Sany Reach Stacker srsc45v5

Quality Changes the World
Reach Stacker
Safety, Operation and Maintenance Manual

Reach stacker
Reach stacker
Safety, Operation and Maintenance Manual
WARNING
Read and follow the safety precautions and instructions in this manual and on the machine
decals. Failure to do can cause serious injury, death or property damage. Keep this manual with
the machine for reading and future reference.
Safety, Operation and Maintenance Manual-June 2019

Reach stacker
Sany Group
SANY MARINE HEAVY INDUSTRY CO., LTD
Sany Industrial Park, Gaolan Port Economic & Development Zone, Zhuhai
City,Guangdong Province, China
Tel: 0086-4006098318
E-mail:crd@sany.com.cn
Website: www.sanyglobal.com
2018 by Sany Group. All rights reserved. No part of this publication may be reproduced, used, distributed or
disclosed except during normal operation 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 your machine and what is presented here. Sany Group assumes no liability.
For more information, contact Sany Group.
Safety, Operation and Maintenance Manual-June 2019

Reach stacker
Disclaimer
Special Statements
The reach stacker is mainly used as auxiliary equipment to hoist, transfer and stack containers in
large ports and docks. Usage beyond the prescribed purpose are not within the range of applica-
tion. Sany will not bear any responsibility for the consequences caused by the usage beyond the
range of application.
Sany shall not be liable for the adverse consequences caused by the following situations:
• Consequences caused by failing to use the reach stacker as stipulated in this Manual.
• Consequences caused by unauthorized change or modification of the reach stacker.
• Any equipment damage or accidents caused by using untested or unauthorized accessories
other than the genuine ones from Sany.
• Machine failure or damage caused by force majeure such as natural disasters (earthquakes,
typhoons, etc.), wars, etc.;
• Consequences caused by other factors other than Sany.
It is impossible for Sany to foresee all the possible hazards on the job site. Therefore, the reach
stacker operators and customers should attach great importance to safety issues.
It is possible that stricter operation regulations are imposed by the local authorities in different re-
gions where the reach stacker are used. If they conflict with these safety operation instructions,
the most stringent safety operating regulations should be followed.
Responsibilities of Sany:
• The quality of the reach stacker provided by Sany is good, and the technical data sheets are
accurate.
• Fulfill the after-sales service promise and document all maintenance and repair work performed
by the after-sales service personnel.
• Provide training for equipment operators and maintenance personnel as needed.
Responsibilities of the customer or other authorized personnel:
• Relevant personnel can only operate and maintain the reach stacker after they have received
sufficient training and fully understand the content of the accessory catalogue and the Operation
and Maintenance Manual of the reach stacker.
• Make sure that the operators and the maintenance personnel of the reach stacker are qualified
for this job and know the corresponding responsibilities.
• Regularly check the safety awareness of relevant personnel at work.
• In the event of any failure that may affect safety, stop the reach stacker immediately.
Safety, Operation and Maintenance Manual-June 2019 1

Reach stacker
• The Sany service personnel have the right to carry out relevant safety inspections on reach
stackers when necessary.
• In addition to the inspections specified by Sany, the reach stacker needs to be inspected
according to the relevant national and regional laws and regulations.
• Ensure timely maintenance and repair of the reach stacker.
• Plan the use of the reach stacker carefully and consciously.
Responsibilities of all working personnel
• If there is any anomaly that may result in abnormal operation of the reach stacker or potential
hazards, report to the supervisor immediately, and correct it in time if possible.
• All personnel working around the reach stacker must follow all warning signs and be alert to the
threats to their and others' safety.
• All the working personnel should know the operation content and procedure.
• Observe whether there is a danger, and warn the operator and the signal man if any. For
example, high-voltage lines, irrelevant personnel, poor ground conditions, etc.
Responsibilities of the managers:
• Ensure that the operator is well trained, fully understands the content of the operation manual
provided by Sany, is in good health, and has an operation certificate, otherwise the operator is
not allowed to operate the reach stacker.
• Ensure that the operator has good judgment, cooperation awareness and psychological quality,
otherwise he or she is not allowed to operate or maintain the reach stacker.
• Ensure that the signalman has good visual and auditory judgment, masters the standard
instructions and can deliver accurate signals clearly, and should have sufficient experience to
identify the dangerous factors and notify the operators to avoid them in time.
• Ensure that the assisting personnel can correctly recognize the model and working conditions of
the reach stackers and select the appropriate one.
• Ensure that the awareness of safe operation is communicated to the working personnel of all
projects. Clearly inform the operators of the safety notes that should be paid attention to during
the operation.
2 Safety, Operation and Maintenance Manual-June 2019

Reach stacker Table of Contents
Table of Contents
1 Introduction........................................................................................................................1-1
1.1 Introduction ............................................................................................................................1-3
1.2 Overview.................................................................................................................................1-3
1.3 Application scope ..................................................................................................................1-4
1.4 Machine Authorizations........................................................................................................1-5
1.5 Your Documentation Package.............................................................................................1-5
1.5.1 Your Documentation Package ....................................................................................1-5
1.5.2 CD system requirements.............................................................................................1-5
1.5.3 Recommendations on using the documentation .....................................................1-6
1.5.4 Documentation storage ...............................................................................................1-6
1.5.5 Manual organization.....................................................................................................1-6
1.6 Terminology............................................................................................................................1-8
1.7 Machine Information .......................................................................................................... 1-10
1.7.1 Machine Information ................................................................................................. 1-10
1.7.2 Machine nameplate................................................................................................... 1-10
1.7.3 Engine nameplate ......................................................................................................1-11
1.7.3.1 VOLVO engine nameplate .................................................................................1-11
1.7.4 Spreader nameplate ..................................................................................................1-11
1.7.4.1 SANY spreader nameplate................................................................................1-11
1.7.4.2 ELME spreader nameplate............................................................................... 1-12
1.7.4.3 BROMMA spreader nameplate........................................................................ 1-12
1.7.5 Transmission case nameplate................................................................................. 1-13
1.7.5.1 DANA transmission case nameplate............................................................... 1-13
1.8 Running in a New Machine............................................................................................... 1-13
1.9 Machine Serial No. and Distributor Info. ......................................................................... 1-13
1.10 Correction Request Form ............................................................................................... 1-14
1.11 Contact Information ......................................................................................................... 1-14
2 Safety.....................................................................................................................................2-1
2.1 Safety Information.................................................................................................................2-5
2.1.1 Safety Information ........................................................................................................2-5
2.1.2 Signal words..................................................................................................................2-5
2.1.3 Examples of using signal words .................................................................................2-6
2.1.4 Other signal words .......................................................................................................2-6
2.1.5 Safety labels..................................................................................................................2-6
2.1.5.1 Safety labels ..........................................................................................................2-6
2.1.5.2 Safety labels - location .........................................................................................2-8
Safety, Operation and Maintenance Manual-June 2019 I

Table of Contents Reach stacker
2.1.5.3 Safety labels - content ..........................................................................................2-9

2.2 General Precautions.......................................................................................................... 2-19
2.2.1 General Precautions ................................................................................................. 2-19
2.2.2 Basic safety instructions........................................................................................... 2-20
2.2.3 Personal protective equipment................................................................................ 2-20
2.2.4 Never operate while in bad health........................................................................... 2-23
2.2.5 No passenger in the cab........................................................................................... 2-23
2.2.6 Hand signals............................................................................................................... 2-24
2.2.7 Preparing safety items .............................................................................................. 2-26
2.2.8 Checking safety equipment...................................................................................... 2-27
2.2.9 Precautions in high voltage areas........................................................................... 2-27
2.2.10 Precautions in thunderstorm.................................................................................. 2-30
2.2.11 Precautions in wind ................................................................................................. 2-30
2.2.12 Abnormal cases....................................................................................................... 2-31
2.2.13 Unauthorized modification ..................................................................................... 2-31
2.3 Safety During Operation.................................................................................................... 2-32
2.3.1 Work area safety........................................................................................................ 2-32
2.3.1.1 Work area safety ................................................................................................ 2-32
2.3.1.2 Work area requirements.................................................................................... 2-32
2.3.1.3 Work area indications ........................................................................................ 2-33
2.3.2 Checks before operation .......................................................................................... 2-33
2.3.3 Keeping machine clean ............................................................................................ 2-36
2.3.4 Climbing on or off the machine safely .................................................................... 2-36
2.3.5 Start-up safety............................................................................................................ 2-38
2.3.5.1 Inside the operator cab...................................................................................... 2-38
2.3.5.2 Adjusting the seat............................................................................................... 2-38
2.3.5.3 Checking the seat belt ....................................................................................... 2-39
2.3.5.4 Machine starting precautions ........................................................................... 2-39
2.3.5.5 In cold weather ................................................................................................... 2-40
2.3.5.6 After starting the engine .................................................................................... 2-40
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 ................................................................................... 2-41
2.3.6.3 Precautions for working on slope..................................................................... 2-42
2.3.6.4 Avoiding injury from reversing.......................................................................... 2-43
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 .............................................................................. 2-46
II Safety, Operation and Maintenance Manual-June 2019
2.3.6.10 Precautions for operating emergency stop button ...................................... 2-46

2.3.6.11 Precautions for operating safety bypass switch .......................................... 2-47
2.3.7 Parking the machine securely ................................................................................. 2-48
2.3.7.1 Parking requirements ........................................................................................ 2-48
2.3.7.2 Turning off the engine........................................................................................ 2-49
2.4 Safety During Maintenance .............................................................................................. 2-51
2.4.1 Safety During Maintenance ..................................................................................... 2-51
2.4.2 Preparation for the work area .................................................................................. 2-51
2.4.3 Maintenance status of the machine ........................................................................ 2-51
2.4.4 Warning label is important........................................................................................ 2-52
2.4.5 Lockout/tagout procedures ...................................................................................... 2-52
2.4.6 Preparation of maintenance..................................................................................... 2-53
2.4.7 Using tools correctly.................................................................................................. 2-53
2.4.8 Regular replacement of safety-related parts ......................................................... 2-53
2.4.9 Preventing hydraulic hazards .................................................................................. 2-53
2.4.9.1 Checking rubber hose regularly ....................................................................... 2-53
2.4.9.2 Releasing the pressure before maintenance ................................................. 2-54
2.4.9.3 Replacing rubber hose regularly...................................................................... 2-55
2.4.9.4 Prevent heat near the hydraulic pipeline ........................................................ 2-56
2.4.9.5 Selecting oils and fuel........................................................................................ 2-56
2.4.9.6 Handling hydraulic oil ........................................................................................ 2-57
2.4.9.7 Filling accumulator ............................................................................................. 2-57
2.4.10 Preventing burn and scald ..................................................................................... 2-58
2.4.10.1 Burn by high temperature liquid..................................................................... 2-58
2.4.10.2 Chemical burn .................................................................................................. 2-58
2.4.11 Preventing fire and explosion ................................................................................ 2-60
2.4.11.1 Handling inflammables safely ........................................................................ 2-60
2.4.11.2 Removing inflammables.................................................................................. 2-60
2.4.11.3 Checking oil leakage........................................................................................ 2-61
2.4.11.4 Checking short circuit ...................................................................................... 2-61
2.4.11.5 Checking ignition key....................................................................................... 2-62
2.4.11.6 Preventing battery explosion .......................................................................... 2-62
2.4.11.7 Evacuating from the machine......................................................................... 2-64
2.4.12 Preventing poisoning and asphyxiation ............................................................... 2-65
2.4.12.1 Handling chemicals safely .............................................................................. 2-65
2.4.12.2 Preventing poisoning by paint........................................................................ 2-66
2.4.12.3 Preventing poisoning by off-gas .................................................................... 2-66
2.4.13 Preventing dust hazard .......................................................................................... 2-67
2.4.14 Working under machine ......................................................................................... 2-67
Safety, Operation and Maintenance Manual-June 2019 III

2.4.15 Precautions in welding............................................................................................ 2-68

2.4.16 Precautions in maintaining the engine ................................................................. 2-69
2.4.17 High voltage precautions........................................................................................ 2-70
2.4.18 Safe maintenance of air conditioning system ..................................................... 2-70
2.4.19 Precautions after maintenance ............................................................................. 2-70
2.4.20 Handling waste properly......................................................................................... 2-71
2.5 Tag........................................................................................................................................ 2-72
3 System functions ............................................................................................................3-1

3.1 Main components of machine .............................................................................................3-5
3.2 Cab..........................................................................................................................................3-6
3.2.1 Cab .................................................................................................................................3-6
3.2.2 Steering column............................................................................................................3-8
3.2.2.1 Steering column ....................................................................................................3-8
3.2.2.2 Steering panel........................................................................................................3-9
3.2.2.3 Gear selector ...................................................................................................... 3-14
3.2.2.4 Direction indication controller ........................................................................... 3-16
3.2.2.5 Adjusting the angle of steering controller ....................................................... 3-19
3.2.3 Pedal ........................................................................................................................... 3-19
3.2.4 Joystick（Option1） ................................................................................................. 3-20
3.2.5 Joystick（Option2） ................................................................................................. 3-21
3.2.6 Right operation panel................................................................................................ 3-22
3.2.6.1 Right operation panel ........................................................................................ 3-22
3.2.6.2 Ignition Switch..................................................................................................... 3-23
3.2.6.3 Emergency retraction/lowering switch ............................................................ 3-24
3.2.6.4 Safety bypass switch ......................................................................................... 3-25
3.2.6.5 Emergency stop switch ..................................................................................... 3-27
3.2.6.6 Cab move enable ............................................................................................... 3-28
3.2.6.7 Top wiper switch ................................................................................................. 3-29
3.2.6.8 Rear wiper switch............................................................................................... 3-30
3.3 Display ................................................................................................................................. 3-31
3.3.1 SANY Display............................................................................................................. 3-31
3.3.1.1 SANY Display ..................................................................................................... 3-31
3.3.1.2 Menu introduction............................................................................................... 3-32
3.3.1.3 Main menu........................................................................................................... 3-33
3.3.1.4 Language setting menu..................................................................................... 3-35
3.3.1.5 Engine information menu .................................................................................. 3-36
3.3.1.6 Gear information menu...................................................................................... 3-37
3.3.1.7 Hydraulic information menu.............................................................................. 3-38
IV Safety, Operation and Maintenance Manual-June 2019

3.3.1.8 Digital analogy menu ......................................................................................... 3-39

3.3.1.9 Help System........................................................................................................ 3-41
3.3.1.10 Function set menu ........................................................................................... 3-42
3.4 Air Conditioning System.................................................................................................... 3-42
3.4.1 Control panel.............................................................................................................. 3-42
3.4.1.1 Control panel....................................................................................................... 3-42
3.4.1.2 Power switch....................................................................................................... 3-44
3.4.1.3 Fan speed switch ............................................................................................... 3-44
3.4.1.4 Temperature or Paging switch.......................................................................... 3-45
3.4.1.5 Mode switch ........................................................................................................ 3-46
3.4.1.6 Fresh air switch .................................................................................................. 3-47
3.4.2 Operation .................................................................................................................... 3-47
3.4.3 Precautions ................................................................................................................ 3-49
3.5 Fuse and controller of the electric control cabinet......................................................... 3-50
3.6 Fuse ..................................................................................................................................... 3-51
3.7 Fire extinguisher................................................................................................................. 3-53
4 Operation.............................................................................................................................4-1
4.1 Before the Starting of Engine ..............................................................................................4-5
4.1.1 Inspection before starting............................................................................................4-5
4.1.1.1 Inspection before starting.....................................................................................4-5
4.1.1.2 Wiper water level, checking.................................................................................4-5
4.1.1.3 Coolant level，checking ......................................................................................4-6
4.1.1.4 Engine oil level，checking...................................................................................4-6
4.1.1.5 Transmission oil level, checking .........................................................................4-6
4.1.1.6 Hydraulic oil level, checking ................................................................................4-7
4.1.1.7 Fuel level, checking ..............................................................................................4-8
4.1.1.8 Brake oil level, checking.......................................................................................4-9
4.1.1.9 Tyres, checking......................................................................................................4-9
4.1.1.10 Electrical components,checking .................................................................... 4-10
4.1.1.11 Working light, checking ....................................................................................4-11
4.1.1.12 Horn, checking ..................................................................................................4-11
4.1.2 Adjustment before operation.....................................................................................4-11
4.1.2.1 Adjusting the seat................................................................................................4-11
4.1.2.2 Adjusting the rearview mirror............................................................................ 4-14
4.1.2.3 Adjusting the safety belt .................................................................................... 4-14
4.2 Starting the Machine.......................................................................................................... 4-16
4.2.1 Starting the machine ................................................................................................. 4-16
4.2.2 Starting the machine at normal temperature ......................................................... 4-16
Safety, Operation and Maintenance Manual-June 2019 V

4.2.3 Starting the machine at low temperature ............................................................... 4-19

4.2.4 Starting the machine with auxiliary measures....................................................... 4-20
4.3 Shutingt down the machine .............................................................................................. 4-21
4.4 Driving.................................................................................................................................. 4-24
4.4.1 Driving requirements................................................................................................. 4-24
4.4.2 Driving forward........................................................................................................... 4-25
4.4.3 Driving backward ....................................................................................................... 4-26
4.4.4 Turning around........................................................................................................... 4-27
4.4.5 Parking ........................................................................................................................ 4-27
4.5 Load Handling..................................................................................................................... 4-29
4.5.1 Operation switches（Option1）.............................................................................. 4-29
4.5.2 Boom, operation（Option1） .................................................................................. 4-30
4.5.3 Spreader, operation（Option1）............................................................................. 4-34
4.5.4 Operation switches（Option2）.............................................................................. 4-38
4.5.5 Boom, operation（Option2） .................................................................................. 4-38
4.5.6 Spreader, operation（Option2）............................................................................. 4-42
4.5.7 Hook, operation ......................................................................................................... 4-47
4.5.8 Load capacity diagram.............................................................................................. 4-48
4.5.8.1 Load capacity diagram ...................................................................................... 4-48
4.5.8.2 Load capacity diagram of SRSC45V5 container reach stacker .................. 4-49
4.5.9 Pick the container ...................................................................................................... 4-50
4.5.10 Stack the container ................................................................................................. 4-53
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 Long-term storage.............................................................................................. 4-56
4.6.3.2 Preparation.......................................................................................................... 4-56
4.6.3.3 During storage .................................................................................................... 4-57
4.6.3.4 Return to service ................................................................................................ 4-58
4.7 Disassembly, assembly and transportation.................................................................... 4-58
4.7.1 Guide for disassembly & assembly and transportation........................................ 4-58
4.7.2 Disassembling the machine..................................................................................... 4-58
4.7.2.1 Disassembling principles .................................................................................. 4-58
4.7.2.2 Disassembly checklist ....................................................................................... 4-59
4.7.2.3 Lifting points of machine parts.......................................................................... 4-60
4.7.3 Packing requirements ............................................................................................... 4-61
4.7.4 Transportation............................................................................................................ 4-62
4.7.4.1 Transporting by platform lorry .......................................................................... 4-62
4.7.4.2 Transporting by container ................................................................................. 4-62
VI Safety, Operation and Maintenance Manual-June 2019

5 Maintenance.......................................................................................................................5-1
5.1 Maintenance information......................................................................................................5-7
5.2 Tightening torques ................................................................................................................5-9
5.2.1 Tightening torques........................................................................................................5-9
5.2.2 Table of standard bolt torque ................................................................................... 5-10
5.2.3 Tightening torque of the hose swivel nuts...............................................................5-11
5.2.4 Tightening torque of pipe fittings ............................................................................. 5-13
5.2.5 Tightening torque of key bolts.................................................................................. 5-14
5.3 Functional oil....................................................................................................................... 5-15
5.3.1 Oil specifications........................................................................................................ 5-15
5.3.2 Oil capacity ................................................................................................................. 5-18
5.3.2.1 Oil capacity.......................................................................................................... 5-18
5.3.2.2 Oil Capacity of SRSC45V5 Reach Stacker.................................................... 5-18
5.3.3 Hydraulic oil................................................................................................................ 5-19
5.3.3.1 Hydraulic oil management ................................................................................ 5-19
5.3.3.2 Hydraulic oil， checking.................................................................................... 5-21
5.3.4 Urea............................................................................................................................. 5-22
5.3.4.1 Urea...................................................................................................................... 5-22
5.3.4.2 Quality requirements for urea........................................................................... 5-22
5.3.4.3 Storage time of urea .......................................................................................... 5-23
5.4 Lubricating points ............................................................................................................... 5-23
5.4.1 Lubricants ................................................................................................................... 5-23
5.4.2 Lubrication points of the whole machine................................................................ 5-23
5.5 Scheduled maintenance ................................................................................................... 5-25
5.5.1 Daily maintenance items .......................................................................................... 5-25
5.5.2 Maintenance every 50 hours ................................................................................... 5-26
5.5.3 Maintenance every 250 hours ................................................................................. 5-27
5.5.4 Maintenance every 500 hours ................................................................................. 5-29
5.5.5 Maintenance every 1000 hours ............................................................................... 5-30
5.5.9 Special instructions for the first maintenance........................................................ 5-32
5.6 Engine.................................................................................................................................. 5-33
5.6.1 General engine inspection ....................................................................................... 5-33
5.6.1.1 General engine inspection ................................................................................ 5-33
5.6.1.2 Charge air pipe, check....................................................................................... 5-35
5.6.1.3 Drive belt, check................................................................................................. 5-36
5.6.1.4 Drive belt, replace (engine option VOLVO) .................................................... 5-38
5.6.1.5 Alternator belt, replace (engine option VOLVO) ............................................ 5-39
Safety, Operation and Maintenance Manual-June 2019 VII

5.6.1.6 Air filter, check .................................................................................................... 5-42

5.6.1.7 Air filter, clean ..................................................................................................... 5-44
5.6.1.8 Air filter, replacing .............................................................................................. 5-46
5.6.1.9 Fan drive gear train and hub............................................................................. 5-49
5.6.1.10 Shock absorber, checking .............................................................................. 5-50
5.6.1.11 Coolant pump, checking.................................................................................. 5-51
5.6.1.12 Urea filter element, replacing ......................................................................... 5-52
5.6.2 Lubrication system .................................................................................................... 5-54
5.6.2.1 Oil level, check and top up................................................................................ 5-54
5.6.2.2 Engine oil, change.............................................................................................. 5-55
5.6.2.3 Oil filter or the bypass filter, replace (VOLVO engine) .................................. 5-57
5.6.2.4 Oil filter, replace (CUMMINS engine) .............................................................. 5-59
5.6.3 Fuel system ................................................................................................................ 5-61
5.6.3.1 Condensate, drain (VOLVO engine) ............................................................... 5-61
5.6.3.2 Condensate, drain (CUMMINS engine)......................................................... 5-63
5.6.3.3 Fuel filter, replace (VOLVO engine)................................................................ 5-64
5.6.3.4 Fuel filter, replace (CUMMINS engine) ........................................................... 5-66
5.6.3.5 Fuel pre-filter, change (VOLVO engine).......................................................... 5-68
5.6.3.6 Fuel system, bleed (VOLVO engine)............................................................... 5-70
5.6.4 Cooling system .......................................................................................................... 5-71
5.6.4.1 Description of cooling system........................................................................... 5-71
5.6.4.2 Coolant, mix ....................................................................................................... 5-71
5.6.4.3 Water quality ....................................................................................................... 5-72
5.6.4.4 Coolant level, check and top up ....................................................................... 5-73
5.6.4.5 Completely empty system, fill........................................................................... 5-74
5.6.4.6 Coolant, drain ..................................................................................................... 5-76
5.6.4.7 Radiator, clean.................................................................................................... 5-77
5.6.4.8 Cooling system, clean ....................................................................................... 5-79
5.6.5 Air intake and exhaust system................................................................................. 5-81
5.6.5.1 Air leaks, check ................................................................................................. 5-81
5.6.5.2 Turbocharger, check .......................................................................................... 5-82
5.7 transmission system .......................................................................................................... 5-85
5.7.1 Description of transmission system ........................................................................ 5-85
5.7.2 Mounting bolts of propeller shaft, checking ........................................................... 5-85
5.7.3 Propeller shaft, lubricating........................................................................................ 5-87
5.7.4 Speed sensor, check................................................................................................. 5-88
5.7.5 Transmission oil level, checking.............................................................................. 5-89
5.7.6 Transmission oil filter, change ................................................................................. 5-91
5.7.7 Transmission oil, change.......................................................................................... 5-92
VIII Safety, Operation and Maintenance Manual-June 2019

5.7.8 Mounting bolts and mounting pad, check .............................................................. 5-94

5.7.9 TE Transmission calibrating.................................................................................... 5-95
5.7.10 Transmission, checking......................................................................................... 5-97
5.8 Drive axle............................................................................................................................. 5-98
5.8.1 Mounting bolts of drive axle to the frame, checking ............................................. 5-98
5.8.2 Mounting bolts of drive axle to the propeller shaft, checking ............................. 5-99
5.8.3 Oil leaking of drive axle and brake components, checking .............................. 5-100
5.8.4 Breather connector, cleaning................................................................................ 5-103
5.8.5 Brake pads and braking function, checking........................................................ 5-104
5.8.6 Main reducer, checking.......................................................................................... 5-106
5.8.7 Main reducer oil, changing ..................................................................................... 5-107
5.8.8 Wheel-side reducer, checking .............................................................................. 5-109
5.8.9 Wheel hub nut, checking and tightening ...............................................................5-111
5.9 Steering axle ......................................................................................................................5-112
5.9.1 Daily check ................................................................................................................5-112
5.9.2 Steering axle, lubricating ........................................................................................5-114
5.9.3 Steering axle components, checking....................................................................5-115
5.9.4 Knuckle pin, checking .............................................................................................5-116
5.9.5 Steering axle cradle, maintaining..........................................................................5-117
5.10 Tyres and rims .................................................................................................................5-118
5.10.1 Tyres and rims .......................................................................................................5-118
5.10.2 Precautions for tires ..............................................................................................5-118
5.10.3 Tyre, inflating..........................................................................................................5-119
5.10.4 Maintenance of rim................................................................................................ 5-122
5.10.4.1 Precautions for rim......................................................................................... 5-122
5.10.4.2 Rim, checking ................................................................................................ 5-122
5.10.4.3 Wheel rim, removing..................................................................................... 5-125
5.10.4.4 Wheel rim, installing ..................................................................................... 5-127
5.10.5 Drive axle tyre, removing and installing ............................................................. 5-128
5.10.5.1 Drive axle tyre, removing ............................................................................. 5-128
5.10.5.2 Drive axle tyre, installing .............................................................................. 5-131
5.10.6 Steering axle tyre, removing and installing........................................................ 5-133
5.10.6.1 Steering axle tyre, removing........................................................................ 5-133
5.10.6.2 Steering axle tyre, installing ........................................................................ 5-135
5.11 Boom................................................................................................................................ 5-136
5.11.1 Boom ...................................................................................................................... 5-136
5.11.2 Basic boom, check ................................................................................................ 5-137
5.11.3 Wear pads, check.................................................................................................. 5-138
5.11.4 Pitch cylinder, checking ....................................................................................... 5-140
5.11.5 Maintenance of the cylinder piston rod.............................................................. 5-141
Safety, Operation and Maintenance Manual-June 2019 IX

5.12 Spreader.......................................................................................................................... 5-142

5.12.1 Twistlock, checking ............................................................................................... 5-142
5.12.2 Twistlock, lubricating............................................................................................. 5-144
5.12.3 Sensor / Indicator of twistlock, checking............................................................ 5-145
5.12.4 Fixed bolts of spreader rotating gearbox, checking ......................................... 5-146
5.12.5 Wear pads of spreader, checking ....................................................................... 5-147
5.13 Air Conditioning System................................................................................................ 5-150
5.13.1 Precautions for service......................................................................................... 5-150
5.13.2 Summary of air conditioner maintenance .......................................................... 5-152
5.13.3 Air conditioner belt，checking............................................................................. 5-153
5.13.4 Air return grid screen and the evaporator screen, checking ........................... 5-154
5.13.5 Refrigerant, checking............................................................................................ 5-155
5.13.6 Refrigerant/refrigeration oil，filling ..................................................................... 5-156
5.13.7 Cleanness of heat-exchanger plate in evaporator and condenser,
checking ............................................................................................................... 5-158
5.13.8 Compressor and air conditioner pipeline fittings for oil and refrigerant
leakage，checking ............................................................................................. 5-160
5.13.9 Pipelines, fittings and wire harness, checking .................................................. 5-161
5.13.10 Tightening of the compressor bolts, checking ................................................ 5-162
5.14 Hydraulic System ........................................................................................................... 5-163
5.14.1 Hydraulic oil level, checking................................................................................. 5-163
5.14.2 Air filter element, replace ..................................................................................... 5-164
5.14.3 Hydraulic oil, change ............................................................................................ 5-166
5.14.4 Hydraulic oil tank, cleaning .................................................................................. 5-167
5.14.5 Oil return filter element, replace .......................................................................... 5-168
5.14.6 Brake pedal, adjusting and lubricating ............................................................... 5-169
5.14.7 Parking brake unit, checking and adjusting....................................................... 5-170
5.14.8 Brake oil filter, checking and replacing............................................................... 5-172
5.14.9 Accumulator ........................................................................................................... 5-174
5.14.9.1 General information of accumulator............................................................ 5-174
5.14.9.2 Brake system accumulator, check............................................................... 5-175
5.14.9.3 Accumulator, charge...................................................................................... 5-176
5.14.10 Hydraulic oil circuit, check ................................................................................. 5-178
5.15 Electrical System ........................................................................................................... 5-179
5.15.1 Electrical system ................................................................................................... 5-179
5.15.2 Fuses, changing .................................................................................................... 5-180
5.15.3 Battery..................................................................................................................... 5-181
5.15.3.1 Battery ............................................................................................................. 5-181
5.15.3.2 Connecting and disconnecting..................................................................... 5-182
5.15.3.3 Battery, cleaning............................................................................................. 5-182
X Safety, Operation and Maintenance Manual-June 2019

5.15.3.4 Battery, checking............................................................................................ 5-184

5.15.3.5 Battery, charging ............................................................................................ 5-185
5.15.4 All working lights and indicators, checking ........................................................ 5-188
5.15.5 Wiper, adjusting ..................................................................................................... 5-189
5.15.6 Wiring terminal, cleaning and tightening............................................................ 5-190
5.15.7 Cable abrasion (specially around the engine), checking................................. 5-191
5.16 Maintenance Record List .............................................................................................. 5-192
6 Troubleshooting ..............................................................................................................6-1
6.1 Precautions ............................................................................................................................6-3
6.2 Troubleshooting Procedures ...............................................................................................6-3
6.3 Troubleshooting the engine system ...................................................................................6-4
6.4 Troubleshooting the transmission system .........................................................................6-5
6.4.1 Overview........................................................................................................................6-5
6.4.2 Troubleshooting procedures .......................................................................................6-6
6.4.3 Troubleshooting table ..................................................................................................6-7
6.5 Troubleshooting the drive axle and brake system............................................................6-8
6.6 Troubleshooting the air conditioning system.....................................................................6-8
6.7 Troubleshooting the hydraulic system ...............................................................................6-9
7 Specifications ...................................................................................................................7-1
7.1 Technical Specifications.......................................................................................................7-3
7.1.1 Basic parameters..........................................................................................................7-3
7.1.2 Technical Parameters ..................................................................................................7-4
7.1.3 System configuration ...................................................................................................7-4
7.1.3.1 Power system configuration ................................................................................7-4
7.1.3.2 Spreader configuration.........................................................................................7-5
7.2 International length and moment unit Conversion ...........................................................7-5
7.2.1 Conversion table, area.................................................................................................7-5
7.2.2 Unit abbreviation explanation .....................................................................................7-6
7.2.3 Conversion table, SI units ...........................................................................................7-6
7.2.4 Conversion table, length..............................................................................................7-7
7.2.5 Conversion table, volume............................................................................................7-8
7.2.6 Conversion table, weight .............................................................................................7-8
7.2.7 Conversion table, pressure .........................................................................................7-8
7.2.8 Conversion table, temperature ...................................................................................7-9
8 Optional Parts ...................................................................................................................8-1

8.1 Engine Preheating Protection Function .............................................................................8-5
8.2 Fire detection and Alarm System / Automatic Extinguishing ..........................................8-5
Safety, Operation and Maintenance Manual-June 2019 XI

8.2.1 Fire Detection and alarm system / automatic extinguishing de .............................8-5

8.2.2 Fire detection and alarm system ................................................................................8-6
8.2.2.1 Fire detection and alarm ......................................................................................8-6
8.2.2.2 Functions description............................................................................................8-6
8.2.2.3 Precautions ............................................................................................................8-7
8.2.2.4 Fire detection and alarm system / automatic extinguishing ............................8-8
8.2.2.5 Maintenance and repair .......................................................................................8-8
8.2.3 Automatic fire extinguishing device ...........................................................................8-9
8.2.3.1 Automatic fire extinguishing device ....................................................................8-9
8.2.3.2 Precautions ......................................................................................................... 8-10
8.2.3.3 Technical parameters ........................................................................................ 8-10
8.3 Loudspeaker and Controller Kit ........................................................................................8-11
8.3.1 Engine Idle Protection Function ...............................................................................8-11
8.3.2 Loudspeaker and controller kit ................................................................................ 8-12
8.3.3 Control panel.............................................................................................................. 8-12
8.3.4 Operations .................................................................................................................. 8-13
8.3.5 Electrical wiring diagram .......................................................................................... 8-13
8.3.6 Precautions ................................................................................................................ 8-13
8.4 Engine hour meter.............................................................................................................. 8-14
8.5 Twist lock counter............................................................................................................... 8-14
8.6 Reversing radar monitor.................................................................................................... 8-15
8.7 Operator-off-seat sensing system ................................................................................... 8-15
8.8 Radio.................................................................................................................................... 8-15
8.8.1 Radio ........................................................................................................................... 8-15
8.8.2 Radio control panel ................................................................................................... 8-16
8.8.3 Mute............................................................................................................................. 8-16
8.8.4 Sound .......................................................................................................................... 8-17
8.8.5 Audio settings............................................................................................................. 8-17
8.8.6 Reception.................................................................................................................... 8-18
8.8.7 RDS function (FM band)........................................................................................... 8-20
8.9 Automatic Lubrication System.......................................................................................... 8-21
8.9.1 Automatic lubrication system................................................................................... 8-21
8.9.2 Operation precautions .............................................................................................. 8-21
8.9.3 Lubrication time settings........................................................................................... 8-22
8.10 CCTV System................................................................................................................... 8-23
8.10.1 CCTV System .......................................................................................................... 8-23
8.10.2 Precautions .............................................................................................................. 8-23
8.10.3 Major parts ............................................................................................................... 8-24
8.10.4 Installation Instructions........................................................................................... 8-24
8.10.5 Shift switch ............................................................................................................... 8-26
XII Safety, Operation and Maintenance Manual-June 2019

8.10.6 Troubleshooting the CCTV system....................................................................... 8-26

8.10.7 System wiring diagram ........................................................................................... 8-28
8.11 Flowmeter.......................................................................................................................... 8-29
Safety, Operation and Maintenance Manual-June 2019 XIII

Reach stacker
XIV Safety, Operation and Maintenance Manual-June 2019

Reach stacker Introduction
Introduction
1 Introduction........................................................................................................................1-1
1.1 Introduction ............................................................................................................................1-3
1.2 Overview.................................................................................................................................1-3
1.3 Application scope ..................................................................................................................1-4
1.4 Machine Authorizations........................................................................................................1-5
1.5 Your Documentation Package.............................................................................................1-5
1.5.1 Your Documentation Package...................................................................................1-5
1.5.2 CD system requirements ...........................................................................................1-5
1.5.3 Recommendations on using the documentation ....................................................1-6
1.5.4 Documentation storage ..............................................................................................1-6
1.5.5 Manual organization ...................................................................................................1-6
1.6 Terminology............................................................................................................................1-8
1.7 Machine Information .......................................................................................................... 1-10
1.7.1 Machine Information ................................................................................................ 1-10
1.7.2 Machine nameplate ................................................................................................. 1-10
1.7.3 Engine nameplate .....................................................................................................1-11
1.7.3.1 VOLVO engine nameplate................................................................................1-11
1.7.4 Spreader nameplate .................................................................................................1-11
1.7.4.1 SANY spreader nameplate...............................................................................1-11
1.7.4.2 ELME spreader nameplate.............................................................................. 1-12
1.7.4.3 BROMMA spreader nameplate ...................................................................... 1-12
1.7.5 Transmission case nameplate ............................................................................... 1-13
1.7.5.1 DANA transmission case nameplate ............................................................. 1-13
1.8 Running in a New Machine............................................................................................... 1-13
1.9 Machine Serial No. and Distributor Info. ......................................................................... 1-13
1.10 Correction Request Form ............................................................................................... 1-14
1.11 Contact Information ......................................................................................................... 1-14
Safety, Operation and Maintenance Manual-June 2019 1-1

Introduction Reach stacker
WARNING
Read and understand all safety precautions and instructions in this manual before reading any
other manuals provided with this machine and before operation or maintaining it.Failure to do
this could result in death or serious injury.
1-2 Safety, Operation and Maintenance Manual-June 2019

1.Introduction
1.1 Introduction
Thank you heartedly for choosing our SRSC45V5 Reach Stacker. We are committed to provide
you with good quality machine and superior after-sales service.
1.2 Overview
WARNING
Before starting operation and maintenance, personnel should observe the following items:
• Only qualified and experienced operators with offical license (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.
This Safety, Operation & Maintenance Manual is a guide to handle the machine correctly. It pro-
vides technique and safety information necessary for operation and maintenance of the machine.
Please make sure to read every parts of this manual in detail.
Information, specifications, and illustrations in thi s publ i c at ion 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 or abusing it might risk the machine’s performance, or
result in potential hazard. Incorrect operation may cause personal injury or damage. SANY as-
sumes 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 specifications and standards 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.
1.3 Application scope

The reach stacker is mainly used as auxiliary
equipment to hoist, transfer and stack contain-
ers in large ports and docks.
With the advantages of low cost as well as

good maneuverability and flexibility compared
to gantry crane, quay crane and other cranes
in the ports, the reach stacker is the main
equipment for container handling operations
in small ports and docks.
Fig.1-1
With the advantages of flexibility, high effi-
ciency and high site utilization, the reach
stacker is the main equipment for container
handling operations in railway and highway
container depots.
The reach stacker is suitable for the operation

of 20-40 feet international standard contain-
ers. The weight of the hoisted or carried con-
tainer must not exceed the maximum
allowable load capacity of the machine, see “”
on page
Fig.1-2

1.4 Machine Authorizations

SANY port machines have all passed Euro-
pean CE authoriaztion, North America ANSI
authorizatin and Customs Union CU-TR
authorization.
All machines and equipment manufactured by Address: Sany Industry Town,

Economic and Technological
SANY Port Machinery Company are labeled Development Zone, Changsha,
Hunan, China
with CE, which certifies their conformity to the
European Union machine safety instructions. 1417
Fig.1-3 CE Label
1.5 Your Documentation Package

1.5.1 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.
1.5.2 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 (popup blocker disabled)
• Acrobat Reader 7.0 or later version

1.5.3 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 ver sions 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. Edition number of Safety, Operation and Maintenance Manual is marked as below:
1.5.4 Documentation storage
• Always keep this manual in the operator cab.

• Keep the parts book either in the workshop area or of fice to be available to the maintenance
personnel when needed.
• The above documents can be printed out from the CD.
1.5.5 Manual organization
CHAPTER 1: INTRODUCTION

This section provides a general outline of what is covered in this manual, including machine name-
plates 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 be-
fore operating or maintaining the machine. Failure to do so may result in serious injury or death.
CHAPTER 3: SYSTEM FUNCTIONS
This sect ion provides an over view of 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
This section provides basic operating procedures for the machine. Study and know all operating
procedures before any operations. This section also introduces the information about transporta-
tion / assembly/ disassembly of the machine.
CHAPTER 5: MAINTENANCE
This section provides all general maintenance and repair procedures. (Detailed adjustment / re-
placement / 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.

1.6 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
Control valve Valves that can be used to control hydraulics, for example, to
release pressure and thus lower the boom
Daily inspection The actions that should be performed daily to ensure the
machine’s functionality
Display Window” showing digital information on steering wheel panel in
cab
Drive axle Receives torque from the drive train
Drive train Parts in machine including engine, torque converter, transmission,
propeller shaft and drive axle with differential and hub reduction
Dust reservoir The air filter collects the coarsest particles in a dust reservoir,
emptied automatically during operation
Electrolyte level Fluid level in battery cells
Environmental waste Used oils, filters, etc., must be handled according to governing
national laws 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

Table 1–1 Terminology (continue)
Term Description
Indicator Manual “sensor”, for example, shows that a filter is clogged and
needs to be changed
Load capacity Indicates machine’s max. load capacity
Hoisting point Attaching point for lift device when lifting an object
Low-emission engine Engine with low emissions of hazardous substances.
Manufactured according to regulations
Machine model Machine type indicated
Main fuse Located by the battery. Relays current to all systems in machine
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
Secur ing machine for 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

Table 1–1 Terminology (continue)
Term Description
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
1.7 Machine Information

1.7.1 Machine Information
Please inform SANY authorized distributors of the following information when ordering replace-
ment parts or requiring assistance for your equipment.
1.7.2 Machine nameplate
SANY Marine Heavy Industry Co., Ltd
Fig.1-4 Machine Nameplate

1.7.3 Engine nameplate
1.7.3.1 VOLVO engine nameplate
Fig.1-5 VOLVO Engine Nameplate
1.7.4 Spreader nameplate
1.7.4.1 SANY spreader nameplate
SANY Marine Heavy Industry Co., Ltd
Fig.1-6 SANY Spreader Nameplate

1.7.4.2 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.1-7 ELME Spreader Nameplate
1.7.4.3 BROMMA spreader nameplate
Spreader ty pe RSX40
Serial No: 12810-12815
General Ass y No: 1031900
Con tain er Rang e 20´and 40´
Fig.1-8 BROMMA Spreader Nameplate

1.7.5 Transmission case nameplate
1.7.5.1 DANA transmission case nameplate
SPICER OFF-HIGHWAY
BRUGES
BELGIUM
MODEL XX.XXXXXXXX-XXX
SERIAL XXXXXXXXXX XX/XX
Fig.1-9 DANA Transmission Case Nameplate
1.8 Running in a New Machine

NOTE：
Your machine has been thoroughly adjusted and tested before shipment. However, initial operation
of the machine under severe conditions can adversely affect its performance or shorten 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.
1.9 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
1.10 Correction Request Form

If you find 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 1-14.
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.)
1.11 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

Website: www.sanyhi.com
Service hotline: 0086 4006098318


Reach stacker Safety
Safety
2 Safety.....................................................................................................................................2-1
2.1 Safety Information.................................................................................................................2-5
2.1.1 Safety Information.......................................................................................................2-5
2.1.2 Signal words ................................................................................................................2-5
2.1.3 Examples of using signal words................................................................................2-6
2.1.4 Other signal words ......................................................................................................2-6
2.1.5 Safety labels ................................................................................................................2-6
2.1.5.1 Safety labels .........................................................................................................2-6
2.1.5.2 Safety labels - location ........................................................................................2-8
2.1.5.3 Safety labels - content.........................................................................................2-9
2.2 General Precautions.......................................................................................................... 2-19
2.2.1 General Precautions................................................................................................ 2-19
2.2.2 Basic safety instructions.......................................................................................... 2-20
2.2.3 Personal protective equipment .............................................................................. 2-20
2.2.4 Never operate while in bad health ......................................................................... 2-23
2.2.5 No passenger in the cab ......................................................................................... 2-23
2.2.6 Hand signals ............................................................................................................. 2-24
2.2.7 Preparing safety items............................................................................................. 2-26
2.2.8 Checking safety equipment .................................................................................... 2-27
2.2.9 Precautions in high voltage areas.......................................................................... 2-27
2.2.10 Precautions in thunderstorm ................................................................................ 2-30
2.2.11 Precautions in wind................................................................................................ 2-30
2.2.12 Abnormal cases ..................................................................................................... 2-31
2.2.13 Unauthorized modification.................................................................................... 2-31
2.3 Safety During Operation.................................................................................................... 2-32
2.3.1 Work area safety ...................................................................................................... 2-32
2.3.1.1 Work area safety ............................................................................................... 2-32
2.3.1.2 Work area requirements .................................................................................. 2-32
2.3.1.3 Work area indications....................................................................................... 2-33
Safety Reach stacker
2.3.2 Checks before operation......................................................................................... 2-33

2.3.3 Keeping machine clean........................................................................................... 2-36
2.3.4 Climbing on or off the machine safely ................................................................... 2-36
2.3.5 Start-up safety .......................................................................................................... 2-38
2.3.5.1 Inside the operator cab .................................................................................... 2-38
2.3.5.2 Adjusting the seat ............................................................................................. 2-38
2.3.5.3 Checking the seat belt...................................................................................... 2-39
2.3.5.4 Machine starting precautions .......................................................................... 2-39
2.3.5.5 In cold weather .................................................................................................. 2-40
2.3.5.6 After starting the engine................................................................................... 2-40
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 .................................................................................. 2-41
2.3.6.3 Precautions for working on slope ................................................................... 2-42
2.3.6.4 Avoiding injury from reversing......................................................................... 2-43
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 ............................................................................. 2-46
2.3.6.10 Precautions for operating emergency stop button..................................... 2-46
2.3.6.11 Precautions for operating safety bypass switch ......................................... 2-47
2.3.7 Parking the machine securely ................................................................................ 2-48
2.3.7.1 Parking requirements ....................................................................................... 2-48
2.3.7.2 Turning off the engine ...................................................................................... 2-49
2.4 Safety During Maintenance .............................................................................................. 2-51
2.4.1 Safety During Maintenance ................................................................................... 2-51
2.4.2 Preparation for the work area................................................................................. 2-51
2.4.3 Maintenance status of the machine....................................................................... 2-51
2.4.4 Warning label is important ...................................................................................... 2-52
2.4.5 Lockout/tagout procedures ..................................................................................... 2-52
2.4.6 Preparation of maintenance ................................................................................... 2-53
2.4.7 Using tools correctly ................................................................................................ 2-53
2.4.8 Regular replacement of safety-related parts........................................................ 2-53
2.4.9 Preventing hydraulic hazards................................................................................. 2-53
2.4.9.1 Checking rubber hose regularly...................................................................... 2-53
2.4.9.2 Releasing the pressure before maintenance................................................ 2-54
2.4.9.3 Replacing rubber hose regularly..................................................................... 2-55
2.4.9.4 Prevent heat near the hydraulic pipeline ....................................................... 2-56
2.4.9.5 Selecting oils and fuel ...................................................................................... 2-56
2.4.9.6 Handling hydraulic oil ....................................................................................... 2-57
2.4.9.7 Filling accumulator............................................................................................ 2-57

2.4.10 Preventing burn and scald.................................................................................... 2-58
2.4.10.1 Burn by high temperature liquid.................................................................... 2-58
2.4.10.2 Chemical burn ................................................................................................. 2-58
2.4.11 Preventing fire and explosion ............................................................................... 2-60
2.4.11.1 Handling inflammables safely ....................................................................... 2-60
2.4.11.2 Removing inflammables ................................................................................ 2-60
2.4.11.3 Checking oil leakage ...................................................................................... 2-61
2.4.11.4 Checking short circuit ..................................................................................... 2-61
2.4.11.5 Checking ignition key ..................................................................................... 2-62
2.4.11.6 Preventing battery explosion......................................................................... 2-62
2.4.11.7 Evacuating from the machine ....................................................................... 2-64
2.4.12 Preventing poisoning and asphyxiation.............................................................. 2-65
2.4.12.1 Handling chemicals safely............................................................................. 2-65
2.4.12.2 Preventing poisoning by paint....................................................................... 2-66
2.4.12.3 Preventing poisoning by off-gas ................................................................... 2-66
2.4.13 Preventing dust hazard ......................................................................................... 2-67
2.4.14 Working under machine ........................................................................................ 2-67
2.4.15 Precautions in welding .......................................................................................... 2-68
2.4.16 Precautions in maintaining the engine................................................................ 2-69
2.4.17 High voltage precautions ...................................................................................... 2-70
2.4.18 Safe maintenance of air conditioning system .................................................... 2-70
2.4.19 Precautions after maintenance ............................................................................ 2-70
2.4.20 Handling waste properly ....................................................................................... 2-71
2.5 Tag........................................................................................................................................ 2-72

WARNING

2.Safety
2.1 Safety Information

2.1.1 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 re-
duce the risk of injury or death, the damage of machine caused by incorrect service, and the risk of
unsafe factors, to the minimum.
2.1.2 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
Risk of injury or death！
It indicates an imminent hazard.
• If not avoided, it will result in serious injury or death.
WARNING
It indicates a potentially hazardous situation.
• if not avoided, could result in injury or possibly death.
CAUTION
Risk of injury or damage！
It indicates a possible potential hazardous situation.
• If not avoided, it could result in minor or major injury.
NOTICE
Risk of damage or pollution！
It indicates a situation which can cause damage or pollution.
• If not avoided, it 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.
2.1.3 Examples of using signal words
CAUTION
Risk of injury!
Failure to follow this alert will result in incorrect operation,
• The driver should turn off the joystick on / off switch on right operation panel before leaving the
cab, and avoid incorrect operation. It will put personal in danger.
2.1.4 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.
2.1.5 Safety labels
2.1.5.1 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 con-
tents 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 re-
placement labels in due time.
1. Safety label example 1
WARNING
Keep clear of moving machinery

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

2.1.5.2 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
1. Spreader 2. Overhead danger 3. Caution for 4. Head injury

electricity
5. No passengers 6. No climbing 7. Tyre precautions 8. Stay clear of moving
machine
9. No ether 10. Battery 11. Warning label, 12. Electrical hazard
disconnect chemical hazard
13. Fire is prohibited 14. Crushing hazard 15. Stay clear 16. Caution for
17. Stay clear disassembling
counterweights

2.1.5.3 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.
Fig.2-4 Attachment Warning
2. Warning label, overhead danger
Never stand beneath swinging load. There is

danger of being hit by it.
For its location on machine, see position 2
Fig.2-5 Caution for Electricity
3. Warning label, caution for electricity
Keep the machine away from power lines.
For its location on machine, see position 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.
For its location on machine, see position 4
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 il-

lustration 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 dis-

tance of at least 8m.

Fig. 2-3.
Fig.2-20 Stay Clear
18.Label, burn hazard
Do not touch the places glued with the label in

the right illustration.
Fig.2-21 Burn Hazard

19.Label, break oil
The information of the machine is listed on the

label include type, engine model and so on.
Fig.2-22 Break oil
20.Label, diesel fuel
Fig.2-23 Diesel fuel
21.Warning label, fan danger
Do not approach rotating parts as which may

cause injury.
Fig.2-24

22.Label, emergency exit
Fig.2-25
23.Label, oil water separator
Fig.2-26

24.Warning label, danger to fall
There is danger to fall. Stay away from the

edge of machine.
Fig.2-27
25.Warning label, jumping
Never jump down from the vehicle. Use the

steps, ladders and gangways provided for get-
ting on and off.
Fig.2-28
26.Warning label, Antislip
Be carefull about the ground under your feet,

sometimes it is very slipping especially in a
raining day. Injuries may occur.
Fig.2-29

27.Warning label, safety belt
Always wear safety belt before staring the

machine.
Fig.2-30
28.Warning label, shut off engine
Always shut off the engine and remove the

key before servicing this machine.
Fig.2-31

29.Label, extinguisher
Fig.2-32
30.Label, safety hammer
Fig.2-33
2.2 General Precautions

2.2.1 General Precautions
WARNING
Risk of injury and damage！
Negligence by maintenance or on-site personnel will lead to injuries, serious damages of machine
and property loss.
• Warning instruction must be read when operating or maintaining the machine.

2.2.2 Basic safety instructions
• Only appointed and trained personnel are allowed to operate and maintain this machine.
• Always keep the machine in good 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
Risk of equipment damage, serious injury or possibly death!
Failure to follow this alert will result in equipment damage, serious injury or possibly death.
• Read and follow all safety precautions before operating or maintaining machine.
2.2.3 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 oper-

ating, maintaining, or repairing the machine.
Take protective tools necessary for tasks.
CAUTION
Risk of injury!
Failure to follow this alert will result in person-
al safety problems.
• work without putting on safety helmet. Fig.2-34 Protective Equipment
• 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.

Be sure to wear safet y helmets while operat-
ing, maintaining, repairing the machine.
Fig.2-35 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.2-36 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.
Fig.2-37 Safety Goggle

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

ger 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.2-38 Ear-muffle
• Dustproof Mouth-muffle
Put on a dustproof mouth-muffle when weld-

ing or working in the area surrounded with
harmful gases or dusts.
Fig.2-39 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; Fig.2-40
• when using impact tools for a long time.

• Protective Clothes
Be sure to wear protective clothes while oper-

ating, 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 with-

out oil dirt, or it may catch fire. Fig.2-41 Protective Clothes
2.2.4 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.
2.2.5 No passenger in the cab
No other passenger except the operator is al-

lowed to stay in the cab. Passengers may
block the operator’s sight, which may result in
an unsafe situation.
Fig.2-42 No Passenger

2.2.6 Hand signals
DANGER
Risk of 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.2-43
LOWER LOAD
With arm extended downward and index fin-

ger pointing down, move hand in a small hori-
zontal circle.
LOWER
LOAD
Fig.2-44

RAISE LOAD SLOWLY
Use one hand pointing upward to give a mo-

tion signal and place the other hand motion-
less above the hand giving the motion signal.
RAISE
LOAD
SLOWLY
Fig.2-45
LOWER LOAD SLOWLY
Use one hand pointing downward to give a

motion signal and place the other hand mo-
tionless below the hand giving the motion
signal.
LOWER
LOAD
SLOWLY
Fig.2-46
NORMAL STOP
Use one hand starting at the waist and move

it outward.
STOP
Fig.2-47

EMERGENCY STOP
Use both hands starting at the waist and move

them outward.
EMERGENCY
STOP
Fig.2-48
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.
2.2.7 Preparing safety items
CAUTION
Risk of injury!
Failure to follow this alert will result in injury.
Firefighters should put on a fire-fighting mask
to prevent injury when extinguishing the fire
with CO2, foam, dry-powder fire extinguisher.
Fig.2-49 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.
• Do regular inspection and maintenance to ensure proper functioning of f ire extinguisher at any
time.
• Check the first aid kit regularly and replenish it when necessary.
• Prepare and implement emergency plan to deal with fire and accidents.
2.2.8 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.2-50 Check Safety Signs
• Hon
• 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.
2.2.9 Precautions in high voltage areas
Operating machine near high frequency tow-

ers (for instance, cell phone towers) or work-
ing 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 addi-
tional equipment used should exceed this lim-
it. If in doubt, contact your local Electrical
Power Utility Company FIRST! Fig.2-51 Electricity Strike

DANGER
Risk of electric shock!
When working with electrical power circuit, there is risk of electrical shock. Failure to observe and
follow this warning could result in death or serious injury.
• 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 l ine 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-thannormal 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, operate the equipment in the area ONLY if a safe minimum
clearance is maintained.For detailed information, See：Table 2–1
• If the power lines are not shut down, operate the equipment in the area ONLY if a safe minimum
clearance (see Table 2-1) is maintained.
• If maintaining safe clearance by visual means is difficult, designate a person to observe 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.

Table 2–1 Safety Distance
Cable Voltage Safety Distance

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 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 contacted 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.

2.2.10 Precautions in thunderstorm
NOTICE
Risk of damage！
Improper working conditions may cause machine damage.
• When the machine wades in water, it is strictly prohibited to exceed the electric fault position
(about 700mm)
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 of Fig.2-52 Thunderstorm
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
2.2.11 Precautions in wind
This machine has passed the operating limit test in wind. According to the ISO 10525 standards,
the machine must not operation when there is strong breeze or stronger wind.
Table 2–2 Standard table of wind speed, wind scales and observations
Wind
Wind speed (m/s) Name Phenomena
scale
0～0.5 Calm 0 No wind, and smoke rises vertically.
0.6～0.7 Light air 1 Direction shown by smoke drift.

Table 2–2 Standard table of wind speed, wind scales and observations (continue)
Wind
Wind speed (m/s) Name Phenomena
scale
1.8～3.3 Light breeze 2 Wind felt on face, and leaves rustle.
Gentle Leaves and small twigs in constant motion;
3.4～5.2 3
breeze light flags extended.
Moderate
5.3～7.4 4 Raises dust and loose paper.
breeze
Small trees in leaf begin to sway; crested
7.5～9.8 Fresh breeze 5
wavelets form on inland waters.
Large branches in motion; whistling heard in
Strong
9.9～12.4 6 telegraph wires; umbrellas used with
breeze
difficulty.
Whole trees in motion; inconvenience felt
12.5～15.2 High wind 7
when walking against the wind.
Twigs break off trees; generally impedes
15.3～18.2 *Gale 8
progress.
18.3～21.5 *Strong gale 9 Slight structural damage (slates removed).
Trees uprooted; considerable structural
21.6～25.1 *Storm 10
damage.
*Violent
25.2～29 11 Widespread damage.
storm
29.1 and above Typhoon 12 Devastation.
NOTE：
Hurricane not caused by tropical depressions are usually not called "typhoons", which are indi-
cated by *.
2.2.12 Abnormal cases
In case of any faults found during operation and maintenance, such as noise, vibration, odor, incor-
rect instrument 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 corrected.
2.2.13 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.
• Operation of different or combined attachments may result in unsafe working condition or
component failure. Before operating the attachments that you are not familiar with, check the
possibility of collision and operate carefully.
2.3 Safety During Operation

2.3.1 Work area safety
2.3.1.1 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.
2.3.1.2 Work area requirements
• The machine should be driven on

substantially firm, smooth, level and
prepared ground.
• There is a possibility of tipping when the
machine works on wharf 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.2-53 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.
Fig.2-54 Indicate the Work Area
2.3.1.3 Work area indications
Do not start working before the area has been indicated by a “blue flag” or some other recogniz-
able indications.
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.2-55 Check Tyre Pressure

• Check whether the attaching bolts of tyre,

driving axle, transmission shaft, mast and
frame are secure.
Fig.2-56 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.2-57 Check Lubrication Points
blocks are adequately lubricated.
• Check if the hydraulic pipes are in good

condition, also if the electric wirings are
secured
Fig.2-58 Check if the hydraulic pipes are in

good condition, also if the electric wirings are
secured

• Check whether the engine oil level, fuel

level, hydraulic oil level, brake oil level and
coolant level are correct.
Fig.2-59 Check Oil Level
• Check the spreader twist lock for anomalies

such as looseness, deformation and
cracks.
Fig.2-60 Check the Spreader Twist Lock
• Check whether the filters of the engine (air

filter, oil filter and diesel filter) and fuel
pipelines are in good conditions.
Fig.2-61 Check the Filters

• Check whether all limit switches work

normally;
• Check whether there is any alarm.
Fig.2-62 Check the Alarm
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.
• 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 Fig.2-63 Avoid Cleaning the Electrical System
cab. with High-pressure Water
• 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
clean and clear 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. Fig.2-64 Climb on the Machine
• Never leave tools or similar objects on the
machine walkway or service areas. These
could drop and get stuck in the machine
operating systems.
• 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.2-65 Slipping Hazard

WARNING
Risk of serious injury！
Failure to follow this alert will result in serious injury.
• 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.
2.3.5 Start-up safety
2.3.5.1 Inside the operator cab
Once inside the operator cab, observe the following:
• Do not allow other personnel inside the operator cab regardless of the situation, and do not
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.
• Check all instruments 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 fa-

tigue and operating mistake. Therefore, oper-
ators 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.2-66 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 ob-
serve 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 sit in
the seat and fasten the seat belt to
minimize the probability of injury resulted Fig.2-67 Check the Seat Belt
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
Risk of serious injury or death！
Machine out of control can cause serious injury or death.
• 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.
WARNING
Risk of serious injury or death！
Failure to follow this alert will result in serious injury or death.
• 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.
Before starting operations, observe 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
starting 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 In cold weather
Cold weather operation requires additional caution:
• Check operating procedures in this manual or the engine manual for cold weather starting. .
• 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.
2.3.5.6 After starting the engine
Run the engine at idle for 3-5 minutes after its starting. Observe the instruments 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.
• Prior to operation, be sure that all personnel
understand the signals and gestures.
• Turn on working lights and headlights of the
machine when working in a dark area. Set
up auxiliary illumination in the work area if Fig.2-68 Ensure Good Visibility
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 bridge 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.
CAUTION
Risk of damage!
Failure to follow this alert will result in damage.
• Slow down the machine before changing gears, or damage may occur to the transmission.
DANGER
Risk of injury or death!
When operating the machine on uneven ground, failure to follow this alert will result in injury or
death.
• 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.

2.3.6.3 Precautions for working on

slope
When working on the slope, the following

rules must be observed:
1. The machine must drive up and down

slowly;
Fig.2-69 Working on Slopes
2. When driving on a slope, you must go up or

down straightly, while turning or crossing the
slope diagonally is not allowed, as it is very
dangerous to turn on a slope or cross a slope;
3. On slopes greater than 10°, the load must

face the slope directly.
Fig.2-70
4. It is not allowed to turn on the slope or cross

the slope. Be sure to go down to a flat ground
to change the position of the machine, and
then go up the slope;
5. Drive slowly on grass, fallen leaves or wet

steel plates, because the machine may have
the risk of slipping even on a small slope;
6. When going downhill, the driver must drive

slowly and avoid emergency braking. If neces-
Fig.2-71
sary, the driver should drive reversely to avoid
a forward tilting accident.
7. When the vehicle is running on a slope, slid-

ing in the neutral gear is not allowed. When

the machine goes downhill, the engine speed

should not be below 1200 rpm, so as to avoid
oil shortage in the gearbox.
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.
• Keep the windows, rearview mirrors and Fig.2-72 Avoid Injury from Reversing
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.2-73 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. Snowcovered or
frozen surfaces are slippery. The ability to maneuver the machine is seriously affected. The ma-
chine 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 or-

der to avoid control failure, you should:
• Do not lift a container with 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.2-74 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.2-75 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.2-76 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. Person-
nel may be seriously injured.
SANY number
Fig.2-77
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.2-78

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 per-
son stand under the load.
Fig.2-79
2.3.6.10 Precautions for operating

emergency stop button
WARNING
Risk of damage!
The emergency stop switch can also work as
an emergency brake, but frequent use may
cuase it to fail.
• The emergency stop switch just be used in
emergency.
• When the reach stacker is traveling, never
the emergency stop switch when the
service brake is effective or not in
emergency.
The emergency stop switch is installed on the

right control panel. When this switch is
pressed, the engine will stop running and the
vehicle will be parked, the electrical system of
the whole vehicle is power-off, and all actions
stop. Fig.2-80 Emergency Stop
After the fault is removed, turn the switch
clockwise as indicated by the arrow on the
switch, the emergency stop switch will auto-
matically rebound, and the emergency stop
will end.

Repair the emergency stop device in case of

anomaly. Operate only after confirming that
the emergency stop device can work
normally.
2.3.6.11 Precautions for operating

safety bypass switch
WARNING
Risk of injury!
The safety bypass function should be used with caution. Failure to follow this alert will result in
injury.
• The safety bypass key must be managed by a dedicated technical manager, and can only be
used with the approval by the person in charge of the relevant department and confirmation by
the technical staff on site under special circumstances.
• Pay special attention to the on-site situation when using the key, and use it only when safety is
ensured.
• Sany Marine shall not be liable for any safety accidents due to operating the machine after
activating the safety bypass without authorization.
Once the safety bypass switch is turned on, a

safety bypass alarm will be issued, and the
protections for boom actions such as "Position
Protection", "Safe Lifting Lock", "Safety Factor
Lock" and "Forward Tilting Lock" will be dis-
abled, allowing the boom to rise, lower, and
retract, and the unlocking and locking actions
can be enforced only when no load is in place.
Fig.2-81 Safety Bypass

WARNING
Risk of damage!
The reach stacker will be protected due to some accidental operation, and the machine will not
work normally. Failure to follow this alert will result in machine damage.
• The protection can be released by the safety bypass switch only after the operator makes sure
that the danger is cleared.
• Never enforce actions.
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.2-82 Safe Area to Park the Machine
The ground on which the machine is parked

or traveling must have sufficient carrying ca-
pacity. It should be hard and horizontal with
even supporting distribution.
Fig.2-83 Park Ground

It is not allowed to park the machine on un-

even and loose ground
Fig.2-84 Avoid Parking on Uneven Ground
If the machine is parked on a slope, wedge

the front and rear wheels with blocks to pre-
vent sliding.
Fig.2-85 Caution for Parking on Slope
2.3.7.2 Turning off the engine
A B
E
Fig.2-86 Ignition Switch

1. Park the machine on solid and even hori- A. OFF position B. ON position
zontal ground.
E. Remove position
2. Retract the spreader and lower it to its low-
est 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 ).

Move the joystick forward, backward, leftward
and rightward respectively two or three times
to depressurize the hydraulic system.
5. Turn the key to OFF position (A ) to stop the

engine.
6. Turn the key to E position as shown in Fig.

2-73. 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 2-36
9. Put blocks under the wheel to avoid the ma-

chine from moving.
Fig.2-87 Secure the Wheel

2.4 Safety During Maintenance

2.4.1 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.
• Maintenance personnel shall be physically
suited for this work, especially their health
and eyesight. Fig.2-88 Read the Manual
• Do not spray water or steam in the cab.
• Never add lubricants or perform
maintenance when your machine is
moving.
• Keep your hands, feet and clothing away
from rotating parts.
2.4.2 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.2-89 Prepare for the Work Area
2.4.3 Maintenance status of the

machine
The machine should be set into the maintenance state before maintenance:

The maintenance state refers to the state used for maintenance, and other states needing the ma-
chine to be fixed.
The maintenance state refers to:
• The reach stacker has been parked, that is, the parking brake is applied.
• The boom is completely bent down and lowered to a horizontal position.
• The engine has stopped.
• The main power supply is disconnected.
2.4.4 Warning label is important
If anyone have started the engine or operated

the joystick during the maintenance, serious
accident s would happen. Before any mainte-
nance work on the machine, be sure to:
• Set the WARNING LABEL of “Shut down!

Under maintenance!” on the steering wheel
or ignition switch. SHUT DOWN
UNDER MAINTENANCE
• If necessary, place a warning label around
the machine.
Fig.2-90 Warning Label
2.4.5 Lockout/tagout procedures
The following steps must be followed in se-

quence when the machine is to be locked-out
and tagged-out for service or repair.
• Inform all staff performing the maintenance

• Safely park machine.
• Safely shut down the machine.
• A locking device must be installed on the
power supply or power source. Make sure
all power is locked.
Fig.2-91 Lock

2.4.6 Preparation of maintenance
See “General Precautions” on page 2-19.
2.4.7 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 is
complete
• Always put shop tools back in their proper
storage location when finished.
Fig.2-92 Tools
2.4.8 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.
2.4.9 Preventing hydraulic hazards
2.4.9.1 Checking rubber hose regularly
CAUTION
Risk of serious injury!
Failure to follow this alert will result in serious injury.
• Contact with coolant of high temperature and high pressure could result in serious injury.

Check the conditions of rubber hose regularly:
• Check whether the hydraulic hose

connection is in good condition.
• 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.
Fig.2-93 Check the Rubber Hose
WARNING
Risk of injury or possibly death!
Failure to follow this alert will result in injury or possibly death.
• In case of any damage on the rubber hose, replace it.
2.4.9.2 Releasing the pressure before

maintenance
1. The machine is in maintenance, see

“Maintenance status of the machine” on page A B
2-51.
P
2. Relieve the pressure of the hydraulic sys-
tem. Turn the ignition key to the position I [B]
to activate the boom pitch function. If there is
pressure inside the hydraulic system, a clear
hiss can be heard. Start the lifting, telescoping
and side moving functions several times.
3. Turn the ignition key to the position O [A]

and turn off the main power supply. Fig.2-94 Ignition Switch

4. Open the drain valve on the accumulator

charging valve to relieve the pressure of the
brake system.
CAUTION
Risk of damage!
Failure to follow this alert will result in
damage.
• Keep the drain valve open during the
operation.
Fig.2-95 Drain Valve
2.4.9.3 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 de-
vice on personnel, etc. These could lead to
serious burn, necrosis or other injuries or Fig.2-96 Replace the Rubber Hose
death.
Fig.2-97 Avoid Hydraulic Injury 1

Fig.2-98 Avoid Hydraulic Injury 2
2.4.9.4 Prevent heat near the hydraulic

pipeline
Heating near the hydraulic pipeline can gener-

ate flammable spray, which can result in seri-
ous 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 the
pipe or hose conveying flammable liquid.
• Before welding or air-cutting the pipeline,
Fig.2-99 Do not Create Heat near the Hydraulic
clear off the flammable liquid thoroughly
Pipe
with nonflammable solvent. Set a
temporary fireproof shield to protect the
hose or other materials.
2.4.9.5 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 difficult 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.
2.4.9.6 Handling hydraulic oil
Hydraulic oil contains harmful and toxic substances. When handling the waste oil, observe the fol-
lowing 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
Risk of personal injury!
Failure to follow this alert will result in personal injury.
• 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.
2.4.9.7 Filling accumulator
The accumulator is filled with nitrogen. Incor-

rect operation will lead to explosion causing
machine damage and personal injury. Pay at-
tention to the following when dealing with
accumulators:
• Do not dismantle the accumulator.

• Keep the accumulator away from fire.
• Do not drill holes In or weld the
accumulator.
• Do not crash or roll the accumulator. Avoid
any shock of accumulator.
Fig.2-100 Caution for Filling Accumulator

• Drain the air before dealing with the

accumulator. Please contact SANY to
conduct this operation.
2.4.10 Preventing burn and scald
2.4.10.1 Burn by high temperature

liquid
Hot water and steam exist in the hot water ho-

ses of the engine, radiator and air 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.
Remove the cap after the pressure has fully Fig.2-101 Caution for Burn
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 Do
not try to tear off the substances like
• 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.
2.4.10.2 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 corro-
sive acids.

WARNING
Risk of burns!
Failure to follow this alert will result in burns.
• 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 could result in injury or possibly death.
When the parts made of elastic materials are used at a temperature that exceeds 300˚C, the fol-
lowing 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, lu-

brication oil and diesel, the following meas-
ures should be taken:
• 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
• Consult a doctor immediately.
Fig.2-102 Go to Hospital

2.4.11 Preventing fire and explosion
2.4.11.1 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
lubricants and some coolants) in a place
Fig.2-103 Avoid Fire
away from fire hazard.
• Do not burn or puncture the pressured
container.
• Do not store oily cloth. They can be ignited
or combusting spontaneously.
2.4.11.2 Removing inflammables
Splashed fuel, oil, waste, grease, scrap, accu-

mulated 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.2-104 Remove Inflammable

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

result in fire. Personnel should observe the
following regulations to prevent fire:
Fig.2-105 Check Oil Leakage
• 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 cooler is not damaged .
• Check whether the flange bolt of oil cooler is not secure.
• Check whether the hoses and high temperature parts (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 replace 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.
2.4.11.4 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
8-10 h operation.
• Check whether the terminal end cover is in place and not damaged before shift or after 8-10 h
operation.
• Do not operate the machine if the cable or wire is secure and not twisted.

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

is on fire, the fire would spread and it will be- A
come difficult to put out. Therefore, you
should: P
• 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 (A) to
confirm whether the engine shuts down.
Fig.2-106 Ignition key
• In case of any abnormality, make sure to fix
it before operating the machine. A. OFF position
2.4.11.6 Preventing battery explosion
Battery electrolyte contains corrosive sulfuric

acid which may create flammable and explo-
sive hydrogen. Incorrect operation could re-
sult in personal injury or fire hazard. Be sure
to follow below regulations:
• Keep the battery away from children.

• Do not smoke near the battery.
• Avoid open fires and kindling materials
while charging or using the battery.
Fig.2-107 Battery Explosion
• 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 off position
before operating the battery.
• Wear protective goggles and rubber gloves
during battery operation.
• Never discharge or charge the battery too
Fig.2-108 Cables
much.
• Connect the battery with proper cables.
Connect plus-cable (red) first and then

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 charging a battery removed from
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.

2.4.11.7 Evacuating from the machine
1. Emergency escape procedure in case of

fire
If the engine is not stopped when a fire disas-

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

you may evacuate from the fire as long as you
are able to evade the danger anytime.
Fig.2-109 Evacuate
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 P
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.2-110 OFF Position
In case that distorted windows and doors in

cab cannot be opened due to the high temper-
ature, or the cab is stuck into cylinders, open
the back window and evacuate from the ma-
chine as below methods:
CAUTION
Risk of injury!
• Always wear protective goggles before
breaking the windows.

NOTE：
There is an emergency exit label placed to the
back window.
Fig.2-111 Emergency Exit Label
2.4.12 Preventing poisoning and asphyxiation
2.4.12.1 Handling chemicals safely
Direct contact with harmful chemicals can re-

sult in serious injury to human body. The
chemicals used in this machine (such as lubri-
cant, coolant, coat and agglutinate) may be
harmful. Personnel should observe the follow-
ing rules while handling chemicals:
Fig.2-112 Respirator
• Properly handle the paint and solvent before welding or heating.

• Remove the paint outdoors or in ventilated 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 If solvent or paint remover is used, wash
• 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.

2.4.12.2 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 gen-
erating potentially toxic gases and dust.
Fig.2-113 Respirator
• Properly handle the paint and solvent before welding or heating.

• Remove the paint outdoors or in ventilated 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, washaway 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.
2.4.12.3 Preventing poisoning by off-

gas
Gases exhausted from the machine contain

carbon monoxide which is an odorless, color-
less and toxic gas. In order to prevent poison-
ing, personnel should observe the following
rules:
• Stay well ventilated if the machine is started

or operated in an enclosed environment.
• If a person is poisoned by off-gas in the
enclosed environment, open the doors and
windows first to reduce the level of harmful
Fig.2-114 Avoid Poisoning by Off-gas
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
2.4.13 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 observe 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 fake or aftermarket parts
may contain asbestos.
Always use genuine SANY replacement parts.
2.4.14 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 perform 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,
empty tyres or stands to support the Fig.2-115 Work under Machine
machine. These things may collapse under
continuous load. Never use only one jack to
support the machine.

2.4.15 Precautions in welding
Fire or electricity hazard may occur if the

welding is performed incorrectly. Observe the
following:
• Only qualified welder with proper

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 Fig.2-116 Main Power Switch
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:
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.

2.4.16 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 en-
gine, there should be at least two personnel
handling the maintenance according to the fol-
lowing rules:
• One person should always be seated in

operator’s seat and ready to shut down the
engine at any time. All personnel must keep
communicate.
• Always lock the machine and fix its wheels
Fig.2-117 Caution for Fan
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.2-118 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.2-119 Parts Flying to Hurt Personnel

2.4.17 High voltage precautions
The high voltage wire harnesses of the ma-

chine are covered by yellow bellows and fixed
by clips, improper operation will still cause
shock danger. Personnel should observe the
following to prevent the danger of electricity
strike:
• Do not touch the high voltage wire

harnesses without protection.
• Wear insulated protective equipment while
doing repair.
• Contact SANY or authorized distributors if
Fig.2-120 Caution for High Voltage
you have to access the high voltage wire
harnesses.
2.4.18 Safe maintenance of air condi-

tioning 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.
• Refrigerant R134a will create the greenhouse effect. 1kg emission of R134a (after twenty years)
equals to 3400g emission of CO². Obey local material disposal regulations of refrigerants. Never
discharge refrigerant directly into the air.
DANGER
Risk of personal injury or even death!
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.
• Keep fire source away when servicing air conditioning system.
• Avoid refrigerants from getting into eyes or splashing onto skin.
2.4.19 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.
2.4.20 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:
Fig.2-121 Disposal of Waste
• Always abide by the national or local regulations, rules and environmental standards. Do not
pour the waste liquid on 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 2-70.
NOTICE
Risk of environment pollution!
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 duster cloth etc.)

Pay attention to the following to prevent envi-

ronmental 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
Fig.2-122 Do not Drop Waste Randomly
according to the local laws and regulations.
2.5 Tag
SANY cannot predict every circumstance that might involve a potential hazard in operation or
maintenance. The safet y chapter in this manual may not include every possibly dangerous cir-
cumstance. 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 our career and responsibility. Wish you work pleasantly!

Reach stacker System functions
System functions
3 System functions ............................................................................................................3-1

3.1 Main components of machine .............................................................................................3-5
3.2 Cab..........................................................................................................................................3-6
3.2.1 Cab................................................................................................................................3-6
3.2.2 Steering column ..........................................................................................................3-8
3.2.2.1 Steering column ...................................................................................................3-8
3.2.2.2 Steering panel ......................................................................................................3-9
3.2.2.3 Gear selector ..................................................................................................... 3-14
3.2.2.4 Direction indication controller.......................................................................... 3-16
3.2.2.5 Adjusting the angle of steering controller ...................................................... 3-19
3.2.3 Pedal .......................................................................................................................... 3-19
3.2.4 Joystick（Option1） ................................................................................................ 3-20
3.2.5 Joystick（Option2） ................................................................................................ 3-21
3.2.6 Right operation panel .............................................................................................. 3-22
3.2.6.1 Right operation panel ....................................................................................... 3-22
3.2.6.2 Ignition Switch ................................................................................................... 3-23
3.2.6.3 Emergency retraction/lowering switch........................................................... 3-24
3.2.6.4 Safety bypass switch........................................................................................ 3-25
3.2.6.5 Emergency stop switch .................................................................................... 3-27
3.2.6.6 Cab move enable.............................................................................................. 3-28
3.2.6.7 Top wiper switch................................................................................................ 3-29
3.2.6.8 Rear wiper switch.............................................................................................. 3-30
3.3 Display ................................................................................................................................. 3-31
3.3.1 SANY Display ........................................................................................................... 3-31
3.3.1.1 SANY Display.................................................................................................... 3-31
3.3.1.2 Menu introduction ............................................................................................. 3-32
3.3.1.3 Main menu ......................................................................................................... 3-33
3.3.1.4 Language setting menu ................................................................................... 3-35
3.3.1.5 Engine information menu................................................................................. 3-36
System functions Reach stacker
3.3.1.6 Gear information menu .................................................................................... 3-37

3.3.1.7 Hydraulic information menu ............................................................................ 3-38
3.3.1.8 Digital analogy menu........................................................................................ 3-39
3.3.1.9 Help System ...................................................................................................... 3-41
3.3.1.10 Function set menu .......................................................................................... 3-42
3.4 Air Conditioning System.................................................................................................... 3-42
3.4.1 Control panel............................................................................................................. 3-42
3.4.1.1 Control panel ..................................................................................................... 3-42
3.4.1.2 Power switch ..................................................................................................... 3-44
3.4.1.3 Fan speed switch .............................................................................................. 3-44
3.4.1.4 Temperature or Paging switch ........................................................................ 3-45
3.4.1.5 Mode switch....................................................................................................... 3-46
3.4.1.6 Fresh air switch ................................................................................................. 3-47
3.4.2 Operation................................................................................................................... 3-47
3.4.3 Precautions ............................................................................................................... 3-49
3.5 Fuse and controller of the electric control cabinet......................................................... 3-50
3.6 Fuse ..................................................................................................................................... 3-51
3.7 Fire extinguisher................................................................................................................. 3-53


WARNING

3.System functions
3.1 Main components of machine
The container reach stacker is composed of the power travel system [1], the steering system [2],
the frame system [3], the boom system [4], the spreader system [5], the cab and console assembly
[6], the hydraulic system [7], the electrical system [8] and the lubrication system [9].
NOTE：
Support for custom.
Numerous spreaders are provided for your options, including container spreader, steel coil spread-
er, steel pipe spreader, etc.
6
5
2
9 8
1
Fig.3-1 Main Components of Reach Stacker
1. Power travel 2. Steering system 3. Frame system 4. Boom system

system
5. Spreader system 6. Cab and console 7. Hydraulic system 8. Electrical system
assembly
9. Lubrication
system

Table 3–1
No. Item Function

Engine and transmission case constitute the power
1 Power travel system travel 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.
Frame is the mounting base as well as the support for
3 Frame assembly
all parts.
Boom is to raise the load. It is composed of a fixed
4 Boom assembly boom, a moving boom and a telescopic cylinder which is
located in the fixed boom.
Spreader is the main working mechanism which is
5 Spreader assembly capable of rotating, pitching, telescoping, as well as
locking and unlocking a container.
Cab is the work area for the operator, where operation
6 Cab and console system
of the machine is performed.
Hydraulic system includes: braking/steering hydraulic
system and working device hydraulic system. It supplies
7 Hydraulic system power for 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
9 Lubrication system
and decentralized lubrication types are included.
Adjust the temperature of the cab to meet the driver's
10 Air conditioning system
operating comfort requirements
3.2 Cab
3.2.1 Cab
NOTE：
To operate correctly and safely, it is important to fully comprehend the methods to operate the con-
trol devices and the meaning of display items.
The composition of the instruments and controls is shown in the figure below.

8 7
6 4
2 3
Fig.3-2 Instruments and Controls
1. Steering controller 2. Brake pedal 3. Accelerator pedal 4. Joystick

5. Right operation 6. Front operation 7. Monitor 8. Air conditioner
panel panel control panel

3.2.2 Steering column
3.2.2.1 Steering column
The composition of the steering controller is

shown in the right figure.
7 3
Fig.3-3 Steering Controller
1. Steering wheel 2. Gear selector

panel
3. Direction indicator 4. Steering column
control lever
5. angle adjusting 6. angle adjusting
handle pedal
7. Steering wheel

3.2.2.2 Steering panel
The steering wheel panel includes four indica-

tors, i.e., the turn-left indicator [1], the fault in-
dicator [2], the parking indicator [3] and the
turn-right indicator [4], as well as four
switches, i.e., the warning lamp switch [5], the
headlight switch [6],the boom lamp and back-
light switch [7] and the spreader lamp switch
[8].
Turn-left indicator
P
8 7
When the left signal is on, the turn-left indica-
tor flashes. Fig.3-4 Steering Wheel Panel
Fault indicator 1. Turn-left indicator 2. Fault indicator

3. Parking indicator 4. Turn-right indicator
5. Warning lamp 6. Headlight switch
switch
7. Boom lamp and 8. Spreader lamp
• When the indicator is on, it indicates that
backlight switch switch
the control system and the monitoring
system have one or more active or inactive
fault codes.
• As long as the fault code is active (parking,
warning or fault message), the indicator will
go on.
Parking indicator
When the parking brake is applied, the indica-

tor will go on.
Turn-right indicator

When the right signal is on, the turn-right indi-

cator flashes.
Parking switch
This switch is used to turn on/off the parking

brake.
Fig.3-5 Parking Switch
After the parking switch is pressed, the park-

ing indicator will go on.
NOTE：
The parking system is on the drive axle. After
the parking switch is turned on, the drive axle
will be locked. There is no need to brake ex-
cept an emergency.
P
Fig.3-6 Parking Indicator
Warning lamp switch
This switch is used to turn on/off the warning

lamp.
Fig.3-7 Warning Lamp Switch

Press the warning lamp switch, the warning

lamp indicator in the cab will go on, and the
warning lamp on the machine will flash.
Fig.3-8 Position of the Warning Lamp
Press the warning lamp switch, and the width

lamps on the machine hood and the side of
the rear fender will go on.
Fig.3-9 Position of the Width Lamp
Headlight switch
This switch is used to turn on/off the

headlights.
Fig.3-10 Headlight Switch

The headlights are mounted on the front of

the vehicle body.
Fig.3-11 The Positions of the Headlights
Some machines are optionally equipped with

8 headlights.
RS-1407028-1
Fig.3-12
Boom lamp and backlight switch
This switch is used to turn on/off the boom

lamp and backlight.
Fig.3-13 Boom Lamp and Backlight Switch

Spreader lamps switch
This switch is used to turn on/off the spreader

lamps.
Fig.3-14 Spreader Lamp
The two spreader lamps are located on the

left and right ends of the spreader's telescopic
beam symmetrically.
Fig.3-15 The Positions of the Spreader Lamps
The four boom lamps are located on the left

and right sides of the middle of the boom.
Fig.3-16 The Positions of the Boom Lamps

The two backlights are located left and right

near the rear bearing of the boom telescopic
cylinder.
Fig.3-17 The Positions of the Backlights
3.2.2.3 Gear selector
Gear selector can be moved forward or back-

ward. Three letters “F, N, R” are marked on
the gear selector.
Driving direction of machine (flip the gear se- 1

2
lector in the direction of arrow): 3
1
• F: Forward gear (flip forward) 2
3
Fig.3-18 Flipping Forward
• N: Neutral gear (in the middle)
1
2
3
1
2
3
1
2
3
Fig.3-19 Flipping

• R: Reverse gear (flip backward)
The rear light illuminates when gear selector

is placed at the R mark. And the reversing
alarm will soon make a sound. 1
2
3
1
2
3
Fig.3-20 Flipping Backward
Gear selector can also be rotated towards 3

positions respectively signifying 1st gear, 2nd
gear, and auto gear.
Gear selector can also be rotated towards 3

positions respectively signifying 1st gear, 2nd
gear, and auto gear.
• 1: 1st gear
• 2: 2nd gear
• 3: auto gear
• With the controller at the neutral position,
the engine can be started. Fig.3-21 Rotating
• In switching over between the forward and
reverse positions, stop the machine
completely to avoid overload on the
gearbox or transmission system.

3.2.2.4 Direction indication controller
Direction indication controller 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 per-

sonnel that the machine is about to change its
driving direction. Steering indicator lights are
used to remind the driver whether the steering
light turns on normally.
Fig.3-22 Flipping Forward/backward
Push the direction indication controller for-

ward. 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.3-23 Left Steering Indicator Light
Push the direction indication controller back-

ward. The right steering light on front mud-
guard and on the upper counterweight as well
as the right steering indicator light in cab will
begin blinking.
Fig.3-24 Right Steering Indicator Light

Front steering lights are fitted together with

headlights.
Fig.3-25 Front Steering Light
Rear steering lights, located at the end of

main frame, are fitted together with tail lights.
Fig.3-26 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.3-27 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
return to its original place and stop spraying
out water. Fig.3-28 Washer Button
The controller can be rotated to four positions,
O, J, I and II, to control the operation of

wipers.
• O- stop wiping.
• J-intermittent wiping.
• I-continuous wiping.
• II- continuous wiping.

3.2.2.5 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.
Steering column angle adjusting pedal (2) 1
1. Step on the pedal
2. Adjust the steering column to a desired

2
position.
3. Release the pedal.
Fig.3-29 Adjustment Handle and Pedal
1. Adjusting handle 2. Adjusting pedal
3.2.3 Pedal
3 4
Fig.3-30 Pedal

Brake pedal [3] 3. Brake pedal 4. Accelerator pedal

The brake pedal is used for main brake
braking.
Accelerator pedal [4]
The accelerator pedal is used to increase the

engine speed for higher power.
3.2.4 Joystick（Option1）
Joystick is located at the right of cab seat. It

can be swayed in different directions to con- 4
3
trol telescopic and pitching of the boom. 2
With the joystick on/off switch on right opera- 1 6
tion panel pressed down, the joystick can be

5
switched and thus realize the signal operation
of boom to four directions without pressing the 7
joystick enable switch at the back of joystick.
CAUTION
Risk of injury!
Failure to follow this alert will result in person- Fig.3-31 Joystick
al injury.
• The driver should turn off the joystick on/off 1. Spreader locking 2. Spreader
switch on right operation panel before unlocking
leaving the cab, and avoid incorrect 3. Spreader side- 4. Spreader rotating
operation. shifting
5. Horn 6. Combined function
When a combination operation is needed,
7. Handle enable
push the joystick directly.
NOTE：
Reaction speed of all operations (except verti-
cal operation) is directly related to the joystick
angle.
When the joystick remains at its neutral posi-

tion, all operations will be ceased.

3.2.5 Joystick（Option2）
Joystick is located at the right of cab seat. It

3 4
can be swayed in different directions to con-
trol telescopic and pitching of the boom.
With the joystick on/off switch on right opera- 2

tion panel pressed down, the joystick can be 5
1 9
switched and thus realize the signal operation
7 6
of boom to four directions without pressing the
joystick enable switch at the back of joystick.
8
CAUTION
Risk of injury!
Failure to follow this alert will result in person-
al injury.
• The driver should turn off the joystick on/off Fig.3-32 Joystick
switch on right operation panel before
1. Spreader rotation 6. Spreader twist lock
leaving the cab, and avoid incorrect
7. Spreader
operation. 2. Spreader extend
unlocking
When a combination operation is needed, 3. Spreader retract 8. Vertical motion
push the joystick directly. 4. Horn 9. Backup
NOTE： 5. Spreader side

Reaction speed of all operations (except verti- movement
cal operation) is directly related to the joystick
angle.
When the joystick remains at its neutral posi-
tion, all operations will be ceased.

3.2.6 Right operation panel
3.2.6.1 Right operation panel
The composition of the right operation panel

5 6 7 8
is shown in the right figure.
11
9
10 12
15
13
16
14
1 2
3 4
Fig.3-33 Right Operation Panel
1. Ignition key 2. Safety bypass

3. Buzzer 4. Emergency stop
switch
5. Top wiper 6. Rear wiper
7. Joystick enabling 8. Manual centralized
lubrication (optional)
9. Cab forward 10. Cab backward
(optional) (optional)
10. Cab backward 12. Spreader 35`
(optional) (optional)
13. Emergency 14. Emergency
lowering retraction
15. Fire alarm 16. Fire extinguishing

3.2.6.2 Ignition Switch
NOTICE
Risk of damage!
If the engine stalls in a non-idling state, the service life of the engine will be reduced.
• Except in emergency, do not perform emergency stop when the engine runs in high speed,
otherwise it may cause fatigue cracks in the engine cylinder head, turbocharger bearing
burnout and other malfunctions.
NOTICE
Risk of damage！
Improper performing may cause engine fault codes and undesirable operation.
The machine body control unit monitors the engine preheating status in real time. When the en-
gine is preheated for 1 second, the display will give the prompt “Preheat running”, accompanying
with audible and visual alarms. Once it is detected that the preheating system has been working
for more than 20 seconds, a preheating fault alarm will be given immediately, and the monitor dis-
plays the fault alarm prompt "Pre_Heat_Err".
• Once the “Pre_Heat_Err” prompts appear, the operator must stop the equipment operation
immediately, shut down the engine and cut off the power supply, and check the engine
preheating system.
The ignition switch (shown in the right figure)

is used to start or shut down the machine. E A B
C
[A]: OFF position P
You can insert or remove the key to turn off all D
electrical equipment.
[B]: ON position
The electrical equipment is powered on, and

the switch key remains in the ON position
when the engine is running.
Fig.3-34 Ignition Switch
[C]: HEAT (preheating) position
A. OFF position B. ON position
If the temperature is below 5°C, insert the key
and turn it clockwise to Position C and keep it C. HEAT (preheat- D. START position
for engine preheating. Some engines have ing) position
automatic preheating function. E. P (Parking)
position
[D]: START position

When starting the engine, insert the key and

turn it clockwise to the START position [D]
and hold it. After the engine starts, immedi-
ately release the key, and it will automatically
return to the ON position [B].
[E]: P (Parking) position
Turn the key to the P position, and the engine

stalls.
3.2.6.3 Emergency retraction/lowering

switch
Buzzer would begin alarming to alert the oper-

ator 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 to cancel the alarm. If the safety value
decreases further due to the misoperation 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.3-35 Boom Emergency Retraction

In some emergency cases, press down the

emergency retraction button to retract the
boom. After the boom retracts to its minimum
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 sus-
pended 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-over-
turning sensor is triggered to send tilting sig-
nal. The boom then can only be retracted.
NOTE：
If the controller fails to work normally, it will re-
set automatically 3 seconds after its power Fig.3-36 Boom Emergency Lowering
supply is disconnected as long as the danger
is eliminated.
3.2.6.4 Safety bypass switch
When the safety bypass switch [1] is turned

on, various safety protection functions of the
reach stacker will be disabled.
WARNING
Risk of injury!
The safety bypass function should be used
with caution. Failure to follow this alert will
result in injury.
• The safety bypass key must be managed
by a dedicated technical manager. See
“Precautions for operating safety bypass 12
switch” on page 2-47.
2
Operation procedure
Fig.3-37 Safety Bypass and Buzzer
1. Safety bypass switch 2. Buzzer

1. Confirm that the safety bypass function

must be used to disable the protection.
2. Before using the safety bypass function,

make sure that the reach stacker is in a safe
state.
3. Insert the key into the safety bypass lock

switch [1].
4. Turn the key clockwise to turn on the safety

bypass function, when the buzzer [2] buzzes,
and the fault warning light gives alarm, the
monitor displays "Safety Bypass Switch On",
and the protection is disabled.
5. When the safety bypass switch is turned

on, the operator must confirm that the ma-
chine is in a safe state before operating the P
handle. The boom can be raised and lowered,

and the spreader can be rotated and moved
sideways, and the machine can be unlocked
and locked when the mechanical lock pin of Fig.3-38 Fault Indicator
the spreader's twist lock mechanism is re-
leased under no load.
6. After adjusting the reach stacker to the nor-

mal state, you must confirm that the safety by-
pass function is turned off, the fault warning
indicator stops giving alarm, and the "Safe By-
pass Switch On" message on the monitor dis-
appears, and then proceed to the next step.
7. After the operation is completed, remove

the key and return it to the keeper.
DANGER
Risk of serious personal injury or death！
Improper or wrong operations can cause property damage, serious personal injury or even death.
• When the safety bypass key switch is turned on, a safety bypass alarm will be given, and the
“Position Protection”, “Safe Lifting Lock”, “Safety Factor Lock”, “Forward Tilt Lock” and like
protection for the boom will be disabled, the boom can move up and down and retract, and the
locking/unlocking actions can only be enforced without load.
Rules for using safety bypass

When the safety bypass switch is turned on, various safety protection functions of the reach stack-
er will be disabled. So the operating rules are stated as follows:
• Users should pay special attention to the on-site situation and use the function only when safety
is guaranteed.
• We are not responsible for any accident caused by using the safety bypass function.
3.2.6.5 Emergency stop switch
WARNING
Risk of injury or damage!
Frequent use will cause the emergency stop
switch to malfunction, and even result in
injury or damage.
• The emergency stop switch just be used in
emergency. See “Precautions for operating
emergency stop button” on page 2-46.
Press the emergency stop switch, the auxili-

ary motor will stop, the vehicle will park, the
whole electrical system of the vehicle will be
powered off, and all actions will stop.
After the fault is removed, turn the switch

clockwise as indicated by the arrow on the
switch, the emergency stop switch will auto-
matically rebound, and the emergency stop
will end. Fig.3-39 Emergency Stop

3.2.6.6 Cab move enable
Before the cab moves, it is necessary to re-

lease the fixing buckle after driving, and close
the door in the cab after confirming that there
is no hanging buckle.
1
Press [1] and [3] at the same time to move for- 3
ward. Press [2] and [3] at the same time to
move backward. 2
After the cab is moved in place, fasten the two

buckles behind the cab.
Fig.3-40 Cab Move Enable
1. Move button 2. Move button

3. Move button

3.2.6.7 Top wiper switch
This switch is used to turn on or off the top

wiper.
Fig.3-41 Top Wiper Switch
1. Top wiper switch

The top wiper is located at the top of cab.
Fig.3-42 Top Wiper

3.2.6.8 Rear wiper switch
This switch is used to turn on or off the rear

wiper.
Fig.3-43 Rear Wiper Switch
1. Rear wiper switch

The rear wiper is located at the back of cab.
Fig.3-44 Rear Wiper

3.3 Display
3.3.1 SANY Display
3.3.1.1 SANY Display
Display is composed of menu display area

(1), function display area (2), and operation
buttons F1-F6 (3). See Fig. Display
1 2 3
Fig.3-45 Display
1. Menu display area 3. Operation buttons F1-F6

2. Function display area

3.3.1.2 Menu introduction
Menu display area (position 1 in Fig. Display)
This area displays system parameters.
Fig.3-46 Menu Display Area
Operation buttons (position 3 in Fig. Display)
By pressing relevant buttons, the desired

menu can be displayed.
Fig.3-47 Operation Buttons

3.3.1.3 Main menu
About 2 seconds after the start menu is dis-

played, main menu will be shown automati-
cally 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, main-
tenance tips, and alarm area.
Below are the explanations of information Fig.3-48 Main Menu

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

blue. heavy 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 rota-

tion speed of engine.
Displayed speed on instrument alters within

the range of 0-25. It signifies the rotation
speed of 0-2500 rpm/min.
Fig.3-49 Engine Speed Instrument
2. Vehicle speed
The right instrument indicates the actual trav-

eling 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.3-50 Vehicle Speed Instrument
3. Load percentage
Load percentage is aimed at protecting the

machine.
• Load percentage≤90%: safe for lifting load Fig.3-51 Load Percentage
• Load per centage>90%: a larm for
dangerous working condition
• Load percentage=100%: impossible to
extend and lower the boom
4. Spreader indicator lights
Three spreader indicator lights on this menu

signify the conditions of spreader twistlocks. Fig.3-52 Spreader Indicator Lights
• 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.
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.
Fig.3-53 Load & Boom Information
• Load weight: the weight is shown as 0
when the machine is unloaded. And it will
change according to the weight of load.
3.3.1.4 Language setting menu
It is able to select the program language from Language

Chinese, English, French and Russian
Fig.3-54 Language Setting Menu

3.3.1.5 Engine information menu
Press F1 to enter engine information menu.
indicates the engine water temperature
indicates the fuel level Fig.3-55 Engine Information Menu
indicates the engine oil pressure
indicates the engine rotation speed
indicates the engine working hours
indicates the system voltage

3.3.1.6 Gear information menu
Press F2 to enter gearbox information menu.
Gearbox parameters:
indicates the gearbox temperature
indicates the gearbox oil pressure Fig.3-56 Gear Information Menu
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.

3.3.1.7 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
Load indicates the load weight
Weight
Total indicates the counting of
twistlock twistlock
Total indicates the counting of
container container
Fig.3-57 Hydraulic System Menu

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

light at the left of the words changes into red.
Fig.3-58 Digital Input Menu
2. Digital output menu

Fig.3-59 Digital Output Menu

3. Analogy input menu
Fig.3-60 Analogy Input Menu
4. 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.3-61 Analogy Output Menu
5. Spreader input menu

Fig.3-62 Spreader Input Menu

6. Spreader output menu

Fig.3-63 Spreader Output Menu
3.3.1.9 Help System
When a failure occurs as shown in the help in-

formation, enter the relevant help information
page to check the internal state of the
program.
Fig.3-64 Help System

3.3.1.10 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.3-65 Function set menu
3.4 Air Conditioning System

3.4.1 Control panel
3.4.1.1 Control panel
AIR CONDITIONER
1 4
OUT
2 C
MODE(
模式) 5
O3 AUTO
3 6
SANY HEAVY INDUSTR

Y CO.,LTD.
Fig.3-66 Control Panel
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

3.4.1.2 Power switch
The power switch is used to start or stop the

functions of air conditioner (refrigeration, de-
humanization, 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 Fig.3-67 Power Switch
on the display).
3.4.1.3 Fan speed switch
This switch is used to adjust the air volume by

circulating from low-speed to medium-speed
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.
Fig.3-68 Fan Speed Switch
• Air volume automatically transits among the

gears during the automatic operation of air
conditioner
Indications of air volume on display screen:
• A: it indicates low air volume

• B: it indicates medium air volume
• B: it indicates medium air volume A B C
Fig.3-69 Air Volume Indication

3.4.1.4 Temperature or Paging switch
1. This switch is used to control the tempera-

ture inside the operator cab.
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
Fig.3-70 Temperature or Paging Switch
once to reduce 1°C of the set temperature.

• No operation for 5 seconds, temperature
returns to the original display condition.
• The temperature is generally set at 25° C
(77°F).
Table 3–2 Temperature Reference
Display Temperature (℃ ) Set Temperature (℃ )

16.0 Max. refrigeration effect
18.5-31.5 Adjust the temperature
32.0 Max. heating effect

3.4.1.5 Mode switch
Mode switch is used to change the modes be-

tween refrigeration, dehumanization, ventila-
tion and heating.
indicates that air conditioner is in refrigeration

mode.
Fig.3-71 Mode Switch
indicates that air conditioner is in ventilation

mode.
indicates that air conditioner is in heating

mode.
indicates that air conditioner is in dehumidifi-

cation mode.

3.4.1.6 Fresh air switch
Fresh air switch is used to change the modes

between fresh air, ozone sterilization, and au-
tomation. Press this switch, and above modes
circulate in proper sequence.
indicates that air conditioner is in fresh air

mode.
Fig.3-72 Fresh Air Switch
indicates that air conditioner is in ozone sterili-

zation mode.
indicates that air conditioner is in automation

mode.
NOTICE
• 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 ventila-
tion, fresh air, refrigeration mode. Do the ad-
justments 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 re-

frigeration. 30 seconds later, the air condi-
tioner starts to refrigerate and
Fig.3-73 Mode Switch

keeps on. If the set temperature is higher than
cab temperature,
would blink all the time. Then the idling lifter

would start to work if the engine is equipped
with idling lifting device.
2. Press
or
one time to raise or reduce 1℃ of the set tem-

perature. The set temperature can be ad-
justed between 16℃ to 32 ℃. Generally,
human body could adapt to the temperature
between 22℃ to 28 ℃. As soon as the cab
Fig.3-74 Temperature or Paging Switch
temperature is lower than the set value, the
sensor would send signals to controller. And
the air conditioner will stop refrigerating.

3. Press
to adjust the air volume.
Fig.3-75 Fan Speed Switch
3.4.3 Precautions
1. Water is not allowed into the air conditioner manipulator.
2. The manipulator is an electrical assembly which can be damaged by water, and the air
conditioner will not operate normally. Key notes:
• After the vehicle is parked, all the doors and windows of the cab should be closed to protect the
manipulator from damage caused by rain.
• When the vehicle is washed, the left and right doors and windows of the cab should be closed to
protect the manipulator from damage caused by water intrusion.
• During driving, the driver's teacup should be kept away from the manipulator to prevent the tea
from splashing into the manipulator to cause damage.
3. The air conditioner can be turned on only after the engine is started:
4. Never use the air conditioner when the fault indicator or the undervoltage indicator is on.
5. When the air conditioner is running, close the doors, windows and ventilation devices (except
the fresh air device).
6. Never close all the air outlets of the air conditioner, and at least 1/3 of the air outlets should be
open.
7. Under normal circumstances, do not short-circuit temperature control or defrost protection (i.e.,
no forced cooling).
8. Never short-circuit the low & high pressure switch under any circumstance.

CAUTION
Risk of worn out!
Failure to follow this will cause early wear of the clutch in long term.
The instantaneous wear of the suction disc caused when the air conditioner stops working
suddenly as the set in-cab temperature is reached is normal. If the air conditioner is turned on
before the engine is started, the clutch will be engaged with the compressor drive disc. If the
engine is started at this time, the instantaneous torque of the engine is very large, and there will
be great friction between the clutch suction disc and the drive disc of the air conditioner
compressor.
• Do not open the air conditioner before the engine.
3.5 Fuse and controller of the electric control cabinet
1 2 3 4
module
Collective electrical box
Earth-terminal board
5
6
Fig.3-76 Cab Electric Control Cabinet
1. Integrated electrical box 2. Relay 3. Fuse 4. Extension module

5. Connector 6. Grounding strip
The control cabinet is installed behind the seat in the cab, while the junction box is installed on the
right side of the equipment near the cab. Its internal layout is shown in the figure below. If any part
is burned out, please replace it with one in the original specifications.

The diagnosis of electrical faults is a professional work which can only performed by professional
technicians. If important components such as circuit breakers and relays are damaged, please re-
fer to the parts catalog for corresponding material codes, and purchase them from Sany Marine.
6 5 1
7 4
8 9 3
Fig.3-77 Electric Control Cabinet of Frame
1. Controller 2. Indicator lamp 3. Knob switch 4. PCB

5. Integrated electrical 6. Circuit breaker 7. High-current relay 8. Connector
box 212
9. Copper busbar
3.6 Fuse
Fuses are located in the electric control cabinet in cab. Fuse protector is a protection electrical ele-
ment of high generality. When burned, it can be replaced with a new one of the same specification
easily.
Fuses are located in the electric control cabinet in cab. Fuse protector is a protection electrical ele-
ment of high generality. When burned, it can be replaced with a new one of the same specification
easily.
Table 3–3 Cab Electric Control Cabinet fuse
No. Size Fuction

BCC-FU1 10A Module power supply 16G/66G
BCC-FU2 20A Backup
BCC-FU3 10A Emergency switch
BCC-FU4 10A Backup
BCC-FU5 20A Backup

Table 3–3 Cab Electric Control Cabinet fuse (continue)
No. Size Fuction

BCC-FU6 20A Front wiper
BCC-FU7 10A Working light
BCC-FU8 5A Running light
BCC-FU9 5A Top wiper
BCC-FU10 5A Rear wiper
BCC-FU11 10A Radio
BCC-FU12 20A Interphone
BCC-FU13 5A Handle action
BCC-FU14 25A Backup
BCC-FU15 5A Steering light
BCC-FU16 10A Cab control
BCC-FU17 5A Parking brake switch
BCC-FU18 10A Reversing system
BCC-FU19 20A Backup
Table 3–4 Frame Electric Control Cabinet fuse
No. Size Fuction No. Size Fuction

Cab constant
BPC-FU01 10A BPC-FU19 25A Backup
electricity
BPC-FU02 10A Backup BPC-FU20 10A 36000 gearbox sensor
BPC-FU03 10A Backup BPC-FU21 10A Backup
BPC-FU06 5A Cabinet light BPC-FU24 10A Boom extend fast
BPC-FU07 10A Head light BPC-FU25 30A Brake oil cooling fan
BPC-FU08 10A Rear light BPC-FU26 20A Boom light
Centralization
BPC-FU09 10A BPC-FU27 10A Reversing light
BPC-FU10 10A Relay BPC-FU28 20A Backup
BPC-FU11 10A Spreader power 1 BPC-FU29 10A Backup
BPC-FU12 10A Spreader light BPC-FU30 10A TE30 gearbox power supply
Controller delay power
BPC-FU13 10A Front horn BPC-FU31 15A
supply 1

Table 3–4 Frame Electric Control Cabinet fuse (continue)
No. Size Fuction No. Size Fuction

Controller delay power
BPC-FU14 10A Rear horn BPC-FU32 15A
supply 2
Gearbox delay power
BPC-FU15 5A Sensor power BPC-FU33 10A
supply
Spreader delay power
BPC-FU16 10A Cab moving BPC-FU34 5A
supply
BPC-FU17 10A Backup BPC-FU35 10A OEM
BPC-FU18 5A Sensor power 2 BPC-FU36 10A OEM1
3.7 Fire extinguisher

There are two fire extinguishers which are ar-
ranged on the left and right sides of the cab.
Fig.3-78 Fire Extinguisher
CAUTION
Risk of burnt out！
Failure to follow this may cause a possible fire.
• Make sure that you have a fire extinguisher, read the label, and master the using method in
case of an emergency.
• Carry out regular inspections to ensure that the fire extinguisher is within the expiration date.
• If the fire extinguisher has expired, replace it in time.
• Replace the fire extinguishers every 2 years at least.
The fire extinguishers in the engine compartment shall be maintained as below:
Check the lead and shell of the fire extinguisher every day for damage, and replace it immediately
if any. Besides, check the electrical circuit of the annular fire extinguisher and replace the damaged
wires.


Reach stacker Operation
Operation
4 Operation.............................................................................................................................4-1
4.1 Before the Starting of Engine ..............................................................................................4-5
4.1.1 Inspection before starting...........................................................................................4-5
4.1.1.1 Inspection before starting ...................................................................................4-5
4.1.1.2 Wiper water level, checking................................................................................4-5
4.1.1.3 Coolant level，checking .....................................................................................4-6
4.1.1.4 Engine oil level，checking .................................................................................4-6
4.1.1.5 Transmission oil level, checking ........................................................................4-6
4.1.1.6 Hydraulic oil level, checking ...............................................................................4-7
4.1.1.7 Fuel level, checking .............................................................................................4-8
4.1.1.8 Brake oil level, checking .....................................................................................4-9
4.1.1.9 Tyres, checking ....................................................................................................4-9
4.1.1.10 Electrical components,checking................................................................... 4-10
4.1.1.11 Working light, checking ...................................................................................4-11
4.1.1.12 Horn, checking .................................................................................................4-11
4.1.2 Adjustment before operation ...................................................................................4-11
4.1.2.1 Adjusting the seat ..............................................................................................4-11
4.1.2.2 Adjusting the rearview mirror .......................................................................... 4-14
4.1.2.3 Adjusting the safety belt................................................................................... 4-14
4.2 Starting the Machine.......................................................................................................... 4-16
4.2.1 Starting the machine................................................................................................ 4-16
4.2.2 Starting the machine at normal temperature........................................................ 4-16
4.2.3 Starting the machine at low temperature.............................................................. 4-19
4.2.4 Starting the machine with auxiliary measures ..................................................... 4-20
4.3 Shutingt down the machine .............................................................................................. 4-21
4.4 Driving.................................................................................................................................. 4-24
4.4.1 Driving requirements ............................................................................................... 4-24
4.4.2 Driving forward ......................................................................................................... 4-25
4.4.3 Driving backward...................................................................................................... 4-26
Operation Reach stacker
4.4.4 Turning around ......................................................................................................... 4-27

4.4.5 Parking....................................................................................................................... 4-27
4.5 Load Handling..................................................................................................................... 4-29
4.5.1 Operation switches（Option1） ............................................................................ 4-29
4.5.2 Boom, operation（Option1） ................................................................................. 4-30
4.5.3 Spreader, operation（Option1） ........................................................................... 4-34
4.5.4 Operation switches（Option2） ............................................................................ 4-38
4.5.5 Boom, operation（Option2） ................................................................................. 4-38
4.5.6 Spreader, operation（Option2） ........................................................................... 4-42
4.5.7 Hook, operation ........................................................................................................ 4-47
4.5.8 Load capacity diagram ............................................................................................ 4-48
4.5.8.1 Load capacity diagram..................................................................................... 4-48
4.5.8.2 Load capacity diagram of SRSC45V5 container reach stacker................. 4-49
4.5.9 Pick the container..................................................................................................... 4-50
4.5.10 Stack the container ................................................................................................ 4-53
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 Long-term storage ............................................................................................ 4-56
4.6.3.2 Preparation ........................................................................................................ 4-56
4.6.3.3 During storage................................................................................................... 4-57
4.6.3.4 Return to service............................................................................................... 4-58
4.7 Disassembly, assembly and transportation.................................................................... 4-58
4.7.1 Guide for disassembly & assembly and transportation ...................................... 4-58
4.7.2 Disassembling the machine.................................................................................... 4-58
4.7.2.1 Disassembling principles ................................................................................. 4-58
4.7.2.2 Disassembly checklist...................................................................................... 4-59
4.7.2.3 Lifting points of machine parts ........................................................................ 4-60
4.7.3 Packing requirements.............................................................................................. 4-61
4.7.4 Transportation........................................................................................................... 4-62
4.7.4.1 Transporting by platform lorry ......................................................................... 4-62
4.7.4.2 Transporting by container................................................................................ 4-62


WARNING

4.Operation
4.1 Before the Starting of Engine

4.1.1 Inspection before starting
4.1.1.1 Inspection before starting
Every time before starting the machine or changing shifts, the staff must perform a daily inspection
on the wiper water tank level, the coolant level, the engine oil level, the gearbox oil level, the hy-
draulic oil level, the fuel level, the brake oil level, the tires, the electrical components, the work
lamps and the horns of the machine, so as to ensure that the machine is in good working
condition.
4.1.1.2 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

4.1.1.3 Coolant level，checking
The expansion tank is at the rear of the cab.
The expansion tank is directly connected with

the engine radiator, so its water level directly
1
reflects the coolant level in the engine
radiator.
See “Coolant level, check and top up” on

page 5-73.
TY-1405097-1
Fig.4-2 Expansion Water Tank
1. Filler Cap
4.1.1.4 Engine oil level，checking
WARNING
Risk of burns！
After the machine is shut down, the parts and oil are still hot, which may cause serious burns.
• Wait for the oil to cool down before this operation.
• For the engine to run normally, check the oil level before starting the engine.
See “Oil level, check and top up” on page 5-54.
4.1.1.5 Transmission oil level, checking
NOTICE
Risk of malfuction！
Failure to follow this can cause machine
malfuction.
• The transmission oil level must be checked
when the engine is idling. L H
• Use the dipstick to check the oil level and
keep the level between the H and L marks.
The transmission oil level should be between

TY-1406071-1
the H and L marks on the dipstick. See
“Transmission oil, change” on page 5-92. Fig.4-3
L. Low level H. High level

4.1.1.6 Hydraulic oil level, checking
NOTICE
Risk of mulfuction！
Failure to follow this can cause machine
malfunction. 1
• When the hydraulic oil level is checked, all
cylinders must be fully retracted.
• Check the hydraulic oil level, and keep it at
3/4 of the sight glass.
2
Check whether the oil in the hydraulic oil tank
is sufficient through the sight glass (the level
must be above the red line, at 3/4 of the sight
Fig.4-4
glass), and fill it up if insufficient. See
“Hydraulic oil level, checking” on page 5-163. 1. Max level 2. Min level

4.1.1.7 Fuel level, checking
WARNING
Risk of burnt out!
Failure to follow this alert will result in burnt
out.
• Avoid spilling or overflowing when filling
fuel, otherwise it may cause a fire.
• If the fuel spills or overflows, wipe it
thoroughly. If the fuel flows to the ground
or sand, remove it.
• The fuel is very flammable and dangerous.
No open flame is allowed near the fuel.
• Welding is not allowed near the fuel tank. Fig.4-5
1. Turn the engine ignition key to the ON

position and check the fuel level displayed on
the monitor, and then turn the key to the OFF
position.
2. If the fuel level is low, open the filler cap on

the fuel tank, and fill fuel through the fuel filler
until the float in the float level gauge reaches
the highest point.
Fig.4-6

4.1.1.8 Brake oil level, checking
Check the oil level and quality status of the

brake oil tank with a liquid gauge. The liquid
level must be between Max (the maximum oil
level) and Min (the minimum oil level). When
the oil is insufficient, fill it to Max. When the
brake oil deteriorates, change it in time.
Fig.4-7
4.1.1.9 Tyres, checking
Carry out a visual inspection of the tyre. Make

sure that the rim and hub cover (1) are not 1
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 in-
2
spected by the maintenance personnel before
being used.
Tyre pressure should be 0.95-1.05 Mpa.

3
Fig.4-8 Check Points of Tyre
1. Rim and hub cover 3. Wheel tread

2. Tyres

DANGER
Risk of serious injury or death!
A exploding lock ring or exploding tyre can
be deadly to anyone close to the tyre.Failure
to do this could result in serious injury or
death.
• Only properly trained personnel are
allowed to service the tyres.
Fig.4-9 Tyre Explosion
4.1.1.10 Electrical components,checking
NOTICE
Risk of machine damage！
Failure to follow this alert will result in machine damage.
• If the fuse is blown out frequently or the wire has traces of short circuit, contact the authorized
dealer of Sany Marine immediately to find the cause and repair it.
• Keep the battery surface clean and check the breather on the battery cover. If the breather is
blocked by dirt or dust, flush the battery cover and clean the breather.
The inspection of electrical components mainly includes the following content:
1. Check whether the fuse is damaged and whether a fuse of the specified capacity is used.
2. Check whether the wire is open-circuited or has traces of short circuit, and whether the wire
coating is damaged.
3. When checking the battery, the engine, the starter motor and the alternator, pay special
attention to the wires.
4. Check whether the terminal is loose, and tighten it if so.
5. Check whether there are flammable materials around the battery, and clear them immediately if
any.

4.1.1.11 Working light, checking
The inspection of the working light mainly in-

cludes the following content:
1. Turn the ignition key of the machine to the

ON position. Turn on the working light switch
and check whether the working light is on. If
any one is not on, the bulb may be burned out
or there is an open circuit, and please contact
the authorized dealer of Sany Marine for
repair.
2. Check the Working light for dirt or damage. Fig.4-10 Working light
4.1.1.12 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.4-11 Horn
4.1.2 Adjustment before operation
4.1.2.1 Adjusting the seat
NOTE：
– Before starting to operate the machine or after changing the driver, adjust the seat position.
– After adjusting the seat, the driver can operate the control devices in the cab freely and
conveniently sitting on the seat.

1. Adjust the headrest

1
Lift the headrest to the desired position and
release to lock it.
Headrest adjustment stroke: 120 mm
2
3
4
4
5
6
4
Fig.4-12 Adjust the Seat
1. Headrest 2. Armrest angle

adjustment adjustment
3. Backrest 4. Extending/
inclination retracting seat belt
adjustment
5. Weight adjustment 6. Seat height
adjustment
2. Adjust the inclination of the armrest
Rotate the hand wheel clockwise [2], the arm-

rest rises. Otherwise, it will lower.
Seat armrest adjustment angle: -50°～+50°

2
Fig.4-13 Adjust the Inclination of the Armrest
2. Hand wheel
clockwise

3. Adjust the inclination of the backrest
When adjusting the angle of the backrest,

move the handle [3] upwards first and turn the
backrest back and forth until you are satisfied
with the position. Then release the handle to
lock the backrest position. 3
Seat backrest adjustment range: 75°～140°。
4. Adjust the seat belt
See “Adjusting the safety belt” on page 4-14.

Fig.4-14 Backrest Inclination Adjustment
3. Handle
5. Adjust the weight
Rotate the lever [5] to the left to make the sus-

pension harder for heavier drivers, and rotate
the lever to the right to soften the suspension
for drivers with lighter weight.
Seat weight adjustment range: 50 kg ～ 130 5

kg.
Fig.4-15 Adjust the Weight
5. Lever
6. Adjust the height of the seat
The seat height adjustment range is 0~60

mm. Lift the lever [6] and lift up the seat.
When you hear a click, seat rises by 30 mm.
Continue to lift it up, and when you hear a sec-
ond click, it rises by 30 mm. If you continue to
lift the seat up, the seat will be lowered to the
lowest position.
Fig.4-16 Adjust the Height of the Seat
6. Lever

4.1.2.2 Adjusting the rearview mirror
WARNING
2
Risk of personal injury or machine
accidents!
Without correct adjust the rearview mirrors, 1
the view cannot be ensured, which may
cause personal injury or machine accidents.
• Before work starts, the rearview mirror
must be adjusted.
Adjust the rearview mirrors [1] and [2] so that

you can see the people and objects behind
the machine. Fig.4-17 Rearview Mirror
1. Rotate the rearview mirrors to suitable 1. Right rearview 2. Left rearview

positions. mirrors mirrors
2. If you cannot move the mirror smoothly

when adjusting the angle, loosen the fixing
bolts and the fastening rod bolts of the mirror.
3. When you adjust the angle of the rearview

mirror, it is a standard to take the side of the
machine into the line-of-sight of the mirror.
4.1.2.3 Adjusting the safety belt
WARNING
Risk of injury!
You must buckle up the safety belt when operating. Failure to follow this alert will result in injury.
• Check the belt, buckles and fasteners of the safety belts carefully before operating the
machine, and replace them immediately if any damage or wear is found.
• It is still recommended to replace the safety belt every three years even it is still in good
condition. The production date of the safety belt is marked on the back.
• Never twist the safety belt when buckling it up.

The safety belt comes with a winding device,

so there is not needed to adjust the length.
Buckle up the safety belt

5 3 2 1
1. Hold the safety belt clip [2] and pull the 4
safety belt out of the winding device [1].
2. Make sure that the safety belt is not twisted,

and then insert the bolt [3] into the buckle [4].
3. Pull the safety belt gently to confirm that it is

buckled up securely. Fig.4-18 Adjust the Safety Belt
Remove the safety belt 1. Winding device 2. Safety belt clip
1. Press the button [5] on the buckle [4], and 3. Bolt 4. Buckle
pull the bolt [3] out of the buckle [4]. 5. Button
2. The safety belt will be drawn into the

winding device [1] automatically.
3. Hold the safety belt clip [2] and slowly wind

the seat belt into the winding device [1].

4.2 Starting the Machine

4.2.1 Starting the machine
WARNING
Risk of personal injury or fire!
The operator can only start or operate the machine while sitting on the seat, Failure to follow this
alert will result in personal injury or fire.
• You must get familiar with all warning devices, instruments and operation controls before
starting the machine.
• Before starting the machine, all controls must be in the Neutral/Parking positions.
• Before starting the machine, make sure no one is on or under the machine or in the
surrounding area, and blow the horn as warning.
• If the machine must be started in an enclosed environment, it is necessary to guarantee
adequate ventilation to avoid inhaling much exhaust gas, which would cause severe personal
injury.
• In cold weather, warm up the machine completely before starting.
• In cold weather, check whether the battery electrolyte is frozen before starting the machine. If
so, melt the battery electrolyte first.
• Never start the machine with auxiliary start fluid and auxiliary cable without permission. It can
cause severe personal injury or fire.
4.2.2 Starting the machine at normal

temperature
1. Turn the main power key clockwise into the

main power switch.
OFF
ON
Fig.4-19 Power Switch

2. Move the shift lever [1] to the neutral posi-

tion and confirm that the emergency stop but-
ton is released.
2
1
2
3
1
1 2
3
1
2
3 I II
0
III
Fig.4-20 Start the Machine
1. Shift lever 2. Ignition switch
3. Insert the ignition key of the machine into

the ignition switch [2] and turn it clockwise to
the ON position [I], so that the entire system is
powered on. P
4. Turn the ignition key clockwise to the ON

position [Ⅲ] and hold it for 3 to 5 seconds, and
the engine will start. Then release the hand,
and the start key will return to the position "I"
automatically.
The ignition key should be kept for no more

than 10 seconds in the ON position during Fig.4-21 Ignition Switch
each start. If the machine fails to start after
three attempts, find out and resolve the fault
before starting again to avoid damage to the
engine.
To protect the battery, an interval of 1~2 mi-

nutes should be maintained between two
starts. The machine can only be started after
the engine is powered on and the monitor is
initialized.

NOTICE
Risk of damage!
If a start fails and the operator restarts the
engine before it stops, the starter motor will 60°c
be damaged.
• The operating time for starting the machine 0°c
should not exceed 15 seconds every time, - 5°c
and an interval of 1~2 minutes should be
maintained between two starts.
• When the engine water is cold, it is not
allowed to run the machine at high speed.
Fig.4-22 Engine Temperature
• If the engine water temperature is below
60℃, the machine is not allowed to
accelerate abruptly or run at full load.
To start the machine, the following conditions

must be met: 0 ℃ SPN 0
0.0 L
1. Observe whether there is an alarm sound
and alarm content on the monitor screen. If 0.0 Bar
any, you must find the cause and resolve it 0 RPM

until the fault disappears. 0 H
2. Observe whether corresponding 0.0 V
parameters meet the conditions on the

second screen of the monitor.
Fig.4-23 Check the Monitor Screen
3. The shift lever must be in the neutral (ON)
position, otherwise it is impossible to start the
engine.
4. The emergency stop button must be

released.
After starting, you can step on the accelerator

pedal to accelerate the engine, and continue
to observe whether the engine parameters
are normal.

4.2.3 Starting the machine at low

temperature
NOTE：
When the ambient temperature is below 50°F
(10°C), it is more difficult to start the machine,
so take special care when starting. Auxiliary P
measures may be needed, but the operation
in the cab is the same as that of the normal
start.
CAUTION
The engine exhaust contains combustion
products harmful to humans. It may result in
Fig.4-24 Ignition Key
personal injury.
• Be sure to run the engine in a well-
ventilated place.
• If operating the engine in an enclosed
place, discharge the exhaust gas to the
outdoors.
NOTICE
Risk of machine damage!
Failure to follow this will result in machine
35° C
damage.
• When the ambient temperature is low
(close to or below 0° C), the hydraulic oil
0° C
heater should be used.
• When the engine is preheated, the - 5° C
preheating indicator will go on, and the
preheating will last for about 1 minute.
Then the preheating indicator goes out.
Fig.4-25 Engine Temperature
• When the ambient temperature is low
(close to or below 0℃), if the engine
cannot start smoothly, stop starting and
restart it after 2 minutes. If it fails to start
for several times, check the heater system.
To protect the engine to the greatest extent

and save the engine starting time at low

temperatures, the following points should be

followed:
1. The battery is fully charged.
2. Keep the fuel clean and free of water.
3. Select lubricant and fuel with appropriate

viscosity based on the ambient temperature
where the engine operates.
4.2.4 Starting the machine with auxili-

ary measures
WARNING
Risk of serious personal injury or death and machine damage!
If the booster battery is connected incorrectly, it may cause serious personal
2 injury or death and
machine damage. 1
• The booster battery must be connected by trained personnel familiar with its using method for
starting.
If the battery of the engine is low, you can start

the machine with the booster battery or by
starting the generator.
1
1. Make sure that the parking switch is turned 2
on and all controls off.
2. When connecting the booster battery or

starting the generator, follow the steps below
to avoid battery explosion due to sparks
around:
• Connect one end of a jumper cable to the Fig.4-26 Use Booster Battery
positive pole (+) [1] of the booster battery,
1. Positive pole(+) 2. Negative pole (-)
and other end to the positive pole (+) of the
machine battery.
• Connect one end of another cable to the
negative pole (-) [2] of the booster battery,
and the other end to the ground connector
on the machine frame far from the battery.
3. Start the machine in the normal way.

4. After the engine starts, disconnect the

negative (-) booster cable from the frame first,
and then the positive (+) booster cable.
NOTE：
Never try to start the machine by dragging or pushing.
WARNING
Risk of serious personal injury!
Explosive gas will be generated during battery charging and power generation. If there is spark or
flame around, the battery may explode, causing severe personal injury.
• Wear goggles when using the booster battery or starting the generator.
ANTIDOTES Recommended By Battery Manufacturer
EXTERNAL: flush with water. flush the eyes with water for at least 15 minutes.
INTERNAL: drink plenty of water and never induce vomiting. Seek medical care immediately!
4.3 Shutingt down the machine

1. Release the accelerator pedal [3] to slow
down the machine.
2. Depress the brake [2] and stop the

machine.
2 3
Fig.4-27 Brake Pedal and Accelerator Pedal
2. Brake 3. Accelerator pedal

3. Turn on the parking switch [4], and the park-

ing indicator light [5] will be on.
4. Parking switch
Fig.4-29 Parking Indicator
5. Parking indicator light
1
2
3
1 2
3
1
2
3
Fig.4-30 Neutral Position

4. Put the shift lever [1] to the neutral position. 1. Shift lever
5. If the engine has been running under a
heavy load, allow the engine to idle for a few
minutes before stopping it.
6. Turn the ignition key counterclockwise to

the "P" position and stop the engine.
7. Pull out the ignition key when leaving the

P
machine.
Fig.4-31 Ignition Key Switch
8. When the machine is not operated, turn the

main power supply key counterclockwise to
get it out of the main power supply switch, so
as to turn off the main power supply.
OFF
ON
Fig.4-32 Turn Off the Power Supply

4.4 Driving
4.4.1 Driving requirements
The operation must be performed by opera-

tors who hold special equipment operation
certificates (issued in accordance with rele-
vant laws and regulations of relevant coun-
tries and regions), and must master the
content of this Manual before operation. F
1
2
N
1. With the engine idling, turn the shift lever [1] 3
to select the travelling direction of the

machine, and rotate it to shift gears. 1 3
2. Release the parking switch [2] and depress

the accelerator pedal [3]. Fig.4-33 Driving Requirements
3. When shifting gears, release the 1. Shift lever 3. Accelerator pedal

accelerator pedal [3].
4. When driving, keep pressing the

accelerator pedal [3]. Keep the machine
travelling smoothly.
2. Parking switch
Speed
The speed of the machine must be adjusted depending on the personnel, visibility, road surface
and load conditions at the job site. Pay special attention when driving on slippery roads. In any
case, the machine must travel in the speed in which it can stop safely.

WARNING
Risk of accident！
The inertia of the machine depends on its speed and mass, which determines the speed of stop-
ping. Failure to follow this will result in anccident.
• As the total mass of the machine is large, it cannot stop immediately when parking. When the
machine is parked, it will continue to travel for a distance, which depends on its speed and
mass. So leave a distance when parking to avoid collision with other objects.
NOTICE
Risk of damage!
Failure to follow this alert will result in drive shaft damage.
• The gear can only be shifted when the machine is in a low speed.
DANGER
Risk of serious injury or death!
In order to maintain the stability of the machine when driving on bumpy roads, must follow this
alert, otherwise will result in serious injury or death.
• The machine must travel at a low speed.
• The boom must be fully retracted, and the load must be as close to the ground as possible.
4.4.2 Driving forward
CAUTION
Risk of personal injury or machine damage！
Failure to follow this will result in personal injury or machine damage.
• When accelerating on a slope, step on the brake pedal first, and release the brake pedal after
the machine has produced sufficient traction, so as to prevent the machine from sliding down
the slope.

1. Push the driving shift lever [1] forward.
2. Release the parking switch [2]. 1
3. Step on the accelerator pedal [3] to allow

the machine to accelerate slowly.
2 3
Fig.4-35 Driving Forward
1. Driving shift lever 2. Parking switch

3. Accelerator pedal
4.4.3 Driving backward
DANGER
Risk of serious injury!
Follow this alert. Otherwise, it may result in injury or possibly death.
• When the machine reverse, you must pay attention to checking whether there are people
behind.
1. Move the shift lever [1] backwards.
1
2. Depress the accelerator pedal [3] gently to
accelerate the machine slowly.
Fig.4-36 Reversing
1. Shift lever 3. Accelerator pedal

4.4.4 Turning around
WARNING
Risk of injury or possibly death!
when the machine is traveling at a high speed, or with spreader elevated higher than its mid-
point,or on uneven ground, failure to follow this will result in injury or possibly death.
• To maintain machine stability and prevent possible tipping, do not turn around the machine
abruptly.
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 . Other-
wise, steering components may overheat.
Fig.4-37 Steering
4.4.5 Parking
WARNING
Risk of injury or machine damage！
Failure to follow this will result in injury or machine damage.
• Do not use the parking brake to stop the machine unless in emergency.

The parking brake switch is located on the left

of front operation panel. Press the parking
brake switch, and the parking indicator light
will be turned on.
The parking system is located on the trans-

mission shaft. Switch on the parking brake,
and the transmission shaft will be locked.
Do not use this parking brake switch for a P
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.4-38 Parking

4.5 Load Handling

4.5.1 Operation switches（Option1）
16 12 13 14 15
3 4
6
18
2
1 5
19
17
7 20
22
21 23
8 9
10 11
Fig.4-39
1. Spreader twist lock 9. Safety bypass 17. Cab backward (optional)

2. Spreader unlocking 10. Buzzer 18. Cab movement enabling
3. Spreader side movement 11. Emergency stop 19. Spreader 35` (optional)
4. Spreader rotation 12. Top wiper 20. Emergency lowering
5. Horn 13. Rear wiper 21. Emergency retraction
6. Combination function 14. Joystick enabling 22. Fire alarm
7. Joystick enabling 15. Manual centralized lubrication (optional)
8. Ignition key 16. Cab forward (optional) 23. Fire extinguishing

4.5.2 Boom, operation（Option1）
In order to avoid misoperation and improve

the safety of the machine, there is a button
"A" on the back of the joystick.
The specific description of each function key

is shown in the table below.
A
Table 4–1
Key Function Type

Joystick Fig.4-40 Enabling Switch
A Automatic reset
enabling
A. Enabling Switch
For the safety of the whole vehicle, the boom is only allowed to extend 9 meters when the boom is
below 40 degrees. The maximum extension of the boom is 16.2 meters, and the boom cannot be
fully extended.
Raising the boom: Pull the joystick backwards.
Fig.4-41 The Boom Rises
Lowering the boom: Push the joystick forwards.

Fig.4-42 The Boom Lowers
Extending the boom: Move the joystick to the right.
Fig.4-43 The Boom Extends
Retracting the boom: Move the joystick to the left.

Fig.4-44 The Boom Retracts
Vertical rising: Press and hold button A on the right of the joystick and pull it backwards.
Vertical upward or downward movement is allowed only when the torque percentage is below
85%.
Fig.4-45 Vertical Rising
A. Enabling Switch
Vertical lowering: Press and hold button A on the right of the joystick and push it forwards.

Fig.4-46 Vertical Lowering
A. Enabling Switch
CAUTION
• After closing the joystick switch F on the right operation panel, you can directly move the
joystick to four directions for single action in the four directions respectively without pressing
the joystick enabling switch B on the back of the joystick. But the driver must turn off the
joystick switch F when leaving the cab, so as to avoid misoperation of the boom as the body
touches the joystick.
• When combined operation is needed, the operator can push the joystick obliquely.
• The speed of various actions (except vertical lift) is proportional to the amplitude that the
joystick is pushed; and when the joystick is in the neutral position, all actions stop.
The vertical lifting speed of the boom is determined by the program itself. Once the movement is
started, its speed has no relation with the angle of the joystick. To switch the boom from the vertical
upward movement to the vertical downward movement, you must release the joystick and pause
for 2-3 seconds first.
Only when the boom extends for short length can it rise vertically. Please operate the boom to rise
or lower vertical as little as possible, and more manual operation is recommended.

4.5.3 Spreader, operation（Option1）
The green lamp [A] indicates that the twist

lock is locked.
Yellow lamp [B] indicates that the ejector pole

is in position.
The red lamp [C] indicates that the twist lock

is unlocked. A B C
Fig.4-47 Spreader Lamps
A. Green lamp B. Yellow lamp

C. Red lamp
Spreader twist lock: After the spreader is in

position, the yellow lamp (middle) will be on. If
the operator has set the automatic twist lock,
the controller will send out a signal for twist
lock of the spreader automatically at this time.
After the twist lock is completed automatically,
the green lamp will be on. If the operator does
not set the automatic twist lock, when the op-
erator presses the twist lock button on the joy-
stick, the spreader is twist locked, and the
green lamp will be on.
Fig.4-48 Spreader Twist Lock
Spreader unlocking: After the container is in

position, press the spreader unlocking button
to unlock the spreader. At this time, the red
lamp will be on and the green lamp off.
WARNING
damage！
When the container is suspended, the
spreader unlocking button does not work.
• Do not carry out the operation by force, so
to avoid the accident of container falling.
Fig.4-49 Spreader Unlocking
Left movement of spreader:
Move A upwards to move the spreader to the left, with the maximum lateral movement of 800mm.

Fig.4-50 Left Movement of Spreader
A. Move switch
Right movement of spreader:
Move A downwards to move the spreader to the right, with the maximum lateral movement of
800mm.
Fig.4-51 Right Movement of Spreader
A. Move switch
Clockwise rotation of spreader:
Move B downwards, and the spreader will rotate clockwise.

Fig.4-52 Clockwise Rotation of Spreader
B. Rotate switch
Counterclockwise rotation of spreader:
Move B upwards, and the spreader will rotate counterclockwise.
Fig.4-53 Counterclockwise Rotation of Spreader
B. Rotate switch
Spreader extension/retraction:
Press and hold the function key C, and move A upwards/downwards to extend/retract the
spreader.

A C
Fig.4-54 Spreader Extension/Retraction
A. Move switch C. Function key

4.5.4 Operation switches（Option2）
13 14 15 16
3 4
2 19
17
5
1 25
18 20
7 6
21
23
8 22 24
9 10
11 12
Fig.4-55
1. Spreader rotation 10. Safety bypass 19. Cab movement enabling

2. Spreader extend 11. Buzzer 20. Spreader 35` (optional)
3. Spreader retract 12. Emergency stop 21. Emergency lowering
4. Horn 13. Top wiper 22. Emergency retraction
5. Spreader side movement 14. Rear wiper 23. Fire alarm
6. Spreader twist lock 15. Joystick enabling 24. Fire extinguishing
16. Manual centralized
7. Spreader unlocking 25. Backup
8. Vertical motion 17. Cab forward (optional)
9. Ignition key 18. Cab backward (optional)
4.5.5 Boom, operation（Option2）
For the safety of the whole vehicle, the boom is only allowed to extend 9 meters when the boom is
below 40 degrees. The maximum extension of the boom is 16.2 meters, and the boom cannot be
fully extended.
Raising the boom: Pull the joystick backwards.

Fig.4-56 The Boom Rises
Lowering the boom: Push the joystick forwards.
Fig.4-57 The Boom Lowers
Extending the boom: Move the joystick to the right.

Fig.4-58 The Boom Extends
Retracting the boom: Move the joystick to the left.
Fig.4-59 The Boom Retracts
Vertical rising: Press and hold button A on the back of the joystick and pull it backwards.
Vertical upward or downward movement is allowed only when the torque percentage is below
85%.

Fig.4-60 Vertical Rising
A. Enabling Switch
Vertical lowering: Press and hold button A on the back of the joystick and push it forwards.
Fig.4-61 Vertical Lowering
A. Enabling Switch

CAUTION
• After closing the joystick switch F on the right operation panel, you can directly move the
joystick to four directions for single action in the four directions respectively without pressing
the joystick enabling switch B on the back of the joystick. But the driver must turn off the
joystick switch F when leaving the cab, so as to avoid misoperation of the boom as the body
touches the joystick.
• When combined operation is needed, the operator can push the joystick obliquely.
• The speed of various actions (except vertical lift) is proportional to the amplitude that the
joystick is pushed; and when the joystick is in the neutral position, all actions stop.
The vertical lifting speed of the boom is determined by the program itself. Once the movement is
started, its speed has no relation with the angle of the joystick. To switch the boom from the vertical
upward movement to the vertical downward movement, you must release the joystick and pause
for 2-3 seconds first.
Only when the boom extends for short length can it rise vertically. Please operate the boom to rise
or lower vertical as little as possible, and more manual operation is recommended.
4.5.6 Spreader, operation（Option2）
The green lamp [A] indicates that the twist

lock is locked.
Yellow lamp [B] indicates that the ejector pole

is in position.
The red lamp [C] indicates that the twist lock

is unlocked. A B C
Fig.4-62 Spreader Lamps
A. Green lamp B. Yellow lamp

C. Red lamp

Spreader twist lock: After the spreader is in

position, the yellow lamp (middle) will be on. If
the operator has set the automatic twist lock,
the controller will send out a signal for twist
lock of the spreader automatically at this time.
After the twist lock is completed automatically,
the green lamp will be on. If the operator does
not set the automatic twist lock, when the op-
erator presses the twist lock button on the joy-
stick, the spreader is twist locked, and the
green lamp will be on.
Fig.4-63 Spreader Twist Lock
Spreader unlocking: After the container is in

position, press the spreader unlocking button
to unlock the spreader. At this time, the red
lamp will be on and the green lamp off.
WARNING
damage！
When the container is suspended, the
spreader unlocking button does not work.
• Do not carry out the operation by force, so
to avoid the accident of container falling. Fig.4-64 Spreader Unlocking
Left movement of spreader:
Move A upwards to move the spreader to the left, with the maximum lateral movement of 800mm.

Fig.4-65 Left Movement of Spreader
A. Move switch
Right movement of spreader:
Move A downwards to move the spreader to the right, with the maximum lateral movement of
800mm.
Fig.4-66 Right Movement of Spreader
A. Move switch
Clockwise rotation of spreader:
Move B downwards, and the spreader will rotate clockwise.

Fig.4-67 Clockwise Rotation of Spreader
B. Rotate switch
Counterclockwise rotation of spreader:
Move B upwards, and the spreader will rotate counterclockwise.
Fig.4-68 Counterclockwise Rotation of Spreader
B. Rotate switch
Spreader extension:
Press and hold the function key C, and the spreader will extend.

Fig.4-69 Spreader Extension
C. Function key
Spreader retraction:
Press and hold the function key D, and the spreader will retract.
Fig.4-70 Spreader Retraction
D. Function key

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

loading bulk.
• 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 20 ft before
loading.
• The four ropes should be of the same
length.
Fig.4-71
The angle between the rope and the plane

normal of the spreader corner fittings is α
(0°≤α ≤30°).
Under different α, the maximum load G of the

spreader does not exceed the curve in the fig-
ure below. E.g., When α is 30°, G ≤ 20 T.
Fig.4-72
In case of carrying heavy load with the hook,

the attachment is required, the dimensions of
which are as follows: A
• A≤5560 mm
• B≤2260 mm
B
• 1≤ A/B ≤2.5
Fig.4-73
A. Length B. Width

4.5.8 Load capacity diagram
4.5.8.1 Load capacity diagram
WARNING
Risk of machine damage or possible death!
Containers of other specifications will damage the machine and cause safety accidents.
• Overloading is not allowed during the operation, which may cause early damage to the
machine and casualties.
• The reach stacker can only be used to lift 20' and 40' containers.
Pay attention to transfer load according to the load capacity diagram.
Unit of the unmarked sizes in the diagram is mm.

4.5.8.2 Load capacity diagram of SRSC45V5 container reach stacker
Fig.4-74

4.5.9 Pick the container
1. Drive the machine to the place where the

containers are stacked.
2. Move the machine slowly to align its center

position with the center of the container.
3. Lift the spreader and move it to the front of

the container.
4. The right lamp (red) in the combined indica-

tor light is on, indicating that the twist locks
are open.
Fig.4-75
5. Drive the machine forward to get as close

as possible to the stacking place of the
container.
6. Turn on the parking switch or depress the

brake to stop the machine.
7. Adjust the position of the spreader by

means of side movement and rotation of the
spreader as well as the extension and retrac-
tion of the boom, so as to align the twist locks
of the spreader with the corner holes of the
container.
Fig.4-76

8. The right lamp (red) in the combined indica-

tor light is on, indicating that the twist locks
are open.
9. Place the spreader on the container.
10.The middle light (yellow) in the combined

light is on, indicating that the four twist locks
are put in place successfully.
11.Press the twist lock button to lock the con-

tainer with the spreader (if without the auto-
matic twist lock function).
Fig.4-77
12.After the twist lock operation starts, the

right lamp (red) will go out.
13.After the twist lock operation is completed,

the left lamp (green) will go on.
14.Now it is ready to lift the container.
Fig.4-78
Fig.4-79

15.The middle lamp (yellow) will go out as A. Vertical gap B. Horizontal gap
soon as the container is lifted. Then the twist
lock operation will be suspended.
16.The lifting height of the container should

be as small as possible, with necessary verti-
cal gap (A) about 20 ~ 40 cm.
17.Reverse the machine, and the lifted con-

tainer should be separated from the container
below. The horizontal reversing distance of
the lifted container should be as small as pos-
sible. And the horizontal gap (B) between two
containers should be about 20 ~ 40 cm. Then
stop the machine and keep still.
18.Retract the boom to the maximum extent,

and the position of the container will be lower.
If the retraction range is too large, the buzzer
will sound, and the control program will lock
the retraction operation.
19.When retracting the boom, take care to

keep a certain distance from the stack in front,
because the container will move forward hori-
zontally while it is falling vertically.
20.Continue to retract the boom and lower the

container till the container reaches the driving
position of the reach stacker.
Fig.4-80

21.Retract the boom as far as possible. C. Level C

22.Lower the container as much as possible
but must be above level C (C) so as to avoid
obstructing the driver's line-of-sight.
23.Move the spreader horizontally and adjust

the center position of the container to align it
with the center of the machine.
24.The best driving position is that where the

load center is as close to the machine as pos-
sible, but the driver's line-of-sight is not
obstructed.
25.The center of gravity of the container must

be adjusted to be aligned with the center of
the machine.
Fig.4-81
4.5.10 Stack the container
1. Drive the machine to the place where the

containers are stacked.
2. Adjust the center position of the container

on the top of the stack.
Fig.4-82

3. Lift the container above the stack.
4. Move the machine to the stacking place as

close as possible.
5. Turn on the parking switch or depress the

brake to stop the machine.
6. Adjust the position of the container to align

it with the stack via the side movement of the
spreader and the extension/retraction of the
boom.
Fig.4-83
7. Lower the container.
8. When the container is put in place, the mid-

dle light (yellow) will go on.
9. The twist lock can be opened at this time.
10.When the twist lock is being opened, the

left light (green) will go out.
11.After the twist lock is fully opened, the right

light (red) will go on.
12.Remove the spreader from the container

and move the machine for the next stacking
or picking operation. Fig.4-84
NOTICE
Failure to follow this alert will result in machine damage!!
• When the spreader is performing the twist lock action, never perform the lifting operation.

4.6 Store the Machine

4.6.1 Overnight storage
1. Park the machine on a flat, level, stable sur-

face away from people, traffic or other
machines.
2. Lower the attachment.
3. Run the engine at idle speed for 3-5 mi-

nutes to allow for heat dissipation. Extend this
cool-down time in hot weather.
4. Shut down the engine.

RS-1406021-1
5. Remove the ignition switch when the engine
comes to a complete stop. Fig.4-85
NOTICE
Risk of damage！
Failure to follow this notice can cause
damage to the machine, personal property or
the environment.
• Always remove the ignition switch and take
it with you, even if you are leaving the
machine for only a moment. Keep it with
you to prevent unauthorized operation of
the machine.
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
Follow the steps described in "Overnight Storage", see “Overnight storage” on page 4-55 and
then:
1. Clean the machine.
2. Keep the machine dry.
3. Keep the machine completely lubricated.
4. Cover the machine to prevent dust.

NOTE：
Short-term storage refers to the storage time within 30 days.
4.6.3 Long-term storage
4.6.3.1 Long-term storage
Proper preparations for long-term storage will reduce the chances for damage or deterioration of
the machine.
NOTE：
Long-term storage is defined as a storage period of more than 30 days.
4.6.3.2 Preparation
1. Park the machine on a flat and firm ground,

and keep it as far from crowds, traffic or other
machines as possible.
2. Lower the attachments.
3. Idle the engine for three to five minutes for

heat dissipation. The time can be extended
appropriately in hot weather.
4. Shut down the engine.
5. Remove the ignition key when the engine

stops running completely.
NOTICE P
Failure to follow this alert will result in dam-
age to the machine and the environment or
loss of property.
• In order to prevent misoperation of the
machine, the operator must remove the
TY-1509015-1
ignition key and carry it himself/herself,
even if he/she just leave the machine Fig.4-86
temporarily.
6. Close and lock the windows.
7. Lock the cab door.

8. Fill fuel till the float in the float level meter

reaches the highest point.
9. Apply lubricant to all exposed piston rods.
10.Change the oil.
11.Turn off the main power switch and remove

the switch key.
OFF
ON
Fig.4-87
4.6.3.3 During storage
WARNING
Risk of serious injury and death!
Failure to observe and follow this warning could result in death or serious injury.
• Open doors and windows to provide adequate ventilation when operation the machine.
Once a month:
1. Start the machine.
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.

4.6.3.4 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.
4.7 Disassembly, assembly and transportation

4.7.1 Guide for disassembly & assembly and transportation
The reach stacker is a special vehicle used in ports, docks and storage yards. Ultra-high, ultra-
wide and overweighted, it cannot drive on highways. When the machine is delivered from the man-
ufacturer to the port, dock, or storage yard, it must be disassembled.
Generally, the reach stacker is disassembled into: large components such as the main machine
body, the boom, the spreader, the upper counterweight, the rear counterweight and the pitch cylin-
der, while other small parts are packed into two to three wooden boxes based on their nature. Pay
attention to fixation and protection of all parts during packaging, so as to avoid scratching the
paint.
Our machines are disassemble and packaged by a professional shipping team when they are
shipped from the factory, which is safe and reliable. When the customer wants to transfer the ma-
chine, the machine also must be disassembled. Because disassembly, assembly and shipping is
complex operation with high safety requirements, Sany Marine provides specific video instructions
for customers. For details, please see the "Disassembly and Assembly CD" attached to this
manual.
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.
• All hydraulic hoses and cables not 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 checklist
Before shipment, the reach stackers SRSC45V5 is need to be disassembled into the main body
[1], the boom [2], the spreader [3], the pitch cylinder [4], the upper counterweight [5], the rear coun-
terweight [6], the lamps [7], the pins, the wooden boxes of spare parts and other parts in the
factory.
3 5
7
1
Fig.4-88
1. Main body 2. Boom 3. Spreader 4. Pitch cylinder

5. Upper 6. Rear counterweight 7. Lamps
counterweight

4.7.2.3 Lifting points of machine parts
Lifting point sign. Before lifting the machine,

please select the lifting points according to the
lifting point signs.
Fig.4-89 Lifting Point Sign
The lifting points of the vehicle body are shown by the serial numbers [1] and [2] in the figure be-
low, which are 4 in total on both the left and right sides of the machine.
Fig.4-90 Lifting Points of the Whole Machine
1. Lifting points of vehicle body 2. Lifting points of vehicle body
The lifting points of boom are shown by the serial number [3] in the figure below, which are 6 in to-
tal on both the left and right sides of the boom.

Fig.4-91 Lifting Points of Boom
3. Lifting points of boom
The lifting points of the spreader are shown by the serial numbers [4] and [5] in the figure below,
which are 4 in total on both the left and right sides of the spreader.
Fig.4-92 Lifting Points of Spreader
4. Lifting points of spreader 5. Lifting points of spreader
4.7.3 Packing requirements
• Pack all the stripped parts except main frame, boom, spreader, counterweight and cylinders 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 mirrors, etc.) should be bound and 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 parts 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 33 t. Load the boom, rear counter-
weight and pitching cylinders to a platform truck whose load capacity is 23 t. Load the spreader,
upper counterweight and wooden cases to a platform truck whose load capacity is 22 t.
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.

Reach stacker Maintenance
Maintenance
5 Maintenance.......................................................................................................................5-1
5.1 Maintenance information......................................................................................................5-7
5.2 Tightening torques ................................................................................................................5-9
5.2.1 Tightening torques ......................................................................................................5-9
5.2.2 Table of standard bolt torque .................................................................................. 5-10
5.2.3 Tightening torque of the hose swivel nuts .............................................................5-11
5.2.4 Tightening torque of pipe fittings............................................................................ 5-13
5.2.5 Tightening torque of key bolts ................................................................................ 5-14
5.3 Functional oil....................................................................................................................... 5-15
5.3.1 Oil specifications ...................................................................................................... 5-15
5.3.2 Oil capacity................................................................................................................ 5-18
5.3.2.1 Oil capacity ........................................................................................................ 5-18
5.3.2.2 Oil Capacity of SRSC45V5 Reach Stacker................................................... 5-18
5.3.3 Hydraulic oil............................................................................................................... 5-19
5.3.3.1 Hydraulic oil management............................................................................... 5-19
5.3.3.2 Hydraulic oil， checking .................................................................................. 5-21
5.3.4 Urea............................................................................................................................ 5-22
5.3.4.1 Urea .................................................................................................................... 5-22
5.3.4.2 Quality requirements for urea ......................................................................... 5-22
5.3.4.3 Storage time of urea ......................................................................................... 5-23
5.4 Lubricating points ............................................................................................................... 5-23
5.4.1 Lubricants.................................................................................................................. 5-23
5.4.2 Lubrication points of the whole machine............................................................... 5-23
5.5 Scheduled maintenance ................................................................................................... 5-25
5.5.1 Daily maintenance items......................................................................................... 5-25
5.5.2 Maintenance every 50 hours .................................................................................. 5-26
5.5.3 Maintenance every 250 hours................................................................................ 5-27
5.5.4 Maintenance every 500 hours................................................................................ 5-29
5.5.5 Maintenance every 1000 hours.............................................................................. 5-30

Maintenance Reach stacker

5.5.9 Special instructions for the first maintenance ...................................................... 5-32
5.6 Engine.................................................................................................................................. 5-33
5.6.1 General engine inspection ...................................................................................... 5-33
5.6.1.1 General engine inspection............................................................................... 5-33
5.6.1.2 Charge air pipe, check ..................................................................................... 5-35
5.6.1.3 Drive belt, check................................................................................................ 5-36
5.6.1.4 Drive belt, replace (engine option VOLVO)................................................... 5-38
5.6.1.5 Alternator belt, replace (engine option VOLVO)........................................... 5-39
5.6.1.6 Air filter, check ................................................................................................... 5-42
5.6.1.7 Air filter, clean .................................................................................................... 5-44
5.6.1.8 Air filter, replacing ............................................................................................ 5-46
5.6.1.9 Fan drive gear train and hub ........................................................................... 5-49
5.6.1.10 Shock absorber, checking ............................................................................. 5-50
5.6.1.11 Coolant pump, checking ................................................................................ 5-51
5.6.1.12 Urea filter element, replacing........................................................................ 5-52
5.6.2 Lubrication system ................................................................................................... 5-54
5.6.2.1 Oil level, check and top up............................................................................... 5-54
5.6.2.2 Engine oil, change ............................................................................................ 5-55
5.6.2.3 Oil filter or the bypass filter, replace (VOLVO engine)................................. 5-57
5.6.2.4 Oil filter, replace (CUMMINS engine)............................................................. 5-59
5.6.3 Fuel system............................................................................................................... 5-61
5.6.3.1 Condensate, drain (VOLVO engine) .............................................................. 5-61
5.6.3.2 Condensate, drain (CUMMINS engine)........................................................ 5-63
5.6.3.3 Fuel filter, replace (VOLVO engine) .............................................................. 5-64
5.6.3.4 Fuel filter, replace (CUMMINS engine).......................................................... 5-66
5.6.3.5 Fuel pre-filter, change (VOLVO engine) ........................................................ 5-68
5.6.3.6 Fuel system, bleed (VOLVO engine) ............................................................. 5-70
5.6.4 Cooling system ......................................................................................................... 5-71
5.6.4.1 Description of cooling system ......................................................................... 5-71
5.6.4.2 Coolant, mix...................................................................................................... 5-71
5.6.4.3 Water quality...................................................................................................... 5-72
5.6.4.4 Coolant level, check and top up...................................................................... 5-73
5.6.4.5 Completely empty system, fill ......................................................................... 5-74
5.6.4.6 Coolant, drain .................................................................................................... 5-76
5.6.4.7 Radiator, clean .................................................................................................. 5-77
5.6.4.8 Cooling system, clean ...................................................................................... 5-79
5.6.5 Air intake and exhaust system ............................................................................... 5-81
5.6.5.1 Air leaks, check ................................................................................................ 5-81
5.6.5.2 Turbocharger, check......................................................................................... 5-82

5.7 transmission system .......................................................................................................... 5-85
5.7.1 Description of transmission system....................................................................... 5-85
5.7.2 Mounting bolts of propeller shaft, checking.......................................................... 5-85
5.7.3 Propeller shaft, lubricating ...................................................................................... 5-87
5.7.4 Speed sensor, check ............................................................................................... 5-88
5.7.5 Transmission oil level, checking ............................................................................ 5-89
5.7.6 Transmission oil filter, change ................................................................................ 5-91
5.7.7 Transmission oil, change ........................................................................................ 5-92
5.7.8 Mounting bolts and mounting pad, check ............................................................. 5-94
5.7.9 TE Transmission calibrating .................................................................................. 5-95
5.7.10 Transmission, checking ....................................................................................... 5-97
5.8 Drive axle............................................................................................................................. 5-98
5.8.1 Mounting bolts of drive axle to the frame, checking ............................................ 5-98
5.8.2 Mounting bolts of drive axle to the propeller shaft, checking ............................ 5-99
5.8.3 Oil leaking of drive axle and brake components, checking ............................. 5-100
5.8.4 Breather connector, cleaning .............................................................................. 5-103
5.8.5 Brake pads and braking function, checking ...................................................... 5-104
5.8.6 Main reducer, checking ........................................................................................ 5-106
5.8.7 Main reducer oil, changing.................................................................................... 5-107
5.8.8 Wheel-side reducer, checking ............................................................................. 5-109
5.8.9 Wheel hub nut, checking and tightening..............................................................5-111
5.9 Steering axle ......................................................................................................................5-112
5.9.1 Daily check...............................................................................................................5-112
5.9.2 Steering axle, lubricating.......................................................................................5-114
5.9.3 Steering axle components, checking ..................................................................5-115
5.9.4 Knuckle pin, checking............................................................................................5-116
5.9.5 Steering axle cradle, maintaining.........................................................................5-117
5.10 Tyres and rims .................................................................................................................5-118
5.10.1 Tyres and rims ......................................................................................................5-118
5.10.2 Precautions for tires.............................................................................................5-118
5.10.3 Tyre, inflating ........................................................................................................5-119
5.10.4 Maintenance of rim .............................................................................................. 5-122
5.10.4.1 Precautions for rim ....................................................................................... 5-122
5.10.4.2 Rim, checking............................................................................................... 5-122
5.10.4.3 Wheel rim, removing ................................................................................... 5-125
5.10.4.4 Wheel rim, installing .................................................................................... 5-127
5.10.5 Drive axle tyre, removing and installing............................................................ 5-128
5.10.5.1 Drive axle tyre, removing............................................................................ 5-128
5.10.5.2 Drive axle tyre, installing............................................................................. 5-131
5.10.6 Steering axle tyre, removing and installing ...................................................... 5-133
5.10.6.1 Steering axle tyre, removing ...................................................................... 5-133

5.10.6.2 Steering axle tyre, installing ....................................................................... 5-135
5.11 Boom................................................................................................................................ 5-136
5.11.1 Boom..................................................................................................................... 5-136
5.11.2 Basic boom, check ............................................................................................... 5-137
5.11.3 Wear pads, check................................................................................................. 5-138
5.11.4 Pitch cylinder, checking ...................................................................................... 5-140
5.11.5 Maintenance of the cylinder piston rod ............................................................ 5-141
5.12 Spreader.......................................................................................................................... 5-142
5.12.1 Twistlock, checking.............................................................................................. 5-142
5.12.2 Twistlock, lubricating ........................................................................................... 5-144
5.12.3 Sensor / Indicator of twistlock, checking........................................................... 5-145
5.12.4 Fixed bolts of spreader rotating gearbox, checking ........................................ 5-146
5.12.5 Wear pads of spreader, checking ...................................................................... 5-147
5.13 Air Conditioning System................................................................................................ 5-150
5.13.1 Precautions for service........................................................................................ 5-150
5.13.2 Summary of air conditioner maintenance......................................................... 5-152
5.13.3 Air conditioner belt，checking ........................................................................... 5-153
5.13.4 Air return grid screen and the evaporator screen, checking.......................... 5-154
5.13.5 Refrigerant, checking .......................................................................................... 5-155
5.13.6 Refrigerant/refrigeration oil，filling.................................................................... 5-156
5.13.7 Cleanness of heat-exchanger plate in evaporator and condenser,
checking ....................................................................................................... 5-158
5.13.8 Compressor and air conditioner pipeline fittings for oil and refrigerant leak-
age，checking ............................................................................................ 5-160
5.13.9 Pipelines, fittings and wire harness, checking ................................................. 5-161
5.13.10 Tightening of the compressor bolts, checking ............................................... 5-162
5.14 Hydraulic System ........................................................................................................... 5-163
5.14.1 Hydraulic oil level, checking ............................................................................... 5-163
5.14.2 Air filter element, replace .................................................................................... 5-164
5.14.3 Hydraulic oil, change ........................................................................................... 5-166
5.14.4 Hydraulic oil tank, cleaning................................................................................. 5-167
5.14.5 Oil return filter element, replace......................................................................... 5-168
5.14.6 Brake pedal, adjusting and lubricating.............................................................. 5-169
5.14.7 Parking brake unit, checking and adjusting ..................................................... 5-170
5.14.8 Brake oil filter, checking and replacing ............................................................. 5-172
5.14.9 Accumulator.......................................................................................................... 5-174
5.14.9.1 General information of accumulator........................................................... 5-174
5.14.9.2 Brake system accumulator, check ............................................................. 5-175
5.14.9.3 Accumulator, charge .................................................................................... 5-176
5.14.10 Hydraulic oil circuit, check ................................................................................ 5-178
5.15 Electrical System ........................................................................................................... 5-179

5.15.1 Electrical system .................................................................................................. 5-179
5.15.2 Fuses, changing................................................................................................... 5-180
5.15.3 Battery ................................................................................................................... 5-181
5.15.3.1 Battery ............................................................................................................ 5-181
5.15.3.2 Connecting and disconnecting ................................................................... 5-182
5.15.3.3 Battery, cleaning ........................................................................................... 5-182
5.15.3.4 Battery, checking .......................................................................................... 5-184
5.15.3.5 Battery, charging........................................................................................... 5-185
5.15.4 All working lights and indicators, checking....................................................... 5-188
5.15.5 Wiper, adjusting.................................................................................................... 5-189
5.15.6 Wiring terminal, cleaning and tightening .......................................................... 5-190
5.15.7 Cable abrasion (specially around the engine), checking ............................... 5-191
5.16 Maintenance Record List .............................................................................................. 5-192

WARNING

5.Maintenance
5.1 Maintenance information
NOTICE
Risk of machine malfunction！
Failure to follow this will result in machine malfunction.
• In order to ensure the good working status, the machine must be maintained regularly in the
intervals provided in this chapter.
• Do not perform any inspection and maintenance not described in this manual.
• Only use genuine replacement parts, grease and oil form SANY Marine.
• When changing or filling oil, do not mix different types of oil. When changing different types of
oil, all old oil must be drained and new oil must be filled completely, and the filter must be
replaced together (It will have no impact if the small amount of remaining oil in the pipeline is
mixed with new oil).
Hour meter reading
Check the hour meter readings every day to see whether it is time for the maintenance.
Genuine vulnerable parts from Sany
Please use the genuine parts from Sany specified in the parts catalog as replacement parts.
Genuine lubricant from Sany
Please use the genuine engine oil and grease from Sany. Select oil and grease with appropriate
viscosity based on the ambient temperature.
Windshield washer fluid
Take care to avoid dirt entering the windshield washer fluid during use.
Clean oil and lubricant
Please use clean oil and grease. And keep the oil and grease containers clean to avoid impurities
mixed in.
Check the drained oil and used filter element
Check the changed old oil and replaced filter element for metal debris and impurities. If a large
amount of metal debris and impurities are found, report to the supervisor and take appropriate
measures.
Primary fuel filter
A primary fuel filter must be installed when the fuel is filled.

Welding instructions
• Disconnect the negative (-) terminal of the battery about one minute after turning off the engine
start switch.
• Connect a grounding cable 1 m away from the welding position. If the grounding cable is
connected to the instrument, connector and other accessories, the instrument will fail.
• If there are seals or bearings between the welding position and the grounding point, change the
grounding point to avoid such parts.
• Do not choose a grounding point in the area around the working device pin or the hydraulic
cylinder.
• Do not use a voltage over 200 V continuously.
Prevent items from falling into the machine
• When opening the inspection window or the fuel tank nozzle for inspection, take care not to drop
nuts, bolts or tools into the inside of the machine. Otherwise, it will damage the machine and
cause a fault, which may result in an accident. Therefore, items falling into the machine should
be taken out immediately.
• Only put items necessary for inspection in your pockets.
Dusty job site
When working in a dusty job site, follow the steps below:
• When inspecting the machine or changing the oil, stop the machine in a place without dust to
prevent dust from entering the oil.
• When the air filter blockage alarm on the air filter gives an alarm, clean the filter element in time.
• Clean the radiator fins and other parts of the heat exchange device frequently, and take care to
prevent the radiator fins from blocking.
• Clean and replace the fuel filter frequently.
• Clean electrical components, especially the starter motor and the alternator, so as to avoid dust
accumulation.
Avoid mixing lubricants
Do not mix lubricants of different brands or grades. If you need to fill lubricant of a different brand
or grade, drain the old lubricant and replace it with the lubricant of a new brand.
Lock the inspection cover
When opening the inspection cover for maintenance, lock the inspection cover at the designated
position securely with the locking rod. If you perform inspection or maintenance without locking the
cover, it may suddenly close due to wind, causing personal injury.
Bleed air in the hydraulic system

When the hydraulic device is repaired or replaced, or the hydraulic pipeline is disassembled and
then assembled, the air in the oil circuit must be bled.
Install the hydraulic hose
• When disassembling parts in areas sealed by O-rings or gaskets, clean the mounting surface
and replace them with new parts. Do not forget to install the O-ring and gasket.
• Do not twist or bend the hose during installation, as this will damage the hose and significantly
shorten its service life.
Checking after inspection and maintenance
If you do not have a check after inspection and maintenance, unexpected faults may occur, result-
ing in serious injury or damage. Do follow the steps below:
• Check when operating the engine.

• Are the items subject to inspection and maintenance working properly?
• Is there any oil leakage when the engine speed rises and load is applied to the oil?
• Check after operation (when the engine is shut down).
• Did you forget the parts subject to inspection and maintenance?
• Have all inspection and maintenance items been performed correctly?
• Whether there are tools or parts falling into the machine. It is very dangerous if parts fall into the
machine and jam into the linkage mechanism!
• Is there water or oil leakage? Are all bolts tightened?
Close the engine hood tightly
When closing the engine hood after inspection and maintenance, hold the handle and lift it slightly
to check whether the latch is firmly locked. If the hood is not locked, it may open and cause
danger.
5.2 Tightening torques

5.2.1 Tightening torques
NOTICE
Risk of malfunction！
If the nuts, bolts or other parts are not tightened to the specified torque, the parts will be loose or
damaged.
• To avoid causing machine malfunction or problems during operation, take special care when
tightening parts.

5.2.2 Table of standard bolt torque
Without special instructions, metric bolts and nuts are tightened with the torque given in the follow-
ing table.
• Bolt strength class 8.8
Table 5–1
Wrench opening width Tightening torque

Thread Tightening torque (Nm)
(mm) (kg·m)
M6 10 10.5±1.5 1.1±0.2
M8 13 26±4 2.7±0.4
M10 16 52±7 5.3±0.7
M12 18 91± 3 9.3±1.3
M14 21 144±20 14.7±2.0
M16 24 225±32 23.0±3.3
M18 27 309±45 31.5±4.6
M20 30 439±63 44.8±6.4
M22 34 579±85 59.1±8.7
M24 36 760±109 77.6±11.1
M27 41 1111±159 113.4±16.2
M30 46 1508±185 153.9±18.9
M33 50 2052±220 209.4±22.4
M36 55 2635±275 268.9±28.1
M39 60 3210±320 327.6±32.7
Table 5–2

Thread Tightening torque (N m)
(mm) (kg·m)
M6 10 13.2±1.4 1.3±0.1
M8 13 31±3 3.2±0.3
M10 16 66±7 6.7±0.7
M12 18 113±10 11.5±1.0
M14 21 177±19 18.1±1.9
M16 24 279±30 28.5±3.1
M18 27 382±39 39.0±4.0
M20 30 549±59 56.0±6.0
M22 34 745±83 76.0±8.5

Table 5–2 (continue)

(mm) (kg·m)
M24 36 927±103 94.6±10.5
M27 41 1320±140 134.7±14.3
M30 46 1720±190 175.5±19.4
M33 50 2210±240 225.5±24.5
M36 55 2750±290 280.6±29.6
M39 60 3290±340 335.7±34.7
Table 5–3

(mm) (kg·m)
M6 10 18.5±2.5 1.9±0.3
M8 13 44±6 4.5±0.6
M10 16 87±12 8.9±1.2
M12 18 153±22 15.6±2.2
M14 21 244±35 24.9±3.6
M16 24 380±54 38.8±5.5
M18 27 523±75 53.4±7.7
M20 30 741±106 75.6±10.8
M22 34 1008±144 102.9±14.7
M24 36 1281±183 130.7±18.7
M27 41 1874±268 191.2±27.3
M30 46 2545±364 259.7±37.1
M33 50 3463±495 353.4±50.5
M36 55 4447±635 453.8±64.8
M39 60 5755±822 587.2±83.9
5.2.3 Tightening torque of the hose swivel nuts
The tightening torques in the table apply to Parker Hannifin's pipe fittings. For hose fittings of other
companies, the tightening torque may be slightly different due to the material and thread.
The tightening torques in the table are applicable to galvanized carbon steel joints. The corre-
sponding tightening torques of fittings of other materials are as follows:
• Brass fitting: 65% of carbon steel

• Stainless steel: Maximum tightening torque of carbon steel fittings

• Connection of different materials: Determined by the lower installing torque
• Metric swivel nut
Table 5–4

Thread Tightening torque (N·m)
(mm) (kg·m)
M12 06L 16±1 1.6±0.1
M14 08L 16±1 1.6±0.1
M16 10L 26±1.5 2.7±0.2
M18 12L 37±2 3.8±0.2
M22 15L 47±2 4.8±0.2
M26 18L 89±4 9.1±0.4
M30 22L 116±5 11.8 ±0.5
M36 28L 137±6 14.0±0.6
M45 35L 226±11 23.1±1.1
M52 42L 347±16 35.4±1.6
M14 06S 26±1.5 2.7±0.2
M16 08S 42±2 4.3±0.2
M18 10S 53±2 5.4±0.2
M20 12S 63±3 6.4±0.3
M22 14S 79±4 8.1±0.4
M24 16S 84±4 8.6±0.4
M30 20S 126±6 12.9±0.6
M36 25S 179±8 18.3±0.8
M42 30S 263±12 26.8±1.2
M52 38S 368±17 37.6±1.7
• BSPP swivel nut
Table 5–5
Thread Tightening torque (N·m) Tightening torque (kg·m)

G1/4 20±5 2.0±0 5
G3/8 34±7 3.5±0.7
G1/2 60±18 6.1±1.8
G5/8 69±25 7.0±2.6
G3/4 115±20 11.7±2.0
G1 140±25 14.3±2.6
G11/4 210±70 21.4±7.1

Thread Tightening torque (N·m) Tightening torque (kg·m)

G11/2 290±75 29.6±7.7
G2 400±100 40.8±10.2
5.2.4 Tightening torque of pipe fittings
The tightening torques in the table apply to Parker Hannifin's pipe fittings. For hose fittings of other
companies, the tightening torque may be slightly different due to material and thread.
The tightening torque listed in the table allows an error of +10%. The thread should be lubricated
with hydraulic oil before screwing in. The tightening torque listed in the table is suitable for steel
materials.
• Metric ISO thread
It is suitable for ISO 9974-1/ISO 6149-1/DIN 3852-T1-X port/DIN 3852-T3-W port
Table 5–6
Mal stud fittings (N·m) Mal stud fittings (kg·m)

Pipe OD
Series Thread Type Type Type Type Type Type Type Type
mm
A B E F A B E F
6 M10 9 18 18 15 0.9 1.8 1.8 1.5
8 M12 20 30 25 25 2.0 3.1 2.6 2.6
10 M14 35 45 45 35 3.6 4.6 4.6 3.6
12 M16 45 65 55 40 4.6 6.6 5.6 4.1
15 M18 55 80 70 45 5.6 8.2 7.1 4.6
L
18 M22 65 140 125 60 6.6 14.3 12.8 6.1
22 M27 90 190 180 100 9.2 19.4 18.4 10.2
28 M33 150 340 310 160 15.3 34.7 31.6 16.3
35 M42 240 500 450 210 24.5 51 45.9 21.4
42 M48 290 630 540 260 29.6 64.3 55.1 26.5
6 M10 20 35 35 35 2.0 3.6 3.6 3.6
8 M12 35 55 55 45 3.6 5.6 5.6 4.6
10 M14 45 70 70 55 4.6 7.1 7.1 5.6
12 M16 55 110 90 70 5.6 11.2 9.2 7.1
S
14 M18 55 150 125 80 5.6 15.3 12.8 8.2
16 M22 65 170 135 100 6.6 17.3 13.8 10.2
20 M27 90 270 180 170 9.2 27.6 18.4 17.3
25 M33 150 410 310 310 15.3 41.8 31.6 31.6

Mal stud fittings (N·m) Mal stud fittings (kg·m)

Pipe OD
Series Thread Type Type Type Type Type Type Type Type
mm
A B E F A B E F
30 M42 240 540 450 330 24.5 55.1 45.9 33.7
38 M48 290 700 540 420 29.6 71.4 55.1 42.9
• BSPP thread
Suitable for ISO 1179-1/DIN 3852-T2-X port
Table 5–7
Pipe OD Mal stud fittings (N·m) Mal stud fittings (kg· m)

Series Thread
mm Type A Type B Type E Type A Type B Type E
6 G1/8A 9 18 18 0.9 1.8 1.8
8 G1/4A 35 35 35 3.6 3.6 3.6
10 G1/4A 35 35 35 3.6 3.6 3.6
12 G3/8A 45 70 70 4.6 7.1 7.1
15 G1/2A 65 140 90 6.6 14.3 9.2
L
18 G1/2A 65 100 90 6.6 10.2 9.2
22 G3/4A 90 180 180 9.2 18.4 18.4
28 G1A 150 330 310 15.3 33.7 31.6
35 G11/4A 240 540 450 24.5 55.1 45.9
42 G11/2A 290 630 540 29.6 64.3 55.1
6 G1/4A 35 55 55 3.6 5.6 5.6
8 G1/4A 35 55 55 3.6 5.6 5.6
10 G3/8A 45 90 80 4.6 9.2 8.2
12 G3/8A 45 90 80 4.6 9.2 8.2
14 G1/2A 65 150 115 6.6 15.3 11.7
S
16 G1/2A 65 130 115 6.6 13.3 11.7
20 G3/4A 90 270 180 9.2 27.6 18.4
25 G1A 150 340 310 15.3 34.7 31.6
30 G11/4A 240 540 450 24.5 55.1 45.9
38 G11/2A 290 700 540 29.6 71.4 55.1
5.2.5 Tightening torque of key bolts
Before starting the machine, check the tightness of key bolts carefully. Loose bolts are likely to
cause severe vibration of the whole machine, component damage, function weakening, bolt break-
age and other dangerous phenomena. Regular inspection will avoid such accidents.

Table 5–8 Tightening Torques of Bolts on Main Components
Bolt Recommended tightening torque (Nm)

Engine fixing bolt M22 650±35
Gearbox fixing bolt M20 540±30
Engine and gearbox connecting bolt M10×1.25 70±5
Drive shaft and drive axle connecting bolt
220±15
M14×1.5
Drive axle fixing bolt M36 1600±100
Steering cylinder fixing bolt M30×2 1400±100
Upper and lower counterweight fixing bolt M36 1600±100
Tightening torque of drive axle pressure plate
430-460
nut M18
Tightening torque of steering axle pressure
350-400
plate nut M22
5.3 Functional oil

5.3.1 Oil specifications
Use the fuels, hydraulic oil, and coolants recommended in writing by Sany Marine correctly, and
check the quality and quantity of all functional fluid regularly. Only when all functional liquid is quali-
fied with sufficient quantity can the machine be started to work.
Please use oil meeting the standards in the manual. Oil of different brands is slightly different in
performance. Before changing the oil, make sure that all the old oil is removed. Never mixing oil of
different brands.
If the temperature in the area where the machine is used exceeds the range listed in the table,
please use the lubricant in a higher grade.
The specific oil standards and specifications are shown in the following table:
Table 5–9 Oil Standard
Recommended viscosity at different ambient temperatures

Filling Lubricant
°C -30 -20 -10 0 +10 +20 +30 +40 +50
position quality
°F -22 -4 +14 +32 +50 +68 +86 +104 +122
Engine Engine oil
VOLVO 　　 SAE 5W-30 　　　　　
API CI-4
CUMMINS 　　　 SAE 10W-30 　　　　　

Table 5–9 Oil Standard (continue)

Filling Lubricant
°C -30 -20 -10 0 +10 +20 +30 +40 +50
position quality
°F -22 -4 +14 +32 +50 +68 +86 +104 +122
Yuchai 　　　　 SAE 15W-40 　　
Gearbox Gearbox oil 　　　　　　　　　　　　　　　　　　　
DEXRON-II
DANA
or 　　 DEXRON II 　　
HR32000
equivalent *
Caterpillar
DANA
TO-4 Allison 　　　 SAE 10 　　
HR36000
C-4
DANA
　　　　
TE17
DANA DEXRONIII
DEXRON III
TE30 only
DANA
　　　　
TE32
Drive axle Gear Oil 　　　　　　　　　　　　　　　　　　　
SAE 75W-140
KESSLER API GL-5 SAE 80W-90
SAE 85W-140 　　
Spreader
Gear Oil
reducer
MOBIL gear
629 is
Reggiana recommend 　　　 ISO-L CKC150 　　
ed by ISO
6743-6
Hydraulic
Hydraulic oil
system
ISO-L HV32
　 ISO 6743-4 ISO-L HV46
ISO-L HV68 　　
Brake
Hydraulic oil
system

Table 5–9 Oil Standard (continue)

Filling Lubricant
°C -30 -20 -10 0 +10 +20 +30 +40 +50
position quality
°F -22 -4 +14 +32 +50 +68 +86 +104 +122
Only for
drive axle
DONAX TD
service
** HV (94%)
brake and 　　　 DONAX TD 5W-30 　　
+ LZ9990A
the external
(6%)
cooling
system
Automotive light diesel fuel complaint with the EN 590 standard (GB/T19147 in
China). 0# diesel fuel is recommended for summer and -35# for winter. The
Fuel
Stage-IV diesel engine should use the low-sulfur diesel fuel with the ppm below
15.
Grease 2# lithium grease/extreme pressure lithium grease
Engine Antifreezes based on ethylene glycol or propylene glycol, and the Volvo engines
coolant need special VCS coolant.
Refrigerat
ing oil (air PAG100 or SP-10 (select based on the type of refrigerating oil on the nameplate
conditioning of the compressor)
system)
Refrigerant
(air
R134a
conditioning
system)
Urea (only
Must be used in accordance with ISO 22241-1 Standard special urea solution for
Stage-IV
AUS32.
product)
* If the friction plate contains graphite, this oil is not applicable.
** No additives
Note: DEXRON is a registered trademark of the General Motors Company (GM).
NOTICE
Risk of damage!
Failure to follow this alert will result in machine malfunction or damage.
• Before starting the engine, the oil should be preheated to the lowest temperature of the
lubricant viscosity grade.
• The user is not allowed to change the oil of the type incompliant with the quality requirements,
or the consequences shall be borne by the user!

5.3.2 Oil capacity
5.3.2.1 Oil capacity
NOTE：
The capacity in the table is for reference. An oil level indicator is provided on the side of the oil tank
for checking the oil level.
5.3.2.2 Oil Capacity of SRSC45V5 Reach Stacker
Table 5–10 Capacity Table
Item Oil to fill Oil capacity ( L) Notes

Hydraulic oil Anti-wear hydraulic oil 800L Capacity of hydraulic
VG68 (hot) oil tank: 605L
Anti-wear hydraulic oil Fuel tank capacity:
VG46 (summer) 650L
Anti-wear hydraulic oil Brake oil tank
VG32 (winter) capacity: 145L
Brake oil TD 5W-30 150L Quantitative filling
Fuel Light diesel fuel 0# 700L Select oil based on
(summer) the season
Light diesel fuel -20#
(winter)
Antifreeze Special for Volvo, VCS 64L Check the Minimum
Coolant Air Temperature table
Required antifreeze for the delivery place,
ratio for minimum air adjust the antifreeze
temperature ( ratio as needed, and
(Original liquid: tap water is not
distilled water): allowed. When the
machine is stopped,
4:6 -24°
fill it slowly to allow
5:5 -37° the air out. After
6:4 -45° starting the machine
for a while, open all
breather cocks for a
short time to bleed the
air. Keep the liquid
level between the MIN
and MAX marks of the
expansion tank.
Engine oil API CI-4 Volvo VDS-3 36L Quantitative filling
certified
Table 5–10 Capacity Table (continue)
Item Oil to fill Oil capacity ( L) Notes

Torque converter Total MPV 65L Quantitative filling
transmission oil
Drive axle lubricant GL-5 80W/90 73.5+11*2L Select the oil product
GL-5 85W/140（≥ based on the air
30℃） temperature of the
destination. When
filling the oil, first open
the oil drain ports at
both ends and in the
middle of the axle,
drain the residual oil
in the axle, and then
fill the oil (till oil
overflows from each
filler port)
Spreader reducer Gear oil ISO 6743-6 RR:3L Before filling, the
lubricant residual oil in the
reducer should be
drained, and
quantitative filling is
required
Air conditioning Refrigerant R134A 1600±30g Quantitative filling is
refrigerant filling required. Drain the old
refrigerant before
refilling
5.3.3 Hydraulic oil
5.3.3.1 Hydraulic oil management
As an important part of the hydraulic system, the hydraulic oil is used to transfer, convert and con-
trol the energy. Furthermore, it also plays a role in system lubrication, rust prevention, corrosion
protection and cooling.
Whether the hydraulic oil is clean not only affects the working performance of the hydraulic system
and the service life of hydraulic components, but also determines whether the hydraulic system
can work normally.
The hydraulic oil in the tank should be inspected every six months via appearance evaluation and
oil analysis.
70% of the hydraulic system faults are due to improper hydraulic oil management. Therefore, if this
management can be improved, the faults in the hydraulic system can be greatly reduced.

Regarding the hydraulic oil management, please pay attention to the following points:
• Prevent debris from mixing into the oil.

• Change the oil as soon as possible when finding poor oil quality.
• Replace the filters as required.
• Ensure the specified amount of oil in the tank as well as the oil quality.
• Ensure smooth cross-ventilation of cooling air in the oil cooler to prevent abnormal oil
temperature rise.
• Plug the removed hydraulic components (pumps, valves, hoses, etc.) with screw plugs (or
wrapped in clean plastic bags), so as to prevent impurities from entering.
WARNING
Risk of injury！
Failure to follow this will result in injury.
• The oil is toxic. Avoid skin contact with oils.
• If you swallow it (even in small doses) accidentally, avoid vomiting and seek medical care
immediately.
• If the skin contacts with the oil accidentally, wash the skin immediately with soap and hot water
but not gasoline or alcohol.

5.3.3.2 Hydraulic oil， checking
• Park the machine safely. See “Parking

requirements” on page 2-48 and “Turning
off the engine” on page 2-49
Fig.5-1 Park Ground
Take about one liter of oil sample from the oil tank every month, fill it into several clean test tubes,
and compare them with the new oil after 10-day and 1-month storage, and visually inspect the col-
or, transparency, mixing degree of impurities, sediments and other items, and then filter the hy-
draulic oil with the filter paper to obtain the impurities.
The contamination degree of the hydraulic oil is usually judged by comparing the oil to be eval-
uated with clean new oil and observing the difference in color and whether it is turbid and with dust
or sediments.
Simple assessment methods practical to use on site are described as below.

Table 5–11 Hydraulic Oil Inspection
Appearance & Contamination

Odor Treatment measures
Color status
Transparent without Normal No contamination Continue to use
change
Transparent with Normal Mixed with other oils Still can be used if the viscosity
faded color is qualified
Transparent and Normal Mixed with metal Filter or change the oil
shiny debris
Transparent with Normal Mixed with impurities Filter or change the oil
black spots
Dark brown Smelly Oxide impurities Change all oil
Milky Normal Mixed with air or water Separate water or change oil
More stringently, you can inspect viscosity, oxidation resistance, moisture content, sediment, color,
specific gravity and flash point of the hydraulic oil based on manufacturer's standards. It is more
advantageous to determine the time to change the hydraulic oil based on the inspection results
and the time taking the oil sample.
5.3.4 Urea
5.3.4.1 Urea
The urea solution for vehicles is a colorless,

transparent and clear liquid with a concentra-
tion of 31.8~33.2%, which is used to reduce
the nitrogen oxides.
In order to reduce nitrogen oxide emissions

and protect the environment, fill the reach
stacker equipped with a Stage IV engine with
the urea for vehicle.
Fig.5-3 Urea Tank
5.3.4.2 Quality requirements for urea
The special AUS32 urea solution meeting the ISO 22241-1 standard must be used.

5.3.4.3 Storage time of urea
In order to reduce decomposition, the urea solution shall be stored in a place with the ambient tem-
perature not exceeding 25℃, and long-term storage shall be avoided as much as possible.
Table 5–12
Storage of Urea for Vehicles

Storage temperature (℃) Safe storage time (months)
≤ 10 36
11–25 18
26-30 12
31-35 6
＞ 35 Test before using
5.4 Lubricating points

5.4.1 Lubricants
Lubricants are applied to ensure smooth rotation and sliding of all parts. Without sufficient lubrica-
tion, the parts may get stuck and have excessive wear. Lubricants are essential for the normal op-
eration of the machine.
Lubricants not specified by Sany Marine are not allowed. For specific requirements in lubricants,
see “Oil specifications” on page 5-15
Method of applying lubricant (grease):
Before applying the grease, clean the grease fitting, and inject grease into the fitting with a grease
gun until the old grease is squeezed out. Clean up excessive grease.
NOTE：
For sliding surfaces, scrape off the old grease firstly, and apply new grease on the contact surfaces
of the sliders.
5.4.2 Lubrication points of the whole

machine
The movable coupling shafts, the boom and the spreader sliders are the key lubrication points. Re-
fer to the schematic diagram of the lubrication points of the whole machine for specific points.

Fig.5-4 Lubrication Points of the Whole Machine
Table 5–13 Lubrication Points of the Whole Machine
Serial number Position Maintenance period

1 Steering axle (13 points)
Including lubrication points on the pitch
2
cylinder and the pin shaft (4 points)
3 Boom pin shaft (4 points)
4 Boom telescopic arm slider (14 points)
5 Spreader telescopic surface (6 points)
6 hinge points of spreader and boom (2 points)
7 Spreader damping cylinder lugs (4 points)
Spreader side movement cylinder lugs (4 60-hour work or weekly
8
points)
9 Spreader side movement surface (4 points)
10 Spreader telescopic cylinder lugs (4 points)
11 Spreader twist lock (8 points)
Spreader upper turntable slewing bearing (4
12
points)
13 Drive shaft (3 points)
14 Parking brake (1 point)
15 Diesel engine (1 point) 250-hour work
16 Brake cylinder (1 point)
17 Drive axle wheel-side reducer (2 points) 1,000-hour work or 1 year
18 Drive axle main reducer (1 point)

Table 5–13 Lubrication Points of the Whole Machine (continue)
Serial number Position Maintenance period

19 Hydraulic oil tank (1 point) 2,000-hour work or 1 year
20 Torque converter (1 point) 1,000-hour work or 1 year
21 Engine radiator (1 point) 1,000-hour work or 1 year
22 Spreader slewing reducer (1 point) 1,000-hour work or 1 year
5.5 Scheduled maintenance

5.5.1 Daily maintenance items
Table 5–14
Maintenance
Maintenance item Page
part
Engine Check the engine oil level See “Oil level, check and top up”
on page 5-54
Check for leakage of coolant, oil, etc. See “Charge air pipe, check” on
page 5-35
Check the drive belt See “Drive belt, check” on page 5-
36
Check the air filter indicator See “Air filter, check” on page 5-42
Check the quality and level of the See “Water quality” on page 5-72
cooling water
Transmission Check the transmission oil level See “Transmission oil level,
system checking” on page 4-6
Check for oil leakage See “ Transmission, checking” on
page 5-97
Check the fixing bolts of the drive shaft See “Mounting bolts of propeller
shaft, checking” on page 5-85
Check whether the fixing bolts and See “Mounting bolts and mounting
fixing seat are loose pad, check” on page 5-94
Steering axle Check and tighten the wheel hub bolts See “Daily check” on page 5-112
Tyres and rims Check the tyres See “ Precautions for tires” on
page 5-118 and “ Rim, checking”
on page 5-122
Boom system Check the basic boom See “Basic boom, check” on page
5-137

Maintenance
part
Inspection and lubrication of the boom See “Wear pads, check” on page
slider 5-138
Check the pitch cylinder See “ Pitch cylinder, checking” on
page 5-140
Maintenance of the cylinder piston rod See “ Maintenance of the cylinder
piston rod” on page 5-141
Spreader Check the twist lock See “Twistlock, checking” on page
system 5-142
Hydraulic Check the hydraulic hose and See “Hydraulic oil circuit, check” on
system connection joints for leakage page 5-178
Electrical Check the battery See “Battery, checking” on page 5-
System 184
Check whether all working lamps and See “All working lights and
indicator lamps are working properly indicators, checking” on page 5-
188
5.5.2 Maintenance every 50 hours
Table 5–15
Maintenance
part
Drive axle Check the drive axle and brake See “ Oil leaking of drive axle
components for oil leakage and brake components,
checking” on page 5-100
Clean the breather connector See “ Breather connector,
cleaning” on page 5-103
Check the main reducer See “ Main reducer, checking”
on page 5-106
Check the wheel-side reducer See “ Wheel-side reducer,
Steering Axle Lubricate the steering axle See “ Steering axle, lubricating”
on page 5-114
Spreader system Check the fixing bolts of the spreader See “Fixed bolts of spreader
rotating gearbox rotating gearbox, checking” on
page 5-146

Maintenance
part
Air Conditioning Check the tightness of the compressor See “Air conditioner belt，
System belt and make adjustments in time checking” on page 5-153
Check the air return grid screen and the See “Air return grid screen and
evaporator screen the evaporator screen,
Check the refrigerant See “Refrigerant, checking” on
page 5-155
Check the heat exchange fins of the See “Cleanness of heat-
evaporator and the condenser cores exchanger plate in evaporator
and condenser, checking” on
page 5-158
Check whether there is oil and fluorine See “Compressor and air
leakage on the compressor and air conditioner pipeline fittings for
conditioner pipeline joints oil and refrigerant leakage，
Check whether the pipeline is well
See “Pipelines, fittings and wire
secured, and whether it is too close to
harness, checking” on page 5-
heating parts, rotating parts and the
161
connecting rod of the control rocker arm.
Check whether the fixing bolts of the air See “Tightening of the
conditioner unit are tightened. compressor bolts, checking” on
page 5-162
Table 5–16
Maintenance
part
Engine Clean the air filter See “Air filter, clean” on page 5-44
Change the engine oil See “Engine oil, change” on page
5-55
Check the intake and exhaust systems See “ Air leaks, check” on page 5-
for air leakage faults 81

Maintenance
part
Replace the oil filter See “Oil filter or the bypass filter,
replace (VOLVO engine)” on page
5-57 and “Oil filter, replace
(CUMMINS engine)” on page 5-
59
Replace the fuel filter See “ Fuel filter, replace (VOLVO
engine)” on page 5-64 and “Fuel
filter, replace (CUMMINS engine)”
on page 5-66
Replace the fuel pre-filter See “Fuel pre-filter, change
(VOLVO engine)” on page 5-68
Drain condensate See “Condensate, drain (VOLVO
engine)” on page 5-61 and “
Condensate, drain (CUMMINS
engine)” on page 5-63
Drive axle Check the bolts connecting the drive axle See “Mounting bolts of drive axle
and the frame to the frame, checking” on page
5-98
Check the bolts connecting the drive axle See “ Mounting bolts of drive axle
and the drive shaft to the propeller shaft, checking”
on page 5-99
Steering axle Check the knuckle pin See “ Knuckle pin, checking” on
page 5-116
Check the steering knuckle See “ Steering axle cradle,
maintaining” on page 5-117
Spreader Lubrication of twist lock See “Twistlock, lubricating” on
system page 5-144
Inspection of the twistlock sensor and See “Sensor / Indicator of
indicator twistlock, checking” on page 5-
145
Check the ear pads of spreader See “Wear pads of spreader,
Inspection and lubrication of slide See “Wear pads of spreader,
Air conditioning Fill the refrigerant See “Refrigerant/refrigeration
system oil，filling” on page 5-156
Hydraulic Check the hydraulic oil level See “Hydraulic oil level, checking”
system on page 5-163

Maintenance
part
Check the hydraulic oil See “Hydraulic oil， checking” on
page 5-21
Inspection and adjustment of the parking See “Parking brake unit, checking
brake and adjusting” on page 5-170
Electrical Clean and tighten the terminals See “Wiring terminal, cleaning
system and tightening” on page 5-190
Charge the battery See “Battery, charging” on page
5-185
Clean the battery See “Battery, cleaning” on page 5-
182
Check and adjust the wipers See “Wiper, adjusting” on page 5-
189
Table 5–17
Maintenance
part
Engine Replace the air filter See “Air filter, replacing ” on
page 5-46
Bleed air in the fuel system See “Fuel system, bleed
(VOLVO engine)” on page 5-
70
Replace the urea filter element See “Urea filter element,
replacing” on page 5-52
Check the turbocharger See “Turbocharger, check” on
page 5-82
Transmission Check the drive shaft and add lubricant to See “Propeller shaft,
system the universal joint lubricating” on page 5-87
Replace the brake oil and the brake oil filter See “Transmission oil filter,
elements change” on page 5-91
Check the speed sensor See “Speed sensor, check” on
page 5-88
Steering axle Check steering axle components See “ Steering axle
components, checking” on
page 5-115

Maintenance
part
Tyres and rims Inflate the tyre See “ Tyre, inflating” on page
5-119
Electrical Check the cables, especially the wiring See “Cable abrasion (specially
system harness near the engine, for abnormal wear around the engine), checking”
on page 5-191
Table 5–18
Maintenance part Maintenance item Page

Transmission Change the gearbox oil See “Transmission oil, change”
system on page 5-92
Drive axle Check and change the drive axle oil See “Main reducer oil, changing”
on page 5-107
Check wheel hub nut See “Wheel hub nut, checking
and tightening” on page 5-111
Check the brake pads and braking See “ Brake pads and braking
function function, checking” on page 5-
104
Table 5–19

Hydraulic system Check the brake system accumulator See “Brake system
accumulator, check” on page
5-175
Charge the accumulator See “Accumulator, charge”
on page 5-176
Table 5–20

Engine Clean the radiator See “Radiator, clean” on page
5-77


Change the drive belt. See “Drive belt, replace
(engine option VOLVO)” on
page 5-38
Change the alternator belt. See “Alternator belt, replace
(engine option VOLVO)” on
page 5-39
Check the fan driving idler pulley See “Fan drive gear train and
hub” on page 5-49
Transmission Calibrate the TE transmission See “ TE Transmission
calibrating” on page 5-95
Hydraulic system Replace the hydraulic oil in the oil tank See “Hydraulic oil, change” on
page 5-166
Remove the impurities in the oil tank See “Hydraulic oil tank,
cleaning” on page 5-167
Replace the air filter of the hydraulic See “Air filter element, replace”
system on page 5-164
Replace the oil return filter element “Oil return filter element,
replace” on page 5-168
Replace the brake oil filter element and
See “Brake oil filter, checking
brake oil (if there is a separate brake oil
and replacing” on page 5-172
tank)
Table 5–21

Engine Check the water pump See “Coolant pump, checking”
on page 5-51
Check the shock absorber See “Shock absorber,
Change the coolant See “Coolant, drain” on page
5-76 and “Completely empty
system, fill” on page 5-74
Flush the cooling system See “Cooling system, clean”
on page 5-79


Tyres and rims Replace the wheel rim See “ Wheel rim, removing”
on page 5-125 and “ Wheel
rim, installing” on page 5-127
Replace the tyre of drive axle See “ Drive axle tyre,
removing” on page 5-128and “
Drive axle tyre, installing” on
page 5-131
Replace the tyre of steering axle See “ Steering axle tyre,
removing” on page 5-133 and
“ Steering axle tyre, installing”
on page 5-135
5.5.9 Special instructions for the first maintenance
The first maintenance of the engine, the gearbox and the drive axle should performed according to
the time and content specified in the following table:
Table 5–22
Mainte- Time for first

nance part maintenance
Engine Replace the oil filter See “Oil filter or the bypass filter,
100h replace (VOLVO engine)” on page
5-57
Replace the fuel filter See “ Fuel filter, replace (VOLVO
100h
Replace the fuel pre-filter See “Fuel pre-filter, change
100h
(VOLVO engine)” on page 5-68
Transmis Change the transmission See “Transmission oil filter,
100h
sion oil filter element change” on page 5-91
Drive axle Change the main reducer See “Main reducer oil, changing”
100h
oil on page 5-107
Change the wheel-side See “ Wheel-side reducer,
100h
reducer oil checking” on page 5-109
Replace the brake oil See “Brake oil filter, checking and
100h
filter replacing” on page 5-172

NOTICE
Improper maintenance may cause machine damage and undesirable operation.
• The first maintenance time applies to the new equipment, and the above components after the
replacement or overhaul.
5.6 Engine
5.6.1 General engine inspection
5.6.1.1 General engine inspection

requirements” on page 2-48 and “” on page
Fig.5-5 Park Ground

Develop the habit of performing "visual in-

spection" of the engine and engine compart-
ment before starting the engine and after
completing the operation. This helps you dis-
cover some abnormalities that have occurred
and will occur in time.
Pay special attention to leakage of lubricant,

fuel and coolant, loose bolts, worn or loose
belts, loose joints or damaged hoses and ca-
bles. This inspection only takes a few mi-
nutes, but can avoid major downtime and Fig.5-7 Check for Oil Leakage
costly repair.
WARNING
Risk of fire!
Fuel, lubricant or grease accumulated on the engine or in the engine compartment is a fire
hazard, which must be removed immediately once found.
• If there is leakage of lubricant, fuel or coolant, the root cause must be found and the problem
must be removed before starting the engine.
• Do not use a high-pressure water gun to clean the interior of the equipment, which may
damage the radiator, pipes, seals, etc. Compressed gas is recommended to clean the
equipment.

5.6.1.2 Charge air pipe, check

Fig.5-8 Park Ground
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.5-10 Charge Air Pipe

5.6.1.3 Drive belt, check


Perform the inspection when the belt is still

hot after running.
1. Disconnect the main switch, and check to

make sure that the engine is not connected to
the system voltage.
2. Remove the fan guard and fan ring around

the cooling fan.
3. Check the condition of the drive belt.

Replace it if necessary.
• Replace the belt if it is worn or chipped.
Tiny cracks across the width of the belt are
acceptable. However, cracks along the
length of the belt are not allowed. Fig.5-13 Check the Drive Belt - VOLVO
• Adjust the belt with a smooth and shiny TAD1151
surface, which indicates that the belt slips.
If the belt is installed and tightened
correctly, the pulley and belt will wear
evenly.
WARNING
Failure to follow this will result in personal
injury.
• Check the drive belt before starting the
machine.
• Run for 5 minutes after the initial
installation, and then recheck and adjust
the belt tension.
• Replace the belt at any time when it is
worn or cracked.
Fig.5-14 Check the Drive Belt - CUMMINS
QSM11

5.6.1.4 Drive belt, replace (engine op-

tion VOLVO)


The alternator belt and drive belt come with

automatic belt tensioners with no adjustment
needed. Check the condition of the drive belt.
1. Disconnect the main power switch, and

have a check to make sure that the engine is
not connected to the system voltage.

the cooling fan.
3. Remove the belt guard.
4. Insert a 1/2" square wrench into the belt

tensioner [1]. Lift the wrench bar to remove
the drive belt.
Fig.5-17 Replace the Drive Belt - VOLVO
5. Move the drive belt around the fan and
TAD1151
remove it.
1. Belt tensioner
6. Check to make sure that the pulley is clean
and undamaged.
7. Put a new drive belt around the fan.
8. Lift up the 1/2" wrench bar and install the

new drive belt.
9. Install the belt guard.
10.Install the fan guard and the fan ring

around the cooling fan.
11.Start the engine to check the functions.
5.6.1.5 Alternator belt, replace (engine

option VOLVO)
CAUTION
Risk of personal injury or machine damage！
Failure to follow this will result in personal injury or machine damage.
• Check the condition of the alternator belt carefully and regularly.
• Always replace drive belts that appear to be worn or broken.



1. Disconnect the main switch, and check to

make sure that the engine is not connected to
the system voltage.

the cooling fan.
3. Remove the belt guard.
4. Put a 1/2" square wrench into the belt

tensioner [1]. Lift up the wrench and remove
the water pump drive belt.
5. Put the 1/2" square wrench into the belt

tensioner [2]. Press down on the wrench to
remove the belt of the alternator.
Fig.5-20 Replace the Belt of the Alternator -
6. Check to make sure that the pulley is clean VOLVO TAD1151
and undamaged.
1. Belt tensioner 2. Belt tensioner
7. Press the 1/2" wrench down into the belt
tensioner [2], and then install a new drive belt
of the alternator.
8. Pull the 1/2" wrench down into the belt

tensioner [1], and then reinstall the drive belt
of the water pump.
9. Install the belt guard.
10.Install the fan guard and the fan ring

around the cooling fan.
11.Start the engine and perform a function

test.

5.6.1.6 Air filter, check


NOTE：
• The maintenance and replacement cycles
are for reference only, and depends on the
dust concentration in the working
environment of the vehicle.
• The service life of the filter elements ranges
from the 200 working hours (in desert
environment) to 1600 working hours (on
clean road).
Fig.5-23 Air Filter Status Indicator
5
4
Fig.5-24 Air Filter
1. Safe filter element 2. Filter element

3. Cover clamp 4. Coarse ash outlet
5. End cap
Check whether the air filtration elements of

the intake system are blocked:
Visually check whether the air filtration status

indicator on the filter element is red on. When
the air filtration status indicator is red on,
clean the filter elements immediately, see “Air
filter, clean” on page 5-44.
Check the following items before replacing the filter elements:
1. The condition of the seal ring.
2. The filter element and the hoses on the engine.

3. Place a light bulb inside the filter element to detect tiny wear and cracks by means of the light;
NOTICE
The crack of filter element may cause machine damage.
• Replace the filter element immediately if there is crack, deformation or perforation.
4. There should be no dust accumulated on the filter element sleeve.
5. The filter element should be accurately installed on the filter element sleeve.
6. The coarse ash outlet [4] should be cleaned regularly to remove residues. Make sure that the
pipe is not damaged, and replace it if necessary.
5.6.1.7 Air filter, clean
When the air filtration status indicator is red

on, clean the filter elements immediately in
the steps below:
NOTE：
Take care to avoid dust entering the filter ele-
ment seat (or the filter element mesh if in-
stalled) during cleaning.

1. Park the machine safely. See “Parking

2. Loosen the cover clamp [1], remove the fil-

ter element cover [3], and pull out the filter ele-
ment [2].
1
3. Wipe the inner wall of the clean air filter
case with a clean cloth, and then remove the
safe filter element.
NOTICE 2
3
Risk of engine worn out!
Failure to follow this alert will result in engine
worn out.
• When disassembling the safe filter Fig.5-27
element, take care avoid the dust on the
Table 5–23
filter element entering the air inlet pipe,
which may cause early engine wear. 1. Cover clamp 2. Filter element
3. Filter cover
4. Clean the filter element with pressurized air.
5. Pressurize the air to 3 Bar, and place the air

nozzle 5 cm from the filter element to clean it
from the inside to the outside.
6. Never knock the filter element on a hard

surface.
Fig.5-28
5.6.1.8 Air filter, replacing
NOTICE
If the filter element is not installed correctly, unfiltered air will be taken in, which could cause
damage to the engine. When the filter element is inserted, if the rubber at the top swells or the
outer filter element is not pushed in straightly, and the cover is forcibly assembled to the cover
clamp, the buckle and the air cleaner case could be damaged.
• The filter element must be installed correctly and carefully. Do not force installation.
• If possible, please contact Sany Marine to assign professional maintenance personnel to
complete the above operations.


off the engine” on page 2-49.
1. Remove the old air filter.
2. Install the new air filter.
3. Check and confirm that the clamps on the

engine intake pipe are connected properly.
Fig.5-31

4. Press the switch at the top of the air filter

indicator.
Fig.5-32
Fig.5-33

5.6.1.9 Fan drive gear train and hub

requirements” on page 2-48 and “Turning off
the engine” on page 2-49
2. Check whether the driving wheel, idler

wheel, tensioning wheel and other parts of the
cooling fan gear train are damaged. Check 1
whether there is any foreign body between
the belt wheel and the belt. If there is, please
clean it up in time.
3. Check whether the fan circumferential ring

is in good condition and whether there is any
abnormality such as crack. 2
4. Check the belt, see “Drive belt, check” on

page 5-36. Fig.5-36
1. Fan Hub 2. Drive Gear Train

NOTICE
Failure to follow this will result in machine damage.
• Check the machine for timely maintenance.
• The above checks must be carried out when the engine stops running.
5.6.1.10 Shock absorber, checking


CAUTION
Risk of malfunction!
After long-term use, the silicone oil in the
shock absorber gradually turns into a solid,
and the shock absorber will fail. The failure of
the shock absorbers can lead to severe
failure of the engine or the transmission
system.
• Check the shock absorber [1] for silicone
oil loss, pits or shaking. 1
• Check the thickness of the shock absorber TY-1610004-1
to see if the shock absorber cover is Fig.5-39

deformed or raised.
1. Shock absorber
5.6.1.11 Coolant pump, checking


2. Remove the belt wound on the coolant

pump and rotate the belt pulley to observe
whether there are abnormal phenomena such
as jacking and eccentricity.
3. Check the installation base of the pump for

any abnormal leakage.
Fig.5-42
5.6.1.12 Urea filter element, replacing
CAUTION
Failure to follow this alert will result in machine damage.
• When replacing the filter element, observe whether the internal thread of the filter element
cover is damaged. If there is any defect, replace a new filter element cover.
• The urea filter element cover does not need to be sealed with an O-ring.
WARNING
Risk of injury!
Failure to follow this alert will result in injury for eyes.
• The urea solution contains urea, so do not put it into the eyes.
• If such a case occurs, rinse the eyes with clean water for 15 minutes immediately.


2. Unscrew the urea filter element cover,

which can be done with the help of a 27 mm
wrench.
3. Take out the filter element balance tube.
4. Take out the old urea filter element. The dis-

posable tool coming with the new filter ele-
ment can be used to assist in removal and
insert the new filter element into the urea sup- Fig.5-43 Park Ground
ply module.
5. After replacing the filter element, re-tighten

the filter element cover with a torque of 20 N.
m [177 in-lb].
Note: The replacement cycle of the filter ele-

ment of the urea supply module is 4,500 h or
3 years.

5.6.2 Lubrication system
5.6.2.1 Oil level, check and top up


The oil level must be in the marked range on

the dipstick, and must be checked before 1
starting for the first time every day.
• Fill up the oil through the filter opening [1].

Have a check to make sure that the correct
oil level is reached. If the engine is not run-
ning, wait a few minutes to allow the oil to
flow down into the oil pan.
• Do not exceed the maximum oil level. Only
fill the oil of the recommended grade.
• Only measure the oil level when the ignition
is on (instead measuring continuously
during operation).
Fig.5-47
1. Filter opening
5.6.2.2 Engine oil, change
CAUTION
Risk of burnt out!
Hot lubricating oil and hot surfaces can cause burns.
• The lubricating oil should be changed when the engine is not cool yet.


1. Connect the drain hose to the oil drain

pump and check to make sure that there is no
leakage.
2. Pump out the oil (or remove the bottom

drain plug to drain the oil). Collect all the old
oil and old filters and send them to the
recycling station for destruction.
3. Remove the drain hose (or install the

bottom drain plug).
4. Fill in oil.
Fig.5-50

NOTICE
Risk of environmental pollution！
Draining hydraulic oil directly onto the ground can do harm to environment and result in fines or
punishment.
• Dispose of waste lubricant and lubricant filter according to environmental requirements.
5.6.2.3 Oil filter or the bypass filter, re-

place (VOLVO engine)
CAUTION
Risk of burns!
Hot engine oil and surfaces can cause burns.
• Check the engine oil temperature to avoid overheating.


1. Clean the oil filter holder [2].

2
2. Remove all oil filters with applicable oil filter
extractor [1].
3. Clean the contact surface of the oil filter

holder. Make sure no old oil seal left. Carefully
clean the inner circumference of the
protective bevel [2] on the oil filter holder.
4
4. Apply a thin layer of oil to the seal ring of
the new oil filter.
5. Install the new oil filter [3]. After the two full- 3
3
flow filters (on the right side of the figure) 1
reach the bottom, tighten them by 1/2– 3/4

turns. Tighten the bypass filter [4] when it
reaches the bottom by 3/4 – 1 turns. Fig.5-53
6. Fill up the oil, start the engine and allow it to 1. Oil filter extractor 2. Protective bevel
run for 20-30 seconds. 3. Oil filter 4. Bypass filter
7. Shut down the engine, check the oil level,

and filled it up as required.
8. Check the sealing condition around the oil

filter.
Please pay attention to the following items when replacing the oil filter element:
Table 5–24
Serial
Phenomena Cause
number
1 The oil level rises Water or coolant enters the lubrication system
2 There are metal particle in There is a large loss on the bearing bush surface
the oil
3 The oil loses rapidly The piston ring is damaged, so the oil enters the
combustion chamber, or leaks from the joint and
edge

5.6.2.4 Oil filter, replace (CUMMINS

engine)
CAUTION
Risk of burns!
Hot engine oil and surfaces can cause burns.
• Check the temperature of oil and surface
to avoid overheating.
Fig.5-54
1. Valve 2. Coolant filter

3. Oil filter


1. Start the engine.
2. Remove the filler cap.
3. Put an oil container below the filter.
4. Remove the drain plug on the engine and drain the old oil.
5. Clean the periphery of the oil filter.
6. Remove the oil filter.
7. Apply a thin layer of oil to the seal ring of the new oil filter.
8. Install the new oil filter and tighten it for 1/2 turn when it reaches the bottom.
9. Install the drain plug with a tightening torque of 88Nm.
10.Fill up the engine oil, start the engine to idle, and check the drain plug and filter for leakage.

11.Shut down the engine and check the oil level. Fill up the oil if necessary.
12.Remove the oil container and dispose of the waste oil in the container in accordance with the
requirements for environmental disposal of waste oil.
5.6.3 Fuel system
5.6.3.1 Condensate, drain (VOLVO

engine)


1. Place a collection container in the fuel filter

to collect condensate and fuel.
2. Open the drain plug in the base of the fuel

pre-filter [1].
3. But tighten the drain plug when the fuel

without water starts to flow out.
Fig.5-59
1. Fuel pre-filter

5.6.3.2 Condensate, drain (CUMMINS

engine)


When the fuel passes through the fuel filter [3]

in the fuel tank pipeline [1], the water will sink
to the bottom of the filter to prevent water from
entering the fuel injection system when the
fuel passes through the delivery pipeline [2]. 1
Discharge condensate frequently.
2
1. Open the drain plug [A] at the bottom of the 3
filter.
2. Discharge the condensate.
3. Re-tighten the drain plug by hand.
35702_10-05
Fig.5-62
1. Fuel tank pipeline 2. Delivery pipeline

3. Fuel filter A. Drain plug
5.6.3.3 Fuel filter, replace (VOLVO

engine)
NOTICE
Risk of damage!
Failure to follow this may bring impurities into the fuel system and cause operation failure or
damage.
• Do not fill fuel into the new fuel filter before installation.
• Clean the area around the fuel filter, and replace the fuel filter timely.
• The fuel filter should be replaced when the engine is in the cold state, thus avoiding the risk of
fire due to fuel splashed on hot surfaces or electrical components.
• Sags soaked in fuel shall be stored in a way not to cause a fire.



1. Clean the area around the fuel filter.
2. Remove the filter with a suitable filter

remover. Collect splashed fuel with a
container.
3. Clean the contact surface of the filter

holder.
4. Lubricate the seal with diesel fuel and

install a new fuel filter. Tighten the fuel filter
according to the instruction on it.
5. Purify the fuel system when necessary.
6. If there is a dehydrator, replace the filter in

the dehydrator when replacing the fuel filter,
Fig.5-65
and clean the dehydrator in the plastic bowl
under the filter with soft cloth.
5.6.3.4 Fuel filter, replace (CUMMINS

engine)
WARNING
Risk of fire!
Failure to follow this alert will result in fire.
• The fuel filter should be replaced in a cold
state to avoid fire.
• Wear the protective gloves during work.
Avoid direct skin contact with fuel.
TY-1610011-1
Fig.5-66


1. Place a oil collection container under the fuel filter.
2. Clean the fuel filter and the periphery of the filter seat.
3. Disconnect the fuel filter and the water level alarm switch.
4. Remove the fuel filter with a filter wrench.
5. Replace the threaded joint seal ring and lubricate it.
6. Fill fuel into the new filter.
7. Install the filter on the filter holder. Turn the filter until the seal ring contacts with the surface of
the filter seat.
8. When the seal ring contacts with the surface of the filter seat, tighten the filter for another 1/2 to
3/4 turns.

9. Turn on the main power supply and start the engine. Check the sealing condition around the fuel
filter.
10.Shut down the engine. Remove the fuel collection container and dispose of the waste fuel and
filter according to environmental protection requirements.
5.6.3.5 Fuel pre-filter, change (VOLVO

engine)


2. Remove the cable from the dehydrator

sensor.
3. Remove the dehydrater filter from the filter

holder. Collect splashed fuel with a container.
4. Remove the lower part of the dehydrater

from the filter.
5. Clean the lower part of the dehydrator with

a soft cloth. Check and make sure that the
lower drain hole is not blocked.
6. Install a new seal in the lower part and lubri-

cate this seal with diesel fuel. Reinstall the
lower part of the filter.
7. Lubricate this seal with diesel fuel. Screw

the filter into the filter holder by hand until the
rubber seal just contacts the contact surface.
Tighten it for another half turn, and no further Fig.5-71
tightening allowed.
8. Connect the cable to the dehydrator sensor.
9. Purify the fuel system when necessary.

5.6.3.6 Fuel system, bleed (VOLVO engine)

The system needs no air purging unless it is completely dry. Then purge the air with the hand
pump on the fuel filter holder.

5.6.4 Cooling system
5.6.4.1 Description of cooling system
NOTICE
Risk of damage!
Failure to follow this alert will result in engine erode.
• A coolant with an appropriate mixture concentration must be used all year round. This is
required even without non-freezing risk to ensure that the engine has sufficient corrosion
resistance.
• If improper coolant is used, or the requirements for mixing the coolant are not followed, the
warranty claims for the engine and its accessories can be rejected.
• The effect of the anti-corrosion additives decreases over time, so the coolant must be changed
regularly.
As the internal cooling system of the engine, the fresh water system keeps the engine running at
the correct temperature. It is a closed system that must always be filled with mixed coolant to pre-
vent corrosion, cavitation and frost fracture inside the engine. It is not allowed to use preservatives
alone in the engine. Never use water as the coolant only.
5.6.4.2 Coolant, mix
NOTICE
Risk of pollution!
It is extremely important to regularize the use of coolants.Otherwise, it may result in environment
pollution.
– All coolants are dangerous and harmful to the environment. NO waste.
– Coolants are flammable.
– NEVER mix coolants of different types!
Mixing ratio of coolant:
40% concentrated solution + 60% distilled

water (with the freezing point of -24°)
Do not use coolant with the concentration

over 60%, which has poor cooling effect and
increases the risk of overheating, thus com-
promising the antifreezing capability.
TY-1405095-1
Fig.5-74
WARNING
Risk of overheating!
It is extremely important to fill the system with the coolant in correct concentration. Or it will result
in overheating.
• The coolant must be mixed with distilled and deionized water. The water quality must meet the
requirements of Sany Group. See “Water quality” on page 5-72.
• The coolant should be mixed properly in a separate clean container to ensure that the solution
is evenly mixed before filling into the system.
• It is not allowed to fill the concentrated solution to the engine or the water tank directly.
5.6.4.3 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

TY-1405096-1
Manganese (acc. to ASTM D858) .... < 0.05
Fig.5-75 Water
ppm
Conductivity (acc. to ASTM D1125) .. < 500

μS/cm
Organic content, CODMn (acc. ISO8467) ....

< 15 mg KMnO4/l

5.6.4.4 Coolant level, check and top up
WARNING
Failure to follow this alert will result in
personal injury.
• It is not allowed to open the filler cap when
the engine is hot under any circumstances.
Otherwise steam or hot fluid may be
ejected.
Fig.5-76
TY-1405097-1
Fig.5-77
1. Filler cap


2. Open the filler cap [1].
3. Check to confirm that the coolant level is

above the MIN mark on the expansion tank.
4. Fill in the coolant as required till the liquid

level is between the MIN and MAX marks. Fill
slowly to let the air out.
5.6.4.5 Completely empty system, fill
Fig.5-80 Filler

1. Filler cap
NOTICE
Risk of damage！
Failure to observe the following advice may
result in damage.
• Do not start the engine until the air in the
system is bled and the system is filled up.
Fig.5-81 Refill Coolant

2. Check whether all discharge points are

closed.
4. Mix correct amount of coolant in advance to

ensure that the cooling system can be filled
up.
5. Fill in the coolant till the liquid level is
between the MIN and MAX marks. Fill it
slowly to allow the air out.
6. Start the engine when the cooling system is

filled up and ventilated. After the engine is
started for a while, open all the ventilation
cocks in order to bleed the remaining air. If the
heating unit is connected to the engine
cooling system, the thermal control valve
must be opened and the unit must be Fig.5-83 Secure the Wheel
ventilated in the filling process.

7. Stop the engine after about an hour and

check the coolant level. Fill it up if necessary.
5.6.4.6 Coolant, drain
CAUTION
Failure to follow this alert will result in personal injury.
• Do not open the filler cap [1] when the engine is hot. Steam or hot coolant will spray out.
• The coolant in the engine to be left unused or stored should be drained. Otherwise, the coolant
may deteriorate and cause the internal damage of the engine or the radiator as it is not used for
long term.


2. Stop the engine.
4. Open all discharge points. Drain the coolant 1

from the radiator and engine water pipeline
with a drain hose. The drain connector is lo-
cated under the radiator on the right side of
the engine.
5. Check to make sure that all the coolant is

drained. Deposits may be found in the drain
TY-1405097-1
plug/cock and need to be removed. Other-
wise, there will be residual coolant, which may Fig.5-86
cause freezing damage. Check whether there
1. Filler cap
is a cock or plug at the lowest point of the
cooling water pipe of the device.
6. Plug all cocks and check to make sure that

the spring-loaded cover on the connector is
closed. Install the rubber plug.
Fig.5-87 Coolant Drainnig
5.6.4.7 Radiator, clean
NOTICE
Risk of damage!
Failure to follow this alert will result in damage.
• Do not flush the radiator with high-pressure water gun.


In order to maximize the amount of air passing

through the engine radiator for best cooling ef-
fect, we must regularly remove debris at-
tached to the surface of the radiator.
Method of removing the debris:
1. Remove the radiator cover;
2. Remove all foreign objects on the radiator

fins;
TY-1405100-1
3. Clean it with water and neutral detergent.

Fig.5-90
When scrubbing it with a soft brush, take care
not to damage the fins;
4. Check for damaged radiator fins and rubber

seals. If necessary, replace damaged parts.

5.6.4.8 Cooling system, clean
Deposits in the radiator and cooling channels will hamper the cooling efficiency. The cooling sys-
tem should be flushed every time the coolant is changed.
NOTICE
Risk of damage!
Avoid freezing the cooling system when cleaning, or it may result in machine damage.
• If there is the risk that the cooling system may be frozen, cleaning is not allowed, because the
flushing fluid is not antifreezing.

1. Drain the cooling system as described above.
2. Insert a hose into the filling port of the expansion tank, and flush it with clean water until the
water flowing out is completely clean.

3. If there are still impurities after flushing for certain time, clean it with the coolant. Otherwise,
please continue with Step 8 as below.
NOTICE
Risk of damage!
Failure to follow this will result in machine damage.
• To prevent deposition of suspended matters,the system must be drained as soon as possible
(within 10 minutes) when the engine stops.
• Remove the filler cap and, if possible, the water pipe at the lower part of the radiator to drain
the system faster.
4. Flush the interior of the radiator, the engine cooling system and the external pipes connected
with distilled water.
5. Discharge the coolant immediately after cleaning. Remove the filler cap and, if possible, the
lower radiator hose to drain it faster. To prevent the suspended materials from returning to the
system, the system should be drained within 10 minutes after the engine stops.
6. Flush the system thoroughly with clean hot water to prevent debris from depositing inside the
engine. Keep flushing until the water flowing out is completely clean. Make sure the heater control
is set to Fully Heating when draining the system.
7. If there are still impurities after flushing for long time, you can clean the system with the radiator
cleaning agent, and then perform final cleaning with neutral cleaning agent.
8. When the cooling system is cleaned, close the drain valve and drain plug. Fill in recommended
coolant as described in “Coolant level, check and top up” on page 5-73.
CAUTION
Risk of injury！
Failure to follow this will result in injury .
• It is especially important to use coolant with correct concentration and dosage in the system.
• Mix the coolant in another container before filling the cooling system. Make sure that the liquid
is thoroughly mixed.

5.6.5 Air intake and exhaust system
5.6.5.1 Air leaks, check
The air taken in by the engine must be filtered

to prevent dirt and debris from entering the
engine. If the intake pipe is damaged or loose,
the unfiltered air will enter the engine and
cause premature wear and faults of the
engine.
Fig.5-93


1. Check the intake pipe once a week for cracked hoses and damaged or loose clamps.
2. If necessary, replace the damaged pipes and tighten loose clamps to ensure that there is no
leakage in the air intake system. Torque: 8 Nm (71 inlb)
3. Check whether the air intake pipe under the clamps and hoses is corroded. Corrosion will
introduce corrosive substances and dirt into the air intake system.
4. Disassemble and clean the intake pipe as needed.
Noise may be caused by air leakage in the following parts:

• The link between the turbocharger and the exhaust elbow.
1. Check whether there is damage and tighten the loose clamps.
2. Torque: 8 Nm (71 in-lb)

• The sealing gasket between the turbocharger and the exhaust manifold.
1. Replace the sealing gasket.
2. Tighten the V-shaped band nut on the air compressor housing.
5.6.5.2 Turbocharger, check
NOTICE
The maintenance of the turbocharger must be performed by the qualified technicians from the
manufacturer with suitable tools. Failure to follow this alert will result in machine damage.
• Timely troubleshooting can extend the service life and improve the performance of the
turbocharger. If the vehicle has insufficient lubrication or abnormal vibration or noise, shut down
the engine immediately.
• When starting and shutting down the engine and turbocharger, observe the following simple
and basic measures:
Starting: After starting, the engine should idle for at least 30 seconds.
Shutting down: Before shutting down, the engine should idle for at least 1 minute.
The turbocharger is a part of the engine and cannot be regarded as a simple accessory. In case of
any problem, repair the turbocharger in time instead of looking for faults in the engine and other
components.
In order to avoid wasting time and increase the service life and functions of the turbocharger, some
important rules and requirements for using the turbochargers are listed here.
The turbocharger may be damaged due to the three main reasons below:
1. Insufficient lubrication: Continuous wear of rotating parts will cause gear damage;

2. Entry of foreign objects: Dirty air brings in small impurities, which damage the turbocharger
blades, and blade fragments may enter the cylinder;
3. Lubricant contamination: It will cause scratches to the shafts and bearings, blockage of the oil
circuit and wear of the seals, which will lead to oil leakage and seizure.
Check the tightness of the air intake and ex-

haust pipe gaskets and screws, and repair it
immediately if any leakage.
Fig.5-96


2. Tighten the mounting nuts of the

turbocharger.
Torque: 61 N·M (45 ft-lb)
3. Check the sealing surface of the turbine

housing for exhaust leakage.
Tighten the V-band nut if any leakage.
Torque: 9 N·M (80 in-lb)
4. Check the sealing surface of the Fig.5-97 Park Ground

compressor housing for exhaust leakage.
Tighten the V-band nut if any leakage.
Torque: 9 N·M (80 in-lb)
Inspection for every 800 working hours:
1. Check the tightness of the air intake and exhaust pipe gaskets and screws, and repair it
immediately if any leakage.
2. Check the oil delivery pipe and the oil return pipe to ensure that there is no oil leakage.
3. When running at high speed, the turbocharger will be damaged if the oil in the oil circuit
decreases.
Inspection for every 6,000 working hours:
1. Remove the intake pipe and the exhaust pipe. Check the turbocharger.
2. Check the compressor or turbine blades for damage or cracks. Check whether the turbocharger
shaft can rotate freely.
3. If any problem is found during the inspection, please contact the maintenance station of SANY
Group for help.

5.7 transmission system

5.7.1 Description of transmission
system
The gearbox transmits the torque flexibly and increases the torque. The engine drives the vehicle
through the gearbox and provides power for the hydraulic system and the braking system. Inside
the gearbox there are many gears that mesh with each other. The gearbox is filled with lubricant
and is in good hydraulic seal condition. The gears can be shifted by switching one of the gears.
5.7.2 Mounting bolts of propeller shaft,

checking
Under the action of load and vibration, loose bolts are easy to be cut off. Before the transmission
shaft transmits torque, the fixing bolts must be checked carefully to avoid accidents.
1. Inspection Method:

2. Check whether the fixing bolts of the drive

shaft are loose;

3. Re-tighten the loose fixing bolts of the drive

shaft with the torque of 75Nm;
TY-1405119-1
Fig.5-101
4. Check whether the universal joint bearing is

damaged.
TY-1405120-1
Fig.5-102

5.7.3 Propeller shaft, lubricating

2. Inject grease into the lubrication fitting at

the connection (crossing) with a manual
grease gun (and high-pressure grease gun is
not allowed);
3. When the grease overflows, it indicates that

the grease is full.
NOTICE
Risk of damage！
Make sure the drive shaft is lubricated,or it TY-1405121-1
will result in machine damage.
• The drive shaft must be lubricated Fig.5-105
manually even if the vehicle has an
automatic central lubrication system

WARNING
Risk of injury!
• The engine must be turned off before any
operation on the drive shaft.
• Never touch the running drive shaft to
avoid accidents.
TY-1405122-1
Fig.5-106
5.7.4 Speed sensor, check


The speed sensor is located at the connection

of the transmission shaft [2] and the gearbox.
Check whether the speed sensor [1] and its
holder are damaged, so as to ensure that the
speed sensor can transmit the accurate speed
signal to the relevant control system.
The speed sensor calculates the actual travel- 1

2
ling speed of the vehicle based on the speed
of the gearbox output shaft and displays it on
the monitor. Besides, it controls the gearbox
TY-1405123-1
shifting by combining the actual travelling
speed and the torque converter input/output Fig.5-109
speed ratio.
1. Speed sensor 2. Transmission shaft
5.7.5 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.

1
3. It is recommended that the oil be filled
when the gearbox is at operating
temperature. Fill- - -wait a moment- - - check Fig.5-112 Check Transmission oil Level
the oil level with dipstick.
1. Oil filler
NOTICE
Work carefully when filling transmission oil to
prevent other fluids or particles from contami-
nating the oil, which means risk of gearbox
damage.

5.7.6 Transmission oil filter, change

If the filter is blocked, the amount of oil re-

quired for gear shifting and lubrication will
reduce.
To replace the gearbox filter elements
Remove the old filter element, lubricate the

sealing ring with gearbox oil, then install the
new filter element by hand till it is in contact,
and then tighten it for 2/3 turns.
TY-1405124-1
Fig.5-115

5.7.7 Transmission oil, change

Fig.5-118

When the engine idles, pull out the dipstick to 1. Switch

check the transmission oil level. The oil level
should be between the H and L marks on the
dipstick. If the oil level is below the L mark,
open the transmission oil cap and fill in oil.
Check whether the old oil contains metal par-

ticles, so as to predict the operating conditions
of transmission components. If the old oil is
contaminated, loosen the oil drain plug [2] and 3
discharge the old oil into the oil basin.
After the old oil is drained, put on the drain 2

plug. Fill new oil until the minimum mark (L)
on the dipstick is reached. Start the engine to
Fig.5-119
warm the oil to reach the working tempera-
ture, check the oil dipstick, and fill in oil until 2. Oil drain plug 3. Transmission oil
the level reaches the maximum mark (H) of pre-filter
the dipstick.
Check the transmission oil pre-filter [3] regu-

larly, which should be replaced in time if
damaged.
NOTICE
Risk of damage！
Lubricant needs to be matched.Otherwise, it may result in machine damage.
• Use appropriate lubricant according to the transmission model.

5.7.8 Mounting bolts and mounting

pad, check

The function of the fixing seat and shock pad:
Fixing the gearbox on the frame; absorbing

shock when the gearbox starts and stops.
Items for inspection: Whether the fixing seat

[2] and the shock pad [1] are damaged;
whether related bolts are loose.
2
1
Fig.5-122
1. Shock pad 2. Fixing seat

5.7.9 TE Transmission calibrating

The gearbox needs to be automatically calibrated to guarantee the effectiveness and service life of
the gearbox. The gearbox needs to be automatically calibrated in the following situations:
• After the gearbox inspection

• After overhaul
• After 2000 hours of working
• After the gearbox program is updated
Before the automatic calibration, the following conditions need to be met:

• The parking switch is enabled;
• The gearbox temperature is above 60 °C, and 62 °C is required in cold weather;
• Engine idles at 800rpm (±200rpm)

For the temperature of the gearbox to meet

the requirements of automatic calibration,
park the vehicle on flat ground and heat the
gear box with the following method:
Set the heating mode to "1", press and hold

"√", and it will display "Confirm starting heat-
ing mode" after sending the command suc-
cessfully. Then set the heating mode to "2",
press and hold "√", and it will display "Auto-
matic heating in progress. Please operate as
per remarks" after sending the command suc- Fig.5-125
cessfully. At this time, you need to follow the
remarks to heat the gearbox to the required
temperature for calibration. When the temper-
ature is reached, set the heating mode to "0"
to cancel the heating mode.
1. Confirm that the parking switch is closed and works.
2. Shift to the forward gear with the joystick and fully depress the accelerator pedal.
3. Keep the engine running at full speed for 15 seconds, shift to the neutral gear and fully depress
the accelerator pedal.
4. Keep the engine running at full speed for 15 seconds in the neutral gear.
5. Release the accelerator pedal and slowly slow down the engine until it stops.
6. Repeat the above Steps 2-5 until the gearbox temperature exceeds 60°C.
Set the automatic calibration to "1", and press and hold "√". After the command is sent success-
fully, the message "Calibration Confirmed" will be displayed. Then set the automatic calibration to
"2", and press and hold the "√". After the command is sent successfully, the message "Automatic
Calibration in Progress" will be displayed. Meanwhile, the operator needs to operate according to
the prompt below the gearbox oil temperature. If "GOF" is displayed, shift to the forward gear. If
the calibration succeeds, the message "Calibration succeeded. Power off and restart".

5.7.10 Transmission, checking

Through observation and touch, check whether there is oil leakage at the installation joint and oil
seal of the gearbox oil circuit. If you have any problems, please contact SANY Marine Service for
processing.

5.8 Drive axle

5.8.1 Mounting bolts of drive axle to the
frame, checking

2
1
Fig.5-130

• Ruptured mounting bolts will lead to serious 1. Drive axle 2. Mounting bolts
damage to machine, or even personal
injuries.
• Check the drive axle’s attachment to the
frame so that there is no corrosion of
structural elements (e.g. mounting bolts).
• Tighten the mounting bolts (2) with 1600
Nm (oiled bolt).
5.8.2 Mounting bolts of drive axle to

the propeller shaft, checking


The tightening torque of the bolt [3] is 75Nm.
TY-1405119-1
Fig.5-133
5.8.3 Oil leaking of drive axle and

brake components, checking
The items for inspection include:


• Check the oil-immersed disc brake and

connecting oil pipes;
Fig.5-136

• Check the parking brake system and the

connecting oil pipes;
Fig.5-137 Parking Brake System
• Check the connection between the main

reducer housing and the axle housing;
Fig.5-138 Main Reducer
• Check the driving wheel;
Fig.5-139 Driving Wheel

• Check the drive axle.
Fig.5-140 Drive Axle
5.8.4 Breather connector, cleaning


Clean the breather to allow the steam inside

the drive axle to escape, so as prevent the
pressure inside the drive axle from increasing.
If the pressure inside the drive axle is too high,
oil may leak from fragile parts such as oil
seals.
Fig.5-143
5.8.5 Brake pads and braking function,

checking
DANGER
Risk of crushing！
As the vehicle may move, there is danger of
crushing.
• Chock the wheels to ensure that the
vehicle will not move when the parking
brake is released, thus avoiding accidents
.
Fig.5-144 Brake Pad


• Brake system
The braking system is a device that stops the running vehicle, which is available on the drive
axle but not on the steering axle.
• Check the brake pads and braking function
1. Start the engine and allow the engine to run until the accumulator is charged;
2. Stop the engine and turn the ignition key to Position I;
3. Release the parking brake and check whether the parking brake caliper can move on the
anchor;
4. Check whether the gap between the brake lining and the brake disc meets the requirements,
and make appropriate adjustment if necessary.

CAUTION
Risk of injury！
Hot and in high pressure, the hydraulic oil can cause trauma, burns, rashes or irritability if
splashed on the human body.
• The pressure in the hydraulic system must be released before work. Avoid direct contact with
hydraulic oil before starting work, and wear gloves when working.
5.8.6 Main reducer, checking


NOTE：
The drive axle is equipped with a star wheel 1 2
20 mm
gear, so the change of the oil level of the main
reducer will affect that of the wheel gear.
1. Wait the oil to cool down and flow back,

shut down the engine, and check the oil level.
2. If the oil flows out from the hole on the oil

level plug [2], the oil level is normal. 3
3. Fill in new oil through the oil level plug hole

Fig.5-149
[2] if needed.
1. Port 2. plug
4. Check the port [1], which must be kept
3. Drain plug
clean and working properly.
5. Check and clean the port of the parking

brake cylinder.
5.8.7 Main reducer oil, changing
NOTICE
Risk of damage！
Failure to follow this alert will result in engine damage.
• The oil can be changed only after the engine is shut down.


1. Loosen the drain plug [3] and the oil filler plug [2], drain the oil into a suitable container, and
check whether there are metal debris in the oil.
2. Clean the interior of the housing carefully with oil of the specified grade for the machine. Before
filling new oil, drain the gasoline used for cleaning.
3. Check the drain plug [3] for metal debris, and then re-tighten the drain plug.
4. Fill new oil through the oil filler plug hole [2] until the oil overflows.
5. Re-tighten the oil filler plug [2].
6. After the test, re-check the oil level (through the plug hole [2]) to ensure that there is no oil
leakage.

NOTICE
Risk of malfunction！
Improper performing may cause main reducer to fail.
• The first oil change should be implemented on new vehicles after the first 100 working hours.
5.8.8 Wheel-side reducer, checking


Every 100 working hours:
1. Turn off the engine, allow the oil to cool and

return, and check the oil level.
2. Place the oil level line horizontally.
3. When the oil flows out through the oil level

plug [1], the oil level is correct.
4. Fill in new oil through the oil level plug hole

[1] if needed.
Fig.5-154 Wheel-side Reducer
Every 1,200 working hours
Check the wheel-side reducer as below:
CAUTION
Risk of damage or injury!
Failure to follow this alert will result in machine damage or personal injury.
• The replacement can only be carried out after the engine is shut down.
1. Arrange the (scaled) oil level line horizon-

tally in a straight line, with the drain plug [2] in
the lowest position. 2
2. Loosen the drain plug [2] and the oil filler

plug [1], drain the oil into a suitable container,
and check whether there are metal debris in
the oil.
NOTICE 1
Risk of damage!
Failure to follow this will result in machine
Fig.5-155 Change the Wheel-side Reducer Oil
damage.
• It is recommended to drain the oil when the 1. Oil level and filler plug 2. Drain plug
drive shaft is still hot, which can facilitate
the draining of the oil.
3. Clean the interior of the housing carefully

with gasoline. Drain the gasoline used for
cleaning before filling new oil.
4. Check the drain plug [2] for metal debris,

and then re-tighten the drain plug.

5. Fill new oil through the oil filler plug hole [1]
until the oil overflows.
6. Re-tighten the oil filler plug [1].
7. After the test, re-check the oil level (through

the plug hole [1]) to ensure that there is no oil
leakage.
5.8.9 Wheel hub nut, checking and

tightening


2. Cleaning the surface and sundry inside rim.
3. Check whether the drive axle and steering

axle are loose.
4. In groups, the tire short press plate is in-

stalled in a symmetrical way and the nut is
tightened. See “Tightening torque of key
bolts” on page 5-14 for torque requirements.
5. During the initial operation of the machine

and 200 hours after the replacement of the
new tire, the hub nut should be pretightened
Fig.5-158
every 50 hours.
5.9 Steering axle

5.9.1 Daily check


2
5
4
3
8
1
6 7
Fig.5-161 Steering Axle
1. Steering axle beam 2. Steering pin 3. Steering cylinder 4. Link

5. Wheel hub 6. Pressure plate 7. Steering knuckle 8. Pivot
1. Check the abrasion and lubrication of the pivot [8], and grease it every 50 hours.
2. Check whether the steering cylinder [3] has oil leakage and whether the piston rod is deformed.
If any damage, replace or repair the part immediately.
3. Check the link [4] for fatigue damage, and replace it immediately if damaged.
4. Check whether each movable joint of the steering pivot [2] can rotate smoothly, and grease the
connecting pivot at both ends every 50 hours.
5. If driving the machine for a long time with insufficient tire pressure, stop it immediately, remove
the tires and wheels, and check whether the steering knuckle [7] is damaged.

5.9.2 Steering axle, lubricating

2. Clean the grease fitting;
3. Inject grease into the fitting with a grease

gun until the old grease is squeezed out;
4. Clean up excessive grease, and scrape off

the old grease on the sliding surface before lu-
bricating it;
5. Apply grease to the contact surface of the

slider.
Fig.5-164 Inject Grease

5.9.3 Steering axle components,

checking

Check whether the steering cylinder, the joint

shafts and bearings, the steering wheel bear-
ings, the steering linkage, the shock pads, the
counterweights and other components are
tight, whether there are abnormal gaps and
damage, and whether there is oil leakage on
the steering axle. If any of the above condi-
tions is found, you should take immediate
measures.
Fig.5-167

5.9.4 Knuckle pin, checking

2. Clean the knuckle pin [1] and bearings [2];

3
3. Check whether the knuckle pin can rotate
smoothly;
4. Check whether the fixing bolt [3] is tight.
1
2
Fig.5-170
1. Knuckle pin 2. Bearings

3. Fixing bolt

5.9.5 Steering axle cradle, maintaining

3
4
6
Fig.5-173

2. Remove the hub cover [1]. 1. Hub cover 2. Steering knuckle

3. Find out the deformation and fatigue of the 3. Hub bearing 4. Hub nut
steering knuckle [2] as early as possible. If 5. Grease fitting 6. Steering shaft
any damage, replace the knuckle
immediately.
4. If the hub bearing [3] is loose, adjust the

gap in time by adjusting the hub nut [4], and
make proper pre-tightening treatment to pre-
vent the destruction of related components
from accelerating.
5. Inject grease to the steering shaft [6]

through the grease fitting [5] until it feels very
difficult to inject more.
5.10 Tyres and rims

5.10.1 Tyres and rims
Tires and rims are important components of wheeled vehicles, and their technical status directly af-
fects the traction, passability, stability, safety, comfort, and economy of wheeled vehicles. Please
perform proper maintenance on the tires and rims as per the technical instructions.
Sany's reach stackers come with 18.00-25-40PR tires, and the tires on the drive axle and the
steering axle tires are in the same specifications.
NOTE：
Some machines are equipped with 18.00-25 solid tires.
5.10.2 Precautions for tires
CAUTION
Risk of injury!
Unmatched tires and rims will cause early damage to the tire toe, or cause tire explosions, which
may threaten the personal safety.
• The tires used on the reach stacker should be of the same or equivalent specifications as the
original tires coming with the reach stacker.
• Tires on the same axle should be of the same brand, specification, structure and type of use,
and must have the same degree of wear to guarantee the same outer diameter. When the
pattern at 1/4 width from the edge is worn to 2-3mm deep, the tire needs to be replaced.

DANGER
Risk of serious injury or possibly death!
Failure to follow this , tires may explode and cause casualties,which will result in serious injury or
possibly death.
• The installation and replacement of tires is a highly dangerous job, which must be performed by
two or more trained professionals working together, and keeping highly vigilant during work.
• When the tires are hot, stop the machine and park it in a cool place for the tires to cool down
naturally. Never cool down the tires by deflation and spray water. Otherwise, the tires may
explode and cause casualties.
• The tire should be replaced in time when they reach the wear limit, otherwise they may explode
and cause casualties.
• Before starting the machine, check the tire

surface for cracks, corrosion and excessive
or uneven wear;
• Replace severely worn tires in time;
• Check and remove debris embedded in
tires, such as glass;
• Check the tire pressure and inflate the tire
in time if the pressure is insufficient.
Insufficient tire pressure will reduce the
stability and carrying capacity of the
vehicle.
Fig.5-174 Tire
5.10.3 Tyre, inflating
CAUTION
When inflating the tires, follow the safety instructions to avoid accidents. Otherwise, it may result
in damage or injury.
• If the tire has been completely deflated, the tire must be removed to check the damage to the
rim.
• During inflation, never install the steel rim components with a hammer, and never knock fully or
partially inflated tires or the steel rims.
• Never inflate the tires until all parts are in place.
• The specified tire pressure (1.0 ~ 1.05MPa) must not be exceeded.



1. Before inflation, make sure that the lock

ring and retaining ring are in the correct
position.
2. Connect the compressor to the air valve on

the tire.
3. During inflation, the operator should stand

on the side of the tire.
Inflate the tire to the specified pressure of 1.0

~ 1.05MPa.
Fig.5-177 Check the tyre condition
Fig.5-178 Check the Tire Pressure

5.10.4 Maintenance of rim
5.10.4.1 Precautions for rim
CAUTION
Failure to follow this will result in injury or
damage. 6
• Replacing the rim is a complicated and
dangerous job. Do not replace the rim 5
without permission. 4
• If you need to replace the rim, please
contact the professional staff authorized by
SANY.
The rim is an important part directly matched

with the hub, and its size parameters must be
3
the same as those of the hub. Use the rims
approved by Sany only.
Sany's reach stacker adopts the a five-piece 2

non-spoke rim composed of a rim body com- 1
ponent, a retaining ring, a bead seater and a
lock ring, the basic structure of which is shown
in the figure on the right.
Fig.5-179 Tire and Rim Structure
1. Retaining ring 2. Retaining ring

3. Tire 4. Retaining ring
5. Bead seater 6. Lock ring
5.10.4.2 Rim, checking
WARNING
Risk of injury!
Perform the following inspections, or it will result in possible accidents during disassembly.
• It is necessary to use the tires of the correct size matching the type and size of the rim. Never
use oversized tires.


2. Remove the rim.
3. Clean the rim, especially the contact sur-

face between the bead and the rim and that
between the rim and the lock ring, and the in-
stallation groove of the O-ring with a wire
brush.
A
4. Measure the wear of the rim lock ring B
groove.
• The wear on the edge of the lock ring often

leaves marks. In [A] in the figure, the mark
Fig.5-182 Measure the Rim Lock Ring Groove
is between the two ends of the lock ring.
• Measure the depth of wear with a steel ruler A. Position A B. Max 0.5 mm
and vernier caliper. If the wear exceeds
0.5mm, the rim, the lock ring and the bead
seater must be replaced with new parts.

4. Check the diameter of the steel ring
• Measure the circumference [O] around the

steel ring with a tape measure and
calculate the diameter [D] ([D] =
circumference [O]/3.14)
D
• Compare the diameter value with the O
standard minimum measurement value. If
the diameter is smaller, it is necessary to
replace the lock ring and the bead seater of
the steel ring with new parts.
5. Check the damage of the area with concen- Fig.5-183 Check the Diameter of the Steel Ring
trated high stress in the two steps below:
• Check whether there are cracks and the

specific location of the cracks with the
magnetic particle testing.
• After the cracks are identified, perform
further inspection by means of penetrating
liquid.
• The typical damage of the steel rings
includes cracks, corrosive damage, rust,
bending and wear.
DANGER
Risk of injury or death!
It may cause casualties if the following rules are not followed.
• The relevant parts of the rim must be replaced immediately if they are cracked or deformed.
• Never repair a damaged rim by welding.

5.10.4.3 Wheel rim, removing


CAUTION
Be sure to work according to the correct
sequences while installing or removing the
tyre from wheel or rim. If the sequence is 1
wrong, the tyre may rupture and thus lead to
personal injury.
• If the personnel has insufficient
experience, or the appropriate tools for
work are not enough, do not install or
remove the tyre. Under such 2
circumstances, contact the authorized and
professional staff related to tyres to deal
with the tyre.
• Wheels can be disassembled horizontally
and vertically. Before disassembly, take
down the valve core and let all the air out.
3
The tire can be disassembled either in a hori-
zontal position or in a vertical position. Before
starting the disassembly, you must remove
the valve core and discharge all the air in the
tire.
1. Remove the bead on the drain side of the

rim with suitable tools, taking care not to
damage the bead [1]. 4
2. Remove the lock ring with a suitable tool

[2].
3. Remove the O-ring seal, which will no

longer be used [3].
4. Remove the bead seater with a suitable tool 5

[4].
5. Remove the rim from the rim seat, loosen Fig.5-186 Disassembly Procedure
the bead on the rear side, and remove the tire 1. Remove bead 2. Remove lock ring
from the rim [5]. 3. Remove O-ring 4. Remove bead
seal seater
5. Remove rim

5.10.4.4 Wheel rim, installing
CAUTION
Failure to follow this alert will result in damage or injury.
• When prying in the bead seater [1] and the lock ring [6], apply force evenly around them, and
do not only tap one position. Check whether the 45° contact surface between the retaining ring
seat and the lock ring fits in the entire circle. If not, re-install it in the following procedure.
• Before starting the disassembly, you must remove the valve core and discharge all the air in the
tire.


1. Install the tires in the direction indicated by

the arrow in the right picture, and the
installation sequence of the components is
shown by the serial numbers in the picture. 6
2. Place the rim [2] vertical on the ground 5

4
padded with a 100mm-high wood block, and
insert the retaining ring [1] into the rim in the
direction shown by the arrow in the right
picture. Then install the valve core, and make
sure that the valve core and the rim fit closely
3
3. Put the tire [3] into the rim with a travelling
crane or other lifting machine, and install the
O-ring in the rim. Put the retaining ring [4] into 2
the inner ring of the tire, knock the bead 1
seater [5] in-between the rim and the retaining
ring with a hammer, and then pry the retaining
ring into the position between the rim [2] and Fig.5-189 Tire and Rim Structure
the bead seater [5] to lock the rim. 1. Retaining ring 2. Retaining ring
3. Tire 4. Retaining ring
5. Bead seater 6. Lock ring
5.10.5 Drive axle tyre, removing and installing
5.10.5.1 Drive axle tyre, removing
WARNING
Risk of injury or possibly death！
Failure to follow this warning could result in injury or possibly death.
• Deflate the tires before replacing. If the valve core is blocked, cut a groove with a depth of
about 1/3 of the diameter with saw to deflate the tire.
• When replacing the tires, be sure to choke the steering axle tires before jacking up the drive
axle, so as to avoid accidental movement of the reach stacker, which can cause injury to the
repair staff.
• The assembly and disassembly of the tire should be carried out by at least two trained
professionals working together.



2. Place two 20-ton jacks under the drive axle,

with a distance of 1.6m between the centers
of the two jacks, which are arranged symmet-
rically with the centerline of the reach stacker
frame. After confirming the positions are cor-
rect, jack the reach stacker up, and stop jack-
ing after the wheels are 50mm off the ground.
3. Unscrew the air tap cap, insert it back into

the air gap against the valve core, and rotate
it for 2-3 turns to deflate the inner and outer
tires respectively.
Fig.5-192
4. Loosen all the nuts in a symmetrical
manner.
5. Leave three nuts evenly distributed, and re-

move all the rest.
6. Lift the outer tires reliably with a forklift or

other cranes.
7. Unscrew the remaining three nuts and re-

move the outer tire [1].
8. Remove the intermediate collar [3] between

Fig.5-193
the tires.
9. Remove the inner tire[5] safely with a forklift

or other cranes.
Fig.5-194

5.10.5.2 Drive axle tyre, installing

1
3
2
4
5
Fig.5-197

2. Remove debris on the surface of the hub 1. Inner tube 2. Pressure plates
and the inner ring of the rim.
3. Middle ring 4. Open ring
3. Install the inner tube [1] into the steering 5. Outer tube
axle with the lock ring facing outward with a
forklift or other lifting machines.
4. Install the middle ring [3].
5. Install the outer tube [5] into the steering

axle with the lock ring facing inward with a
forklift or other lifting machines.
6. Install the open ring [4].
7. Install the pressure plates [2] for the tire in a

symmetrical manner, and tighten the nuts with
a torque of 430～460Nm. Fig.5-198
8. Rotate the tire several times to ensure that

the left and right swing at the maximum outer
diameter of the tire is less than 3mm.
9. Inflate the tire with the pressure of 0.95 ～

1.05Mpa
10.The hub nuts should be pre-tightened

every 50 hours within 200 hours after the ma-
chine is operated for the first time and new
tires are replaced.
Fig.5-199

5.10.6 Steering axle tyre, removing and installing
5.10.6.1 Steering axle tyre, removing
WARNING
Risk of injury or possibly death！
Failure to follow this warning could result in
injury or possibly death.
• Deflate the tires before replacing. If the
valve core is blocked, cut a groove with a
depth of about 1/3 of the diameter with saw
to deflate the tire.
Fig.5-200
CA-
UTION
• Replacing the steering axle tyre is a complicated and dangerous job and must be careful.
• When disassembling a tire, the workers are not allowed stand at one side of the tire, so to avoid
injury when the tire fall down.
• If the bead seater and lock ring are visibly broken, be sure to knock the rim first for the broken
bead seater and lock ring to release the force under the resistance of the long pressure plate,
and then remove the long pressure plate in a symmetrical manner.


1. Place two 20-ton jacks under the steering axle, with the distance between the centers of the two
jacks is 1.4m, which are arranged symmetrically with the centerline of the reach stacker frame.
After confirming the positions are correct, jack the reach stacker and stops when the wheels are
50mm off the ground.
2. Turn the tire to allow the tire valve upward, and deflate the tire.
3. Remove the nuts on the short pressure plate in a staggered and symmetrical manner, and take
out the short pressure plate.
4. Loosen the nuts on the long pressure plate by 2 to 3 threads with a torque wrench.
5. Check the pressure plates, rim, bead seater and lock ring for damages such as breakage.
6. Lift the tires reliably with a forklift or other lifting machines.
7. Remove the long pressure plate in a symmetrical manner.
8. Remove the tires with forklift or other lifting machines safely.

5.10.6.2 Steering axle tyre, installing

2. Remove debris on the surface of the hub

and the inner ring of the rim.
3. Install the tire into the steering axle with the

lock ring facing outward with a forklift or other
lifting machines.
4. Install the long pressure plates for the tire in

a symmetrical manner, and tighten the nuts
with a torque of 380Nm.
5. Install the short pressure plates for the tire

in group in a symmetrical manner, and tighten
the nuts with a torque of 380Nm. Fig.5-205

6. Rotate the tire several times to ensure that

the left and right swing at the maximum outer
diameter of the tire is less than 3mm.
7. Inflate the tire with the pressure of 1.0-

1.05Mpa
8. The hub nuts should be pre-tightened every

50 hours within 200 hours after the machine is
operated for the first time and new tires are
replaced.
NOTE：
There are 5 short pressure plates between
the two long pressure plates.
5.11 Boom
5.11.1 Boom
The boom system of the reach stacker is composed of the main components such as the basic
boom, the telescopic boom, the telescopic cylinder, the pitch cylinder, the drag chain and the slider.
Its working principle is to adjust the pitch angle of the boom with the telescopic cylinder, and adjust
the extension length of the telescopic boom with the telescopic cylinder. The two actions cooperate
with each other to grasp containers in different positions.
4 1 2 3 5 6
Fig.5-206 Boom Structure Diagram
1. Basic boom 2. Pitch cylinder 3. Drag chain 4. Telescopic cylinder

5. Slider 6. Telescopic boom

5.11.2 Basic boom, check

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 weld-
ing of mounting pad, pin shaft, pin-hole bear-
ing and mounting bolts should be periodically
checked. If needed, conduct dye check.
Fig.5-209 Check of Boom

Visually check for crack
Boom is an important element to directly lift

the container. The stability of its structure di-
rectly 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.5-210 Crack of Boom
5.11.3 Wear pads, check


• 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.

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.
1. The min. thickness of wear pads is 15mm. Fig.5-213 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.
5.11.4 Pitch cylinder, checking


Check the fixing seat and pin on the pitch

cylinder.
Check whether there are cracks in the area

near the fixing seat, and dye it if necessary for
further inspection.
Fig.5-216
5.11.5 Maintenance of the cylinder pis-

ton rod
The following maintenance measures should be implemented for the cylinder piston rod during
storage, transportation, installation and use:
• After the oil cylinder is painted or assembled, the section of the piston rod exposed outside of
the cylinder should protected with rust-proof oil or grease against corrosion.
• During long-distance road or sea transportation, the exposed cylinder piston rod should be
coated with anti-rust oil or hydraulic oil for sealing.
• If the cylinder is not used for a long time (more than 15 days) after the main machine is installed
and adjusted, the exposed piston rod should be coated with anti-rust oil or hydraulic oil for
protection, and inspection and maintenance should be carried out weekly.
• If the equipment is not used for a long time (more than 15 days) in the course of use, apply anti-
rust oil or hydraulic oil to the exposed piston rod for protection, and perform regular inspections
and maintenance every week.
• During the use of the equipment, any soil, concrete and other dirt on the surface of the piston
rod should be cleaned in time to keep its surface clean. Take care not to impact, smash or
scratch the piston rod during use.

5.12 Spreader
5.12.1 Twistlock, checking

1
Fig.5-219 Twist Lock 1

Check whether the twistlock element [1] [3] is 1. Twistlock element 2. Twistlock link
damaged. Change it if damaged.
Check whether the position of the twistlock

link [2] [4] is correct and firm, and check
whether the sensors are tightened. Adjust and
tighten them as needed.
Fig.5-220 Twist Lock 2
3. Twistlock element 4. Twistlock link

5.12.2 Twistlock, lubricating

Spreader is an important part for lifting con-

tainers. Lubricating the twist lock of the
spreader can reduce the wear and extend the
service life of the twist lock.
Fill lubricant through the lubricant port [3] until

it is full every 200 hours.
Replace the twist lock if it is severely worn

with the cross-sectional dimension below
3
25mm; in case of overhaul, replace the twist
lock which has worked for more than 5,000
hours. Fig.5-223
The twist locks and related components play 3. Lubricant port
a key role in lifting containers accurately and

safely, so it is very important to check their

conditions.
5.12.3 Sensor / Indicator of twistlock,

checking


The items for inspection include:
1. Whether the sensor [4] and the wiring are in

good condition.
2. Whether the sensor are fastened or

damaged.
3. Whether the gap with the sensing block is 4

normal.
Fig.5-226
4. sensor
5.12.4 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 parts fas-
tened 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, pro-

vides 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. Fig.5-229 Fixed Bolts of Spreader
Thus strengthen the output of motor and disc
brake.
5.12.5 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.


2. Sideshift wear pads

1
Lubricating
When the surface of wear pad has little sliding

effect, be sure to smear grease on the surface 2
in time. No need to consider the lubrication
interval. 3
Replacing
Replace the wear pad if its worn depth ex-

ceeds 3mm. Follow the below steps:
1) Screw out the bolts (2) at both ends. Fig.5-232 Sideshift Sliding Block
Remove the end baffle (3).
1. Wear pad 2. Bolts
2) Install a new wear pad (1). Adjust the 3. End baffle
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 antiloosing
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.
3. Telescopic wear pads
Lubricating
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
interval.
Replacing
Replace the wear pad if its worn depth ex- 4

ceeds 3mm. Follow the below steps:
7 6 5
1) Screw out the bolts (6) at both ends.
Remove the end baffle (5). Fig.5-233 Telescopic Sliding Block
2) Install a new wear pad (4) or lower wear 4. Wear pad 5. End baffle
pad (7). Adjust the clearance between 6. Bolts 7. Lower wear pad
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 70 N.m. Spread antiloosing
glue on the bolt before installing it.
4) Smear lubricants on the surface of sliding

block.

5.13 Air Conditioning System

5.13.1 Precautions for service
NOTICE
Risk of damage！
The compressor refrigerating oil has strong water absorption. It need to avoid deterioration of the
refrigerating oil in the compressor due to absorbing water.Failure to follow this will result in
damage.
• It should block or connect the pipe fittings at the compressor end in time.
NOTICE
Risk of damage！
Improper or wrong maintenance can cause property damage.
• The air-conditioning system fault must be repaired by professional air-conditioning service
personnel.
1. Service for insufficient refrigerant:

The leakage location must be found, which it can be detected with a portable detector or by apply
soapy water on the fittings. After finding the leakage position and fixing it, add refrigerant as de-
scribed in 5.13.11 together with 10mL refrigerating.

2. When the compressor is damaged, try the best to confirm the cause, and repair it based on the
following conditions:
• Only the coil fails and the clutch does not engage, but the compressor is normal inside. Retrieve
the refrigerant, disassemble the compressor, replace the coil only, and reassemble the air-
conditioning system. Add refrigerant according to 5.13.11 together with 10ml refrigerating oil. To
judge whether the compressor is normal inside: pull the clutch, and the compressor rotation
resistance is normal without jams or suffocation; pull the clutch, and block the high-low pressure
interface of the compressor with hand, and you can clearly feel the pressure change there.
• The clutch is abnormally worn and the coil is melted, but the compressor is normal inside.
Retrieve the refrigerant, disassemble the compressor, replace the whole compressor, and
reassemble the air-conditioning system. Add refrigerant according to 5.13.11 with no refrigerant
oil needed.
• The pulley is skewed or stuck, or the pulley bearing is damaged, but the compressor is normal
inside. Retrieve the refrigerant, disassemble the compressor, replace the whole compressor,
and reassemble the air-conditioning system. Add refrigerant according to 5.13.11 with no
refrigerant oil needed.
• The compressor is damaged or abnormally worn and dirty inside (the drained refrigerating oil is
black, or contains obvious debris, rust and other impurities). Recover the refrigerant,
disassemble the compressor, the refrigeration system pipeline, the dry accumulator, the
condenser and the evaporator, clean the pipeline, the condenser flow path and the evaporator
flow path with professional cleaning agent and blow them dry with nitrogen or compressed air
after cleaning, replace the dry accumulator, the expansion valve and the damaged compressor,
reassemble the air conditioning system, and add refrigerant according to 5.13.11 with no
refrigerant oil needed.
• The compressor is damaged inside, but the drained refrigerant oil is clear. Retrieve the
refrigerant, disassemble the compressor, replace the whole compressor, and reassemble the
air-conditioning system. Add refrigerant according to 5.13.11 with no refrigerant oil needed.
3. Service for damaged refrigeration pipeline:

Retrieve the refrigerant, disassemble and replace the damaged pipeline, and reassemble the air-
conditioning system. Add refrigerant according to 5.13.11 together with 30mL refrigerant oil.
4. Service for damaged condenser core or blocked flow channel:

• In case of blocking: Retrieve the refrigerant, disassemble the condenser, clean the flow channel
with special cleaning agent, blow it dry with nitrogen or compressed air after cleaning, and re-
assemble the air conditioning system. Add refrigerant according to 5.13.11, together with 50mL
refrigerating oil. Check the condition of the compressor before service, and rule out the
condenser blocking due to damaged internal parts of the compressor.
• In case of damage: Recover the refrigerant, disassemble and replace the condenser,
reassemble the air-conditioning system, add refrigerant according to 5.13.11, and add 50mL of
refrigerating oil.

5. Service for damaged evaporator core or blocked flow channel:

• In case of blocking: Retrieve the refrigerant, disassemble the evaporator, clean the flow channel
with special cleaning agent, blow it dry with nitrogen or compressed air after cleaning, and re-
assemble the air conditioning system. Add refrigerant according to 5.13.11, together with 50mL
refrigerating oil. Check the condition of the compressor before service, and rule out the
evaporator blocking due to damaged internal parts of the compressor.
• In case of damage: Retrieve the refrigerant, disassemble and replace the evaporator,
reassemble the air conditioning system, and add refrigerant according to 5.13.11, together with
50mL refrigerating oil.
6. Service for other damaged parts constituting the air conditioning refrigeration circuit:
• Retrieve the refrigerant, disassemble and replace the damaged parts, reassemble the air
conditioning system, and add refrigerant according to 5.13.11, together with 10mL refrigerating
oil.
5.13.2 Summary of air conditioner maintenance
• Avoid sun exposure

When parking in summer, try to avoid the vehicle being exposed to sun, due to which the heat
load of the air-conditioning system will increase sharply, with the cooling rate slowing down.
• Maintenance of air conditioning system when idle
When the air-conditioning system is not needed, make sure to turn on the cooling mode of the
air conditioner once a month and for 3-5 minutes each time, so as to guarantee the lubrication of
the components in the compressor.
• Maintenance of the air conditioning system in winter
In winter (when the average daily temperature is below 10°C), make sure to turn on the cooling
mode of the air conditioner once every half a month for 5-10 minutes each time, so as to to en-
sure the lubrication of the components in the compressor.
For regions where the temperature in winter is below 0°C, when summer comes and before the
air conditioning system is activated for the first time, the following procedure must be followed:
Before starting the vehicle, hold the compressor clutch with your hand or an adjustable wrench
and rotate it for 2 turns clockwise and 2 turns counterclockwise, and repeat this operation. Ｗ
hen you feel that the resistance against the compressor rotation is significantly reduced, start
the vehicle and turn on the cooling mode of the air conditioner, and turn it off after about 5 sec-
onds. 30 seconds later, turn on the cooling mode again, and turn it off again after about 5-10
seconds. After the above procedure is completed, the air conditioning system can be turned on
to run.

5.13.3 Air conditioner belt，checking

Check the belt tension and wear every month

(the first inspection should be performed after
the new vehicle has run for 48 hours). For the
belt tensioned by screw, check the belt ten-
sion with the method shown in the figure: Ap-
ply a pressure of 2kg (about 20N) vertically at
the middle point of the belt with the index fin-
ger, and the belt deflection (offset of the belt
midpoint) should be 4mm. It is not needed to 3-4mm
4mm
adjust the tension for belts with automatic ten-
sioning wheels.
Replace belts that have worn gaps or longitu- Fig.5-236

dinal cracks in time.

5.13.4 Air return grid screen and the

evaporator screen, checking
NOTICE
Risk of damage！
If the screens of the air conditioner are not cleaned as required, a large amount of dust and oil
stain may enter the evaporator core, which will seriously affect the heat exchange efficiency of the
evaporator, and the cooling effect will significantly decreased!
• Clean the air conditioner in correct way as required.


Check the cleanliness of the air return grid

screen and the evaporator screen, and clean
the screens regularly:
• Generally it is required to clean the screens

once a week. In dusty areas, the cleaning
interval can be shortened based on actual
conditions.
• In the seasons when the air conditioner is
not used, the filter should be cleaned at
least once a month.
Fig.5-239
5.13.5 Refrigerant, checking


When the engine is idling at high speed,

switch the air conditioner to a powerful cooling
1
state. Observe the sight glass [1] on the con-
denser liquid tank [2] to check the refrigerant
gas flowing into the refrigerant pipeline.
3
• The refrigerant flows without bubbles:

There are bubbles 2
• in the properly flowing refrigerant (bubbles

pass continuously): Low refrigerant level 4
• Colorless and transparent: No refrigerant
Fig.5-242
1. Sight glass 2. Condenser liquid tank

3.sufficient 4.insufficient injuection
injection
NOTE：
When there are bubbles, the refrigerant gas level is low. Please fill in refrigerant. If the air condi-
tioner operates at a low refrigerant level, the compressor will be damaged.
5.13.6 Refrigerant/refrigeration oil，filling
NOTICE
Improper maintenance may cause air-conditioning system damage
• The air-conditioning system fault must be repaired by professional air-conditioning service
personnel.
NOTICE
Improper performing may cause damage while checking the refrigerant.
• The operating time of the system should be at least 30 minutes when the refrigerant is added.
• Check the pipeline, the condensing fan, the working pressure of the circulating fan system and
other related items in this process to ensure that the installation quality of the air conditioner
meets the requirements.


The refrigerant added to the air conditioning system must be R134a, and the refrigerating oil model
should be selected as described in 5.3.1. The compressor refrigerating oil does not need to be
added separately but together with the refrigerant. Requirements for filling the refrigerant/refriger-
ating oil filling operation:
• Before adding the refrigerant, it must be confirmed that all faults have been resolved and all the
components and pipelines of the system have been installed in place.
• During the filling operation, take care not to allow water and oil into the system. The
vacuumizing time of the system shall be 60 minutes at least, and the pressure-holding
verification time shall be 30 minutes. The refrigerant can be filled only if the pressure holding
verification is passed. If the pressure holding verification is not passed, check the system for
leakage. After the leakage point is found and solved, the vacuumization and pressure holding
verification shall be carried out again.
• When the compressor refrigerating oil is needed, inject it into the system with the device for
adding the refrigerant first.
• The weight of the added refrigerant should meet the specified value for the system. (Reach
stacker: 1.6kg; stacking and heavy forklift: 1.4kg.）

• The operating time of the system should be at least 30 minutes when the refrigerant is added.
Check all pipe fittings to ensure that there is no leakage during the filling process.
NOTICE
Failure to observe the following advice may result in the system damage.
• The vacuumizing time of the system shall be 60 minutes at least, and the pressure-holding
verification time shall be 30 minutes.
• The refrigerant can be filled only after the system passes pressure holding verification.
• The operating time of the system should be at least 30 minutes when the refrigerant is filled.
5.13.7 Cleanness of heat-exchanger

plate in evaporator and condenser,
checking


The evaporator and the condenser cores

should be cleaned at least once a year with
the following two methods:
• Clean the outer surface of the condenser

and the evaporator cores with a high-
pressure water gun and detergent.
• Blow the outer surface of the evaporator
and the condenser cores with high-
pressure air.
Fig.5-247
NOTE：
Adjust the high-pressure water gun or the air gun to the appropriate pressure before using, and do
not blow down the fins. If the cores are very dirty, especially when the dust screen of the evapora-
tor core has not been cleaned for a long time and the fins are covered with a large amount of dust
and dirt, it is necessary to be rinsed with the special fin cleaning liquid for air conditioner diluted
with water.

5.13.8 Compressor and air conditioner pipeline fittings for oil and refrigerant leak-
age，checking

Check the compressor shaft seal and the pipe joints of the air conditioner every half month for oil
and refrigerant leakage. If any, traces of oil infiltration can be seen at those positions. During the
250-hour running-in period of the compressor, oil leakage at the compressor shaft seal is normal.
After the running-in period, the oil leakage traces should dry out gradually.

5.13.9 Pipelines, fittings and wire harness, checking

Check the bare copper pipes, the hoses and the pipe fittings every month for interference, wear,
squeezing, looseness, etc.
Frequently check the bare wiring harness, wiring harness connectors and wiring terminals for inter-
ference, wear and looseness.

5.13.10 Tightening of the compressor bolts, checking

The tilt Angle of the compressor during loading is not allowed to exceed about 30°, and the front
and rear are not allowed to exceed 10°. After the compressor is installed, the compressor pulley
and the driving wheel should be parallel, and the end face is positive. The symmetry planes of the
corresponding wheel grooves must coincide, and the error shall not exceed 20'. The bolts of the
fixed bracket should be checked regularly to prevent loosening and abnormal sound, resulting in
damage to the clutch and connectors.

5.14 Hydraulic System

5.14.1 Hydraulic oil level, checking

Check whether the amount of oil in the hy-

draulic oil tank and brake oil tank is sufficient
through the sight glass (the oil level must be
above the red line, which is at 3/4 of the sight
glass). Fill the oil if insufficient.
Fig.5-256 Check the Brake Oil Level

NOTE：
When the hydraulic oil level is checked, all cylinders must be fully retracted.
5.14.2 Air filter element, replace
NOTICE
Risk of damage！
Dust and particles can cause mechanical damage.
• When operating the hydraulic oil tank, keep the filter, the filler port and the around area clean.


1. Shut down the engine and disconnect the

main power supply. 1 2
2. Remove the cover plate on the hydraulic oil

filter.
3. Lift the filter assembly and place it in the

container, then drain the hydraulic oil.
4. Disassemble the filter assembly and

remove the filter element. Dispose of the filter
element as environmental waste. Pay
attention to the location of the components.
3
5. Clean the filter seat parts.

Fig.5-259
6. Install the new filter and assemble the filter 1. Air filter element 2. Filter element
assembly. 3. Brake oil filter
7. Install the filter assembly and the cover, and

tighten the screws in a crosswise manner.
8. Check the oil level in the hydraulic oil tank,

which should be at the top of the hydraulic
sight glass. Fill up the hydraulic oil if
necessary.
NOTICE
Risk of damage！
Failure to follow this will result in damage.
• Make preparation work as required before checking the hydraulic oil level.
• When checking the hydraulic oil level, the boom should be completely lowered and retracted.

5.14.3 Hydraulic oil, change

1. Remove the filter cover and pump out the hydraulic oil into a collection container.
2. When most of the oil is pumped out, place a collection container under the oil drain plug of the
hydraulic oil tank to drain the remaining oil.
3. Install the drain plug after the hydraulic oil is drained.
CAUTION
Risk of damage or personal injury！
Incorrect installation may cause the machine to damage or personal injury.
• Make sure the gasket is installed in place.
4. If needed, the hydraulic oil filter should be replaced before the hydraulic oil tank is filled with oil.
5. Fill new hydraulic oil through the filler hole on the filter cover to filter and purify the filled oil, thus
protect the hydraulic system against impurities.

5.14.4 Hydraulic oil tank, cleaning

The machine uses anti-wear hydraulic oil, and the tank should be cleaned every six months.
The fuel tank should be cleaned with the following steps:
1. Open the drain plug at the bottom of the hydraulic oil tank to drain the hydraulic oil in the tank
and the pipeline;
2. Open the clean hole cover of the hydraulic oil tank;
3. Clean the tank with cleaning fluid (e.g., diesel) and dough;
4. If the cleaning is judge as meeting requirement after inspection, re-install the cleaning hole
cover;
5. Fill the tank: Open the air filter cover on the tank, and fill the hydraulic oil filtered by the 5μm filter
(filter vehicle) to the tank through the air filter element to the full scale of the oil leveler.

5.14.5 Oil return filter element, replace

A blocked filter element will hinder the oil flow,

which may result in too high pressure at the
pump outlet and burst the oil pipe.
The oil return filter element is located at the

outlet of the hydraulic oil tank.
When the filter element is replaced:
1. Remove the hydraulic oil return filter from

the hydraulic oil tank. DGH-1703001-1
2. Loosen the fixing bolt inside the filter. Fig.5-266 Replace the Oil Return Filter
Element
3. Take out the oil return filter element.
4. Install a new oil return filter element.

5.14.6 Brake pedal, adjusting and

lubricating

2. Clean the floor around the brake pedal and

confirm that nothing is obstructing the move-
ment of the brake pedal.
3. Confirm that the brake pedal can fully

bounce back, and the distance between the
brake pedal and the brake valve is 1-1.5mm.
If necessary, adjust the positioning screw of
the brake pedal for correct distance.
4. Confirm that the brake pedal can move

TY-1407020-1
freely.
5. Lubricate the brake pedal pivot with grease. Fig.5-269 Lubrication Points of the Brake Pedal

5.14.7 Parking brake unit, checking and

adjusting

WARNING
There is danger of crushing as the machine may move, which may result in injury or possibly
death.
• Chuck the tire to prevent the machine from moving.

Fig.5-272 Parking Brake
1. position
1. Start the engine and run the hydraulic sys-

tem until the accumulator is fully charged, and
the accumulator charging valve switches to
the cooling state.
2. Shut down the engine and turn the start key

to the position (1).
3. Release the parking brake.
4. Confirm that the parking brake caliper can

move on the anchor.
5. Remove the cover from the brake caliper.
Fig.5-273 Brake Caliper

6. Loosen the lock nut.
7. Adjust the screw to enable the brake.
8. Reverse the adjustment screw for 3/4 turn.
9. Tighten the lock nut.
NOTICE
Risk of damage！
Failure to follow this will result in damage.
• Avoid turning the adjusting screw.
• The lock nut must keep stationary when
Fig.5-274 Adjusting Screw
being tightened.
10.Reinstall the cover on the brake caliper.
11.Test the operation of the parking brake.
5.14.8 Brake oil filter, checking and

replacing
CAUTION
Risk of pollution！
The filter protects the brake system from
impurity intrusion. Failure to follow this will
result in pollution.
• When replacing the filter, you must prevent
new impurities from entering the brake
system.
DGH-1703002-1
Fig.5-275 Brake Oil filter


1. Shut down the machine and open the ball valve to release the brake system pressure.
CAUTION
Risk of injury！
Failure to observe the following advice may result in personal injury.
• When replacing the filter, keep the valve open.
2. Remove the drain plug from the bottom of the filter to allow the oil to flow out. As the oil flows
slowly, it takes some time.
3. Remove the filter base.
NOTICE
Risk of damage！
Filter base is heavy, and have a risk of crushing, producting damage.
• Handle the filter base carefully when loosening.

4. Remove the filter cartridge.
NOTE：
Note the position of the O-ring.
5. Clean the filter base.
6. Install the O-ring on the filter cartridge and filter base, and lubricate the it with the brake fluid.
7. Install the new filter element on the filter holder.
8. Install the filter base and the drain plug.
9. Close the open ball valve, so that the brake system can accumulate pressure.
10.Start the engine and confirm that there is no leakage in the filter base.
5.14.9 Accumulator
5.14.9.1 General information of

accumulator
WARNING
Risk of machine damage and personal injury！
Filled with high-pressure nitrogen, the accumulator can explode in case of misoperation, causing
damage to the machine and personal injury.
• There is residual pressure in the hydraulic circuit. Do not stand in the direction in which the oil is
ejected when disassembling a hydraulic device, and loosen the bolts slowly.
• Do not disassemble the accumulator.
• Keep away from fire.
• Do not punch or weld the accumulator.
• Do not hit or roll the accumulator or allow it to be exposed to any other impact.
• When handling the accumulator, bleed all gas inside. Please contact dealers authorized by
SANY Marine for this work.
The hydraulic system comprises two accumulators: A brake system accumulator and a control sys-
tem accumulator.
Normally the accumulator pressure of the control system meets the requirements of the control
system.

5.14.9.2 Brake system accumulator,

check
The accumulator is filled with nitrogen. When

1
the warning light for low brake pressure is on,
check for leakage in the following procedure: P
Fig.5-278
1. Position O

2. Start the engine and allow the engine to run

until the accumulator is charged.

3. Stop the engine, and then turn the start key

to Position O [1]. Depress the brake pedal [2]
in long stroke repeatedly, and keep it at the
depressed position for a short time.
4. Before the warning light is on, the braking

can be performed at least 5 times.
5. Start the engine to charge the accumulator,

and repeat the above test for several times.
6. If the braking can be performed for 5 times

before the warning light is on, the accumulator 2
is faulty. In such a case, the fault must be
eliminated as soon as possible, and the accu- Fig.5-281
mulator shall be charged with nitrogen. 2. Brake pedal
5.14.9.3 Accumulator, charge


The accumulators have been pre-charged with nitrogen at a certain pressure before installation,
and the pre-charged nitrogen pressure of each accumulator is specified in the hydraulic flow chart
of the Operation and Maintenance Manual. The manufacturer's instructions on the charging pres-
sure must be strictly followed.
1. The pressure of the hydraulic accumulator must be measured before charging, so as to confirm
that there is no pressure in the system.
2. Pre-charge the accumulator with a specific device and check the pressure.
CAUTION
Failure to observe the following advice may result in personal injury or property damage
• As the pre-charge pressure will change with temperature, recheck the pressure of the
accumulator two minutes after the charge ends. The difference between the pressure and the
specified value must be corrected.
• Tighten the accumulator pressure fastening bolt with a torque of 25 Nm, and then close the
bleed valve of the nitrogen cylinder. Open the bleed valve of the charging device to bleed the
excess nitrogen. Remove the charging device and check the tightness of the tightening valve
with soapy water and the like. If there is a leak, it must be repaired immediately.
• The pressure accumulator can be installed after the fastening bolts are sealed with sealing
paint.
3. Open the accumulator cover first and remove the sealing paint around the plug.
4. Clean the sealing surface of the accumulator port and the external threads, and loosen the
fastening bolts slightly with a hexagonal wrench.
5. Connect the charging device to the accu-

mulator first, and then connect the charging
hose to the nitrogen cylinder. The O-ring be-
tween the charging device and the sealing
surface of the accumulator must be in place.
6. Open the pressure fastening bolt of the ac-

cumulator with a square wrench and the auxil-
iary tool of the charging device to the degree
for just obtaining the reading of the pressure
gauge.
7. If the pre-charge pressure is too high, re- Fig.5-284

duce the pressure by opening the bleed valve
of the charging device. Note: To get the cor-
rect pressure reading, the bleed valve must
be closed.

5.14.10 Hydraulic oil circuit, check

Check whether there are loose bolts or oil

leakage at the position where the hydraulic oil
circuit is installed by means of observing and
touching. If there is any problem, please con-
tact the dealers authorized by Sany Marine to
change the parts.
Fig.5-287

5.15 Electrical System

5.15.1 Electrical system
WARNING
Risk of short circuit and fire！
If the fuse is blown out, it indicates that the electrical system has fault,which will result in short cir-
cuit and fire
• Repair the electrical system before installing a new fuse.
CAUTION
Risk of damage！
The specifications and location of the fuse are specified in the wiring diagram. The use of a
mismatched fuse may cause machine damage.
• The specifications of the new fuse must be exactly the same as those of the broken one!
The rated voltage of general electrical systems is 24 VDC.
All electrical systems use only one type of conductor, with the frame of the electrical appliance as
another type of conductor. In order to detect the fault easily and find the solution quickly, all wires
must be labeled with the designated marks in the circuit diagram.
The external insulating material of the safe conductor is oil-proof generally. But do not allow the
wire to contact with oil or other solvents when wiring. It must be ensured that the insulation of the
wires close to the engine and hot surfaces is not broken. Replace the wire immediately if broken.

5.15.2 Fuses, changing

WARNING
Risk of cable damage and fire in cable harnesses! Always use fuses with the correct am-
pere 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 Battery
5.15.3.1 Battery
Fig.5-290
DANGER
Risk of explosion！
There is a danger of explosion. When the battery is charged, it will release hydrogen, which will
form an explosive gas when mixed with the air. A short circuit, open flame or sparks can cause a
powerful explosion.
• The battery electrolyte is highly corrosive. Protect your eyes, skin and clothing, and keep it
away from children. Wear protective glasses and gloves. If it contacts with your skin, rinse the
skin with soap and plenty of water. If it contacts with eyes, rinse the eyes with plenty of water
immediately and seek medical care as soon as possible. Good ventilation should be ensured.
• The charger must be disconnected before the charging clamps are released. Do not misidentify
the positive pole (+) and the negative pole (-) of the battery, otherwise it may cause electric
shock, fire or other accidents.
• Connect the batteries with suitable wires with the terminals connected firm, otherwise it will
heat up to cause fire.
• A large amount of hydrogen and oxygen can be produced when the battery is charged or used.
Keep the battery away from open flames or high-temperature heat sources, otherwise it may
cause explosion or accident.
• Never expose the battery to direct sunlight in hot season.
• For better performance, it is not allowed to over-discharge, under-charge or over-charge the
battery during use.

5.15.3.2 Connecting and disconnecting
When connecting the battery, connect the (+)

cable (red) to the (+) pole of the battery first.
Then connect the (-) cable (black) to the (-)
pole of the battery.
When disconnecting the battery, remove the

(-) cable (black) first, and then the (+) cable
(red).
Fig.5-291
5.15.3.3 Battery, cleaning


Check whether the liquid plug is blocked regu-

larly during use. Check the liquid level at any
time, and add pure water when it reaches the
lowest level. The battery should be recharged
in time for the capacity loss due to various
reasons.
Keep the battery clean and dry. Dirt and oxide

on the battery and terminals will cause leak-
age, voltage drop and discharge, especially in
humid weather. Remove the oxides on battery
terminals and cable joints with a copper wire
brush. Tighten the cable joints and apply pro- Fig.5-294
tective grease or petroleum jelly.
If the battery installed in the machine is be

used for a long time (more than 15 days), it
should be removed, charged and stored, and
recharged every 2 months with the supple-
mentary charging method.

5.15.3.4 Battery, checking

The battery may not start normally sometimes during use due to improper use and maintenance,
or manufacturing issues. The routine testing methods are as follows.
1. Common testing instrument:

• Multimeter;
• Conductivity meter;
• Hydrometer.
2. Testing method
Observe the battery indicator to judge whether the battery is low in capacity, which can also be
judged with a multimeter or conductivity meter.
Observing battery indicator:
• When the battery indicator is green, the battery is normal;
• When the battery indicator is black, the battery is under-voltage and need to be charged;
• When the battery indicator is white, the electrolyte is insufficient. Replace the battery.

Measuring the voltage:

• If the voltage is above 12.5V, the battery is normal;
• If the voltage is 12.5 ~ 11.5V, the battery is undercharged. Measure the voltage again after
recharging the battery;
• If the voltage is below 11.5V, the battery is over-discharged or has internal failure. Measure the
voltage again after recharging the battery.
5.15.3.5 Battery, charging


Detailed rules for charging ordinary

batteries:
Fig.5-299
1. The current and time of auxiliary charging, auxiliary charging for new battery and daily auxiliary
charging are shown in the table below:
Table 5–25
Auxiliary charging for new battery

Model
Current (A) Time (h)
6-QA-180 18 June 10
Daily auxiliary charging
Model
Current (A) Time (h)
Depending on the capacity loss
6-QA-180 18
of the battery
NOTE：
The specific charging time is determined by measuring whether the battery is fully charged, which
is closely related to the battery status, so the daily auxiliary charging varies greatly. (Specifically,
when the voltage is higher than 12.56V, and the specific gravity of the electrolyte reaches 1.28
+0.05, the battery is fully charged).
2. The battery should be charged in a well-ventilated environment at a temperature of 10°C - 30°C.

If the electrolyte temperature is above 45℃, the charging current value should be reduced by half
immediately until the battery is fully charged.
3. When being charged, the battery's positive pole (+) and negative pole (-) are connected with the
positive pole (+) and the negative pole (-) output of the DC charger respectively, and the
connection is in good and firm contact. Reverse connection is not allowed, or the battery will be
damaged.

4. Phenomena when charging is completed:

• The voltage at the battery's positive pole (+) and negative pole (-) reaches 12.56 V (measured
by the battery tester), without significant change within 3 hours.
• The electrolyte density is above 1.275g/cm3 (25℃) and is uniform in each cell, without
significant change within 3 hours.
• Even and fine bubbles appeared inside the battery.
NOTE：
When the three phenomena above appear at the same time, it can be judged that the battery is
fully charged.
Detailed rules for charging maintenance-free batteries:
Precautions:
• Please follow the battery inspection process strictly before charging the battery, see “Battery,
checking” on page 5-184. Make a judgment on the battery and start the following charging
procedure if the charging conditions are met.
• Do not charge a battery with a broken jar/white areometer or solidified electrolyte.
• The battery must be charged in a well-ventilated environment.
• In the charging process, if the battery temperature exceeds 50℃, lower the charging voltage
appropriately, or stop charging; and if acid is sprayed from the battery vent or the areometer
indicates white, stop charging immediately and the battery is scrapped.
5. Charging process:
1) Choose suitable charger.
2) Connect the battery terminals with the charger turned off.
3) Connect the positive output of the charger (usually red) to the positive terminal of the battery,
while the negative output (blue or black) to the negative terminal of the battery, and confirm that
the connection is firm.
4) Turn on the charging switch of the charger, and adjust the charging voltage or current gradually
using the charger regulator until the required setting range is reached.
5) When the areometer turns green, it indicates that the charging is complete.
6) When charging is complete, turn off the power switch of the charger first, and then disconnect
the battery charging cable (do not remove the charging cable without disconnecting the power
supply in the charging process).

5.15.4 All working lights and indicators,

checking

Check whether the work lamps can be turned

on normally.
Check whether there is dirt or damage.
If any lamp cannot be turned on, the bulb may

be burned or there is an open circuit. Please
contact the dealer authorized by Sany Marine
for repair.
1. Turn the start switch to the ON position.
2. Turn on the work lamp switch and check

whether the work lamp is on. Fig.5-302

5.15.5 Wiper, adjusting

2. Adjust the angle of the wiper manually to

adjust the coverage of its stroke.
3. If there is dust on the wiper, lift the wiper,

clean it and then put it back in place, so as to 1
reduce the resistance during work.
4. Adjust the tightness of the locking bolt (1) of

the wiper arm, so that the motor can drive the
wiper easily.
5. If the wiper is damaged, loosen the nut, re-

move the old wiper from the wiper arm, and in-
stall a new one. Fig.5-305
1. Locking bolt

5.15.6 Wiring terminal, cleaning and tightening

1. Regularly check the electric control cabinet and upper electric control cabinet of the frame body
for dust and other sundries and clean them up.
2. Keep the surface of the battery clean. When dust and acid are found on the surface, it should be
wiped in time.
3. Check the exhaust plug of the battery to keep it well ventilated. Regularly check the battery and
the main power switch terminal to prevent loosening.
4. Regularly check the terminal posts of the integrated electrical box and high-current relay in the
electric control cabinet of the frame body to prevent loosening.
5. Regularly check the terminal posts of the integrated electrical box in the electric control cabinet
of the cab to prevent loosening.

5.15.7 Cable abrasion (specially around the engine), checking

1. Check the wiring harness of the frame body regularly whether there is pressure, interference
wear.
2. Check the wiring harness on the engine regularly.
3. Check the wiring harness of the corresponding sensor on the gearbox periodically.
4. Regularly check whether the solenoid valves and sensor connectors are loose or in bad contact.

5.16 Maintenance Record List

Table 5–26 Machine Maintenance Record 1
Machine Start date Jobsite

name
Name
Mainte Mainte Machine
Serial and grade Quantity of Source of Per
nance nance service
number of material material formed by
part date time
material
1 　　　　　　　
2 　　　　　　　
3 　　　　　　　
4 　　　　　　　
5 　　　　　　　
6 　　　　　　　
7 　　　　　　　
8 　　　　　　　
9 　　　　　　　
10 　　　　　　　
11 　　　　　　　
12 　　　　　　　
13 　　　　　　　
14 　　　　　　　
15 　　　　　　　
16 　　　　　　　
17 　　　　　　　
18 　　　　　　　
19 　　　　　　　
20 　　　　　　　
21 　　　　　　　
22 　　　　　　　
23 　　　　　　　

Reach stacker Troubleshooting
Troubleshooting
6 Troubleshooting ..............................................................................................................6-1
6.1 Precautions ............................................................................................................................6-3
6.2 Troubleshooting Procedures ...............................................................................................6-3
6.3 Troubleshooting the engine system ...................................................................................6-4
6.4 Troubleshooting the transmission system .........................................................................6-5
6.4.1 Overview.......................................................................................................................6-5
6.4.2 Troubleshooting procedures......................................................................................6-6
6.4.3 Troubleshooting table .................................................................................................6-7
6.5 Troubleshooting the drive axle and brake system............................................................6-8
6.6 Troubleshooting the air conditioning system.....................................................................6-8
6.7 Troubleshooting the hydraulic system ...............................................................................6-9

Troubleshooting Reach stacker
WARNING

6.Troubleshooting
6.1 Precautions
CAUTION
Each machine has undergone strict factory inspection before shipment to ensure that the
supplied machines can maintain the best working status. In order to ensure the good working
status, the machine must be maintained regularly in the intervals provided in this chapter.
• Do not perform any inspection and maintenance not described in this manual.
• Only use genuine replacement parts, grease and oil form SANY Marine.
• When changing or filling oil, do not mix different types of oil. When changing different types of
oil, all old oil must be drained and new oil must be filled completely, and the filter must be
replaced together. (It will have no impact if the small amount of remaining oil in the pipeline is
mixed with new oil)
6.2 Troubleshooting Procedures

You can perform the following 6 basic steps to find out the failure cause and work out the corre-
sponding 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 Troubleshooting the engine system
Table 6–1
Failure Symptom Possible Causes Suggested Actions

Too low temperature
Insufficient preheating time of Completely preheat the engine.
engine
Not easy to start Clean or change the air filter. See

the engine Blocked air filter “Air filter, clean” on page 5-44 and
“Air filter, replacing ” on page 5-46.
Check if the battery lack of voltage.
Insufficient starting voltage See “Battery, checking” on page 5-
184.
Engine stops
No fuel Fill the tank with fuel.
unexpectedly
Engine See “Coolant level, check and top

Insufficient coolant in water tank
overheating or up” on page 5-73.
running hot The drive belt is loose See “Drive belt, check” on page 5-36
Lubrication oil Refill the lubrication oil. See “Oil
pressure is too The oil level is too low level, check and top up” on page 5-
low 54


Replace the filter.
See “Oil filter or the bypass filter,
The oil filter is blocked replace (VOLVO engine)” on page 5-
57 and “Oil filter, replace (CUMMINS
Change the engine. See “Engine oil,
The engine oil is too thin
change” on page 5-55
The power of Check if the air intake pipe is
engine is not The air intake pipe is damaged blocked. See “Turbocharger, check”
sufficient on page 5-82.
Change the pre-filter and fuel filter.
See “ Fuel filter, replace (VOLVO
The pre-filter and engine)” on page 5-64, “Fuel filter,
fuel filter are The filter is too dirty replace (CUMMINS engine)” on
blocked page 5-66 and “Fuel pre-filter,
change (VOLVO engine)” on page 5-
68.
Replace belt. See “Drive belt,
The engine fan
The quality of belt itself replace (engine option VOLVO)” on
belt is broken
page 5-38.
6.4 Troubleshooting the transmission system

6.4.1 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 trans-
mission 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 consid-
er 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 and functioning correctly, the correct 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 op-
eration, to engage and hold the clutches from slipping, and to cool and lubricate the working
components.

6.4.2 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 forward (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
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 temper-
ature (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 fol-
lowing 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.
• Be sure that all components of the 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. noload 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 oper-
ating at stall RPM.
6.4.3 Troubleshooting table
Table 6–2

Low oil pressure Check the oil level.
Slipping of clutch See “Transmission oil level,
Insufficient oil checking” on page 5-89
Check the level of lubrication oil.
High oil
Low or high oil level See “Transmission oil level,
temperature
Inadequate oil
pressure Check the oil level.
displayed by oil Low oil level See “Transmission oil level,
pressure checking” on page 5-89
instrument
Excessive Tighten the mounting bolts.
vibration and The mounting bolts are loose See “Mounting bolts and mounting
noise in cab pad, check” on page 5-94

6.5 Troubleshooting the drive axle and brake system
Table 6–3

Oil pressure of braking system is Examine if the brake oil has leakage.
low See “ Oil leaking of drive axle and
brake components, checking” on
The force of Braking oil circuit has air
page 5-100.
service brake is
Examine the brake components.
not sufficient
See “ Oil leaking of drive axle and
The brake components are worn out
brake components, checking” on
page 5-100.
No parking brake
Examine the parking brake function.
or the parking
Failure of parking brake See “ Brake pads and braking
brake functions
function, checking” on page 5-104.
bad
6.6 Troubleshooting the air conditioning system
Table 6–4

Cab temperature is lower than the set
Set a lower temperature.
temperature
Turn on the refrigeration
High temperature changes during one day mode after the temperature
is getting higher.
No refrigeration
effect Check if the inserting fuse in
electric cabinet is blown. If
yes, change the fuse.
Fuse of condenser burns out See “Fuses, changing” on
page 5-180.
Check if the fuse is fixed.
Close all the windows and
Bad sealing of cab
doors.
Bad refrigeration Fill in refrigerant.
effect See “Refrigerant/
Refrigerant is not enough
refrigeration oil，filling” on
page 5-156.

6.7 Troubleshooting the hydraulic system
Table 6–5
High oil Low flow of cooler Clean the cooler.

temperature Outer radiator fins are too dirty Wash the outer radiator fins.
Hydraulic oil of substandard quality Replace the hydraulic oil.
Hydraulic oil of substandard See “Hydraulic oil, change” on page
viscosity 5-166.
Replace the filter core periodically.

The constant entrance of dust, sand
See “Oil return filter element,
and other debris
Hydraulic oil is replace” on page 5-168.
polluted and High temperature, oxidation
deteriorated metamorphism Replace the hydraulic oil.
See “Hydraulic oil, change” on page
Entry of water and air, as a result of 5-166.
cavitation, erosion, etc.
Clean it or replace it.
Clogged filter See “Air filter element, replace” on
page 5-164.
The hydraulic or
Replace the fuse.
brake cooling
The fuse of cooling system is burnt See “Fuses, changing” on page 5-
system does not
180.
cool automatically


Reach stacker Specifications
Specifications
7 Specifications ...................................................................................................................7-1
7.1 Technical Specifications.......................................................................................................7-3
7.1.1 Basic parameters ........................................................................................................7-3
7.1.2 Technical Parameters.................................................................................................7-4
7.1.3 System configuration ..................................................................................................7-4
7.1.3.1 Power system configuration ...............................................................................7-4
7.1.3.2 Spreader configuration........................................................................................7-5
7.2 International length and moment unit Conversion ...........................................................7-5
7.2.1 Conversion table, area ...............................................................................................7-5
7.2.2 Unit abbreviation explanation....................................................................................7-6
7.2.3 Conversion table, SI units ..........................................................................................7-6
7.2.4 Conversion table, length ............................................................................................7-7
7.2.5 Conversion table, volume ..........................................................................................7-8
7.2.6 Conversion table, weight............................................................................................7-8
7.2.7 Conversion table, pressure........................................................................................7-8
7.2.8 Conversion table, temperature..................................................................................7-9

Specifications Reach stacker
WARNING

7.Specifications
7.1 Technical Specifications

7.1.1 Basic parameters
F
D E
A B
Fig.7-1
Table 7–1
Item Unit SRSC45V5 Reach stacker

A Total length mm 11286
Front wheel
B mm 4140
width
C Total height mm 4850
D Wheelbase mm 6000
Rear wheel
E mm 3048
width
Minimum
F ground mm 330
clearance
G Total width mm 6053～12185
mm Load center 1965
1st row Layers 1-4 45000
kg
Layer 5 43000
Load mm Load center 3815
capacity 2nd row Layers 1-4 31000
kg
Layer 5 (8′6″) 30000
mm Load center 6315
3rd row
kg Layers 1-3 15000

Item Unit SRSC45V5 Reach stacker

Layer 4 (8′6″) 14000
Total weight kg 71500
7.1.2 Technical Parameters
Table 7–2
Model Technical Parameters

Max lifting height 15100mm
Boom
Inclination 0-60°
Maximum lifting speed (No load/Full load) 420/250mm/s
Maximum lowering speed (No load/Full load) 360/300mm/s
SRSC45V /
SRSC45V1A Maximum travel speed (No load/Full load) 25/21 km/h
Reach Gradeability (No load/Full load) 46/28 %
Stacker
Minimum turning radius 8000mm
Braking distance (No load/with the load of 31t, 10km/h) 8.5/1.5 m
Total system displacement 210 ml/r
Hydraulic system working pressure 280 bar
7.1.3 System configuration
7.1.3.1 Power system configuration
Table 7–3
Machine model SRSC45V5

Model VOLVO TAD1181
In-line 6-cylinder, 4-stroke, air-to-air cooling,
Type
Engine turbocharging, and electronic fuel injection
Rated power 265kw/2100rpm
Emission standard Euro Ⅴ
Gearbox Model DANA 15.7TE30
Drive axle Model Kessler D102PL341

7.1.3.2 Spreader configuration
Table 7–4
Model System Parameters

Rotation angle +105°/-195 °
Side movement ±800 mm
SDJ450H-R1
Maximum load 45000 kg
Scope of Application 20′～40′ international standard container
Side movement ±800 mm
ELME817
Maximum load 45000 kg
BROMMA Side movement ±800 mm
RSX40 Maximum load 45000 kg
7.2 International length and moment unit Conversion

7.2.1 Conversion table, area
Table 7–5 Area Conversion Table
Unit cm² m² km² A ft² yd² in²

cm² 1 0.0001 - 0.000001 0.001076 0.000012 0.155
m² 10000 1 0.000001 0.01 10.764 1.1958 1550.000
km² - 1000000 1 10000 1076400 1195800 -
a 0.01 100 0.0001 1 1076.4 119.58 -
ft² - 0.092903 - 0.000929 1 0.1111 144.000
yd² - 0.83613 - 0.008361 9 1 1296.001
in² 6.4516 0.000645 - - 0.006943 0.000771 1
iha=100a 1mile²=259ha=2.59km²

7.2.2 Unit abbreviation explanation
Table 7–6 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
7.2.3 Conversion table, SI units
Table 7–7 SI Units Conversion Table
Recalculation
SI-unit Non-SI Non-SI SI
factor
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
Pressure (Pa=N/m2)
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
kp/cm2 x 14.22 =psi x 0.070 =kp/cm2
N/cm2 x 145.04 =psi x 0.069 =bar

Table 7–7 SI Units Conversion Table (continue)
Recalculation
SI-unit Non-SI Non-SI SI
factor
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/s x 0.305 =m/s
m/s2 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 x rpm 5252 = bhp
TQ(lb·ft)
Temperature
℃ =（T-32)/1.8 °F=（℃ x 1.8) +32
Flow factor
l/min (dm3/min) x 0.264 = US gal/min x 3.785 = liter/min
7.2.4 Conversion table, length
Table 7–8 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 100 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

Table 7–8 Length Conversion Table (continue)
Unit cm m km in ft yd mile
mile 160930 1609.3 1.6093 63360 5280 1760 1
1 mm = 0.1 cm - 1mm = 0.001 mm
7.2.5 Conversion table, volume
Table 7–9 Volume Conversion Table
Unit cm³=cc m³ l in³ ft³ yd³

cm³=ml 1 0.0000001 0.001 0.061024 0.000035 0.000001
m³ 1000000 1 1000 61024 35.315 1.30796
dm³(l) 1000 0.001 1 61.024 0.035315 0.001308
in³ 16.387 0.000016 0.01638 1 0.000578 0.000021
ft³ 28316.8 0.028317 28.317 1728 1 0.03704
yd³ 764529.8 0.76453 764.53 46656 27 1
1gal(US)=3785.41cm³=231in³=0.83267gal(UK)
7.2.6 Conversion table, weight
Table 7–10 Weight Conversion Table
Unit g kg t oz lb
g 1 0.001 0.0000001 0.03527 0.0022
kg 1000 1 0.001 35.373 2.20459
t 1000000 1000 1 35273 2204.59
oz 28.3495 0.02835 0.000028 1 0.0625
lb 453.592 0.45359 0.000454 16 1
1ton(metric)=1.1023tonz (US)=0.9842tonz(UK)
7.2.7 Conversion table, pressure
Table 7–11 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

Table 7–11 Pressure Conversion Table (continue)
Unit kp/cm² bar Pa=N/m² kPa lbf/in² lbf/ft²

lbf/in² 0.07032 0.0689 6894.76 6.89476 1 144
lbf/ft² 0.00047 0.00047 47.88028 0.04788 0.00694 1
kp/cm²=735,56Torr(mmHg)=0.96784atm
7.2.8 Conversion table, temperature
Table 7–12 Celsius-Fahrenheit Temperature Conversion Table
℉ ℃ ℉ ℃ ℉ ℃ ℉ ℃ ℉ ℃ ℉ ℃
-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
Conversion formula: t℃=5(T℉-32)/9, T℉=(9Xt℃+160)/5


Reach stacker Optional Parts
Optional Parts
8 Optional Parts ...................................................................................................................8-1

8.1 Engine Preheating Protection Function .............................................................................8-5
8.2 Fire detection and Alarm System / Automatic Extinguishing ..........................................8-5
8.2.1 Fire Detection and alarm system / automatic extinguishing de............................8-5
8.2.2 Fire detection and alarm system...............................................................................8-6
8.2.2.1 Fire detection and alarm .....................................................................................8-6
8.2.2.2 Functions description ..........................................................................................8-6
8.2.2.3 Precautions...........................................................................................................8-7
8.2.2.4 Fire detection and alarm system / automatic extinguishing...........................8-8
8.2.2.5 Maintenance and repair ......................................................................................8-8
8.2.3 Automatic fire extinguishing device ..........................................................................8-9
8.2.3.1 Automatic fire extinguishing device...................................................................8-9
8.2.3.2 Precautions........................................................................................................ 8-10
8.2.3.3 Technical parameters ....................................................................................... 8-10
8.3 Loudspeaker and Controller Kit ........................................................................................8-11
8.3.1 Engine Idle Protection Function ..............................................................................8-11
8.3.2 Loudspeaker and controller kit ............................................................................... 8-12
8.3.3 Control panel............................................................................................................. 8-12
8.3.4 Operations................................................................................................................. 8-13
8.3.5 Electrical wiring diagram ......................................................................................... 8-13
8.3.6 Precautions ............................................................................................................... 8-13
8.4 Engine hour meter.............................................................................................................. 8-14
8.5 Twist lock counter............................................................................................................... 8-14
8.6 Reversing radar monitor.................................................................................................... 8-15
8.7 Operator-off-seat sensing system ................................................................................... 8-15
8.8 Radio.................................................................................................................................... 8-15
8.8.1 Radio.......................................................................................................................... 8-15
8.8.2 Radio control panel .................................................................................................. 8-16
8.8.3 Mute ........................................................................................................................... 8-16
Optional Parts Reach stacker
8.8.4 Sound......................................................................................................................... 8-17

8.8.5 Audio settings ........................................................................................................... 8-17
8.8.6 Reception .................................................................................................................. 8-18
8.8.7 RDS function (FM band) ......................................................................................... 8-20
8.9 Automatic Lubrication System.......................................................................................... 8-21
8.9.1 Automatic lubrication system.................................................................................. 8-21
8.9.2 Operation precautions ............................................................................................. 8-21
8.9.3 Lubrication time settings ......................................................................................... 8-22
8.10 CCTV System................................................................................................................... 8-23
8.10.1 CCTV System......................................................................................................... 8-23
8.10.2 Precautions............................................................................................................. 8-23
8.10.3 Major parts .............................................................................................................. 8-24
8.10.4 Installation Instructions ......................................................................................... 8-24
8.10.5 Shift switch.............................................................................................................. 8-26
8.10.6 Troubleshooting the CCTV system ..................................................................... 8-26
8.10.7 System wiring diagram.......................................................................................... 8-28
8.11 Flowmeter.......................................................................................................................... 8-29


WARNING

8.Optional Parts
8.1 Engine Preheating Protection
Function
The control unit monitors the preheating situation of engine 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.
8.2 Fire detection and Alarm System / Automatic Extinguishing

8.2.1 Fire Detection and alarm system /
automatic extinguishing de
Press the fire detection and alarm switch on

the right operation panel to activate the fire
detection and alarm.
Fig.8-1 Fire Detection and Alarm Switch

8.2.2 Fire detection and alarm system
8.2.2.1 Fire detection and alarm
The fire detection and alarm system (FZZK/

W03) (hereinafter referred to as "the system")
is used by the engine compartment host to an-
alyze, recognize and process the signals in
each area in real time by various fire detection
components monitoring the ambient tempera-
ture (in the engine compartment) continuously
in real time, thus realizing the functions of
monitoring, alarming and automatic fire extin-
guishing. The system also has the function of
automatic online fault detection and alarm,
high temperature/ fire warning and automatic Fig.8-2 Fire Detection and Alarm System
output for starting the fire extinguisher to im-
plement automatic fire extinguishing.
8.2.2.2 Functions description
• Normal work test function:

When the system enters the working state after installation, the fault output L+ drive line outputs
a 12V-24V level, and the system enters the inspection work state. When powered on for the first
time, if the fault output L+ drive line outputs a 12V-24V level which flashes at 0.5HZ for 4 sec-
onds and then goes out, the system works normally.
• High-temperature alarm and automatic fire extinguisher function:
When the engine compartment detection host detects that the temperature of the engine room
detected by the NTC fire detection component reaches 110° C, the high-temperature warning
output T+ drive line outputs a +12V-24V level to inform the operator of the high temperature in
the engine compartment through an external device. After the driver processes the alarm man-
ually, the temperature returns to normal level. When the host detects that the temperature drops
below 110℃, the high-temperature alarm will be cancelled automatically.
• Fault detection function:
When the connection lines of the engine compartment fire detection component, the fire extin-
guisher and the control system host is short/open-circuited, the system will perform fault detec-
tion automatically, and the detection alarm light will flash for 1 seconds every 12 seconds. Note:
Fault at any one line will not affect other functions.
• Function of intelligent recognition of fire signal for automatic activation of fire extinguisher:
When the engine compartment NTC fire detection component detects that the ambient tempera-
ture is above 85°C, and the rise rate is over 30°C /MIN, or the absolute temperature is over 130°
C (the fire point) and lasts for a certain time, it will judge that is the fire state, and the alarm host
will activate the high temperature warning function first at 110° C, and the high temperature

warning output T + drive line output sends a high temperature alarm signal. If the temperature
continues to rise to reach the conditions of fire, the system outputs the fire extinguisher auto-
matically to implement the automatic fire extinguishing function.
• Fire extinguisher activation alarm function:
When the fire extinguisher starts to spray, the fault output L+ drive line and the high-temperature
warning output T+ drive line output a +12V-24V level to inform the operator that a fire occurs in
the engine compartment via an external device and the fire extinguisher has started to extin-
guish the fire.
• Function of starting the fire extinguisher manually:
After the fire is discovered manually, the automatic fire extinguisher can be forced to start by the
manual starting switch.
• In the event of a fire, the system will start the fire extinguisher automatically. Disconnect the
power supply to the machine, and replace the system host, the probe wire harness and other
parts to avoid unknown damage.
8.2.2.3 Precautions
The following procedures should be performed after the initial installation, repair and maintenance
of this product, otherwise it may not work properly.
1. When performing test after installation, do not plug in the connector between the host and the
fire extinguisher, but connect a 12V-24V test lamp to the fire extinguisher output F+ and F- drive
lines of the host; or measure the voltage on both terminals with the voltage meter of a multimeter.
2. Power on the host to start it. Then check whether the fault output L+ drive line has 3 high-level
pulses; if this is normal, it indicates that the host has entered the normal patrol inspection state;
then observe the fault output L+ drive line status within 1 minute, and check the fault detection for
every 12 seconds. In this step, the 12V-24V test lamp should always be off, or the voltage meter of
the multimeter is always 0.
3. If there is a flash in 1 minute, it means that there is an installation fault. After troubleshooting,
repeat Steps 1 and 2 above. If there is no flash within 1 minute, it indicates that there is no
installation fault, and the host works normally. Go to next step and check the engine compartment
detector.
4. Heat the metal probe of any engine compartment NTC temperature detector with a lighter or
other methods to simulate a fire. After heating slowly for 10 seconds, the high-temperature
warning starts first, the high temperature warning T+ drive line outputs a 12V-24V level, then the
fault output L+ drive line, the high-temperature warning T+ drive line and the fire extinguisher
output F+ and F- drive lines all output a 12V-24V high level, and the 12V-24V test lamp is on or the
multimeter displays 12V-24V. It indicates that the host and this detector work normally.

5. If the host resumes its initial state when powered off, this product is qualified and can be used
normally.
6. After the installation passed the test, connect the power supply of the machine and the fire
extinguisher, and then the machine can be used normally.
8.2.2.4 Fire detection and alarm system / automatic extinguishing
1. During the inspection of the machine, check the NTC temperature detector in the engine
compartment for short circuit and open circuit, and the fire extinguisher for open circuit; if any, the
L+ drive line 1s high-level pulse will be output every 12s to report a fault.
2. When one of the NTC temperature detectors fails, a fault will be reported, which will not affect
the other two NTC temperature detectors and other functions.
3. If there are several fire extinguishers, no fault will be reported as long as one of them is normal.
If the fire extinguisher fails, the host may start but fail to extinguish the fire.
4. If the fault output L+ drive line on the instrument panel is always at a high level of 12V-24V after
power-on, it means that the host cannot work normally. Please replace the host.
5. Once there is a fire in the engine compartment, after the host starts to extinguish the fire, the
output F+ and F- drive lines all output a high level of 12V-24V, and the state cannot be restored
automatically until the power is off.
6. After a fire, please cut off the power to replace the host and temperature sensor. Check and
replace the wiring harness, sensor, etc. and perform strict tests to avoid potential hazards.
8.2.2.5 Maintenance and repair
1. The NTC temperature detectors for the main engine and engine compartment should be
installed before commissioning only, and kept properly before installation.
2. Before the maintenance and service of the machine, disconnect the power supply of the engine
at the battery to stop the engine working, thus avoiding false alarm linkage. After the maintenance
and service are completed, the power supply should be turned on in time to allow the engine and
temperature sensors to work.
3. Do not replace or modify the components and structures that affect the detection performance
during maintenance, and never install them less than 20cm away from the location with a
temperature over 100°C during the normal operation of the engine (exhaust pipe, engine housing
surface, etc.) .

4. Check whether the surface of the NTC temperature detector is clean and wipe it regularly. The
unclean surface of the NTC temperature detector will affect its sensitivity, and the detector may not
alarm when a fire occurs if the surface is too dirty.
5. Never use non-specified and non-standard 12V-24V power supply to avoid damage to the
engine.
6. Never perform maintenance and service when the engine is powered on.
7. The engine and the detector should be installed firmly, and the internal and external grounding
should be firm.
8. A simulated fire alarm test should be carried out every six months to test whether the NTC
temperature detector works properly.
9. During maintenance, take care to protect the NTC temperature detector and its wiring harness
against collision and damage. Replace the wiring harness or the NTC temperature detector timely
if damaged.
10.When the engine components fail, you can contact Sany Marine to replace new ones. Users
are not allowed to disassemble the engine and the NTC temperature detector without
authorization so as to avoid unnecessary losses.
8.2.3 Automatic fire extinguishing device
8.2.3.1 Automatic fire extinguishing

device
Designed for the hot and fire-hazardous parts

of the machine, the automatic fire extinguisher
is a device with certain shock-resistant capa-
bility and suitable for harsh working environ-
ment. This device is composed of the ultra-
fine dry powder fire extinguishing agent, the
driving medium, two fire extinguishing agent
storage tanks, the constant pressure release
valve, the multi-nozzle hose, the initiator as-
sembly (the thermal initiation assembly or the
electric initiation assembly optional) and other Fig.8-3 Fire Extinguishing Device
components. When linked with the fire alarm 1. Nozzle 2. Powder chamber
system, it start automatically to extinguish the
3. Dual driving chamber
fire when there is a fire at a hot part of the ma-
4. Pipe connector 5. Hose
chine. And the fire extinguisher can also be
activated manually with the optional activation
switch.

8.2.3.2 Precautions
The following procedures should be performed after the initial installation, repair and maintenance
of this product, otherwise it may not work properly.
1. When performing test after installation, do not plug in the connector between the host and the
fire extinguisher, but connect a 12V-24V test lamp to the fire extinguisher output F+ and F- drive
lines of the host; or measure the voltage on both terminals with the voltage meter of a multimeter.
2. Power on the host to start it. Then check whether the fault output L+ drive line has 3 high-level
pulses; if this is normal, it indicates that the host has entered the normal patrol inspection state;
then observe the fault output L+ drive line status within 1 minute, and check the fault detection for
every 12 seconds. In this step, the 12V-24V test lamp should always be off, or the voltage meter of
the multimeter is always 0.
3. If there is a flash in 1 minute, it means that there is an installation fault. After troubleshooting,
repeat Steps 1 and 2 above. If there is no flash within 1 minute, it indicates that there is no
installation fault, and the host works normally. Go to next step and check the engine compartment
detector.
4. Heat the metal probe of any engine compartment NTC temperature detector with a lighter or
other methods to simulate a fire. After heating slowly for 10 seconds, the high-temperature
warning starts first, the high temperature warning T+ drive line outputs a 12V-24V level, then the
output F+ and F- drive lines all output a 12V-24V high level, and the 12V-24V test lamp is on or the
multimeter displays 12V-24V. It indicates that the host and this detector work normally.
5. If the host resumes its initial state when powered off, this product is qualified and can be used
normally.
6. After the installation passed the test, connect the power supply of the machine and the fire
extinguisher, and then the machine can be used normally.
8.2.3.3 Technical parameters
Table 8–1 Technical Parameters
Specification and model FZBA0.4-C/GW FZBA1-C/GW

Quantity of extinguishing 400 1000
agent (g)
Total flooding protection ≥4 ≥8
volume (m3)

Table 8–1 Technical Parameters (continue)
Specification and model FZBA0.4-C/GW FZBA1-C/GW

Start method Electrically controlled and Electrically controlled and
temperature controlled temperature controlled
Spray time (s) ≤5 ≤5
Use environment -40～9 0 -40～9 0
temperature (℃)
Safe current (mA) ≤ 150 ≤ 150
Starting current (mA) ≥ 600 ≥ 600
Use voltage (V) DC6V-24V DC6V-24V
Weight (g) 1735±5 4420±5
Dimensions (mm) Φ60*300 Φ89*350
8.3 Loudspeaker and Controller Kit

8.3.1 Engine Idle Protection Function
Choose the engine idle protection function at

PARAMATER SETTING
the setting menu of display.
Item Adjusting value Feedback value
Within 60 seconds after the engine is started, Automatic lock 0000 No
there is no response from throttle and the en- Curve selection 0000 Opti-index 1.2
Slope selection 0000 2-section slope
gine keeps running at idle. After 60 seconds,
Pre-buffer index 0000 0
it is able to operate the machine normally and Auto speeding 0000 0 Item
Switch
there is no limitation to the throttle. Idle_Protect 0000 No
Send
When the engine is running at maximum
speed, switching ignition key to P position
Back
cannot stop the engine immediately. This pro-
tection allows a few seconds for the engine to Fig.8-4 Setting Menu
run idle before stopping. But the emergency
stop button is still effective even if the idle pro-
tection function is activated.

8.3.2 Loudspeaker and controller kit
Main functions and features:
• Loudspeaker-first alarm;
• Continuously tuning volume;
• Supporting both speaking and
broadcasting;
• Various alarm tones are available;
• Synchronous sound and light alarm
(optional);
• Multiple combined configuration modes for
flexible and convenient system application; Fig.8-5 Loudspeaker
• Novel appearance and structure, and
convenient operation.
8.3.3 Control panel
The composition of control panel is shown in

the right figure.
1
2
4
5 6 7 8
Fig.8-6 Control Panel
1. Alarm indicator 5. Tone select

2. Power indicator 6. Alarm switch
3. Power switch 7. Volume (-)
4. Light switch 8. Volume (+)

8.3.4 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 will 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.
8.3.5 Electrical wiring diagram
Fig.8-7 Electrical Diagram
8.3.6 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 normal phenomenon that the temperature in control box rises during the operation.
• Never open the control box without permission.
• Any questions in operation, please contact SANY.
8.4 Engine hour meter

The engine hour meter displays the number of
the engine's working hours.
The engine hour meter is used to determine

when the machine needs scheduled mainte-
nance. All scheduled maintenance is based
on the working time (hours) of the machine.
TY-1407006-1
Fig.8-8 Engine Hour Meter
8.5 Twist lock counter

The twist lock counter displays the work times
of the spreader twist lock.
The twist lock counter is used to determine

when the twist lock is scheduled for mainte-
nance. All the regular maintenance time is
subject to the actual work times of the spread-
er twist lock.
TY-1407007-1
Fig.8-9 Twist Lock Counter

8.6 Reversing radar monitor

When the machine is reversing, the reversing
radar will be activated automatically, and the
reversing radar monitor will show the rear
view of the vehicle, which is convenient for
reversing.
TY-1407008-1
Fig.8-10 Reversing Radar Monitor
8.7 Operator-off-seat sensing system

The operator-off-seat sensing system judges whether the operator is in place by the pressure
switch under the seat, so as to protect the machine by terminating its actions (engine start, attach-
ment action, etc.) when no one is operating.
The operator-off-seat protection of Sany's machines are enabled in the factory, and the default pro-
tection time is 1 minute. You can enable/diable this function and adjust the protection time through
the General Settings page on the monitor. The machine will have corresponding action protection
if the function is enabled, which will fail if the function is disabled; the adjusting range of the protec-
tion time is 0~60 minutes.
8.8 Radio
8.8.1 Radio
Radio is an option for the machine, and the in-

stallation position is shown on the right.
CAUTION
Risk of personal injury！
Too much noise affects one’s hearing.
• Please adjust the volume of the radio to
the level that it does not impact hearing
traffic information (such as hooter and
siren).
TY-1407009-1
Fig.8-11 Radio

8.8.2 Radio control panel
8 7 13
TA DISC
SOUND LOUD
AF AST PRISAT
9 11
1 4 BAND
VOLUME
2 VOCAL ROCK CLASS
IC 5 10
VOLUME JAZZ FLAT POP
3 TA AF AST
RDS
9 12
321 456 10
Fig.8-12 Radio Panel
1. Preset key 1 2. Preset key 2 3. Preset key 3 4. Preset key 4

5. Preset key 5 6. Preset key 6 7. Sound mode 8. On/Off
9. volume 10. Radio mode 11. FM/AM 12. Automatic
13. Display channel locking
8.8.3 Mute
Short press the key to enable/disable the

Mute mode.
Fig.8-13 Mute

8.8.4 Sound
Select the sound effect you need based on

your preferences.
• Press the key to select BASS-

TRE, and press the volume keys +/- to
adjust the sound effect type.
BASS-TRE: You can set the

-
volume by yourself
- FLAT: Original
- JAZZ: Jazz
- VOCAL: Speech Fig.8-14 Sound Button
- POP: Pop music
- CLASSIC: Classical music
- ROCK: Rock music
8.8.5 Audio settings
• Press the key to choose the

option you want to adjust.
Sound effect types: (BASS-

-
TRE, FLAT, JAZZ
VOCAL, POP, CLASSIC,
ROCK)
- BASS: Bass
- TREBLE: Treble
- BALANCE: Balance
- FADER: Fader
Fig.8-15 Sound Type
- LOUD: (off, low, medium, high)
• Press Volume +/- again to adjust the option

you chose. 5 seconds later, the display will
return to the last operating mode. Only
when BASS-TRE is chosen can the bass
and treble settings be adjusted.

8.8.6 Reception
Wave band
b
• Press the key to select [b] the
desired wave band.
a a
Auto Search
• Press the or key to search [a] for

radio stations automatically.
c
• Press the key to tune to the radio
stations at the low end of the band, or press Fig.8-16 Band Button
the key to tune to the radio stations at
A. Select B. Search
the high end.
C. Activate auto storage
• To search for another radio station, just
press the same key.
Manual search
• Long press the search key or for

about 2 seconds to enter the manual
search mode.
• Press the key to search for radio
stations at he low end of band, and press
to search for those at the high end.
• Without search actions for 5 seconds, the
system will return to the last operating state
automatically.

Pre-selected station (the frequency of the de-

sired radio station is known)
Manually store radio stations and preset keys
6 stations can be stored in each band with the

preset keys (1 to 6)
• Tune to the desired radio station

• Press and hold the desired preset key (1 to
6) for at least 2 seconds to save the radio
station to this preset key.
Recall preset Fig.8-17 Station Button
• Press the desired preset key (1 to 6) to

recall the preset radio station.
Auto storage
• This function can automatically store the 6

FM radio stations with the strongest signals
in the FMAST band or the 6 MW (AM) radio
stations in the MW (AM) AST band. When
auto storage function is used, the new radio
stations will replace the radio stations
previously stored in the FMAST band or the
MW(AM)AST band.
• Press the key to activate auto

storage [c].
• The main unit beeps and then mutes.
• You will hear a beep after the storage is
complete.
• Sometimes 6 stations may not be found.
Display mode switching (non-RDS radio

station)
• Press the DISP key to switch between the

radio station name, the frequency, the
sound mode and the clock.

8.8.7 RDS function (FM band)
Many FM radio stations broadcast RDS channels, and this machine provides the following conven-
ience for you with the RDS information (The radio stations in China does not provide RDS informa-
tion now)
Show station name

• The host displays the station name instead of the frequency
Alternative station name

• If this key is activated, the host will search for the best receiving frequency of this station while
keeping the current station.
note: You can turn off the AF function if not needed.
Alarm (PTY alarm)

• This machine automatically receives emergency information sent by the broadcast.
• During the alarm, the monito displays "ALARM" and the station name alternately.
TA mode (traffic information)

• You can activate the TA/News/Weather mode to listen to related information with priority.
Activate/deactivate TA mode
• Press the TA key to activate/deactivate TA.
If you activate the TA/NEWS mode

• You will hear the broadcast traffic information/news.
• If the tuned radio station cannot receive traffic information, the monitor will display"NO TA", and
the host will search for another suitable radio station automatically.

8.9 Automatic Lubrication System

8.9.1 Automatic lubrication system
The automatic lubrication system is consisted

Lubrication Overflow
of the main machine lubrication system and pump valve Grease nipple
the spreader lubrication system. The main
machine and the spreader are lubricated by
two electric lubrication pumps respectively.
The lubrication system is perform lubrication
in a completely automatic manner, and the op-
erator does not need any operation generally.
The main machine lubrication pump is located

on the left side of the rear wing of the frame.
Fig.8-18
The spreader lubrication pump is located on

the upper part of the main beam of the
spreader.
RS-1407033-1
Fig.8-19
8.9.2 Operation precautions
When operating the automatic lubrication system, you must pay attention to the following items:
• Observe whether there is enough grease in the tank of the oil pump and add grease in time, and
the oil pump must not run empty.
• See whether the upper cover of the oil storage tank is tightly closed, so as to prevent dust and
dirt from entering the tank and causing system fault.
• Add grease with a grease fitting and do not open the upper cover.
• 2# grease can be used in high ambient temperature, while 0# grease in low temperature.
• Observe whether there is grease overflow in the overflow valve of the pump. If so, it indicates
that the system has a fault which should be eliminated in time.

• Usually, the lubrication time and intermittent time are set as follows when the equipment leaves
the factory: running for 6 minutes with an intermittent time of 3 hours. However, you can press
the trigger switch on the operating panel in the cab (for more than 2 seconds) to add grease
temporarily after the equipment is repaired and when necessary.
8.9.3 Lubrication time settings
If the time setting is changed based on specif-

ic needs or accidentally, the user can change
the lubrication time and interval settings or re-
store the factory settings as follows:
1. Remove the protective cover on the base

and set the lubrication and interval.
NOTE：
After completing the time setting, make sure
to install and tighten the protective cover.
RS-1407034-1
Fig.8-20
2. The interval is set in the following way, with

the value in the Hour column of the table ap-
plicable to this machine. 3
Interval setting: 9
The interval can be set to 15 different times 1

with the blue button [1].
NOTE：
If the knob is set to the "0" position, the LED
on the right will go on as a fault signal. And it 2
will default to the factory set time.
Fig.8-21
forced lubricating:
1. Blue switch 2. Forcible start key
Use the forcible start key [2] to activate inter-
mittent lubrication

Table 8–2 Interval description
Rotation
1 2 3 4 5 6 7 8 9 A B C D E F
position
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. The running time is set in the following way,

with the value in the Minute column of the ta-
ble applicable to this machine.
3
Lubrication time setting:
9 3
The lubrication time can be set to 15 different
times with the red button [3].
NOTE：
Do not set the knob to the "0" position in the
above operations.
Fig.8-22
3. Red switch
Table 8–3 Lubrication time description
Rotation
1 2 3 4 5 6 7 8 9 A B C D E F
position
10 11 12
Minute 8 16 24 32 40 48 56 64 72 80 88 96
4 2 0
Hour 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
8.10 CCTV System

8.10.1 CCTV System
LD Series CCTV System is widely used on hoisting machinery, handling machinery, loading equip-
ment and other specialized equipment. With this equipment, operator can easily get actual infor-
mation to work safely and conveniently.
8.10.2 Precautions
The working staff must pay attention to the following items:

• The system should be installed and debugged by professional technicians or under the
guidance of professionals.
• Though the outdoor equipment is waterproof, waterproof measures should be taken for the
connected parts such as the cable entry and the screw hole for fixing device to the chassis,
otherwise the damage not caused by the leakage of the equipment will be on your own account.
• Before using the equipment for the first time, please read this manual carefully to avoid
malfunction of or damage to the equipment due to improper use.
• Take proper protection during use and avoid scratches.
• DO NOT try to remove the cover and perform repair by yourself, which may damage the
equipment or cause other dangers. It is recommended that all repairs should be carried out by
professional technical service personnel.
• DO NOT install the equipment in places where there is flammable and explosive gas or
corrosive gas.
• Please use original parts or parts recommended by the manufacturers.
8.10.3 Major parts
This monitoring system is composed of the front-end camera part, the transmission part, the cab
display and the control part. Used on the reach stacker, it provides 6 channels of video images for
the operator, which are displayed on a 10.4' LCD monitor.
1. Front camera part

The four spreader camera systems are installed in proper location at the four corners of the
spreader. 2 fixed camera systems, which are respectively installed at proper locations under the
front boom and on the rear of the reach stacker. The front-end camera part is used for collecting
front-end video signals.
2. Transmission part
The video signal collected by the front-end camera system is transmitted to the cab of the reach
stacker via a wiring device near the camera system and then an integrated cable (including the vid-
eo cable and the power cable).
3. Cab display and control part

A shift switch and an LCD monitor are installed in the cab. Switch the display mode of the 6 front-
end camera systems with the shift switch.
8.10.4 Installation Instructions
The installation locations and functions of each device in this CCTV system is shown in the follow-
ing table.

Table 8–4
Serial
Device name Installation location Function
number
Anti-shock spreader Installed in the upper Monitor the working conditions of
camera system 1-4 left corner, lower left the spreader
corner, upper right
1–4
corner and lower right The cable wiring for power supply
Wiring device 1-4 corner of the spreader to the camera system
respectively
Semi-fixed front-view Monitor the forwarding of the reach
camera Installed under the stacker
5
boom The cable wiring for power supply
Wiring device 5
to the camera system
Semi-fixed rear-view Monitor the reversing the reach
camera Installed behind the stacker
6
reach stacker The cable wiring for power supply
Wiring device 6
to the camera system
Onboard hard disk the video signals from the cameras
7 Receive and process
video recorder in the cab
the switching of the image display
8 Shifting switch Control
modes in the cab
the video images collected by the
9 LCD monitor Display front-end camera system in the
cab
NOTE：
The wiring device of the front-end devices is installed at an appropriate position less than 1.5 me-
ters from the camera.
The wiring device of the devices in the cab is installed at a suitable position in the cab.

8.10.5 Shift switch
The shifting switch has 4 positions:

• In Gear 0, a multi-screen view composed of 0
1
6 cameras can be provided for the driver to
2
view the surrounding situation;
• Gear 1 indicates that the driver gives a 3
forwarding signal, and the view of the front

camera of the reach stacker will be
displayed synchronously;
• Gear 2 indicates that the driver gives a
reversing signal, and the view of the rear
RS-1510005-1
camera of the reach stacker will be
displayed synchronously; Fig.8-23
• Gear 3 indicates that the driver sends the
signal to start the spreader, and the views
of the four cameras on the spreader are
synchronously displayed on the 10.4-inch
monitor.
8.10.6 Troubleshooting the CCTV system
Table 8–5
Fault
Location Fault analysis Testing method Solution
Symptoms
Confirm whether
the camera has
The camera and video output first, If there is no
the integrated and then check image, replace the
Camera No video output cable are broken whether there is cable
system from camera image on the
monitor
The camera is No video output Replace the
faulty from the camera camera
Measure whether
The DVR has no the power input
-
The DVR has no power input voltage is normal
DVR
display with a multimeter
The switch of the
- Replace the switch
DVR is broken

Fault
Location Fault analysis Testing method Solution
Symptoms
Check whether the
The DVR shows
camera displayed
whether the
by the DVR has
camera of this
been connected to
number exists
the system
Blue screen of No video signal
Whether the cable
the LCD monitor input
between the DVR Reconnect the
and the monitor is cable
well connected
Whether the DVR Check the indicator
Display part is turned on lamp of the DVR
Whether the
monitor power Replug the power
output line is input line
The power supply plugged in
Black screen of is not connected or Measure whether
Whether the
the LCD monitor the monitor is there is power
monitor has an AC
broken input with a
power input
multimeter
Return it to the
Broken monitor
factory for repair

8.10.7 System wiring diagram
On the upper left corner of the spreader

Operator Cabin Composite
Cable
Monitoring the work of the spreader
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
Cabl e 2-7 Cable
cable 13
cable 14
RS 422 POWER
POWERI N
Composite
CH1 CH 3 OUT RS 232 Cable
CH2 CH 4
CH 5 CH 6 ALARM
IN 1-3 1 2345 6
控制电缆
Composite
Cable Junction Equipment 5
Cabl e 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"LCDMoni t or
Fig.8-24
NOTE：
The control cable is a 4-core cable, of which one is the common terminal (negative pole) and 3 are
control terminals (front, rear and spreader). When the switch is closed, the voltage between the
control terminal and the common terminal must be 5V (low level) or 6-36V (high level).

8.11 Flowmeter
The flowmeter is an instrument for measuring
the flow rate and can be provided to custom-
ers together with the machine.
The quick connector connects the flowmeter

between the pipelines of the oil pump and the
main valve. In order to avoid hydraulic dam-
age, a warning sign is hung on the quick con-
nector to remind the staff that the machine is
not allowed to start before the quick connector
is tightened. See the figure on the right.
The flow is measured in the following way:
Relieve the pressure in the shutdown state,

unscrew the quick connector at the pump out-
Fig.8-25
let, and connect the quick connecters on both
sides of the flowmeter to the quick connecters
in the pump outlet circuit. Pay attention to the
matching of the male and female heads. Be-
fore measuring the flow, take care to tighten
each quick connector. Then start the machine
to test the outlet flow of the pump. The total
flow of the system is the sum of the flows
measured on the two pumps at the same
time.


www.sanyglobal.com
SANY MARINE HEAVY INDUSTRY CO., LTD

Sany Industrial Park, Gaolan Port Economic & Development Zone, Zhuhai City,Guangdong
Province, China
Tel: 0086-4006098318
E-mail: crd@sany.com.cn
Website: www.sanyglobal.com

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Quality Changes the World

Safety, Operation and Maintenance Manual

Safety, Operation and Maintenance Manual-June 2019

Safety, Operation and Maintenance Manual-June 2019

Responsibilities of the customer or other authorized personnel:

Safety, Operation and Maintenance Manual-June 2019 1

Responsibilities of all working personnel

Responsibilities of the managers:

2 Safety, Operation and Maintenance Manual-June 2019

Safety, Operation and Maintenance Manual-June 2019 I

2.1.5.3 Safety labels - content ..........................................................................................2-9

2.3.6.10 Precautions for operating emergency stop button ...................................... 2-46

Safety, Operation and Maintenance Manual-June 2019 III

2.4.15 Precautions in welding............................................................................................ 2-68

3 System functions ............................................................................................................3-1

IV Safety, Operation and Maintenance Manual-June 2019

3.3.1.8 Digital analogy menu ......................................................................................... 3-39

Safety, Operation and Maintenance Manual-June 2019 V

4.2.3 Starting the machine at low temperature ............................................................... 4-19

VI Safety, Operation and Maintenance Manual-June 2019

Safety, Operation and Maintenance Manual-June 2019 VII

5.6.1.6 Air filter, check .................................................................................................... 5-42

VIII Safety, Operation and Maintenance Manual-June 2019

5.7.8 Mounting bolts and mounting pad, check .............................................................. 5-94

Safety, Operation and Maintenance Manual-June 2019 IX

5.12 Spreader.......................................................................................................................... 5-142

X Safety, Operation and Maintenance Manual-June 2019

5.15.3.4 Battery, checking............................................................................................ 5-184

8 Optional Parts ...................................................................................................................8-1

Safety, Operation and Maintenance Manual-June 2019 XI

8.2.1 Fire Detection and alarm system / automatic extinguishing de .............................8-5

XII Safety, Operation and Maintenance Manual-June 2019

8.10.6 Troubleshooting the CCTV system....................................................................... 8-26

Safety, Operation and Maintenance Manual-June 2019 XIII

XIV Safety, Operation and Maintenance Manual-June 2019

Safety, Operation and Maintenance Manual-June 2019 1-1

1-2 Safety, Operation and Maintenance Manual-June 2019

Safety, Operation and Maintenance Manual-June 2019 1-3

1.3 Application scope

With the advantages of low cost as well as

The reach stacker is suitable for the operation

1-4 Safety, Operation and Maintenance Manual-June 2019

1.4 Machine Authorizations

All machines and equipment manufactured by Address: Sany Industry Town,

1.5 Your Documentation Package

1.5.2 CD system requirements

• Windows 2000, XP, Vista or Windows 7 operating system

Safety, Operation and Maintenance Manual-June 2019 1-5

1.5.3 Recommendations on using the documentation

2. Page number of the Content part is marked as below:

3. Edition number of Safety, Operation and Maintenance Manual is marked as below:

1.5.4 Documentation storage

• Always keep this manual in the operator cab.

1.5.5 Manual organization

1-6 Safety, Operation and Maintenance Manual-June 2019

CHAPTER 3: SYSTEM FUNCTIONS

CHAPTER 8: OPTIONAL PARTS

Safety, Operation and Maintenance Manual-June 2019 1-7

Table 1–1 Terminology

1-8 Safety, Operation and Maintenance Manual-June 2019

Table 1–1 Terminology (continue)

Safety, Operation and Maintenance Manual-June 2019 1-9

Table 1–1 Terminology (continue)