英文PS00004801

Quality Changes the World
Empty Container Handler
Operation and Maintenance Manual

Sany Port
SANY Marine Heavy Industry Co.,LTD
SANY Industrial Park, Gaolan Port Economic And
Development Zone, Zhuhai City, Guangdong Province, China
Tel: 0086-756-7266945
Fax: 0086-731-84031999-149
Website: www.sanyhi.com
Service hotline: 0086 4006098318
© 2017 by Sany Port. 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 Port assumes no liability. For
more information, contact Sany Port.
Operation and Maintenance Manual-May 2022

SPECIFIC DECLARATION
SANY heavy duty container handler is applicable for transferring, lifting and stacking containers on
ports, quaysides, and yards. Any other uses or operations beyond the specified working range are
not authorized uses. SANY expressly bears no liability for any consequences due to unauthorized
uses.
Information on this manual is used to guide qualified operators to operate and maintain container
handlers correctly. SANY expressly bears no liability for any consequences due to the violation of
following rules:
• The personnel should observe the information on this manual.

• It is forbidden to convert the machine without authorization.
• When cracks or electrical failures on the machine occur, please contact the supplier instead of
conducting welding or making changes without permission.
• Use genuine spare parts from SANY rather than untested or unauthorized spare parts or tools.
• Machine failures or damages due to force majeure of natural disasters (earthquake, typhoon)
and wars are not the responsiblity of SANY.
SANY cannot predict every circumstance that might involve a potential hazard in operation or
maintenance. Operators and owners should highly attach importance to safety. Local specific
safety rules of the countries may be stricter. If they differ from the regulations on this manual, ob-
serve the stricter one.
Duty of SANY
• Be responsible for providing qualified products and correct documentations.

• Fulfill the promises on after-sales service, and document all maintenance and repair working
done by after-sales service personnel.
• Train the operator and maintenance personnel based on their needs.
Duty of Owners or Other Authorized Personnel
• Only after each personnel involved in the product’s operation, maintenance and repair is trained
and fully understands the Parts Book and Operation & Maintenance Manual, can they operate
and maintain the heavy duty container handler.
• Ensure the operation and maintenance personnel are qualified and know their related
responsibilities.
• Periodically check related personnel's safety consciousness during working.
• If any failure which would lead to unsafety occurs, stop the machine immediately.
• If necessary, SANY service personnel have the right to check the machine for safety.
• Except for checking items regulated by SANY, please do the related inspections according to
local laws and regulations.
Operation and Maintenance Manual-May 2022 1

• Ensure timely maintenance and repair on this machine.
• Carefully plan the use of this machine.
Duty of All Working Personnel
• If there is any abnormality which may cause the failure of this machine or a potential hazard,
please report to your leader. If possible, eliminate the failure in time.
• All personnel working around the machine must observe all warning signals and take care of
their own and others' safety.
• All personnel should know their working tasks and procedures.
• Watch out high voltage wire, unrelated personnel and poor ground for potential danger, or report
to the operators and signalmen.
Duty of Managers
• Ensure the operators are trained and fully understand the Operation & Maintenance Manual
supplied by SANY. Ensure they are in physical fitness and have the certification of operation.
Otherwise, it is forbidden to operate this machine.
• Ensure the operators have good judgment ability, teamwork consciousness and psychological
quality. Otherwise, it is forbidden to operate or repair this machine.
• Ensure the signalmen have good vision and acoustic judgment as well as master standard
command signals. At the same time, they should have enough experience in recognizing
dangers correctly and informing the operators of dangers to avoid them in time.
• Ensure assistant workers can identify the model and working condition to choose a proper
machine.
• Publicize safety consciousness to working personnel, and make them aware of safety
precautions and their related responsibilities.
2 Operation and Maintenance Manual-May 2022

Table of Contents
Table of Contents
1 INTRODUCTION ...............................................................................................................1-1
1.1 Preface ...................................................................................................................................1-5
1.2 Overview.................................................................................................................................1-5
1.3 Application Range.................................................................................................................1-6
1.3.1 Intended use..................................................................................................................1-6
1.3.2 Unauthorized use .........................................................................................................1-6
1.4 Machine Authorizations........................................................................................................1-7
1.5 Your Documentation Package.............................................................................................1-7
1.5.1 Documentations............................................................................................................1-7
1.5.2 CD system requirements.............................................................................................1-8
1.5.3 Recommendations on using the documentation .....................................................1-8
1.5.4 Documentation storage ...............................................................................................1-9
1.5.5 Manual organization.....................................................................................................1-9
1.6 Terminology......................................................................................................................... 1-10
1.7 Abbreviation Explanation .................................................................................................. 1-13
1.8 Machine Information .......................................................................................................... 1-13
1.8.1 Information.................................................................................................................. 1-13
1.8.2 Machine nameplate................................................................................................... 1-14
1.8.3 Engine nameplate ..................................................................................................... 1-14
1.8.3.1 VOLVO engine nameplate ................................................................................ 1-14
1.8.3.2 CUMMINS engine nameplate .......................................................................... 1-15
1.8.3.3 YUCHAI engine nameplate .............................................................................. 1-15
1.8.4 Spreader nameplate ................................................................................................. 1-16
1.8.4.1 SANY spreader nameplate............................................................................... 1-16
1.8.4.2 ELME spreader nameplate............................................................................... 1-16
1.8.5 Transmission case nameplate................................................................................. 1-17
1.8.5.1 DANA transmission case nameplate............................................................... 1-17
1.8.5.2 ZF transmission case nameplate..................................................................... 1-17
1.8.6 Drive axle nameplate ................................................................................................ 1-18
1.9 Running a New Machine ................................................................................................... 1-18
1.10 Machine Serial No. and Distributor Info........................................................................ 1-18
1.11 Correction Request Form................................................................................................ 1-19
1.12 Contact Information ......................................................................................................... 1-19
2 SAFETY ................................................................................................................................2-1
2.1 Safety Information.................................................................................................................2-5
2.1.1 General ..........................................................................................................................2-5
Operation and Maintenance Manual-May 2022 I

Table of Contents
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 on the machine ..............................................................................2-6
2.1.5.2 Safety labels, location...........................................................................................2-8
2.1.5.3 Safety labels, contents .........................................................................................2-9
2.2 General Precautions.......................................................................................................... 2-24
2.2.1 Precautions ................................................................................................................ 2-24
2.2.2 Basic safety instructions........................................................................................... 2-24
2.2.3 Personal protective equipment................................................................................ 2-25
2.2.4 No operation while in bad health ............................................................................. 2-28
2.2.5 No passenger in the cab........................................................................................... 2-28
2.2.6 Hand signals............................................................................................................... 2-29
2.2.7 Preparing safety items .............................................................................................. 2-31
2.2.8 Checking safety equipment...................................................................................... 2-32
2.2.9 Precautions in high voltage areas........................................................................... 2-33
2.2.10 Precautions in thunderstorm.................................................................................. 2-35
2.2.11 Precautions in wind ................................................................................................. 2-35
2.2.12 Abnormal cases....................................................................................................... 2-36
2.2.13 Unauthorized modification ..................................................................................... 2-36
2.2.14 Fire Extinguisher ..................................................................................................... 2-37
2.2.15 Emergency exit........................................................................................................ 2-37
2.3 Safety During Operation.................................................................................................... 2-37
2.3.1 Work area safety........................................................................................................ 2-37
2.3.1.1 Overview.............................................................................................................. 2-37
2.3.1.2 Work area requirements.................................................................................... 2-38
2.3.1.3 Work area indications ........................................................................................ 2-38
2.3.2 Checks before operation .......................................................................................... 2-38
2.3.3 Keeping machine clean ............................................................................................ 2-41
2.3.4 Going up or down the machine safely .................................................................... 2-41
2.3.5 Start-up safety............................................................................................................ 2-42
2.3.5.1 In the operation cab ........................................................................................... 2-42
2.3.5.2 Adjusting the seat............................................................................................... 2-43
2.3.5.3 Checking the seat belt ....................................................................................... 2-43
2.3.5.4 Machine starting precautions ........................................................................... 2-44
2.3.5.5 Jump-start the engine, precautions ................................................................. 2-44
2.3.5.6 In cold weather ................................................................................................... 2-45
2.3.5.7 After starting the engine .................................................................................... 2-45
2.3.6 Precautions for safe operation................................................................................. 2-45
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Table of Contents
2.3.6.1 Ensuring good visibility...................................................................................... 2-45

2.3.6.2 Safety rules for traveling ................................................................................... 2-46
2.3.6.3 Precautions while operating on slopes ........................................................... 2-47
2.3.6.4 Avoiding injury from reversing.......................................................................... 2-47
2.3.6.5 Precautions while operating on snow or frozen surfaces............................. 2-48
2.3.6.6 Preventing control failure .................................................................................. 2-48
2.3.6.7 Do not lift a load without container................................................................... 2-49
2.3.6.8 Never hoist the load over people ..................................................................... 2-50
2.3.6.9 Do not stay below the load................................................................................ 2-50
2.3.6.10 Precautions for operating emergency stop button ...................................... 2-51
2.3.6.11 Precautions for operating safety bypass switch .......................................... 2-51
2.3.7 Parking the machine securely ................................................................................. 2-52
2.3.7.1 Parking requirements ........................................................................................ 2-52
2.3.7.2 Stop the engine .................................................................................................. 2-53
2.4 Safety During Maintenance .............................................................................................. 2-54
2.4.1 General ....................................................................................................................... 2-54
2.4.2 Preparation for the work area .................................................................................. 2-55
2.4.3 Warning label is important........................................................................................ 2-55
2.4.4 Lockout/tagout procedures ...................................................................................... 2-56
2.4.5 Self-preparation before maintenance..................................................................... 2-57
2.4.6 Using tools correctly.................................................................................................. 2-57
2.4.7 Regular replacement of safety-related parts ......................................................... 2-57
2.4.8 Removing attachments carefully............................................................................. 2-58
2.4.9 Adding fluids to the machine.................................................................................... 2-58
2.4.10 Towing or lifting the machine ................................................................................. 2-59
2.4.11 Keep clear of moving machinery ........................................................................... 2-60
2.4.12 Preventing hydraulic hazards ................................................................................ 2-61
2.4.12.1 Checking rubber hose regularly..................................................................... 2-61
2.4.12.2 Release the pressure before the maintenance ........................................... 2-61
2.4.12.3 Replacing rubber hose regularly.................................................................... 2-62
2.4.12.4 Prevent heat near the hydraulic pipeline ...................................................... 2-63
2.4.12.5 Filling accumulator........................................................................................... 2-63
2.4.12.6 Selecting oils and fuel ..................................................................................... 2-64
2.4.12.7 Handling hydraulic oil ...................................................................................... 2-64
2.4.13 Preventing burn and scald ..................................................................................... 2-65
2.4.13.1 Burn by high temperature liquid..................................................................... 2-65
2.4.13.2 Chemical burn .................................................................................................. 2-65
2.4.14 Preventing fire and explosion ................................................................................ 2-66
2.4.14.1 Handling inflammables safely ........................................................................ 2-66
Operation and Maintenance Manual-May 2022 III

Table of Contents
2.4.14.2 Removing inflammables ................................................................................. 2-67

2.4.14.3 Checking oil leakage ....................................................................................... 2-67
2.4.14.4 Checking short circuit ...................................................................................... 2-68
2.4.14.5 Preventing battery explosion.......................................................................... 2-69
2.4.14.6 Examine the ignition key ................................................................................. 2-70
2.4.14.7 Evacuating from the machine......................................................................... 2-70
2.4.15 Preventing poisoning and asphyxiation ............................................................... 2-71
2.4.15.1 Handling chemicals safely .............................................................................. 2-71
2.4.15.2 Preventing poisoning by paint........................................................................ 2-71
2.4.15.3 Preventing poisoning by off-gas .................................................................... 2-72
2.4.16 Preventing dust hazard .......................................................................................... 2-72
2.4.17 Working under machine ......................................................................................... 2-73
2.4.18 Precautions in welding............................................................................................ 2-73
2.4.19 Safe maintenance of air conditioning system ..................................................... 2-74
2.4.20 Precautions in maintaining the engine ................................................................. 2-74
2.4.21 High voltage precautions........................................................................................ 2-75
2.4.22 Precautions after maintenance ............................................................................. 2-76
2.4.23 Handling waste properly......................................................................................... 2-76
2.5 Tag........................................................................................................................................ 2-77
3 SYSTEM FUNCTIONS ...................................................................................................3-1

3.1 Primary Components of Machine .......................................................................................3-3
3.2 Cab Control System..............................................................................................................3-4
3.2.1 General information......................................................................................................3-4
3.2.2 Steering column............................................................................................................3-5
3.2.2.1 Steering column ....................................................................................................3-6
3.2.2.2 Steering wheel panel ............................................................................................3-7
3.2.2.3 Gear selector .......................................................................................................3-11
3.2.2.4 Direction indication controller ........................................................................... 3-12
3.2.2.5 Adjusting the angle of steering controller ....................................................... 3-16
3.2.3 Pedals ......................................................................................................................... 3-16
3.2.4 Joystick ....................................................................................................................... 3-17
3.2.5 Right operation panel................................................................................................ 3-18
3.2.5.1 Right operation panel ........................................................................................ 3-18
3.2.5.2 Ignition switch ..................................................................................................... 3-18
3.2.5.3 Safety bypass switch ......................................................................................... 3-21
3.2.5.4 Emergency stop switch ..................................................................................... 3-22
3.2.5.5 Rear wiper switch............................................................................................... 3-23
3.2.5.6 Top wiper switch ................................................................................................. 3-23
IV Operation and Maintenance Manual-May 2022

Table of Contents
3.2.5.7 Front wiper switch .............................................................................................. 3-24

3.2.5.8 Auto/Manual lock ............................................................................................... 3-25
3.2.5.9 Ignore alarm........................................................................................................ 3-25
3.2.5.10 Inner light switch .............................................................................................. 3-25
3.2.6 Front operation panel................................................................................................ 3-27
3.2.6.1 Front operation panel ........................................................................................ 3-27
3.2.6.2 Cab top light switch............................................................................................ 3-27
3.2.6.3 Rear light switch ................................................................................................. 3-28
3.2.6.4 Mast light switch ................................................................................................. 3-29
3.2.6.5 Spreader light switch ......................................................................................... 3-29
3.2.6.6 Width light switch................................................................................................ 3-30
3.2.6.7 Failure detection switch..................................................................................... 3-31
3.3 Display ................................................................................................................................. 3-31
3.3.1 SANY display ............................................................................................................. 3-31
3.3.1.1 General ................................................................................................................ 3-31
3.3.1.2 Start menu........................................................................................................... 3-32
3.3.1.3 Main menu........................................................................................................... 3-33
3.3.1.4 Engine information menu .................................................................................. 3-35
3.3.1.5 Gearbox information menu ............................................................................... 3-37
3.3.1.6 Hydraulic information menu.............................................................................. 3-38
3.3.1.7 Fault alarm menu ............................................................................................... 3-38
3.3.1.8 Digital input menu .............................................................................................. 3-39
3.3.1.9 Digital output menu ............................................................................................ 3-40
3.3.1.10 Analogy input menu......................................................................................... 3-40
3.3.1.11 Analogy output menu....................................................................................... 3-41
3.3.1.12 Setting menu..................................................................................................... 3-41
3.4 Air Conditioning System.................................................................................................... 3-42
3.4.1 Precautions for air conditioning system ................................................................. 3-42
3.4.2 Control panel.............................................................................................................. 3-43
3.4.2.1 Control panel....................................................................................................... 3-43
3.4.2.2 Power switch....................................................................................................... 3-43
3.4.2.3 Fan speed switch ............................................................................................... 3-44
3.4.2.4 Temperature or Paging switch.......................................................................... 3-45
3.4.2.5 Mode switch ........................................................................................................ 3-45
3.4.3 Operation .................................................................................................................... 3-46
3.5 Electric Control Cabinet .................................................................................................... 3-47
3.6 Fuse ..................................................................................................................................... 3-48
4 OPERATION .......................................................................................................................4-1
Operation and Maintenance Manual-May 2022 V

Table of Contents
4.1 Before starting the engine....................................................................................................4-3

4.1.1 Operator responsibility.................................................................................................4-3
4.1.2 Check before operation ...............................................................................................4-4
4.1.2.1 General ...................................................................................................................4-4
4.1.2.2 Wiper water level, checking.................................................................................4-4
4.1.2.3 Coolant level, checking ........................................................................................4-5
4.1.2.4 Engine oil level, checking.....................................................................................4-6
4.1.2.5 Transmission oil level, checking .........................................................................4-6
4.1.2.6 Hydraulic oil level, checking ................................................................................4-6
4.1.2.7 Fuel level, checking ..............................................................................................4-7
4.1.2.8 Brake oil level, checking.......................................................................................4-8
4.1.2.9 Tyres, checking......................................................................................................4-9
4.1.2.10 Electrical components, checking ......................................................................4-9
4.1.2.11 Working light, checking ................................................................................... 4-10
4.1.2.12 Horn, checking ................................................................................................. 4-10
4.1.3 Adjustment before operation.....................................................................................4-11
4.1.3.1 Seat, adjusting.....................................................................................................4-11
4.1.3.2 Rearview mirrors, adjusting .............................................................................. 4-13
4.1.3.3 Safety belt, adjusting ......................................................................................... 4-14
4.2 Starting the Machine.......................................................................................................... 4-15
4.2.1 Start in normal weather............................................................................................. 4-15
4.2.2 Start in cold weather ................................................................................................. 4-18
4.2.3 Start with booster battery or starting generators................................................... 4-19
4.3 Stopping the Machine........................................................................................................ 4-20
4.3.1 Engine shutdown procedures .................................................................................. 4-20
4.3.2 Emergency shutdown ............................................................................................... 4-23
4.4 Driving.................................................................................................................................. 4-24
4.4.1 Driving description..................................................................................................... 4-24
4.4.2 Driving forward........................................................................................................... 4-25
4.4.3 Driving backward ....................................................................................................... 4-26
4.4.4 Turning around........................................................................................................... 4-26
4.4.5 Parking ........................................................................................................................ 4-27
4.5 Load Handling..................................................................................................................... 4-28
4.5.1 Operation switches.................................................................................................... 4-28
4.5.2 Mast, operation .......................................................................................................... 4-29
4.5.3 Spreader, operation................................................................................................... 4-35
4.5.4 Load capacity diagrams............................................................................................ 4-39
4.5.5 Picking up a container from a stack ........................................................................ 4-43
4.5.6 Depositing a container on the stack........................................................................ 4-48
4.6 Store the machine .............................................................................................................. 4-53
VI Operation and Maintenance Manual-May 2022

Table of Contents
4.6.1 Overnight storage...................................................................................................... 4-53

4.6.2 Short-term Storage.................................................................................................... 4-53
4.6.3 Long-term storage ..................................................................................................... 4-54
4.6.3.1 General ................................................................................................................ 4-54
4.6.3.2 Preparations........................................................................................................ 4-54
4.6.3.3 During storage .................................................................................................... 4-55
4.6.3.4 Return to service ................................................................................................ 4-56
4.7 Transportation and Assembly........................................................................................... 4-56
4.7.1 Guidelines................................................................................................................... 4-56
4.7.2 Disassembling the machine..................................................................................... 4-56
4.7.2.1 Disassembling principles .................................................................................. 4-56
4.7.2.2 Disassembly list.................................................................................................. 4-57
4.7.2.3 Hoisting points of parts...................................................................................... 4-59
4.7.3 Packing requirements ............................................................................................... 4-61
4.7.4 Transportation............................................................................................................ 4-62
4.7.4.1 Transporting by platform truck.......................................................................... 4-62
4.7.4.2 Transporting by container ................................................................................. 4-62
5 MAINTENANCE ................................................................................................................5-1
5.1 General Maintenance Information ......................................................................................5-7
5.2 Tightening Torques ...............................................................................................................5-9
5.2.1 General tightening torques..........................................................................................5-9
5.2.1.1 General ...................................................................................................................5-9
5.2.1.2 Fastener torque value...........................................................................................5-9
5.2.1.3 Hydraulic coupling torque values..................................................................... 5-10
5.2.1.4 Tapered connections ..........................................................................................5-11
5.2.1.5 O-ring and flange connections ......................................................................... 5-12
5.2.1.6 Low pressure hose clamps ............................................................................... 5-13
5.2.2 Specific tightening torques....................................................................................... 5-13
5.3 Recommended fuel, coolant............................................................................................. 5-14
5.3.1 Recommended fuel, coolant and lubricant ............................................................ 5-14
5.3.2 Specification............................................................................................................... 5-14
5.3.3 Capacity of the tanks................................................................................................. 5-16
5.3.4 Description of hydraulic oil ....................................................................................... 5-16
5.3.5 Quality of hydraulic oil............................................................................................... 5-17
5.3.6 Urea............................................................................................................................. 5-19
5.4 Lubricating Points............................................................................................................... 5-19
5.4.1 Lubricant ..................................................................................................................... 5-19
5.4.2 Lubricating points of whole machine ...................................................................... 5-20
5.5 Scheduled maintenance ................................................................................................... 5-21
Operation and Maintenance Manual-May 2022 VII

Table of Contents
5.5.1 Special instructions for the first maintenance........................................................ 5-21

5.5.2 Maintenance each day.............................................................................................. 5-22
5.5.3 Maintenance each 50 hours..................................................................................... 5-23
5.5.4 Maintenance each 250 hours .................................................................................. 5-24
5.5.5 Maintenance each 500 hours .................................................................................. 5-25
5.5.6 Maintenance each 1000 hours ................................................................................ 5-27
5.6 Engine.................................................................................................................................. 5-29
5.6.1 General engine inspection ....................................................................................... 5-29
5.6.1.1 Engine, examine................................................................................................. 5-29
5.6.1.2 Charge air pipe, check....................................................................................... 5-30
5.6.1.3 Drive belt, check and change (engine option VOLVO) ................................. 5-31
5.6.1.4 Drive belt, check (engine option CUMMINS) ................................................. 5-34
5.6.1.5 Drive belt, change (engine option CUMMINS)............................................... 5-35
5.6.1.6 Air filter, check .................................................................................................... 5-36
5.6.1.7 Air filter, clean ..................................................................................................... 5-38
5.6.1.8 Air filter, replace ................................................................................................. 5-39
5.6.1.9 Engine mounting pads, check .......................................................................... 5-41
5.6.2 Lubrication system .................................................................................................... 5-43
5.6.2.1 Oil level, check and top up................................................................................ 5-43
5.6.2.2 Engine oil, change.............................................................................................. 5-45
5.6.2.3 Oil filter, change.................................................................................................. 5-47
5.6.3 Fuel system ................................................................................................................ 5-49
5.6.3.1 Fuel condensate, drain(engine option VOLVO)............................................. 5-49
5.6.3.2 Fuel condensate, drain (engine option CUMMINS) ...................................... 5-51
5.6.3.3 Fuel filter, replace (engine option VOLVO)..................................................... 5-52
5.6.3.4 Fuel pre-filter, change (engine option VOLVO).............................................. 5-54
5.6.3.5 Fuel filter, change (engine option CUMMINS) ............................................... 5-57
5.6.3.6 Fuel pre-filter, change (engine option CUMMINS) ........................................ 5-58
5.6.3.7 Fuel system, bleed (engine option VOLVO)................................................... 5-59
5.6.3.8 Fuel system, bleed (engine option CUMMINS) ............................................. 5-63
5.6.4 Cooling system .......................................................................................................... 5-64
5.6.4.1 General ................................................................................................................ 5-64
5.6.4.2 Coolant mixture .................................................................................................. 5-64
5.6.4.3 Water quality ....................................................................................................... 5-65
5.6.4.4 Coolant level, check and top up ....................................................................... 5-66
5.6.4.5 A completely empty system, fill ........................................................................ 5-68
VIII Operation and Maintenance Manual-May 2022

Table of Contents
5.6.4.6 Coolant, drain ..................................................................................................... 5-69

5.6.4.7 Radiator, clean.................................................................................................... 5-72
5.6.4.8 Radiator fan, check ............................................................................................ 5-73
5.6.4.9 Cooling system, clean ....................................................................................... 5-75
5.6.5 Air intake and exhaust system................................................................................. 5-76
5.6.5.1 Air leakage, check.............................................................................................. 5-76
5.6.5.2 Turbocharger and blast pipe, check ................................................................ 5-79
5.6.6 Urea filter element, change...................................................................................... 5-80
5.7 Transmission....................................................................................................................... 5-80
5.7.1 Attaching bolts of propeller shaft, check ................................................................ 5-80
5.7.2 Speed sensor, check................................................................................................. 5-83
5.7.3 Attaching bolts and mounting pad, check .............................................................. 5-84
5.7.4 Propeller shaft, lubricate........................................................................................... 5-85
5.7.5 Transmission oil, change.......................................................................................... 5-88
5.7.6 Transmission oil level, check ................................................................................... 5-90
5.7.7 Transmission oil filter, change ................................................................................. 5-92
5.7.8 TE Transmission calibration..................................................................................... 5-93
5.8 Drive Axle ............................................................................................................................ 5-95
5.8.1 Attaching bolts of drive axle to the frame, check .................................................. 5-95
5.8.2 Attaching bolts of drive axle to the propeller shaft, check ................................... 5-96
5.8.3 Oil leakage of drive axle and brake components, check ..................................... 5-98
5.8.4 Brake function, check.............................................................................................. 5-100
5.8.5 Breather connector, clean ...................................................................................... 5-102
5.8.6 Differential oil, replace ............................................................................................ 5-103
5.8.7 Drive axle oil, change.............................................................................................. 5-105
5.8.8 Brake pedal, check and adjust .............................................................................. 5-106
5.8.9 Parking brake pads, change .................................................................................. 5-108
5.8.10 Brake oil filter, change .......................................................................................... 5-108
5.9 Steering Axle......................................................................................................................5-110
5.9.1 General check for steering axle..............................................................................5-110
5.9.2 Steering axle, lubricate ............................................................................................5-111
5.9.3 Steering axle components, check ..........................................................................5-112
5.9.4 Knuckle pin, check ...................................................................................................5-113
5.9.5 Stub axle, maintain...................................................................................................5-113
5.9.6 Steering axle cradle, check.....................................................................................5-114
5.9.7 Steering pressure, check.........................................................................................5-115
5.10 Tyres and rims .................................................................................................................5-116
5.10.1 Description of tire ...................................................................................................5-116
5.10.2 Tyre, inflate..............................................................................................................5-117
5.10.3 Tyres, check ............................................................................................................5-118
Operation and Maintenance Manual-May 2022 IX

Table of Contents
5.10.4 Drive axle tyre, remove and install.......................................................................5-119

5.10.4.1 Drive axle tyre, remove ..................................................................................5-119
5.10.4.2 Drive axle tyre, install .................................................................................... 5-122
5.10.5 Steering axle tyre, remove and install ................................................................ 5-123
5.10.5.1 Steering axle tyre, remove............................................................................ 5-123
5.10.5.2 Steering axle tyre, install............................................................................... 5-125
5.10.6 Description for wheel rim...................................................................................... 5-126
5.10.7 Rim, check.............................................................................................................. 5-126
5.10.8 Wheel rim, install and remove ............................................................................. 5-128
5.10.8.1 Wheel rim, install............................................................................................ 5-128
5.10.8.2 Wheel rim, remove......................................................................................... 5-130
5.11 Mast.................................................................................................................................. 5-131
5.11.1 General information of mast................................................................................. 5-131
5.11.2 Basic check ............................................................................................................ 5-132
5.11.3 Fixed bolts, check.................................................................................................. 5-133
5.11.4 Sliding blocks, check............................................................................................. 5-133
5.11.5 Chain, maintain ...................................................................................................... 5-134
5.11.6 Cylinder piston rod, maintain ............................................................................... 5-136
5.12 Spreader.......................................................................................................................... 5-137
5.12.1 Twistlock, lubricate................................................................................................ 5-137
5.12.2 Sliding blocks of telescopic beam riser, lubricate ............................................. 5-138
5.12.3 Sliding block between the basic beam and telescopic beam,
lubricate................................................................................................................ 5-138
5.12.4 Sideshift cylinder bearing, lubricate.................................................................... 5-139
5.12.5 Top and bottom sideshift sliding blocks, lubricate ............................................ 5-139
5.12.6 Sliding block, check .............................................................................................. 5-140
5.12.7 Twistlock, check..................................................................................................... 5-140
5.13 Air Conditioning System................................................................................................ 5-140
5.13.1 General recommendations .................................................................................. 5-140
5.13.2 Air conditioning, check.......................................................................................... 5-141
5.13.3 Refrigerant quantity, check .................................................................................. 5-143
5.13.4 Refrigerant, fill........................................................................................................ 5-144
5.13.5 Cleanness of heatexchanger plate in evaporator and condenser,
check .................................................................................................................... 5-145
5.13.6 Leakage or lack of oil in condenser, check........................................................ 5-146
5.13.7 Radiator, clean....................................................................................................... 5-147
5.13.8 Maintenance table for air conditioning ............................................................... 5-147
5.14 Hydraulic System ........................................................................................................... 5-149
5.14.1 Hydraulic oil level, check...................................................................................... 5-149
5.14.2 Air filter element, change ..................................................................................... 5-149
X Operation and Maintenance Manual-May 2022

Table of Contents
5.14.3 Hydraulic oil, change ............................................................................................ 5-150

5.14.4 Oil return filter element, replace .......................................................................... 5-152
5.14.5 Hydraulic oil tank, clean ....................................................................................... 5-153
5.14.6 Accumulator ........................................................................................................... 5-154
5.14.6.1 Precaution....................................................................................................... 5-154
5.14.6.2 Brake system accumulator, check............................................................... 5-155
5.14.6.3 Accumulator, charge...................................................................................... 5-156
5.14.7 Hydraulic oil circuit, check.................................................................................... 5-158
5.14.8 Brake oil filter, change .......................................................................................... 5-159
5.15 Electrical System ........................................................................................................... 5-160
5.15.1 General information of electrical system............................................................ 5-160
5.15.2 Battery..................................................................................................................... 5-161
5.15.2.1 Precautions for battery .................................................................................. 5-161
5.15.2.2 Battery, clean .................................................................................................. 5-162
5.15.2.3 Battery, check ................................................................................................. 5-162
5.15.2.4 Battery, detect................................................................................................. 5-163
5.15.2.5 Battery, charge ............................................................................................... 5-163
5.15.2.6 Battery cables, check .................................................................................... 5-165
5.15.2.7 Scheduled maintenance of battery.............................................................. 5-167
5.15.3 Fuses, change ....................................................................................................... 5-167
5.15.4 All working lights and indicators, check ............................................................. 5-168
5.15.5 Wiper, adjust .......................................................................................................... 5-169
5.15.6 Wiper, replace........................................................................................................ 5-170
5.16 Maintenance Record List .............................................................................................. 5-171
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.......................................................................................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 steering system .................................................................................6-8
6.7 Troubleshooting the mast system.......................................................................................6-9
6.8 Troubleshooting the spreader system................................................................................6-9
6.9 Troubleshooting the air conditioning ..................................................................................6-9
6.10 Troubleshooting the hydraulic system .......................................................................... 6-10
Operation and Maintenance Manual-May 2022 XI

Table of Contents
7 SPECIFICATIONS ............................................................................................................7-1
7.1 Technical Specification.........................................................................................................7-3
7.1.1 General ..........................................................................................................................7-3
7.1.2 Basic parameters..........................................................................................................7-4
7.1.3 System configuration ...................................................................................................7-5
7.1.3.1 Engine configuration.............................................................................................7-5
7.1.3.2 Gearbox configuration ..........................................................................................7-6
7.1.3.3 Drvie axle configuration........................................................................................7-7
7.1.3.4 Spreader configuration.........................................................................................7-7
7.2 Unit Conversion.....................................................................................................................7-7
7.2.1 Abbreviation Explanation ............................................................................................7-7
7.2.2 Conversion table, SI units ...........................................................................................7-8
7.2.3 Conversion table, length..............................................................................................7-9
7.2.4 Conversion table, area.............................................................................................. 7-10
7.2.5 Conversion table, volume......................................................................................... 7-10
7.2.6 Conversion table, weight .......................................................................................... 7-10
7.2.7 Conversion table, pressure .......................................................................................7-11
7.2.8 Conversion table, temperature .................................................................................7-11
8 OPTIONAL PARTS ..........................................................................................................8-1

8.1 Fire Detection and Alarm System / Automatic Extinguishing Device ............................8-3
8.1.1 Control button................................................................................................................8-3
8.1.2 Fire detection and alarm system ................................................................................8-3
8.1.2.1 General ...................................................................................................................8-3
8.1.2.2 Function description..............................................................................................8-3
8.1.2.3 Precautions ............................................................................................................8-5
8.1.2.4 Troubleshooting.....................................................................................................8-5
8.1.2.5 Maintenance and repair .......................................................................................8-6
8.1.3 Automatic fire extinguishing........................................................................................8-7
8.1.3.1 Automatic fire extinguishing device ....................................................................8-7
8.1.3.2 Precautions ............................................................................................................8-7
8.1.3.3 Technical parameters ...........................................................................................8-7
8.2 Loudspeaker and Controller ................................................................................................8-8
8.2.1 Loudspeaker and controller kit ...................................................................................8-8
8.2.2 Control panel.................................................................................................................8-9
8.2.3 Operations .....................................................................................................................8-9
8.2.4 Precautions ................................................................................................................ 8-10
8.3 Engine Idle Protection Function ....................................................................................... 8-10
8.4 Engine Preheating Protection Function .......................................................................... 8-10
8.5 Engine Hour Calculator ......................................................................................................8-11
XII Operation and Maintenance Manual-May 2022

Table of Contents
8.6 Twistlock Calculator ............................................................................................................8-11

8.7 Reversing Radar Display .................................................................................................. 8-12
8.8 Operator Presence System .............................................................................................. 8-12
8.9 Radio.................................................................................................................................... 8-12
8.9.1 Radio general............................................................................................................. 8-12
8.9.2 Radio panel ................................................................................................................ 8-13
8.9.3 Mute (Silence)............................................................................................................ 8-13
8.9.4 Sound .......................................................................................................................... 8-14
8.9.5 Audio setting............................................................................................................... 8-14
8.9.6 Radio ........................................................................................................................... 8-15
8.9.7 Radio troubleshooting............................................................................................... 8-16
8.10 Automatic Lubrication...................................................................................................... 8-17
8.10.1 Automatic lubrication system................................................................................. 8-17
8.10.2 Operation precautions ............................................................................................ 8-17
8.10.3 Time setting.............................................................................................................. 8-18
Operation and Maintenance Manual-May 2022 XIII

Table of Contents
XIV Operation and Maintenance Manual-May 2022

INTRODUCTION
INTRODUCTION
1.1 Preface ...................................................................................................................................1-5
1.2 Overview.................................................................................................................................1-5
1.3 Application Range.................................................................................................................1-6
1.3.1 Intended use ................................................................................................................1-6
1.3.2 Unauthorized use ........................................................................................................1-6
1.4 Machine Authorizations........................................................................................................1-7
1.5 Your Documentation Package.............................................................................................1-7
1.5.1 Documentations ..........................................................................................................1-7
1.5.2 CD system requirements ...........................................................................................1-8
1.5.3 Recommendations on using the documentation ....................................................1-8
1.5.4 Documentation storage ..............................................................................................1-9
1.5.5 Manual organization ...................................................................................................1-9
1.6 Terminology......................................................................................................................... 1-10
1.7 Abbreviation Explanation .................................................................................................. 1-13
1.8 Machine Information .......................................................................................................... 1-13
1.8.1 Information ................................................................................................................ 1-13
1.8.2 Machine nameplate ................................................................................................. 1-14
1.8.3 Engine nameplate .................................................................................................... 1-14
1.8.3.1 VOLVO engine nameplate............................................................................... 1-14
1.8.3.2 CUMMINS engine nameplate ......................................................................... 1-15
1.8.3.3 YUCHAI engine nameplate ............................................................................. 1-15
1.8.4 Spreader nameplate ................................................................................................ 1-16
1.8.4.1 SANY spreader nameplate.............................................................................. 1-16
1.8.4.2 ELME spreader nameplate.............................................................................. 1-16
1.8.5 Transmission case nameplate ............................................................................... 1-17
1.8.5.1 DANA transmission case nameplate ............................................................. 1-17
1.8.5.2 ZF transmission case nameplate ................................................................... 1-17
1.8.6 Drive axle nameplate............................................................................................... 1-18
1.9 Running a New Machine ................................................................................................... 1-18
1.10 Machine Serial No. and Distributor Info........................................................................ 1-18
Operation and Maintenance Manual-May 2022 1-1

INTRODUCTION
1.11 Correction Request Form................................................................................................ 1-19

1.12 Contact Information ......................................................................................................... 1-19
1-2 Operation and Maintenance Manual-May 2022

INTRODUCTION

INTRODUCTION

INTRODUCTION
1.INTRODUCTION
1.1 Preface
Thank you heartedly for choosing our Empty
Container Handler. We are commited to pro-
vide you with good-quality machine and supe-
rior after-sales service.
Fig 1-1 Read the Manual
1.2 Overview
WARNING
Risk of injury or death!
Failure to follow this could result in personal injuries or possibly death.
Before starting operation and maintenance, personnel should observe the following items:
• Only qualified and experienced operators with official license (according to the local laws) are
allowed to operate the machine.
• 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.
This operation & maintenance manual is a guide to handle the machine correctly. It provides tech-
nique 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 this publication are based on the latest available in-
formation. Continuous improvements in the design of this machine can lead to changes which may
not be covered in this manual. SANY reserves the right to change the information at any time with-
out prior notice. Please consult SANY authorized distributors to obtain the latest information if you
have any question on the information in this manual.
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.

INTRODUCTION
• 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 devi-
ces or technical requirements necessary for using in your country.
• In case you question whether the machine is in accordance with the specifications and stand-
ards of your country, please contact SANY authorized distributors before operating the machine.
1.3 Application Range

1.3.1 Intended use
Empty container handlers are applicable for

the operation of 20’ and 40’ international
standard containers. Do not hoist or transport
heavier load than the max. lifting capacity of
this machine. (For detailed information, see:
“Load capacity diagrams” on page 4-39.)
The rules for intended and approved uses of

this machine must be followed under all cir-
cumstances by the responsible personnel, es-
pecially by the operator and service
personnel.
The user, and not SANY, is responsible for

any danger arising from applications not au-
thorized by the manufacturer.
Machines covered by this manual are used for

Fig 1-2 Empty Container Handler
various operations under normal conditions. If
you are not sure about the safety of some pro-
cedures, please contact SANY directly
1.3.2 Unauthorized use
If any procedures or actions not specified, recommended or allowed in this manual are performed,
you must be sure that you and others can perform such procedures and actions safely without
damaging the machine or injuring yourself and other personnel.
Improper uses include:

• Transporting people. Inside the cab, there is only one seat for the operator. No additional people
may be transported.
• Transporting people inside or on containers.
• Applying load to or on the machine.
• Using cables, chains or other items attached to the boom to transport or lift objects.

INTRODUCTION
• Pulling or pushing vehicles, trailers or containers.

• Operating, driving and crossing on roads.
• Starting, retracting and operating in public areas with risks of explosion.
• Overloading the machine beyond its max. lifting capacity listed in the load capacity diagram.
• Transporting non-centered loads.
• Leaving the machine with a hanging load.
NOTE：
SANY assumes no liability for damage to people, the environment or the machine for improper
uses.
Modifying the machine without any approval or abusing it might risk the machine’s performance, or
result in potential hazard. Improper operation may cause personal injury or damage. SANY as-
sumes no liability for such losses.
1.4 Machine Authorizations

SANY port machines have all passed Euro-
pean CE authoriaztion, North America ANSI
authorizatin and Russia GOST authorization.
All machines and equipment (some equip-

ment installed on the machines or installed Address: Sany Industry Town,
Economic and Technological
with used spare parts are exclusive) manufac- Development Zone, Changsha,
Hunan, China
tured by SANY Port Machinery Company are
labeled with CE, which certifies their conform- 1417
ity to the European Union machine safety
instructions. Fig 1-3 CE Label
1.5 Your Documentation Package

1.5.1 Documentations
Several documents will be packed along with the machine, as listed below:
Several documents will be packed along with the machine, as listed below:
• 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.

INTRODUCTION
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).
• Replace the old versions of some pages with SANY replacement pages if necessary. Destroy
the old ones.
• 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:

INTRODUCTION
3 - 20
chapter 3, page 20
chapter 3
3. Edition number of Operation and Maintenance Manual is marked as below:
Operation & Maintenance Manual - July 2012
updated month of this edition

updated year of this edition
1.5.4 Documentation storage
• Keep this manual in the box on the back of the seat in the operator cab.
• Keep the parts book either in the workshop area or office to be available to the maintenance per-
sonnel 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.

INTRODUCTION
CHAPTER 3: SYSTEM FUNCTIONS
This section provides an overview 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
Prevents oxidation, in simple terms, rust-proofing
compound
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
Buzzer Acoustic alarm to catch the operator’s attention

INTRODUCTION
Table 1–1 Terminology (continue)
Term Description
Valves that can be used to control something, for example, to release
Control valve
pressure and thus lower a mast
The actions that should be performed daily to ensure the machine’s
Daily inspection
functionality
Display “Window” showing digital information on steering wheel panel in cab
Drive axle Receives torque from the drive train
Parts in machine involved in power transmission, engine, torque convert-
Drive train er, transmission, propeller shaft and drive axle with differential and hub
reduction
The air filter collects the coarsest particles in a dust reservoir, emptied
Dust reservoir
automatically during operation
Electrolyte level Fluid level in battery cells
Empty container
Machine with special top lift attachment for containers
handler
Environmental Used oils, filters, etc., must be handled according to governing national
waste laws and regulations
Expansion tank Tank for coolant
Fixed displacement Pump with fixed pump volume
Hanging load Lifted load
Type of final drive (often next to drive wheel) that reduces rpm and in-
Hub reduction
creases torque from the drive train
Hydraulic oil Oil for hydraulic system
Hydraulic oil pump Pump in hydraulic system
Hydraulic system System that uses oil pressure to transfer power to different functions
Manual “sensor”, for example, shows that a filter is clogged and needs to
Indicator
be changed
Load capacity Indicates machine’s max. load capacity
Hoisting point Attaching point for lift device when lifting an object
Low-emission Engine with low emissions of hazardous substances. Manufactured ac-
engine cording to regulations
Machine model Machine type indicated
Main fuse Located by the battery. Cuts off current of all systems in machine
Periodic maintenance actions so that machine functions safely and for
Maintenance
long life.
Overload protection. Overloading system to warn when machine is
OP
overloaded
INTRODUCTION
Table 1–1 Terminology (continue)
Term Description
Number of hours machine has been in operation, shown on hour meter in
Operating hours
cab
Optional Optional equipment for machine
Overloading system See OP
Planetary gear Type of transmission with gears in constant engagement
One of several alternatives is selected for a machine, i.e. engine
Product alternative
alternative
An electro-magnetically controlled valve. If a current is applied, the valve
is activated in proportion to the current’s amplitude. In simple terms, infin-
Proportional valve
itely variable valve, as opposed to on/off valve. For example, on trans-
mission’s valve housing
Fluid/gas in air conditioning. May only be handled by authorized trained
Refrigerant
person
Secur ing machine
Actions before transporting machine
for transport
Serial number Unique machine designation. On machine nameplate
Service position How machine should be safely positioned before service may be started
A low control pressure to control a higher pressure, for example, to a
Servo pressure
valve
Side-shift Parallel sideways movement of attachment
Solenoid valve An electro-magnetically controlled valve
Spreader Widening attachment
Start procedure for control and monitoring system (from powerless to
Start-up
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
Four lock pins, one in each corner of the attachment, pushed down in
Twistlock corresponding holes in container and twisted to lock the container when
lifting
Variable
Adjustable volume (capacity) of a pump
displacement
Variable pump Pump with adjustable flow rate
Wet brakes Brake discs in oil-bath

INTRODUCTION
1.7 Abbreviation Explanation
Table 1–2 Abbreviation Explanation
Name Abbreviation
Newton metre N·m
Kilo pound metre kp·m
Kilo pascal kPa
Mega pascal MPa
Kilowatt kW
Kilojoule kJ
British termel unit Btu
Calorie cal
Inch in
Feet ft
Yard yd
Mile mile
Centimeter cm
Metre m
Rotation per minute rpm
Kilometer km
1.8 Machine Information

1.8.1 Information
Please inform SANY authorized distributors of the following information when ordering replace-
ment parts or requiring assistance for your equipment.

INTRODUCTION
1.8.2 Machine nameplate
Hunan Sany Port Machinery Co., LTD
1 2
3 4
5 6
7 8
9
10 11
12
Fig 1-4 Machine Nameplate
1.8.3 Engine nameplate
1.8.3.1 VOLVO engine nameplate
Fig 1-5 VOLVO Engine Nameplate

INTRODUCTION
1.8.3.2 CUMMINS engine nameplate
Fig 1-6 CUMMINS Engine Nameplate
1.8.3.3 YUCHAI engine nameplate
Fig 1-7 YUCHAI Engine Nameplate

INTRODUCTION
1.8.4 Spreader nameplate
1.8.4.1 SANY spreader nameplate
Fig 1-8 SANY Spreader Nameplate
1.8.4.2 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 1-9 ELME Spreader Nameplate

INTRODUCTION
1.8.5 Transmission case nameplate
1.8.5.1 DANA transmission case nameplate
SPICER OFF-HIGHWAY
BRUGES
BELGIUM
MODEL XX.XXXXXXXX-XXX
SERIAL XXXXXXXXXX XX/XX
Fig 1-10 DANA Transmission Case Nameplate
1.8.5.2 ZF transmission case nameplate
ZAHNRADFABRIK PASSAU
G.m.b.H.
MADE IN GERMANY
TYPE / SERIAL NO.
PARTS LIST NO. TOTAL RATIO
OPERATING PRESS. (bar)
TORQUE CONVERTER
PARTS LIST NO. TYPE
OEL-LEVEL
CHECK AT IDLING SPEED
USE OIL ONLY ACCORDING TO

ZF SPEC. TE-ML 03
Fig 1-11 ZF Transmission Case Nameplate

INTRODUCTION
1.8.6 Drive axle nameplate
TEL07366/8132
FAX07366/8169
73453 ABTSGMUND/GERMANY
Order Nr. 1
Fabrik Nr. 2
OIL : MIL - L - 2105 B SAE 90
Fig 1-12 Drive Axle Nameplate
1.9 Running a New Machine
NOTICE
Risk of machine damage!
Your machine has been thoroughly adjusted and tested before shipment. However, initial opera-
tion of the machine under severe conditions could 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 whole 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.
1.10 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.

INTRODUCTION
Machine Serial No.
Engine Serial No.
Distributor Name
Address
Tel /Fax
1.11 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 1-19.
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 erro-
neous procedure, etc.)
1.12 Contact Information

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

SAFETY
SAFETY
2 SAFETY ................................................................................................................................2-1
2.1 Safety Information.................................................................................................................2-5
2.1.1 General .........................................................................................................................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 on the machine .............................................................................2-6
2.1.5.2 Safety labels, location .........................................................................................2-8
2.1.5.3 Safety labels, contents........................................................................................2-9
2.2 General Precautions.......................................................................................................... 2-24
2.2.1 Precautions ............................................................................................................... 2-24
2.2.2 Basic safety instructions.......................................................................................... 2-24
2.2.3 Personal protective equipment .............................................................................. 2-25
2.2.4 No operation while in bad health............................................................................ 2-28
2.2.5 No passenger in the cab ......................................................................................... 2-28
2.2.6 Hand signals ............................................................................................................. 2-29
2.2.7 Preparing safety items............................................................................................. 2-31
2.2.8 Checking safety equipment .................................................................................... 2-32
2.2.9 Precautions in high voltage areas.......................................................................... 2-33
2.2.10 Precautions in thunderstorm ................................................................................ 2-35
2.2.11 Precautions in wind................................................................................................ 2-35
2.2.12 Abnormal cases ..................................................................................................... 2-36
2.2.13 Unauthorized modification.................................................................................... 2-36
2.2.14 Fire Extinguisher .................................................................................................... 2-37
2.2.15 Emergency exit....................................................................................................... 2-37
2.3 Safety During Operation.................................................................................................... 2-37
2.3.1 Work area safety ...................................................................................................... 2-37
2.3.1.1 Overview ............................................................................................................ 2-37

SAFETY
2.3.1.2 Work area requirements .................................................................................. 2-38

2.3.1.3 Work area indications....................................................................................... 2-38
2.3.2 Checks before operation......................................................................................... 2-38
2.3.3 Keeping machine clean........................................................................................... 2-41
2.3.4 Going up or down the machine safely................................................................... 2-41
2.3.5 Start-up safety .......................................................................................................... 2-42
2.3.5.1 In the operation cab.......................................................................................... 2-42
2.3.5.2 Adjusting the seat ............................................................................................. 2-43
2.3.5.3 Checking the seat belt...................................................................................... 2-43
2.3.5.4 Machine starting precautions .......................................................................... 2-44
2.3.5.5 Jump-start the engine, precautions................................................................ 2-44
2.3.5.6 In cold weather .................................................................................................. 2-45
2.3.5.7 After starting the engine................................................................................... 2-45
2.3.6 Precautions for safe operation ............................................................................... 2-45
2.3.6.1 Ensuring good visibility .................................................................................... 2-45
2.3.6.2 Safety rules for traveling .................................................................................. 2-46
2.3.6.3 Precautions while operating on slopes .......................................................... 2-47
2.3.6.4 Avoiding injury from reversing......................................................................... 2-47
2.3.6.5 Precautions while operating on snow or frozen surfaces ........................... 2-48
2.3.6.6 Preventing control failure................................................................................. 2-48
2.3.6.7 Do not lift a load without container ................................................................. 2-49
2.3.6.8 Never hoist the load over people.................................................................... 2-50
2.3.6.9 Do not stay below the load .............................................................................. 2-50
2.3.6.10 Precautions for operating emergency stop button..................................... 2-51
2.3.6.11 Precautions for operating safety bypass switch ......................................... 2-51
2.3.7 Parking the machine securely ................................................................................ 2-52
2.3.7.1 Parking requirements ....................................................................................... 2-52
2.3.7.2 Stop the engine ................................................................................................. 2-53
2.4 Safety During Maintenance .............................................................................................. 2-54
2.4.1 General ...................................................................................................................... 2-54
2.4.2 Preparation for the work area................................................................................. 2-55
2.4.3 Warning label is important ...................................................................................... 2-55
2.4.4 Lockout/tagout procedures ..................................................................................... 2-56
2.4.5 Self-preparation before maintenance.................................................................... 2-57
2.4.6 Using tools correctly ................................................................................................ 2-57
2.4.7 Regular replacement of safety-related parts........................................................ 2-57
2.4.8 Removing attachments carefully............................................................................ 2-58
2.4.9 Adding fluids to the machine .................................................................................. 2-58
2.4.10 Towing or lifting the machine ................................................................................ 2-59
2.4.11 Keep clear of moving machinery.......................................................................... 2-60
2.4.12 Preventing hydraulic hazards............................................................................... 2-61
SAFETY
2.4.12.1 Checking rubber hose regularly ................................................................... 2-61

2.4.12.2 Release the pressure before the maintenance .......................................... 2-61
2.4.12.3 Replacing rubber hose regularly .................................................................. 2-62
2.4.12.4 Prevent heat near the hydraulic pipeline..................................................... 2-63
2.4.12.5 Filling accumulator ......................................................................................... 2-63
2.4.12.6 Selecting oils and fuel .................................................................................... 2-64
2.4.12.7 Handling hydraulic oil..................................................................................... 2-64
2.4.13 Preventing burn and scald.................................................................................... 2-65
2.4.13.1 Burn by high temperature liquid.................................................................... 2-65
2.4.13.2 Chemical burn ................................................................................................. 2-65
2.4.14 Preventing fire and explosion............................................................................... 2-66
2.4.14.1 Handling inflammables safely....................................................................... 2-66
2.4.14.2 Removing inflammables ................................................................................ 2-67
2.4.14.3 Checking oil leakage ...................................................................................... 2-67
2.4.14.4 Checking short circuit..................................................................................... 2-68
2.4.14.5 Preventing battery explosion ........................................................................ 2-69
2.4.14.6 Examine the ignition key................................................................................ 2-70
2.4.14.7 Evacuating from the machine ....................................................................... 2-70
2.4.15 Preventing poisoning and asphyxiation.............................................................. 2-71
2.4.15.1 Handling chemicals safely............................................................................. 2-71
2.4.15.2 Preventing poisoning by paint....................................................................... 2-71
2.4.15.3 Preventing poisoning by off-gas ................................................................... 2-72
2.4.16 Preventing dust hazard ......................................................................................... 2-72
2.4.17 Working under machine ........................................................................................ 2-73
2.4.18 Precautions in welding .......................................................................................... 2-73
2.4.19 Safe maintenance of air conditioning system .................................................... 2-74
2.4.20 Precautions in maintaining the engine................................................................ 2-74
2.4.21 High voltage precautions ...................................................................................... 2-75
2.4.22 Precautions after maintenance ............................................................................ 2-76
2.4.23 Handling waste properly ....................................................................................... 2-76
2.5 Tag........................................................................................................................................ 2-77

SAFETY

SAFETY
2.SAFETY
2.1 Safety Information

2.1.1 General
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 personal injury or death, the damage of machine caused by improper 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
It indicates an imminent hazard.
• If not avoided, 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 minor or major injury!
It indicates a possible potential hazardous situation.
• If not avoided, could result in minor or major injury.
NOTICE
It indicates a situation which can cause damage to the machine.
• Personal property and/or the environment, or cause the equipment to be operated improperly.

SAFETY
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.
Other than the above ones, the following signal words indicate matters to be observed for protect-
ing your machine, or provide you with very useful information.
NOTE is the term used whenever information requires additional emphasis beyond the standard
text.
Examples of using signal words
CAUTION
Risk of injury!
Steam or hot fluid could spray out, which could cause injury.
• Do not open the filler cap when the machine is hot, except in emergencies.
2.1.3 Examples of using signal words
CAUTION
Risk of injury!
Steam or hot fluid could spray out.
• Do not open the filler cap when the machine is hot, except in emergencies.
2.1.4 Other signal words
Other than the above ones, the following signal words indicate matters to be observed for protect-
ing 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 on the machine
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, covered or
removed.
SAFETY
• The use of organic solution or gasoline to clean the labels is not allowed, or 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. Do not 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.
a. Safety label example 1
WARNING
Keep clear o f moving machiner y

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

SAFETY
2.1.5.2 Safety labels, location
18 19 6
40 6
26 5 5 39
30 19 18
31 36
21 32 38 37
20
41
1
20 2
34
3 33
4 35
1
2 7
3 24
27 28 23 29 4 25
14
7 8 9 8 9 22 10 1112
13 15 16 17
Fig 2-3 Safety Labels of Whole Machine
1. Warning label, cau- 2. Warning label, 3. Warning label, 4. Label, no passing

tion for electricity overhead danger spreader through
5. Label, no climbing 6. Label, line of sight 7. Label, tyre pressure 8. Warning label, tyre
precautions
9. Label, pre-tighten- 10. Warning label, no 11. Warning label, fire 12. Warning label,
ing the hub screw ether is prohibited electrical hazard
13. Warning label, 14. Label, battery 15. Warning label, 16. Warning label, dis-
chemical hazard disconnect stay clear assembling
counterweights
17. Warning label, 18. Warning label, 19. Label, no riders 20. Label, stand clear
stay clear head injury of moving machine
21. Label, burn 22. Label, break oil 23. Label, diesel fuel 24. Warning label, fan
hazard danger
25. Warning label, 26. Label, emergency 27. Label, oil water 28. Label, hydraulic
accumulator exit separator pressure
29. Label, lubricant 30. Warning label, 31. Label, CE 32. Label,
char precautions before maintenance
starting the engine

SAFETY
33. Warning label, 34. Warning label, 35. Warning label, 36. Warning label,
danger to fall jumping Antislip safety belt
37. Warning label, 38. Label, 39. Label, safety 40. Warning label,
shut off engine extinguisher hammer operation
41. Label, machine
type plate
2.1.5.3 Safety labels, contents
1. Caution for Electricity label
Keep the machine away from power lines.
Fig 2-4 Caution for Electricity
2. Overhead Danger label
Do not stay below a swinging load. There is

danger of being hit by it.
Fig 2-5 Overhead Danger

SAFETY
3. Attachment Warning label
Do not stand close to the spreader. There is a

danger of being hit by it.
Fig 2-6 Attachment Warning
4. No Passing Through label
Passing through is prohibited where this label

is glued.
Fig 2-7 No Passing Through
5. No Climbing label
Do not climb on the place glued with this no

climbing label.
Fig 2-8 No Climbing

SAFETY
6. Line of Sight label
Always travel with container bottom on your

line of sight.
Fig 2-9 Line of Sight
7. Tyre Pressure label
The pressure range of tyres should be 138

Psi - 152 Psi.
Fig 2-10 Tyre Pressure
8. Tyre Precautions label
Observe the precautions listed in the right il-

lustration when repairing or maintaing the
tyres.
Fig 2-11 Tyre Precautions

SAFETY
9. Pre-tightening the Hub Screw label
During 200 hours after the machine is started

for the first time or the new tyre is replaced, be
sure to pre-tighten the hub screw every 50
hours.
Fig 2-12 Pre-tightening the Hub Screw
10. No Ether label
Do not use ether to avoid explosion and se-

vere injury.
Fig 2-13 No Ether
11. Fire is Prohibited label
Do not smoke or use any open fires. Other-

wise, fire disaster or explosion may occur.
Fig 2-14 Fire is Prohibited

SAFETY
12. Electrical Hazard label
Always disconnect and lock the power before

servicing the machine.
Fig 2-15 Electrical Hazard
13. Chemical Hazard label
The battery contains corrosive and hazardous

materials. Do not pucture the battery.
Fig 2-16 Chemical Hazard
14. Battery Disconnect label
Disconnect the battery before servicing the

machine.
Fig 2-17 Battery Disconnect

SAFETY
15. Stay Clear label
Death or serious injury may occur if you are

hit by the machine. Do not go nearby or stay
there.
Fig 2-18 Stay Clear
16. Caution for Disassembling Counter-

weights label
Do not stand under or on counterweights

when assembling or disassembling them.
Fig 2-19 Caution for Disassembling

Counterweights
17. Stay Clear label
Please keep away from the machine with a

distance of at least 8 m.
Fig 2-20 Stay Clear

SAFETY
18. Head Injury label
Keep away from the machine in the operation

process and be cautious of the hanged
objects.
Fig 2-21 Head Injury
19. No Riders label
Only the operator is allowed in the cab if not

otherwise indicated when the machine is
traveling.
Fig 2-22 No Riders
20. Stand Clear of Moving Machine label
Do not stand in places where there is a label

as shown in the right illustration.
Fig 2-23 Stand Clear of Moving Machine

SAFETY
21. Burn Hazard label
Do not touch the places glued with the label in

the right illustration.
Fig 2-24 Burn Hazard
22. Label, break oil
The information of the machine is listed on the

label include type, engine model and so on.
Fig 2-25 Break Oil
23. Label, diesel fuel
Fig 2-26 Diesel Fuel

SAFETY
24. Warning label, fan danger
Do not approach rotating parts as which may

cause injury.
Fig 2-27
25. Warning label, accumulator
Fig 2-28
26. Label, emergency exit
Fig 2-29

SAFETY
27. Label, oil water separator
Fig 2-30
28. Label, hydraulic pressure
Fig 2-31

SAFETY
29. Label, lubricant chart
Indicates the maintenance points and inter-

vals in relation to lubricants and operating ma-
terials for the vehicle.
Fig 2-32
30. Warning label, precautions before starting

the engine
Pay attention to the precautions listed in the

label.
Fig 2-33

SAFETY
31. Label, CE
Fig 2-34
32. Label, maintenance
Fig 2-35
33. Warning label, danger to fall
There is danger to fall. Stay away from the

edge of machine.
Fig 2-36

SAFETY
34. Warning label, jumping
Do not jump down from the vehicle. Use the

steps, ladders and gangways provided for get-
ting on and off.
Fig 2-37
35. Warning label, Antislip
Be careful about the ground under your feet,

sometimes it is very slipping especially in a
raining day. Injuries may occur.
Fig 2-38
36. Warning label, safety belt
Always wear safety belt before staring the

machine.
Fig 2-39

SAFETY
37. Warning label, shut off engine
Always shut off the engine and remove the

key before servicing this machine.
Fig 2-40
38. Label, extinguisher
Fig 2-41

SAFETY
39. Label, safety hammer
Fig 2-42
40. Warning label, operation
Fig 2-43

SAFETY
41. Label, machine type plate
The information of the machine is listed on the

label include type, engine model and so on.
Fig 2-44
2.2 General Precautions

2.2.1 Precautions
CAUTION
Risk of injury!
Neglect by maintenance or on-site personnel could lead to personal injuries, serious damages of
machine and huge property loss.
• Follow all general precautions.
2.2.2 Basic safety instructions
WARNING
Failure to do so could result in equipment damage, serious injury or possibly death.
• Read and follow all safety precautions before operating or maintaining this machine.
CAUTION
Risk of injury!
Neglect by maintenance or on-site personnel could lead to personal injuries, serious damages of
machine and huge property loss.
• Follow all general precautions.

SAFETY
• 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 or 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.
2.2.3 Personal protective equipment
CAUTION
Risk of injury!
Failure to follow this could result in personal injuries.
• Do not have long hair that is hanging loose.
• Do not work without putting on safety helmet.
• Do not wear loose clothing, including rings, earrings or similar accoutrement.
• Do not Wear music earphone while operating.
Protective equipment ensures only the proper

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

ating, maintaining, or repairing the machine.
Take protective tools necessary for tasks.
Operator responsibilities:
Fig 2-45 Protective Equipment
• Wear protective equipment.
• Clean and maintain personal protective equipment at regular intervals.
• Change damaged or inapplicable protective equipment.

SAFETY
Protective equipment should contain:

• Safety Helmets:
Safety helmets can protect head from harm.

Be sure to wear safety helmets while operat-
ing, maintaining, repairing the machine.
Fig 2-46 Safety Helmet
• Safety Shoes
Safety shoes can decrease foot injuries, so

wear safety shoes while operating, maintain-
ing, repairing the machine.
Fig 2-47 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 2-48 Safety Goggle

SAFETY
• 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 2-49 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 2-50 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 ex-
tremely low. Fig 2-51 Protective Glove
• when using impact tools for a long time.

SAFETY
• 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 these type of garments may
hook on the control lever or protrusion of ma-
chine and thus lead to personal injuries.
Clothes should be in good condition and with-

out oil dirt, or it may catch fire. Fig 2-52 Protective Clothes
2.2.4 No operation 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 2-53 No Passenger

SAFETY
2.2.6 Hand signals
DANGER
Operation without signals and instructions will result in machine damage or injuries even death
• Follow all signals and instructions before operation.
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.
Fig 2-54 Raise Load
LOWER LOAD
With arm extended downward and index fin-

ger pointing down, move hand in a small hori-
zontal circle.
Fig 2-55 Lower Load

SAFETY
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.
Fig 2-56 Raise Load Slowly
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.
Fig 2-57 Lower Load Slowly
NORMAL STOP
Use one hand starting at the waist and move

it outward.
Fig 2-58 Normal Stop

SAFETY
EMERGENCY STOP
Use both hands starting at the waist and move

them outward.
Tips for safe signaling
• A new operator or signalman should brief

each other to ensure that they understands
each other.
• Do not 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
Fig 2-59 Emergency Stop
operations.
• If communication with the signalman is ob-
structed in any way, all movements of the
machine must be stopped until communica-
tions are restored.
• Obey a signal to stop from anyone.
• There should be only one designated per-
son 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 out-
side the machine’s operating area. Any re-
quests 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 could result personal injury.
• Firefighter should put on a fire-fighting mask to prevent injury when extinguishing the fire with
CO2, foam, dry-powder fire extinguisher.

SAFETY
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 Fig 2-60 Safety Items
ensure proper functioning of fire extin-
guisher at any time.
• Check the first aid kit regularly and replen-
ish it when necessary.
• Prepare and implement emergency plan to
deal with fire and accidents.
2.2.8 Checking safety equipment
To protect yourself and others, your machine

may be fitted with the following safety equip-
ment. Ensure that each item is securely in
place and in operating condition.
• Guard against falling objects

• Handrail
• Lights
• Safety labels Fig 2-61 Check Safety Signs
• Hon
• Reverse alarm buzzer
• Rearview mirrors
• Fire extinguisher
• First aid kit
• Wipers
Be sure that the above devices are available

for operation. Do not remove or disconnect
any safety devices.

SAFETY
2.2.9 Precautions in high voltage areas
Operating machine near high frequent towers

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

maintained irrespective the voltage is. During
operation no part of the load, machine or addi-
tional equipment used must exceed this limit.
If in doubt, contact your local Electrical Power
Utility Company.
Fig 2-62 Electricity strike
DANGER
Do not operate the machine below electrical power lines. Electrical energy under high voltage
can go to ground through the machine without direct contact with the machine’s structure. It will
result in serious injury or death.
• If the power line is discharging electricity, operator must stay in the cab and prevent others from
touching the machine.
• High voltage charge of machine can result in equipment damage and person injury.
• Do not touch the power supply while you operate the electrical equipment.
• Do not operate in the areas of high voltage wires or near high voltage power supply.
To address these risks:
• Identify overhead power lines and mark safe routes where the equipment must go again and
again.
• Tell the local Electrical Power Utility Company to stop this system until your work is completed.
• Operate the equipment at a speed slower than usual speed in the vicinity of power lines.
• When you operate around overhead power lines, stop and ground them, or take other safety
measures for example 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 (see Table 2-1) is maintained.
Table 2–1 Safety Distance
Cable Voltage Safety Distance

6,600 V about 2 m (7 ft)
22,000 V about 3 m (10 ft)

SAFETY
Table 2–1 Safety Distance (continue)
Cable Voltage Safety Distance

66,000 V about 4 m (14 ft)
154,000 V about 5 m (17 ft)
187,000 V about 6 m (20 ft)
275,000 V about 7 m (23 ft)
500,000 V about 12 m (38 ft)
• 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 must keep away from the equipment when it is near power lines.
• Do not touch the equipment until the signalman tells that it is safe to operate.
• The use of electrocution hazard devices is not a substitute for de-energizing lines, or maintaining
safe clearance.
If the equipment or its components touch an energized power source, you must:
1. Stay calm.
2. Immediately tell personnel in the vicinity to stay away.
3. Try to move the equipment away from the contacted power source.
4. If in the cab, stay there until the power company has been contacted and the power source
stops.
5. Do not move near the equipment until the power stops.
6. If it is fully necessary to go out of the cab, jump fully clear of the equipment. Maintain balance
and land with both feet, legs, arms and hands still together. Your hands, arms or other part of you
must not touch the equipment.
7. When you touch the ground, continue to jump away from the affected area as far as you are pos-
sible. Do not walk or run as this will cause an electrical arc resulting in serious injury or death.

SAFETY
2.2.10 Precautions in thunderstorm
If the thunderstorm occurs, operator and

others around may be caught in danger.
Some parts of the machine could be
damaged.
Fig 2-63 Thunderstorm
• 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 the machine before re-operating it. If any faults found,
contact the local SANY distributors to troubleshoot and fix it.
Check the defects:
• whether the machine is burnt or damaged

• whether the electrical equipment are working normally
• whether all the functions are in good condition
NOTE:
When a machine is traveling across the puddles, always maintain the machine 700 mm above the
water (not flooding the battery).
2.2.11 Precautions in wind
Wind can have a significant effect on loads that may be lifted by the machine. Wind forces act dif-
ferently on the machine, depending upon the direction from which it is blowing.
SANY recommends that operation of this machine in wind speed over 30 mph (48 km/ h) be pro-
hibited. To assist you in determining prevailing wind conditions, refer to the following table.

SAFETY
Table 2–2 Wind speeds and Their Effects
Wind Force
Wind Velocity Visible Indicator
Beaufort
Designation km/h (mph) Effects of wind as observed on land
Scale
Zero (0) Calm <2 (<1) No wind: smoke rises vertically
Wind direction seen by smoke but not by wind
1 Light air 2-5 (1-3)
vanes
Wind felt on face: leaves rustle: wind vane moves
2 light breeze 6-11 (4-7)
slightly
Leaves/small twigs in constant motion: wind ex-
3 Gentle breeze 13-19 (8-12)
tends flag
Moderate Raises dust & loose paper: moves small
4 21-29 (13-18)
breeze branches
Small trees in leaf begin to sway: on ponds,
5 Fresh breeze 31-39 (19-24)
crested wavelets form
Large branches in motion: telegraph wires whis-
6 Strong breeze 40-50 (25-31)
tle: umbrellas used with difficulty
Whole trees in motion: walking against wind is
7 Moderate gale 52-61 (32-38)
inconvenient
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 com-
ponent failure. Before operating the attachments that you are not familiar with, check the possi-
bility of collision and operate carefully.

SAFETY
2.2.14 Fire Extinguisher
There are two fire extinguishers in the cab, re-

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

the following items:
NOTE:
• Make sure to put fire extinguishers in cab

and read carefully the instructions. Under-
stand its usage under emergency
circumstances.
• Check whether the lead wire and shell of
Fig 2-64 Fire Extinguisher
fire extinguisher are in good condition daily.
If damaged, change it immediately. Check
the electrical wiring of circular fire extin-
guisher and change the wires if damaged.
• Be sure that the fire extinguisher is in the
guarantee period. If the fire extinguisher ex-
ceeds the guarantee period, you must
change it in time.
• Change the fire extinguisher at least every
two years.
2.2.15 Emergency exit
• If it should be impossible to open the door of the cab, break the window glass with the safety
hammer supplied and use the window as an emergency escape.
• To escape from the operator's cab, use the safety hammer to break the glass and escape
through the window.
• When escaping, remove all the pieces of glass from the window frame first and be careful not to
cut yourself on the glass. Be careful also not to slip on the broken pieces of glass on the ground.
2.3 Safety During Operation

2.3.1 Work area safety
2.3.1.1 Overview
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.
SAFETY
2.3.1.2 Work area requirements
• The machine should be driven on substan-

tially 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 seri-
ous injury or death. It is essential to check
the operating surface condition in advance
to avoid accidents.
• Make a work plan and select a machine that
is suitable for such work or site.
Fig 2-65 Do not Work on Uneven Ground
• When working on a narrow site, try to oper-
ate 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 ma-
chine only on even and firm ground.
• Reinforce the ground prior to work when it
is too loose or soft.
Fig 2-66 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
Examine the machine carefully before you start it each day or at the start of the shift:

SAFETY
• Examine if the air pressure in tires is cor-

rect. The applicable tire pressure must be
0.95 MPa - 1.05 MPa.
Fig 2-67 Examine the Tire Pressure
• Examine if the attaching bolts of tire, driving

axle, transmission shaft, mast and frame
are safe.
Fig 2-68 Examine the Bolts
• Examine if the lubrication points of connect-

ing shaft of mast swinging cylinder and
frame, steering cylinder and its connecting
plate, hinge point of spreader cylinder, and
sliding blocks are adequately lubricated.
Fig 2-69 Examine Lubrication Points

SAFETY
• Examine if the hydraulic pipes are in good

condition without oil leaks, also if the elec-
tric wires are secured.
Fig 2-70 Examine the Hydraulic Pipe
• Examine if the engine oil level, fuel level,

hydraulic oil level and coolant level are
correct.
Fig 2-71 Examine Oil Level
• Examine if the twistlocks are in good condi-

tion, for example looseness, deformation,
cracks.
• Examine the indication.
Fig 2-72 Examine Twistlock

SAFETY
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.
Fig 2-73 Avoid High-pressure-water Cleaning
• Do not 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.
• Do not leave any tools, personal items or any other objects in the operator cab. Keep these
items in the tool box rather than in the cab.
• Do not bring dangerous objects or fluids into the operator cab, for these may spill, ignite or
explode.
2.3.4 Going up or down the machine safely
WARNING
Risk of serious injury!
Failure to obey these instructions could result in serious injury..
• Turn your face to the machine when you go up or down.
• Do not go on a machine which moves.
• Do not go onto the machine and try to stop it.
• The machine must be at an applicable position for you to go on or off.
To avoid a person injury from moving or falling from the machine, follow below instructions:
• Make sure that the machine is at a full stop before you try to access it. Do not go onto or out of
the machine.
• 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 the loose bolts.

SAFETY
• 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 the shoes before you go on-
to the machine.
• Do not go on or off the machine when you
transmits the tools or supplies.
• Do not keep the tools or other objects on
the machine walkway. These can fall and
Fig 2-74 Climb on the Machine
catch in the machine operation systems.
• Do not go on the engine cover, cover, or
counterweight without the anti-slip sticker.
• Do not step on surfaces of the machine that

are not approved for you walk and work.
You can fall from the machine.
• Do not exit or enter the machine cab or
deck by any other means than the access
system’s provided steps and grab handles.
• Do not change the access system that ex-
amined and approved by SANY.
Fig 2-75 Avoid Slipping
2.3.5 Start-up safety
2.3.5.1 In the operation cab
When in the operation cab, obey the instructions:
• Do not let other personnel go in the operation cab.

• Do not put objects into the operation cab that can do your movement or vision.
• Close or latch all doors or windows.
• Examine the work area to make sure that all personnel and equipment are clear from your
machine.
• Examine all instruments and fully warm up the engine before you do the operations.

SAFETY
2.3.5.2 Adjusting the seat
Incorrect seat position can easily lead to oper-

ator fatigue and operating mistake. Therefore,
operators should observe the following:
• Seat in a comfortable position before oper-

ating the machine.
• Adjust the seat and console so that you can
easily access all controls from a seated po-
sition and be sure that your vision is clear in
all directions as viewed from the seated
position.
Fig 2-76 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 from Fig 2-77 Check the Seat Belt
accident.
• To reduce the danger, it is preferred to re-
place the seat belt every three years.

SAFETY
2.3.5.4 Machine starting precautions
DANGER
Machine out of control will cause serious injury or death.
• Prior to operation, be sure that you can properly control the speed, direction, braking, and turn-
ing of the machine.
• Understand the control mode of work equipment before operating.
• Do not start the machine by tampering with or shorting the starter terminals.
Before starting operations, observe the following:
• Ask for inspection and maintenance records and verify that the appropriate operation & mainte-
nance 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 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, instruments and operation controls.
• Do not allow anyone else inside the cab or on the machine during operation.
• Check your view. Be sure you can see all work areas around your machine clearly.
• Ample ventilation must be guaranteed if you have to start the engine or operate the machine in
an enclosed environment.
2.3.5.5 Jump-start the engine, precautions
Do the operation of the jumper cable to start the engine refer to the instruction of the operation sec-
tion. Improper operation can lead to battery explosion and machine out of control, hence personal
injury and death.
• Do not use the jumper cable to start the engine without approval. Speak to SANY approved dis-
tributor when it is necessary.
• 2 personnel must operate together to start the engine with the jumper cable. One is seated in
the operator's seat and the other handles the battery.
• Wear goggles and rubber gloves before you start the engine with the jumper cable.
• When you use the jumper cable to connect a machine with the unserviceable machine, stop the
power switch of machines.
• Do not use an equipment with a higher voltage system to jump-start the machine. It can cause
damage to the machine electrical system or cause an explosion or fire. Jump-start the engine
with same voltages.

SAFETY
• When you connect the jumper cable, con-

nect the positive (+) (1) first. When you dis-
connect the jumper cable, disconnect the
negative (-) (2) first. 1
2
• Prevent the clips of the jumper cable from
touching each other or the machine when
you remove the cable.
Fig 2-78 Booster Battery
1. Positive (+) 2. Negative (-)
2.3.5.6 In cold weather
Cold weather operation requires additional caution:
• Check operating procedures in this manual or the engine manual for cold weather starting.
• Do not touch metal surfaces that could cause you to be frozen by them.
• Keep the machine clear of all ice and snow.
• Allow time for the hydraulic oil to warm up.
• Park the machine in an area where it cannot be frozen to the ground.
• Sufficient warm-up operation is necessary before starting engine in cold weather. Incomplete
warming up may result in slow reaction and accidents.
• In cold weather, check the battery before the starting to see if its electrolyte is frozen or leaking.
In case of frozen electrolyte, do not charge the battery or use another power source to start the
engine. The electrolyte of battery should be melted, or it has the danger of catching on fire.
2.3.5.7 After starting the engine
Run the 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 Precautions 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.

SAFETY
• Turn on working lights and headlights of the machine when working in a dark area. Set up auxili-
ary illumination in the work area if necessary.
• Stop operation if a clear view 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
WARNING
Failure to obey below instructions could result in possibly death, injury or machine damage.
• 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 .
• Slow down the machine before changing gears.
• 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, or the machine may tumble down.
• 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.

SAFETY
2.3.6.3 Precautions while operating on slopes
When operating on slopes, observe the fol-

lowing rules:
1. The machine must move up and down

slopes slowly.
2. Do not turn the machine on slopes, nor

drive across slopes.
3. The load must face uphill when the machine

is driving up or down gradients of over 10%.
Fig 2-79 Operate on Slope
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 re-
versing. Keep the traveling alarm device in
working condition. Always keep alert
whether someone enters the work area.
• Keep the windows, rearview mirrors and
lights clean and in good condition. Fig 2-80 Avoid Injury from Reversing
• Before moving the machine, warn others
with horn or other signals.

SAFETY
• 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 sig-
nalman and operator understand the mean-
ing of all flags, signals and marks.
• Avoid sudden acceleration or braking when
reversing. In addition, the driver should ad-
just the speed properly in reversing process
to avoid slippage or tipping.
Fig 2-81 Avoid Injury from Reversing
2.3.6.5 Precautions while operating on snow or frozen surfaces
Be careful when traveling or operating the machine on frozen or snowy surfaces. Snow-covered or
frozen surfaces are slippery. The ability to maneuver the machine is seriously affected. The 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 whith weight exceed-

ing 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
rather than on a slope. Maintain a proper Fig 2-82 Signalman
distance from other machines.

SAFETY
Operation on a slope has tipping hazard,

which can result in serious injury or death. In
case of the machine tipping, do not 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 2-83 Go to Hospital
In case of tipping accidents, always stay in

the cab holding the steering wheel tight. Do
not jump out of the cab.
Fig 2-84 Never Jump Down
2.3.6.7 Do not lift a load without container
Do not use the container handler to lift a load

without container. For example, do not tighten
a sling on spreader to lift other load. If you do
not obey this instruction, it can cause injury.
Fig 2-85

SAFETY
2.3.6.8 Never hoist the load over people
The load hoisted over people may fall down

and result in personal injuries.
Never hoist the load over people. Besides, do

not let any person stand under the load.
Fig 2-86
2.3.6.9 Do not stay below the load
Personnel below the load can be important in-

jury if the load falls down. Do not let a person
stay below the load.
Fig 2-87

SAFETY
2.3.6.10 Precautions for operating emergency stop button
The emergency stop button can also be used

to brake the machine in emergency cases.
However it can only be used when the brake
system fails in a real emergency situation.
NOTE:
It is prohibited to use the emergency stop but-

ton when the brake pedal is still working nor-
mally or in not real emergency situations.
If the emergency stop button has been used

twice, replace the brake lining block immedi-
ately. Be sure to readjust it for a good parking
brake effect if the parking brake has been
Fig 2-88 Emergency Stop Button
separated from the machine.
2.3.6.11 Precautions for operating safety bypass switch
OPERATING RULES OF SAFETY

BYPASS
All safety protection functions are canceled

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

kept by a special technician. Only in special
cases can it be used after approval by the
principals of relevant departments.
• When using this function, note to find out
the condition of work area to ensure the
safe operation.
• SANY assumes no responsibilities for any
accidents caused by improper operation of Fig 2-89 Safety Bypass Switch
the safety bypass function.

SAFETY
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 2-90 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 2-91 Park Ground
It is not allowed to park the machine on un-

even and loose ground.
Fig 2-92 Avoid Parking on Uneven Ground

SAFETY
If the machine is parked on a slope, wedge its

front and rear wheels with blocks to prevent
sliding.
Fig 2-93 Caution for Parking on Slope
2.3.7.2 Stop the engine
Before maintenance for the machine:
1. Park the machine on the solid smooth hori-

zontal ground.
Fig 2-94 Safety the Wheel
2. Retract the spreader and lower it to its lowest position.
3. Turn the gear to neutral position. Operate the engine idle for 3 - 5 minutes to cool it down.
4. Turn the ignition key to ON position (B). Move the joystick forward, rearward, leftward and right-
ward 2 or 3 times to release the pressure from the hydraulic system.
5. Turn the key to OFF position (A) to stop the engine.

SAFETY
6. Remove the key from the switch.
A B
Fig 2-95 Ignition Switch
A. OFF position B. ON position
7. Close all the doors and windows in the cab.
8. Dismount the machine safely. Do not jump out of it. For referred information, see:“Going up or
down the machine safely” on page 2-41
9. Put blocks near the wheel to prevent the machine from moving.
2.4 Safety During Maintenance

2.4.1 General
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 infor-
mation covered in this manual prior to
maintenance.
• Maintenance personnel shall be physically
suited for this work, especially their health
and eyesight. Fig 2-96 Read the Manual
• Do not spray water or steam in the cab.
• Never add lubricants or perform mainte-
nance when your machine is moving.
• Keep your hands, feet and clothing away
from rotating parts.

SAFETY
2.4.2 Preparation for the work area
Before maintenance, you should:
• Choose a clean and even area with enough

space, light, good ventilation to conduct the
maintenance.
• Clean the working ground. Wipe away the
fuel, lubrication oil and water. Spread sand
or other absorbing materials on sliding
ground.
• Do not leave any tools in work area.
Fig 2-97 Prepare for the Work Area
2.4.3 Warning label is important
If anyone have started the engine or operated

the joystick during the maintenance, serious
accidents 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 2-98 Warning Label

SAFETY
2.4.4 Lockout/tagout procedures
The following steps shall be followed in se-

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

affected by the repair or maintenance of the
machine.
2. Secure the machine in a safe position.
3. Identify, remove or disconnect all power or

energy sources and be sure to install a lock-
out / tagout device to them. Fig 2-99 Lock
4. Attach the warning lable to the machine.
5. If the service personnel is issued a lock and

key, he/she shall not share the lock or key with
other personnel until all maintenance proce-
dures are complete and the machine is ready
to put back into service.
6. Be sure all personnel involved in the main-

tenance have installed their own locks on the
power source before performing. Each one
who completes his/her work must remove his/
her own lock and not access the machine
further.

SAFETY
2.4.5 Self-preparation before maintenance
For detailed information, see: “Personal

protective equipment” on page 2-25.
Fig 2-100 Protective Equipment
2.4.6 Using tools correctly
• Only use appropriate tools in a correct man-

ner. 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 2-101 Tools
2.4.7 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 in time.
• Replace the worn or damaged par ts regularly.
• Replace or repair the defective safety parts or components immediately.

SAFETY
2.4.8 Removing attachments carefully
• When removing large and heavy attach-

ments, always be sure to use the correct lift-
ing equipment rated for the capacity of the
load you will be lifting.
• After the attachment or part has been re-
moved, store it where it cannot fall or move.
Always be sure that the attachment is sta-
ble on a solid surface and clear of all walk-
ways or fire exits.
• When installing and using optional attach-
ments, read and follow Chapter 8 for the
Fig 2-102 Crushed by Removed Attachments
instructions.
• Do not use attachments that are not author-
ized by SANY. Use of unauthorized attach-
ments could result in hazards and
adversely affect proper operation and use-
ful life of the machine. Any injuries, acci-
dents, product failures resulting from the
use of unauthorized attachments will not be
the responsibility of SANY.
2.4.9 Adding fluids to the machine
WARNING
Failure to follow this could result in serous injury.
• If fluids must be added to the equipment during operation, be aware that these systems are
under high pressure and hot.

SAFETY
Before adding fluids, shut down the engine

and allow the systems to cool to outdoor am-
bient temperature before removing any caps.
Failure to do so could result in serious burns
or a sudden loss of fluid. Read and under-
stand the following:
• Refueling the machine could pose some

hazards
• Grease, fuel, oil or coolant spills pose a
hazard if not cleaned up immediately.
• When refueling or adding any fluids to the Fig 2-103 Refueling
machine, be sure you are in a well-venti-
lated area.
• Never smoke or allow open flames near
while refueling the machine.
• Never mix gasoline with diesel or fuel. Gas-
oline is extremely flammable and could
cause an explosion.
• Always allow room for the fuel to expand
when filling the fuel tank.
2.4.10 Towing or lifting the machine
WARNING
Risk of death or serious injury!
Serious injury or death could occur if a faulty machine is towed or lifted incorrectly or if the wrong
cables or towing points are selected. Failure to follow below instruction could result in death or
serious injury.
• Only tow or lift the machine after you have confirmed that everybody is clear of the machine.

SAFETY
• Use only the designated lift points to lift the

machine and designated tow points to tow
the machine. Be sure that the lift and tow
points are in good condition.
• Tow or lift in the direction indicated by the
label. If the label is missing or damaged,
contact your SANY distributors for the prop-
er procedures.
• Wear leather gloves when handling cables.
• During the towing operation, do not stand
between the towing machine and the ma-
chine being towed.
Fig 2-104 Hoisting Point
• Do not tow a machine on a slope.
• Do not use towing equipment that is dam-
aged, stretched or overstressed.
2.4.11 Keep clear of moving machinery
Death or serious injury could result if you are

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

is working and keep all unnecessary person-
nel out of the work area.
Keep clear of moving machine ry
Never allow anyone to stand or work near the Death or serious inju ry can occur
machine while the machine is in operation.
Fig 2-105 Keep Clear of Moving Machinery

SAFETY
2.4.12 Preventing hydraulic hazards
2.4.12.1 Checking rubber hose regularly
WARNING
Risk of serious injury death!
Damage on rubber hose could result in injury or possibly death.
• Do not contact with coolant of high temperature and high pressure.
• In case of any damage on the rubber hose, replace it immediately after the pressure is
released.
Check the conditions of rubber hose regularly:
• Check whether the hydraulic hose connec-

tion 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 is not bent or
flatted.
• Check whether the external bracket of hose
is not loose. Fig 2-106 Check the Rubber Hose
2.4.12.2 Release the pressure before the maintenance
1. Park the machine.

2
2. Retract the spreader and lower it to its low-
1 3
est position.
4
3. Stop the engine.
4. Release the pressure in hydraulic system.
5. Turn the ignition key to ON position (3).

If there is the pressure in the hydraulic sys-
tem, you can hear a clear sound of “hiss-hiss”.
Then start the pitching, telescoping and side- Fig 2-107 Ignition Key
shifting function of spreader for some times.
1. HEAT position 3. ON position
Turn the ignition key to OFF position (2).
Stop the primary power. 2. OFF position 4. START position

SAFETY
• Open the pressure-releasing valve on the

accumulator charging valve to release the
pressure in the brake system
Fig 2-108 Release the Brake Pressure
2.4.12.3 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 2-109 Replace the Rubber Hose
death.
Fig 2-110 Avoid Hydraulic Injury 1

SAFETY
Fig 2-111 Avoid Hydraulic Injury 2
2.4.12.4 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.
Fig 2-112 Do not Create Heat near the Hy-

draulic Pipe
2.4.12.5 Filling accumulator
The accumulator is filled with nitrogen. Wrong

operation will lead to explosion, causing ma-
chine damage and personal injury. Pay atten-
tion to the following items 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 2-113 Caution for Filling Accumulator

SAFETY
• Drain the air before dealing with the accu-

mulator. Please contact SANY to conduct
this operation.
2.4.12.6 Selecting oils and fuel
Pay attention to the following items 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. There-
fore, 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 with-
out 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.
2.4.12.7 Handling hydraulic oil
CAUTION
Risk of injury!
Failure to follow this could result in injuries.
• Keep the lubrication oil out of the reach of children.
• Do not store the lubrication oil in an uncovered or unmarked container.
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 oil stained clothing in the pocket.
• Wash the dirty clothes thoroughly before wearing them. Dispose oily shoes as required.

SAFETY
2.4.13 Preventing burn and scald
2.4.13.1 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. Re-
move the cap after the pressure has fully Fig 2-114 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, and make him/her roll on the ground.
• Do not try to tear off the substances like fiber attached on the skin.
• In case of scald by liquid, take off the wet clothes immediately. Special attention must be paid
when taking off the clothes.
• The wound should be wrapped or bound with protective bandage.
• If serious, go to the hospital immediately.
2.4.13.2 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
Failure to follow this could result in pollution to the environment and could result in injury or possi-
bly death.
• Do not burn fluorinated rubber materials or related parts, which will generates toxic gases or
substances.
When the parts made of elastic materials are used at a temperature that exceeds 300˚C, follow be-
low instruction:

SAFETY
• 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 lo-
cal 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 sub-
stances 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:
1. Wash the eyes with fresh water for at least

20 min. Keep the eyes open to wash the eye-
balls with fresh water. Roll the eyeballs in dif-
ferent directions
2. Consult a doctor immediately.
Fig 2-115 Go to Hospital
2.4.14 Preventing fire and explosion
2.4.14.1 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.
Fig 2-116 Avoid Fire

SAFETY
• Store the flammable liquid (all fuels, most

lubricants and some coolants) in a place
away from fire hazard.
• Do not burn or puncture the pressured
container.
• Do not store oily cloth. They can be ignited
or combusting spontaneously.
2.4.14.2 Removing inflammables
Splashed fuel, oil, waste, grease, scrap, accu-

mulated coal dust and other inflammables can
result in fire. Oil or fuel absorbed on the parts
and hoses in engine cabin can also result in
fire disaster.
Check and clean the machine daily. Remove

the splashed or accumulated inflammables
immediately to prevent fire.
Fig 2-117 Remove Inflammable
2.4.14.3 Checking oil leakage
Leakage of fuel, hydraulic oil and grease can

result in fire. Personnel should observe the
following regulations to prevent fire:
• Check whether the clamp is in place and

secure.
• Check whether the hose is not twisted.
• Check whether the hose and pipeline do
not rub each other.
• Check whether the oil cooler is not dam-
aged .
Fig 2-118 Check Oil Leakage
• Check whether the flange bolt of oil cooler
is secure.
• Check whether the oil hoses and high tem-
perature parts (e. g. turbocharger, exhaust
pipeline, silencer) have the contact
protection.

SAFETY
• Check whether the pipe connectors of high

temperature parts (e. g. turbocharger, ex-
haust pipeline, silencer) are secure and not
leaking.
• Tighten, repair or replace all loose, dam-
aged 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 pipe-
lines, tubes, or hoses.
2.4.14.4 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.

SAFETY
2.4.14.5 Preventing battery explosion
Battery electrolyte contains corrosive sulfuric

acid which may create flammable and explo-
sive hydrogen. Improper operation would re-
sult in personal injury or fire hazards. 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.
• Never put the battery under direct sunlight
Fig 2-119 Battery Explosion
in hot seasons.
• Avoid battery terminals contacting with tools
and other metal objects.
• Switch the main power switch to OFF posi-
tion before operating the battery.
• Wear protective goggles and rubber gloves
during battery operation.
• Never discharge or charge the battery too
much.
• Connect the battery with proper cables.
Connect plus-cable (red) first and then mi-
nus-cable (black). Make sure that all the ter- Fig 2-120 Cables
minals are firmly fixed.
• Disconnect the battery approximately one
minute after the engine is turned off. Re-
move minus-cable (black) first and then
plus-cable (red).
• If charging a battery removed from ma-
chine, 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.

SAFETY
• If the battery magic eye shows green, the

battery has been fully charged. Stop charg-
ing it.
• Fit the battery cover after charging. And in-
stall 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 im-
mediately with water and contact a doctor
immediately.
2.4.14.6 Examine the ignition key
If the engine is stopped when the machine is

on fire, the fire can spread and it will become A
not easy to put out. Thus, you must:
P
• Examine the function of ignition key before
you operate the machine each day.
• Start the engine and make it operate at an
idle speed.
• Turn the key switch to OFF position (A) to
make sure that the engine stops.
• If a defect occurs, find a solution for it be-
fore you operate the machine.
Fig 2-121 OFF Position
A. OFF position
2.4.14.7 Evacuating from the machine
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 put out the fire as long as you are
able to evacuate from the danger in time.
In case of fire, you must:

• Switch the ignition key to OFF position and
Fig 2-122 Evacuate
make sure that the engine is stopped. Evac-
uate from the machine.

SAFETY
• Call the fire agency.

• If time permits, put the gear selector to neu-
tral position and press brake button to keep
it in the “P” position.
• If time permits, use the fire extinguisher.
2.4.15 Preventing poisoning and asphyxiation
2.4.15.1 Handling chemicals safely
Direct contact with harmful chemicals can result in serious injury to human body. The chemicals
used in this machine (such as lubricant, coolant, coat and agglutinate) may be harmful. Personnel
should observe the following rules while handling chemicals:
• Dispose of the chemicals according to related national and local regulations.

• Always wear protective gloves and goggles.
• Avoid direct contact of chemicals with skin.
• Never smoke or take diet when handling chemicals.
• If chemicals are splashed on bare skin, wash with a lot of fresh water immediately.
Go to hospital if serious.
• If chemicals have gotten into eyes, rinse the eye with water and contact a doctor immediately.
2.4.15.2 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.
• Properly handle the paint and solvent be-

fore welding or heating.
• Remove the paint outdoors or in ventilated
place.
• If sand paper and grinding wheel are used
Fig 2-123 Respirator
to remove the paint, prevent inhaling dust
by wearing a qualified respirator.
• If solvent or paint remover is used, wash
away the paint remover with soap and
water before welding. Clear up the solvent
or paint remover container and other flam-
mables in the work area. Wait for at least 15
min before welding or heating to make the
volatile gases go away.

SAFETY
• Never put the paint, solvent or paint remov-

er near the combustion source.
• Dispose of the paint or solvent according to
related national and local regulations.
2.4.15.3 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:
• Keep well ventilated if the machine is

started or operated in an enclosed
environment.
• If a person is poisoned by off-gas in the en-
closed environment, open the doors and
Fig 2-124 Avoid Poisoning by Off-gas
windows first to reduce the level of harmful
gases before conducting the first aid
treatment.
• Put the poisoned person in a ventilated
place or outdoors. If the poisoned person is
unconscious, make him/her lie sideways
2.4.16 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.

SAFETY
2.4.17 Working under machine
Always do 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 ma- Fig 2-125 Work under Machine
chine. These things may collapse under
continuous load. Never use only one jack to
support the machine.
2.4.18 Precautions in welding
DANGER
Fire or electricity strike may occur if welding is performed incorrectly which could cause personal
injury or death.
• Do not weld directly on the machine.
Observe the following:
• Only qualified welder with proper equipment

is approved to weld the machine.
• Welding must be performed in correct pro-
cedures to prevent damaging the electronic
control device and bearing.
• Before welding on the machine or engine
equipped with electronic control device, you
should turn the main power switch to OFF
position first. And then remove the positive
Fig 2-126 Remove the Cables
and negative cables from the battery.
• Prevent wire harness from contacting with
sparks generated in the welding process.

SAFETY
2.4.19 Safe maintenance of air conditioning system
DANGER
Refrigerant R134a is a harmless gas less than the usual temperature. It changes into very toxic
gas when it burns, which will cause injury or death .
• Deal with it correctly to prevent injury or death.
Make sure that you obey below items:
• Keep the fire source far when you do a maintenance for the air conditioning system.
• In maintenance of air conditioning system, obey the instructions on the refrigerant container and
use it correctly. The type of refrigerant is R134a. Do not use an other refrigerants, which can
cause damage for the air conditioning system.
• Do not let refrigerants go into your or onto your skin.
• Refrigerant R134a can make the greenhouse effect. 1 kg emission of R134a (after twenty years)
is same as 3400 g emission of CO2. Obey the local material disposal regulations of refrigerants.
Do not let the refrigerant go directly into the air.
2.4.20 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 op-

erator’s seat and ready to shut down the en-
gine at any time. All personnel must keep in
touch.
• Always lock the machine and fix its wheels
Fig 2-127 Caution for Fan
with wedges to prevent it from moving or
operating.

SAFETY
• Never enter into the movable places of ma-

chine and do not put your hand or foot into
there. Otherwise, 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 2-128 Be Clamped by the Rotating Parts
• Do not leave or insert any tools or other ob-

jects 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 2-129 Parts Flying to Hurt Personnel
2.4.21 High voltage precautions
When the engine is running or has just been

shut down, high voltage can occur in fuel in-
jector and engine controller. Personnel should
observe the following to prevent the danger of
electricity strike:
• Do not touch the fuel injector or the engine

controller, it might cause electrocution.
• Contact SANY authorized distributors if you
have to access the fuel injector or the en-
gine controller.
Fig 2-130 Caution for High Voltage

SAFETY
2.4.22 Precautions after maintenance
Personnel should observe the following after the maintenance 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.
2.4.23 Handling waste properly
NOTICE
Risk of environmental problems!
If not handling the waste properly could result in environmental problems.
• Strictly observe laws and regulations of the region/country where the machine works. Any ac-
tions that violate these laws and regulations can and will lead to prosecution.
• Do not drop waste product, waste oil and relevant washing goods without permission. The
waste should be handled according to the local laws and regulations.
The potential harmful substances used in this

machine include oil, fuel, coolant, brake fluid,
filter and battery etc. Incorrect disposal of
waste can negatively impact the environment
and ecosystem. Therefore, pay attention to
the below items:
• Always abide by the national or local regu-

lations, rules and environmental standards.
Do not pour the waste liquid on the ground,
in the sewer or into any water source.
Fig 2-131 Disposal of Waste
• Consult the local environmental protection
organization or recovery center for the cor-
rect method of recovering or handling the
waste.
• Use a leakage-proof container when drain-
ing the liquid. Do not use food or beverage
container, this might mislead somebody to
drink accidentally.

SAFETY
NOTE:
The following substances and liquids must be

delivered to a certified waste treatment facility
for disposal:
• Battery
• Waste lubricating oil
• Lubricating grease
• Mixture of water and anti-freezing fluid
• Filter element
• Waste tyre Fig 2-132 Do not Drop Waste Randomly
• Other auxiliaries (such as grease or oily
duster cloth etc.).
2.5 Tag
SANY cannot predict every circumstance that might involve a potential hazard in operation or
maintenance. The safety chapter in this manual may not include every possibly dangerous circum-
stance. But the safety measures and regulations you have understood will help you to make posi-
tive 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
empty container handler.
Safety is your career and responsibility. Wish you work pleasantly!

SAFETY

SYSTEM FUNCTIONS
SYSTEM FUNCTIONS
3 SYSTEM FUNCTIONS ...................................................................................................3-1

3.1 Primary Components of Machine .......................................................................................3-3
3.2 Cab Control System..............................................................................................................3-4
3.2.1 General information ....................................................................................................3-4
3.2.2 Steering column ..........................................................................................................3-5
3.2.2.1 Steering column ...................................................................................................3-6
3.2.2.2 Steering wheel panel...........................................................................................3-7
3.2.2.3 Gear selector ......................................................................................................3-11
3.2.2.4 Direction indication controller.......................................................................... 3-12
3.2.2.5 Adjusting the angle of steering controller ...................................................... 3-16
3.2.3 Pedals ........................................................................................................................ 3-16
3.2.4 Joystick ...................................................................................................................... 3-17
3.2.5 Right operation panel .............................................................................................. 3-18
3.2.5.1 Right operation panel ....................................................................................... 3-18
3.2.5.2 Ignition switch.................................................................................................... 3-18
3.2.5.3 Safety bypass switch........................................................................................ 3-21
3.2.5.4 Emergency stop switch .................................................................................... 3-22
3.2.5.5 Rear wiper switch.............................................................................................. 3-23
3.2.5.6 Top wiper switch................................................................................................ 3-23
3.2.5.7 Front wiper switch............................................................................................. 3-24
3.2.5.8 Auto/Manual lock ............................................................................................. 3-25
3.2.5.9 Ignore alarm....................................................................................................... 3-25
3.2.5.10 Inner light switch ............................................................................................. 3-25
3.2.6 Front operation panel .............................................................................................. 3-27
3.2.6.1 Front operation panel ....................................................................................... 3-27
3.2.6.2 Cab top light switch........................................................................................... 3-27
3.2.6.3 Rear light switch................................................................................................ 3-28
3.2.6.4 Mast light switch................................................................................................ 3-29
3.2.6.5 Spreader light switch ........................................................................................ 3-29

SYSTEM FUNCTIONS
3.2.6.6 Width light switch .............................................................................................. 3-30

3.2.6.7 Failure detection switch ................................................................................... 3-31
3.3 Display ................................................................................................................................. 3-31
3.3.1 SANY display............................................................................................................ 3-31
3.3.1.1 General............................................................................................................... 3-31
3.3.1.2 Start menu ......................................................................................................... 3-32
3.3.1.3 Main menu ......................................................................................................... 3-33
3.3.1.4 Engine information menu................................................................................. 3-35
3.3.1.5 Gearbox information menu.............................................................................. 3-37
3.3.1.6 Hydraulic information menu ............................................................................ 3-38
3.3.1.7 Fault alarm menu .............................................................................................. 3-38
3.3.1.8 Digital input menu ............................................................................................. 3-39
3.3.1.9 Digital output menu........................................................................................... 3-40
3.3.1.10 Analogy input menu........................................................................................ 3-40
3.3.1.11 Analogy output menu ..................................................................................... 3-41
3.3.1.12 Setting menu ................................................................................................... 3-41
3.4 Air Conditioning System.................................................................................................... 3-42
3.4.1 Precautions for air conditioning system ................................................................ 3-42
3.4.2 Control panel............................................................................................................. 3-43
3.4.2.1 Control panel ..................................................................................................... 3-43
3.4.2.2 Power switch ..................................................................................................... 3-43
3.4.2.3 Fan speed switch .............................................................................................. 3-44
3.4.2.4 Temperature or Paging switch ........................................................................ 3-45
3.4.2.5 Mode switch....................................................................................................... 3-45
3.4.3 Operation................................................................................................................... 3-46
3.5 Electric Control Cabinet .................................................................................................... 3-47
3.6 Fuse ..................................................................................................................................... 3-48

SYSTEM FUNCTIONS
3.SYSTEM FUNCTIONS
3.1 Primary Components of Machine
7 6
5
4
8
1 3 2
Fig 3-1 Primary Components of Empty Container Handler

SYSTEM FUNCTIONS
Table 3–1
Position Item Function

The engine and transmission case constitute the
1 Drive system power drive system of empty container handler. It sup-
plies power to go, brake, stack and pick up containers.
The steering system controls the direction of machine
2 Steering system
during going and operation.
Frame is the mounting base as well as the support for
3 Frame
all parts.
Mast assembly supports the spreader and allows it to
4 Mast assembly
move up or down to perform the hoisting of container.
The spreader assembly is the primary work mecha-
5 Spreader assembly nism which is capable of pitching, sliding, telescoping,
locking and unlocking a container.
Cab control system is the work area for the operator,
6 Cab control system
where operations of the machine are performed.
The hydraulic system includes: braking / steering hy-
draulic system and working device hydraulic system. It
7 Hydraulic system supplies power for steering and braking of the ma-
chine, motions of the working mechanisms such as
mast and spreader.
The electrical system has the control circuits of going,
8 Electrical system driving, and working mechanisms. Working mecha-
nism is controlled through the circuits.
3.2 Cab Control System

3.2.1 General information
NOTE:
To operate correctly and safely, you must know the methods to operate the control devices and the
operation of display.
The cab control system has steering column (1), brake pedal (2), accelerator pedal (3), joystick
(4), right operation panel (5), front operation panel (6), display (7), air conditioner panel (8).

SYSTEM FUNCTIONS
8 7
6
4
2 3
Fig 3-2 Control Device
1. Steering column 3.Accelerator pedal 5.Right operation 7. Display

panel
2.Brake pedal 4.Joystick 6.Front operation 8.Air conditioner
panel panel
3.2.2 Steering column

SYSTEM FUNCTIONS
3.2.2.1 Steering column
66 3
11
Fig 3-3 Steering Column
1. Steering wheel 4. Steering wheel an-

panel gle adjusting handle
2. Gear selector 5. Steering column
angle adjusting pedal
3. Direction indication 6. Steering wheel
controller

SYSTEM FUNCTIONS
3.2.2.2 Steering wheel panel
There are 4 indicator lights and 3 switches on

the steering wheel panel. 1 2 3 4
5 6 7
Fig 3-4 Steering Wheel Panel
1. Left steering indi- 5. Parking brake

cator light switch
2. Fault indicator light 6. Warning light
switch
3. Parking indicator 7. Headlight switch
light
4. Right steering indi-
cator light
1. Left steering indicator light (1)
This left steering indicator

light can blink if the left steer-
ing light is on.
Fig 3-5 Left Steering Indicator Light

SYSTEM FUNCTIONS
2. Fault indicator light (2)
This fault indicator light can il-

luminate to tell the operator if
there is a fault in the
machine.
Fig 3-6 Fault Indicator Light
3. Parking indicator light (3)
This parking indicator light

can illuminate if the parking
brake is engaged.
Fig 3-7 Parking Indicator Light
4. Right steering indicator light (4)
This right steering indicator

light can blink if the right
steering light is on.
Fig 3-8 Right Steering Indicator Light

SYSTEM FUNCTIONS
5. Parking brake switch (5)
Push this switch to turn on or

off the parking brake.
9
NOTICE
If not release the parking brake before travel-
ling, the drive axle can be damaged.
• Release the parking brake before
travelling. Fig 3-9 Parking Brake Switch
6. Warning light switch (6)

off the warning light.
Fig 3-10 Warning Light Switch
The warning light is on the top of cab.
Fig 3-11 Warning Light

SYSTEM FUNCTIONS
7. Headlight switch (7)

off the headlight.
Fig 3-12 Headlight Switch
The headlights are in the center front of front

wheel arches.
Fig 3-13 Headlights

SYSTEM FUNCTIONS
3.2.2.3 Gear selector
Gear selector can be moved forward or

rearward.
F
Driving direction of machine (flip the gear se-
1
lector in the direction of arrow): 2
3
• F: Forward gear (flip forward)
1
N 2
3
Fig 3-14 Flipping Forward
F. Forward gear N. Neutral gear
• N: Neutral gear (in the middle)

F
1
2
3
1
N 2
3
1
2
3
Fig 3-15 Flipping
F. Forward gear R. Reverse gear

N. Neutral gear

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

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

3
1
2
3
Fig 3-16 Flipping Backward
N. Neutral gear R. Reverse gear
Gear selector can also be rotated towards 3

positions respectively signifying 1st gear, 2nd
gear, and auto gear.
1 2 3
Driving speed of machine (rotate the gear se-
lector in the direction of arrow):
• 1: 1st gear N
• 2: 2nd gear
• 3: auto gear
• With the controller at the neutral position,
the engine can be started.
• In switching over between the forward and Fig 3-17 Rotating
reverse positions, stop the machine com-
1. 1st gear 3. Auto gear
pletely to avoid overload on the gearbox or
transmission system. 2. 2nd gear N. Neutral gear
3.2.2.4 Direction indication controller
Direction indication controller (3 in Fig. 3-3) can be moved forward or backward to turn on or off the
left / right steering lights.

SYSTEM FUNCTIONS
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 3-18 Flipping Forward/Backward
Push the direction indication controller for-

ward. The left steering light on the front mud-
guard and the left steering indicator light in
cab will start blinking.
Fig 3-19 Left Steering Indicator
Pull the direction indication controller rear-

ward. The right steering light on front mud-
guard and the right steering indicator light in
cab will begin blinking.
Fig 3-20 Right Steering Indicator

SYSTEM FUNCTIONS
Front steering lights are fitted together with

headlights.
Fig 3-21 Front Steering Lights
Rear steering lights, located at the end of

main frame, are fitted together with tail lights.
Fig 3-22 Rear Steering Lights
Horn buttons
Horn buttons are located at the ends of both

gear selector and direction indication
controller.
Keep pushing the button, and the horn will

alarm continuously.
Fig 3-23 Horn Buttons

SYSTEM FUNCTIONS
Wiper switch
Direction indication controller is equipped with

a wiper switch.
• Push down the controller as shown in the

right figure, water will be sprayed out.
• Hold the controller, and water will be
sprayed out continuously.
• The controller will automatically return to its
original place and stop spraying out water
when released.
The controller can be rotated to four positions, Fig 3-24 Wiper Switch
O, J, I and II, to control the operation of

wipers.
• O: stop wiping
• J: intermittent wiping
• I: continuous wiping at low speed
• II: continuous wiping at high speed

SYSTEM FUNCTIONS
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 3-25 Adjustment Handle and Pedal
1. Steering wheel an- 2. Steering column

gle adjusting handle angle adjusting pedal
3.2.3 Pedals
Brake pedal (3)
Brake pedal is used to reduce the machine

speed or stop it completely.
Accelerator pedal (4)
Accelerator pedal is used to speed up the

machine.
3 4
Fig 3-26 Pedals
3. Brake pedal 4. Accelerator pedal

SYSTEM FUNCTIONS
3.2.4 Joystick
Joystick is located at the right of cab seat. It

can be swayed in different directions to con- 3
trol telescopic and pitching of the mast. Six 2
buttons at its front are to control telescoping, 5
side-shifting, locking and unlocking of the
spreader. Two buttons at its back are joystick 1
enable switch and spare switch. 6
7
To realize the signal operation of mast to all
4
four directions, you don’t need to push the joy-
8
stick enable switch at the back of joystick. You
can directly switch on the joystick by pushing
the joystick on / off switch on the right opera-
tion panel.
NOTE:
Fig 3-27 Joystick
To avoid incorrect operation, the driver should
turn off the joystick on / off switch on right op- 1. Spreader locking 5. Spreader side-
eration panel before leaving the cab. shifting rightward
2. Spreader 20 feet 6. Spreader 40 feet
When a combination operation is needed,
push the joystick directly. 3. Spreader 7. Spare switch
unlocking
Reaction rate of all operations (except vertical
4. Spreader side- 8. Joystick enable
operation) is directly related to the joystick an-
shifting leftward
gle. When the joystick remains at its neutral
position, all operations will be ceased.

SYSTEM FUNCTIONS
3.2.5 Right operation panel
3.2.5.1 Right operation panel
1. Ignition switch 6. Top wiper switch

7. Front wiper switch 5
2. Safety bypass
6
switch
7
3. Buzzer 8. Joystick on / off 8
switch 9
4. Emergency stop 9. Alarm resetting
switch switch
10
5. Rear wiper switch 10. Inner light switch
2
4
1
3
Fig 3-28 Right Operation Panel
3.2.5.2 Ignition switch
NOTICE
Stopping engine on high speed could shorten the service life of engine, lead to fatigue cracks in
the engine cylinder head and burnout of the turbocharger bearing.
• Unless in emergency, never stop the machine running at high speed.

SYSTEM FUNCTIONS
Ignition switch is used to start or stop the

engine. A
E B
C
P
D
A: OFF position D: START position

B: ON position E: PARK position
C: HEAT position
A: OFF position
A
The key can be plugged in or pulled out.
When the key is at position 0(A), all the electri-
P
cal equipment is switched off.
Fig 3-30 OFF position

SYSTEM FUNCTIONS
B: ON position
The key stays at position I (B) during engine B

operation.
P
Fig 3-31 ON position
C: HEAT position
Plug in the key. Turn it clockwise to position

C
Ⅱ(C) and keep it there to preheat the engine.
P
NOTE:
1. Volvo & CUMMINS : not used.
2. The system will automatically detect the

preheating completion. When the preheating
is completed, the engine speed will rise when
the accelerator is pressed down.
Fig 3-32 HEAT position
D: START position
Plug in the key. Turn it clockwise to position

Ⅲ(D) and keep it there to start the engine.
P
Release the key after the engine is started, D
and it will automatically return to position I (B).
Fig 3-33 START position

SYSTEM FUNCTIONS
E: PARK position
The key can be plugged in or pulled out at po- E

sition P(E).
P
When it is at position P (E), the engine is
stopped.
Fig 3-34 PARK position
3.2.5.3 Safety bypass switch
The bypass switch (1) is used to operate the

empty container handler when machine func-
1
tion has stopped due to unexpected factors. If
this condition occurs the operator must con-
tact their supervisor and a SANY representa-
tive to resolve the underlying problem.
Fig 3-35 Safety Bypass Switch
1. Bypass switch 2. Buzzer

SYSTEM FUNCTIONS
When the safety bypss function is activated,

the buzzer (2) near the safety bypass would
begin to make alarm. Meanwhile, the malfunc-
tion indicator light will begin to flash and the
screen would display “Safety Bypass Switch
Activated”. The protection is canceled.
Fig 3-36 Malfunction Indicator Light
3.2.5.4 Emergency stop switch
The emergency stop switch is used to shut

down the entire electrical system and stop all
movements of the empty container handler. 1
This button can also be used to brake the ma-

chine in emergency cases. However it can on-
ly be used when the brake system fails in a
really emergency circumstance.
Fig 3-37 Emergency Stop Switch

SYSTEM FUNCTIONS
3.2.5.5 Rear wiper switch
This switch is used to turn on or off

the rear wiper.
Fig 3-38 Rear Wiper Switch
The rear wiper is located at the back of cab.
Fig 3-39 Rear Wiper
3.2.5.6 Top wiper switch
This switch is used to turn on or

off the top wiper.
Fig 3-40 Top Wiper Switch

SYSTEM FUNCTIONS
The top wiper is located at the top of cab.
Fig 3-41 Top Wiper
3.2.5.7 Front wiper switch
This switch is used to turn on or

off the front wiper.
Fig 3-42 Front Wiper Switch
The front wiper is located at the front of cab.
Fig 3-43 Front Wiper

SYSTEM FUNCTIONS
3.2.5.8 Auto/Manual lock
This switch is used to achive auto or manual

lock
Fig 3-44 Auto/Manual lock
3.2.5.9 Ignore alarm
This switch is used to eliminate alarm.
Fig 3-45 Ignore alarm
3.2.5.10 Inner light switch
The inner lights are located at both sides of inner cab. There are two inner lights in the cab.

SYSTEM FUNCTIONS
Moving the switch below the inner light will

turn on or off the lights.
Fig 3-46 Inner Light Switch
• A: ON positon. The light is on.

• B: OFF position. The light is off
NOTE:
Even if the ignition key is at position O, the in-

ner light could be turned on.
Fig 3-47 Inner Light

SYSTEM FUNCTIONS
3.2.6 Front operation panel
3.2.6.1 Front operation panel
1 2 3 4 5 6
Fig 3-48 Front Operation Panel
1. Cab top light 4. Spreader light

switch switch
2. Rear light switch 5. Side light switch
3. Mast light switch 6. Failure detection
switch
3.2.6.2 Cab top light switch
This switch is used to turn on or off the

light on the roof of cab.
Fig 3-49 Cab Top Light Switch

SYSTEM FUNCTIONS
There are four lights located on the roof of

cab.
Fig 3-50 Cab Top Light
3.2.6.3 Rear light switch

rear light.
Fig 3-51 Rear Light Switch
There are two rear lights located at the back

of cab.
Fig 3-52 Rear Light

SYSTEM FUNCTIONS
3.2.6.4 Mast light switch

mast light.
Fig 3-53 Mast Light Switch
There are two mast lights located on the mast.
Fig 3-54 Mast Light
3.2.6.5 Spreader light switch

spreader light.
Fig 3-55 Spreader Light Switch

SYSTEM FUNCTIONS
There are four spreader lights located on the

spreader, each two at both ends of spreader.
Fig 3-56 Spreader Light
3.2.6.6 Width light switch

Width light.
Fig 3-57 Width Light Switch
There are two Width lights respectively lo-

cated at the flank of front and rear
mudguards.
Fig 3-58 Width Light

SYSTEM FUNCTIONS
3.2.6.7 Failure detection switch
This switch is used to detect the engine fail-

ure. Press down the button, and the detection
indicator light blinks.
Fig 3-59 Failure Detection Switch
3.3 Display
3.3.1 SANY display
3.3.1.1 General
Display is composed of menu display area 1 2 3

(1), function display area (2), and operation
buttons F1-F6 (3).
10 15 12 18 F1
Menu display area displays system parame- 5 20
0L
6 24
0
0 25 30 F2
ters and fault information. When a fault oc- x100 RPM
0
km/h
G Y R F3
curs, main menu will display the real-time 0 0.0
F4
information about this fault. Manual:
0.0 m
Gear: 0.0 t F5
0%
The functions of 6 operation buttons from F1 Load:
F6
to F6 are corresponded to the indications on

function display area. By pressing relevant
buttons, the desired menu can be displayed. Fig 3-60 SANY Display
NOTE: 1. Menu display area

SANY display is normally used in H1C/H2/H3/ 2. Function display area
H4 container handlers. 3. Operation buttons F1-F6

SYSTEM FUNCTIONS
3.3.1.2 Start menu
When the ignition key is turned to ON position

(B), the screen would display start menu as
shown in the right figure.
Quality Changes the World
Initializing
Fig 3-61 Start Menu
B. ON position

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

played, main menu will be shown automati-
10 15 12 18
cally under normal circumstances. Or you can
5 20 6 24
0
press F1 directly to enter main menu. 0 25 L
0 0 30
x100 RPM km/h

Main menu displays engine rotation speed, G Y R
0 0.0
vehicle speed, fuel level, traveling gear,
hoisted weight and spreader lights.
0.0 m
Manual:
The explanations of information are shown Gear: 0.0 t
on main menu below. Load: 0%
indicates the fuel level

Fig 3-63 Main Menu
Engine rotation speed
The left instrument indicates the actual rota-

tion speed of engine.
10 15 12 18
5 20 24
Displayed speed on instrument alters within 0 6
0
0 25 L 30
the range of 0-25. It signifies the rotation 0
x100 RPM km/h

speed of 0 rpm - 2500 rpm. G Y R
0 0.0
0.0 m
Manual:
Gear: 0.0 t
Load: 0%
Fig 3-64 Engine Rotation Speed

SYSTEM FUNCTIONS
Vehicle speed
The right instrument indicates the actual trav-

eling speed of machine.
10 15 12 18
Displayed speed on instrument alters within 5 20

0 6 24
0
the range of 0-30. It signifies the vehicle 0 25 L 0 30
x100 RPM km/h

speed of 0 km/h - 30 km/h. G Y R
0 0.0
0.0 m
Manual:
Gear: 0.0 t
Load: 0%
Fig 3-65 Vehicle Speed
Traveling gear
• Manual signifies the gear shifting way Auto/

Manual.
• Gear signifies the actual traveling gear of
machine.
• With gear selector rotated to 1, the machine Manual:
travels at 1st gear. With gear selector ro-
Gear:
tated to 2, the machine travels at 2nd gear.
With gear selector rotated to 3, the machine
travels at 1st-3rd gear automatically.
Fig 3-66 Traveling Gear
Spreader indicators
Three spreader indicators on this menu signify

the conditions of spreader twistlocks. G Y R
• When the “G” indicator is on, it indicates
that the spreader is locked.
• When the “Y” indicator is on, it indicates that
the spreader is seated.
• When the “R” indicator is on, it indicates Fig 3-67 Spreader Indicators
that the spreader is unlocked.

SYSTEM FUNCTIONS
Torque percentage
Torque percentage is aimed at protecting the

machine.
• Torque percentage≤90%: safe for lifting Load: 0%

load
• Torque percentage between 90% and
100%: alarm for dangerous working
condition Fig 3-68 Torque Percentage
• Torque percentage =100%: impossible to tilt
and lower the mast
Functions of operation buttons F1–F6

F1
Table 3–2
F2
Button Function
F1 Engine information menu F3
F2 Gearbox information menu F4
F3 Hydraulic information menu

F5
F4 Fault alarm menu
F6
F5 Digital input menu
F6 Setting menu
Fig 3-69 Operation Buttons
3.3.1.4 Engine information menu
Press F1 to enter engine information menu.

Engine
indicates the engine rotation
speed
0 RPM 0 H
indicates the engine water
temperature
0 0 L
℃
indicates the engine oil pressure
indicates the engine working 0 KPa 0.0 V

hours
SPN： 0 0 Year 0 Number
indicates the fuel level

Fig 3-70 Engine Information Menu
indicates the system voltage
SPN indicates the engine SPN codes

SYSTEM FUNCTIONS
H4 container handlers equipped with stage IV

engines will display the second engine infor-
mation menu as shown in the right figure.
• The Regen_Inhabit_Lamp indicates that re-

ENGINE
generation disabled (inhabit) switch is ac-
tive, therefore automatic and manual (non- Regen_In hibit_L Wait_To_Star
mission) exhaust system cleaning cannot amp t_Lamp
Amber_Warning_La
occur. DPF_Lamp
mp
• The DFP_Lamp notifies the operator that HEST_Lamp Red_Stop_Lamp
the after-treatment system has not auto re- DEF_Tan

DEF_Low_Lamp 0
K Level
generated at the required time limit and re-
Regeneratio
quires an exhaust system cleaning. 0 0
n Inhibit
• The HEST lamp will illuminate during man-

Regeneratio
n Force
0 0
ual (non-mission) exhaust system cleaning

Fig 3-71 Engine Information Menu 2 (For Ma-
and when the exhaust temperature exceeds
chines Equipped with Stage IV Engine)
the calibrated temperature threshold.
• The DEF_Low_Lamp signal controls an in-
dicator lamp or LED that is used to alert the
machine operator that the diesel exhaust
fluid is low and must soon be replenished.
• The Wait_To_Start_Lamp indicates the driv-
er has turned the keyswitch to an engine
run position, but should wait to start the
machine.
• The Amber_Warning_Lamp displays mes-
sages that require prompt operator atten-
tion and diagnostics messages.
• The Red_Stop_Lamp displays critical oper-
ator messages and diagnostics fault codes.
The regeneration inhabit switch disallows any

automatic or manual (non-mission) exhaust
system cleaning.
The regeneration force switch initiates a man-

ual (non-mission) exhaust system cleaning of
the after-treatment system when the machine
is in non-mission condition.

SYSTEM FUNCTIONS
Functions of operation buttons F1– F6 on

stage IV engine information menu F1
Table 3–3 F2
Button Function F3
F1 Return to the previous menu
F4
F2 The next page
F5
F3 Shift up and down
F4 Numerical increase F6
F5 Numerical reduction
F6 Confirm Fig 3-72
3.3.1.5 Gearbox information menu
Press F2 to enter gearbox information menu.

Gear Information
Gearbox parameters:
0.0 km/h
indicates the driving speed
0 RPM Manual:
indicates the gearbox rotation
speed 0 Bar Gear:
indicates the gearbox oil
temperature 0 ℃
0 Year 0 Number
indicates the gearbox oil pressure
Fig 3-73 Gearbox Information Menu

Traveling gear information:
Manual indicates respectively 1st gear,

2nd gear, and auto gear
Gear indicates the actual traveling gear

SYSTEM FUNCTIONS
3.3.1.6 Hydraulic information menu
Press F3 to enter hydraulic information menu.

Hydraulic
This menu displays lock length, system pres-
sure, lock counting, load weight, and load Length 0.0 m Weight_Fix 0.0 t
percentage.
System 0.0 MPa Load 0 %
Count_Lock 0
Fig 3-74 Hydraulic System Menu
3.3.1.7 Fault alarm menu
Press F4 to enter fault alarm menu.
In alarming, the on the left changes into .
1. Fault alarm menu 1

Alarm_1
01.Loaded_overspeed 13.Engine_OilPress_L
The default menu of fault alarm menus is as
02.GearboxTemp_H 14.Battery_voltage_L
shown in the right figure. 03.Hyd_OilTemp_H 15.Safety_bypass
04.Oilwater_Alarm 16.LockUnlock_Alarm
05.ACC_PL_Alarm 17.Load_Over_90%
06.Engine_coolant_L 18.Over_Load
07.HYD_FJ_Alarm 19.SYMT_CanFault
08.Brake_FJ_Alarm 20.CAN_ERROR
09.Senser_Error 21.GPS_LOCKED
10.FuelLevel_L 22.RollOver_limit_Alarm
11.GearboxlPressure_L 23.BrkOilTemp_Alarm
12.Engine_Tem_H 24.Altimetry_Sensor_Err
Fig 3-75 Fault alarm menu 1

SYSTEM FUNCTIONS
2. Fault alarm menu 2

Alarm_2
Press F4 on fault alarm menu 1 to enter fault 25.WarmUp_Alarm

26.IdleSpeed_Alarm
alarm menu 2.
27.Engine_preheating
28.GearBox_Error_Alarm
NOTE:
29.SPN_Alarm
30.Engine_Status_Alarm
Only the fault alarm menu 2 of machine 31.DEF_Tank_L_Alarm
equipped with stage IV engine will display
alarm information item 29-31.
Fig 3-76 Fault alarm menu 2
3.3.1.8 Digital input menu
Press F5 to enter digital input menu.

Digital In
For Shift Brak Temp H
When a specific signal is “1” (activated), the Sprd Lock
Back Shift Hyd Temp H Sprd Unlock
on the left changes into . Shift 1 ACC Press L Sprd Left
Shift 2 Cool Water L Sprd Right
Shift 3 Water In Fuel Sprd Out
DI Handbrake Brak Filter J Sprd In
Foot Brake Hyd Filter J Proximity1
Neutral Shift Lift interrupt Proximity2
Sprd Seated Allow Lower
Sprd Unlocked Spread Act
Sprd Locked Engine Preheat
Alarm Reset Safe Bypass
Fig 3-77 Digital Input Menu
Functions of operation buttons F1– F6 on the

I/O menu. F1
Table 3–4 F2
Button Function F3
F1 Main menu
F4
F5
F4 Analogy input menu F6
F5 Analogy output menu

F6 Setting menu Fig 3-78

SYSTEM FUNCTIONS
3.3.1.9 Digital output menu
Press F3 on digital input menu to enter digital Digital Out

output menu. For Valve Sprd Lock Valve
Back Valve Sprd Unlock Valve
When a specific signal is “1” (activated), the Gear Valve1 Sprd Left Valve
on the left changes into . Gear Valve2 Sprd Right Valve

Soud Alarm Sprd Extend Valve
DO N Sprd Ret Valve
DO HandBrake Lam Locked
Sprd Move Unlocked
HighSpeed Lock Seated
Down Valve1 Spare
Down Valve2 Spare
DO AddLift Valve
Fig 3-79 Digital Output Menu
3.3.1.10 Analogy input menu
Press F4 on digital input menu to enter analo-

gy input menu. Analogy Input
Engine Spd 0 RPM Fuel Lev 0.0 L

Water Temp 0 ℃ NULL 0
Engine Press 0 KPa
Batter Vol 0.0 V
Gear Speed 0 RPM
Gear Temp 0 ℃
Gear Press 0 Bar
Drive Speed 0.0 km/h
Handle LR 0
Handle FB 0
Load Pre 0.0 MPa
Pedal Pos 0
Fig 3-80 Analogy Input Menu

SYSTEM FUNCTIONS
3.3.1.11 Analogy output menu
Press F5 on digital input menu to enter analo-

Analogy Output
gy output menu.
Mast Lift PWM 0 Batter Vo 0.0 V
Mast Down PWM 0
Mast Fore PWM 0
Mast Back PWM 0
Lock Count 0
Load Weight 0.0 T
Load Percent 0
Lock High 0.0 m
Total Fuel Count 0 L
Work Fuel Count 0 L
Drive Fuel Count 0 L

Non Work Fuel Co 0 L
Fig 3-81 Analogy Output Menu
3.3.1.12 Setting menu
Press F6 to enter password menu.

Parameter Setting
Enter in the correct password, and it is able to
display setting menu. Only the SANY author-
2016-03-08
ized distributors and SANY service engineers
have the password to access the menus.
0 * ** **
F1
F2
F3
F4
F5
F6
Fig 3-82 Setting Menu
Functions of operation buttons F1–F6 on the setting menu.

SYSTEM FUNCTIONS
Table 3–5
Button Function
F1 Main menu
F2 Shift left
F3 Shift right
F4 Numerical increase
F5 Numerical reduction
F6 Confirm
3.4 Air Conditioning System

3.4.1 Precautions for air conditioning system
NOTICE
Turning on air conditioner before the operation of engine would make the clutch engage with the
driving disc of condenser. Starting engine at that time could create a large torque of engine and
make the clutch fraction with the driving disc. Consequently, the clutch could be worn out in a
short time.
• Do not turn on the air conditioner until the engine starts.
1. As an electric component, once the controller is damaged by water, air conditioner would fail to
function. Pay particular attention to following:
• Remember to close the windows when parking and cleaning the machine in case that rain
splashes and thus ruins the controller.
• The operator should keep the tea cup away from the controller while driving to avoid tea splash-
ing and thus ruining the controller.
2. Do not turn on the air conditioner until the engine starts.
3. Do not use the air conditioner when the lights indicating air conditioner fault or insufficient pres-
sure light up.
4. Close windows, doors and ventilation devices (except fresh air device) during the operation of
air conditioner.
5. Do not close all the air outlets. Keep at least one third of air outlets open.

SYSTEM FUNCTIONS
3.4.2 Control panel
3.4.2.1 Control panel
AIR CONDITIONER
4
OUT
2 模式)
MODE( 5
C
O3 AUTO
3 6
SANY HEAVY INDUSTRY CO.,LTD.
Fig 3-83 Control Panel
1. LCD display 3 .Power switch 5. Mode switch

2 .Fan speed switch 4. Temperature up or 6. Temperature down
page up switch or page down switch
3.4.2.2 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 illu-
minate. Press it again to stop the air condi-
tioner, and the indicator light would go out.
• Air conditioner cannot function while the fan
is turned off (no indication of fresh air mode
on the display). Fig 3-84 Power Switch

SYSTEM FUNCTIONS
3.4.2.3 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 vol-

ume increases gradually.
• Press this switch when the system reaches
its highest air volume, and the air volume
would return to its original condition.
• Air volume automatically transits among the
gears during the automatic operation of air Fig 3-85 Fan Speed Switch
conditioner
Indications of air volume on display screen:
• A: it indicates low air volume

• B: it indicates medium air volume
• C: it indicates high air volume
A B C
Fig 3-86 Air Volume Indication
A. Low air volume C. High volume

B. Medium air
volume

SYSTEM FUNCTIONS
3.4.2.4 Temperature or Paging switch
This switch is used to control the temperature

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 once to reduce 1° C of the set

temperature.
• No operation for 5 seconds, temperature re-
Fig 3-87 Temperature or Paging Switch
turns to the original display condition.
• The temperature is generally set at 25° C
(77°F).
Table 3–6 Temperature Reference
Display Temperature (℃ ) Set Temperature (℃ )

16.0 Max. refrigeration effect
18.5-31.5 Adjust the temperature
32.0 Max. heating effect
3.4.2.5 Mode switch
Mode switch is used to change the modes

among refrigeration, dehumidification, ventila-
tion and heating.
indicates that air condi-

tioner is in refrigeration
mode.
tioner is in ventilation
mode.
tioner is in heating mode.
Fig 3-88 Mode Switch
tioner is in dehumidifica-
tion mode.

SYSTEM FUNCTIONS
3.4.3 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 condi-
tion of ventilation, fresh air, refrigeration mode. Do the adjustments according to your needs.
1. Press mode switch to choose the op-

eration mode of air conditioner. For example,
begins blinking when the mode is set to

be refrigeration. 30 seconds later, the air con-
ditioner starts to refrigerate and keeps on.

If the set temperature is higher than cab tem-
perature, would blink all the time. Then

the idling lifter would start to work if the engine
is equipped with idling lifting device.
Fig 3-89 Mode Switch
2. Press or one time to raise or re-

duce 1℃ of the set temperature. The set tem-
perature can be adjusted between 16℃ and
32℃ . Generally, human body could adapt to
the temperature between 22℃ and 28℃ . As
soon as the cab temperature is lower than the
set value, the sensor would send signals to
controller. And the air conditioner will stop
refrigerating.
Fig 3-90 Temperature or Paging Switch

SYSTEM FUNCTIONS
3. Press to adjust the air volume. See

“Fan speed switch” on page 3-44.
Fig 3-91 Fan Speed Switch
3.5 Electric Control Cabinet

The electric control cabinet is located behind the operator’s seat, and the junction box is installed
on the right side of the machine, next to the cab. The inner layouts are shown in the below figures.
When an electrical component is burned, replace it with a new one of the same specification. Elec-
trical diagnosis requires professional techniques and must be conducted by a qualified and specif-
ic personnel. When important parts like a breaker or a relay are damaged, please refer to the Parts
Book and find out the relative material code, then purchase them from SANY.

SYSTEM FUNCTIONS
1 2 3 4 5 6
Fig 3-92 Electric Control Cabinet
1. Breaker 3. Fuse protector 5. Large current relay 7. Intermediate relay

2. Monopole breaker 4. Intermittent relay 6. SANY controller
3.6 Fuse
Fuses are located in the electric control cabinet of cab. Fuse protector is a protective electrical ele-
ment of high generality. When burned, it can be replaced with a new one of the same specification
easily.
Below fuse table has listed the necessary data of each fuse.
Table 3–7 Specifications of the Fuse
Code Fuse Function

QF1 63 A Battery
QF2 63 A Battery
QF3 32 A Air conditioner power supply
FU1 20 A Start the engine
FU2 15 A Working light of machine body
FU3 15 A Brake oil radiating
FU4 15 A Spreader power supply
FU5 15 A Spreader light switch

SYSTEM FUNCTIONS
Table 3–7 Specifications of the Fuse (continue)
Code Fuse Function

FU6 10 A Headlight
FU7 10 A Cab lighting
FU8 10 A Front wiper
FU9 10 A Steering indication system
FU10 10 A Reversing light
FU11 10 A Brake system
FU12 10 A Rear light
FU13 10 A Mast light
FU14 10 A Width light control
FU15 10 A Radio control
FU16 10 A Oil radiating system
FU17 10 A Power supply of spreader motion control
FU18 10 A Controller power supply
FU19 10 A Controller power supply
FU20 10 A Gear selector
FU21 10 A Fuel level signal
FU22 10 A Gearbox oil pressure
FU23 5A Alarm light
FU24 5A Spare
FU25 5A Top wiper
FU26 5A Rear wiper
FU27 5A Display
FU28 5A Distant terminal

SYSTEM FUNCTIONS

OPERATION
OPERATION
4 OPERATION .......................................................................................................................4-1
4.1 Before starting the engine....................................................................................................4-3
4.1.1 Operator responsibility ...............................................................................................4-3
4.1.2 Check before operation..............................................................................................4-4
4.1.2.1 General..................................................................................................................4-4
4.1.2.2 Wiper water level, checking................................................................................4-4
4.1.2.3 Coolant level, checking .......................................................................................4-5
4.1.2.4 Engine oil level, checking ...................................................................................4-6
4.1.2.5 Transmission oil level, checking ........................................................................4-6
4.1.2.6 Hydraulic oil level, checking ...............................................................................4-6
4.1.2.7 Fuel level, checking .............................................................................................4-7
4.1.2.8 Brake oil level, checking .....................................................................................4-8
4.1.2.9 Tyres, checking ....................................................................................................4-9
4.1.2.10 Electrical components, checking.....................................................................4-9
4.1.2.11 Working light, checking .................................................................................. 4-10
4.1.2.12 Horn, checking ................................................................................................ 4-10
4.1.3 Adjustment before operation ...................................................................................4-11
4.1.3.1 Seat, adjusting....................................................................................................4-11
4.1.3.2 Rearview mirrors, adjusting............................................................................. 4-13
4.1.3.3 Safety belt, adjusting ........................................................................................ 4-14
4.2 Starting the Machine.......................................................................................................... 4-15
4.2.1 Start in normal weather ........................................................................................... 4-15
4.2.2 Start in cold weather ................................................................................................ 4-18
4.2.3 Start with booster battery or starting generators ................................................. 4-19
4.3 Stopping the Machine........................................................................................................ 4-20
4.3.1 Engine shutdown procedures................................................................................. 4-20
4.3.2 Emergency shutdown.............................................................................................. 4-23
4.4 Driving.................................................................................................................................. 4-24
4.4.1 Driving description ................................................................................................... 4-24

OPERATION
4.4.2 Driving forward ......................................................................................................... 4-25

4.4.3 Driving backward...................................................................................................... 4-26
4.4.4 Turning around ......................................................................................................... 4-26
4.4.5 Parking....................................................................................................................... 4-27
4.5 Load Handling..................................................................................................................... 4-28
4.5.1 Operation switches .................................................................................................. 4-28
4.5.2 Mast, operation......................................................................................................... 4-29
4.5.3 Spreader, operation ................................................................................................. 4-35
4.5.4 Load capacity diagrams .......................................................................................... 4-39
4.5.5 Picking up a container from a stack....................................................................... 4-43
4.5.6 Depositing a container on the stack ...................................................................... 4-48
4.6 Store the machine .............................................................................................................. 4-53
4.6.1 Overnight storage..................................................................................................... 4-53
4.6.2 Short-term Storage .................................................................................................. 4-53
4.6.3 Long-term storage.................................................................................................... 4-54
4.6.3.1 General............................................................................................................... 4-54
4.6.3.2 Preparations ...................................................................................................... 4-54
4.6.3.3 During storage................................................................................................... 4-55
4.6.3.4 Return to service............................................................................................... 4-56
4.7 Transportation and Assembly........................................................................................... 4-56
4.7.1 Guidelines ................................................................................................................. 4-56
4.7.2 Disassembling the machine.................................................................................... 4-56
4.7.2.1 Disassembling principles ................................................................................. 4-56
4.7.2.2 Disassembly list ................................................................................................ 4-57
4.7.2.3 Hoisting points of parts..................................................................................... 4-59
4.7.3 Packing requirements.............................................................................................. 4-61
4.7.4 Transportation........................................................................................................... 4-62
4.7.4.1 Transporting by platform truck ........................................................................ 4-62
4.7.4.2 Transporting by container................................................................................ 4-62

OPERATION
4.OPERATION
4.1 Before starting the engine

4.1.1 Operator responsibility
DANGER
Risk of death!
Failure to follow this warning will result in death, serious injury, loss of control of the machine or
equipment damage.
• Do not leave the machine while a load is on the machine.
• Operate the machine slowly and cautiously, to avoid sudden and rapid movements.
The machine operator must follow below instructions:
• Reject the work site if they have doubts regarding safety.

• Be familiar with the working area and surroundings before beginning to work.
• Read and completely understand the instructions in this manual prior to first operation.
• Know and obey the operating procedures, relevant laws and regulations.
• Know and follow the requirements for safe operation.
• Know and use the required safety precautions and protective devices.
• Know basic information about the systems of this machine.
• Know and use the correct hand signals between the machine operator and a signalman.
• The operator must concentrate only on machine operation when using the machine.
• Stop machine operations in case any defects endangering safety are found.
• The operator must control the machine to protect the personnel or other facilities in the vicinity of
the machine.
• Ensure that all control devices are set to neutral or idle position before supplying power to the
drive components.
• Ensure that the control devices are set to neutral or idle position and the power supply is shut off
before leaving the operator cab.
• The operator must give warning signals when necessary.
• The operator must be provided with necessary personal protective equipments.

OPERATION
4.1.2 Check before operation
4.1.2.1 General
Every time before starting the machine or

changing shift, the driver should check wiper
water level, coolant level, engine oil level,
transmission oil level, hydraulic oil level, fuel
level, brake oil level, tyres, electrical compo-
nents, working lights and horn to ensure that
the machine is in good condition and ready for
operation.
Fig 4-1 Check the switches
4.1.2.2 Wiper water level, checking
The wiper water tank is located in the right

side of the machine body. Fill it when
necessary.
Fig 4-2 Wiper Water Tank

OPERATION
4.1.2.3 Coolant level, checking
CAUTION
Risk of scald!
Coolant temperature and the pressure in tank are still high when the engine just stops. Removing
the cap to check the coolant level at this time could cause personal scald.
• Do not open the tank cap when the engine is running.
• Do not touch it within 10 min after the engine stops.
• Loosen the cap 1/4 turn to check whether the expansion tank is under high pressure. If yes,
open the cap after the pressure is lower.
The expansion water tank, located on the en-

gine cabin cover, is directly connected to the
engine radiator. The water level in this tank in-
1
dicates the amount of coolant in the radiator.
Precautions for coolant inspection:
1. Maintain the oil level between the MAX and

MIN markings. If the coolant level is below the
MIN marking, fill in coolant through the filler
cap (1) until it reaches the MAX marking.
Tighten up the cap after filling in coolant.
Fig 4-3 Expansion Water Tank
2. If the tank is empty, the coolant may be
1. Filler cap
leaking. Check the coolant pipelines for leak-
age. If yes, fix the problem immediately. Top
up the tank if the coolant level is low.
3. Clean the expansion tank when it is too dirty

to see the level.

OPERATION
4.1.2.4 Engine oil level, checking
Examine the engine oil level prior to starting

the engine. This will help you to quickly notice
if any abnormal conditions have occurred or
are occurring.
1
2
Fig 4-4 Examine Engine Oil Level (VOLVO

engine)
1. MAX 2. MIN
4.1.2.5 Transmission oil level, checking
Check oil level daily with engine running at 500 rpm - 600 rpm and oil at 180 °F - 200 °F (82.2 °C -
93.3 °C). Maintain oil level to H marking.
4.1.2.6 Hydraulic oil level, checking
Hydraulic oil directly determines whether the hydraulic system would work normally. Be sure to
check the level daily.

OPERATION
4.1.2.7 Fuel level, checking
WARNING 20
10 15 25
15
5 20 10 30
0
Risk of fire hazard! 0
0 25 L 0 35
Failure to do this could result in fire hazard. x100 RPM Km/h
• Do not splash or drip the fuel.
0
G Y R
0.0
• If the fuel is splashed out, wipe it away
completely. If the fuel is dripped on ground 0.0 m
Manual:
or sand, make sure it will be cleaned. Gear: 0.0 t
• Fuel is flammable and dangerous. Keep Load: 0%

the fuel away from open fire.
• Do not weld around the fuel tank to avoid
Fig 4-5
spark splashing.
1. Turn the ignition switch to position I and

check the fuel level shown on display. After
checking, turn the switch back to position O.
P
0 ℃
0.0 L
0.0 Bar
SPN 0 0 RPM
Stop_Case 0 0 H
Fuel_Rate 0 ml/h 0.0 V
Fig 4-7 Display Menu

OPERATION
2. If the fuel level is low, release the cap of

filling port on fuel tank, and fill in fuel through
the filling port until oil floater reaches its high-
est point.
NOTE:
Tank capacity see:“Capacity of the tanks” on

page 5-16
Fig 4-8 Oil Filling Port of Fuel Tank
4.1.2.8 Brake oil level, checking
The level in brake oil tank can be indicated by

level-temperature indicator mounted on the
tank. The oil level must be maintained be-
tween the HIGH and LOW markings. You can
also check the quality of brake oil by its color.
When the oil level is lower than the LOW
marking, refill the tank up to the HIGH mark-
ing. Change the oil when it is necessary.
NOTE:
Tank capacity: 100 L (22 gal)

Fig 4-9 Brake Oil Tank

OPERATION
4.1.2.9 Tyres, checking
DANGER
Risk of serious injury or death !

A splashed lock ring or exploding tyre will be
deadly to anyone close to the tyre. Failure to
follow this will result in serious injury or
death.
• Only properly trained personnel are al-
lowed to serve the tyres.
Fig 4-10 Tyre Explosion
Carry out a visual inspection of the tyres.

Make sure that the rim and hub cover (1) are 1
not deformed on both sides of the tyres (2)
and the wheel tread (3) is not damaged. In
case of faults, the tyre will have to be carefully
inspected by the maintenance personnel be- 2
fore being used.
Tyre pressure should be 0.95 MPa - 1.05

MPa.
3
Fig 4-11 Check Points of Tyre
1. Rim and hub cover 3. Wheel tread

2. Tyres
4.1.2.10 Electrical components, checking
Check the following electrical components:
• Check if the fuses are not blown and conform to the subscribed value.
• Check for open circuit or short circuit in cables, and if the cover of cables is damaged.
• Check if the terminals are secure. If loose, tighten them up.
• Pay particular attention to the cables when checking the battery, engine, start motor, and alter-
nator. Be sure to check if there are flammable materials accumulated around the battery. If yes,
clear them away immediately.
NOTE:

OPERATION
• If the fuses are burnt out frequently or there is a sign of short circuit in cables, please contact
SANY authorized distributors to find out the reasons and repair it.
• Keep the top surface of battery clean and check the air vent on battery cover. If it is clogged by
dirt or dust, wash the battery cover and clean the air vent.
4.1.2.11 Working light, checking
Start the machine. And turn on the working

light switch.
• Check if the working light can be turned on

normally.
• Check for dirt or damage of the working
light.
• Check whether the working light is on.
• If the working light is off, maybe the bulb is
burnt out or the electricity is disconnected.
Please contact SANY authorized distribu-
tors to repair it. Fig 4-12 Working Light
4.1.2.12 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 alarm or the horn sound
is abnormal, please contact SANY author-
ized distributors to repair it.
Fig 4-13 Horn

OPERATION
4.1.3 Adjustment before operation
4.1.3.1 Seat, adjusting
NOTE：
Adjust the seat before operating or after changing the driver.
Adjust the seat until the driver can freely and conveniently operate the joystick, brake pedal and
switches while seated.
1. Adjustment of headrest
1
Lift the headrest to a desired position, and
then release it to get locked.
Distance: 0 mm – 120 mm
3
3
4
4
5
Fig 4-14 Seat
1. Adjustment of 4. Adjustment of
headrest safety belt
2. Adjustment of 5. Adjustment of
armrest suspension
3. Adjustment of 6. Adjustment of seat
backrest height

OPERATION
2. Adjustment of armrest
Turn the armrest adjustment handle (2) clock-

wise, and the height of armrest is increased.
Turn it anticlockwise, and the height is
decreased. 2
Angle range: -50° – 50°
Fig 4-15 Armrest Adjustment Handle
2. Armrest adjustment handle
3. Adjustment of backrest
When adjusting the inclination of backrest,

firstly pull the backrest adjustment handle (3)
upward and tilt the backrest to a desired posi-
tion, then loosen the handle to get the back-
rest locked properly. 3
Angle range: 75° – 140°
Fig 4-16 Backrest Adjustment Handle
3. Backrest adjustment handle
4. Adjustment of safety belt
For detailed information, see: “Safety belt, adjusting” on page 4-14.

OPERATION
5. Adjustment of suspension
Turn the suspension adjustment handle (5) to

left, and the suspension becomes firm to ac-
commodate the drivers of large weight.
Turn this handle to right, and the suspension

becomes soft to accommodate the drivers of
5
small weight.
Weight range: 50 kg – 130 kg
Fig 4-17 Suspension Adjustment Handle
5. Suspension adjustment handle
6. Adjustment of seat height
The first hearing of “snip-snap” after the seat

height adjustment handle (6) is lifted means
that the seat is lifted up for 30 mm. Continue
to lift this handle, and the seat is lifted up for
another 30 mm after the second hearing of
“snip-snap”. Lift it one more time, and the seat
is lowered to its original position.
6
Height range: 0 mm – 60 mm
Fig 4-18 Seat Height Adjustment Handle
6. Seat height adjustment handle
4.1.3.2 Rearview mirrors, adjusting
CAUTION
Risk of injury!
Failure to follow this could result in injuries
due to limited view.
• Adjust the rearview mirror before
operation.
Fig 4-19

OPERATION
Adjust the rearview mirrors to make it conven-

ient for the driver to see the situation at the
back of machine.
2
Steps to adjust the rearview mirrors:
1. Rotate the rearview mirrors to a proper

angle.
2. If the mirror cannot move smoothly when

1
adjusting the angle, loosen the fixing bolts of
mirror and the bolts in fixing lever of mirror.
3. Take the view of machine’s profile in mirror

as the standard while adjusting the angle of Fig 4-20 Rearview Mirror
rearview mirrors.
4.1.3.3 Safety belt, adjusting
NOTE:
• Check whether the safety belt and its mounting base are in good condition before using it.
Change it if worn or damaged.
• Change the safety belt every three years even if they are in good condition. Date of manufacture
is marked on the back of safety belt.
• Always wear the safety belt during operation.
• Do not bend the safety belt while wearing it.
Fixing and disassembling
An intertwist device is attached to the safety belt. Therefore, it is unnecessary to adjust the length
of safety belt.

OPERATION
Safety belt, fixing
1. Hold the safety belt clamp (2).
2. Pull the safety belt out of the intertwist de-

5 4 3 2 1
vice (1). Make sure that the safety belt is not
bent.
3. Plug the lock tongue (3) in the shackle (4).
4. Pull slightly the safety belt to check if it is

fastened.
Fig 4-21 Safety Belt
1. Intertwist device 4. Shackle

2. Safety belt clamp 5. Button
3. Lock tongue
Safety belt, disassembling
1. Press down the button (5) on shackle (4).
2. Pull out the lock tongue (3) from the shackle (4).
3. Safety belt will automatically roll back to the intertwist device (1).
4. Hold the safety belt clamp (2) and make the safety belt roll back slowly to intertwist device (1).
4.2 Starting the Machine

4.2.1 Start in normal weather
WARNING
Risk of injury!
Do not start the engine by short circuiting the engine, because this could result in severe personal
injury or fire disaster.
• Do not start the engine until you are in the driver’s seat.
• Make sure that there is no one or no obstacles around the machine. Then press down the horn
and start the engine.
• Do not use the starting auxiliary liquid that could cause explosion.
• Exhaust air is poisonous. Pay particular attention to the ventilation while starting engine in the
closed space.

OPERATION
CAUTION
Risk of harmful to personal health!
Emission of the diesel engine contains substances which could be harmful to personal health.
• Operate the machine in a well ventilated area.
• Discharge the exhaust gas to outdoor while operating in the closed space.
NOTICE
Risk of starting failure!
Failure to follow this could result in machine damage. The ignition key should not stay at position
III for more than 10 seconds. If the engine continuously fails to start for three times, make sure to
find out the reason and solve the problem before attempting starting it again, so as to avoid dam-
aging the engine.
• Do not operate the starter motor for longer than 10 seconds.
• In order to protect the battery, an interval of 1–2 minutes should be kept between two starts.
• Only start the engine after the system is power on and the start menu displays.
1. Turn the main power switch clockwise to

ON position.
OFF
NO
Fig 4-22 Main Power Switch

OPERATION
2. Put the gear selector (1) in neutral posi-

tion. Make sure that the emergency parking
switch is released.
2
1
2
3
1
1
2
3
1
2
3 I II
0
III
Fig 4-23 Gear Selector
1. Gear selector 2. Ignition switch
3. Insert the ignition key into the ignition switch (2), and turn it to position I to electrify the entire
system.
4. Turn the key to start position (III) and hold

for 3-5 seconds until the engine is started suc-
cessfully, the key will return to position (II)
automatically. P

OPERATION
NOTE:
• When the temperature of engine is low, do

not run it at a high speed.
• Before the temperature of engine rises to 60°c
60˚C, do not run it under high acceleration
or at full load. 0°c
- 5°c
Fig 4-25 Thermometer
The following conditions must be met to start

the engine. 0 ℃
• Observe if there is any alarm information 0.0 L
showing on the display. If there is, correct 0.0 Bar

standards. SPN 0 0 RPM
• Put the gear selector in the neutral position.
Stop_Case 0 0 H
• Release the emergency stop button.
• Step on the accelerator pedal with observa-
Fuel_Rate 0 ml/h 0.0 V
tion on the parameters of the engine.
Fig 4-26 Engine Information Menu
4.2.2 Start in cold weather
NOTE:
When the temperature is below 50°F (10°C),

special care should be taken to start the en- 35° C
gine. A start in cold weather may require
some assistant devices, but the operations in
the driver’s cab are identical to a normal start. 0° C
- 5° C
Fig 4-27 Thermometer

OPERATION
For maximum engine protection and easier start at low temperature, observe the following
precautions:
• Keep the batteries fully charged.

• Keep the fuel clean and free of water.
• Use lubricating oil with correct viscosity for the ambient temperature range where the engine
has to be operated.
A hydraulic oil heater should be used when the machine is operating in cold environment (temper-
ature below 0˚C). A preheating light would illuminate to inform the driver that the preheating is in
process and go out when the preheating is finished after about 1 minute.
If a normal start fails in cold environment, wait for 2 minutes before trying to start again. If the en-
gine continuously fails to start for several times, do not attempt start it again before finding out the
reason and solving the problem. Besides, ask the maintenance personnel to check the air intake
preheating system.
4.2.3 Start with booster battery or starting generators
WARNING
Battery produce explosive gases when being charged or discharged. Battery can explode if a
spark or flame comes near the battery, and could result in injury or possibly death.
Failure to connect the booster battery correctly could also result in injury or possibly death.
• Wear safety goggles when using booster battery and/or starting generators.
• Keep the battery away from fire when charging.
• Only professionals can handle the connection of booster battery.
Antidotes recommended by battery manufacturers:
• Flush eyes with water at least 15 minutes.

• Drink large quantities of water. Do not induce vomiting. Go to hospital immediately.

2
OPERATION 1
If the battery of machine is barely charged,

use booster battery or a starting generator to
start the engine.
1
1. Make sure that parking brake is engaged 2
and all electrical controllers are turned off.
2. Connect the booster battery or starting gen-

erator in the following procedures to prevent
sparks near the battery, or explosion may
happen:
a. Connect a jumper cable with the positive
(+) terminal of the booster battery at one end Fig 4-28 Booster Battery
and with the positive (+) terminal of the battery 1. Positive (+) 2. Negative (-)
on machine at the other end.
b. Connect another jumper cable with the neg-
ative (-) terminal of the booster battery and
with the grounding connector (the one away
from the battery) on the machine frame at the
other end.
3. Start the engine in a normal manner.
4. After the engine has been started, first dis-

connect the negative (-) jumper cable from the
frame, then remove the positive (+) jumper
cable.
4.3 Stopping the Machine

4.3.1 Engine shutdown procedures
DANGER
Risk of serious injury or death!

Failure to follow below instruction will cause serious injury or death.
• Do not leave the machine with a load suspended.

OPERATION
WARNING
Failure to follow the instruction could result in injury or possibly death.
• When the machine is loaded with tilted mast, do not brake it suddenly.
1. Release the accelerator pedal (3) to slow

down the machine.
1
2
3
1 2 3
Fig 4-29
1. Gear selector 3. Accelerator pedal

2. Brake pedal
2. Step down the brake pedal (2) to disconnect the gearbox and the propeller shaft.
3. When the machine is totally still, press

down the parking brake switch (4), and the
parking indicator light (5) will illuminate. 5
Fig 4-30 Parking Brake
4. Parking brake 5. Parking indicator

switch light

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

position.
1
2
3
1
1 2
3
1
2
3
Fig 4-31 Gear Selector
1. Gear selector
5. Allow the engine to run idle for a few minutes if it has been running constantly under load.
6. Turn the ignition key to position P to stop

the engine.
7. Remove the key from ignition switch when leaving the machine.

OPERATION
8. Turn the main power switch anticlockwise

to OFF position to turn off the main power.
OFF
NO
4.3.2 Emergency shutdown
Emergency stop switch, located on the right

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

in the arrow direction as shown in right illustra-
tion to cancel the emergency stop.
If the emergency stop button has been used RS-1406049-1
twice, replace the brake lining block immedi- Fig 4-34 Emergency Stop Switch
ately. Be sure to readjust it for a good parking
brake effect if the parking brake has been
separated from the machine.
NOTE:
It is prohibited to use the emergency stop but-

ton when the brake pedal is still working nor-
mally or in not real emergency situations.

OPERATION
4.4 Driving
4.4.1 Driving description
WARNING
Failure to follow this could result in injury or possibly death.
• Do not drive the machine when there is a tipping alarm.
• Do not lift the load too high or too low when operating the machine on uneven ground.
• Check if all safety facilities work normally before operating.
NOTICE
Risk of damage!
Unexpected damage could occur to the propeller shaft.
• Slow the machine down before changing gears.
Only the authorized operators are allowed to operate this machine.
1. Adjust the operator’s seat to a comfortable

and suitable position.
2. Run the engine idle and select driving direc-

tion and traveling gear with the gear selector
F
(1). N
1
2
3
3. Release the parking brake, and step on the

accelerator pedal (3). 1 2 3
4. Before changing the gear, release the ac- Fig 4-35 Driving
celerator pedal first, and then speed up nor-
1. Gear selector F. Forward gear
mally after the desired gear has been
2. Brake pedal N. Neutral gear
selected.
3. Accelerator pedal R. Reverse gear
5. Keep stepping on the accelerator pedal
when driving.
Speed:
• Adjust the speed according to personnel, visibility, surface and load of the work area.
• Special care must be taken on wet and slippery surfaces, such as snow or ice.

OPERATION
• Under all circumstances, the machine must be operated at a speed that enables it to be stopped
in a safe manner.
Operating on gradients (slopes)
When operating on slopes, observe the following rules:
• The machine must move up and down the slopes slowly.

• Do not turn the machine on slopes, nor drive across slopes.
• The load must face uphill when driving up or down gradients of over 10%.
4.4.2 Driving forward
1. Push the gear selector (1) forward.
1 11 2
1
3
1
2
3
2 3
Fig 4-36 Driving Forward

2. Brake pedal
2. Release the parking brake.
3. Step on the accelerator pedal (3) slowly so that the machine starts gently.
NOTE:
When accelerating up a hill, do not release the brake pedal (2) until the machine has sufficient pull-
ing power.

OPERATION
4.4.3 Driving backward
WARNING
If not avoided, this could result in injury or possibly death.
• Before driving backward, make sure that no personnel stays near the machine.
1. Turn the gear selector (1) backward. 3

2
1
1
2
3
1
2
11 3
Fig 4-37 Driving Backward
2. Step on the accelerator pedal (3) to speed up the machine slowly.
4.4.4 Turning around
WARNING
To maintain machine stability and prevent possible tipping, do not turn around the machine
abruptly, especially:
• when the machine is traveling at a high speed.
• with spreader elevated higher than its mid-point.
• on uneven ground.

OPERATION
With the help of a hydraulic assisted system,

the machine is characterized by a relatively
small turning torque.
To minimize unnecessary tyre wear, do not

the steering wheels 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 4-38 Turning Around
4.4.5 Parking
The parking switch (1) is located on the left of

2
front operation panel. Press the parking
switch, and the parking indicator (2) would be
turned on.
If the driver leaves the seat without pressing

the parking brake switch, the machine would
give off an alarm.
1
NOTE:
The parking system is located on the propeller Fig 4-39 Parking

shaft. Switch on the parking brake, and the
propeller shaft will be locked. Do not use the 1. Parking switch 2. Parking indicator
parking brake to brake the machine unless in
emergency.

OPERATION
4.5 Load Handling

4.5.1 Operation switches
3 9
2 10
5 11
12
13
1
6
14
7
4
17
8 18
15
16
Fig 4-40 Joystick
1. Spreader locking 2. Spreader 20 feet 3. Spreader unlocking 4. Spreader shifting

leftward
5. Spreader shifting 6. Spreader 40 feet 7. Spare switch 8. Joystick enable
rightward
9. Rear wipe 10. Top wiper 11. Front wiper 12. Joystick on / off
13. Alarm resetting 14. Inner light 15. Ignition key 16. Buzzer
17. Safety bypass 18. Emergency stop

OPERATION
4.5.2 Mast, operation
To avoid improper operation and elevate the

security of machine, this container handler
has been equipped with a switch “B” at the
back of joystick and a switch “F” on the right F
operation panel.
B
See the functions of enable switches in below

table.
Table 4–1
Fig 4-41 Enable Switches
Key Function Category
Joystick enable
B Inching button
switch
Joystick on / off Two-position
F
switch rocker switch
Two ways to enable handle
1. Press down the joystick enable switch (B),

and keep it held during the operation of the
handle.
• This method can avoid the wrong operation
of the handle, and is recommended to use.
2. Press down the joystick on / off switch (F).
• When using this method, the joystick can

be operated without pressing other buttons.
• This method is easy to operate, but after
the joystick on / off switch (F) is on, atten-
tion should be paid to avoid the collision or
extrusion of the joystick, resulting in the
wrong operation of the joystick.
For the first method of handle enabling opera-

tion is more secure, it is used by default in the
following introduction to handle operation.
Mast, lifting

OPERATION
1. Press down the joystick enable switch (B)

and hold it.
2. Pull the hydraulic joystick backward.
Fig 4-42 Mast Lifting
B. Joystick enable switch
Mast, lowering

and hold it.
2. Push the hydraulic joystick forward.

OPERATION
Fig 4-43 Mast Lowering
Mast, tilting forward

and hold it.
2. Turn the hydraulic joystick rightward.
Fig 4-44 Mast Tilting Forward

OPERATION
Mast, tilting backward

and hold it.
2. Turn the hydraulic joystick leftward.
Fig 4-45 Mast Tilting Backward
Mast, lowering in emergency
When the torque percentage of load is larger

than 100% or the mast / spreader sensor is
functioning abnormally, the mast can be low-
ered in emergency following the steps below.

OPERATION
1. Open the covering board at the head part

of machine.
Fig 4-46
2. Loosen the fastening nut of one-way throt-

tle valve on transition valve block. Then loos-
en the bolt for 2-3 turns with inner hexagon
spanner.
Fig 4-47

OPERATION
3. Turn on the safety bypass and push the

joystick forward at the same time. Then the
mast can be lowered urgently.
Fig 4-48 Safety Bypass
Fig 4-49 Joystick

OPERATION
4.5.3 Spreader, operation
DANGER
Failure to follow this will result in personal in-
juries or possibly death.
• Do not continue side-shifting the spreader
after the container is lifted and tilted.
A B C
• Do not press the spreader unlocking but-
ton when the load is suspended, or the
Fig 4-50 Spreader Light
load may fall down accidently.
A. Light A C. Light C
When light A becomes green, it indicates that B. Light B
the twistlock is locked.
When light B becomes yellow, it indicates that

the crown bar is seated.
When light C becomes red, it indicates that

the twistlock is unlocked.
Spreader, locking:
1. When the spreader is seated, light B will be-

come yellow.
2. If the operator has set up the automatic

locking program, the controller will send a
locking signal and thus realize the automatic
locking of spreader. Then, light A will become
green.
3. If the operator has not set up the automatic

Fig 4-51 Spreader Locking Switch
locking program, spreader will be locked and
light A will become green after the locking
switch on joystick is pressed down.

OPERATION
Spreader, unlocking:
1. When the spreader is seated, press down

the unlocking switch and joystick enable
switch to unlock the spreader.
2. Then light C will become red and light A will

go out.
Fig 4-52 Spreader Unlocking Switch
Matters to be concerned:
1. Opening condition of clip hook:

Only when the machine is travelling at the speed lower than 2 km/h can the clip hook of double
empty container spreader be opened.
2. The operation of crown bar:

The yellow lamp lights up when the left and right crown bars are plugged into the corner holes of
container.
3. The operation of clip hook:

The clip hook can only be operated when the spreader is seated (the yellow lamp is on).
4. Lifting:
When the clip hook is closed (green lamp is on), the spreader loaded can be lifted or lowered at
the normal speed.
When the clip hook is open (red lamp is on), the spreader loaded can be lifted or lowered at 60%
of the normal speed. Meanwhile, the yellow lamp on mast will begin blinking to warn the operators.
5. Machine loaded travelling:

When the spreader is loaded and the clip hook is opened (the red lamp is on), the max rotating
speed of engine should be limited to 800 rpm and the travelling speed of machine should be limited
to 3 km/h.
Spreader, side-shifting (leftward):
When the spreader is not seated, press down the side-shifting switch (left), and the spreader will
shift leftward.

OPERATION
Fig 4-53 Spreader Side-shifting Leftward
Spreader, side-shifting (rightward):
When the spreader is not seated, press down the side-shifting switch (right), and the spreader will
shift rightward.
Fig 4-54 Spreader Side-shifting Rightward
Spreader 40 feet:
Press down the spreader 40 feet switch, and the spreader will be automatically extended for oper-
ating the container of 40 feet.

OPERATION
Fig 4-55 Spreader 40 Feet
Spreader 20 feet:
Press down the spreader 20 feet switch, and the spreader will be automatically retracted for oper-
ating the container of 20 feet.
Fig 4-56 Spreader 20 Feet

OPERATION
4.5.4 Load capacity diagrams
WARNING
Overload could result in injury or possibly death. Only use the container handler to lift 20′and 40′
containers. Failure to follow this could result in injury or possibly death.
• Do not overload during operations.
Pick up and stack containers according to the load capacity diagram.
Diagram 1 is for SDCY90K8XX container handlers.

OPERATION
1
2
2
1
2 1
Fig 4-57 Load Capacity Diagram 1
1. Standard container 8'6" 2. Superstandard container
Diagram 2 is for SDCY90K7XX container handlers.

OPERATION
2
1
2
1
Diagram 3 is SDCY90K6XX container handlers.

OPERATION
2
1
2
1

OPERATION
4.5.5 Picking up a container from a stack
1. Approach the stack with the mast in the

vertical position.
NOTE:
The red light (3) is lit, indicating that the

spreader is unlocked. 1 2 3
Fig 4-60
1. Green light 3. Red light

2. Yellow light
2. Lift the spreader and tilt the mast forward

slightly when the machine is near the stack.
NOTE:
The red light is lit, indicating that the spreader

is unlocked.
Fig 4-61

OPERATION
3. Approach the stack slowly and lift the

spreader to the correct height for picking up
the container, making sure that the spreader
is positioned centrally with respect to the con-
tainer (take the vertical parts of container as a
guide).
NOTE:

is unlocked.
Fig 4-62
4. Lower the spreader and check whether

the twistlocks enter the container’s blocks
correctly.
NOTE:

is unlocked.
Fig 4-63

OPERATION
5. Proceed with the next step after confirming

that the twistlocks have entered in the corner
blocks and are seated correctly. Otherwise,
reoperate from step 4.
NOTE:
The yellow light (2) will illuminate if the

spreader is successfully seated.

is still unlocked.
Fig 4-64
6. Lock the container, and then the right light

goes off. If not, unlock and lift the spreader.
Reoperate from step 4.
NOTE:
The green light (1) will illuminate if the spread-

er is locked.
The yellow light is lit, indicating that the

spreader is seated.
Fig 4-65

OPERATION
7. Lift the spreader carefully until the yellow

light goes off after confirming that the contain-
er is locked. Then proceed with the next step.
NOTE:
The green light is lit, indicating that the

spreader is locked.
Fig 4-66
8. Tilt the mast steadily backward.
NOTE:

spreader is locked.
Fig 4-67

OPERATION
9. Make sure that no personnel or vehicle is

behind the machine. Reverse away from the
stack without steering for at least 3 m or mak-
ing any sudden operations.
NOTE:

spreader is locked.
Fig 4-68
10. Lower the mast until the container is at the

traveling position.
NOTE:

spreader is locked.
Fig 4-69

OPERATION
11. Drive the machine with container to its

destination slowly without suddenly braking
the machine. The container should not block
the view of operator.
NOTE:

spreader is locked.
Fig 4-70
4.5.6 Depositing a container on the stack
1. Approach the stack with the mast tilted

backward.
NOTE:
The left light (green) is lit, indicating that the

spreader is locked.
WARNING
Risk of injury!
Lift the spreader during the locking moment,
the container could be locked loosely and
fall, which could cause personal injuries.
• Do not lift the spreader during the locking
moment. Fig 4-71

OPERATION
2. Lift the spreader to a proper height for de-

positing the container when the machine is
near the stack.
NOTE:

spreader is locked.
Fig 4-72
3. Move the container slowly towards the top

of stack.
NOTE:

spreader is locked.
Fig 4-73

OPERATION
4. Center the container over the stack by

side-shifting the spreader and tilting the mast
forward.
NOTE:

spreader is locked.
Fig 4-74
5. Lower the container onto the stack to

make it properly seated. Or lift the spreader
again and reoperate from step 4.
NOTE:

spreader is still locked.
The middle light (yellow) will illuminate if the

spreader is successfully seated.
Fig 4-75

OPERATION
6. Unlock the twistlocks once the container is

completely seated. If one or more twistlocks
are not released, relock the container and lift
the spreader. Reoperate from step 4.
NOTE:
The red light (green) will illuminate if the

spreader is successfully unlocked.
The middle light (yellow) is lit, indicating that

the spreader is seated.
Fig 4-76
7. Lift the spreader carefully away from the

container until all the twistlocks are out of the
corner blocks. Or lower down the spreader
and reoperate from step 6.
NOTE:
The red light (green) is lit, indicating that the

spreader is unlocked.
Fig 4-77

OPERATION
8. Make sure that no personnel or vehicle is

behind the machine. Reverse away from the
stack without turning for at least 3 m or mak-
ing any sudden operations.
NOTE:

Fig 4-78
9. Lower the mast until the spreader is at the

traveling position.
NOTE:

Fig 4-79

OPERATION
4.6 Store the machine

4.6.1 Overnight storage
NOTICE
Risk of damage!
Failure to follow this could cause damage to the machine, personal property and the
environment.
• Remove the ignition key and take it with you, even if you are leaving the machine for only a mo-
ment. Keep it with you to prevent unauthorized operation of the machine.
1. Park the machine on a flat, level, stable

surface away from people, traffic or other
machines.
Fig 4-80
2. Lower the attachment.
3. Run the engine at idle speed for 3 min – 5 min to allow for heat dissipation. Extend this cool-
down time in hot weather.
4. Shut down the engine.
5. Remove the ignition switch when the engine comes to a complete stop.
6. Close and lock the windows.
7. Exit the cab and lock the cab door.
8. Fill the fuel tank to the maximum level.
4.6.2 Short-term Storage
Complete the “Overnight Storage” procedure and then:
1. Clean the machine.

OPERATION
2. Keep it dry.
3. Keep it fully lubricated.
4. Cover it to protect from dust.
NOTE:
Short-term storage is defined as a storage period of 30 days or less.
4.6.3 Long-term storage
4.6.3.1 General
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 Preparations
NOTICE
Risk of damage!
Failure to follow this could cause damage to the machine, personal property and the
environment.
• Remove the ignition key and take it with you, even if you are leaving the machine for only a mo-
ment. Keep it with you to prevent unauthorized operation of the machine.
1. Park the machine on a flat, level, stable

surface away from people, traffic or other
machines.
P
TY-1509015-1
Fig 4-81 Ignition Key
2. Lower the attachment completely.

OPERATION
3. Run the engine at idle speed for 3-5 minutes to allow for heat dissipation. Extend this cool-down
time in hot weather.
4. Shut down the engine.
5. Remove the ignition key when the engine comes to a complete stop.
6. Close and lock the windows.
OFF
NO
7. Exit the cab and lock the cab door.
8. Fill the fuel tank to the maximum level.
9. Apply spray lubricant to any exposed piston rods.
10. Change the engine oil.
11. Turn the main power switch to the off position and remove the handle.
4.6.3.3 During storage
WARNING
Failure to observe and follow this warning could result in death or serious injury.
• When operating the machine inside a building and to prevent asphyxiation, it is necessary to
open doors and windows to provide adequate ventilation.
Once a month:
1. Start the machine.
2. Drive the machine a short distance.

OPERATION
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 Transportation and Assembly

4.7.1 Guidelines
Empty container handler is a special type of vehicle used in ports, wharfs and stacking yards and
so on.
NOTE:
Empty container handler can’t be directly driven on road, thereafter in order to get the machine to
the clients’ designated wharfs or stacking yards and so on, the container handler has to be disas-
sembled before transported by road or sea.
A container handler is disassembled to: main frame, mast, spreader, twistlock assembly, cab,
swinging cylinder, exhaust tail pipe and handrails assembly. Other small parts are packed in two or
three wooden cases based on their properties. All these parts should be fixed and protected to
avoid paint damage.
Our professional transporting team will disassemble and pack the machine before it is delivered. If
you wish to transfer this machine to another work area, the machine should be disassembled first.
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.

OPERATION
• 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 pre-
vent dust and water.
4.7.2.2 Disassembly list
Before transportation, the container handlers should be first disassembled into several parts: main
frame (1), cab (2), mast (3), spreader (4), twistlock assembly (5), swinging cylinder (6), exhaust tail
pipe (7) and handrail assembly (8), etc.

OPERATION
7
5
2
1 8
Fig 4-83
1.Main frame 3.Mast 5.Twistlock assembly 7.Exhaust tail pipe

2.Cab 4.Spreader 6.Swinging cylinder 8.Handrail assembly

OPERATION
4.7.2.3 Hoisting points of parts
Label, hoisting point:
Please choose suitable hoisting points before

using a hoisting equipment.
NOTE:
It is the machine owner’s responsibility to en-

sure all hoisting chain cables, hangers and
hook blocks are in safe condition and with suf-
ficient capacity rating to hoist the attached
load.
Fig 4-84 Hoisting Point Label
1. Hoisting points of main frame
There are 4 hoisting points on the main frame, with two at each side of machine.
2
1
Fig 4-85 Hoisting Points of Main Frame
1. Position 1 2. Position 2

OPERATION
2. Hoisting points of mast
There are 4 hoisting points on the mast, with

two at each side of mast (position 3, 4, 5, 6).
3
5
4
6
Fig 4-86 Hoisting Points of Mast
3. Hoisting points of spreader
There are 2 hoisting points on the spreader, each one at both sides of spreader.

OPERATION
7
8
Fig 4-87 Hoisting Points of Spreader
4. Hoisting points of cab
There are 4 hoisting points on the cab, all at 9 10 11 12

the top of cab (position 9, 10, 11, 12).
Fig 4-88 Hoisting Points of Cab

4.7.3 Packing requirements
• Pack all the dismounted parts except main frame, mast, spreader, cab and cylinderss with plas-
tic 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.

OPERATION
• 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 wearing 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 truck
To transport the machine to a nearby yard by road:
1. Disassemble the machine into several parts.
2. Bind the main frame and the cab to a platform truck.
3. Bind and pack the other parts, including mast, spreader, twistlock assembly, swinging cylinders,
exhaust tail pipe and handrail.
4. Bind the packed parts to another platform truck.
NOTE:
• Weight of the parts should not exceed load capacity of the platform truck.
• Protect binding positions to avoid paint damage.
4.7.4.2 Transporting by container
If the machine is to be transferred to a distant place by sea, a total two containers should be pre-
pared. Encase the main frame and cab in a 40 feet frame container. Besides, load the other parts
such as mast, spreader in a 40 feet standard container. All the parts should be fixed inside the con-
tainers to avoid moving.

MAINTENANCE
MAINTENANCE
5 MAINTENANCE ................................................................................................................5-1
5.1 General Maintenance Information ......................................................................................5-7
5.2 Tightening Torques ...............................................................................................................5-9
5.2.1 General tightening torques ........................................................................................5-9
5.2.1.1 General..................................................................................................................5-9
5.2.1.2 Fastener torque value .........................................................................................5-9
5.2.1.3 Hydraulic coupling torque values ................................................................... 5-10
5.2.1.4 Tapered connections .........................................................................................5-11
5.2.1.5 O-ring and flange connections........................................................................ 5-12
5.2.1.6 Low pressure hose clamps.............................................................................. 5-13
5.2.2 Specific tightening torques...................................................................................... 5-13
5.3 Recommended fuel, coolant............................................................................................. 5-14
5.3.1 Recommended fuel, coolant and lubricant........................................................... 5-14
5.3.2 Specification.............................................................................................................. 5-14
5.3.3 Capacity of the tanks ............................................................................................... 5-16
5.3.4 Description of hydraulic oil...................................................................................... 5-16
5.3.5 Quality of hydraulic oil ............................................................................................. 5-17
5.3.6 Urea............................................................................................................................ 5-19
5.4 Lubricating Points............................................................................................................... 5-19
5.4.1 Lubricant.................................................................................................................... 5-19
5.4.2 Lubricating points of whole machine ..................................................................... 5-20
5.5 Scheduled maintenance ................................................................................................... 5-21
5.5.1 Special instructions for the first maintenance ...................................................... 5-21
5.5.2 Maintenance each day ............................................................................................ 5-22
5.5.3 Maintenance each 50 hours ................................................................................... 5-23
5.5.4 Maintenance each 250 hours ................................................................................. 5-24
5.5.5 Maintenance each 500 hours ................................................................................. 5-25
5.5.6 Maintenance each 1000 hours............................................................................... 5-27

MAINTENANCE

5.6 Engine.................................................................................................................................. 5-29
5.6.1 General engine inspection ...................................................................................... 5-29
5.6.1.1 Engine, examine ............................................................................................... 5-29
5.6.1.2 Charge air pipe, check ..................................................................................... 5-30
5.6.1.3 Drive belt, check and change (engine option VOLVO)................................ 5-31
5.6.1.4 Drive belt, check (engine option CUMMINS)................................................ 5-34
5.6.1.5 Drive belt, change (engine option CUMMINS) ............................................. 5-35
5.6.1.6 Air filter, check ................................................................................................... 5-36
5.6.1.7 Air filter, clean .................................................................................................... 5-38
5.6.1.8 Air filter, replace ............................................................................................... 5-39
5.6.1.9 Engine mounting pads, check......................................................................... 5-41
5.6.2 Lubrication system ................................................................................................... 5-43
5.6.2.1 Oil level, check and top up............................................................................... 5-43
5.6.2.2 Engine oil, change ............................................................................................ 5-45
5.6.2.3 Oil filter, change ................................................................................................ 5-47
5.6.3 Fuel system............................................................................................................... 5-49
5.6.3.1 Fuel condensate, drain(engine option VOLVO) ........................................... 5-49
5.6.3.2 Fuel condensate, drain (engine option CUMMINS)..................................... 5-51
5.6.3.3 Fuel filter, replace (engine option VOLVO) ................................................... 5-52
5.6.3.4 Fuel pre-filter, change (engine option VOLVO) ............................................ 5-54
5.6.3.5 Fuel filter, change (engine option CUMMINS).............................................. 5-57
5.6.3.6 Fuel pre-filter, change (engine option CUMMINS)....................................... 5-58
5.6.3.7 Fuel system, bleed (engine option VOLVO) ................................................. 5-59
5.6.3.8 Fuel system, bleed (engine option CUMMINS)............................................ 5-63
5.6.4 Cooling system ......................................................................................................... 5-64
5.6.4.1 General............................................................................................................... 5-64
5.6.4.2 Coolant mixture ................................................................................................. 5-64
5.6.4.3 Water quality...................................................................................................... 5-65
5.6.4.4 Coolant level, check and top up...................................................................... 5-66
5.6.4.5 A completely empty system, fill....................................................................... 5-68
5.6.4.6 Coolant, drain .................................................................................................... 5-69
5.6.4.7 Radiator, clean .................................................................................................. 5-72
5.6.4.8 Radiator fan, check........................................................................................... 5-73
5.6.4.9 Cooling system, clean ...................................................................................... 5-75
5.6.5 Air intake and exhaust system ............................................................................... 5-76
5.6.5.1 Air leakage, check ............................................................................................ 5-76
5.6.5.2 Turbocharger and blast pipe, check............................................................... 5-79
5.6.6 Urea filter element, change..................................................................................... 5-80
5.7 Transmission....................................................................................................................... 5-80
MAINTENANCE
5.7.1 Attaching bolts of propeller shaft, check ............................................................... 5-80

5.7.2 Speed sensor, check ............................................................................................... 5-83
5.7.3 Attaching bolts and mounting pad, check............................................................. 5-84
5.7.4 Propeller shaft, lubricate ......................................................................................... 5-85
5.7.5 Transmission oil, change ........................................................................................ 5-88
5.7.6 Transmission oil level, check.................................................................................. 5-90
5.7.7 Transmission oil filter, change ................................................................................ 5-92
5.7.8 TE Transmission calibration ................................................................................... 5-93
5.8 Drive Axle ............................................................................................................................ 5-95
5.8.1 Attaching bolts of drive axle to the frame, check ................................................. 5-95
5.8.2 Attaching bolts of drive axle to the propeller shaft, check .................................. 5-96
5.8.3 Oil leakage of drive axle and brake components, check .................................... 5-98
5.8.4 Brake function, check ............................................................................................ 5-100
5.8.5 Breather connector, clean..................................................................................... 5-102
5.8.6 Differential oil, replace ........................................................................................... 5-103
5.8.7 Drive axle oil, change ............................................................................................ 5-105
5.8.8 Brake pedal, check and adjust ............................................................................. 5-106
5.8.9 Parking brake pads, change................................................................................. 5-108
5.8.10 Brake oil filter, change ......................................................................................... 5-108
5.9 Steering Axle......................................................................................................................5-110
5.9.1 General check for steering axle ............................................................................5-110
5.9.2 Steering axle, lubricate...........................................................................................5-111
5.9.3 Steering axle components, check.........................................................................5-112
5.9.4 Knuckle pin, check ..................................................................................................5-113
5.9.5 Stub axle, maintain .................................................................................................5-113
5.9.6 Steering axle cradle, check....................................................................................5-114
5.9.7 Steering pressure, check .......................................................................................5-115
5.10 Tyres and rims .................................................................................................................5-116
5.10.1 Description of tire ..................................................................................................5-116
5.10.2 Tyre, inflate ............................................................................................................5-117
5.10.3 Tyres, check...........................................................................................................5-118
5.10.4 Drive axle tyre, remove and install .....................................................................5-119
5.10.4.1 Drive axle tyre, remove.................................................................................5-119
5.10.4.2 Drive axle tyre, install ................................................................................... 5-122
5.10.5 Steering axle tyre, remove and install............................................................... 5-123
5.10.5.1 Steering axle tyre, remove .......................................................................... 5-123
5.10.5.2 Steering axle tyre, install ............................................................................. 5-125
5.10.6 Description for wheel rim .................................................................................... 5-126
5.10.7 Rim, check ............................................................................................................ 5-126
5.10.8 Wheel rim, install and remove............................................................................ 5-128
5.10.8.1 Wheel rim, install .......................................................................................... 5-128
MAINTENANCE
5.10.8.2 Wheel rim, remove ....................................................................................... 5-130

5.11 Mast.................................................................................................................................. 5-131
5.11.1 General information of mast ............................................................................... 5-131
5.11.2 Basic check ........................................................................................................... 5-132
5.11.3 Fixed bolts, check ................................................................................................ 5-133
5.11.4 Sliding blocks, check ........................................................................................... 5-133
5.11.5 Chain, maintain..................................................................................................... 5-134
5.11.6 Cylinder piston rod, maintain .............................................................................. 5-136
5.12 Spreader.......................................................................................................................... 5-137
5.12.1 Twistlock, lubricate............................................................................................... 5-137
5.12.2 Sliding blocks of telescopic beam riser, lubricate............................................ 5-138
5.12.3 Sliding block between the basic beam and telescopic beam,
lubricate........................................................................................................ 5-138
5.12.4 Sideshift cylinder bearing, lubricate .................................................................. 5-139
5.12.5 Top and bottom sideshift sliding blocks, lubricate ........................................... 5-139
5.12.6 Sliding block, check ............................................................................................. 5-140
5.12.7 Twistlock, check ................................................................................................... 5-140
5.13 Air Conditioning System................................................................................................ 5-140
5.13.1 General recommendations ................................................................................. 5-140
5.13.2 Air conditioning, check ........................................................................................ 5-141
5.13.3 Refrigerant quantity, check ................................................................................. 5-143
5.13.4 Refrigerant, fill ...................................................................................................... 5-144
5.13.5 Cleanness of heatexchanger plate in evaporator and condenser,
check ............................................................................................................ 5-145
5.13.6 Leakage or lack of oil in condenser, check ...................................................... 5-146
5.13.7 Radiator, clean ..................................................................................................... 5-147
5.13.8 Maintenance table for air conditioning .............................................................. 5-147
5.14 Hydraulic System ........................................................................................................... 5-149
5.14.1 Hydraulic oil level, check..................................................................................... 5-149
5.14.2 Air filter element, change .................................................................................... 5-149
5.14.3 Hydraulic oil, change ........................................................................................... 5-150
5.14.4 Oil return filter element, replace......................................................................... 5-152
5.14.5 Hydraulic oil tank, clean ...................................................................................... 5-153
5.14.6 Accumulator.......................................................................................................... 5-154
5.14.6.1 Precaution...................................................................................................... 5-154
5.14.6.2 Brake system accumulator, check ............................................................. 5-155
5.14.6.3 Accumulator, charge .................................................................................... 5-156
5.14.7 Hydraulic oil circuit, check .................................................................................. 5-158
5.14.8 Brake oil filter, change ......................................................................................... 5-159
5.15 Electrical System ........................................................................................................... 5-160
5.15.1 General information of electrical system .......................................................... 5-160
MAINTENANCE
5.15.2 Battery ................................................................................................................... 5-161

5.15.2.1 Precautions for battery................................................................................. 5-161
5.15.2.2 Battery, clean................................................................................................. 5-162
5.15.2.3 Battery, check................................................................................................ 5-162
5.15.2.4 Battery, detect ............................................................................................... 5-163
5.15.2.5 Battery, charge .............................................................................................. 5-163
5.15.2.6 Battery cables, check................................................................................... 5-165
5.15.2.7 Scheduled maintenance of battery ............................................................ 5-167
5.15.3 Fuses, change...................................................................................................... 5-167
5.15.4 All working lights and indicators, check ............................................................ 5-168
5.15.5 Wiper, adjust ......................................................................................................... 5-169
5.15.6 Wiper, replace....................................................................................................... 5-170
5.16 Maintenance Record List .............................................................................................. 5-171

MAINTENANCE

MAINTENANCE
5.MAINTENANCE
5.1 General Maintenance Information
Do not perform any maintenance or repair not authorized in operation & maintenance manual of
this machine. Always observe and follow all safety precautions and use the proper tools when per-
forming any repair or maintenance operation. Pay special attention to Chapter 2 SAFETY.
Hour meter readings
Always take notice of the hour meter reading on a daily basis. Confirm meter readings with the re-
quired maintenance schedule listed in this manual.
Genuine SANY quick-wear part
Please replace the worn parts with genuine SANY parts stipulated in Parts Book.
Genuine SANY oils and greases
Please use SANY recommended lubrication oils and greases. Choose oils and greases of appro-
priate viscosity in accordance with ambient temperature.
Windshield washer fluid
Use automotive windshield washer fluid only. Do not mix concentrates into the detergent.
Clean oils and greases
Please use clean oils and greases. Always keep them clean and avoid impurities into oils and
greases.
Oil and filter inspection
Always inspect the drained oils and old filters for signs of metal particles and impurities. Report to
the man in charge if any abnormality is found in the filter or oil.
Fuel strainer
Fuel strainer should be installed when fuel is filled.
Avoid dropping objects inside the machine
• After performing maintenance or repair to the machine, always take time to inventory your tools,
parts used and nuts and bolts to be sure none of these items were left on or inside the machine.
Failure to do so could result in unexpected failure or damage to the machine.
• Do not put unnecessary objects inside your pocket other than those required for maintenance.
Dusty work area conditions
Observe the following items before working in a dusty environment.

MAINTENANCE
• Park the machine in a dustless place to prevent dust from getting into oil when checking the ma-
chine or changing oils.
• Frequently clean the radiator fins and other heat-exchanger parts to avoid clogging.
• Clean or replace the fuel filter and air filter frequently.
• Check and clean any electrical components especially the starter motor and alternator to avoid
any accumulated corrosion.
Avoid mixed oils
Never mix lubricants of different brands. If necessary, make sure to drain out the old oils and
change with the new ones.
Covers and locks
When servicing the machine with the covers open, be sure they are properly supported in place
and the lock (if exists) is properly latched for security.
Bleed the hydraulic system
If any hydraulic components have been replaced or removed, always bleed the air from the system
before resuming operation. Be sure there are no leakages and the hoses or lines do not rub on oth-
er components.
Installation of hydraulic tube
• When disassembling the parts at the place sealed by o-rings or sealing gaskets, clean the sur-
face before changing with the new parts. Do not forget to install the o-ring and sealing gasket.
• Do not distort or bend the tube during its installation, because this would damage the tube and
shorten its service life.
Securing of engine bonnet
When closing the engine bonnet after maintenance and repair, hold the handle and slightly lift up
the bonnet to examine if the pin has been locked. It is dangerous to start the engine without the
bonnet secure.
Cleaning parts of the machine
• Do not clean the machine with caustic chemicals or steam cleaners to avoid damages to the
paint or operating system.
• Instead, use mild soaps and a pressure washer to clean the machine. Always protect electrical
parts when cleaning the machine.
• Never flood or pressure-wash the inside of the operator’s cab as this will damage the electrical
system.
• Use only nonflammable cleaning solvents. Never use caustic or flammable liquids to clean parts
or systems.

MAINTENANCE
Check after maintenance or repairs
Always do the following after performing any maintenance or repairs to the machine.
Check during operation
• Check if the maintained or repaired part is working normally.

• Check for any leakage or overheating in the system after you have completed repairs or
maintenance.
• Be sure there are no abnormal sounds coming from the engine or hydraulic system and nothing
is loose.
Check after operation (when the engine is stopped)
• Be sure you have completed all the steps in the maintenance or repair of the machine you have
worked on.
• Check if every item is examined and maintained correctly.
• Check that no tools or parts have fallen inside the machine.
• Check if the water or oil is leaking, and all the bolts are tightened up.
5.2 Tightening Torques

5.2.1 General tightening torques
5.2.1.1 General
Premature component failure could occur if fasteners or couplings are not torqued to the specified
torque value. All fasteners, hose or pipe couplings on this machine have a torque value.
If a value is not specificity listed for the fastener or coupling, always refer to the charts below in this
section for a torque value.
5.2.1.2 Fastener torque value
Table 5–1 All Types of Fasteners

MAINTENANCE
Wrench Wrench (A) Socket, Open or Boxed end

(B) All en Wrench
Diameter Bolt Type Type Wrench
(A) (B) lb f•ft kgf•m N•m lb f•ft kgf•m N•m
M6 10.9 10 4 9.74 1.37 13.2 9.74 1.37 13.2
M8 10.9 13 6 22.87 3.16 31 22.87 3.16 31
M10 10.9 17 8 48.7 6.73 66 48.7 6.73 66
M12 10.9 19 10 83.39 11.53 113 83.39 11.53 113
M14 10.9 22 12 130.6 18.06 177 130.6 18.06 177
M16 10.9 24 14 205.9 28.47 279 205.9 28.47 279
M18 10.9 27 14 281.9 38.98 382 281.9 38.98 382
M20 10.9 30 17 405.16 56.02 549 405.16 56.02 549
M27 10.9 41 19 974.16 134.7 1,320 974.16 134.7 1,320
M10 12.9 17 6 57.76 7.96 78 57.76 7.96 78
M12 12.9 19 8 101.1 13.98 137 101.1 13.98 137
M16 12.9 24 14 250.18 34.6 339 250.18 34.6 339
M20 12.9 30 17 490 67.75 664 490 67.75 664
B
A A A
10.9 8.8 12.9
5.2.1.3 Hydraulic coupling torque values
Table 5–2 “M” and “G” Couplings
Port Tightening Torque Value Tube Tightening Torque Value

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

MAINTENANCE
5.2.1.4 Tapered connections
Table 5–3 Male Coupling
Wrench Tightening Torque Value o

30
Union lbf•ft kgf•m N•m
19 44 6 59
22 72 10 98
27 87 12 118
36 173 24 235
41 218 30 295
50 316 50 490
60 494 68 670 Fig 5-1 Female End
70 723 100 980
Table 5–4 Female Coupling
Wrench Tightening Torque Value o

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

MAINTENANCE
5.2.1.5 O-ring and flange connections
• Replace the O-ring (1) when disconnecting

hose end fittings
• Check the condition of the O-ring retaining
1
groves or flanges, replace the fitting or
flange if the groves are damaged or worn.
• Be sure the O-ring fits into the groves prop-
erly and is not too small or too large for the
fitting or flange.
• Always torque the fitting, flange or hose end
to the value listed below.
1. O-ring
Fig 5-3
Table 5–5 O-ring Fittings
Wrench Wrench Tightening Torque Value

Fitting (1) Hose Nut (2) lbf•ft kgf•m N•m
19 17 44 6 59
22 19 72 10 98
27 22 87 12 118
36 30, 32 173 24 235
41 36 218 30 295
50 46 361 50 490
Table 5–6 Split Flange Bolts
Bolt Thread Width Across Tightening Torque

Diameter Flats lbf•ft kgf•m N•m
10 14 44 to 55 6.0 to 7.5 59 to 74
12 17 72 to 90 10.0 to 12.5 98 to 123
16 22 173 to 210 23.5 to 29.5 235 to 285

MAINTENANCE
5.2.1.6 Low pressure hose clamps
The tightening torque for a low pressure hose

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

A T-bolt type 39 4.4
B Worm type 52-61 5.9-6.9
5.2.2 Specific tightening torques
NOTICE
Risk of machine malfunction or operation failures!
Failure to follow this could result in machine malfunction or operation failures.
• Tighten bolts according to recommended torque.
Before starting the machine, check critical bolts for tightness. Loose bolt has a great possibility to
result in dramatic vibration of the machine, component damage or weakened function of bolts, etc.
Periodical check can avoid unexpected results.
The following bolts must be checked:
Table 5–8 Recommended Tightening Torque of Bolts on Main Components
Bolt Recommended tightening torque(N·m)

Attaching bolts of engine and frame 210
Attaching bolts of transmission case 210
Bolts coupling engine and transmission case 72
Bolts coupling propeller shaft and drive axle 65
Attaching bolts of drive axle 1000
Attaching bolts of steering cylinder 475±10
Attaching bolts of upper and lower counterweights 1600±10

MAINTENANCE
5.3 Recommended fuel, coolant

5.3.1 Recommended fuel, coolant and lubricant
Fuel, hydraulic oil, and coolant recommended by SANY in this manual must be used. The quality
and quantities of all functional liquids should be periodically checked. Only when their quality and
quantities are up to standard can the machine be put in operation.
NOTE:
Oil produced by different manufacturers have different properties. It is best to use the oil recom-
mended by SANY.
Be sure to drain out all the oil in tank before filling in new oil.
5.3.2 Specification
If the environment temperature exceeds the range listed in the below table, use the oil of higher
standard.
For the oil standard, refer to the below table for information.
NOTE:
Before starting the engine, preheat the oil to the minimum temperature to meet the requirement of
oil adherence.
Table 5–9
Recommended Oil Adherence under Different

Temperature
Filling Position Oil Quality
°C -30 -20 -10 0 +10 +20 +30 +40 +50
°F -22 -4 +14 +32 +50 +68 +86 +104 +122
Engine Engine oil
VOLVO series SAE 5W-30
CUMMINS series API CH-4 SAE 10W-30
YUCHAI series SAE 15W-40
Transmission Transmis-
case sion oil
DEXRON-II DEXRON II or SAE 5W-30
DANA HR32000
or equiva-
series DEXRON II or SAE 10W-30
lent *
DANA TE10
series DEXRON-III
DEXRON III
DANA TE14 only
series

MAINTENANCE
Table 5–9 (continue)
Recommended Oil Adherence under Different

Temperature
Filling Position Oil Quality
°C -30 -20 -10 0 +10 +20 +30 +40 +50
°F -22 -4 +14 +32 +50 +68 +86 +104 +122
DANA TE17
series
Drive axle Gear oil
SAE 75W-90
KESSLER series API GL-5 SAE 80W-90
SAE 85W-140
Hydraulic system Hydraulic oil
ISO-L HV32
ISO 6743-4 ISO-L HV46
ISO-L HV68
Brake system Hydraulic oil
Travel brake and HV (94%) +
outer cooling sys- LZ9990A ISO-L HV 32 / 46 / 68 or 5W-30
tem only (6%)
Light diesel for vehicle meeting EN590 or GB/T 19147 standard. It is recom-
Fuel mended to use 0# diesel in summer and -35# diesel in winter. Machine
equipped with stage IV engines should apply ultra-low sulfur diesel.
Grease 2# or general lithium-based grease
Anti-freezing fluid of ethylene glycol or propylene glycol. VOLVO engines
Engine coolant
adopt the VOLVO anti-freezing fluid VCS.
Freezing oil (air
conditioning PAG100
system)
Cooling oil (drive
axle brake Transmission oil Donax TD 5W-30
system)
Refrigerant (air
conditioning R134a
system)
Urea (stage IV en-
AUS32 specific urea solution meeting ISO 22241-1 standard only
gines only)
NOTE:
• If the friction disc contains graphite, do not use this oil.

MAINTENANCE
DEXRON is the registered brand of US GM Co., LTD.
5.3.3 Capacity of the tanks
Table 5–10 Single Empty Container Handler Oil Capacity Table
Items Capacities (unit: L/gal)

Hydraulic oil tank 535 L (117.7 gal)
Fuel tank 350-410 L (77-90 gal)
Brake oil tank 100 L (22 gal)
Engine oil 30-35 L (6.6-7.7 gal)
Engine coolant 45-48 L (9.9-10.6 gal)
Gearbox and torque converter 45 L (9.9 gal)
Main reducer of drive axle 50-55 L (11-12 gal)
Hub reduction 3.2 L (0.7 gal)
Table 5–11 Double Empty Container Handler Oil Capacity Table
Items Capacities (unit: L/gal)

Hydraulic oil tank 500 L (110 gal)
Fuel tank 510 L (111.95 gal)
Brake oil tank 160 L (35.2 gal)
Engine oil 30-35 L (6.6-7.7 gal)
Engine coolant 45-48 L (9.9-10.6 gal)
Gearbox and torque converter 45 L (9.9 gal)
Main reducer of drive axle 50-55 L (11-12 gal)
Hub reduction 3.2 L (0.7 gal)
Values in the above table are only used for reference.
Oil level indicator is installed on the side of oil tank for oil level checking.
5.3.4 Description of hydraulic oil
Hydraulic oil, a very important part of hydraulic system, is used to realize the transition and control
of power. It is rust-proof and anticorrosive, able to lubricate and cool the system.
The cleanness of hydraulic oil can influence the performance of hydraulic system and service life
of hydraulic components. Besides, it directly determines whether the hydraulic system would func-
tion normally.

MAINTENANCE
Check the hydraulic oil in tank every six months with the means of visual inspection and oil
analysis.
The malfunction of hydraulic system is mainly due to the bad management of hydraulic oil. There-
fore, make sure to improve the management of hydraulic oil:
• Do not mix impurities into oil.

• Replace the oil immediately when the oil is of bad quality.
• Change the filter as regulated.
• Ensure the capacity and quality of oil in tank.
• Keep the oil cooler ventilated to prevent the abnormal increase of oil temperature.
• Block off the oil filling port with screw plug (or wrap it with clean plastic bag) after the hydraulic
components (pump, valve, rubber hose, etc.) are stripped.
5.3.5 Quality of hydraulic oil
• Park the machine safely. See “Parking

requirements” on page 2-52 and “Stop the
engine” on page 2-53.
Fig 5-5 Park Ground
Fig 5-6 Secure the Wheel

MAINTENANCE
The common way to evaluate the pollution degree of hydraulic oil is to compare the tested oil with
the clean oil. Check whether the oil color is different, or if there is dust or sediment in the oil.
1. Each month take about one liter of oil sample out of the oil tank.
2. Inject them into numerous clean test tubes.
3. Keep those test tubes respectively for ten days and one month.
4. Compare them with new oil and examine their color, transparency, impurities and sediments,
etc.
5. Use the filter paper to filter the impurities out of the hydraulic oil.
Below table is a simple way to evaluate the oil quality on the spot:
Table 5–12 Evaluation Method of Oil Quality
Color Odor Pollution Status Measures

Transparent Normal No pollution Keep using
Keep using if the viscosity
Thin transparent Normal Different oil mixed
is qualified
Transparent but gleamy Normal Metal particles mixed Filter or change the oil
Transparent with macula Normal Impurities mixed Filter or change the oil
Black brown Stinky Oxidated materials mixed Change all the oils
Seperate water from oil or
Milky white Normal Air or water mixed
change the oil
More strictly, check the viscosity, oxidation, water content, sediment, specific gravity, color and
flash point of oils in accordance with the standards of hydraulic oil manufacturer. It is better to plan
for changing oils based on the examination result and sample time.

MAINTENANCE
5.3.6 Urea
Vehicle urea solution is colorless, transparent,

and clear. This fluid, whose strength is be-
tween 31.8% and 33.2%, is used to deoxidize
the nitrogen oxide.
Sany port machines equipped with stage 4

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

urea which is conformed with standard ISO
22241-1.
Fig 5-7 Urea Jar

To reduce its decomposition, the urea solution
should avoid the long-term storage as far as
possible. Besides, it is better not to store the
urea solution in the environment whose tem-
perature is higher than 25°C.
Table 5–13
Urea Storage
Temperature (°C) Storage term (month)
≤10 36
11-25 18
26-30 12
31-35 6
35 Detect before usage
5.4 Lubricating Points

5.4.1 Lubricant
Lubricant is used to ensure the smooth rotation and sliding of all parts. Insufficient lubrication
would lead to the seizing of components and excessive wear. Lubricant is critical for the lubrication
of the engine to ensure smooth operation. Never use lubricants not specified by SANY.
Application method of lubricants (grease):

MAINTENANCE
Please clean the grease nipple before applying grease. Inject grease into the nipple with grease
gun until old grease is extruded. Remove the excessive grease.
NOTE:
As for sliding surface, remove the old grease and apply grease on the contact surface of sliding
block.
5.4.2 Lubricating points of whole machine
The movable connecting shafts, mast and spreader are key positions to be lubricated. Refer to be-
low figure and table for details.
7 14
6 15
9 10 11 12
5
16 17
4 18
3
2
20 13
21 19
Fig 5-8 Lubricating Points for Whole Machine
Table 5–14 Lubricating Points of Whole Machine(Corresponded to Fig. 5-6)
No. Position Oil change intervals

1 Transmission case (1 point)
2 Hub reduction of drive axle (2 points) Every 1000 hours or 1 year
3 Differential mechanism of drive axle (1 point)
4 Connection between mast and frame (2 points)
Lower roller and sliding block (decided by the mast
5
type) Every 60 hours or weekly
6 Connection between mast and tilt cylinder (2 points)
7 Upper chain wheel of lifting cylinder (2 points)

MAINTENANCE
Table 5–14 Lubricating Points of Whole Machine(Corresponded to Fig. 5-6) (continue)
No. Position Oil change intervals

8 Guide rail (all the surfaces)
9 Diesel engine (1 point) Every 250 hours
10 Radiator (1 point) Every 1000 hours or 1 year
11 Connection between tilt cylinder and frame (2 points)
12 Steering axle (13 points)
13 Wheel hub (2 points)
14 Inner mast (1 point)
15 Chain (all the chains) Every 60 hours or weekly
16 Spreader roller (4 points)
17 Support lug of spreader cylinder (3 points)
18 Sideshift surface of spreader (4 points)
19 Propeller shaft (3 points)
20 Hydraulic oil tank (1 point) Every 2000 hours or 1 year
21 Brake oil tank (1 point) Every 500 hours or half year
5.5 Scheduled maintenance

5.5.1 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 5–15
Mainte- Time for first

Maintenance item Page
nance part maintenance
See “Oil filter, change” on page 5-
Replace the oil filter 100h
47
See “Fuel filter, replace (engine
option VOLVO)” on page 5-52or
Replace the fuel filter 100h
“Fuel filter, change (engine option
Engine CUMMINS)” on page 5-57
See “Fuel pre-filter, change
(engine option VOLVO)” on page
Replace the fuel pre-filter 100h 5-54 or “Fuel pre-filter, change
(engine option CUMMINS)” on
page 5-58

MAINTENANCE
Mainte- Time for first

Maintenance item Page
nance part maintenance
Transmis- Change the transmission See “Transmission oil filter,
100h
sion oil filter element change” on page 5-92
Change the main reducer See “Differential oil, replace” on
100h
oil page 5-103
Change the wheel-side See “Drive axle oil, change” on
Drive axle 100h
reducer oil page 5-105
Replace the brake oil See “Brake oil filter, change” on
100h
filter page 5-108
5.5.2 Maintenance each day
Table 5–16
System Maintenance Item Reference

Refer to “Charge air pipe, check” on
Examine the charge air pipe.
page 5-30.
Refer to “Engine, examine” on page 5-
Examine the engine before operation.
29.
Refer to “Drive belt, check and change
(engine option VOLVO)” on page 5-31
Examine the drive belt.
and “Drive belt, check (engine option
CUMMINS)” on page 5-34.
Engine
Refer to “Air filter, check” on page 5-
Examine the air filter.
36.
Refer to “Coolant level, check and top
Examine the coolant level.
up” on page 5-66.
Refer to “Oil level, check and top up”
Examine the engine oil level.
on page 5-43.
Refer to “Fuel level, checking” on page
Examine the fuel level.
4-7.
Examine the attaching bolts of propel- Refer to “Attaching bolts of propeller
ler shaft. shaft, check” on page 5-80.
Examine if the attaching bolts and Refer to “Attaching bolts and mounting
Transmission
mounting pad is loosened. pad, check” on page 5-84.
Refer to “Transmission oil level,
Examine the transmission oil level.
check” on page 5-90.

MAINTENANCE

Refer to “General check for steering
Steering Axle General check for steering axle.
axle” on page 5-110.
Tires and Refer to “Tyres, check” on page 5-118
Examine the tires and rims.
Rims and “Rim, check” on page 5-126.
Examine the mast. Refer to “Basic check” on page 5-132.
Mast System Refer to “Fixed bolts, check” on page
Examine the fixed bolts of mast.
5-133.
Hydraulic Examine the hydraulic pipes and Refer to “Hydraulic oil circuit, check”
System connectors. on page 5-158.
Examine if all the working lights and in- Refer to “All working lights and
dicator lights are working normally. indicators, check” on page 5-168.
Electrical Refer to “Battery, check” on page 5-
Examine the battery.
System 162.
Refer to “Battery, detect” on page 5-
Detect the battery.
163.
Tire Examine the tire pressure. Refer to “Tyre, inflate” on page 5-117.
5.5.3 Maintenance each 50 hours
Table 5–17

Refer to “Oil leakage of drive axle and
Examine the drive axle and brake
brake components, check” on page 5-
components for oil leakage.
Drive Axle 98.
Refer to “Breather connector, clean”
Clean the breather connector.
on page 5-102.
Refer to “Steering axle, lubricate” on
Steering Axle Lubricate the steering axle.
page 5-111.
Refer to “Sliding blocks, check” on
Examine the sliding blocks of mast.
page 5-133.
Refer to “Cylinder piston rod, maintain”
Mast System Maintenance for cylinder piston rod.
on page 5-136.
Refer to “Chain, maintain” on page 5-
Maintenance for the mast chain.
134.
Air Condition- Examine the performance of air Refer to “Air conditioning, check” on
ing System conditioner. page 5-141.

MAINTENANCE

Refer to “Refrigerant quantity, check”
Examine the quantity of refrigerant.
on page 5-143.
Examine the air condenser for oil Refer to “Leakage or lack of oil in
leakage. condenser, check” on page 5-146.
Refer to “Cleanness of heatexchanger
Examine the heat-exchanger plate. plate in evaporator and condenser,
Table 5–18

Clean the air filter. Refer to “Air filter, clean” on page 5-38.
Examine the air intake system and ex- Refer to “Air leakage, check” on page
haust system for leaks. 5-76.
Refer to “Engine oil, change” on page
Replace the engine oil.
5-45.
Engine
Refer to “Fuel condensate, drain
Drain condensate.
and “Fuel condensate, drain (engine
option CUMMINS)” on page 5-51.
Refer to “Oil filter, change” on page 5-
Replace the engine oil filter.
47.
Examine the fixed bolts of drive axle to Refer to “Attaching bolts of drive axle
frame. to the frame, check” on page 5-95.
Refer to “Attaching bolts of drive axle
Examine the fixed bolts of drive axle to
Drive Axle to the propeller shaft, check” on page
propeller shaft.
5-96.
Refer to “Brake pedal, check and
Examine and adjust the brake pedal.
adjust” on page 5-106.
Examine the steering shaft for Refer to “General check for steering
damage. axle” on page 5-110.
Refer to “Knuckle pin, check” on page
Examine the knuckle pin for damage.
5-113.
Steering Axle
Refer to “Stub axle, maintain” on page
Examine the stub axle.
5-113.
Refer to “Steering pressure, check” on
Examine the steering pressure.
page 5-115.

MAINTENANCE

Refer to “Steering axle cradle, check”
Examine the steering axle cradle.
on page 5-114.
Refer to “Refrigerant, fill” on page 5-
Fill the refrigerant.
Air Condition- 144.
ing System Refer to “Radiator, clean” on page 5-
Clean the radiator.
147.
Hydraulic Refer to “Hydraulic oil level, check” on
Examine the hydraulic oil level.
System page 5-149.
Electrical Refer to “Battery, charge” on page 5-
Charge the battery.
System 163.
Refer to “Battery, clean” on page 5-
Clean the battery.
162.
Refer to “Wiper, adjust” on page 5-
Examine and adjust the wiper.
169.
Table 5–19

Refer to“Charge air pipe, check” on
Examine the charge air pipe.
page 5-30.
Refer to “Air filter, replace ” on page 5-
Replace the air filter.
39.
Refer to “Urea filter element, change”
Engine Replace the urea filter element.
on page 5-80.
Refer to “Fuel system, bleed (engine
option VOLVO)” on page 5-59 and
Bleed the fuel system.
“Fuel system, bleed (engine option
Refer to “Speed sensor, check” on
Examine the speed sensor.
page 5-83.
Examine and lubricate the propeller Refer to “Propeller shaft, lubricate” on
Transmission
shaft. page 5-85.
Refer to “Transmission oil filter,
Replace the transmission oil filter.
change” on page 5-92.
Refer to “General check for steering
Steering Axle Examine and tighten the bolts.
axle” on page 5-110.

MAINTENANCE

Examine the steering axle Refer to “Steering axle components,
components. check” on page 5-112.
Refer to “Steering axle cradle, check”
Examine the steering axle cradle.
on page 5-114.
Tyre Inflate the tyre. Refer to “Tyre, inflate” on page 5-117.
Refer to “Twistlock, lubricate” on page
Lubricate the twistlock.
5-137.
Lubricate the sliding blocks of tele- Refer to “Sliding blocks of telescopic
scopic beam riser. beam riser, lubricate” on page 5-138.
Refer to “Sliding block between the
Lubricate the sliding blocks between
basic beam and telescopic beam,
the basic beam and telescopic beam.
lubricate” on page 5-138.
Spreader Lubricate the sideshift cylinder Refer to “Sideshift cylinder bearing,
System bearing. lubricate” on page 5-139.
Refer to “Top and bottom sideshift
Lubricate the top and bottom sideshift
sliding blocks, lubricate” on page 5-
sliding blocks.
139.
Refer to “Sliding block, check” on page
Examine the sliding blocks.
5-140.
Refer to “Twistlock, check” on page 5-
Examine the twistlock.
140.
Refer to “Air filter element, change” on
Replace the air filter.
page 5-149.
Hydraulic Refer to “Oil return filter element,
Replace the oil return filter element.
System replace” on page 5-152.
Refer to “Brake oil filter, change” on
Replace the brake oil.
page 5-108.
Refer to “Battery cables, check” on
Examine the cables.
Electrical page 5-165.
System Refer to “Fuses, change” on page 5-
Replace the fuses.
167.

MAINTENANCE
Table 5–20

Refer to “Fuel filter, replace (engine
option VOLVO)” on page 5-52 and
Replace the fuel filter.
“Fuel filter, change (engine option
Engine
Refer to “Fuel pre-filter, change
Replace the fuel pre-filter.
and “Fuel pre-filter, change (engine
option CUMMINS)” on page 5-58.
Refer to “Transmission oil, change” on
Transmission Replace the transmission oil.
page 5-88.
Refer to “Brake function, check” on
Examine the manual brake function.
page 5-100.
Examine and replace the differential Refer to “Differential oil, replace” on
Drive Axle
oil. page 5-103.
Refer to “Drive axle oil, change” on
Examine and replace the drive axle oil.
page 5-105.
Table 5–21

Refer to“Brake system accumulator,
Examine the accumulator.
Hydraulic check” on page 5-155.
System Refer to“Accumulator, charge” on page
Charge the accumulator.
5-156.
Table 5–22

Refer to “Drive belt, check and change
Engine Replace the drive belt.
and “Drive belt, change (engine option

MAINTENANCE

Refer to “Turbocharger and blast pipe,
Examine the turbocharger.
Refer to “TE Transmission calibration”
Transmission Calibrate the TE transmission.
on page 5-93.
Refer to “Parking brake pads, change”
Drive Axle Replace the parking brake pads.
on page 5-108.
Refer to “Hydraulic oil, change” on
Replace the hydraulic oil.
Hydraulic page 5-150.
System Refer to “Hydraulic oil tank, clean” on
Clean the oil tank.
page 5-153.
Electrical Refer to “Wiper, replace” on page 5-
Replace the wiper.
System 170.
Table 5–23

Refer to “A completely empty system, fill”
Replace the coolant. on page 5-68 and “Coolant, drain” on
page 5-69.
Refer to “Cooling system, clean” on page
Clean the cooling system.
Engine 5-75.
Refer to “Radiator fan, check” on page 5-
Examine the radiator fan.
73.
Refer to “Engine mounting pads, check”
Examine the engine mounting pad.
on page 5-41.
Refer to “Wheel rim, install” on page 5-
Replace the wheel rim. 128 and “Wheel rim, remove” on page 5-
130.
Tires Refer to “Drive axle tyre, remove” on
and Replace the tire of drive axle. page 5-119 and “Drive axle tyre, install”
rims on page 5-122.
Refer to “Steering axle tyre, remove” on
Replace the tire of steering axle. page 5-123 and “Steering axle tyre,
install” on page 5-125.

MAINTENANCE
5.6 Engine
5.6.1 General engine inspection
5.6.1.1 Engine, examine
DANGER

Obey the following items to prevent machine damage, personal injuries or possibly death.
• Maintenance and service work shall be performed on a stopped engine if not otherwise
indicated.
• Stop the engine before the engine cover / hood is opened or removed.
• Make inadvertent start-up impossible by removing the ignition key and disconnect the power
by using the main switch.
• If you discover a leakage of oil, fuel or coolant, investigate the cause and fix the fault before
you start the engine.
• Remove the deposits of fuel, oils and grease on the engine.
Examine the engine and engine compartment

before you start the engine and after opera-
tion when the engine has stopped. This will
help you to quickly realize if something unusu-
al has occurred or is occurring.
Examine for oil, fuel and coolant leakage,

loose screws. Examine for worn or loose drive
belts, loose connections or damaged hoses
and wires. The inspection only takes a few mi-
nutes but can mean that serious service inter-
ruptions and costly repairs can be avoided. Fig 5-9 Check Oil Leakage

MAINTENANCE
5.6.1.2 Charge air pipe, check

engine” on page 2-53
Examine the condition of the charge air pipe,

pipe connections and clamps for cracks and
other damages. Replace them if it is
necessary.
Tighten the clamps with a torque of 9±2 N·m

(6.6±1.5 lbf.ft.).
Fig 5-12 Charge Air Pipe

MAINTENANCE
5.6.1.3 Drive belt, check and change (engine option VOLVO)
CAUTION
Risk of injury！
• Be careful when checking and changing the drive belt.
NOTE:
Change a belt that is oily, worn or damaged.
Check
Check the drive belt after operation, when the belt is hot. It should be possible to depress the drive
belt about 3 mm - 4 mm (0.12"–0.16") between the pulleys. The drive belt has an automatic belt
tensioner and therefore does not need to be adjusted.

MAINTENANCE

Replacement
1. Remove the right belt guard.
Fig 5-15

MAINTENANCE
2. Undo the belt tensioner and restrain it with

a mandrel. Remove the old drive belt.
Fig 5-16
3. Fit the new drive belt.
4. Remove the mandrel restraining the belt tensioner.
5. Re-install the belt guards.
6. Check that the belts are correctly aligned in their grooves and are correctly tensioned. It should
be possible to depress the drive belt about 3 mm - 4 mm (0.12"–0.16") between the pulleys.

MAINTENANCE
5.6.1.4 Drive belt, check (engine option CUMMINS)

Check drive belt every day. If the belt is worn or cracked, be sure to replace it. Tiny cracks along
the width direction of belt are allowed. Cracks along its length direction are not allowed. The belt of
sleek and lucent surface is slippery, adjust the slippery belt immediately.
The damage of belt may be caused by the following reasons:
• Incorrect tension
• Incorrect belt length
• No aligning belt wheel
• Incorrect installation
• Bad working environment
• Oil or grease on the belt

MAINTENANCE
5.6.1.5 Drive belt, change (engine option CUMMINS)
CAUTION
Risk of injury！
• Be careful when changing the drive belt.

1. Lift up the belt tensioner to remove the drive belt.

NOTE:
The belt tensioner is tensioned in the direction that the springs are bent over the tensioner arm. To
reduce the tension on the belt, rotate the tensioner in order to tighten the springs more firmly.
2. Lift up the belt tensioner and install the drive belt. If it is difficult to install the drive belt (the belt
seems too short), first place the belt in the grooved belt pulley. Then continue to hold up the belt
tensioner and pry the belt over the coolant pump’s belt pulley.

MAINTENANCE
3. Loosen the belt tensioner and check that the belt is sitting correctly in the grooves and is cor-
rectly tensioned.
5.6.1.6 Air filter, check


MAINTENANCE
NOTE:
• The maintenance and replacement inter-

vals is just for reference.
• The service life of filter core is within 200
working hours (working in desert) and 1600
working hours (on clean ground).
• Replace the main filter every 300 working
hours.
• Replace the filter at least a year under any
circumstances. Replace a worn, bent or
damaged filter immediately.
Fig 5-23 Air Filter Indicator
The engine is equipped with electronic air fil-

ter indicator. When the indicator turns red as a
warning of pressure drop, the filter element
must be checked and possibly changed. Re- 2
set the indicator after replacing the filter
element.
If the indicator turns red, clean the filter core

1
in following steps: 3
1. Loosen the cover clamp (2).
2. Remove the filter core cover (3).

Fig 5-24 Air Filter of Machine Equipped with
3. Drag out the filter core (1) and clean it. For Stage III Engine
detailed information, see: “Air filter, clean” on 1. Filter core 3. Cover
page 5-38. 2. Cover clamp

MAINTENANCE
NOTE:
Pay attention not to let dust into the filter seat

(or filter net, if installed) when cleaning the fil-
ter core.
Fig 5-25 Air Filter of Machine Equipped with

Stage IV engine
5.6.1.7 Air filter, clean


MAINTENANCE
NOTE:
Before replacing the filter element, be sure to

clean the inside of filter housing. In event of
emergency, the main filter element must be
cleaned and reinstalled. Do not use com-
pressed air to clean the filter element.
1. Clean the filter element with pressurized air.
2. Pressurize the air to 3 Bar. Put the nozzle at

5 cm around the filter element and start to
clean it from the inner to the outer. Fig 5-28 Cleaning Air Filter
3. Never knock the filter element with the hard
surface of nozzle.
NOTE:
Never clean the filter element for more than 6

times. If done, replace it.
5.6.1.8 Air filter, replace
NOTICE
If the filter element is not installed correctly, unfiltered air will be taken in, which could cause dam-
age 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 com-
plete the above operations.

MAINTENANCE

1. Remove the old air filter.
Fig 5-31
2. Install the new air filter.
3. Check and confirm that the clamps on the engine intake pipe are connected properly.

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

indicator.
Fig 5-32
Fig 5-33
5.6.1.9 Engine mounting pads, check
NOTICE
Risk of engine fault!
Failure to follow this could result in the ineffectiveness of the engine mounting pads, which could
result in serious engine fault or transmission malfunction.
• Silicone oil in the engine mounting pads would turn solid if it is used for a long time.

MAINTENANCE

Functions of engine mounting pads:
• Fix the engine on the frame.

• Reduce the shock when the engine is
started, running and stopped.
• Check whether the silicone oil in engine

mounting pads is lacked.
• Check if the engine mounting pads are
shaking.
1
• Check the depth of engine mounting pads.
• Check if the cover plate of engine mounting
pads is deformed. Fig 5-36 Engine Mounting Pads
1. Mounting pads

MAINTENANCE
5.6.2 Lubrication system
5.6.2.1 Oil level, check and top up
WARNING
Parts and oil remain high temperature after the engine stops, which could result in serious injury.
• Make sure to conduct this operation after the oil temperature becomes low.


MAINTENANCE
Steps to check engine oil level:
1. Open the engine bonnet.
2. Take the dipstick (3) out and wipe away the

oil on it.
3. Plug the whole dipstick in oil tank and then

take it out.
4. The oil level must be maintained between

the MAX (1)and MIN (2) markings. If it is be-
low the MIN marking, fill in oil through the fill-
ing port (4).
1
2
NOTE:
• At least 15 minutes are needed for oil to
Fig 5-39 Check Engine Oil Level (VOLVO
flow into the engine before rechecking the
engine)
oil level.
• If the machine is sloping, keep it horizontal 1.MAX 2.MIN
before the check.
5. If the oil level is proper, tighten up the cap

of filling port and close the engine bonnet.
NOTE:
Tank capacity see:“Capacity of the tanks” on

page 5-16
4
3
Fig 5-40 Check Engine Oil Level (CUMMINS

engine)
3. Dipstick 4. Filling port

MAINTENANCE
5.6.2.2 Engine oil, change
High engine oil level will cause foam, which decreases the lubrication effect. Low engine oil level is
insufficient for running through the whole lubrication system.
CAUTION
Risk of burn!
Hot oil and hot surfaces could cause burns.
• Wear gloves when changing engine oil.
• Follow the recommended oil change interval.
• Change the oil filter at the same time when changing engine oil.


MAINTENANCE
1. Stop the engine.
Fig 5-43 Drain plug
2. Remove the drain plug to drain the oil.
NOTE:
Collect the old oil and old filters and hand them to a recycling station.
3. Install the drain plug with a new gasket.
4. Change the oil filter, refer to “Oil filter, change” on page 5-47.
5. Fill oil to the correct level, refer to “Oil level, check and top up” on page 5-43.
NOTE:
Do not fill above the MAX level.
6. Start the engine and let it idle. Check that the oil pressure is normal.
7. Stop the engine. Check that there is no oil leakage around the filters. Check the oil level and top
up with oil as necessary. Refer to “Oil level, check and top up” on page 5-43

MAINTENANCE
5.6.2.3 Oil filter, change


MAINTENANCE
CAUTION
Risk of burns!
Hot oil and hot surfaces could cause burns.
Make sure to conduct this operation after the
oil temperature becomes low.
• Wear gloves when changing engine oil.
• Follow the recommended oil change
interval.
• Change the oil filter at the same time when
changing engine oil.
Removal
1. Drain the oil according to the instructions in

“Engine oil, change” on page 5-45.
NOTE:
Place a collection vessel underneath the filter
to avoid oil spillage.
2. Clean around the oil filter.
3. Carefully remove the filter cover together

with the filter.
4. Remove the O-ring and filter from the cover.

Fig 5-46 Change Oil Filter (VOLVO engine)
5. Let the oil drip off into a collection vessel.
Installation
1. Lubricate the new O-ring and the gasket of the new filter before installation.
2. Install the new filter and new O-ring in the filter cover. Make sure the filter is correctly installed in
the cover.
3. Install the filter cover and filter in the bracket. Tighten the cover to: 40 Nm (29.5 lbf.ft.)
4. Fill with required volume of oil. Refer to “Engine oil, change” on page 5-45.
5. Switch the engine off and check the oil level after a few minutes. Top up with oil as necessary.
6. Start the engine and check that there is no oil leakage from the oil filter or drain plug.

MAINTENANCE
5.6.3 Fuel system
5.6.3.1 Fuel condensate, drain(engine option VOLVO)
1. Park the machine safely. See “Parking


MAINTENANCE
2. Stop the engine and close the fuel tap.
Fig 5-49
1. Drain plug 2. Water separator
3. Put a collection vessel under the fuel prefilter to collect the condensate and fuel.
4. Open the drain plug (1) at the bottom of the water separator (2).
5. Drain the water contained in the water separator into the collection vessel.
NOTE:
Do not drain the water separator completely.
6. Tighten the drain plug and open the fuel tap.
7. Start the engine and check there

MAINTENANCE
5.6.3.2 Fuel condensate, drain (engine option CUMMINS)

2. Open the drain plug and drain fuel / water.
NOTICE
Risk of damage!
Failure to follow this could result in threads
damage.
• Do not over-tighten the drain plug.
Fig 5-52

MAINTENANCE
3. Close the drain plug by pushing the nipple up and tightening it by hand. Bleed the fuel system.
4. Start the engine and check sealing.
5.6.3.3 Fuel filter, replace (engine option VOLVO)


MAINTENANCE
NOTICE
1
Risk of material damage!
The wrong type of fuel filter could damage 2
the fuel injection circuit.
• Use only a fuel filter approved by the
3
manufacturer.
NOTE:
Working with the fuel system requests special

cleanliness.
Removal
1. Clean around the filter cover and housing.
2. Carefully remove the fuel filter cover (1).
NOTE:
Be prepared to gather up fluid. The filter is still
Fig 5-55 Fuel Filter
full of fuel and there is a risk of spillage when
the cover is removed. 1. Fuel filter cover 3. Filter
2. O-ring
3. Remove the O-ring (2) and filter (3). Let the
fuel drip off into a collection vessel.
Installation
1. If the new filter housing is completely empty, lubricate with diesel around the inner section of the
filter sealing surface.
2. Lubricate the O-ring with diesel before installing the filter cover.
3. Install the filter in the filter cover. Make sure the filter seats properly in the cover.
4. Install the filter cover and filter in the bracket. Carefully screw in the cover and check that the O-
ring does not get twisted. Re-lubricate the seal as necessary. Tighten the cover to 25 N·m (18.4
lbf. ft.)
5. Bleed the fuel system according to “Fuel system, bleed (engine option VOLVO)” on page 5-59
6. Start and warm up the engine. Check that no leakage occurs.

MAINTENANCE
5.6.3.4 Fuel pre-filter, change (engine option VOLVO)
CAUTION
Risk of injury !
Failure to follow this could cause personal injuries.
• Use protective gloves for work which will contact with oil, fuel etc.


MAINTENANCE
NOTE:
Put a collection vessel under the fuel filter to

collect the condensate and fuel. Store the
used filter in a suitable container.
Removal
1. Undo the cable (1) from the water trap

sensor.
4
2. Clean thoroughly around the pre-fuel filter
and water separator
3. Open the drain plug (2) in the base of the 3

fuel prefilter and drain the filter.
4. Tighten the drain plug again. 2 1
5. Remove the fuel pre-filter (4) and seal to-

gether with the lower section of the water sep-
arator (3). Put the used filter in a suitable Fig 5-58
container. 1. Cable 3. Water separator
6. Clean the lower section of the water sepa- 2. Drain plug 4. Fuel pre-filter
rator and the contact surfaces.

MAINTENANCE
Installation
1. Clean the seal surfaces thoroughly and lu-

bricate the gasket with diesel.
2. Lubricate the new O-ring with diesel and in-

stall the lower part of the water separator to
the new filter.
3. Screw the filter onto the filter bracket by

hand until the rubber seal bottoms on the mat-
ing surface. Then tighten a further 1/2– 2/3
turn.
4. Connect the cable from the water trap

sensor.
5. Open fuel taps and purge the system.
6. Start the engine and check that no leakage

occurs. Fig 5-59

MAINTENANCE
5.6.3.5 Fuel filter, change (engine option CUMMINS)

1. Remove the fuel filter.
2. Clean the filter’s contact face on the filter bracket.
3. Moisten the O-ring on the new filter with fuel.
NOTICE
Risk of damage!
Failure to follow this could cause malfunction or damage.
• Do not fill the new fuel filter with fuel before installing.
4. Install the new filter on the engine. Screw on the fuel filter until it makes contact with the contact
face. Then tighten a further 3/4 turn.

MAINTENANCE
5. When needed, bleed the fuel system.
5.6.3.6 Fuel pre-filter, change (engine option CUMMINS)


MAINTENANCE
2. Open the drain plug and drain any water.
Fig 5-64
3. Remove the filter.
4. Check that the new filter is absolutely clean and that the gasket is intact. Brush a little oil on the
gasket.
5. Screw the filter onto the filter bracket.
6. Bleed the fuel system.
5.6.3.7 Fuel system, bleed (engine option VOLVO)
The system does not need to be purged unless it has been run completely dry. Bleeding is then
done with the hand pump on the fuel filter bracket.
NOTE：
Put a collection vessel under the fuel filter to collect the condensate and fuel.

MAINTENANCE


MAINTENANCE
2. Remove the protective cap on the bleeder

nipple.
Fig 5-67
3. Loosen the nipple, at least two turns.
4. Connect a transparent hose to the nipple. Feed the hose to the collection vessel to avoid
spillage.
5. Tighten the bleeder nipple while fuel is flowing out.

MAINTENANCE
6. Remove the hose.
Fig 5-68
Fig 5-69
7. Tightening the bleeder nipple with torque 3.5 N·m.
8. Bleed the fuel system by pumping up fuel with the hand pump until air-free fuel flows out. Pump
rapidly to maintain pressure in the pump.
NOTE:
Bleeding is not complete while resistance is felt in the pump.
9. Wait 15 seconds and then repeat step 7.
10. Fit the protective cap on the bleeding nipple.

MAINTENANCE
5.6.3.8 Fuel system, bleed (engine option CUMMINS)

The fuel system must be bled after fuel filter

replacement, if the fuel tank has been run dry
or after long periods of operation for example.
1. Open the air bleeder screw.
2. Turn the hand pump anticlockwise to open

the pump.
3. Pump until the fuel is completely free of air

bubbles.
4. Tighten the air bleeder screw and close the Fig 5-72
fuel hand pump.

MAINTENANCE
5.6.4 Cooling system
5.6.4.1 General
The cooling system ensures that the engine works at the right temperature. It is a closed system
and must therefore always be filled with a mixture of at least 40% concentrated coolant and 60%
water to prevent interior corrosion, cavitation and frost rupture.
The coolant should contain ethylene glycol of a good quality with a suitable chemical consistency
that offers complete engine protection. Using an anti-corrosion mixture exclusively is not permitted
in engines. Never use water by itself as the coolant.
NOTE:
• Coolant with a suitable chemical formula must be used all year round. This also applies in areas
where there is never any risk of frost to give the engine full corrosion protection.
• Future warranty claims on the engine and ancillaries may be rejected if an unsuitable coolant
has been used or if the instructions concerning coolant mixing have not been adhered to.
• The anti-corrosive distributors become less effective after a time, which means that the coolant
must be replaced.
5.6.4.2 Coolant mixture
CAUTION
Risk of fire hazard!
Glycol is flammable. Failure to follow below instructions could cause fire or even injury.
• Keep glycol away from fire.
• Do not mix ethylene glycol with other types of glycol.

MAINTENANCE
Mix 40% concentrate coolant and 60% water.
Do not mix more than 60% concentrate cool-

ant in the cooling liquid, because it will reduce
the cooling effect and increase the risk of
overheating and frost damage.
TY-1405095-1
Fig 5-73 Mix Coolant
NOTE:
• Coolant shall be mixed with pure water or distilled – deionized water. The water must fulfill the
requirements specified by SANY, see “Water quality” on page 5-65.
• It is extremely important that the correct concentration of coolant is added to the system. Mix
them in a separate clean vessel before filling the cooling system. Make sure that the liquids mix.
NOTE:
VOLVO engine adopts the VOLVO anti-freezing fluid which does not need to be mixed.
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

TY-1405096-1
ppm
Fig 5-74 Water
Manganese (acc. to ASTM D858) ...... < 0.05
ppm
Conductivity (acc. to ASTM D1125) .... < 500

μS/cm

MAINTENANCE
Organic content, CODMn (acc. ISO8467) ......

< 15 mg KMnO4/l
5.6.4.4 Coolant level, check and top up


MAINTENANCE
CAUTION
Risk of injury! 1
Steam or hot coolant could cause injury.
• Do not open the coolant filler cap (1) when
the engine is warm.
Coolant filling must be performed with the en-

gine stopped. Check the coolant level daily
before starting.
1. Open the filler cap (1) of the machine, find Fig 5-77 Check Coolant Level
the observation window behind radiator. Open
1. Filler cap
the door before radiator, find the tank hanged
on right side.
2
2. Check the coolant level through observation

window (2) and MAX-MIN mark on the expan-
sion tank.
NOTE:
Only use the coolant recommended by SANY.

Fig 5-78 Check Coolant Level of Radiator
Top up with the same type of coolant as al-
ready used in the system. Different types of
2. Observation window
coolant must not be mixed.
Fig 5-79 Check Coolant Level of Tank

MAINTENANCE
5.6.4.5 A completely empty system, fill


MAINTENANCE
NOTE:
Mix the correct amount of coolant in advance,

to ensure that the cooling system is com- 1
pletely filled.
1. Check that all drain points are closed.
2. Open filler cap (1).
3. Fill with coolant, so that the level is between

the MIN and MAX marks. Fill slowly, to allow
air to flow out.
Fig 5-82 Filler
NOTE: 1. Filler cap

Do not start the engine until the system is
completely filled and bled.
4. Start the engine when the cooling system

has been completely filled and bled. Open
any bleeding nipples a short while after start-
ing, to allow trapped air to escape.
5. If a heating unit is connected to the engine

cooling system, the heat control valve must
be opened and the installation vented during
filling.
6. Stop the engine after about an hour and

check the coolant level. Top up as necessary.
Fig 5-83 Refill Coolant
5.6.4.6 Coolant, drain
CAUTION
Risk of injury !
Failure to follow this could cause injury.
• Stop the engine before draining the cooling system and remove the expansion tank cap.
• Do not open the filler cap when the engine is hot, except in emergencies.
• Do not drain the cooling system when the engine is in storage.

MAINTENANCE


MAINTENANCE
On engines which are to be put in storage, the

engine cooling system must be drained.
1. Stop the engine. 1
2. Remove the filler cap (1).
3. Open all drain points. Drain the coolant

from the radiator and engine block, using the
drain hose. The drain plugs are situated under
the radiator on the right side of the engine
block.
Fig 5-86 Filler Cap
4. Check that all coolant drains out. Deposits
may be found inside the drain plug/tap, and 1. Filler cap
need to be cleared away. There is otherwise a

risk that coolant could remain and cause dam-
age due to freezing.
5. Check whether the installation has any fur-

ther taps or plugs at the lowest points of the
cooling water pipes.
6. Shut any taps and check that the spring-

loaded covers on the nipples close com-
pletely. Install the rubber plugs.
Fig 5-87 Coolant Draining

MAINTENANCE
5.6.4.7 Radiator, clean

NOTICE
Risk of damage!
Failure to follow this could result in the radia-
tor damage.
• Do not flush the radiator with high-pres-
sure water.
Clear away the impurities on the surface of ra-

diator at regular intervals to ensure the maxi-
mum air through engine radiator for the best
cooling effect.
Fig 5-90 Radiator

MAINTENANCE
Perform the following steps to clear away the

impurities:
1. Remove the radiator cover.
2. Wipe away all the dirt and dust on the radia-

tor fins.
3. Clean the radiator with special detergent.
4. Check the radiator fins and rubber sealing

parts for damage. If necessary, replace it.
5.6.4.8 Radiator fan, check


MAINTENANCE
CAUTION
1
Risk of injury!
Failure to follow this could result in personal
injuries or property loss.
• Do not start the engine by dragging or priz-
ing the radiator fan.
• Do not rotate the curve shaft when work-
ing on the radiator fan. 2
• Do not bend the fan blades.
1. Check the radiator fan everyday.
2. Check if the fan blade (1) is cracked, if the Fig 5-93 Radiator Fan
bolts (2) are loose, and if the blade is bent or
1. Fan blade 2. Bolts
loosened.
3. Check the fan and make sure that it is firmly

mounted.
4. If necessary, tighten up the bolts (2).

MAINTENANCE
5.6.4.9 Cooling system, clean

NOTE:
Never clean the cooling system if there is any risk of freezing, since the cleaning solution does not
have any frost prevention ability.
Cooling performance is reduced by deposits in the radiator and cooling galleries. The cooling sys-
tem should be cleaned out when the coolant is changed.
1. Empty the cooling system. For detailed information, see “Coolant, drain” on page 5-69.
NOTE:
To prevent suspended materials from settling back in the system, emptying should be done rapidly
within 10 minutes before the engine has not been standing still for a long time. Remove the filler
cap and possibly the lower radiator hose to increase the speed of emptying.

MAINTENANCE
2. Put a hose into the expansion tank filling hole and flush with clean water as specified by SANY
until the water draining out is completely clear.
3. If there should still be some contamination left after flushing for a long time, clean the system
with coolant. Otherwise, continue as in item 8 below.
4. Fill the cooling system with 15% mixture of concentrated coolant. Use only SANY recommended
concentrated coolant mixed with clean water.
NOTE:
It is extremely important that the correct concentration and volume of coolant is put in the system.
Mix them in a separate clean vessel before filling the cooling system. Make sure that the liquids
mix.
5. Drain the coolant after 1-2 days of operation.
6. Flush the system immediately and thoroughly with clean hot water to prevent dirt from settling in
the inner areas. Flush until the water that runs out is completely clean. Make sure that any heater
controls are set to full heating during emptying.
7. If contamination should still be left after a long period of flushing, you can do a clean-out with ra-
diator cleaner, followed by finishing-off with neutralizer. Otherwise, continue as in item 8 below.
8. When the cooling system is completely free from contamination, close the drain taps and plugs.
9. Fill up with SANY recommended coolant, following the instructions in the chapters entitled
“Coolant mixture” on page 5-64 and “A completely empty system, fill” on page 5-68.
5.6.5 Air intake and exhaust system
5.6.5.1 Air leakage, check
NOTICE
Risk of damage to engine!
If the inlet pipe is damaged or loose, unfiltered air will enter into the engine, which cause damage
to engine.
• Air should be filtered before flowing into the engine to avoid impurities and scraps into engine.

MAINTENANCE

2. Check weekly that there is no ruptured

pipe or damaged / loose clamp in the inlet
pipeline.
Fig 5-98 Inlet Pipe
3. If necessary, replace the damaged pipe and tighten all loose clamps to ensure that the air intake
system is sealed.

MAINTENANCE
Torque: 8 N·m
4. Check whether the intake pipe under the clamp and hose is corroded.
Corrosion can introduce corrosive substances and dirt into the intake system.
5. Dismantle if necessary and clean the air intake pipeline.
Noise can be created due to the air leaking from below parts:
• Connecting parts between the turbocharger and exhaust bent pipe.
1) Check if there are any damages.
2) Tighten all loose clamps. Torque: 8 N·m
• Sealing gaskets between the turbocharger and exhaust manifold pipe.
1) Change the sealing gaskets.
2) Tighten the V-band clamped screw of air compressor housing.

MAINTENANCE
5.6.5.2 Turbocharger and blast pipe, check

Before starting the engine, check if there is

leakage of oil pipes in the turbocharger and of
all the blast pipe connectors. If yes, replace all
the damaged sealing ring, connecting pipes
and couplings where the leakage occurs. If
the ventilation hole in crankcase is blocked,
increasing pressure will lead to the entrance
of oil into the air-intake system of turbocharg-
er and engine.
Fig 5-101
Turbocharger, checking:

MAINTENANCE
1. Tighten the mounting nut of turbocharger. Torque: 61 N·m
2. Check if there is any air leakage in sealing surface of turbocharger housing. If yes, tighten the V-
band clamped nut.
Torque: 9 N·m
3. Check if there is any air leakage in sealing surface of air compressor housing. If yes, tighten the
V-band clamped nut.
Torque: 9 N·m
5.6.6 Urea filter element, change
CAUTION
Risk of injury!
Failure to follow this could cause injury.
• Do not let the urea inject into your eyes. If so, rinse your eyes with water for 15 minutes.
1. Use a 27 mm spanner to unscrew the urea filter cover .
2. Take out the filter balance tube .
3. Take out the used filter element and plug the new one into the urea supply module.
4. Tighten up the filter cover again after changing the filter element with a torque of 20 N·m [177 in-
lb].
NOTE:
1. Check if the inner screw thread of filter cover is damaged when changing the filter element. If
yes, replace it with a new filter cover.
2. It is unnecessary to seal the urea filter cover with O-rings.
5.7 Transmission
5.7.1 Attaching bolts of propeller shaft, check
Loose bolts will easily rupture under load and vibration. Fixed bolts of propeller shaft should be
checked carefully before torque force is transmitted.

MAINTENANCE

2. Check if the attaching bolts of propeller

shaft are secure.
TY-1405119-1
Fig 5-104 Attaching Bolts of Propeller Shaft

MAINTENANCE
3. Check if the universal joint bearing is in

good condition.
TY-1405120-1
Fig 5-105 Universal Joint
4. Tighten the loose bolts of propeller shaft with a torque of 65 N·m.

MAINTENANCE
5.7.2 Speed sensor, check

Speed sensor is located at the connecting

parts between gearbox and propeller shaft
(2). Check if the speed sensor (1) or its bear-
ing is damaged to ensure that speed signals
of the machine can be transmitted to relative
control system exactly. Thus, steering can be
carried out only in low speed, and transmis-
1
sion device can be protected. 2
Fig 5-108 Speed Sensor
1. Speed sensor 2. Propeller shaft

MAINTENANCE
5.7.3 Attaching bolts and mounting pad, check


MAINTENANCE
Functions of mounting pad and damping pad:
• Fix the transmission on the frame.

• Reduce the shock in the start, operation,
and stop of transmission.
1
Check:
• If damage exists on mounting pad (2) and

damping pad (1).
• If bolts are tight.
Fig 5-111 Attaching Bolts and Mounting Pad
1. Damping pad 2 .Mounting pad
5.7.4 Propeller shaft, lubricate
DANGER

Touching a running propeller shaft will cause serious injuries even death.
• Turn off the engine before operating the propeller shaft.

MAINTENANCE


MAINTENANCE
2. Inject the grease into lubrication points

with manual lubrication gun (not with high
pressure lubrication gun).
Fig 5-114
Fig 5-115
3. Stop injecting grease if the grease squeezes out.
NOTE:
Manually lubricate the propeller shaft even if the machine is equipped with a central lubrication
system.

MAINTENANCE
5.7.5 Transmission oil, change

2. Let the engine run idle.
Fig 5-118 Change Transmission Oil 1
1. Oil filler

MAINTENANCE
3. Check the transmission oil level. For detailed information, see: “Transmission oil level, check”
on page 5-90. If necessary, fill transmission oil through the oil filler (1).
NOTE:
• Wipe off the dipstick before checking.

• The oil dipstick is long. Use gloves.
• Make sure that the drain plug’s washer seal is also removed.
• Place a container under the drain plug to receive the drained oil.
4. Remove the drain plug (2) for transmission

oil and let the oil drain into the container.
Fig 5-119 Change Transmission Oil 2
2. Drain plug 3. Oil prefilter
5. Check the transmission oil prefilter (3). If the filter core is damaged, replace it immediately.
6. When the transmission oil has drained, fit the drain plug (2). Make sure that the washer for the
oil plug is included.
7. Remove the gearbox dipstick and fill new transmission oil through the dipstick’s hole to the cor-
rect level.
8. Turn on the main electric power and start the engine. Let the engine run idle for at least two
minutes.
9. Check the transmission oil level with the engine running at idle and top up to the marking for cor-
rect level.
10. Check the drain plug’s sealing.
11. Operate and warm up the gearbox until the operating menu shows oil temperatures between
60℃ - 65 ℃ .
12. Let the engine run idle. Check the transmission oil level.

MAINTENANCE
5.7.6 Transmission oil level, check
NOTICE
Risk of gearbox damage !
Failure to follow this could result in risk of gearbox damage.
• Work carefully when filling transmission oil to prevent other fluids or particles from contaminat-
ing the oil.


MAINTENANCE
The oil level must be maintained between the

FULL and ADD markings. The oil level should
be at the FULL marking.
1. Check the oil level with the engine at idle,

gearbox in neutral position and at operating
1
temperature (approximately 60°C - 65°C). 2
2. Fill transmission oil if needed. (Tank ca- Fig 5-122

pacity see:“Capacity of the tanks” on page 5- 1. FULL marking 2. ADD marking
16] )
3. It is recommended that the oil be filled when

the gearbox is at operating temperature. Fill-
wait a moment-check the oil level with
dipstick.

MAINTENANCE
5.7.7 Transmission oil filter, change

NOTE:
The gearbox does not need to be emptied of

oil before the filter is changed.
If the transmission oil is to be changed,

change the transmission oil before starting
the engine.
1. Park the machine in service position.
2. Remove the oil filter with the filter tool.
3. Lubricate the O-ring on the new oil filter with

transmission oil.
Fig 5-125 Transmission oil Filter

MAINTENANCE
4. Install the new filter on the gearbox. Tighten

to contact and then another 2/3 turn.
5. Turn on the main electric power and start

the engine. Let the engine run at idle.
6. Check the transmission oil filter’s sealing.
7. Check the transmission oil level, see

“Transmission oil filter, change” on page 5-92.
5.7.8 TE Transmission calibration
TE transmission needs automatic calibration to optimize the shift quality of the transmission. TE17
transmission uses APC200 or APC300 controller. The APC200 firmware contains an automatic
transmission calibration procedure. An automatic calibration has to be done:
• When the machine is built at the OEM

• Every 2000 hours of transmission operation
• When an overhaul of the transmission is done
• When the transmission is repaired
• When the APC200 is replaced
ENTERING AUTOMATIC CALIBRATION

MODE
The automatic calibration mode is entered by

pressing the S-button on the APC200 display
for 15 seconds during power-up.
Fig 5-126
PERFORMING AUTOMATIC CALIBRATION

MAINTENANCE
Before the automatic calibration can be started, a number of conditions need to be fulfilled:
• The parking brake on the vehicle has to be activated.

• The transmission temperature needs to be above 60°C.
• The engine speed has to be kept at around 800 rpm (± 200 rpm) during the complete calibration.
If the APC200 has control over the engine, the engine speed will be adapted automatically.
1. If all the conditions mentioned above are met, the actual automatic calibration can be performed
starting from the following display on the APC200:
2. To trigger the automatic calibration procedure, push the S-button once. The APC200 display
readout will show:
3. The APC200 asks for the shift lever to be put in FORWARD. The automatic transmission calibra-
tion procedure starts. This is indicated on the APC200 display:
‘C1’ stands for ‘clutch 1’ being forward,

while ‘M1’ stands for ‘mode 1’ of the calibration.
4. When all clutches have been calibrated, the APC200 displays:
5. At this point, the automatic calibration has completed successfully. The normal duration of a
complete transmission calibration is around 15 minutes.
6. To exit the automatic calibration mode, switch off the vehicle ignition key. Make sure that the
APC200 has powered down – wait for 2 seconds. Now restart the vehicle and the new tuning re-
sults will be activated automatically.

MAINTENANCE
5.8 Drive Axle

5.8.1 Attaching bolts of drive axle to the frame, check

Check the drive axle’s attachment to the

frame so that there is no corrosion of structur-
al elements (e.g. attaching bolts).
• Loose bolts tend to rupture when machine

is overloaded and vibrating.
• Ruptured attaching bolts would lead to seri-
ous damage to machine, or even personal
injuries.
• Tighten the attaching bolts with 1000 N·m
(oiled bolt).
Fig 5-129 Attaching Bolts of Drive Axle to the
Frame

MAINTENANCE
5.8.2 Attaching bolts of drive axle to the propeller shaft, check


MAINTENANCE
Tighten the attaching bolt (1) with 65 N·m

(oiled bolt).
Fig 5-132 Attaching Bolts of Drive Axle to the

Propeller shaft
1. Attaching bolt

MAINTENANCE
5.8.3 Oil leakage of drive axle and brake components, check

2. Check the oil-immersion disc brake and its

connecting pipe.
Fig 5-135

MAINTENANCE
3. Check the parking brake system and its

connecting pipe.
Fig 5-136
4. Check the connection between main re-

ducer and axle shell.
Fig 5-137
5. Check the drive wheel.
Fig 5-138
6. Check the oil level.

MAINTENANCE
5.8.4 Brake function, check
WARNING
The machine may move and could result in injury or possibly death.
• Always block the tyres to ensure that the machine would not move when the parking brake is
released.
CAUTION
Risk of injury!
Hydraulic oil is of high temperature and pressure, spray of it could result in injury.
• Release the pressure of hydraulic system before doing hydraulic related work.
• Avoid direct contact with hydraulic oil, and remember to wear gloves properly.

MAINTENANCE


MAINTENANCE
Brake system is applied to stop a traveling ve-

hicle. The brake is mounted on drive axle, not
on steering axle.
Check manual brake sheet and manual brake

function:
1. Start the engine and run it until the accumu-

lator is pressurized.
2. Stop the engine, and turn the ignition switch

to ON position (B).
3. Release the parking brake, and check if the Fig 5-141 Manual Brake Sheet
parking brake pliers can move on the bracket.
4. Check if the space between brake liner and B

brake disc meets the need of braking. Adjust
P
it if necessary.
B. ON position
5.8.5 Breather connector, clean
Clean the breather connector to release pres-

sure from the drive axle. If the pressure is too
high in the drive axle, there is a possibility of
oil leakage in fragile parts, like oil seal.
Fig 5-143 Breather Connector

MAINTENANCE
5.8.6 Differential oil, replace


MAINTENANCE
NOTE:
Only replace the oil after the engine is shut 1 2

down.
1. Remove the oil drain plug (3) and oil filling

plug (2). Drain the oil into proper container
and check if there are metal scraps in the oil.
2. Clean the inner of shell body with gasoline.

Drain all the gasoline before filling in new oils.
3
3. Check if there are metal scraps around the
Fig 5-146
oil drain plug and retighten it.
1. Opening 3. Oil drain plug
4. Fill in new oil into the oil filling plug until the
2. Plug hole / Oil fill-
oil overflows.
ing plug
5. Retighten the oil filling plug.
6. After the test and trial running, recheck the

oil level from oil filling plug to make sure that
no oil leakage is happening.
NOTE:
Replace the differential oil of new machine

after it has run for the first 100 hours.

MAINTENANCE
5.8.7 Drive axle oil, change
NOTICE
Risk of breakdown!
Dirt and impurities in the drive axle oil could 1
cause breakdown.
• Pay particular attention to cleanliness
when working on the drive axle.
Fig 5-147 Filler Plug and Drain Plug
1. Filler plug 2. Drain plug
1. Place the machine in position so that the hub’s drain plug (2) is at the lowest point vertically.
NOTE:
This applies to all drive wheels.
• Front wheel: move forward or backward to obtain the correct position.
• Rear wheel: lift the wheel from the ground (raise the machine under the drive axle) and rotate
the wheel into the correct position.
2. Place a drainage receptacle at every hub. Place a piece of sheet metal or similar in the wheel to
lead the oil to the receptacle.
3. Remove the hubs’ drain plugs on both sides. Also remove the hub lever and filler plug (1) to facil-
itate draining. Both sides shall be drained separately.
4. Remove the differential’s drain plug. Also remove the differential lever and filler plug to facilitate
draining.
5. Clean the drive axle’s breather while the oil is draining.
6. Install the drain plugs on the hubs and the differential.
7. Fill oil until the oil level is at level with the filter and lever holes.
8. Install the hub lever and filler plug on the differential.
9. Fill oil in the differential until the oil is flushed with the filter and lever holes.

MAINTENANCE
10.Install the lever and filler plug on the differential.
11.Turn on the main electric power.
12.Check the sealing and the oil level in the drive axle after a short test-drive.
NOTE:
Make sure that the seals are in place.
The oil is very viscous and filling should be slow. Level check should be done in stages so that the
oil has time to distribute itself.
5.8.8 Brake pedal, check and adjust


MAINTENANCE
2. Clean the floor around brake pedal and

check that nothing blocks the movement of
brake pedal.
Fig 5-150
TY-1407020-1
Fig 5-151 Brake Hinge
3. Check that the brake pedal springs back adequately and that the clearance between brake ped-
al and brake valve is 1-1.5 mm. If needed, adjust the stop bolt of brake pedal to correct the
clearance.
4. Check that the pedal’s travel is smooth.
5. Grease the pedal hinges with grease.
6. Check that the rubber on the pedal is intact and that the tread pattern isn’t worn out. Change it if
needed.

MAINTENANCE
5.8.9 Parking brake pads, change
Fig 5-152 Parking Brake Pads
2. Remove the cover from the brake caliper.
3. Loosen the lock nut.
4. Loosen the adjusting screw so that the brake pads become loose.
5. Remove the split pin and loosen the nut on the attaching bolt holding the parking brake caliper.
6. Pull out the attaching bolt so that the brake pads can be twisted out and removed.
NOTE:
The bolt does not have to be removed.
7. Remove the parking brake pads.
8. Clean the brake disc with methylated spirit.
9. Fit the new parking brake pads.
10. Press back the attaching bolt.
11. Fit the nut and fit a new split pin.
12. Adjust the parking brake.
5.8.10 Brake oil filter, change
NOTE:
The filter protects the brake system from impurities. It is very important that no impurities enter the
brake system when changing the filter.

MAINTENANCE
DGH-1703002-1
Fig 5-153 Brake Oil Filter
2. Depressurize the hydraulic and brake system.
NOTE:
Leave the valves open when changing.
3. Remove the drain plug on the underside of the filter. Let the oil drain. Wait a while as the oil
drains slowly.
4. Remove the filter housing.
NOTE:
The filter housing is heavy. Loosen it carefully.
5. Remove the filter insert.
NOTE:
Note the position of O-rings.
6. Clean the filter housing.
7. Fit the O-rings on the filter cartridge and filter housing. Lubricate the O-rings with hydraulic oil.
8. Fit the new filter insert to the filter bracket.
9. Fit the filter housing and the drain plug.
10. Close the valves that were opened to release the pressure in the hydraulic system.
11. Start the engine and check that the filter housing does not leak.

MAINTENANCE
5.9 Steering Axle

5.9.1 General check for steering axle
4
3
5
Fig 5-154 Main Components of Steering Axle
1. Connecting shaft of frame 3. Steering cylinder 5. Stub axle

2. End cover of king pin 4. Link arm
1. Check the wear condition of connecting shaft (1). Inject with grease every 50 hours.
2. Remove the end cover of king pin (2) to check the wear condition of king pin. Inject grease onto
it every 50 hours.
3. Check steering cylinder (3) for leakage. Check piston rod for deformation. Replace or repair
parts with damage.
4. Check whether the link arm (4) is worn, if worn it must be replaced immediately.
5. Check whether the link arm (4) can rotate smoothly. Inject grease onto the connecting pin shafts
of both ends every 50 hours.
6. If the machine has driven for a long distance with insufficient tyre pressure, stop the machine im-
mediately, and remove the wheels. Then check the condition of the stub axle (5).
7. If there is abnormal noise from the stub axle shaft or the steering tyre is abnormal when the ma-
chine is steering, it can be concluded that the stub axle shaft is seriously worn. Replace it
immediately.

MAINTENANCE
5.9.2 Steering axle, lubricate


MAINTENANCE
2. Clean the grease nipple.
Fig 5-157 Lubricate Steering Axle
3. Use the grease gun to inject grease into the nipple until remained grease is drained away.
4. Clear the redundant grease. Lubricate the lubrication points after scraping the remained grease
on sliding surface.
5. Smear grease on the lubrication point.
5.9.3 Steering axle components, check
• Check if the steering cylinder, stub axle and

its bearing, steering wheel bearing, steering
connecting shaft, damping pad, and coun-
terweight, etc are tightened.
• Check if there is abnormal clearance and
damage on the steering axle.
• Check if the steering axle is leaking oil.
DG-1407124-1
Fig 5-158

MAINTENANCE
5.9.4 Knuckle pin, check
1. Clean the knuckle pin (1) and bearing (2).

3
1
2
DG-1407125-
Fig 5-159
1.Knuckle pin 3.Fixed bolts

2.Bearing
2. Check if the knuckle pin (1) can rotate smoothly.
3. Check if the fixed bolts (3) are tightened.
5.9.5 Stub axle, maintain
1. Remove the wheel ring cover (1).

6
5
3
3
2
1
4
Fig 5-160
1. Wheel ring cover 4. Hub nuts

2. Stub axle 5. King pin
3. Wheel ring bearing 6. Grease nipple
2. Check the stub axle (2) for deformation, fatigue and damage as early as possible, and replace it
with a new one if there is damage.

MAINTENANCE
3. If the wheel ring bearing (3) is loose, adjust the hub nut (4) of wheel ring to adjust its clearance.
Take proper pre-screw measure to prevent from speeding up damage of other components.
4. Inject grease through the grease nipple (6) to lubricate the king pin (5) until it is hard to inject
further.
5.9.6 Steering axle cradle, check
Fig 5-161 Take the Measurement
2. Check that the bushings in the suspension are intact.
3. Measure the distance between the frame and the steering axle cradle. Note down the
measurement.
4. Lift the machine under the rear counter-weight.
NOTE:
Do not lift under the steering axle.
5. Re-measure the distance between the frame and the steering axle cradle. Note the
measurement.
6. Calculate the difference between the two measurements. The difference may not be more than
3 mm.

MAINTENANCE
5.9.7 Steering pressure, check

1. Operate and warm up the machine so that the oil in the brake system reaches operating temper-
ature (at least 50°C).
3. Connect a pressure instrument (0 MPa - 25 MPa) to the measuring outlet on the hydraulic oil
pump for steering and load handling.
4. Start the engine and increase engine speed to approximately 1200 rpm.
5. Turn the steering wheel fully and read pump pressure during the steering wheel movement.
Compare this to the steering pressure on the hydraulic plate.
6. Remove the pressure instrument and fit the protective cap on the measuring outlet.
7. Turn the ignition key to position 0 and turn off the main electric power.

MAINTENANCE
5.10 Tyres and rims

5.10.1 Description of tire
DANGER

Replace the tire timely when it reaches its max wearing limit. Otherwise, tire explosion and per-
sonal injuries or even death will occur.
• Stop the machine when the tire temperature is too high. Park the machine in a cool place to let
it cool down. Never discharge the air to release pressure or splash water on the tire to cool it
down.
• At least two professional technicians are needed, and high alert is required during the work.
• Type of the tire should be the same or have the same performance of the original tire.
Tires are the points of contact between the

machine and the ground, and they absorb un-
evenness and provide suspension. Specifica-
tion of the tire in this machine is 14.00-24-28
PR.
Fig 5-164 Tire
NOTE:
Tires on the same axle should be of the same brand, type, structure, and wear. The wear limit of
tires should be the same to ensure the identical outer radius. Tire should be replaced when the
tread at 1/4 of the tire edge is worn to a depth of 2 mm - 3 mm.

MAINTENANCE
NOTE:
Before starting the machine, check if crack,

corrosion, excessive or uneven wear exists on
the tire surface. Replace tires that are seri-
ously worn in time. Check and clean impur-
ities such as glass from the tire. Check the air
pressure of tire, and charge air in time when
the pressure is low, because low pressure re-
duces stability and load capacity of the overall
machine.
Fig 5-165 Check the tire condition
5.10.2 Tyre, inflate
Always follow the instructions for inflating

tyres to avoid the risk of accidents.
• Only use approved rim components.

• If the tyre has been completely deflated, the
tyre must be dismantled and the rim
checked for damage.
• Never install rim components by striking
with a hammer during inflating. Never strike
fully or partly inflated tyres or rim
assemblies.
• Never inflate tyres before all parts are in Fig 5-166 Inflate the Tyre
place.
• Wheels shall be inflated on the machine or
in a protective device, designed and dimen-
sioned so that it can handle or dissipate a
shock wave from a tyre explosion as well as
catch the ejected parts.
• Do not exceed prescribed tyre pressure that
is to be checked at ambient temperature.
• Never stand directly opposite the tyre when
deflating or inflating. The lock ring and re-
tainer ring may release and shoot off when
the pressure changes.

MAINTENANCE
• Check that all parts are in place when the

tyre pressure is 0.95 MPa - 1.05 MPa.
Steps to inflate the tyre:
1. Make sure that the lock ring and retainer ring are in the correct position before inflating.
2. Connect the compressor with the air valve of tyre.
3. Stand to the side of the tyre while the inflation is in progress.
4. Inflate the tyre to the prescribed level of 0.95 MPa - 1.05 MPa.
Other tyre pressure may apply when changing tyre or rim version, contact SANY.
5.10.3 Tyres, check

• Check for uneven and accelerated wear which is caused by mechanical problems such as un-
even brake action. Make sure that such malfunctions are corrected immediately.
• Remove penetrating objects such as crushed glass, wood pieces, metal fillings, etc.

MAINTENANCE
If the tyre is damaged, dismantle the wheel and change the tyre in time. If the tyres have no de-
fects, check and tighten the wheel nuts with a torque of 650 N·m (oiled bolt).
5.10.4 Drive axle tyre, remove and install
5.10.4.1 Drive axle tyre, remove
WARNING
• Discharge the air before replacing tyre. If the valve core is blocked, use a saw blade to saw a
notch with a depth of about 1/3 of the diameter.
• In replacing, always lay blocks under the steering axle before lifting the drive axle, otherwise
personal injuries would be caused by unexpected move of the machine.


MAINTENANCE
2. Put two jacks of 10 t under the drive axle.

They should be placed symmetrically around
the centerline of frame, with their centers 1.4
m away from each other. After all the positions
have been checked to be right, lift the drive
axle until the tyres are 50 mm clear from the
ground.
Fig 5-171 Drive Axle Tyre
Fig 5-172
Fig 5-173
3. Screw out the air valve cover and turn it round. Insert the cover in the air valve and turn it for 2-3
circles after it sticks to the valve core. Then discharge air of the inner and outer tyres.
4. Loosen all nuts symmetrically.

MAINTENANCE
5. Remove all nuts except three proportionally spaced ones.
6. Support the outer tyre with a forklift or other reliable lifting devices.
7. Remove the rest three nuts and displace the outer tyre.
8. Take down the spacer ring between tyre.
9. Displace inner tyre safely with a forklift or other lifting device.

MAINTENANCE
5.10.4.2 Drive axle tyre, install
1. Remove the dust and impurities on hub

surface and in inner ring of wheel rim.
Fig 5-174 Drive Axle Tyre
Fig 5-175
Fig 5-176
2. Mount the inner tyre to drive axle with a forklift or other lifting devices, with the lock ring
outwardly.

MAINTENANCE
3. Mount the spacer ring.
4. Mount the outer tyre to drive axle with a forklift or other lifting devices, with the lock ring inwardly.
5. Mount the open end thimble.
6. Mount the pressure plate symmetrically and tighten the nuts with a torque of 650 N·m.
7. Turn the tyre for several circles and ensure that swing range at the max. radius do not exceed 3
mm.
8. Charge the tyre with a pressure of 0.95~1.05 MPa.
9. During 200 hours after the machine is started for the first time or the new tyre is replaced, be
sure to pre-tighten the hub screw every 50 hours.
5.10.5 Steering axle tyre, remove and install
5.10.5.1 Steering axle tyre, remove
WARNING
• Discharge the tyre before replacing.

MAINTENANCE

2. Lay two jacks of 20 t under the steering

axle. They should be placed symmetrically
around the centerline of frame, with their cen-
ters 1.4 m away from each other. After all the
positions have been checked to be right, lift
the drive axle until the tyres are 50 mm clear
from the ground.
Fig 5-179 Jack
3. Turn the tyres to make nozzle jets upwards. Discharge the tyres.

MAINTENANCE
4. Take down nuts of short pressure plate symmetrically, and take out the short pressure plate.
5. Loosen the nuts of long pressure plate for 2-3 circles with a torque spanner.
6. Check if crack exists in wheel rim, shelter ring, or lock ring.
7. Lift the tyre with a forklift or other lifting device.
8. Take down the long pressure plate symmetrically.
9. Displace tyres with a forklift or other lifting device.
NOTE:
If serious crack exists in shelter ring or lock ring, first knock the wheel rim to discharge force of the
cracked shelter ring or lock ring under the retaining of long pressure plate, then take down the long
pressure plate.
5.10.5.2 Steering axle tyre, install
1. Remove the dust and impurities on hub

surface and in inner ring of wheel rim.
Fig 5-180 Steering Axle Tyre
2. Mount the tyre to steering axle with a forklift or other lifting devices, with the lock ring outwardly.
3. Mount the long pressure plate symmetrically and tighten the nuts with a torque of 600 N·m.
4. Mount the short pressure plate symmetrically in group and tighten the nuts with a torque of 600
N·m.
5. Turn the tyre for several circles and ensure that swing range at the max. radius do not exceed 3
mm.
6. Charge the tyre with a pressure of 0.95~1.05 MPa.
7. Within 200 hours after the initial operation or tyre replacement, the nuts of hub should be tight-
ened once per 50 hours.

MAINTENANCE
NOTE:
A group consists of a long pressure plate and two short pressure plates.
5.10.6 Description for wheel rim
Wheel rim fits directly on hub, and its dimen-

sions must be the same to that of the hub. On- 3
ly use the wheel rim that is approved by
2
SANY.
Our container handler applies three-element 1

type wheel rim. The wheel rim is composed of
wheel rim body, retainer ring, and lock ring.
Fig 5-181 Wheel Rim
1. Wheel rim body 3. Retainer ring

2. Lock ring
5.10.7 Rim, check
Perform the following checks to minimize the

risk of accidents for all split rims.
• Always use the correct tyre dimension and

design corresponding to the manufacturer’s
rim type and dimension. Oversize tyres will
not be used.
• Replace all damaged, worn or corroded
rims or mounting parts.
• Check the rim in connection with tyre
changing once a year.
Fig 5-182 Check the Wheel Rim

MAINTENANCE
1. Dismantle the rim.
B A
Fig 5-183 Measure Wear
A. Mark A B. Max 0.5 mm
2. Carefully clean the outside of the rim edge with a steel brush.
3. Measure the wear condition of lock ring.
• The lock ring’s wearing on the tyre bead often results in a mark A in the figure. The mark shows
up between the lock ring’s ends.
• Measure the depth of this wearing with a steel ruler and sliding gauge. If the wearing exceeds
0.5 mm, scrap the rim, lock ring and the tapered rim course and replace them with new parts
when necessary.
D
O
Fig 5-184
O. Circumference D. Diameter
4. Check the rim’s diameter
• Measure the rim edge’s circumference (O) with a measuring tape and calculate the diameter (D)
(D=O/3.14).

MAINTENANCE
• Compare the value of the diameter with the specified min. measurement. If the diameter is
smaller, the rim, lock ring and the tapered rim will be discarded and replaced with new parts.
5.10.8 Wheel rim, install and remove
5.10.8.1 Wheel rim, install
CAUTION
Risk of injury!
Failure to follow this could cause personal injury.
• Be sure to work according to the correct procedures while installing or removing the tyre from
wheel or rim.
• If the personnel has insufficient experience, or the appropriate tools for work are not sufficient,
do not install or remove the tyre.
• Under such circumstances, contact the authorized and professional staff related for tyres to
deal with it.
Wheel rim can be assembled or disassembled

horizontally and vertically. Before assembly or
disassembly, always remove the valve core
and release all the air out from the tyre.
Clean the rim seat and tyre seat with a wire

brush.
Fig 5-185
1. Check if there are any damages or nails in the tyre. Clean the inner and outer surfaces of tyre
and clear all the impurities before installing the inner tube.
2. Put the inner tube into the outer tube slowly and carefully from the bottom. Then inflate the in-
ner tube for its extension in the outer tube to avoid folds.
3. Mount the cushion belt from the top of outer tube and check if it is folded and placed between
the tyre beads. If the clearance between the tyre beads is too small, expand it with a jack and
lubricate the cushion belt and inner tube with dry lubricants such as soap.
4. Clean the dusts and rusts on lock ring with steel brush. Pay special attention to clean the groove
of lock ring and replace the cracked parts.

MAINTENANCE
5. Insert the rear wheel flange into the rim seat and the lock pin into the groove.
6. Hoist or roll the tyre to where the rim is placed. Check if the valve core rod is in the valve core
hole before mounting the tyre into the rim.
If the tyre is not hoisted for assembling, lower the position of rim for the convenience of installing
the outer tube.
7. Insert two A-type tool near the valve

groove. Put the tyre bead onto the side wheel
flange and fix it onto the rim seat. A
Fig 5-186
A. A-type tool B. B-type tool
8. Insert two B-type tool into the grooves of A-type tools as a pivot. Press the tyre bead bezel in.
Keep one tool there and pry the tyre bead into tyre bead bezel little by little with the other tool.
9. After the installation of rim, insert one B-type tool into the lock ring groove as a pivot and pry the
tyre bead bezel into lock ring groove for 30 mm.
10. Push the lock ring completely in with the sharp head of B-type tool along the perimeter of lock
ring groove.
11. Pull the tyre bead bezel out carefully with the crowbar until it contacts with the lock ring.

MAINTENANCE
12. Check if the lock pins at both sides of

wheel flange engage with each other. Mount
the tyre bead correctly onto the rim and inflate
it with the pressure of 525 kPa. Before adjust-
ing the air pressure, release all the air to cor-
rect the torsion or deformation. It is necessary
to inflate it for twice to prevent the inner tube
from early damage.
Fig 5-187
13. Before staring the machine, check if the air pressure is appropriate. Recheck the air pressure
when the machine has been running for the initial two or three times after the tyre is installed.
5.10.8.2 Wheel rim, remove
NOTE:
• Always remove the valve core and release all the air in tyre before removal.
• If all the air in tyre is released, dismount the tyre and check the steel rim for damage.
1. Before dismounting the tyre, remove the valve core and release all the air. Remember to mount
the valve cap after releasing the air to prevent the metal screw from damaging when dismounting
the tyre.
2. Choose proper tools and methods to lower the tyre bead onto the drainage groove at the inner
of rim. Pay attention not to damage the tyre bead.
3. Insert two crowbars into the groove of rim seat to take the lock ring out. Insert a B-type tool be-
tween the wheel flange and tyre bead bezel to pull the bezel into lock ring groove. Then remove
the bezel together with wheel flange.

MAINTENANCE
5.11 Mast
5.11.1 General information of mast
Mast system of forklift truck is composed of

outer mast (1), inner mast (2), lifting cylinder
(3), tilt cylinder (4), chain, sliding blocks, etc. 6
The mast angle is adjusted through the tele-
scopic movement of tilt cylinder, while the
mast height is adjusted by that of lifting cylin-
der. Under the function of these two cylinders,
the machine realizes the cargo operation.
1
2
NOTE:
The maintenance items of different masts are

the same. Below only introduces the mainte-
nance of K8C mast.
3
Fig 5-188
1. Outer mast 4. Tilt cylinder

2. Inner mast 5. Drag-chain
3. Lifting cylinder 6. Pulley

MAINTENANCE
5.11.2 Basic check
• Visually check the mast pillar for deforma-

tion and check if the paint on machine is
twinkled.
In normal conditions, the left / right pillars
should be parallel and symmetrical with the
center. If the deformation of pillars is found
to be serious, check immediately whether
its connections are cracked.
• Inspect carefully the crinkle and flake of

painting because it always indicates cracks
of weldment. If yes, weld it again Fig 5-189
immediately.
When welding, remove paint on the welding
area thoroughly and re-paint it again after
the welding is finished.

MAINTENANCE
5.11.3 Fixed bolts, check
• Check if the connecting bolts on mounting

pad of tilt cylinder (1, 2) and lifting cylinder
(3, 4) are damaged. If yes, replace them 1
2
timely.
• Check if the fixed bolts are connected cor-
rectly and tightened up. If necessary, adjust
and tighten them again.
3
4
Fig 5-190
1.Tilt cylinder 3.Lifting cylinder

2.Tilt cylinder 4.Lifting cylinder
5.11.4 Sliding blocks, check
Check if the sliding block is loose. If yes, ad-

just it with gaskets.
The steps to replace the sliding blocks:
1. Use a feeler gauge to measure the clear-

ance between the sliding block of outer mast
and web plate of inner mast.
2. If the clearance is over 2 mm, remove the

sliding block seat, gasket and sliding block to
measure the thickness of sliding block.
Fig 5-191 Sliding Block of Mast

MAINTENANCE
3. When the thickness is between 31 mm and

33 mm, adjust the clearance with gaskets.
When the thickness of sliding block is less
than 31 mm, replace it with a new sliding
block.
Check if the sliding block of side-sliding bracket is lubricated well. The good lubrication of sliding
block can reduce the wear and increase its service life.
1. The thickness of sliding plate is 35 mm. When the wear of sliding block exceeds 2 mm. adjust it
with gaskets.
2. When the the thickness is less than 30 mm, the mounting bolts of sliding block will come into
contact with the outer mast, resulting in the abrasion of mast. Thus replace it with a new sliding
block.
5.11.5 Chain, maintain
NOTE:
Remove the grease on the chain before checking it, and lubricate it properly before using it again.
• Lubricant for Chain

After the chain is cleaned by solvent, soak the chain with SAE20/50 multi-level lean oil to lubri-
cate it sufficiently.
• Lubrication Method for Chain

1. Manual Lubrication:
Inject grease periodically with a brush or a grease bottle. It is recommended to lubricate it once
after 50 operating hours. The lubrication amount and frequency should ensure that the chain is just
wet enough and clean lubricant can saturate into the joints.
2. Injecting Lubrication or Pressure Lubrication:
Inject grease drop or grease mist into the gap between edges of chain plate. Lubrication amount
and frequency should be just enough to make lubricant saturate into the chain.

MAINTENANCE
Matters to be concerned for chain lubrication:
• The lubricants should be saturated into 1

every gaps between chain plates. The
wearing place between pin and chain sec-
tions should be lubricated well.
• Always slide the chain on chain wheel for
the best lubrication effect.
• If there is abrasive materials (such as
sands) attached on the chain, be sure to lu-
bricate the chain after cleaning the dirt off
the chain completely.
Fig 5-192 Chain Gap
• When the chain is lubricated before it is
cleaned, the abrasive materials may enter 1. Chain gap
into the chain and cause the wearing of
chain.
• Check extension of the chain

The chain may not have lengthened more
P P
than 3%. Measure the length of the 25 links
that during lifting first (and most often)
break over the chain wheel.
NOTE:
Compare with the values in below table. If the

3% limit is exceeded, the chains must be Fig 5-193 Distance Between 2 Pins
replaced.
P: Distance Between 2 Pins
Table 5–24 Measurement Index of Chain
P-measurement Measurement over 25 links [mm]

P-measurement [in]
[mm] New chain Max. Measurement
2 50.8 1270 1308
2 1/2 63.5 1587.5 1635
P-measurement = the distance between 2 pins
• Check connecting joints for cracks
Check key structural mechanism frequently. If cracks are found and properly handled, further dam-
age can be prevented.
• Check the chain for mechanical damage

MAINTENANCE
The chain is a key structural component for directly lifting loads, whose structural stability di-
rectly influences the reliability and safety of whole machine.
• Check the Chain for Corrosion
• Check the Chain Connectors

Inspect the chain connectors regularly. Check if the connectors are cracked. If yes, change it.
Table 5–25 Inspection Plan
Work Time Inspection Interval

Within 5000 hours Every 1000 hours
5000-10000 hours Every 300 hours
10000-20000 hours Every 200 hours
Above 20000 hours Every 150 hours
5.11.6 Cylinder piston rod, maintain
Perform the following maintenance during transporting, installing and operating the cylinder piston
rod:
• After coating or assembling the cylinder, seal the exposed section of piston rod with anti-rust oil
or grease to prevent corrosion.
• During the long transportation or ocean shipping, seal and pack the exposed section of piston
rod with anti-rust oil or hydraulic oil.
• If the machine installed with cylinder will be parked for more than half month, coat the exposed
section of piston rod with antirust oil or hydraulic oil. Besides, check and maintain the cylinder
every week regularly.
• When operating the machine, keep the surface of piston rod clean. Clear the piston rod of mud
or dust. Pay attention not to bump, cut or damage the piston rod.

MAINTENANCE
5.12 Spreader
5.12.1 Twistlock, lubricate
Spreader is the major working mechanism for

lifting the container. Lubricate spreader twist-
lock properly to reduce its wear and extend its
service life.
All spreaders have four grease nipples which

should be lubricated every 250 hours. All pro-
tective sleeves have a grease nipple (A). All
twistlocks have a grease nipple (B).
Check the wear and possible damages of

twistlock and its protective sleeve when lubri-
cating. Replace them if necessary.
B A
Fig 5-194
A.Grease nipple B.Grease nipple

MAINTENANCE
5.12.2 Sliding blocks of telescopic beam riser, lubricate
There is no fixed grease nipple at sliding

blocks of telescopic beam riser. Lubricate the
sliding block and its working track every 500
hours.
When lubricating, check the wear condition of

the nylon sliding block. Replace it before the
twistlock riser rubs against the sliding block
seat of the telescopic beam riser.
Fig 5-195
5.12.3 Sliding block between the basic beam and telescopic beam, lubricate
There is a total of totally 16 lubricating points.

Lubricate the sliding block and its working
track every 500 hours.

sliding block seat of cross beam rubs against
the telescopic beam.
Fig 5-196

MAINTENANCE
5.12.4 Sideshift cylinder bearing, lubricate
There are two grease nipples in the joint bear-

ing of every oil cylinder, with 4 lubricating
points in common. Add lubricant to the grease
nipple every 500 hours.
Fig 5-197
5.12.5 Top and bottom sideshift sliding blocks, lubricate
There is no fixed grease nipple. Lubricate the

sliding block and its working track (C) every
500 hours.

main beam assembly rubs against the sliding
block plate and the guide plate of main beam
rubs against the baffler of sliding block.
5
C
Fig 5-198
C. Working track

MAINTENANCE
5.12.6 Sliding block, check
Check the wear condition of nylon sliding

block and lubricate its working track. If the
thickness of sliding block is about 18 mm, re-
place it with a new one immediately.
• When the telescopic beam is extended, dis-

mount the sliding block mounting to replace
the sliding blocks on basic beam and sliding
bracket without moving the beam.
• When replacing the sliding block on riser,
be sure to remove the twistlock first. Fig 5-199 Thickness
5.12.7 Twistlock, check
The twistlock is a device easy that is exposed

to damage. Be sure to inspect it periodically
and lubricate it once every month. When there
is wear or damage of the twistlock, lubricate
or replace it.
When the twistlock is excessively worn, that

is, the size of cross section is smaller than 25
mm, replace it. If the worn part is beyond the
range of shaded area , replace the twistlock A
immediately.
Generally the twistlock should be replaced

after it has operated for over 5000 working Fig 5-200
hours. A. Size
5.13 Air Conditioning System

5.13.1 General recommendations
WARNING
Risk of personal injury!
Electric fans could cause injury to hands.
• Avoid placing hands near the cooling fans when the engine is running.
Authorization is required to perform repairs on the climate control unit.

MAINTENANCE
• If there is a rupture in the cooling coils or a leakage on the attachment – immediately switch off
the unit.
• It is dangerous to allow refrigerant to come in contact with skin or eyes.
• Do not release refrigerant in a closed area, the gas can cause asphyxiation in, for example, pits.
• Do not weld on or in the vicinity of a closed cooling system.
• Drain the refrigerant during repairing the air conditioning.
• Work may only be performed on the refrigerant circuit by an accredited company.
5.13.2 Air conditioning, check
NOTICE
Risk of function fault!
Failure to follow this could cause the air conditioning function fault.
• Check the pressure in the refrigerant system.


MAINTENANCE
Please check the air conditioning system during continuous operation every week from early
spring to late autumn as well as during long periods of high humidity in winter.
In winter, the compressor should be run for a few minutes every week so that the rubber hoses,
couplings, gaskets and axle seals are well lubricated.
1. Check that the condenser is not clogged–clean condenser flanges with compressed air as
needed.
2. Check that the compressor turns on and off without error.
3. Check that the drain for the cooling element’s condensation water is not clogged.
4. Check that there is no leakage of refrigerant. Leaking often causes oil and gas to form a dusty
and dirty stain.
5. Start the engine and turn on the cooling function set to max cooling. With EEC: Choose Cool
mode with temperature on minimum.
Let the engine run at least 1500 rpm. (At temperatures below approximately 0°C, the cooling func-
tion will not start due to low pressure in the system.)
6. Set the fan to intermediate speed.
7. After running for 10 mins, check that there are no bubbles visible in the receiver dryer’s sight
glass. (Bubbles should occur only when the compressor starts and stops.)
8. Place a thermometer at the exhaust nozzle nearest the evaporator. After 5 mins - 10 mins, the
temperature should be under 10°C. (Deviations in the measurement result can occur if the per-
formance test is conducted when the ambient temperature is under approximately 18°C.) If bub-
bles occur, subsequent filling should be done by an expert.

MAINTENANCE
5.13.3 Refrigerant quantity, check


MAINTENANCE
Check the refrigerant condition from the ob-

servation window (1) on condenser refrigerant
container (2) when the engine is running at 1
high speed and air conditioner is refrigerating
at maximum.
3
Fig 5-205 Check Refrigerant Quantity
1. Observation 3. Sufficient injection

window
2. Condenser refrig- 4. Insufficient
erant container injection
2. Start the engine and let it run idle.
3. Switch on the air conditioning at max cooling and fan speed.
4. Check that a few bubbles are visible in the sight glass on the receiver dryer.
5. Bubbles in the glass means that the quantity of refrigerant is incorrect or that the condenser is
defective, clogged by e.g. dust, or that the ambient temperature is very high.
It is the easiest way to detect bubbles by examining the sight glass while the compressor is being
started. Visible bubbles should not normally be noticeable when the air conditioning system is in
operation. Bubbles can occur if the system contains the incorrect quantity of refrigerant, in connec-
tion with the compressor stopping and starting, and if the condenser is defective or at very high
ambient temperatures.
NOTE:
Reliable checking of refrigerant quantity through the sight glass can only be made when the ambi-
ent temperature is above approximately 15°C.
5.13.4 Refrigerant, fill
The type of refrigerants and freezing oil should be up to the requirements of air conditioning sys-
tem. Choose the refrigerant of genuine quality.

MAINTENANCE
Check the system for leakage.
1. Fill 150cc of cooling lubricants. Make sure that no water or dirty oil enters into the system.
2. Vacuum the system for no less than 40 minutes.
3. Fill the refrigerants according to the specified quantity of system. Too much or too little refriger-
ants will influence the cooling effect.
4. Check the condition of system and if it is leaking air.
Run the air conditioning system for no less than 30 minutes when filling refrigerants. During that
period, check the system pressure of pipeline, condenser fan, circulating fan to ensure that the air
conditioning system is properly installed for use.
5.13.5 Cleanness of heatexchanger plate in evaporator and condenser, check
Clean the evaporator and condenser at least

once every year by below means:
• Use high-pressure hydraulic gun and deter-

gent to clean the outer surface of condens-
er and evaporator core.
• Use high-pressure pneumatic gun to clean
the outer surface of condenser and evapo-
rator core.
Fig 5-206 Evaporator
NOTE:
High-pressure hydraulic gun and pneumatic gun pressure should be adjusted before cleaning. Do
not punch down the fin. As to those dirty cores, especially the evaporator core with dust strainer
mesh unwashed for a long time, use fin detergent special for air conditioner to wash after diluted
because the fins are covered with lots of dust and dirt.

MAINTENANCE
5.13.6 Leakage or lack of oil in condenser, check

Observe the leakage of condenser through the shaft seals. The running-in period of condenser is
250 hours, when the leakage is normal then. After 250 hours, leakage amount per hour should be
less than 0.05 cm3.
Observe the flatness of refrigerant oil in condenser through the observation window: check oil level
10-15 minutes after starting the condenser. The condenser can be installed at different places (tilt
place). Therefore, it is better to check oil level through two glass holes, or to catch sight of oil level
at least through one glass hole.

MAINTENANCE
5.13.7 Radiator, clean
NOTICE
Risk of damage!
Failure to follow this could cause damage for radiator.
• Do not flush the radiator with high-pressure water.
Follow below steps to clear away the impurities on the surface of radiator at regular intervals:
1. Remove the radiator cover.
2. Wipe away all the dirt and dust on the radiator fins.
3. Clean the radiator with special detergent.
4. Check the radiator fins and rubber sealing parts for damage. If necessary, replace it.
5.13.8 Maintenance table for air conditioning
Table 5–26 Maintenance Table for Air Conditioning
Maintenance
Item Condition Requirements
interval
Before / Make sure that 2/3 of air outlets are opened and
after the well ventilated when the air conditioning is running.
Air outlet Everyday
start of Check whether the air volume of two sides are
machine proximal.
Air return Before the Clean the air return grid filter screen (sponge
grid filter Every week start of block) with clean water. Clean in advance the ma-
screen machine chine running in areas surrounded by lots of dust.
Filter screen Before the Clean the filter screen of evaporator core with
of evapora- Every month start of clean water. Clean in advance the machine run-
tor core machine ning in areas surrounded by lots of dust.
Check whether the condensed water is drained
After the from the condenser water pipe one hour after the
Condenser
Everyday start of air conditioning has started. The volume of drained
water pipe
machine water is relatively high at the south or inshore
areas of high humidity or in the rainy season.
Check the tightness and abrasion condition of belt.
Before the
Transmis- Adjust or change it if necessary. Impose vertically
Every week start of
sion belt the pressure of 10 kg (approximately 98 N) on the
machine
belt between the two belt wheels with thumb.

MAINTENANCE
Table 5–26 Maintenance Table for Air Conditioning (continue)
Maintenance
Item Condition Requirements
interval
Check the oil quantity of compressor. The flatness
of compressor cooling oil can be seen from the ob-
servation window. Compressor oil should exceed
Before / 4/5 of the total oil quantity 30 minutes after the air
Oil quantity
Everyday or after the conditioning is stopped and be within the range of
of
every week start of 1/4 to 3/4 when the air conditioning is running.
compressor
machine If the oil is less than the above standard in the 250
hours of running-in period, change the felt and fill
cooling oil. If the oil is less than the above standard
after the running-in period, replace the shaft seal.
Before / Check the noise of clutch bearing before the elec-
Electromag- after the trification. Check after the electrification whether
Everyday
netic clutch start of the electromagnetic clutch can occlude and sepa-
machine rate quickly and whether it is slippy.
Before the
Check if the bolts on fixing bracket of compressor
Every year start of
are loose.
machine
If the compressor will be unused for a long time,
run it once for several minutes every week. Check
Compressor
After the if all parts are functioning normally. (If the com-
Every week start of pressor cannot be started due to low temperature,
machine you can warm up the machine by opening the
warm wind firstly and then run the air
conditioning.)
After the
Check if there is abnormal noises while the blower
Blower Every year start of
is running.
machine
After the Change it. (Note: If the test paper does not turn
Dryer Every year start of yellow and the system is refrigerating normally,
machine there is no need to change the dryer.
Plug-in Before the
Check whether the wires of compressor clutch and
parts, Every month start of
terminals of generator are loose.
terminals machine
Check whether the main fuse of power supply,
Before the
blower fuse, and inserting fuse are normal. Check
Fuse Every month start of
whether two ends of fuse and fixed bolts of seat
machine
are loose.

MAINTENANCE
5.14 Hydraulic System

5.14.1 Hydraulic oil level, check
NOTICE
Risk of damage!
Failure to follow this could result in leakage
and environmental damage.
• Do not overfill.
Fig 5-209 Hydraulic Oil Level
NOTE:
The oil level is checked with the spreader low-

ered and retracted.
2. Check the oil level in the hydraulic tank.

The oil level should be visible from the level
indicator glass. Top up with oil when needed.
Fig 5-210 Check the Hydraulic Oil Level
5.14.2 Air filter element, change
NOTICE
Risk of damage!
Dirt particles could cause damage to the machine.
• Ensure cleanliness around the filter and filling point when working on the hydraulic tank and
the brake oil tank.

MAINTENANCE
1. Turn off the engine and main electric power.
2. Remove the cover plate over the air filters

1
(1 & 2).
3. Lift up the filter unit and place it in a recep-

tacle. Drain the hydraulic oil.
4. Part the filter unit and remove the filter ele-

ment. Dispose the filter element as environ-
mentally hazardous waste. Note the
conditions of these parts.
Fig 5-211 Air Filter
5. Clean the filter housing’s parts.
1. Air filter
6. Fit the new filter and assemble the filter
unit.
2
7. Install the filter unit and the cover. Tighten

the screws crosswise.
8. Check the oil level with dipstick in the hy-

draulic oil tank. The oil level shall be at the top
of the level glass. Top up as needed.
Fig 5-212
2. Air filter
5.14.3 Hydraulic oil, change
NOTICE
Risk of damage!
Dirt particles could cause damage to the machine.
• Ensure cleanliness around the filter and filling point when working on the hydraulic tank.

MAINTENANCE
1. Turn off the engine and main electric power.

2 1
2. Remove the filler cap (1) and pump out the
hydraulic oil in a receptacle.
3. When most of the oil have been pumped

out, place a receptacle under the hydraulic oil
tank’s drain plug (4) and drain out the hydraul-
ic oil.
4. Fit the drain plug when the oil has been

drained completely.
Fig 5-213
5. Thoroughly clean the cover plate (2) and
surrounding area. 1. Filler cap 2. Cover plate
NOTICE
3 4
Risk of damage!
Failure to do this could result in leakage and
environmental damage.
• Do not overfill.
NOTE:
Make sure that the seal washer (3) is installed
as well.
6. If necessary, change the filter before filling

the tank with oil, see “Air filter element, Fig 5-214
3. Seal washer 4. Drain plug
7. Fill new hydraulic oil through the filler hole
on the filter’s cover. Then the oil can be fil-
tered and the hydraulic system can be pro-
tected from impurities.

MAINTENANCE
5.14.4 Oil return filter element, replace
WARNING
• Depressurize the hydraulic system before operation.
• Use protective gloves.
• Avoid skin to contact with the oil.
The oil return filter element is located on the

top of hydraulic oil tank. Blocked filter element
will influence the flow of oil, resulting in high
pressure at the oil outlet of pump and bursting
of oil pipe.
Steps to replace the filter element:
1. Dismantle the hydraulic oil return filter from

the hydraulic oil tank.
DGH-1703001-1
2. Loosen the fixed screws in the filter. Fig 5-215 Oil Return Filter
3. Take out the filter element.
4. Replace with a new filter element.

MAINTENANCE
5.14.5 Hydraulic oil tank, clean

This machine adopts anti-wear hydraulic oil. Be sure to clean the oil tank every half year.
The steps to clean the oil tank are as follows:
1. Remove the oil drain plug at the bottom of hydraulic oil tank. Drain out the hydraulic oil in the
tank and pipeline.
2. Remove the cover of cleaning hole.
3. Clean the oil tank with cleanout fluid (diesel, etc.) .
4. After the tank is cleaned, install the cleaning hole cover.
5. Open the air filter cover on the tank. Fill filterd hydraulic oil into the tank until the oil reaches the
“H” marking as shown on dipstick.

MAINTENANCE
5.14.6 Accumulator
5.14.6.1 Precaution
WARNING
Failure to follow this could cause serious personal injuries or even death.
• Hydraulic oil-way remains pressurized. Do not stand in oil spraying direction when dismantling
the hydraulic devices. Besides, loosen the screws slowly.
• Do not dismantle the accumulator.
• Keep the accumulator away from fire.
• Do not drill holes on or weld on the accumulator.
• Do not crash or roll the accumulator. Avoid any shock of accumulator.
• Drain the air before dealing with the accumulator. Please contact SANY to conduct this
operation.

MAINTENANCE
5.14.6.2 Brake system accumulator, check
The accumulator is filled with nitrogen. Im-

proper operations will lead to explosion caus- A
ing machine damage and personal injuries.
Follow below items when dealing with P
accumulators: D
1. Turn the ignition key to position D to start

the engine, and let it run until the accumulator
is fully pressurized.
2. Turn the ignition key to position A to stop

the engine. Step on the brake pedal (3) to its
bottom and hold it there for a short interval,
then repeat this operation several times. D. Start the engine A. Stop the engine
3. Brake at least 5 times before the warning

light is on.
4. Start the engine to pressurize the accumu-

lator, and then repeat step 2 several times.
Fig 5-219 Brake Pedal
3. Brake pedal
NOTE:
If the brake cannot function normally for 5 times before the alarm light turns on, it means that there
is a failure of the accumulator. Find out the cause and eliminate the failure as soon as possible.
The accumulator should be charged again.

MAINTENANCE
5.14.6.3 Accumulator, charge

The accumulator has already been charged with nitrogen gas before the installation.
NOTE:
• As the precharging pressure changes along with the temperature, recheck the accumulator
pressure approximately 2 minutes after charging. Correct the possible deviation of pressure.
• Tighten the accumulator pressure tightening screw to 25 N·m, and close the nitrogen exhaust
valve. Open the bleed valve of charging device to discharge the gas. Remove the charging de-
vice, and check the tightening valve for tightness with, for example, soap liquid. Repair it if air
leakage occurs.
• Seal the tightening screw with sealing lacquer. The pressurized accumulator is now ready to be
installed.

MAINTENANCE
Steps to charge the accumulator:
1. Measure the hydraulic accumulator before

charging to confirm that there is no pressure
in the system.
2. Precharge the accumulator with a special

charging device and check its pressure.
3. Remove the cap and clear away the sealing

lacquer around.
4. Clean the sealing surface and external Fig 5-222 Accumulator

thread at the accumulator opening.
5. Loosen the tightening screw just a little with

a hexagon spanner.
6. Connect the charging device to accumula-

tor and the hose to a nitrogen gas bottle.
7. Make sure that the O–ring is properly posi-

tioned between the charging device and accu-
mulator sealing surface.
8. Open the accumulator pressure tightening

screw with a square spanner and auxiliary
tools of charging device until it is just enough
to see the readings on pressure instrument.
NOTE:
If the precharging pressure is too high, please open the bleed valve of charging device to reduce
the pressure. Note that the bleed valve must be closed to check the correct reading.

MAINTENANCE
5.14.7 Hydraulic oil circuit, check

By observing and touching, check for loose

bolts or oil leaks on installation position of hy-
draulic oil circuit. If yes, contact SANY author-
ized distributors to replace the parts.
TY-1407026-1
Fig 5-225 Hydraulic Oil Hose

MAINTENANCE
5.14.8 Brake oil filter, change
NOTE:
The filter protects the brake system from impurities. It is very important that no impurities enter the
brake system when changing the filter.
DGH-1703002-1
Fig 5-226 Brake Oil Filter
2. Depressurize the hydraulic and brake system.
NOTE:
Leave the valves open when changing.
3. Remove the drain plug on the underside of the filter. Let the oil drain. Wait a while as the oil
drains slowly.
4. Remove the filter housing.
NOTE:
The filter housing is heavy. Loosen it carefully.
5. Remove the filter insert.
NOTE:
Note the position of O-rings.
6. Clean the filter housing.
7. Fit the O-rings on the filter cartridge and filter housing. Lubricate the O-rings with hydraulic oil.
8. Fit the new filter insert to the filter bracket.
9. Fit the filter housing and the drain plug.

MAINTENANCE
10. Close the valves that were opened to release the pressure in the hydraulic system.
11. Start the engine and check that the filter housing does not leak.
5.15 Electrical System

5.15.1 General information of electrical system
WARNING
Failure to follow the instruction could result in injury or possibly death.
• The blowing of a fuse always indicates a fault in the electric system. Eliminate the fault prior to
fitting a new fuse.
The nominal voltage of electrical system is 24 V DC.
The whole electrical system adopts only one type of conductor, while the electrical frame acts as
the other conductor. For the convenience of detecting failures, all wires are numbered according to
the markings specified in the circuit diagrams.
SAFETY
The insulation material outside of the conductor is oil resistant. However, please avoid the contact
of lead with oils or other solvent fluids. Make sure that the insulation layer of the lead close to the
engine and other hot surfaces is not damaged. If necessary, replace the lead.

MAINTENANCE
5.15.2 Battery
5.15.2.1 Precautions for battery
Fig 5-227 Precautions for Battery
WARNING
Failure to follow this could result in fire and explosion, which could cause serious injuries or possi-
bly death.
• Avoid contact with flames or sparks.
• Do not confuse the positive terminal with the negative one.
• Battery electrolyte contains corrosive sulphuric acid. Avoid contact with skin, eyes, and clothes
when moving the batteries.
• Use gloves and protective glasses.
• If electrolyte splashes on bare skin, wash with soap and a lot of water immediately. If electro-
lyte has gone into eyes, rinse with water and contact a doctor immediately.
• Prevent the electrolyte level from descending to expose the pole group.
1. Battery should be charged under below circumstances:
• If the battery on machine will not be used for a long time (more than half month), you should well
store the battery after dismantling and charging it. Besides, recharge the battery every two
months, or remove the lead of cathode to prevent the battery from over-discharging electricity.
• If the battery being used alarms for low voltage, charge it.
• When the machine is parked for more than five days, fully charge the battery before using it if
the machine is hard to start and the light is gloomy.
2. Keep the surface of battery clean and dry.
3. Clean the exhaust bolt with distilled water frequently. Keep it well ventilated.

MAINTENANCE
4. When the engine is not functioning, do not use the electrical equipment of large power such as
lights, air conditioner to prevent the battery from over-discharging electricity.
5. Make sure to turn off the main power immediately after parking the machine. This could prevent
the battery from over-discharging electricity and thus the poles from acidation.
6. It is hard to prevent natural creepage caused by machine load. If the machine is to be stored for
over 10 days, be sure to remove the cable connected to negative terminal to avoid serious dis-
charge of battery.
7. The start time of machine is 3-5 seconds. The interval between two starts should be no less than
15 seconds.
8. Improper disposal of battery can result in environmental pollution. It is suggested to handle the
used batteries to Recycling Institute.
5.15.2.2 Battery, clean
Keep the battery clean and dry. Dirt and oxi-

dated materials on battery and battery con-
nector may cause electrical leakage,
decreased voltage and discharge, especially
in the wet weather.
Use copper wire brush to clean the oxidated

materials off battery connector. Tighten the
cable connector and lubricate with protective
grease or vaseline.
Fig 5-228 Clean the Battery
5.15.2.3 Battery, check
CAUTION
Risk of injury!
Battery electrolyte is very caustic which could cause injury.
• If electrolyte comes into contact with clothing or skin, flush the areas immediately with water.
• In case of eye contact, rinse with plenty of water and see a doctor immediately.
The battery is fitted in the battery compartment on the left side of machine.
• Check the battery for cracks in the casings, and leaked electrolyte.
• Remove any corrosion on battery terminals and check the connections for tightness.

MAINTENANCE
• Tighten up the terminals and coat with non-acidic grease.
5.15.2.4 Battery, detect
Due to improper usage or maintenance, the battery may be unable to be started normally. Detect
the battery as follows.
1. Common detect equipment

• Multimeter
• Electric conductometer
• Gravimeter
2. Detection measures
Estimate the service condition of battery through magic eye or with the multimeter.
Through magic eye:
• Green magic eye signifies the normal battery.

• Black magic eye signifies lack of voltage. Charge the battery immediately.
• White magic eye signifies lack of electrolyte . Change the battery immediately.
With the multimeter:
• If the battery voltage is higher than 12.5 V, the battery is normal.

• If the battery voltage is between 11.5 V and 12.5 V, the battery lacks of voltage. Charge the bat-
tery and check its voltage again.
• If the battery voltage is lower than 11.5 V, the battery discharges too much or there is malfunc-
tion of this battery. Charge the battery and check its voltage again.
5.15.2.5 Battery, charge
DANGER
Risk of death or serious injury!

The battery will release hydrogen when charging. Mixing hydrogen and air will generate explosive
gas, which will cause severe explosion resulting in death or serous injury.
• Keep ventilated.
Principles of charging common batteries:
1. The current and time for charging the battery can be referred to below table:
Table 5–27 Battery Charging Current & Time
Model Charging the new battery

MAINTENANCE
Table 5–27 Battery Charging Current & Time (continue)
Current (A) Time (h)

6-QA-180 18 6-10
Charging the battery daily
Model
Current (A) Time (h)
6-QA-180 18 according to the battery status
NOTE:
The accurate charging time can vary a lot according to the battery status. (The voltage should be
above 12.56 V and the specific density of electrolyte should be above 1.28+0.05 g/cm3.)
2. Charge the battery in a well ventilated place with the temperature of 10°C - 30°C. If the tempera-
ture of electrolyte exceeds 45°C, reduce the current value by half firstly and then recharge it until
the electricity is full.
3. The anode of battery should be connected with that of DC charging equipment, and the same
rule applies to the cathode. The connections should be firm and well contacted. Do not connect
the anode with the cathode, or the battery would be damaged.
4. If the battery is fully charged, the following phenomena would appear:

• The voltage of anode and cathode exceeds 12.56 V (as to the measurement of battery detection
equipment), and it would not change obviously in three hours.
• The density of electrolyte is above 1.275 g/cm3 (25°C) and that of each cell should be the same.
The density would not change obviously in three hours.
• The bubble is closely and well distributed in battery.
NOTE:
Only when all the above three phenomena appear can reckon that the battery is fully charged.
Principles of charging maintenance-free batteries:
Precautions of charging batteries:

• Detect the battery before charging (For detailed information, see chapter “Battery, detect”). Only
if the battery needs to be charged can the charging be started.
• Do not charge the batteries of broken cover, with white magic eye or whose electrolyte is frozen.
• Always charge the battery in the ventilated area.
• If the battery temperature exceed 50° C during the charging procedures, reduce the charging
voltage properly or stop the charging. If acid fluid sprays out from the exhaust hole or the magic
eye is white, stop the charging immediately and discard the battery as useless.
Charging procedures:

MAINTENANCE
1. Select a proper charging equipment.
2. Connect the terminals of battery when the charging equipment is turned off.
3. Connect the plus cable (normally red) of generator with the positive terminal of battery. Connect
the minus cable (blue or black) of generator with the negative terminal of battery. Make sure they
are firmly connected.
4. Turn on the charging switch of generator. Slowly adjust the charging voltage or current from
small to large with the generator adjuster.
5. When the magic eye becomes green, the battery finishes charging.
6. After the charging, turn off the charging switch of generator first. Then disconnect the cables of
battery (never remove the charging cables during the charging).
5.15.2.6 Battery cables, check
WARNING
Failure to follow this could result in fire hazard or serious injury.
• Check that the battery cables are correctly clamped and free from damage.
• Repair or replace damaged clamps and check that no machine parts wear or chafe against bat-
tery cables. Replace damaged battery cables.

MAINTENANCE

The following battery cables must be checked for clamping, risk of chafing and cable damages.
Rectify incorrect clamping and risks of chafing. Replace battery cables that show signs of damage.
• Plus-cable between battery and battery disconnector

• Plus-cable between battery and start motor
• Plus-cable between star t motor and alternator
• Plus-cable between battery disconnector and main fuses
• Plus-cable between star t motor and preheating relay
• Plus-cable between preheating relay and preheating coil
• Ground cable between battery and frame
• Ground cable between engine and frame

MAINTENANCE
5.15.2.7 Scheduled maintenance of battery
Table 5–28 Scheduled Maintenance of Battery
Items Standards Schedule

Tighten the positive and negative binding post of bat-
Check if the binding
tery at regular intervals to avoid loosening. Smear per week
post is loose
adequate vaseline to avoid corrosion.
Check if the fastening Check if the screws at two ends of the iron plate fix-
per 15 days
iron plate is loose ing the battery are loose.
Clean the dirt away from the battery surface. Use
Check if the battery
distilled water to clean the exhaust bolt. Keep the per 15 days
surface is clean
battery ventilated.
Add electrolyte to meet the max. marking. Fill elec-
Check the electrolyte per week
trolyte when it is below the min. marking.
Stop the machine immediately when the battery
Check the voltage everyday
alarms for difficult start or low voltage. And charge it.
Maintenance for long- Turn off the main power if the battery is unused for
per month
time unused over half month. Charge the battery every month.
Deposit the battery alone. Keep ventilated and avoid
Check the battery
sunshine. Charge immediately as soon as the open- per 60 days
storage
ing voltage is less than 12.55 V.
5.15.3 Fuses, change
WARNING
Risk of damage or serious personal injury!
Failure to follow this could result in cable damage and fire in cable harnesses.
• Use fuses with the correct ampere rating.
1. Turn off the main power supply (battery disconnector).
2. Remove the cover from the fuse holder.
3. Check if the fuse is intact, and change it if needed.

MAINTENANCE
5.15.4 All working lights and indicators, check

Check whether working lights can be opened

normally.
Check if there is dirt or damage.
If the lights do not illuminate, bulbs may burn

out or short circuit occurs. Please contact
SANY authorized distributor to repair.
1. Turn the ignition switch to position I.
2. Turn on working lights to check whether

they illuminate normally.
Fig 5-233 Working Light

MAINTENANCE
5.15.5 Wiper, adjust

2. Adjust the angle of wiper blade by hand to

vary its covering range.
Fig 5-236 Fixed Screw of Wiper
1.Fixed screw

MAINTENANCE
3. If there is dust on the wiper blade, lift the blade up and clean it, then place it back to its original
position so as to reduce the wiping resistance.
4. Adjust the tightness of fixed screws (1) to make the motor run the wiper blade easily.
5. If there is damage on the wiper blade, loosen the screw, dismantle the old wiper blade from the
arm, and replace it with a new blade.
5.15.6 Wiper, replace

The wiper arm is fixed on the motor axle with a taper spline. When installing the wiper, tighten the
screw enough to make the spline squeezed into the connector as a supporting frame.
Wiper, dismantling
1. Loosen the screw, and knock it.
2. Swing the wiper arm with care to take it down.

MAINTENANCE
Wiper, installing
1. Make sure that no soft materials on the wiper connector are dropped onto the spline of motor
axle. If yes, clean the spline to make it fully squeezed into the connector of wiper arm.
2. Install the wiper arm onto motor axle, and tighten the screw with a torque of 16-20 N·m.
3. When tightening, fix the wiper arm to make it bear the torque pressure. Do not let the torque
transfer to the motor, or it would be damaged.
5.16 Maintenance Record List

Machine
Model
Serial No.
Table 5–29
Finished Maintenance
Working Working Mainte-
Strategies Signature
hours hours nance Date
50
250
500
750
1000
1250
1500
1750
2000
2250
2500
2750
3000
3250
3500
3750
4000
4250
4500
4750

MAINTENANCE
Finished Maintenance
Working Working Mainte-
Strategies Signature
hours hours nance Date
5000
5250
5500
5750
6000
6250
6500
6750
7000
7250
7500
7750
8000
8250
8500
8750
9000
9250
9500
9750
10000

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.......................................................................................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 steering system .................................................................................6-8
6.7 Troubleshooting the mast system.......................................................................................6-9
6.8 Troubleshooting the spreader system................................................................................6-9
6.9 Troubleshooting the air conditioning ..................................................................................6-9
6.10 Troubleshooting the hydraulic system .......................................................................... 6-10

TROUBLESHOOTING

TROUBLESHOOTING
6.TROUBLESHOOTING
6.1 Precautions
If two or more personnel are engaged in the repair or maintenance meanwhile, they should come
to an agreement about the operation procedures before the work. Prior to the repair or mainte-
nance, they should firstly notice other personnel involved in it.
Troubleshooting is aimed to find out the causes of failures and repair the machine to avoid further
malfunction. The key to detect the failures is to understand the structure and functions of machine.
Asking to the operators for knowing the possible reasons of failures is a shortcut for
troubleshooting.
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. Before checking, you should consult relevant personnel (the driver) for all the failure details.
• The current operation condition of the machine.
• When the failure occurs and how the machine is working at that time.
• Whether the failure occurs for the first time or becomes worse recently..
• Whether any other failures occur 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 re-
cord for any irregular or improper operation or maintenance.
• Check if any part of the machine is abnormal such as: the lacking or leaking of oil and water,
loosening pipe, wire or circuit. abnormal crack, etc.
• In addition, check the electrical system such as battery voltage. Check whether power wire con-
necting end is loose or burnt. Use multi-meter to check whether fuse is burnt or not.
4. Operate machine in person (trial run)

• After making sure that there is no failure in the above third item, start the machine according to
standard operating methods to inspect and confirm the failure cause. 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

TROUBLESHOOTING
NOTE:
It should be noticed that displayed error code may not indicate the current machine failure due
to those temporary electrical failures stored in the controller. Therefore, “repeated trial” is re-
quired to erase the error codes accumulated in controller memory and confirm whether the error
code is displayed after “repeated trial”. 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 5-38 and
“Air filter, replace ” on page 5-39.
Check if the battery lack of voltage.
Insufficient starting voltage
See “Battery, detect” on page 5-163.
Engine stops
No fuel Fill the tank with fuel.
unexpectedly
See “Coolant level, check and top
Insufficient coolant in water tank
up” on page 5-66.
Engine overheat-
ing or running hot See “Drive belt, check and change
The drive belt is loose (engine option VOLVO)” on page 5-
31
Refill the lubrication oil. See “Oil
The oil level is too low level, check and top up” on page 5-
Lubrication oil 43
pressure is too Replace the filter.
The oil filter is blocked
low See “Oil filter, change” on page 5-47
Change the engine. See “Engine oil,
The engine oil is too thin
change” on page 5-45
The power of en- Check if the air intake pipe is
gine is not The air intake pipe is damaged blocked. See “Turbocharger and
sufficient blast pipe, check” on page 5-79.

TROUBLESHOOTING

Change the pre-filter and fuel filter.
See “Fuel filter, replace (engine
option VOLVO)” on page 5-52, “Fuel
The pre-filter and pre-filter, change (engine option
fuel filter are The filter is too dirty VOLVO)” on page 5-54, “Fuel filter,
blocked change (engine option CUMMINS)”
on page 5-57 and “Fuel pre-filter,
change (engine option CUMMINS)”
on page 5-58.
Replace belt. See “Drive belt, check
and change (engine option VOLVO)”
The engine fan
The quality of belt itself on page 5-31 and “Drive belt,
belt is broken
change (engine option CUMMINS)”
on page 5-35.
6.4 Troubleshooting the transmission

6.4.1 Overview
When troubleshooting a transmission problem, remember that the transmission is only the central
unit of a group of related powertrain components. Proper operation of the transmission depends
on the condition and correct functioning of other components of the group. Therefore, to properly
diagnose a suspected problem in the transmission, it is necessary to consider the transmission flu-
id, 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.

TROUBLESHOOTING
6.4.2 Troubleshooting procedures
NOTICE
Excessive temperature (120° C/250° F maximum) could cause damage to the transmission
clutches, fluid, converter, and seals.
• Do not operate the converter at stall condition longer than 30 seconds at one time, shift to neu-
tral for 15 seconds and repeat the procedure until desired temperature is reached.
Step 1: Stall test
Use a stall test to identify 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 approximately 1/2 throttle and hold un-
til transmission (converter outlet) oil temperature reaches the operating range.
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 check:
Prior to checking any part of the system for hydraulic function (pressure testing), make the follow-
ing 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 connect-
ing points.
• The controls are actuated electrically. Check the wiring and electrical components.

TROUBLESHOOTING
• Be sure that all components of the cooling system are in good condition and operating correctly.
The radiator must be clean to maintain the proper cooling and operating temperatures for the en-
gine 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 cor-
rect idle and max. noload governed speed specifications.
Step 4: Hydraulic check
Also, 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 at full 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 Examine the oil level.
Slipping of clutch Refer to “Transmission oil level,
Not sufficient oil check” on page 5-90
Examine the level of lubrication oil.
High oil
Low or high oil level Refer to “Transmission oil level,
temperature
check” on page 5-90
Inadequate oil
Examine the oil level.
pressure shown
Low oil level Refer to “Transmission oil level,
by oil pressure
check” on page 5-90
instrument
Excessive vibra- Tighten the mounting bolts.
tion and noise in The mounting bolts are loose Refer to “Attaching bolts of propeller
cab shaft, check” on page 5-80

TROUBLESHOOTING
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 Refer to“Oil leakage of drive axle
and brake components, check” on
The force of serv- Braking oil circuit has air
page 5-98.
ice brake is not
Examine the brake components.
sufficient
Refer to“Oil leakage of drive axle
The brake components are worn out
and brake components, check” on
page 5-98.
No service brake
Examine and adjust the brake pedal.
or the service
Failure of brake valve pedal Refer to“Brake pedal, check and
brake functions
adjust” on page 5-106.
bad
• Examine the parking brake func-

tion. Refer to“Brake function,
No parking brake
or the parking
brake functions
Failure of parking brake • Examine if the parking brake pads
bad broken, replace them if necessary.
Refer to“Parking brake pads,
6.6 Troubleshooting the steering system
Table 6–4

Examine the steering pressure. Re-
Not sufficient oil supply fer to“Steering pressure, check” on
page 5-115.
Not effective or Lubricate the steering axle. Refer
not possible to Not sufficient lubrication to“Steering axle, lubricate” on page
steer 5-111.
Examine the steering axle compo-
Failure of the steering axle
nents. Refer to“Steering axle
components
components, check” on page 5-112.

TROUBLESHOOTING
6.7 Troubleshooting the mast system
Table 6–5
Fault Causes of faults Methods

Adjust or replace the sliding block.
The mast sways
Sliding block loose Refer to“Sliding blocks, check” on
too much
page 5-133.
Replace the fuse.
No operation of Power supply fuse of mast control
Refer to“Fuses, change” on page 5-
the mast circuit is blown
167.
6.8 Troubleshooting the spreader system
Table 6–6

Lubricate the sliding blocks. Refer
to“Sliding blocks of telescopic beam
riser, lubricate” on page 5-138,
Not sufficient lubrication of the slid- “Sliding block between the basic
ing blocks beam and telescopic beam,
The spreader is lubricate” on page 5-138 and “Top
not easy to move and bottom sideshift sliding blocks,
lubricate” on page 5-139.
Lubricate the side-shift cylinder
Not sufficient lubrication of the side-
bearing. Refer to“Sideshift cylinder
shift cylinder bearing
bearing, lubricate” on page 5-139.
Replace the fuse.
No movement of The power supply fuse of spreader
Refer to“Fuses, change” on page 5-
the spreader control device is blown
167.
6.9 Troubleshooting the air conditioning
Table 6–7
Failure Symptom Possible Causes Steps

Cab temperature is lower than the set
Set a lower temperature.
temperature
No refrigeration
Set the refrigeration mode
effect
High temperature changes during the day after the temperature be-
comes high.

TROUBLESHOOTING

Examine if the fuse in elec-
tric cabinet blows. If yes, re-
place the fuse.
Fuse of condenser burns out Refer to “Fuses, change” on
page 5-167.
Examine if the fuse
attaches.
Stop the refrigeration mode.
Examine the condenser for
Refrigerant is leaking leakage.
Refer to “Leakage or lack of
oil in condenser, check” on
page 5-146.
Close all the windows and
Bad sealing of cab
doors.
Bad refrigeration
Fill in refrigerant.
effect
Refrigerant is not sufficient Refer to “Refrigerant, fill” on
page 5-144.
6.10 Troubleshooting the hydraulic system
Table 6–8

High oil Low flow of cooler Clean the cooler.
temperature Outer radiator fins are too dirty Clean the outer radiator fins.

TROUBLESHOOTING

Hydraulic oil of bad quality Replace the hydraulic oil.
Hydraulic oil of bad viscosity page 5-150.
Replace the filter core periodically.
The constant entrance of dust, sand
Refer to “Oil return filter element,
and other debris
replace” on page 5-152.
Hydraulic oil is
polluted and High temperature, oxidation
metamorphism Replace the hydraulic oil.
deteriorated
Entry of water and air, as a result of page 5-150.
cavitation, erosion, etc.
Clean it or replace it.
Clogged filter Refer to “Air filter element, change”
on page 5-149.
The hydraulic or
Replace the fuse.
brake cooling sys-
The fuse of cooling system blows Refer to “Fuses, change” on page 5-
tem does not cool
167.
automatically

TROUBLESHOOTING

SPECIFICATIONS
SPECIFICATIONS
7 SPECIFICATIONS ............................................................................................................7-1
7.1 Technical Specification.........................................................................................................7-3
7.1.1 General .........................................................................................................................7-3
7.1.2 Basic parameters ........................................................................................................7-4
7.1.3 System configuration ..................................................................................................7-5
7.1.3.1 Engine configuration............................................................................................7-5
7.1.3.2 Gearbox configuration.........................................................................................7-6
7.1.3.3 Drvie axle configuration ......................................................................................7-7
7.1.3.4 Spreader configuration........................................................................................7-7
7.2 Unit Conversion.....................................................................................................................7-7
7.2.1 Abbreviation Explanation ...........................................................................................7-7
7.2.2 Conversion table, SI units ..........................................................................................7-8
7.2.3 Conversion table, length ............................................................................................7-9
7.2.4 Conversion table, area ............................................................................................ 7-10
7.2.5 Conversion table, volume ....................................................................................... 7-10
7.2.6 Conversion table, weight......................................................................................... 7-10
7.2.7 Conversion table, pressure......................................................................................7-11
7.2.8 Conversion table, temperature................................................................................7-11

SPECIFICATIONS

SPECIFICATIONS
7.SPECIFICATIONS
7.1 Technical Specification

7.1.1 General
Fig 7-1 Technical Specification

SPECIFICATIONS
7.1.2 Basic parameters
Table 7–1 Basic Parameters
SDCY90K8H1C/ SDCY90K7H1C/
Per- SDCY90K8H2 / SDCY90K7H2 / SDCY90K6H1C
missi- SDCY90K8H3 / SDCY90K7H3 / / SDCY90K6H2
Item Unit
ble SDCY90K8H4 / SDCY90K7H4 / / SDCY90K6H3
error SDCY90K8H8A / SDCY90K7H8A / / SDCY90K6H4
SDCY90K8H85A SDCY90K7H85A
A Overall length ±1% mm 6916 6900 6916
Overall width
B (without ±1% mm 4200 4100 4200
spreader)
Overall width
C ±1% mm 5852-11985 6038-12170 5852~11985
(with spreader)
Overall height
D ±1% mm 12300 10873 9517
(not lifted)
Overall height
E ±1% mm 2250 2250 2250
of spreader
Overall height
F ±1% mm 4550±15 4550 4550±15
(max. lifted)
Machine weight ±3% kg 41000 39800 38500
Max. lifting weight - kg 9000 9000 9000
lay- 8 layers (8′6″) or 7 7 layers (8′6″) or 6 layers (8′6″) or
Max. layer -
er layers (9′6″) 6 layers (9′6″) 5 layers (9′6″)
0%~
Max. lifting height mm 21250 18750 16050
1.5%
Front suspension
±1% mm 1167 1140 1167
distance
Max. lifting speed mm/
±10% 600/450 600/550 600/450
(unloaded/loaded) s
Max. lowering
mm/
speed (unloaded/ ±10% 600/600 600/600 600/600
s
loaded)
Max. traveling
km/
speed (unloaded/ ±10% 27/22 27/22 27/22
h
loaded)

SPECIFICATIONS
Table 7–1 Basic Parameters (continue)
SDCY90K8H1C/ SDCY90K7H1C/
Per- SDCY90K8H2 / SDCY90K7H2 / SDCY90K6H1C
missi- SDCY90K8H3 / SDCY90K7H3 / / SDCY90K6H2
Item Unit
ble SDCY90K8H4 / SDCY90K7H4 / / SDCY90K6H3
error SDCY90K8H8A / SDCY90K7H8A / / SDCY90K6H4
SDCY90K8H85A SDCY90K7H85A
Hill climbing ca-
pacity (unloaded/ - % 35/25 35/25 35/25
loaded)
Tilting angle of
mast (forward/ ±0.5/ ±1 ° 2/4 2/4 2/4
backward)
Min. grounding 0%~
mm 323 323 288
clearance +5%
Min. turning radius ±5% mm 6000 6000 6000
Overall
- ml/r 170 170 163
displacement
Max. working
±2% bar 240 240 240
pressure
Cab noise ≤ dB 70 72 70
7.1.3 System configuration
7.1.3.1 Engine configuration
Table 7–2 Engine configuration
SDCY90K8H1C / SDCY90K7H1C / SDCY90K6H1C / SDCY90K8H8A /

Model
SDCY90K8H85A / SDCY90K7H8A / SDCY90K7H85A
Model No. VOLVO TAD851VE
6 In-line Cylinders, 4 Strokes, Turbo Pressured, Centralized Air-air
Type
Cooling, Electric Control, etc.
Rated power 185 kW/2200 rpm
Max. torque 1160 N·m/1350 rpm
Exhaust gas standard EU Stage III
Model SDCY90K8H2 / SDCY90K7H2 / SDCY90K6H2
Model No. Cummins QSB6.7
Type

SPECIFICATIONS
Table 7–2 Engine configuration (continue)
Rated power 164 kw/2300 rpm

Model SDCY90K8H3 / SDCY90K7H3 / SDCY90K6H3
Model No. VOLVO TAD871VE
Type
Model SDCY90K8H4 / SDCY90K7H4 /SDCY90K6H4
Model No. Cummins QSB6.7 Tier4
Type
Exhaust gas standard EU Stage IV
7.1.3.2 Gearbox configuration
Table 7–3 Gearbox configuration
SDCY90K8H1C / SDCY90K7H1C / SDCY90K6H1C / SDCY90-

K8H8A / SDCY90K8H85A / SDCY90K7H8A / SDCY90K7H85A /
Machine model SDCY90K8H2 / SDCY90K7H2 / SDCY90K6H2 / SDCY90K8H3 /
SDCY90K7H3 / SDCY90K6H3 / SDCY90K8H4 / SDCY90K7H4
/SDCY90K6H4
Gearbox model No. DANA 13.7HR32300
Type Hydraulic torque conversion
Gear shifting way Auto/Manual
Gear position 3 Positions of Forward/Backward
Speed ratio 4.04-1.94-0.93

SPECIFICATIONS
7.1.3.3 Drvie axle configuration
Table 7–4 Drvie Axle Configurtion
SDCY90K8H1C / SDCY90K7H1C / SDCY90K6H1C /

SDCY90K8H8A / SDCY90K8H85A / SDCY90K7H8A /
SDCY90K7H85A / SDCY90K8H2 / SDCY90K7H2 /
Machine model
SDCY90K6H2 / SDCY90K8H3 / SDCY90K7H3 /
SDCY90K6H3 / SDCY90K8H4 / SDCY90K7H4 /
SDCY90K6H4
Drive axle model No. Kessler D81 PL488
Max. allowable dynamic axle load 420 kN (26 km/h)
Max. allowable static axle load 600 kN
7.1.3.4 Spreader configuration
Table 7–5 Spreader Configuration
Model Technical Parameters

Rotating angle +105°/-195 °
Side-shifting distance ±600 mm
ELME588
Max. load capacity 9000 kg
Applicable range 20′-40′ international standard containers
Rotating angle +105°/-195 °
SDJ90II / Side-shifting distance ±600 mm

SDJ90H Max. load capacity 9000 kg
Applicable range 20′-40′ international standard containers
7.2 Unit Conversion

7.2.1 Abbreviation Explanation
Table 7–6 Abbreviation Explanation
Name Abbreviation
Newton metre N·m
Kilo pound metre kp·m
Kilo pascal kPa
Mega pascal MPa

SPECIFICATIONS
Table 7–6 Abbreviation Explanation (continue)
Name Abbreviation
Kilowatt kW
Kilojoule kJ
British termel unit Btu
Calorie cal
Inch in
Feet ft
Yard yd
Mile mile
Centimeter cm
Metre m
Rotation per minute rpm
Kilometer km
7.2.2 Conversion table, SI units
Table 7–7 SI Units Conversion Table
Recalculation Recalculation
SI-unit Non-SI SI
factor factor
Torque
N·m x 10.2 = kg·cm x 0.8664 =lb·in
N·m x 0.74 =lbf·ft x 1.36 =N·m
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
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

SPECIFICATIONS
Table 7–7 SI Units Conversion Table (continue)
Recalculation Recalculation
SI-unit Non-SI SI
factor factor
W x 0.74 =ft·lb/s x 1.36 =W
Energy (J=N·m)
kJ x 0.948 =Btu x 1.055 =kJ
J x 0.239 =calorie x 4.19 =J
Speed and acceleration
m/s² x 3.28 =ft/s² x 0.305 =m/s²
m/s x 3.28 =ft/s x 0.305 =m/s
km/h x 0.62 =mph x 1.61 =km/h
Horsepower/torque
Bhp x 5252 rpm = TQ(lb·ft) TQ x rpm 5252 = bhp
Temperature
℃ =（°F -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
7.2.3 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 1000 1 39370.7 3280.8 1093.6 0.62137
in 2.54 0.0254 0.000025 1 0.083333 0.02777 0.000015
ft 30.48 0.3048 0.000304 12 1 0.3333 0.000189
yd 91.44 0.9144 0.000914 36 3 1 0.000568
mile 160930 1609.3 1.6093 63360 5280 1760 1
1 mm = 0.1 cm - 1mm = 0.001 mm

SPECIFICATIONS
7.2.4 Conversion table, area
Table 7–9 Area Conversion Table
Unit cm² m² km² a ft² yd² in²

cm² 1 0.0001 - 0.000001 0.001076 0.000012 0.155000
m² 10000 1 0.000001 0.001 10.764 1.1958 1550.000
km² - 10000000 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 1296.00
in² 6.4516 0.000645 - - 0.006943 0.000771 1
1 ha = 100a - 1 mile² = 259 ha = 2.59 km²
7.2.5 Conversion table, volume
Table 7–10
Unit cm³= cc m³ l in³ ft³ yd³

cm³ = ml 1 0.000001 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
1 gal (US) = 3785.41 cm³ = 231 in³ = 0.83267 gal (UK)
7.2.6 Conversion table, weight
Table 7–11 Weight Conversion Table
Unit g kg t oz lb
g 1 0.001 0.000001 0.03527 0.0022
kg 1000 1 0.001 35.273 2.20459
t 100000 1000 1 35273 2204.59
oz 28.3495 0.02835 0.000028 1 0.0625
lb 453.592 0.45359 0.000454 16 1
1 ton (metric) = 1.1023 ton (US) = 0.9842 ton (UK)

SPECIFICATIONS
7.2.7 Conversion table, pressure
Table 7–12 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 0.0102 0.01 1000 1 0.14504 20.886
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
kg/cm² = 735.56 Torr (mmHg) = 0.96784 atm
7.2.8 Conversion table, temperature
Table 7–13 Temperature Conversion Table
°F °C °F °C °F °C °F °C °F °C °F °C
-90 -67.78 -40 -40 10 -12.22 60 15.56 110 43.33 160 71.11
-80 -67.22 -30 -34.44 20 -6.67 70 21.11 120 48.89 170 76.67
-70 -56.67 -20 -28.89 30 -1.11 80 26.67 130 54.44 180 82.22
-60 -51.11 -10 -23.33 40 -4.44 90 32.22 140 60 190 87.78
-50 -45.56 0 -17.78 50 -10 100 37.78 150 65.56 200 93.33
C = 5(T°F-32)/9, T°F = (9*t°C+160)/5

SPECIFICATIONS

OPTIONAL PARTS
OPTIONAL PARTS
8 OPTIONAL PARTS ..........................................................................................................8-1

8.1 Fire Detection and Alarm System / Automatic Extinguishing Device ............................8-3
8.1.1 Control button ..............................................................................................................8-3
8.1.2 Fire detection and alarm system...............................................................................8-3
8.1.2.1 General..................................................................................................................8-3
8.1.2.2 Function description ............................................................................................8-3
8.1.2.3 Precautions...........................................................................................................8-5
8.1.2.4 Troubleshooting ...................................................................................................8-5
8.1.2.5 Maintenance and repair ......................................................................................8-6
8.1.3 Automatic fire extinguishing.......................................................................................8-7
8.1.3.1 Automatic fire extinguishing device...................................................................8-7
8.1.3.2 Precautions...........................................................................................................8-7
8.1.3.3 Technical parameters ..........................................................................................8-7
8.2 Loudspeaker and Controller ................................................................................................8-8
8.2.1 Loudspeaker and controller kit ..................................................................................8-8
8.2.2 Control panel................................................................................................................8-9
8.2.3 Operations....................................................................................................................8-9
8.2.4 Precautions ............................................................................................................... 8-10
8.3 Engine Idle Protection Function ....................................................................................... 8-10
8.4 Engine Preheating Protection Function .......................................................................... 8-10
8.5 Engine Hour Calculator ......................................................................................................8-11
8.6 Twistlock Calculator ............................................................................................................8-11
8.7 Reversing Radar Display .................................................................................................. 8-12
8.8 Operator Presence System .............................................................................................. 8-12
8.9 Radio.................................................................................................................................... 8-12
8.9.1 Radio general ........................................................................................................... 8-12
8.9.2 Radio panel ............................................................................................................... 8-13
8.9.3 Mute (Silence)........................................................................................................... 8-13
8.9.4 Sound......................................................................................................................... 8-14

OPTIONAL PARTS
8.9.5 Audio setting ............................................................................................................. 8-14

8.9.6 Radio.......................................................................................................................... 8-15
8.9.7 Radio troubleshooting ............................................................................................. 8-16
8.10 Automatic Lubrication...................................................................................................... 8-17
8.10.1 Automatic lubrication system ............................................................................... 8-17
8.10.2 Operation precautions........................................................................................... 8-17
8.10.3 Time setting ............................................................................................................ 8-18

OPTIONAL PARTS
8.OPTIONAL PARTS
8.1 Fire Detection and Alarm System / Automatic Extinguishing Device

8.1.1 Control button
With the fire detection and alarm switch on

the right operation panel pressed down, the
fire detection and alarm system will be
activated.
DG-1407120-1
Fig 8-1
8.1.2 Fire detection and alarm system
8.1.2.1 General
Fire detection and alarm system (FZZK/ W03)

(Hereinafter referred to as system) continu-
ously monitors (Engine compartment) ambi-
ent temperature real-time, recognizes and
analyzes signals from all areas of machine, as
well as realizes monitoring alarm and auto-
matic fire disposal function through the linear
heat / fire detection components by the cabin
detection host. The system also has online
automatic fault detection and alarm function,
high temperature / fire alarm function and au-
tomatic fire extinguishing function. Fig 8-2
8.1.2.2 Function description
Detection function:
When the system is installed, it will enter the inspection status after power on.

OPTIONAL PARTS
High temperature alarm and automatic fire extinguishing function:
When the cabin detection host detects that the temperature of cabin NTC (negative temperature
coefficient) detector reaches 110° C, the system would warn the operator of high temperature
through an alarm device. After the operator cools down the cabin and recovers the temperature,
the high temperature alarm would be automatically canceled as long as the host detects that the
temperature has dropped to below 110°C.
Fault detection function:
When there is short or open circuit to the connecting wires of cabin fire detection components, fire
extinguishing device and control system host, the system would perform automatic fault detection
and the detection alarm light will flash for 1 second every 12 seconds.
NOTE:
The failure of any one circuit does not affect its other functions.
Intelligent identification of fire signal and automatic fire extinguishing function:
When the cabin NTC fire detector detects that the ambient temperature is above 85° C, the rise
rate is greater than 30°C / min, or absolute temperature of fire disaster is higher than 130°C, the
system would intelligently reckon that a fire disaster is happening. Therefore it would firstly star t
the high temperature forewarning function as soon as the temperature reaches 110°C and then au-
tomatically start the fire extinguisher if the temperature continues to rise and reaches 130°C.
Fire extinguisher alarm function:
When the device begins spraying, the system would inform the operator through an external de-
vice that fire disaster is happening and the fire extinguisher is putting out the fire.
Manual fire extinguishing function:
The operator, who discovered the fire foremost, can manually start the fire extinguishing device by
himself.
NOTE:
Once the fire extinguisher is automatically star ted after fire disaster, make sure to disconnect the
power supply of this machine as well as replace the host and detector harness for preventing any
unknown damages.

OPTIONAL PARTS
8.1.2.3 Precautions
The following steps should be performed after the initial installation, repair and maintenance of this
product. Otherwise, the system may be unable to work normally.
1. Do not directly connect the host with the connector of fire extinguisher when testing after installa-
tion. Instead, connect a 12 V-24 V test lamp with the F + and F- driving lines of system host or use
a multimeter to measure the voltage at both ends.
2. If the light blinks in 1 minute, it indicates that the system is incorrectly installed. Eliminate the fail-
ure immediately. If the light does not blink in 1 minute, it indicates that the system is correctly in-
stalled and the host will function properly. Go on to the next step for checking the cabin detector.
3. Heat any one of the cabin NTC temperature detectors with a lighter or by other means to simu-
late the occurrence of fire disaster. If the 12 V-24 V test light turns on or the multimeter displays
12V-24V, it means that the host and detectors are working normally.
4. Disconnect the power supply, and then the host is recovered to original status. That is, the de-
vice is a qualified product which can be used normally.
5. After the installation and detection, connect the power supply of machine and install the fire ex-
tinguisher. The fire extinguishing and alarm system is ready for operation.
8.1.2.4 Troubleshooting
1. During the inspection, check whether there is short or open circuit of the cabin NTC temperature
detectors and fire extinguisher. If yes, eliminate the fault.
2. When one circuit of NTC temperature detectors is in malfunction, the system would report the
fault without influencing the operations and functions of the other two circuits.
3. If the fire extinguisher has several faulty circuits simultaneously, the system would not report the
fault as long as there is one normal circuit. When the fire extinguisher is in malfunction, it would be
unable to put out a fire although the host can be activated.
4. If the fault output L + driving line is constantly 12 V-24 V high level after the system is started, it
means that the host cannot function normally. Replace the host immediately.
5. Once the cabin catches fire and the host starts extinguishing the fire, the system cannot be auto-
matically recovered until the power is off.
6. After the fire disaster, please disconnect the power supply to replace the host and temperature
sensor. Strictly check and test the replaced harness and sensors to avoid potential hazards.

OPTIONAL PARTS
8.1.2.5 Maintenance and repair
1. The host and cabin NTC temperature detectors should be installed just before the debugging.
Store them properly before installation.
2. Before the maintenance or repair, disconnect the power supply of host to avoid wrong alarm link-
age. After the maintenance or repair, remember to connect the power supply timely to make the
host and temperature sensor work.
3. Never replace or modify the devices and structures which may affect the detection performance
during maintenance or repair. Do not install the devices closer than 20 cm to area where the tem-
perature will exceed 100 °C when the engine is working normally (such as exhaust pipes, engine
housing, etc.).
4. Frequently check if the surface of NTC temperature detectors are clean and wipe them regularly.
Otherwise, the sensitivity of NTC temperature detectors would be affected or even worse the de-
tectors may not alarm when the fire happens.
5. Never use non-prescribed and nonstandard 12 V-24 V power supply to avoid damage to the
host.
6. Never perform maintenance or repair when the host is powered.
7. Host and detectors should be installed firmly. The internal and external iron grounding should al-
so be firm.
8. Carry out a mock fire test every six months to test if the NTC temperature sensor is working
properly.
9. Pay attention to protect NTC temperature detectors and harness from collision and damage dur-
ing the maintenance. If necessary, replace it immediately.
10.When the host components are in malfunction, contact SANY to replace a new host compo-
nent. Personnel should not randomly disassemble the host and NTC temperature detectors to
avoid unnecessary losses.

OPTIONAL PARTS
8.1.3 Automatic fire extinguishing
8.1.3.1 Automatic fire extinguishing device
Automatic fire extinguishing device, specially

designed for inflammable parts of high tem-
perature, is of certain aseismatic capacity and
applies to harsh working environments. The 1 2 3 4 5
device consists of: dry powder extinguisher,
driving medium, extinguishing tank, constant
pressure release valve, multinozzle distribu-
tion pipe, trigger component (electric trigger
and thermal trigger to be chosen) etc. Be
equipped with early fire detection and alarm
system, it can warn the early fire in the pro- Fig 8-3 Fire Extinguishing Device
tected area, and automatically start extin-
1. Nozzle 4. Pipe connector
guishing fire in time.
2. Powder chamber 5. Hose
3. Dual driving chamber
8.1.3.2 Precautions
• Naked flame or electriferous operation is forbidden during the installation.

• Ensure that the nozzle of the fire extinguishing device is installed securely.
• The extinguisher with electric trigger device must apply the nominal operating voltage and
current.
• Check fire extinguishing device regularly. If this device has been damaged or started, make sure
to replace it.
• Keep the storage warehouse dry and well ventilated.
• Load and put the device gently to prevent collisions. Avoid exposure or rain.
8.1.3.3 Technical parameters
Table 8–1
Items FZBA0.4-C/GW FZBA1-C/GW

Fire extinguisher weight (g) 400 1000
Whole protection volume (m³) ≥4 ≥8
Electric or temperature Electric or temperature
Start-up mode
control control
Injection time (s) ≤5 ≤5
environmental temperature (°C) -40 - 90 -40 - 90

OPTIONAL PARTS
Items FZBA0.4-C/GW FZBA1-C/GW

Safe current (mA) ≤150 ≤150
Start-up current (mA) ≥600 ≥600
voltage (V) DC6V-24V DC6V-24V
Weight (g ) 1735 ± 5 4420 ± 5
Dimensions (mm) Ø60*300 Ø89*350
8.2 Loudspeaker and Controller

8.2.1 Loudspeaker and controller kit
Main functions and features:
• Speaking prior to alarm.

• Volume adjustable.
• Microphone & Loudspeaker available.
• Various tones to choose.
• Visible and audible alarm synchronous
(optional).
• Several kinds of combination mode for
choice.
• Good appearance, convenient operation. Fig 8-4 Loudspeaker

OPTIONAL PARTS
8.2.2 Control panel
The composition of control panel is shown in

the right figure.
1
2
4
5 6 7 8
Fig 8-5 Control Panel
1. Alarm indicator 5. Tone select

2. Power indicator 6. Alarm switch
3. Power switch 7. Volume (-)
4. Light switch 8. Volume (+)
8.2.3 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.

OPTIONAL PARTS
8.2.4 Precautions
• The control box of this product can only be installed indoors.

• Connect the wire correctly. Never make the wires short circuit.
• Check if the rated voltage of alarm is in accordance with that of power supply.
• Standardize the horn power.
• It is a 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.
8.3 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 8-6 Setting Menu
run idle before stopping. But the emergency
stop button is still effective even if the idle pro-
tection function is activated.
8.4 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.

OPTIONAL PARTS
8.5 Engine Hour Calculator

Engine hour calculator can display the running
hours of engine.
It is used to confirm the due time for regular

maintenance. All the maintenance time is
based on the working hours of engine.
TY-1407006-1
Fig 8-7 Engine Hour Calculator
8.6 Twistlock Calculator

Twistlock calculator can display the locking
times of spreader.
It is used to confirm the due time for regular

maintenance. All the maintenance time is
based on the locking times of spreader.
TY-1407007-1
Fig 8-8 Twistlock Calculator

OPTIONAL PARTS
8.7 Reversing Radar Display

When the machine is reversing, the reversing
radar would start automatically. Meanwhile,
the reversing radar display would show the
rear view at the back of machine for the con-
venience of reversing.
Fig 8-9 Reversing Radar Display
8.8 Operator Presence System

The operator presence system (OPS) feature has an electrical switch in the seat which senses the
presence of the operator. This allows the transmission in internal combustion engine trucks to be
engaged only when the operator is in the seat.
The operator can activate / deactivate this protection function and adjust the protection time
through the display menu. The OPS is defaulted to be activated and its protection time is defaulted
to be 1 minute when the machine leaves factory. The protection time can be adjusted in the range
of 0-60 minutes.
8.9 Radio
8.9.1 Radio general
This machine has equipped with an optional

radio. It is located at the left side of the
console.
Fig 8-10 Radio

OPTIONAL PARTS
8.9.2 Radio panel
8 7 13
TA DISC
SOUND LOUD
9 AT AST PRISAT
11
1 4 BAND
VOLUME
2 VOCAL ROCK CLASSIC 5 10
VOLUME JAZZ FLAT POP
3 TA AF AST
RDS
12
321 456 10
Fig 8-11 Radio Panel
1. Preset button 1 8. Power on/off

2. Preset button 2 9. Volume button
3. Preset button 3 10. Tuner mode
4. Preset button 4 11. FM/AM
5. Preset button 5 12. RDS on/off
6. Traffic tune 13. Display
7. Select sound / audio styles
8.9.3 Mute (Silence)
Short press button to mute or cancel the

mute (silence).
NOTE:
The silence period may be interrupted by

ALARM announcement or traffic announce-
ment messages (if TA is switched on).
Fig 8-12 Power Supply Button

OPTIONAL PARTS
8.9.4 Sound
Whether you listen to Jazz, Vocal, Pop, Clas-

sic or Rock music, this button is the perfect
choice for your setting.
Press to select BASS-Treb for your

own sound style, or adjust the settings with
the volume up/down buttons to select one of
the pre-define sound styles:
-BASS-TRE: Self settings

-FLAT: Original
-JAZZ: Jazz music
Fig 8-13 Sound Button
-VOCAL: Speech
-POP: Pop music
-CLASSIC: Classical music
-ROCK: Rock music
8.9.5 Audio setting
• Press to select desired audio mode.

Table 8–2
-Sound BASS-TRE, FLAT,

style JAZZ, VOCAL, POP,
CLASSIC, ROCK
-BASS low notes
-TREBLE high notes
-BAL- left-right
ANCE
-FADER rear-front
-LOUD OFF, LOW, MID, Fig 8-14 Sound Type
HIGH
• Press the volume button to adjust the se-

lected audio mode. After 5 seconds the dis-
play returns to show the last mode of
operation. Adjustment of Bass and Treble
setting is only possible when BASS-TRE is
selected as the sound style.

OPTIONAL PARTS
8.9.6 Radio
Waveband
• Press BAND to select the desired band:
Automatic search
• Press or to tune to a station of a lower

frequency or of a higher frequency.
• To search for another station, press the but-
ton again. Fig 8-15 Band Button
Manual tuning (if you know the frequency

of the required station)
• Long press the search button or for

more than 2 seconds, and the manual tun-
ing is activated.
• Then press or to tune to a station of a
lower frequency or of a higher frequency.
• If no station is searched in 5 seconds, the
system would return to its last operation.
Preselected stations
Manually storing stations in a preset
By using the preset keys (1 to 5), five stations

per band can be stored and recalled.
• Tune to the desired station.

• Press the desired preset key (1 to 5) for
more than 2 seconds to store the current
tuned station.
Preset, recalling
Fig 8-16 Station Button
Press the desired preset key (1 to 5) to recall
the stored station.
Automatically storing stations (AUTO-STORE)

OPTIONAL PARTS
• You can automatically store 5 strongest FM stations on the FM AST band or 5 strongest MW
(AM) stations on the MW(AM) AST band. When you use Auto- Store, the new stations replace
any stations previously stored in the FM AST band or the MW(AM) AST band.
• Press AST to activate auto-store.
• The system gives out a beep and then mutes.
• When the station is stored successfully, you can hear a beep followed by the storing.
• Sometimes it may be impossible to find 5 stations.
8.9.7 Radio troubleshooting
When you suspect that your radio is not functioning normally, please check the below trouble-
shooting table before calling for service.
If you still have to send your radio set for service, always send the complete set (with detachable
panel). Do not try to open the set to service it yourself.
Table 8–3 Radio Troubleshooting Table
No. Fault Troubleshooting method

The sset does not function. 1. Check the fuse (set and car) and connections.
1
No display 2. Check the operating voltage.
1. Adjust the volume of the set.
The set functions with no
2 2. Check the radar and balance settings.
sound.
3. Check the aerial and its connection.
1. Check that the aerial is fully extended and prop-
erly connected.
The system cannot be tuned 2. Check that the negative terminal (brown lead) is
3
to a desired station. connected to the machine frame.
3. Desired station is too weak. Try the manual tun-
ing function.
Display shows frequency in- 1. The set is tuned to non-RDS station
4
stead of station name 2. The RDS function is switched off.

OPTIONAL PARTS
8.10 Automatic Lubrication

8.10.1 Automatic lubrication system
The automatic lubrication system is com-

posed of machine lubrication system and
spreader lubrication system. The lubrications
of machine and spreader are respectively
driven by two automatic lubrication pumps.
The lubrication is fully automatic. Therefore, it
is not necessary for the operator to lubricate.
The machine lubrication pump is located at

the right of frame cover plate.
The spreader lubrication pump is located at

the sideshift bracket of spreader.
Fig 8-17
1.Lubrication pump
8.10.2 Operation precautions
Pay special attention to below items when operating the automatic lubrication system:
• Check if there is enough grease in the grease reservoir of lubrication pump. Fill in grease in time.
Never make the grease pump run without grease.
• Make sure that the upper cover of grease reservoir is tightened to prevent dust and dirt from en-
tering. Otherwise, the system may become ineffective.
• Use the grease nipple to fill grease. Never open the upper cover when filling.
• It is suggested to apply 2# grease when the temperature is high and 0# one when the tempera-
ture is low.
• Check if grease spills over from the overflow valve of grease pump. If yes, troubleshoot it
immediately.
• Usually the lubrication time is set to be 6 minutes and the intermittent time is set to be 3 hours
when the machine leaves factory.

OPTIONAL PARTS
8.10.3 Time setting
When the operator has changed the time setting by accident, it is able to set the lubrication time
and intermittent time according to below steps.
1. Remove the protective cover at the base

to set up the time.
NOTE:
Tighten the protective cover after the time

setting.
RS-1407034-1
Fig 8-18
2. Set the intermittent time:
Rotate the blue switch (1) to set the intermit- 3

tent time.
9
NOTE:
If the switch is at position 0, the right diode

would light up and the system would send out
the malfunction signal. Meanwhile the inter-
mittent time is defaulted to be the initial time. 1 2
Fig 8-19
1. Blue switch 2. Forcible start key
Table 8–4 Intermittent Time Setting Table
Position 1 2 3 4 5 6 7 8 9 A B C D E F
Minute 4 8 12 16 20 24 28 32 36 40 44 48 52 56 60
Hour 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

OPTIONAL PARTS
3. Set the lubrication time:
Rotate the red switch to set the lubrication

3
time.
9
NOTE:
Do not set the switch at position 0.
Fig 8-20
3. Red switch
Table 8–5 Lubrication Time Setting Table
Position 1 2 3 4 5 6 7 8 9 A B C D E F
Second 8 16 24 32 40 48 56 64 72 80 88 96 104 112 120
Minute 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30

Index

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

Empty Container Handler

Operation and Maintenance Manual

Operation and Maintenance Manual-May 2022

• The personnel should observe the information on this manual.

• Be responsible for providing qualified products and correct documentations.

Duty of Owners or Other Authorized Personnel

Operation and Maintenance Manual-May 2022 1

Duty of All Working Personnel

2 Operation and Maintenance Manual-May 2022

Operation and Maintenance Manual-May 2022 I

2.1.2 Signal words..................................................................................................................2-5

II Operation and Maintenance Manual-May 2022

2.3.6.1 Ensuring good visibility...................................................................................... 2-45

Operation and Maintenance Manual-May 2022 III

2.4.14.2 Removing inflammables ................................................................................. 2-67

3 SYSTEM FUNCTIONS ...................................................................................................3-1

IV Operation and Maintenance Manual-May 2022

3.2.5.7 Front wiper switch .............................................................................................. 3-24

Operation and Maintenance Manual-May 2022 V

4.1 Before starting the engine....................................................................................................4-3

VI Operation and Maintenance Manual-May 2022

4.6.1 Overnight storage...................................................................................................... 4-53

Operation and Maintenance Manual-May 2022 VII

5.5.1 Special instructions for the first maintenance........................................................ 5-21

VIII Operation and Maintenance Manual-May 2022

5.6.4.6 Coolant, drain ..................................................................................................... 5-69

Operation and Maintenance Manual-May 2022 IX

5.10.4 Drive axle tyre, remove and install.......................................................................5-119

X Operation and Maintenance Manual-May 2022

5.14.3 Hydraulic oil, change ............................................................................................ 5-150

Operation and Maintenance Manual-May 2022 XI

8 OPTIONAL PARTS ..........................................................................................................8-1

XII Operation and Maintenance Manual-May 2022

8.6 Twistlock Calculator ............................................................................................................8-11

Operation and Maintenance Manual-May 2022 XIII

XIV Operation and Maintenance Manual-May 2022

Operation and Maintenance Manual-May 2022 1-1

1.11 Correction Request Form................................................................................................ 1-19

1-2 Operation and Maintenance Manual-May 2022

1-3 Operation and Maintenance Manual-May 2022

1-4 Operation and Maintenance Manual-May 2022

Fig 1-1 Read the Manual

Operation and Maintenance Manual-May 2022 1-5

1.3 Application Range

Empty container handlers are applicable for

The rules for intended and approved uses of

The user, and not SANY, is responsible for

Machines covered by this manual are used for

1.3.2 Unauthorized use

Improper uses include:

1-6 Operation and Maintenance Manual-May 2022

• Pulling or pushing vehicles, trailers or containers.

1.4 Machine Authorizations

All machines and equipment (some equip-

1.5 Your Documentation Package

Operation and Maintenance Manual-May 2022 1-7

1.5.2 CD system requirements

• Windows 2000, XP, Vista or Windows 7 operating system

1.5.3 Recommendations on using the documentation

2. Page number of the Content part is marked as below:

1-8 Operation and Maintenance Manual-May 2022

3. Edition number of Operation and Maintenance Manual is marked as below:

Operation & Maintenance Manual - July 2012