8.10.1 Operation precautions�� 8-24
8.10.2 Time setting�� 8-25
8.11 CCTV System�� 8-27
8.11.1 Safety precautions�� 8-27
8.11.2 Major parts�� 8-28
8.11.3 Installation�� 8-29
8.11.4 Shift switch�� 8-30
8.11.5 Troubleshooting the CCTV system�� 8-31
8.11.6 Wiring diagram�� 8-32
8.12 Flowmeter�� 8-33
8.13 Manual regeneration switch and inhibited regeneration switch function test( 27.10-J)��
�� 8-34

8. OPTIONAL PARTS
8.1 Fire Detection and Alarm

System / Automatic Extinguishing
Device
With the fire detection and alarm switch on the

right operation panel pressed down, the fire
detection and alarm system will be activated.
Fig. 8-1
8.1.1 Fire detection and alarm system
Fire detection and alarm system (FZZK /

W03( (Hereinafter referred to as system)
continuously monitors (Engine compartment)
ambient temperature real-time, recognizes and
analyzes signals from all areas of machine,
as well as realizes monitoring alarm and
automatic fire disposal function through the
linear heat / fire detection components by the
cabin detection host. The system also has
online automatic fault detection and alarm
Fig. 8-2
function, high temperature / fire alarm function
and automatic fire extinguishing function.

8.1.1.1 Function description
Detection function:
When the system is installed, it will enter the
inspection status after power on.
High temperature alarm and automatic fire

extinguishing function:
When the cabin detection host detects that
the temperature of c abin NTC detector
reaches 110°C, the system would warn the
operator of high temperature through an alarm
device. After the operator cools down the
cabin and recovers the temperature, the high
temperature alarm would be automatically
canceled as long as the host detects that the
temperature has dropped to below 110 °C.
Fault detection function:

When there is short or open circuit to the
connecting wires of cabin fire detection
components, fire extinguishing device and
control system host, the system would perform
automatic fault detection and the detection
alarm light will flash for 1 second every 12
seconds.
NOTE:
The failure of any one circuit does not affect its
other functions.
Intelligent identification of fire signal and

automatic fire extinguishing function:
When the cabin NTC fire detector detects
that the ambient temperature is above 85 °C,
the rise rate is greater than 30 °C / min, or
absolute temperature of fire disaster is higher
than 130 °C, the system would intelligently
reckon that a fire disaster is happening.
Therefore it would f irstly star t the high
temperature forewarning function as soon
as the temperature reaches 110 °C and then

automatically start the fire extinguisher if the

temperature continues to rise and reaches 130
°C.
Fire extinguisher alarm function:

When the device begins spraying, the system
would inform the operator through an alarm
device that fire disaster is happening and the
fire extinguisher is putting out the fire.
Manual fire extinguishing function:

The operator, who discovered the fire foremost,
can manually start the fire extinguishing device
by himself.
NOTE:
Once the fire extinguisher is automatically
star ted af ter fire disaster, make sure to
disconnect the power supply of this machine
as well as replace the host and detector
harness for preventing any unknown damages.

8.1.1.2 Precautions
The following steps should be performed after

the initial installation, repair and maintenance
of this product. Otherwise, the system may be
unable to work normally.
1. Do not directly connect the host with
the connector of fire extinguisher when
testing after installation. Instead, connect
a 12V-24V test lamp with the F + and
F- driving lines of system host or use a
multimeter to measure the voltage at both
ends.
2. If the light blinks in 1 minute, it indicates
that the system is incorrectly installed.
Eliminate the failure immediately. If the
light does not blink in 1 minute, it indicates
that the system is correctly installed and
the host will function properly. Go on to the
next step for checking the cabin detector.
3. H e a t a n y o n e o f t h e c a b i n N T C
temperature detectors with a lighter or by
other means to simulate the occurrence of
fire disaster. If the 12V-24V test light turns
on or the multimeter displays 12V-24V,
it means that the host and detectors are
working normally.
4. Disconnect the power supply, and then the
host is recovered to original status. That is,
the device is a qualified product which can
be used normally.
5. After installation and detection, connect
the power supply of machine and install
the fire extinguisher. The fire extinguishing
and alarm system is ready for operation.

8.1.1.3 Troubleshooting
1. During the inspection, check whether

there is short or open circuit of the cabin
NTC temperature detectors and f ire
extinguisher. If yes, eliminate the fault.
2. When one circuit of NTC temperature
detectors malfuction, the system would
report the fault without influencing the
operations and functions of the other two
circuits.
3. If the fire extinguisher has several faulty
circuits simultaneously, the system would
not report the fault as long as there is one
normal circuit. When the fire extinguisher
malfuction, it would be unable to put out a
fire although the host can be activated.
4. If the fault output L + driving line is
constantly 12V-24V high level after the
system is started, it means that the host
cannot function normally. Replace the host
immediately.
5. Once the cabin catches fire and the host
starts extinguishing the fire, the system
cannot be automatically recovered until the
power is off.
6. After the fire disaster, please disconnect
the power supply to replace the host and
temperature sensor. Strictly check and test
the replaced harness and sensors to avoid
potential hazards.
8.1.1.4 Maintenance and repair
1. The host and cabin NTC temperature

detectors is installed just before the
debugging. Store them properly before
installation.
2. B e f o r e t h e m a i n t e n a n c e o r r e p a i r,

disconnect the power supply of host to

avoid wrong alarm linkage. Af ter the
maintenance or repair, remember to
connect the power supply timorously to
make the host and temperature sensor
work.
3. Never replace or modify the devices and
structures which may affect the detection
performance during maintenance or repair.
Do not install the devices closer than
20cm to area where the temperature will
exceed 100 °C when the engine is working
normally (such as exhaust pipes, engine
housing, etc.).
4. Frequently check if the surface of NTC
temperature detectors are clean and wipe
them regularly. Otherwise, the sensitivity
of NTC temperature detectors would be
affected or even worse the detectors may
not alarm when the fire happens.
5. Never use non - prescr ibed and non -
standard 12V-24V power supply to avoid
damage to the host.
6. Never perform maintenance or repair when
the host is powered.
7. Host and detectors is installed firmly. The
internal and external iron grounding should
also be firm.
8. Carry out a mock fire test every six months
to test if the NTC temperature sensor is
working properly.
9. Pay attention to protect NTC temperature
detectors and harness from collision
and damage during the maintenance. If
necessary, replace it immediately.
10. W h e n t h e h o s t c o m p o n e n t s a r e i n
malfunction, contact SANY to replace a
new host component. Personnel should
not randomly disassemble the host and
NTC temperature detectors to avoid
unnecessary losses.

8.1.2 Automatic fire extinguishing

device
Automatic fire extinguishing device, specially

designed for inf lammable par ts of high
temperature, is of certain aseismatic capacity
and applies to harsh working environments.
The device consists of: dr y powder
extinguisher, driving medium, extinguishing
tank, constant pressure release valve, multi-
nozzle distribution pipe, trigger component 1. Nozzle 4. Pipe connector
(electric trigger and thermal trigger to be 2. Powder chamber 5. Hose
chosen) etc. Be equipped with early fire 3. Dual driving chamber
detection and alarm system, it can warn Fig. 8-3 Fire Extinguishing Device
the early fire in the protected area, and
automatically start extinguishing fire in time.
8.1.2.1 Precautions
• Naked flame or electriferous operation is

prohibited during the installation.
• Ensure that the nozzle of the f ire
extinguishing device is installed securely.
• The extinguisher with electric trigger
device must apply the nominal operating
voltage and current.
• Check fire extinguishing device regularly. If
this device has been damaged or started,
make sure to replace it.
• Keep the storage dry and well ventilated.
• Load and put the device gently to prevent
collisions. Avoid exposure or rain.

8.1.2.2 Technical parameters
Table 8-1
Items FZBA0.4-C/GW FZBA1-C/GW

Fire extinguisher weight (g) 400 1000
Whole protection volume (m³) ≥4 ≥8
Electric or temperature
Start-up mode Electric or temperature control
control
Injection time (s) ≤5 ≤5
environmental temperature (°C) -40 - 90 -40 - 90
Safe current (mA) ≤150 ≤150
Start-up current (mA) ≥600 ≥600
voltage (V) DC6V-24V DC6V-24V
Weight (g ) 1735 ± 5 4420 ± 5
Dimensions (mm) Ø60*300 Ø89*350

Fig. 8-4
Overall Diagram of FZZK / W03 Fire Detection Alarm System
Reach Stacker
Engine cabin fire extinguishing device
To fire extinguisher
Solid gas transfer type
172133-1 male end

Power supply negative V- (black) Power supply positive V+ (red)
Break it to
put out
the fire
Fire extinguisher output G (green)
Red 0.5mm
Fire extinguisher output A (blue)
Thermal cable
8.1.3 Electrical diagrams
Black 0.5mm
172134-1 female end 24V+power supply 1mm2
172133-1 male end Fire extinguisher output A 1mm2

Fire extinguisher output G 1mm2
see from end panel
To manual switch
To at least 3 circuits of fire extinguisher
Instrument panel
Sound & light alarm lamp
see from end panel

171898-1
Yellow lamp female end
+24V power supply
Black
Fire extinguisher Fire- 1mm2 Temperature sensor 1
Buzzer Fire extinguisher Fire+ 1mm2
Yellow Green 24V+ power supply 1mm2
Green lamp Yellow Cabin high temperature alarm output T+ 1mm2
Green Failure detection ouput L+ 1mm2 Temperature sensor 2
174200-1 male end 172136-1 172135-1

female end male end
172132-1 female end Temperature sensor 3
To soud & light alarm lamp 171897-1
see from end panel
To FZZK/W03 control box male end
Temperature sensor 4
Yellow, green, black
Cabin NTC temperature

detector components
Fire detection alarm

Instrument panel Frame harness system Pay attention to keep the detector 20MM away from
the places of high temperature during the installation
Battery cabin Engine cabin
Safety, Operation & Maintenance Manual - August 2019

Optional Parts
8-11
8-12
Unmarked Tolerance
Size Table
Fig. 8-5
Size Tolerance
FZZK / W03 Fire Detection Alarm System A direction

Optional Parts
Structure Size Diagram
FZZK / W03
Sensor connector
Fire Detection
Alarm System
Power supply,
Length L = 300+/-20mm self-inspection feedback,
high temperature feedback
fire extinguisher connector

Reach Stacker
Fig. 8-6
Reach Stacker
FZZK / W03 Fire Detection Alarm System Wiring Diagram
Cabin sensor connector

FZZK / W03
Fire detection Alarm
System
The length of sensor harness is 3M. If it is too short to install,
A direction please contact the manufacturer to alter the harness or length
the harness.
Power supply, high temperature,

detection fire extinguisher connector
Installed in the cabin Sensor components
Postpositive engine is installed in the battery cabin

Prepositive engine is installed near the instrument panel

AL-001
AN-001A1
NTC-MF58-1
FZZK/W03
Optional Parts
8-13
8.2 Loudspeaker and Controller

Kit
Main functions and features:

• Speaking prior to alarm.
• Volume adjustable.
• Microphone & Loudspeaker available.
• Various tones to choose.
• Visible and audible alarm synchronous
(optional).
Fig. 8-7 Loudspeaker
• Several kinds of combination mode for
choice.
• Good appearance, convenient operation.
8.2.1 Control panel
Control panel of call controller is composed

of alarm indicator light, power supply indicator
light, power supply switch, alarm light switch,
tone selection, alarm switch, volume (-), and
volume (+) keys.
Fig. 8-8 Control Panel

8.2.2 Operations
1. Connect the power supply, and the red

indicator light on control panel turns on.
Press the power switch on panel, and this
light goes out. At this time, the control box
enters standby mode. Press the power
switch again to enter work mode.
2. Press the alarm light switch on the panel,
and the yellow indicator light turns on.
Press this switch again, and this light goes
out.

3. When the alarm switch is pressed, the

alarm system will work and the horn will
sound an alarm. Press this switch again,
and the system stops working.
4. Press the tone button, and A, B, E tones
would alarm circularly. Please select the
appropriate tone according to your own
requirement.
5. Press the volume (-) and volume (+) keys
to increase or decrease the volume. When
the alarm system is working, press these
two keys to adjust the alarm volume. Press
the mike switch, and the speaking function
is activated. Hold this switch and press the
volume (-) and volume (+) keys to adjust
the speaking volume.
8.2.3 Electrical wiring diagram
Fig. 8-9 Electrical Diagram

8.2.4 Precautions
• The control box of this product can only be

installed indoors;
• Connect the wire correctly. Never make
the wires short circuit.
• Check if the rated voltage of alarm is in
accordance with that of power supply.
• Standardize the horn power.
• It is a nor mal phenomenon that the
temperature in control box rises during the
operation.
• Never open the c ontrol box without
permission.
• Any questions in operation, please contact
SANY.
8.3 Engine Idle Protection

Function
Choose the engine idle protection function at

the setting menu of display.
Within 60 seconds after the engine is started,

there is no response from throttle and the
engine keeps running at idle. After 60 seconds,
it is able to operate the machine normally and
there is no limitation to the throttle. The screen
displays “Idle_Protect”.
When the engine is running at max. rotation

1
speed (approx. 2400rpm), switching ignition
key to P position cannot stop the engine P
immediately. This protection allows a few
seconds for the engine to run idle before
stopping. But the emergency stop button is still
effective even if the idle protection function is
activated.
TY-1509018-1

8.4 Engine Preheating Protection

Function
The control unit monitors the preheating

conditions of engine in real time. Once the
preheating system is detected to be working
over 20 seconds, the system would alarm for
“Pre_Heat_Err”. In this case, make sure to
stop the machine and turn off the electricity
immediately to check the engine preheating
system.
8.5 Engine Hour Meter
Engine hour meter displays the running hours

of engine.
It is used to confirm the due time for regular

maintenance. All the maintenance time is
based on the working hours of engine.
TY-1407006-1
Fig. 8-11 Engine Hour Meter
8.6 Twistlock Counter
Twistlock counter displays the locking times of

spreader.
It is used to confirm the due time for regular

maintenance. All the maintenance time is
based on the locking times of spreader.
TY-1407007-1
Fig. 8-12 Twistlock Counter

8.7 Reversing Radar Display
When the machine is reversing, the reversing

radar would activate automatically. The
reversing radar display would show the
rear view at the back of machine for the
convenience of reversing.
Fig. 8-13 Reversing Radar Display
8.8 Operator Presence System
The operator presence system (OPS) feature

has an electrical switch in the seat which
senses the presence of the operator. This
allows the transmission in internal combustion
engine trucks to be engaged only when the
operator is in the seat.
The operator can activate / deactivate this
protection function and adjust the protection
time through the display menu. The OPS is
defaulted to be activated and its protection
time is defaulted to be 1 minute when the
machine leaves factory. The protection time
can be adjusted in the range of 0-60 minutes.

8.9 Radio
This machine has equipped with an optional

radio. It is located at the left side of the
console.
TY-1509020-1
Fig. 8-14 Radio
8.9.1 Control panel
8 7 13
TA DISC
SOUND LOUD
AF AST PRISAT
9 11
1 4 BAND
VOLUME
2 VOCAL ROCK CLASSIC 5
VOLUME JAZZ FLAT POP
3 TA AF AST
RDS
9 12
321 456 10 10
1. 1………………Preset button 1 9. ……Increase the volume

2. 2………………Preset button 2 ……Decrease the volume
3. 3………………Preset button 3 10. …………Tuner mode
4. 4………………Preset button 4 Short press: Auto search
5. 5………………Preset button 5 Long press: Manual search
6. 6( )………Preset button 6 (traffice tune) 11. ………FM/AM
Short press: TA on/off Long press: AF on/off 12. …………RDS on/off
7. …………Select sound / audio styles 13. Display
8. ………………Power on/off
Fig. 8-15 Radio Panel

8.9.2 Mute (Silence)
Short press button to mute or cancel the

mute (silence).
NOTE:
The silenc e per iod may be inter r upted
by AL ARM announcement or traf f ic
announcement messages (if TA is switched
on).
Fig. 8-16 Power Supply Button
8.9.3 Sound
Whether you listen to Jazz, Vocal, Pop, Classic

or Rock music, this button is the perfect choice
for your setting.
Press to select BASS-Treb for your

own sound style, or adjust the settings with the
volume up/down buttons to select one of the
pre-define sound styles:
-BASS-TRE: Self settings
-FLAT: Original
-JAZZ: Jazz music
-VOCAL: Speech Fig. 8-17 Sound Button
-POP: Pop music
-CLASSIC: Classical music
-ROCK: Rock music
8.9.4 Audio setting

• Press to select desired audio mode.
-Sound style BASS-TRE, FLAT,
JAZZ, VOCAL, POP,
CLASSIC, ROCK
-BASS low notes
-TREBLE high notes
-BALANCE left-right
-FADER rear-front
Fig. 8-18 Sound Type
-LOUD OFF, LOW, MID, HIGH

• Press the volume button to adjust the

selected audio mode. After 5 seconds the
display returns to show the last mode of
operation. Adjustment of Bass and Treble
setting is only possible when BASS-TRE is
selected as the sound style.
8.9.5 Radio
11
Waveband
• Press to select the desired band:
10 10
12
Automatic search
• Press or to tune to a station of a lower
frequency or of a higher frequency. Fig. 8-19 Band Button
• To search for another station, press the
button again.
Manual tuning (if you know the frequency

of the required station)
• Long press the search button or for
more than 2 seconds, and the manual
tuning is activated.
• Then press or to tune to a station of a
lower frequency or of a higher frequency.
• If no station is searched in 5 seconds, the
system would return to its last operation.

Preselected stations
Manually storing stations in a preset

By using the preset keys (1 to 5), five stations
per band can be stored and recalled.
• Tune to the desired station.

• Press the desired preset key (1 to 5) for
more than 2 seconds to store the current
tuned station.
Fig. 8-20 Station Button
Preset, recalling
Press the desired preset key (1 to 5) to recall

the stored station.
Automatically storing stations (AUTO-

STORE)
• You can automatically store 5 strongest

FM stations on the FM AST band or
5 strongest MW(AM) stations on the
MW(AM) AST band. When you use Auto-
Store, the new stations replac e any
stations previously stored in the FM AST
band or the MW(AM) AST band.
• Press to activate auto-store.
• The system gives out a beep and then
mutes.
• When the station is stored successfully,
you can hear a beep followed by the
storing.
• Sometimes it may be impossible to find 5
stations.

8.9.6 Radio troubleshooting
When you suspect that your radio is not

functioning normally, please check the below
troubleshooting table before calling for service.
If you still have to send your radio set for

service, always send the complete set (with
detachable panel). Do not try to open the set
to service it yourself.
Table 8-2 Radio Troubleshooting Table
No. Fault Troubleshooting method

The set does not function. No 1. Check the fuse (set and car) and connections.
1
display 2. Check the operating voltage.
1. Adjust the volume of the set.
The set functions with no
2 2. Check the radar and balance settings.
sound.
3. Check the aerial and its connection.
1. Check that the aerial is fully extended and properly
connected.
The system cannot be tuned 2. Check that the negative terminal (brown lead) is
3
to a desired station. connected to the machine frame.
3. Desired station is too weak. Try the manual tuning
function.
Display shows frequency 1. The set is tuned to non-RDS station
4
instead of station name 2. The RDS function is switched off.

8.10 Automatic Lubrication Lubrication Overflow

pump valve Grease nipple
System
The automatic lubrication system is composed

of machine lubrication system and spreader
lubrication system. The lubrications of machine
and spreader are driven by two automatic
lubrication pumps. The lubrication is fully
automatic. Therefore, it is not necessary for
the operator to lubricate.
The machine lubrication pump is located at the

Fig. 8-21
left of machine back.
The spreader lubrication pump is located at

the upper of spreader main beam.
8.10.1 Operation precautions
Pay special attention to below items when

operating the automatic lubrication system:
●● Check if there is enough grease in the
grease reservoir of lubrication pump. Fill
in grease in time. Never make the grease RS-1407033-1
pump run without grease.
●● Make sure that the upper cover of grease Fig. 8-22
reservoir is tightened to prevent dust and
dirt from entering. As, the system may
become ineffective.
●● Use the grease nipple to fill grease. Never
open the upper cover when filling.
●● It is suggested to apply 2# grease when
the temperature is high and 0# one when
the temperature is low.
●● Check if grease spills over from the
overflow valve of grease pump. If yes,
troubleshoot it immediately.
●● Usually the lubrication time is set to be 6
minutes and the intermittent time is set
to be 3 hours when the machine leaves
factory.

8.10.2 Time setting
When the operator has changed the time

setting by accident, it is able to set up the
lubrication time and intermittent time according
to below steps.
1. Move the protective cover at the base, and

then set up the time.
NOTE:
Make sure to tighten the protective cover after
the time setting.
RS-1407034-1
Fig. 8-23
2. Set up the intermittent time:

3
By rotating the blue switch, 15 kinds of
intermittent time can be set up. 9
NOTE:
If the button is located at position 0, the right
diode would light up and the system would
send out the malfunction signal. Meanwhile
the intermittent time is defaulted to be the Blue switch to set up Forcible start key to activate
intermittent time intermittent lubrication
initial time.
Fig. 8-24
Table 8-3 Intermittent Time Setting Table
Position 1 2 3 4 5 6 7 8 9 A B C D E F
Minute 4 8 12 16 20 24 28 32 36 40 44 48 52 56 60
Hour 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

3. Set up the lubrication time:

3
By rotating the red switch, 15 kinds of
lubrication time can be set up. 9
NOTE:
Never located the button at position 0.
Red switch to set up

lubrication time
Fig. 8-25
Table 8-4 Lubrication Time Setting Table
Position 1 2 3 4 5 6 7 8 9 A B C D E F
Second 8 16 24 32 40 48 56 64 72 80 88 96 104 112 120
Minute 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30

8.11 CCTV System
LD Series CCTV System is widely used on

hoisting machiner y, handling machiner y,
loading equipment and other specialized
equipment. With this equipment, operator can
easily get actual information to work safely and
conveniently.
8.11.1 Safety precautions
Personnel should observe the following items:

• The installation of this system should
b e o p e r ate d un de r t h e gui danc e of
professionals or technicians.
• Outdoor equipment is waterproof, but
when being applied, please make sure that
the connections such as screw holes fixed
to the chassis should be waterproof. Or
you shall take the consequences caused
by leakage.
• Please read the manual carefully to avoid
damage to devices caused by misuse.
• Pay attention to protect equipment from
scuffing.
• Remember not to maintain it by yourself
so as to avoid damage to equipment or
other dangers. It is recommended that
all maintenance work should be made by
professionals or technicians.
• K e e p t h e e q u i p m e n t a w a y f r o m
e nv i r o n m e n t f i l l e d w i t h f l a m m a b l e,
explosive or corrosive gases.
• Please use the original accessories or the
ones recommended by the manufacturers
of accessories.

8.11.2 Major parts
This CCTV system is composed of the front

camera part, the transmission part and the
display and control part in driver's cabin. It can
supply six video images for the operator and
display them on a 10.4 inch LCD monitor.
1. The camera
Four spreader cameras are mounted on four
corners of the spreader. Two fixed cameras
were installed separately at the underside
of boom and the rear of reach stacker. The
cameras are used to capture the video signal.
2. The transmission part

The video signal collected by the cameras
is transmitted from the junction device near
camera through composite cable (including
video, power supply) to the driver’s cabin.
3. Monitor and controller in the driver’s

cabin
There are a set of shift switches and a set of
10.4 LCD monitor in the driver’s cabin. The
display modes of six cameras are switched by
the shift switch.

8.11.3 Installation
The installation locations and functions of

CCTV devices are included in below table:
Table 8-5
No. Device Location Function

Aseismatic camera system Respectively at the
Monitoring the work of spreader
of spreader 1-4 upper left, lower left,
1 upper right, and lower
Wiring, and providing power to the
Junction box 1-4 right corners of the
camera system
spreader
Monitoring the situation in front of the
Front view semi-fixed camera
machine
5 At the bottom of boom
Junction box 5
camera system
Monitoring the situation behind the
Rear view semi-fixed camera
machine
6 At the rear of machine
Junction box 6
camera system
Receiving and processing the camera
7 Vehicle DVR In the driver's cabin
video signal
Controlling the switchover of display
8 Shift switch In the driver's cabin
modes
9 LCD monitor In the driver's cabin Displaying the video image
NOTE:
The distance between camera and junction
box should be less than 1.5m.

8.11.4 Shift switch
There are four gears of the shift switch: 0

1
• Turn the shift switch to gear 0, and the
2
images of all the six cameras can be
3
displayed together for the operator to
observe comprehensively the surrounding
circumstances.
image of f ront view c amera c an be
displayed for the operator to observe the
situation in front of machine.
• Tur n the shif t switch to gear 2, and
the image of rear view camera can be
displayed for the operator to observe the
situation at the rear of machine.
images of four cameras installed at the
spreader can be displayed for the operator
to obser ve t he wo r k ing situat i on of
spreader.
Fig. 8-26

8.11.5 Troubleshooting the CCTV

system
Table 8-6
Part Symptom Analysis Detection method Solution
Make sure whether there
is some video signal of
The camera and cable Change the cable if
No video output are damaged. camera. Then check if
Camera there is no image.
there are images on the
System signal of camera monitor.
No video output signal of
The camera is damaged. Change the camera.
camera.
Measure the input
There is no power voltage of power
-
DVR can’t display supplied for DVR. supply with a
DVR
any images multimeter.
The switch of DVR is
- Change the switch.
damaged.
Check if the DVR Connect this camera
displays this camera. into the system.
Check if the cable
The screen of
between DVR and Reconnect the video
LDC monitor is No video signal input.
monitor is connected cable.
blue
well.
Check if the DVR is Check the power
turned on. indicator light of DVR.
Monitor
Check if the power
Reconnect the power
output cable of monitor
cable.
is connected.
T h e s c r e e n o f The power supply is not
Ch eck if th ere is AC M e a s u r e i t w i t h a
LDC monitor is connected or the monitor
power input of monitor. multimeter.
black is damaged.
Send it back to the
manufacturer for
repair.

8.11.6 Wiring diagram
On the upper left corner of the spreader

Operator Cabin Composite Monitoring the work of the spreader
Cable
Junction Equipment 1
cable 11
On the lower left corner of the spreader

Composite Monitoring the work of the spreader
Cable
Junction cable 12
Equipment 7
On the spreader
Monitoring the work of the spreader
Composite
Cable 2-7 Cable
cable 13
cable 14
RS 422 POWER
POWER IN
Composite
CH 1 CH 3 OUT RS 232 Cable
CH 2 CH 4
CH 5 CH 6 ALARM
IN 1-3 123456
控制电缆
Composite
Cable Junction Equipment 5
Cable 1
cable 15 Junction Equipment 6
2 3 cable 16
1 4 switch
Composite
Cable
外部电源直流
DC 6V~24V
+-
10.4"LCD Monitor
Fig. 8-27
NOTE:
The control cable is a four-core wire, with
one core as common terminal (negative) and
three cores as control terminals (front, rear,
spreader). The voltage between control and
common terminals should be 5V ( low level ) or
6-36V ( high level ) when the switch is turned
off.

8.12 Flowmeter
Flowmeter is a gauge for measuring the flow. It

can be supplied to customers as an accessory
tool.
Quick connectors are installed to connect the
flowmeter between oil pump and main valve.
A warning label is suspended at the quick
connector to avoid hydraulic harm. See Fig.
8-28.
Fig. 8-28
Steps to measure the flow:

Release the pressure after the machine is
stopped. Then loosen the quick connector
at the oil outlet of pump. Connect the quick
connectors at two sides of flowmeter with
that at the oil outlet of pump. Note to match
the male and female heads. Tighten up all
the connectors before measuring the flow.
Start the machine to measure the outlet flow
of pump. The overall flow of system is the
summation of two pump flows.

8.13 Manual regeneration switch

and inhibited regeneration switch
function test( 27.10-J)
Follow step a to g, the exhaust system

cleaning lamp turn on.
Push t h e m anual re g e n e r at i o n sw itc h,
SRegen_switch (need add this parameter in
the 27.10-J screen file) number will change
from 0 to 1, when we release the switch it will
back to 0. The engine speed will up to 1000-
1200rpm, At the same time, HEST lamp will
turn on, and exhaust system cleaning lamp will
turn off. This mean the manual regeneration
switch function is OK.
Stop manual regeneration switch just by two
ways. change the engine speed or push the
inhibited switch.
Normally regeneration it will be stopped by
itself.
W hen testing the manual regeneration
function, the engine must be idling. If the
engine is controlled by PTO or TSCI, the
engine speed must be ±50 rpm within the
range of the defined engine idling speed.
These signals such as the neutral gear of the
gearbox and the parking brake switch startup
must be accordance with the requirements of
AEB15.131.
According to the actual indicators, generally

first check the generation indicator and then
press the manual regeneration switch. The
generation indicator will go out and the high
temperature indicator will light up.
During the actual operation, if the speed is too

high and the load rate is excesive, the engine
will automatically start the generation function
without the manual generation switch pressed.

Answers to questions:
1. Normally, when we push the manual reg
switch, there is nothing changed on the
engine. is that right?
The engine only has to accelerate if the
system needs it to in order to create enough
heat from the combustion cycle to support
the system cleaning. Since we are idling high
at 1000rpm the engine is burning enough
fuel to support the regen and so you don’t
see the speed change. The state of EXM_
NonMission_Regen_Active does change to 1
in both after pushing the switch so we know
the system has entered state for regen.
2. When the manual reg switch should be

used? I am familiar with the DPF reg, it is basic
on the soot level, how about SCR system?
NOx transfer efficiency?
Under normal operation when soot begins
to collect in the system this is detected and
the Exhaust System Cleaning Lamp (DPF
lamp) will come on solid to indicate a need
for manual regen. When the engine is in
that state the operator may then park the
application and push the manual regen switch
to start the system cleaning. Pushing the
switch will not do anything unless the system
detects soot load and lights the DPF lamp.
3. Are there any lamp warming and indicating?

See my answer above. The DPF / SCR
System Cleaning lamp comes on when the
system detects the need for a regen.
4. How long time the manual regeneration

will take and how long period the manual
regeneration need be activated?
The time it takes for a system cleaning varies,
but it is typically about 45 minutes and should
not exceed 60 minutes. The period depends
on the actual load.

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Quality Changes the World
Reach Stacker
Electrical and Hydraulic Schematics

Table of Contents
1 Symbol Explanation..............................................................................................................................................................................................................................................................................................................1-1
1.1 Symbol Explanation .....................................................................................................................................................................................................................................................................................................................1-2
2 Hydraulic Schematics..........................................................................................................................................................................................................................................................................................................2-1
2.1 Hydraulic Schematic Diagrams ..................................................................................................................................................................................................................................................................................................2-2
3 Electrical Schematic Diagrams ......................................................................................................................................................................................................................................................................................3-1

3.1 H type container reach stacker...................................................................................................................................................................................................................................................................................................3-2
4 Schematic Diagrams of Spreader System ...............................................................................................................................................................................................................................................................4-1

4.1 Hydraulic schematic diagram of spreader system ..................................................................................................................................................................................................................................................................4-2
4.1.1 SDJ450 Spreader ................................................................................................................................................................................................................................................................................................................4-2
4.1.2 SJD450F-R3 / SDJE100-R1 Spreader.............................................................................................................................................................................................................................................................................4-3
4.1.3 SJD450E-R1 / SJD450F-R1 Spreader.............................................................................................................................................................................................................................................................................4-4
4.1.4 ELME817 Spreader.............................................................................................................................................................................................................................................................................................................4-5
4.1.5 BROMMA RSX40 Spreader...............................................................................................................................................................................................................................................................................................4-6
4.2 Electrical schematic diagram of spreader system ...................................................................................................................................................................................................................................................................4-7
4.2.1 SDJ450 Spreader ................................................................................................................................................................................................................................................................................................................4-7
4.2.2 SDJ450F-R1 Spreader .......................................................................................................................................................................................................................................................................................................4-9
4.2.3 SDJ450E-R1 Spreader .....................................................................................................................................................................................................................................................................................................4-11
4.2.4 SDJ450F-R3 Spreader .................................................................................................................................................................................................................................................................................................... 4-13
4.2.5 SJE100-R1 Spreader....................................................................................................................................................................................................................................................................................................... 4-15
4.2.6 ELME817 Spreader.......................................................................................................................................................................................................................................................................................................... 4-17
4.2.7 BROMMA RSX40 Spreader............................................................................................................................................................................................................................................................................................ 4-23
Electrical and Hydraulic Schematics-March 2019 I

Reach Stacker Symbol Explanation
Symbol Explanation
1 Symbol Explanation..............................................................................................................................................................................................................................................................................................................1-1
1.1 Symbol Explanation ..................................................................................................................................................................................................................................................................................................................1-2
Electrical and Hydraulic Schematics-March 2019 1-1

Reach Stacker Symbol Explanation
1 Symbol Explanation
1.1 Symbol Explanation
The following symbols are standard ones used in wiring and hydraulic diagrams.
1. Electric control signal 21.Counter 1 2

3 4
2. Current flow 22.Flow control valve
5 6
3. Hydraulic control signal 23.Check valve
7 8 M
4. Hydraulic flow 24.Hydraulic cylinder
5. Hydraulic motor 25.Double-acting hydraulic cylinder 9 10
6. Hydraulic oil pump with variable displacement 26.Single-acting hydraulic cylinder 11 12
7. Hydraulic oil pump with fixed displacement 27.Valve block

13 14
8. Electric motor 28.Shuttle valve
U
15 P 16
9. Accumulator 29.Fuse protecter 17 18
10.Disc brake 30.Relay 19 20

21 22
11.Filter 31.Solenoid valve
23 24
12.Radiator 32.Breaker
25
13.Heater 33.Resistor
26 27
14.Bulb 34.Proximity switch
28 29
15.Analog signal output pressure sensor 35.Temperature switch
30 31
16.Pressure meter 36.Limit switch 32 33
17.Temperature gauge 37.Button 34 35
36 37
18.Fluid level gauge 38.Emergency stop switch
38 39
19.Flow gauge 39.Buzzer
40
20.RPM meter 40.Horn
Fig.1-1 Symbols

Reach Stacker Hydraulic Schematics
Hydraulic Schematics
2 Hydraulic Schematics..........................................................................................................................................................................................................................................................................................................2-1
2.1 Hydraulic Schematic Diagrams ..............................................................................................................................................................................................................................................................................................2-2

Reach Stacker Hydraulic Schematics
2 Hydraulic Schematics
2.1 Hydraulic Schematic Diagrams
Right pitching cylinder Left pitching cylinder Telescopic cylinder
BP2 BP3 BP4
YV11
Spreader anti-swinging cylinder
YV6 YV5
YV12 YV10
YV21
YV8 YV7
YV9 YV22
Spreader
hydraulic
system
YV1 YV4
Multi-way Valve
Cab moving cylinder Countweight moving cylinder (optional)
SP6
Spreader multi-channel body
160bar
1L 、15bar G3/8
ELLM16
280bar
YV2 YV5
YV16 YV15 YV18 YV17 YV14
Back pressure valve
Torque converter radiator
Oil draining multi-ported body

M8
25bar
YV19 YV20
270bar
260bar
steering axle
BP5
Pilot oil supply valve group 270bar
205bar
105ml/r
Cooling control valve Cooling control valve BP6

P2105R00C1C23LA20N00A1B1P/parker
12×2
320bar\2300r/min B220301000262
Brake valve
ELLM16
4L 、100bar
130bar
Flow amplifier
Driving axle
ELLM16
BP7 Brake control valve group
25bar 1bar 12×2
145bar
260bar Prefill valve

YV23
180bar
105r/min
Steering Gear
320bar/2300r/min Brake oil tank 210bar
BP8
B220301000240 21r/min\180bar
P2105+PGP511/Parker PGP511A0210/Parker
B220301000639
SP5
Brake oil filter
Hydraulic oil tank
ST3 ST4
Fig.2-1

Reach Stacker Electrical Schematic Diagrams
Electrical Schematic Diagrams
3 Electrical Schematic Diagrams ......................................................................................................................................................................................................................................................................................3-1

3.1 H type container reach stacker...............................................................................................................................................................................................................................................................................................3-2

3 Electrical Schematic Diagrams

3.1 H type container reach stacker
Symbol Explanation Function Description Harness Explanation
Line Symbol Name LineName Explanation LineName Explanation
Relay Description part Front control panel harness

Power supply and engine
Fuse part Right control panel harness
Illumination auxiliary control Control panel harness of
Battery part steering mechanism
Engine PLC part Air conditioner harness
Motor Drag-chain harness 1

Radio,
loudspeaker Drag-chain harness 2
Loudspeaker Drag-chain harness 3

Middle front frame body
Valve
harness
Rotary switch, Torque converter / gear
rocker switch solenoid valve harness
Button Location Description Power supply harness
Steering mechanism Rear frame body harness

Line Symbol Name
Temperature sensor Oblique boom harness
+CAB CAB CAGE
Pressure switch Boom harness 1
+PSG STEERING GEAR BOX
Proximity switch Boom harness 2
+PLO LEFT CONTROL PANEL
Illumination lamp
+PRO RIGHT CONTROL PANEL
Signal lamp
+PFO FRONT CONTROL PANEL
Horn, buzzer
+BCC CAB CABINET
Potentialmeter
+BPC BODY CABINET
Breaker
+BOOM BOOM
Pressure sensor
+COB CHASSIS ELECTRICAL BOX
SANY GROUP
Description
Fig.3-1

1 2 3 4 5 6 7 8
A A
1.4-E
+BPC-P6 +BPC-XS9 110
1.4-D
12 +BPC-KA11 3
B B
C C
D D
1.5-B
+BPC-KA11
1 110
-COB-QD1
E Engine star(CUMMINS) E
2
F SANY GROUP F
Power supply
1 2 3 4 5 6 7 8
Fig.3-2

1 2 3 4 5 6 7 8
A A
B B
+BCC-XS12
20
C C
1 2 3 4 5 6 7
EM T1 T2
D D
EM
+BCC-XS12
21
E E
F SANY GROUP F
Auxiliary part 1
1 2 3 4 5 6 7 8
Fig.3-3

+BCC-XS6
2 11
+BCC-XS5
11
Middle low beam
Lower high beam
56 56b 56a
Front panel swit c h la mp Ri gnt panel swit c h la mp
SANY GROUP
Auxiliary part 2
Fig.3-4

+BCC-P2
12
+BCC-P2
10
+BCC-P2
8
SANY GROUP
Auxiliary part 3
Fig.3-5

SANY GROUP
Auxiliary part 4
Fig.3-6

+BCC-XS12
17
+BCC-XS12
18
SANY GROUP
Auxiliary part 5
Fig.3-7

OPTION OPTION
SANY GROUP
Auxiliary part 6
Fig.3-8

1 2 3 4 5 6 7 8
A A
B Extinguisher ON Extinguisher B
manual alarm
C C
+
24V +
D - + Talkie D
5V Red Blue Brow
- walkie Central
Extinguisher controller lubrication Tyre pressure
- Middle
system host monitor syste
relay
host
Black Blue
E E
F SANY GROUP F
Optional
1 2 3 4 5 6 7 8
Fig.3-9

SANY GROUP
PLC part 1
Fig.3-10

1 2 3 4 5 6 7 8
A A
B B
21 16 17 18 +BPC-XS6
15
C C
D D
E E
F F
SANY GROUP
PLC part 2
1 2 3 4 5 6 7 8
Fig.3-11

12.8-A
1022
SANY GROUP
PLC part 3
Fig.3-12

+PTC-XS3 1022
11.4-A
10
931
9.3-C
SANY GROUP
PLC part 4
Fig.3-13

12.8-A
104
+BPC-FU24 104
1
10A
APC POWER
2
+BPC-P3
14
OPTION
1201
+BPC-XS6
1.7-B
10
107B
-APC300
1 2 3 4 5 6 11 12
A13 B9 B7 A4 A2 A7 B1:CAN1H B2:CAN1L
TE30Transmission(Option)
A20 B24 B2 B34 OPTION
7 8 9 10
SANY GROUP
CAN-BUS
Fig.3-14

REV Pre. Sensor 2ND Pre. Sensor FLO Pre.Sensor 3RD/1DT Pre. Sensor FHI Pre. Sensor
P P P P P
Analogue Analogue Analogue Analogue
Analogue
A B C A B C A B C A B C A B C
1201
B28 B10 A11 A10 A9 B5 B3

B28 B10 A11 A10 A9 B5 B3
+S4
B28-SGND
B5-ANINA3
B3-ANINA2
B10-5VREF
A9-ANINA0
A11-ANAINA1
A10-ANINA4
APC300
DANA TE30 CONTROLER
B21-ANAOUT-4
B19-DIGOUT+0
A14-DIGOUT-2
B31-ANAOUT2
B22-ANAOUT0
B18-ANAOUT1
A1-ANAOUT3
A8-DIGOUT-1
A5-DIGOUT-0
B34-GNDSE
A22-ANIR0
A7-P_PWR
A13-WAKE
B32-ANIR1
A4-SPWR1
A2-SPWR1
B9-SPWR2
B7-SPWR2
B29-SPIN3
B27-SPIN2
B28-SGND
B1-CAN H
A26-GND
A3-SPIN0
A6-SPIN1
A26-GND
B2-CAN L
B23-GND
B24-GND
A13 B9 B7 A4 A2 A7 A26 B24 B23 B34 B1 B2 B19 A14 A1 A5 B31 B22 B18 A26 A3 A6 B29 B27 B28 A22 B32 B21 A8
A13 B9 B7 A4 A2 A7 A26 B24 B23 B34 B1 B2 B19 A14 A1 A5 B31 B22 B18 A26 A3 A6 B29 B27 B28 A22 B32 B21 A8
+S2 -X0 27 :2
+S4 -XP40 1 2 3 4 5 6 7 8 9 10 11 12
2 3 4 5 6 7 8 9 10 11 12
+S4 -XS40 1
2 1 2 1
T T
Analogue Analogue
+S2 -X0 28:1
Pump Temp. CONVETER OUT

Temp.
2 1 1 2 2 1 2 1
107B 1 1 1 1 1 1
Pump Speed Output Speed Turbine Speed Engine Speed
F/R F/R PRO. 2ND FLO 3RD/1ST
SELECTOR SOLENOID PRO. PRO. PTO.
LOCKUP Pro. SOLENOID
+S2 -X1 355 :2 2 2 2 2 2 2

+S2 -X1 352 :2
CAN2_H
CAN2_L
0 0
DANA TE30 Gearbox Circuit Diagram SANY GROUP

Optional
Fig.3-15

Reach Stacker Schematic Diagrams of Spreader System
Schematic Diagrams of Spreader System
4 Schematic Diagrams of Spreader System ...............................................................................................................................................................................................................................................................4-1

4.1 Hydraulic schematic diagram of spreader system............................................................................................................................................................................................................................................................4-2
4.1.1 SDJ450 Spreader..............................................................................................................................................................................................................................................................................................................4-2
4.1.2 SJD450F-R3 / SDJE100-R1 Spreader ..........................................................................................................................................................................................................................................................................4-3
4.1.3 SJD450E-R1 / SJD450F-R1 Spreader ..........................................................................................................................................................................................................................................................................4-4
4.1.4 ELME817 Spreader ..........................................................................................................................................................................................................................................................................................................4-5
4.1.5 BROMMA RSX40 Spreader ............................................................................................................................................................................................................................................................................................4-6
4.2 Electrical schematic diagram of spreader system ............................................................................................................................................................................................................................................................4-7
4.2.1 SDJ450 Spreader..............................................................................................................................................................................................................................................................................................................4-7
4.2.2 SDJ450F-R1 Spreader.....................................................................................................................................................................................................................................................................................................4-9
4.2.3 SDJ450E-R1 Spreader ..................................................................................................................................................................................................................................................................................................4-11
4.2.4 SDJ450F-R3 Spreader.................................................................................................................................................................................................................................................................................................. 4-13
4.2.5 SJE100-R1 Spreader .................................................................................................................................................................................................................................................................................................... 4-15
4.2.6 ELME817 Spreader ....................................................................................................................................................................................................................................................................................................... 4-17
4.2.7 BROMMA RSX40 Spreader ......................................................................................................................................................................................................................................................................................... 4-23

4 Schematic Diagrams of Spreader System
4.1 Hydraulic schematic diagram of spreader system

4.1.1 SDJ450 Spreader
Side-shifting cylinder Side-shifting cylinder
Damping (anti-swinging) cylinder
Left locking Right locking

cylinder cylinder
Left telescoping Right telescoping

cylinder cylinder
Fig.4-1 Hydraulic Schematic Diagram of SDJ450 Spreader

4.1.2 SJD450F-R3 / SDJE100-R1 Spreader
Side-shifting & telescoping & locking valve group Telescoping & locking valve group
Solenoid reversing valve Solenoid reversing valve
Solenoid reversing valve

Dual one-way throttle valve
Dual one-way throttle valve

Solenoid reversing valve Solenoid reversing valve
Overflow valve
Overflow valve Overflow valve
Side-shifting cylinder Left telescoping cylinder Right telescoping cylinder
Left locking cylinder Right locking cylinder
Fig.4-2 Hydraulic Schematic Diagram of SJD450F-R3 / SDJE100-R1 Spreader

4.1.3 SJD450E-R1 / SJD450F-R1 Spreader
Left locking cylinder Left locking cylinder
Slewing motor

Left side-shifting Right side-shifting
cylinder cylinder
Telescopic motor
Oil leakage way

Oil return way
Pressurized oil
Fig.4-3 Hydraulic Schematic Diagram of SJD450E-R1 / SJD450F-R1 Spreader

4.1.4 ELME817 Spreader
Fig.4-4 Hydraulic Schematic Diagram of ELME817 Spreader

4.1.5 BROMMA RSX40 Spreader
Fig.4-5 Hydraulic Schematic Diagram of BROMMA RSX40 Spreader

4.2 Electrical schematic diagram of spreader system

4.2.1 SDJ450 Spreader
Power supply + Cab operation directives

Right rotating Left side- Right side- Main beam Main beam Locking Unlocking 30” (optional) Safety bypass Automatic twist-
Left rotating shifting shifting extending retracting lock (optional)
From cab
From cab
SYMC controller
From cab
Right telescope Left rotation Right rotation Left telescope

Left locked Right locked Left unlocked Right unlocked Left/front seated Right/front seated Left/rear seated Right/rear seated in position buffering
buffering in position
Position sensor signal
Fig.4-6 Electrical Schematic Diagram of SDJ450 Spreader 1

Control signal output (solenoid valve)

Left main beam Right main beamLeft main beam Right main beam Left side- Left side- Right side- Right side-
Left locking Right locking Left unlocking Right unlocking extending extending retracting retracting shifting shifting shifting shifting Brake released 1 Brake released 2 Left rotating Right rotating Quick valve Left valve
buffering Right buffering
valve
SYMC controller
Main oil Locked alarm Locked signal Seated alarm Seated signal Unlocked Unlocked Lifting interru- Working condi-
supply valve lamp lamp alarm lamp signal pted signal tion indication
To body To cab To cab To cab Power supply - CAN BUS (optional)
Fig.4-7 Electrical Schematic Diagram of SDJ450 Spreader 2

4.2.2 SDJ450F-R1 Spreader

From cab
SYMC controller
From cab
Left rotation Right rotation Left anti- Right anti- Anti-striking

20” in position Left locked Right locked Left unlocked Right unlocked Left/front seatedRight/front seated Left/rear seated Right/rear seated in position in position 40” buffering 40” in position 20” buffering striking sensor striking sensor Debugging button effective Input spare Input spare
Position Sensor Signals
Fig.4-8 Electrical Schematic Diagram of SDJ450F-R1 Spreader 1


main beam Right main beamLeft main beam Right main beam Left side- Left side- Right side- Right side-
Left locking Right locking Left unlocking Right unlocking Leftextending extending retracting retracting shifting shifting shifting shifting Brake released 1 Brake released 2 Left rotating Right rotating Quick valve Throttle
valve
SYMC controller
To body To cab To cab To cab Power supply - CAN BUS

4.2.3 SDJ450E-R1 Spreader

From cab
SYMC controller
From cab
Right locked Left unlocked Right unlocked Left/front seated Right/front seated Left/rear seated Right/rear seated Left rotation Right rotation Anti-striking Input spare
Left locked in position in position Debugging button effective Input spare
Fig.4-10 Electrical Schematic Diagram of SDJ450E-R1 Spreader 1


Left main beam Right main beamLeft main beam Right main beam Left side- Left side- Right side- Right side- Overflow
Left locking Right locking Left unlocking Right unlocking extending extending retracting retracting shifting shifting shifting shifting Brake released 1 Brake released 2 Left rotating Right rotating Quick valve valve
SYMC controller
Fig.4-11 Electrical Schematic Diagram of SDJ450E-R1 Spreader 2

4.2.4 SDJ450F-R3 Spreader

Left rotating Right rotating Left side- Right side- Main beam Main beam Locking Unlocking Safety bypassEnable switch Single hook Single hook Double hook Double hook Hook moving Hook moving
shifting shifting extending retracting extending retracting extending retracting forward backward
From cab From cab
SYMC controller
From cab
Left/front hook Left/rear hook Left hook Right hook Left hook Right hook
20” right Left rotation Right rotation Right/front hook Right/rear hook moving moving
Left locked Right locked Left unlocked Right unlocked Left/front seated Right/front seated Left/rear seated Right/rear seated in position 20” left 40” right 40” left moving forward moving
in position in position in position in position in position forward backward backward
Position Sensor Signals Hook moving forward / leftward solenoid valve


Left main beam Right main beamLeft main beam Right main beam Left side- Left side- Right side- Right side-
Left locking Right locking Left unlocking Right unlocking extending extending retracting retracting shifting shifting shifting shifting Brake released 1 Brake released 2 Left rotating Right rotating Quick valve Left valve
buffering Right buffering
valve
SYMC controller
Left/front hook Right/front hook Left/front hook Right/front hook Left/rear hook Right/rear hook Left/rear hook Right/rear hook Main oil Locked alarm Locked Seated Seated Unlocked Unlocked Working condi-
extending extending retracting retracting extending extending retracting retracting supply valve lamp signal alarm signal alarm lamp signal tion indication
lamp
Control signal output (solenoid valve) To body To cab To cab To cab Power supply -

4.2.5 SJE100-R1 Spreader

From cab
From cab
SYMC controller
From cab
Left rotation Right rotation Left anti-striking Right anti-striking Anti-striking Input spare Input spare
20” right Left locked Right locked Left unlocked Right unlocked Left/front seated Right/front seated Left/rear seated Right/rear seated 20” left 40” right 40” left Debugging button effective
in position in position sensor sensor
Fig.4-14 Electrical Schematic Diagram of SJE100-R1 Spreader 1


Right locking Left main beam Right main beam Left main beam Right main beam Left side- Right side- Left buffering Right buffering
Left locking Left unlocking Right unlocking extending extending retracting retracting shifting shifting Brake released 1 Brake released 2 Left rotating Right rotating Quick valve valve valve
SYMC controller
Fig.4-15 Electrical Schematic Diagram of SJE100-R1 Spreader 2

4.2.6 ELME817 Spreader
Fig.4-16 Electrical Schematic Diagram of ELME817 Spreader 1






4.2.7 BROMMA RSX40 Spreader
- X1 Power / / 9. 01
- X1 Gnd / / 8. 01
- X9 Power / / 9. 01
- X6 Gnd / / 8. 06
- X9 Power / / 9. 02
- X6 Gnd / / 8. 03
601C
701C
704A
606B
704B
606C
- + - - - - - -
+ + + + + +
-S13 Anal ogue -S97 -S99 -S1 -S5 -S9 -S10
Yel l ow
Pi nk
White
Gr ey
Green
Br own
-XP2 44 22 55 66 33 11
408
409
428
410
429
411
430
601A
701A
/ 8. 01 / - X1 Gnd
/ 9. 01 / - X1 Power
-XP4 :8
:8 :27 :9
:9 :28 :10 :29 :11 :30
-B1
I I W 03 I IX 0.01 I IX 0.02 I IX 0.03 I IX0.04 I IX0.05 I IX0.06 I I X0. 7
O O O O O O O O
S1 S5 S9 S10
S13 S97 S99
Spar e Unlocked Locked Landed Landed
Tel escope pos. Rot at i on st op c. w Rot at i on st op c. c. w
left left left near side l ef t f ar si de
Fig.4-22 Electrical Schematic Diagram of BROMMA RSX40 Spreader 1

-B1
O O O O
PWM I QX 0.00 PWM I QX 0.01 PWM I QX 0.02 PWM I QX 0.03
-XP4 :44 :45 :4 6 :4 7
447
445
446
444
+ - + - + - + -
-S3 -S7 -S11 -S12
-Y19 -Y20 -Y21 -Y22

1 1 1 1
A 2 B 2 A 2 B 2
Yel l ow
Pi nk
White
Gr ey
Green
Br own
-XP3 44 22 55 66 33 11
Yel l ow
Pi nk
White
Gr ey
Green
Br own
603A
603B
604A
604B
- XP30 44 22 55 66 33 11
/ 8. 04 / - X5
/ 8. 05 / - X5
/ 8. 03 / - X3 Gnd
/ 8. 03 / - X3 Gnd
420
402
421
438
601B
701B
/ 8. 01 / - X1 Gnd
/ 9. 01 / - X1 Power
-XP4 :2 0 :2
:2 :2 1 : 38
-B1
I IX 0.12 I IX 0.13 I IX 0.14 I IX 0.15
O O O O
S3 S7 S11 S12
Y19 Y20 Y21 Y22 Sensor
Unlocked Locked Landed Landed
Si de shift t o l ef t Si de shift t o r i ght Rotate c.w Rot at e c. c. w power 24Vdc
right right r i ght f ar si de r i ght near si de

-B1
O O O O
PWM I QX 0.04 PWM I QX 0.05 PWM I QX 0.06 PWM I QX 0.07
-XP4 :36 :54 :17 :53
454
436
-Y100 -Y101
1 1
B 2 B 2
603C
6053
/ 8. 04 / - X5
/ 8. 03 / - X3 Gnd
-XP4 :19 :55 :18 :37
-B1
I IX1.04 I IX1.05 I IX1.06 I IX1.07
O O O O
Y100 Y101
Prop. Prop. Spar e Spar e Spar e Spar e Spar e Spar e
Rotate si de shi f t / t el escope

-B1
O O O
I QX 0.13 I QX 0.14 I QX 0.15
-XP4 :42 : 43 :4
:4
404
- XPHL4 11
-HL4
- XPHL4 22
6041
-X4
-XP4 :39 :3
:3 :40 :22 :41
-B1
I IX1.08 I IX1.09 I IX1.10 I IX1.11 I IX1.12
O O O O O
Wor ki ng l i ght l ef t
Spar e Spar e Spar e Spar e Spar e Spar e Spar e
Cmd

-B1
O O O O O O O O
I QX 1.00 I QX 1.01 I QX 1.02 I QX 1.03 I QX 1.04 I QX 1.05 I QX 1.06 I QX 1.07
-XP4 :48 :49 :31 :50 :51 :52 :16 :35
449
431
450
451
452
416
435
448
-XP6 11 22 33
11 -Y7 -Y8 -Y17 -Y18

- XPHL5
1 1 1 1
2 2 2
-HL5 -HL1 -HL2 -HL3
A 2 B 2 A 2 B 2
1 1 1
- XPHL5 22 Gr een Yel l ow Red
6042
-XP6 44
-X4
602A
602B
602C
602D
6021
/ 8. 06 / - X6 Gnd
/ 8. 02 / - X2 Gnd
/ 8. 02 / - X2 Gnd
/ 8. 02 / - X2 Gnd
/ 8. 02 / - X2 Gnd
Wor ki ng l i ght r i ght Y7 Y8 Y17 Y18 HL1 HL2 HL3

Cmd TWL unl ock TWL l ock Ext end Retract Green locked Yel l ow l anded Red unlocked

Reach Stacker
.
601A
- X1 Gnd / / 3. 09
-X1
601B
601 - X1 Gnd / / 3. 09
: Gnd
.
601C - X1 Gnd / / 4. 09
602A
- X2 Gnd / / 7. 02
602B
- X2 Gnd / / 7. 03
-X2
-X2
602
: Gnd
602C
- X2 Gnd / / 7. 04
602D
- X2 Gnd / / 7. 05
-B1
6021
- X6 Gnd / / 3. 09
603A
-XP4
GND S 608A - X3 Gnd / / 4. 01
- X8 Gnd / / 9. 05
-X3
:1
:1
-X3
603B
- X3 Gnd / / 4. 02
- X8 Gnd / / 9. 09
603
: Gnd
603C - X3 Gnd / / 5. 02
-X8
GND O
608B - X8 Gnd / / 9. 05
Gnd
:15
: Gnd
608C
t o Cont r ol syst em B1
GND A
607A
:12
-X5
6051
- X5 / / 5. 01
6052
- X5 / / 4. 03
6053
- X5 / / 4. 04
-X7
- X10
607C
: Gnd
-XP1
609A
606
11
-X9
607B
: Gnd
609B
-X6
Electrical and Hydraulic Schematics-March 2019

22
: Gnd
606B - X6 Gnd / / 3. 09
610A 606C - X6 Gnd / / 7. 06

22
22
Gnd

f r om Tr uck
.
4-28
Schematic Diagrams of Spreader System
- X1 Power / / 3. 09
- X1 Power / / 3. 09
- X1 Power / / 4. 09
- X9 Power / / 3. 09
- X9 Power / / 3. 09
701A -XP5 33 22 44 55 11
701B
704A
704B
701C
/ 8. 03 / - X8 Gnd
Bl ack
Bl ue
White
Red
: Power
-X1
701
/ 8. 04 / - X8 Gnd
Red
423
-XP1 14
14 15
15 - XP14 22 11 44
: Power
-X9 CANopen cabl e must be
Twi st ed pai r
/ 8. 03 / - X8 Gnd
XP5 BLUE
405
XP5 WHI TE
432 BLUE
414 WHI TE
434 424
1 1
-R1 -R2
120 Ohm 120 Ohm
2 2
709A
710A
710B
-XP4 : 34 :5
:5 :23 -XP4 :13 : 24 :1 4 :3 2 :26 :25 :33 :6
:6 :7
:7
-XP1 18
18 33 44 -B1
GND
TxD
RxD
VBB O
VBB R
VBB S
Can H
Can H
Er r or
Can L
Can L
Test
2A Fuse 10A Fuse
Mai n suppl y Mai n suppl y

Er r or / Test CANopen1 CANopen2 RS-232
f r om Tr uck t o Cont r ol syst em B1

SDCY90K8C15 Hurdling Single-container Handler
Safety, Operation & Maintenance Manual June-2012 I

www.sanygroup.com
SANY MARINE HEAVY INDUSTRY CO., LTD

Sany Industrial Park, Gaolan Port Economic & Development Zone, Zhuhai City,
Guangdong Province, China
Tel: 0086-756-7266945
Fax: 0086-731-84031999-149
B03T01ENAR5-SRSC45CX / SRSC45HX / SRSC4535X / SRSC4540X / SRSC4545X /

SRSC1009-6E / SRSC0808-6EH / SRSC3615-3

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Quality Changes the World

Safety, Operation & Maintenance Manual

Safety, Operation & Maintenance Manual - August 2019 I

II Safety, Operation & Maintenance Manual - August 2019

Safety, Operation & Maintenance Manual - August 2019 III

Duty of Owners or Other Authorized Personnel

IV Safety, Operation & Maintenance Manual - August 2019

Duty of All Working Personnel

Safety, Operation & Maintenance Manual - August 2019 V

Safety, Operation & Maintenance Manual - August 2019 I

II Safety, Operation & Maintenance Manual - August 2019

2.3.6.2 Safety rules for traveling������������������������������������������������������������������������� 2-40

Safety, Operation & Maintenance Manual - August 2019 III

2.4.13.1 Handling inflammables safely���������������������������������������������������������������� 2-63

IV Safety, Operation & Maintenance Manual - August 2019

3.2.4.5 Cab moving switch��������������������������������������������������������������������������������� 3-21

Safety, Operation & Maintenance Manual - August 2019 V

VI Safety, Operation & Maintenance Manual - August 2019

Safety, Operation & Maintenance Manual - August 2019 VII

4.7.2.2 Disassembly list ������������������������������������������������������������������������������������� 4-60

VIII Safety, Operation & Maintenance Manual - August 2019

5.6.1 General engine inspection ����������������������������������������������������������������������������� 5-34

Safety, Operation & Maintenance Manual - August 2019 IX

5.6.6 Urea filter element, changing�������������������������������������������������������������������������� 5-60

X Safety, Operation & Maintenance Manual - August 2019

5.10.6.2 Wheel rim, removing������������������������������������������������������������������������������5-81

Safety, Operation & Maintenance Manual - August 2019 XI

XII Safety, Operation & Maintenance Manual - August 2019

6.3.2.2 Troubleshooting procedures��������������������������������������������������������������������� 6-9

Safety, Operation & Maintenance Manual - August 2019 XIII

XIV Safety, Operation & Maintenance Manual - August 2019

Safety, Operation & Maintenance Manual - August 2019 XV

XVI Safety, Operation & Maintenance Manual - August 2019

Safety, Operation & Maintenance Manual - August 2019 1-1

1.7 Running in a New Machine ������������������������������������������������������������������������������������1-19

1-2 Safety, Operation & Maintenance Manual - August 2019

1.1 Overview WARNING

Failure to do this would result in personal

Safety, Operation & Maintenance Manual - August 2019 1-3

Information, specifications, and illustrations

Modifying the machine without any approval

1-4 Safety, Operation & Maintenance Manual - August 2019

1.2 Application Range

1.2.1 Intended use

Reach stacker is a type of auxiliary equipment

Never hoist or transport heavier load than

The rules for intended and approved uses

The user is responsible for any danger arising

Fig. 1-2 Steel Coil Reach Stacker

Fig. 1-3 Steel Pipe Reach Stacker

Safety, Operation & Maintenance Manual - August 2019 1-5

1.2.2 Unauthorized use

If any procedures or actions not specified,

Unauthorized uses include:

1-6 Safety, Operation & Maintenance Manual - August 2019

1.3 Machine Authorizations

All machines and equipment manufactured by

Safety, Operation & Maintenance Manual - August 2019 1-7

1.4 Your Documentation Package

Several documents will be packed along with

1.4.1 CD system requirements

The requirements of computer configuration

1-8 Safety, Operation & Maintenance Manual - August 2019

1.4.2 Recommendations on using the

2.3.6.2 Safety rules for traveling�� 2-40

2.4.13.1 Handling inflammables safely�� 2-63

3.2.4.5 Cab moving switch�� 3-21

4.7.2.2 Disassembly list �� 4-60

5.6.1 General engine inspection �� 5-34

5.6.6 Urea filter element, changing�� 5-60

5.10.6.2 Wheel rim, removing��5-81

6.3.2.2 Troubleshooting procedures�� 6-9

1.7 Running in a New Machine ��1-19